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Big Lift Big Joe S22 Series Operation, Maintenance, Repair Parts

Self-propelled, straddle lift truck
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S22 SERIES
SELF-PROPELLED,
STRADDLE LIFT TRUCK
Operation
Maintenance
Repair Parts List
PDF editing password: 60148
Big Lift LLC
MANUAL NO. BL-S22-1214 - 02-20-2015
www.bigjoeforklifts.com

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  • Page 1 S22 SERIES SELF-PROPELLED, STRADDLE LIFT TRUCK Operation Maintenance Repair Parts List PDF editing password: 60148 Big Lift LLC MANUAL NO. BL-S22-1214 - 02-20-2015 www.bigjoeforklifts.com...
  • Page 2 WARNING Do not operate this truck unless you have been autho- Do not overload truck. Check nameplate for capacity rized and trained to do so, and have read all warnings and load center information. and instructions in Operator’s Manual and on this When using forks, space forks as far apart as load will truck.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Page Section Page 5-1.5 SPEED POTENTIOMETER 1 DESCRIPTION ............1-1 REPLACEMENT .......... 5-3 INTRODUCTION ..........1-1 5-1.6 BELLY-BUTTON SWITCH GENERAL DESCRIPTION ......1-1 REPLACEMENT .......... 5-3 SAFETY FEATURES........1-1 5-1.7 HORN SWITCH REPLACEMENT....5-4 5-1.8 LIFT AND LOWER SWITCH 2 OPERATION ...............2-1 REPLACEMENT ..........
  • Page 4 TABLE OF CONTENTS Cont. Section Page Section Page 10 ELECTRICAL COMPONENTS ......... 10-1 10-1.15 LED INDICATOR REMOVAL ..... 10-5 10-1 ELECTRICAL CONTROL PANEL....10-1 10-1.16 LED INDICATOR INSTALLATION ..... 10-5 10-1.1 MAINTENANCE ......... 10-1 10-1.17 EMERGENCY DISCONNECT REMOVAL . 10-5 10-1.2 CLEANING ..........

  • Page 5: Section 1 Description

    SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the 24 volt S22 lift truck dis- tributed by Big Lift LLC. Included are operating instruc- S22-62 427131964 tions, planned maintenance instructions, lubrication procedures, corrective maintenance procedures and a 2200/998 24/610 62/1575 complete parts list with part location illustrations.
  • Page 6 R6841 Figure 1-2 S22 Lift Truck ITEM COMPONENT ITEM COMPONENT Battery Control handle. Chassis Key switch Caster LED indicator Cover Mast cover Drive wheel Lift cylinder Cover Battery indicator Hydraulic reservoir Battery charger connector Hydraulic pump Emergency brake switch Forks BL-S22-1214 - 02-20-2015...

  • Page 7: Section 2 Operation

    SECTION 2 OPERATION 2-1. GENERAL. • Be certain that the lifting mechanism is operating smoothly throughout its entire height, both empty This section gives detailed operating instructions for and loaded. the S22 lift truck. The instructions are divided into the various phases of operations, such as operating lift, •...

  • Page 8: Before Operation

    • When stacking pallets in racks and it is necessary to Figure 2-2 shows a sample format for an Operator move the load in a raised position, use caution. Checklist, which can be modified as necessary to fit Operate truck smoothly. your operation.
  • Page 9 R6479 Figure 2-2 Sample of Operator Check List BL-S22-1214 - 02-20-2015...

  • Page 10: General Control Operation

    2-4. GENERAL CONTROL OPERATION. Lower the steering arm to a comfortable position above horizontal to disengage the brake and to The speed control (See Figure 2-3) located on each energize the electrical circuits. If the truck is not side of the control head provides fingertip control for moved, the electrical circuits will time out and will driving the truck.

  • Page 11: Belly-Button Switch

    2-7. STEERING ARM GAS SPRING. The steering arm gas spring automatically raises the steering arm to the upright position when the steering arm is released. If the steering arm does not return fully, the steering arm gas spring requires replace- ment.
  • Page 12 NOTES BL-S22-1214 - 02-20-2015...

  • Page 13: Section 3 Planned Maintenance

    Leakage voltage from battery terminals to battery case accordingly. These procedures must be performed by can cause misleading trouble symptoms with the truck a qualified service technician or your Big Lift LLC Ser- electrical system. Since components of the truck elec- vice Representative.

  • Page 14: 3-3.2 Safety Rules

    Although a leakage voltage reading of zero volts may Battery terminals should be checked and cleaned not be possible, a cleaner battery will have more of corrosion regularly. Good battery terminal con- usable charge for truck operation and not affect opera- tact is essential not only for operation, but also for tion of electronic devices on the unit.

  • Page 15: Charging Batteries

    3-4. CHARGING BATTERIES Charging requirements will vary depending on depth of discharge and temperature. Follow safety rules when placing a battery on charge. Proceed as follows: Park truck at charging station with carriage low- ered and turn the key switch off. Check the condition of the AC cord and battery cables.

  • Page 16: Lubrication

    Tag and disconnect the three cables from the bat- teries and replace the batteries. Install in the reverse order of removal. 3-6. LUBRICATION. Refer to Table 3-2 for the recommended types of grease and oil. Table 3-3 in conjunction with Figure 3-4 identifies the items requiring lubrication.
  • Page 17 R6871 Figure 3-4 Lubrication Diagram Table 3-3 Lubrication Chart FIG 3-2 LOCATION METHOD OF TYPE APPLICATION INDEX APPLICATION (Table 3-3) LUBRICANT Inner & Outer Mast Brush No. 2 Full length of channel where rollers operate. Lift Chain Brush or Spray No.
  • Page 18 NOTES BL-S22-1214 - 02-20-2015...

  • Page 19: Section 4 Troubleshooting

    SECTION 4 TROUBLESHOOTING 4-1. GENERAL ate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Lower- Table 4-1 as a guide to determine possible ing, and Miscellaneous malfunctions. causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Oper- Table 4-1 Troubleshooting Chart MALFUNCTION...
  • Page 20 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING Truck does not slow with brake, or a. Defective deadman switch (16, Check deadman switch for brake does not engage. Figure 12-1). continuity. If none found when the control arm is in the brake position, replace switch.
  • Page 21 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir and the oil lines to the lift cylin- der, and repair as required.

  • Page 22: Controller Troubleshooting

    4-2.2. Hand Held Programmer (Optional) The hand held programmer is available that is designed specifically for use with the controller. The programmer is available through your Big Lift LLC dealer. 4-2.3. Fault Recording. Fault events are recorded in the controller's memory.
  • Page 23 Put the controller into the diagnostic mode by Put the controller into the test mode by using the pressing the "Menu Navigation Key" (1, Figure 4- Navigation key (1) to select the "Monitor" menu. 2). Using the Navigation key, select the Faults Select the Monitor mode by pressing the "Right"...

  • Page 24: 4-2.5 Diagnostic History

    4-2.5. Diagnostic History Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn on key switch The handheld programmer can be used to access the Figure 12-26 or 4, Figure 12-28). controller's diagnostic history file. When the program- Leave the key switch on and remove the in-line mer is connected to the unit, the error log file is auto- fuse wire.

  • Page 25: Drive Menu

    Table 4-2 Programmable Parameters Parameter Factory Setting Description DRIVE MENU Sets the rate (in seconds) at which the speed command increases when throttle is applied with the speed limit pot is in its maximum speed position, and the vehicle is traveling Accel Max Speed 3.5 sec.
  • Page 26 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description DRIVE MENU Cont. Sets the rate (in seconds) that is used to slow down the vehicle when it is traveling in reverse at low speed and throttle is reduced. Larger values represent slower response. Rev Decel Low Speed 2.0 sec.

  • Page 27: Speed Menu

    Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description SPEED MENU During forward operation, defines the requested speed at full Max Speed throttle when the speed limit pot is in its maximum speed position. Mode 1 100% 100% Note: Allowable range is restricted by the M1/M2 Min Speed Mode 2 setting.

  • Page 28: Throttle Menu

    Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU The 1212 controller can accept inputs from both 5k, 3-wire pot throttles and voltage throttles. Set the throttle type param- eter to match the throttle used in your application. 5k, 3-wire pot throttles 0 = wigwag 1 = inverted wigwag...

  • Page 29: Current Menu

    Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU - Continued The throttle map parameter adjusts the static throttle map. The parameter setting corresponds to the throttle command at half throttle. Throttle Map A setting of 50% provides linear response. Values below 50% reduce the throttle command at low throttle positions, provid- ing enhanced slow speed maneuverability.
  • Page 30 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description INHIBIT MENU The flexible speed input at J1 Pin 6 can be used to limit or to inhibit speed under certain conditions. For example, a switch could be installed under the seat so that if the operator drives the scooter while they are standing the max speed will be lim- ited.
  • Page 31 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description MOTOR MENU Sets the system resistance (motor + brushes + wiring + con- nections) used for load compensation and speed estimation. System Resistance Control system performance depends on this parameter being set correctly;...

  • Page 32: Compensation Menu

    Parameter Factory Setting Description BDI MENU - Cont. Voltage above which the battery is considered to start charging. Start Charger 25.2V 25.2V Voltage Note: Allowable range is restricted by the Full Voltage and Full Charge Voltage settings. Voltage at which the BDI calculator will be reset to 100%, after the charger is disconnected and the controller is powered up.

  • Page 33: 4-2.8.1 Led Diagnostics

    The motor controller provides diagnostics information For suggestions about possible causes of the various to assist in troubleshooting drive system problems. faults, refer to Table 4-4 Troubleshooting Chart. The diagnostics information can be obtained in two 4-2.9. Programmer Diagnostics ways: With a programmer, diagnostics and troubleshooting is •...

  • Page 34: Fault Clearance

    Table 4-4 Troubleshooting Chart PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY Battery Disconnect Battery disconnected 1. Battery not connected. Fault 2. Poor connection to battery terminals. Battery OFF Fault Brake OFF Fault 1. Electromagnetic brake driver open. 2. Electromagnetic brake coil shorted. Brake ON Fault Brake ON fault 1.
  • Page 35 Table 4-4 Programmable Parameters - Continued PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY Throttle Fault PotLow and /or PotWiper out of range 1. Throttle input wire open or shorted. 2. Throttle pot defective. 3. Wrong throttle type selected. Undervoltage Fault Battery voltage too low 1.
  • Page 36 NOTES 4-18 BL-S22-1214 - 02-20-2015...

  • Page 37: Steering Arm, Control Head And Compartment

    SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD Remove four screws (17, Figure 5-1), lift up cap assembly (24) and disconnect harness from har- 5-1.1. Cap Assembly Removal. ness (15, Figure 5-2). Engage the emergency stop switch (29, Figure 12-26 or 29,...

  • Page 38: 5-1.2 Cap Assembly Installation

    5-1.2. Cap Assembly Installation. Position cap assembly (24, Figure 5-1) on control head and secure with four screws (17). Hold cap assembly (24, Figure 5-1) in place and Disengage the emergency stop switch (29, Figure connect harness to harness (15, Figure 5-2).

  • Page 39: 5-1.3 Control Head Removal

    5-1.3. Control Head Removal Position new potentiometer (21) in bracket (20) and secure with screw (16), lock washer (6) and Remove the cap assembly as described in para- flat washer (7). graph 5-1.1. Install screw (22), lock washer (6) and flat washer Disconnect harness (15, Figure 5-2) from potenti-...

  • Page 40: 5-1.7 Horn Switch Replacement

    R6810 Figure 5-3 Emergency Reverse Switch Assembly 5-1.7. Horn Switch Replacement. Position the new switch in bracket (10) and secure with two pins (10). Remove the cap assembly as described in para- Position bracket (10) in cover (1) and secure with graph 5-1.1.
  • Page 41 R6847A Figure 5-4 Cap Assembly BL-S22-1214 - 02-20-2015...

  • Page 42: 5-1.8 Lift And Lower Switch Replacement

    5-1.8. Lift and Lower Switch Replacement. Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn on key switch Remove the cap assembly as described in para- Figure 12-26 or 4, Figure 12-28). graph 5-1.1. Remove switch assembly (13 or 14, Figure 5-4) 5-2.2.

  • Page 43: Mono Mast Cover

    5-4. MONO MAST COVER 5-4.2. Installation. Install cover (3, Figure 12-6) and secure with six 5-4.1. Removal. screws (1) and six washers (2). Engage the emergency stop switch (29, Figure Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn off key switch 12-26...
  • Page 44 NOTES BL-S22-1214 - 02-20-2015...

  • Page 45: Section 6 Brake Servicing

    SECTION 6 BRAKE SERVICING 6-1. BRAKES. Disconnect electric brake from harness (1, Figure 12-30). The brake system consists of a drive motor mounted Remove the two mounting screws (7, Figure 6-1) brake. This brake is spring applied and electrically and the brake. released.
  • Page 46 R7131A Figure 6-1 Transmission, Motor, Brake Assembly BL-S22-1214 - 02-20-2015...

  • Page 47: Transmission, Drive Wheel, Load Wheel

    SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL 7-1. Drive Wheel. Remove the steering arm as described in para- graph 5-2. Remove the transmission as described in para- Raise the truck off the ground to provide clear- graph 7-2. ance for transmission out the bottom. Securely Remove the two mounting screws (7, Figure 7-1)
  • Page 48 R7131A Figure 7-1 Transmission, Motor, Brake Mounting BL-S22-1214 - 02-20-2015...

  • Page 49: Load Wheel

    NOTE: Inspect the load wheel assembly. If the load wheel is worn within 1/8" of the metal sleeve, or is cracked or damaged, replace the entire load wheel and bearing assembly. Big Lift LLC recommends that both load wheel assemblies be replaced at the same time.
  • Page 50 NOTES BL-S22-1214 - 02-20-2015...

  • Page 51: Section 8 Elevation System Servicing

    SECTION 8 ELEVATION SYSTEM SERVICING 8-1. GENERAL. The elevation system includes the outer mast, inner mast, lift linkage, lift chains, lift cylinder and ram head. 8-2. LIFT CHAIN LENGTH ADJUSTMENT. 8-2.1. Mono Fully lower the lift carriage. Engage the emergency stop switch (29, Figure 12-26 or 29,...

  • Page 52: 8-2.2 Telescopic

    8-2.2. Telescopic Fully lower the lift carriage. Engage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn off key switch Figure 12-26 or 4, Figure 12-28). WARNING: Before attempting any adjustment, make certain power is disconnected. Loosen jam nut (3, Figure 8-2), located the above...

  • Page 53: Lift Chain Replacement

    8-4. LIFT CHAIN REPLACEMENT. 8-4.2. Telescopic With the lift truck wheels securely blocked, raise 8-4.1. Mono the forks approximately three feet from floor and With the lift truck wheels securely blocked, raise position blocks or strong supports under the inner the forks approximately three feet from floor and mast.
  • Page 54 NOTES BL-S22-1214 - 02-20-2015...

  • Page 55: Section 9 Hydraulic System Servicing

    SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS Remove the compartment covers as described in paragraph 5-3. WARNING: When forks are raised, pressure exists in Remove the mono mast cover as described in the hydraulic system lines and fittings. To paragraph 5-3.

  • Page 56: Hydraulic Pump, Motor, And Reservoir Assy

    Check level of hydraulic oil. If required, add 11. Install the mono mast cover as described in para- hydraulic oil to bring to proper level. Use hydraulic graph 5-3. oil listed in Table 3-2. 9-2. HYDRAULIC PUMP, MOTOR, AND RESER- Disengage the emergency stop switch ((29, Fig- VOIR ASSY...

  • Page 57: 9-2.1 Removal

    9-2.1. Removal Check level of hydraulic oil. If required, add hydraulic oil to bring to proper level. Use hydraulic Lower forks fully. oil listed in Table 3-2. Engage the emergency stop switch (29, Figure Install the compartment covers as described in 12-26 or 29, Figure...
  • Page 58 R6854 Figure 9-3 Elevation System (Mono) BL-S22-1214 - 02-20-2015...

  • Page 59: 9-3.2 Repair

    9-3.2. Repair Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn on key switch CAUTION: To prevent damage, use proper pipe Figure 12-26 or 4, Figure 12-28). clamp vise. The cylinder will be distorted 10. Operate the lift and lower buttons to refill the if the vise is tightened too much.

  • Page 60: Lift Cylinder (Telescopic)

    9-4. Lift Cylinder (Telescopic) Remove bearing and bushing (4). Remove piston (2) and O-ring (3) from rod (1). 9-4.1. Removal Remove guide ring (10) and seal (11) from piston With the lift truck wheels securely blocked, raise (2). the forks approximately three feet from floor and position blocks or strong supports under the inner Coat all parts with hydraulic oil (Table...
  • Page 61 R6855A Figure 9-6 Elevation System (Telescopic) BL-S22-1214 - 02-20-2015...

  • Page 62: 9-4.3 Installation

    9-4.3. Installation Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn on key switch Position the cylinder in the mast. Figure 12-26 or 4, Figure 12-28). Install screw (32, Figure 9-6), lock washer (11) Operate the lift and lower buttons to refill the and flat washer (12) to secure the bottom of the cylinder and lines with hydraulic oil.

  • Page 63: Section 10 Electrical Components

    SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL Tag and disconnect remaining leads from the con- troller. Refer to Figure 12-31 Figure 12-32). 10-1.1.Maintenance Remove mounting screws, lock washers and remove controller (17, Figure 10-1 or 17, Figure NOTE: Erratic operation of the truck may be caused 10-2) and heat sink (18).
  • Page 64 R6865A Figure 10-1 Electrical System (Mono) 10-2 BL-S22-1214 - 02-20-2015...
  • Page 65 R6866A Figure 10-2 Electrical System (Telescopic) BL-S22-1214 - 02-20-2015 10-3...

  • Page 66: 10-1.7 Cooling Fan Removal (Mono)

    Reconnect remaining two charger leads. Disengage the emergency stop switch (29, Figure 12-26 or 29, Figure 12-28) and turn on key switch Install compartment covers as described in para- Figure 12-26 or 4, Figure 12-28). graph 5-3. Disengage the emergency stop switch (29, Figure 10-1.11.Key Switch Removal.

  • Page 67: 10-1.15 Led Indicator Removal

    Disengage the emergency stop switch (29, Figure Reconnect cables (3 and 4, Figure 12-31 Fig- 12-26 or 29, Figure 12-28) and turn on key switch 12-32) to emergency disconnect (29, Figure Figure 12-26 or 4, Figure 12-28). 10-1 or 29, Figure 10-2).

  • Page 68: Deadman Switch

    10-4.DEADMAN SWITCH Remove two screws (7) and switch (16) from bracket (8). Engage the emergency stop switch (29, Figure Position the new switch (16) on bracket (8) and 12-26 or 29, Figure 12-28) and turn off key switch secure with the two screws (7). Figure 12-26 or 4, Figure...

  • Page 69: Section 11 Optional Equipment

    SECTION 11 OPTIONAL EQUIPMENT 11-1.LOAD BACKREST A load backrest is available for addition to the lift truck to allow handling of high loads. BL-S22-1214 - 02-20-2015 11-1...
  • Page 70 NOTES 11-2 BL-S22-1214 - 02-20-2015...

  • Page 71: Section 12 Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the S22 Lift Truck. BL-S22-1214 - 02-20-2015 12-1...
  • Page 72 R6846A Figure 12-1 Steering System 12-2 BL-S22-1214 - 02-20-2015...

  • Page 73: Switch Assembly

    Steering System QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000322-00 SCREW M8×25 0000-000030-00 SCREW M10×16 Used up to Serial # 0000-000386-00 SCREW M6×20 S2117024 Used from Serial # 0000-000026-00 SCREW M8×30 S2117025 Used up to Serial # 0000-000056-00 LOCKWASHER Ø6 S2117024 Used from Serial # 0000-000159-00...
  • Page 74 R6808A Figure 12-2 Control Head 12-4 BL-S22-1214 - 02-20-2015...

  • Page 75: Accelerator Assembly

    Control Head QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 1120-342000-00 CAP ASSEMBLY 1120-340005-00 CONTROL KNOB 0000-000038-00 LOCKWASHER Ø3 0000-000037-00 SCREW M3×12 0000-000004-00 SCREW M5×12 0000-000206-00 LOCKWASHER Ø5 0000-000390-00 FLATWASHER Ø5 0000-000088-00 SCREW M4×8 0000-000122-00 LOCKWASHER Ø4 0000-000702-00 FLATWASHER Ø4 0000-000322-00 SCREW M8×25 0000-000159-00 LOCKWASHER Ø8...
  • Page 76 R6847A Figure 12-3 Cap Assembly 12-6 BL-S22-1214 - 02-20-2015...
  • Page 77 Cap Assembly QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 1120-342001-00 UPPER COVER 1120-342203-00 BUTTON FOR LOWERING(R) 1120-342202-00 BUTTON FOR LIFTING(R) 1120-342102-00 SPRING 1120-342201-00 BUTTON BRACKET(R) 1120-342105-00 1120-342104-00 BUTTON FOR LIFTING(L) 1120-342103-00 BUTTON FOR LOWERING(L) 1120-342101-00 BUTTON BRACKET (L) 1120-342002-00 HORN BUTTON 1120-342005-00 1120-342003-00 SPRING...
  • Page 78 R6810A Figure 12-4 Emergency Reverse Switch Assembly 12-8 BL-S22-1214 - 02-20-2015...
  • Page 79 Emergency Reverse Switch Assembly QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 1120-343002-00 COVER 1120-343003-00 SPRING 1120-342005-00 1120-343001-0A BRACKET 1120-343004-00 1120-520004-0A REVERSING SWITCH 1220-560002-00 SWITCH BL-S22-1214 - 02-20-2015 12-9...
  • Page 80 R7131A Figure 12-5 Transmission, Motor, Brake Assembly 12-10 BL-S22-1214 - 02-20-2015...
  • Page 81 Transmission, Motor, Brake Assembly QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-200000-00 DRIVING ASSEMBLY 2108-220000-00 BRAKE ASSEMBLY 1115-250000-00 MOTOR 1115-240001-00 BRAKE 0000-000657-00 BEARING 0000-000668-00 BEARING Used up to Serial # 2108-210001-00 GEAR BOX CASING S2117024 Used from Serial # 2108-200002-00 GEAR BOX CASING S2117025 0000-000665-00...
  • Page 82 R6849A Figure 12-6 Compartment, Mono 12-12 BL-S22-1214 - 02-20-2015...
  • Page 83 Compartment, Mono QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-100006-00 SCREW M6×10 2214-150002-00 WASHER Ø6 Used for Lift Height of 62” 2108-100001-00-01 COVER Used up to Serial # 2108-100002-00 COVER S2313110 Used from Serial # 2108-100002-0A COVER S2313111 0000-000179-00 SCREW M6×10 Used up to Serial # 2108-100004-00 ROTATION COVER...
  • Page 84 R6850A Figure 12-7 Compartment, Telescopic 12-14 BL-S22-1214 - 02-20-2015...
  • Page 85 Compartment, Telescopic QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 1120-150004-00 SCREW M6×25 2214-150002-00 WASHER Ø6 Used up to Serial # 2108-100002-00 COVER S2313110 Used from Serial # 2108-100002-0A COVER S2313111 0000-000179-00 SCREW M6×10 Used up to Serial # 2108-100004-00 ROTATION COVER S2313110 Used from Serial # 2108-100004-0A...
  • Page 86 R6851A Figure 12-8 Adjustable Straddle, Mono 12-16 BL-S22-1214 - 02-20-2015...

  • Page 87: Caster Assembly

    Adjustable Straddle, Mono QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-140000-1A CASTER ASSEMBLY II 0000-000322-00 SCREW M8×25 0000-000159-00 LOCKWASHER Ø8 0000-000194-00 FLATWASHER Ø8 Used up to Serial # 2108-110000-10 FRAME S2312115 Used from Serial # 2108-110000-1A FRAME S2312116 0000-000369-00 SCREW M5×16 2125-101003-00 WASHER 0000-000424-00...
  • Page 88 R6852A Figure 12-9 Adjustable Straddle, Telescopic 12-18 BL-S22-1214 - 02-20-2015...
  • Page 89 Adjustable Straddle, Telescopic QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-140000-1A CASTER ASSEMBLY II 0000-000322-00 SCREW M8×25 0000-000159-00 LOCKWASHER Ø8 0000-000194-00 FLATWASHER Ø8 Used up to Serial # 2108-110000-60 FRAME S2216039 Used from Serial # 2108-110000-A0 FRAME S2216040 to S2312115 Used from Serial # S2312116 to Serial # 2108-110000-6A...
  • Page 90 R8004 Figure 12-10 Frame System, Mono Mast - Fork Over Style 12-20 BL-S22-1214 - 02-20-2015...
  • Page 91 Frame System, Mono Mast - Fork Over Style QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 1220-140000-00 CASTER ASSEMBLY I 0000-000322-00 SCREW M8×25 0000-000159-00 LOCKWASHER Ø8 0000-000194-00 FLATWASHER Ø8 Used up to Serial # 2108-110000-00 FRAME S2312115 Used from Serial # 2108-110000-0A FRAME S2312116...
  • Page 92 R8005 Figure 12-11 Caster I (Mono Mast - Fork Over Style) 12-22 BL-S22-1214 - 02-20-2015...
  • Page 93 Caster I (Mono Mast - Fork Over Style) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000093-00 NUT M27×1.5 0000-000094-00 LOCKWASHER Ø27 1220-140001-00 RING 1220-140005-00 WASHER 0000-000420-00 BEARING 1220-140002-00 BEARING BLOCK 0000-000421-00 BEARING 0000-000242-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 1220-140004-00 WASHER 1220-141000-00 WHEEL BRACKET 1220-142001-00...
  • Page 94 R6853 Figure 12-12 Caster II (Adjustable Straddle Leg Design) 12-24 BL-S22-1214 - 02-20-2015...
  • Page 95 Caster II (Adjustable Straddle Leg Design) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000093-00 NUT M27×1.5 0000-000094-00 WASHER Ø27 1220-140001-00 SNAP RING 0000-000420-00 BEARING 2140-140002-00 BEARING BLOCK 0000-000421-00 BEARING Used up to 03-31-2012 2108-140004-10 SPRING Used from 04-01-2012 2140-140004-00 SPRING 2140-141000-00 YOKE 0000-000242-00...
  • Page 96 R6854 Figure 12-13 Elevation System (Mono) 12-26 BL-S22-1214 - 02-20-2015...
  • Page 97 Elevation System (Mono) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000756-00 RETAINER RING Ø40 2108-600001-00 SHAFT 2108-600003-00 WASHER 2108-600002-00 CHAIN ROLLER 2108-620000-00 CHAIN BRACKET 0000-000374-00 SCREW M12×30 0000-000060-00 LOCKWASHER Ø12 0000-000373-00 FLATWASHER Ø12 0000-000321-00 SCREW M8×20 2108-600004-00 CYLINDER BRACKET 2110-410000-00-01 LIFTING CYLINDER 0000-000159-00 LOCKWASHER Ø8...
  • Page 98 R6855A Figure 12-14 Elevation System (Telescopic) 12-28 BL-S22-1214 - 02-20-2015...
  • Page 99 Elevation System (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000761-00 SCREW M12×20 2108-600002-60 BOLT 0000-000757-00 NUT M20X1.5 2108-600003-60 SPRING 2108-600004-60 POSITIONING ROD 2108-600005-60 CHAIN ROLLER Ø84/Ø52X33 0000-000100-00 BEARING 0000-000294-00 RETAINER RING Ø25 ELASTIC COLLAR Φ52 0000-000758-00 0000-000374-00 SCREW M12×30 0000-000060-00 LOCKWASHER Ø12 0000-000373-00...
  • Page 100 R6855A Figure 12-15 Elevation System (Telescopic) Continued 12-30 BL-S22-1214 - 02-20-2015...
  • Page 101 Elevation System (Telescopic) Continued QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. Used up to Serial # 2108-620000-60-04 INNER MAST S2216039 - Lift Height 96” Used up to Serial # 2108-620000-60-02 INNER MAST S2216039 - Lift Height 116” Used from Serial # S2216040 to S2320186 2108-620000-6A-04 INNER MAST...
  • Page 102 R6856A Figure 12-16 Lift Carriage (Mono Mast) 12-32 BL-S22-1214 - 02-20-2015...
  • Page 103 Lift Carriage (Mono Mast) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2125-630001-10 SHAFT 2108-630001-10 FORK 0000-000008-00 SCREW M10×20 0000-000063-00 LOCKWASHER Ø10 2125-631104-00 SCREW 2125-612007-00 SNAP RING 2125-612002-00 BRACKET ASSEMBLY 2125-612001-00 ROLLER ASSEMBLY 2125-612005-00 DUST SNAP 0000-000183-00 RETAINER RING Ø35 2125-631100-00 ROLLER ASSEMBLY 2108-631000-10 FORK FRAME...
  • Page 104 R6857A Figure 12-17 Lift Carriage (Telescopic) 12-34 BL-S22-1214 - 02-20-2015...
  • Page 105 Lift Carriage (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000284-00 BOLT M12×30 0000-000060-00 LOCKWASHER Ø12 0000-000373-00 FLATWASHER Ø12 2125-632000-00 BLOCKING SHELF Used up to Serial # 2108-631000-60 FORK FRAME S2320186 Used from Serial # 2111-631000-10 FORK FRAME S2320187 2108-600006-60 COLUMN 0000-000761-00 SCREW M12×20...
  • Page 106 R8019 Figure 12-18 Chain Assembly (Mono Mast - Fork Over Style) 12-36 BL-S22-1214 - 02-20-2015...
  • Page 107 Chain Assembly (Mono Mast - Fork Over Style) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-640004-00-01 CHAIN 2108-640001-00 BOLT 0000-000237-00 NUT M16×1.5 2108-640002-00 PIN SHAFT 0000-000188-00 PIN Ø3.2×20 2108-640003-00 CHAIN ANCHOR 0000-000176-00 FLATWASHER Ø8 BL-S22-1214 - 02-20-2015 12-37...
  • Page 108 R6858A Figure 12-19 Chain Assembly (Mono Mast - Adjustable Straddle Style) 12-38 BL-S22-1214 - 02-20-2015...
  • Page 109 Chain Assembly (Mono Mast - Adjustable Straddle Style) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-640004-00-01 CHAIN 2108-640001-00 BOLT 0000-000237-00 NUT M16×1.5 2108-640002-00 PIN SHAFT 0000-000188-00 PIN Ø3.2×20 0000-000176-00 FLATWASHER Ø8 BL-S22-1214 - 02-20-2015 12-39...
  • Page 110 R6859A Figure 12-20 Chain Assembly (Telescopic) 12-40 BL-S22-1214 - 02-20-2015...
  • Page 111 Chain Assembly (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. Used for Lift Height 96” 2108-640001-60-04 CHAIN Used for Lift Height 116” 2108-640001-60-02 CHAIN 2108-640002-60 BOLT 0000-000237-00 NUT M16 × 1.5 0000-000220-00 WASHER Ø16 0000-000188-00 PIN Ø3.2 × 20 0000-000779-00 PIN Ø6 x 30 BL-S22-1214 - 02-20-2015 12-41...
  • Page 112 R6860 Figure 12-21 Hydraulic System (Mono) 12-42 BL-S22-1214 - 02-20-2015...
  • Page 113 Hydraulic System (Mono) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-413000-00 HYDRAULIC PUMP ASSEMBLY 0000-000109-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 2112-410004-00 WASHER 0000-000056-00 LOCKWASHER Ø6 0000-000259-00 SCREW M6×16 2108-411000-00 TANK 0000-000472-00 CLIP 2108-400002-00-01 OIL RETURN HOSE 0000-000069-00 WASHER Ø16 2701-161600-00 CONNECTOR M16×1.5-M16×1.5...
  • Page 114 R6861A Figure 12-22 Hydraulic System (Telescopic) 12-44 BL-S22-1214 - 02-20-2015...
  • Page 115 Hydraulic System (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-413000-60 HYDRAULIC PUMP ASSEMBLY 0000-000109-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 2112-410004-00 WASHER 0000-000056-00 LOCKWASHER Ø6 0000-000259-00 SCREW M6×16 2108-421000-60 TANK 0000-000472-00 CLIP Used for Lift Height 96” 2108-400002-00-06 OIL RETURN PIPE Used for Lift Height 116”...
  • Page 116 R6862A Figure 12-23 Pump & Motor Assy 12-46 BL-S22-1214 - 02-20-2015...
  • Page 117 Pump & Motor Assy QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-422001-00 DC MOTOR 2108-422002-00 RELAY STARTER 2108-422003-00 RELIEF VALVE 2108-422004-00 SCREW PLUG 2108-422005-00 VALVE 2108-422006-00 PLASTIC VALVE PLUG 2108-422007-00 CHECK VALVE PLUG 2108-422008-00 SCREW PLUG 2108-422009-00 PLASTIC VALVE PLUG 2108-422010-00 SOLENOID VALVE 2108-422011-00...
  • Page 118 R6863A Figure 12-24 Lift Cylinder (Mono) 12-48 BL-S22-1214 - 02-20-2015...
  • Page 119 Lift Cylinder (Mono) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. Used for Lift Height 62” 2110-410000-00-01 CYLINDER ASSEMBLY Includes position # 8, 9 & 2110-2BG SEAL KIT 2125-410001-00-12 PISTON ROD 2125-410002-00 PISTON 2125-410003-00 COLLAR 2125-410006-00 BUSHING 2110-411000-00-01 CYLINDER TUBE 2125-410004-0A 0000-000084-00 RING WIPER Ø35×43×5-6.5 0000-000370-00...
  • Page 120 R6864A Figure 12-25 Lift Cylinder (Telescopic) 12-50 BL-S22-1214 - 02-20-2015...
  • Page 121 Lift Cylinder (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. Used for Lift Height 96” 2108-410000-60-04 CYLINDER ASSEMBLY Used for Lift Height 116” 2108-410000-60-02 CYLINDER ASSEMBLY Includes position # 8, 9 & 2110-2BG SEAL KIT Used for Lift Height 96” 2125-410001-00-01 PISTON ROD Used for Lift Height 116”...
  • Page 122 R6865A Figure 12-26 Electrical System (Mono) 12-52 BL-S22-1214 - 02-20-2015...

  • Page 123: Fuse Holder

    Electrical System (Mono) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000666-00 SCREW M3×8 1115-520015-00 BUZZER ASSEMBLY Without Hour Meter 1115-510006-00 BATTERY INDICATOR (BDI) Used up to 08/29/2012 1115-520003-00 SWITCH ASSEMBLY Used from 08/30/2012 1115-520019-00 2-WAY SWITCH WITH BLACK CAP Used up to 08/29/2012 1115-500010-00 2 WAY SWITCH KEY Used from 08/30/2012...
  • Page 124 R6865A Figure 12-27 Electrical System (Mono) Continued 12-54 BL-S22-1214 - 02-20-2015...
  • Page 125 Electrical System (Mono) Continued QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-520006-00 LIMIT SWITCH HARNESS 0000-000010-00 SCREW M5×6 0000-000616-00 SCREW M5×10 1115-510008-00 EMERGENCY STOP SWITCH 1115-500006-10 CHARGER CABLE USA 1115-520007-00 FAN ASSEMBLY 1115-500007-00 FAN COVER 0000-000121-00 SCREW M4×35 2108-510000-00 BRACKET 2125-500003-00 LIFTING PROXIMITY SWITCH Used from 05/31/2013...
  • Page 126 R6866A Figure 12-28 Electrical System (Telescopic) 12-56 BL-S22-1214 - 02-20-2015...
  • Page 127 Electrical System (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 000-000666-00 SCREW M3×8 1115-520015-00 BUZZER ASSEMBLY Without Hour Meter 1115-510006-00 BATTERY INDICATOR (BDI) 1115-520003-00 2-WAY SWITCH ASSEMBLY 1120-500016-00 2 WAY SWITCH KEY 1115-520013-00 LED LAMP WIRE HARNESS For BDI without Hour 1115-520005-0A HARNESS FOR BATTERY INDICATOR Meter...
  • Page 128 R6866A Figure 12-29 Electrical System (Telescopic) Continued 12-58 BL-S22-1214 - 02-20-2015...
  • Page 129 Electrical System (Telescopic) Continued QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-520006-00 LIMIT SWITCH HARNESS 0000-000010-00 SCREW M5×6 0000-000616-00 SCREW M5×10 1115-510008-00 EMERGENCY STOP SWITCH 1115-500006-10 CHARGER CABLE USA 2125-500003-00 LIFTING PROXIMITY SWITCH Used from 05/31/2013 1115-510009-00 LAMP HOLDER Used from 08/15/2012 1115-500009-00 CHARGER HOOP BL-S22-1214 - 02-20-2015...
  • Page 130 R6868A Figure 12-30 Wiring Harness 12-60 BL-S22-1214 - 02-20-2015...
  • Page 131 Wiring Harness QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-520001-00 MASTER WIRING HARNESS 1120-500010-00 FUSE 10A Not pictured 2108-520008-00 REMOTE CONTROL HARNESS BL-S22-1214 - 02-20-2015 12-61...
  • Page 132 R6869A Figure 12-31 Wiring Cables (Mono) 12-62 BL-S22-1214 - 02-20-2015...
  • Page 133 Wiring Cables (Mono) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-530006-00 P- CABLE 2108-530005-00 P+ CABLE 2108-530009-00 C3 CABLE 2108-530010-00 C4 CABLE 2108-530008-00 C2 CABLE 2108-530007-00 C1 CABLE 2108-530001-00 B+ CABLE 2108-530004-00 M2 CABLE 2108-530003-00 M1 CABLE 2108-530002-00 B- CABLE 0000-000646-00 SCREW M4×10 0000-000004-00...
  • Page 134 R6870A Figure 12-32 Wiring Cables (Telescopic) 12-64 BL-S22-1214 - 02-20-2015...
  • Page 135 Wiring Cables (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2108-530006-60 P- CABLE 2108-530005-60 P+ CABLE 2108-530009-60 C3 CABLE 2108-530010-60 C4 CABLE 2108-530008-60 C2 CABLE 2108-530007-60 C1 CABLE 2108-530001-60 B+ CABLE 2108-530004-60 M2 CABLE 2108-530003-60 M1 CABLE 2108-530002-60 B- CABLE 0000-000646-00 SCREW M4×10 0000-000004-00...
  • Page 136 R8006 Figure 12-33 Windshield (Telescopic) 12-66 BL-S22-1214 - 02-20-2015...
  • Page 137 Windshield (Telescopic) QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. Used up to Serial # 1220-150007-00 SCREW M8X25 A.R. S2316069 Used from Serial # 0000-001176-00 NUT M8 A.R. S2316070 2214-150002-00 WASHER Used up to Serial # S2118082 - 2108-610004-00 WINDSHIELD Lift Height 96” - 6 Bolts Used up to Serial # S2118082 - 2108-610004-01...
  • Page 138 Big Lift LLC...

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