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G-S22-0812

12-41

INDEX

NO.

PART

NO.

PART NAME

NO.

REQD.

0000-000666-00

SCREW, M3 X 8

1115-520015-00

BUZZER

1115-520003-00

KEY SWITCH

1120-500016-00

• KEY

1115-520013-00

LED INDICATOR

1115-520005-00

BATTERY INDICATOR
(WITHOUT HOURMETER)

1115-520005-20

HARNESS, INDICATOR
(WITHOUT HOURMETER)

1115-520005-30

BATTERY INDICATOR
(WITH HOURMETER)

0000-000664-00

SCREW, M4 X 40

0000-000122-00

WASHER, LOCK, M4

1115-510004-00

CONTROLLER

1115-510005-00

HEATSINK

0000-000010-00

SCREW, M5 X 6

2108-520006-00

SWITCH, LIMIT

0000-000378-00

SCREW, M4 X 16

1120-500005-00

TERMINAL

0000-000196-00

NUT, M8

0000-000194-00

WASHER, FLAT, M8

1115-510003-00

FUSE, 100A

0000-000126-00

SCREW, M6 X 16

1120-540001-00

FUSE HOLDER

0000-000109-00

SCREW, M8 X 16

0000-000159-00

WASHER, LOCK, M8

0000-000176-00

WASHER, FLAT, M8

—

BATTERY

0000-000088-00

SCREW, M4 X 8

0000-000702-00

WASHER, FLAT, M4

2108-520014-00

CHARGER ASSEMBLY

0000-000616-00

SCREW, M5 X 10

1115-510008-00

EMERGENCY STOP
SWITCH

2108-540000-00

BRACKET

1115-500006-10

CHARGER CABLE

INDEX

NO.

PART

NO.

PART NAME

NO.

REQD.

Содержание EPS-22

Страница 1: ...RUCK ISSUE DATE APRIL 3 2014 REV 0 PART 038 925E WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual Failure to do so may result in property damage bodily injury or death ...

Страница 2: ...al care when operating on ramps travel slowly and do not angle or turn Travel with load downhill Do not overload truck Check nameplate for capacity and load center information When using forks space forks as far apart as load will permit Before lifting be sure load is centered forks are completely under load and load is as far back as possible against load backrest Do not handle unstable or loosel...

Страница 3: ...N 5 2 5 1 3 CONTROL HEAD REMOVAL 5 3 5 1 4 CONTROL HEAD INSTALLATION 5 3 5 1 5 SPEED POTENTIOMETER REPLACEMENT 5 3 5 1 6 BELLY BUTTON SWITCH REPLACEMENT 5 3 5 1 7 HORN SWITCH REPLACEMENT 5 4 5 1 8 LIFT AND LOWER SWITCH REPLACEMENT 5 6 5 2 STEERING ARM 5 6 5 2 1 RETURN SPRING REPLACEMENT 5 6 5 2 2 STEERING ARM REMOVAL 5 6 5 2 3 STEERING ARM INSTALLATION 5 6 5 3 COMPARTMENT COVERS 5 6 5 3 1 REMOVAL ...

Страница 4: ... 6 2 7 1 TRANSMISSION MOTOR BRAKE MOUNTING 7 2 8 1 CHAIN ASSEMBLY MONO 8 1 8 2 CHAIN ASSEMBLY TELESCOPIC 8 2 9 1 HYDRAULIC SYSTEM MONO 9 1 9 2 HYDRAULIC SYSTEM TELESCOPIC 9 2 9 3 ELEVATION SYSTEM MONO 9 4 9 4 LIFT CYLINDER MONO 9 5 9 5 LIFT CYLINDER TELESCOPIC 9 6 9 6 ELEVATION SYSTEM TELESCOPIC 9 7 10 1 ELECTRICAL SYSTEM MONO 10 2 10 2 ELECTRICAL SYSTEM TELESCOPIC 10 3 12 1 STEERING SYSTEM 12 2 1...

Страница 5: ...ngineered to provide maximum safety for operator and payload Some of the safety features incorporated into the design are Figure 1 1 Name Plate Dead man brake to apply the brake and cut off drive power when the steering arm is released Emergency brake switch to apply the brake and cut off drive power when depressed Belly button switch to reverse truck should the oper ator accidentally pin himself ...

Страница 6: ...rol handle 2 Key switch 3 LED indicator 4 Mast cover 5 Lift cylinder 6 Battery indicator 7 Battery charger connector 8 Emergency brake switch 9 Forks 10 Battery 11 Chassis 12 Caster 13 Cover 14 Drive wheel 15 Cover 16 Hydraulic reservoir 17 Hydraulic pump ITEM COMPONENT ...

Страница 7: ...alified person on a regular basis Do not exceed the rated capacity Overloading may result in damage to the hydraulic system and struc tural components Be certain that the lifting mechanism is operating smoothly throughout its entire height both empty and loaded Be sure that mast is vertical do not operate on a side slope Be sure the truck has a firm and level footing Avoid overhead wires and obstr...

Страница 8: ... until it has been restored to a safe operating condition Do not make any unauthorized repairs or adjustments All service must be performed by a qualified maintenance technician Table 2 1 Operator Checks ITEM PROCEDURE Transmission and hydraulic systems Check for signs of fluid leakage Forks Check for cracks and damage and that they are properly secured Chains cables and hoses Check that they are ...

Страница 9: ... Check Off List Date Big Joe Manufacturing Company Operator Truck No Model No Dept Check Tires Load Wheels Horn Lift Lower Control Need Maintenance O K Shift Hour Meter Reading Drive Hoist Attachment Operation Forward Reverse Controls Steering Brakes Hydraulic Leaks Cylinders Valves Hoses Etc ...

Страница 10: ...gages slowing or stopping the truck 5 Procedures for movement in reverse are the same as in the forward direction except slowly press the speed control backward See Figure 2 3 2 5 1 Stopping The brake pattern of the truck depends on the ground conditions The driver must take this into account when operating the truck The driver must be looking ahead when traveling If there is no hazard brake moder...

Страница 11: ...uttons are located on the steering control head Figure 2 4 To lift forks push in either LIFT button and hold until forks reach desired height To lower forks push in either LOWER button and hold until forks descend to desired height 2 9 LOADING AND UNLOADING 1 Move truck to location where load is to be picked up 2 Move the truck into position so forks are within pallet or skid and the load is cente...

Страница 12: ...2 6 BG S22 0812 NOTES ...

Страница 13: ...hen eyes are affected A baking soda solution one pound to one gallon of water applied to spilled acid until bub bling stops neutralizes the acid for safe handing and disposal Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system Since components of the truck elec trical system are insulated from truck frame leakage voltage wil...

Страница 14: ...hecked and cleaned of corrosion regularly Good battery terminal con tact is essential not only for operation but also for proper charging of the battery 3 The charging requirements will vary depending on the use of the truck The battery should be given as equalizing charge on a weekly basis This charge should normally be an additional three hours at the finish rate 4 Make certain battery used meet...

Страница 15: ...empt to charge the batteries Contact appropriate personnel for repairs to be made 3 Pull the charger cord out of the cover 1 Figure 3 1 and connect to the appropriate power supply 4 The LED 2 flashes red to indicate that the charger is connected 5 Charge the batteries until the LED 2 produces a permanent green light 6 Disconnect the charger cord and insert it in its receptacle on the truck Figure ...

Страница 16: ...ains as they move over chain sheaves Ensure chain is aligned and tracking properly and all links are pivoting freely With lift carriage fully lowered spray or brush on a film of SAE 30 or 40 engine oil Table 3 2 Recommended Lubricants See Table 3 3 for Application R6874 R6875 No 1 Transmission oil EP SAE 80W 90 Transmission oil EP SAE 10W 30 Note No 2 Grease Lithium base general purpose No 3 Hydra...

Страница 17: ...st Brush No 2 Full length of channel where rollers operate 2 Lift Chain Brush or Spray No 4 See Paragraph 3 7 3 Lift Carriage Brush No 2 Light coating where forks slide 4 Transmission Capacity 2 pints Can No 1 Fill to level plug 5 Hydraulic Reservoir Capacity 1 quarts Can No 3 With lift carriage fully lowered fill reservoir with hydraulic oil to level on breather dip stick R6871 ...

Страница 18: ...3 6 BG S22 0812 NOTES ...

Страница 19: ...23 defective Bypass keyswitch to determine if it is malfunctioning f Defective wiring Check for open circuit Repair as required TRUCK DOES NOT OPERATE FORWARD OR REVERSE Truck does not travel forward or reverse All other functions oper ate normally a Check all wiring A loose con nection may be the cause of malfunction Tighten all loose connections before further troubleshooting b Defective deadman...

Страница 20: ...BLE WITH LIFTING OR LOWERING Oil sprays or flows from the top of the lift cylinder Defective packing in lift cylinder Repair lift cylinder Squealing sounds when lifting forks a Oil level too low Identify oil leak and fill reservoir b Dry channels in mast Apply grease c Defective mast or carriage roll ers Replace rollers Forks do not lift to top a Oil level too low Add oil to reservoir b Load large...

Страница 21: ...oad larger than capacity Refer to nameplate on side of mast for maximum load capacity c Batteries need charging Change batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylin der or lowering valve Check for leaking fitting in hydrau lic line and repair as required Repack lift cylinder or replace valve assembly Figure 12 19 MISCELLANEOUS Steering arm ...

Страница 22: ...he following checkout procedure If you find a problem during the checkout refer to paragraph 4 2 8 for further information The checkout can be conducted with or without the handheld programmer See Paragraph 4 2 2 How ever the checkout procedure is easier with a program mer To evaluate the system without a programmer observe the LED and note the flashing pattern and refer to Table 4 3 for the code ...

Страница 23: ...orward reverse switches and motor The motor should run proportionally faster with increasing throttle If not refer to Paragraph 4 2 8 5 Put the controller into the test mode by using the Navigation key 1 to select the Monitor menu Select the Monitor mode by pressing the Right arrow on the Navigation key Press the Navigation key Down arrow to scroll down to observe the status of the forward reverse...

Страница 24: ...2 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 5 Leave the key switch on and remove the in line fuse wire The vehicle status should continue to remain off 6 Cycle the key switch off and on Release the brake and apply the throttle The vehicle should now operate normally 4 2 7 Programmable Parameters The controller has a number of parameters that can be programmed using the handheld pr...

Страница 25: ...eed setting Decel Low Speed 8 Sets the rate in seconds that is used to slow down the vehicle when it s traveling forward at low speed and throttle is reduced Larger values represent slower response Note Allowable range is restricted by the Decel High Speed setting Rev Accel Max Speed 1 5 Sets the rate in seconds at which the speed command increases when throttle is applied while the speed limit po...

Страница 26: ... with gear slack in the transaxle when throttle is applied from the neutral state Larger values provide a softer slack take up Gear Soften 100 This parameter is intended to soften the bump associated with gear slack in the transaxle when throttle is released and then reapplied while the vehicle is still moving Larger values pro vide a softer slack take up Creep Speed 10 Creep Speed helps to preven...

Страница 27: ...ply a speed limit pot must be installed in parallel with the throttle and the Speed Limit Pot parameter must be programmed On see Throttle menu M1 M2 Rev Max Speed 100 During reverse operation defines the requested speed at full throttle when he speed limit pot is in its maximum speed posi tion Note Allowable range is restricted by M1 M2 Rev Min Speed setting M1 M2 Rev Min Speed M1 100 M2 60 Durin...

Страница 28: ...hrottle itself Neutral Deadband 30 Sets the throttle range the controller interprets as neutral Increasing the parameter setting increases the neutral range This parameter allows the neutral deadband to be defined wide enough to ensure the controller goes into neutral when the throttle is released Throttle Max 100 Sets the pot wiper voltage required to produce 100 controller output Increasing the ...

Страница 29: ... driving and puts the controller into throttle autocalibration mode Setting the parameter Off returns the controller to normal oper ation CURRENT MENU Main Current Limit 70 Sets the maximum current the controller will supply to the motor during normal driving By limiting the current supplied this parameter can be used to protect the motor from poten tially damaging currents or to reduce the maximu...

Страница 30: ...4 A high initial voltage is applied to the brake coil when the brake is first released After approximately 1 second this peak volt age drops to the programmed Hold Voltage The parameter should be set high enough to hold the brake released under all the shock and vibration conditions the vehicle will be sub jected to Brake Light OFF When set to On the horn output J1 Pin 3 will act as a brake light ...

Страница 31: ...te varia tions in maximum speed that would otherwise result when driving with a fully charged battery vs a partially discharged battery If Speed Scaler is set to 23 volts for example the maximum vehicle speed will be the same whether the actual battery voltage is 27 volts or 23 volts or any value in between Current Rating 70 This parameter should be set to the current rating provided by the motor ...

Страница 32: ...le speed when the battery charge falls below the programmed Low BDI Level COMPENSATION MENU IR Comp 90 Sets the motor load compensation Higher values provide stronger disturbance rejection while lower values provide smoother operation Note Allowable range is restricted by the Anti Rollback Comp setting Anti Rollback Comp 125 Sets the motor load compensation after the throttle is released to neutra...

Страница 33: ...ith the LED alone The programmer presents complete diagnostic information in plain lan guage no code to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The following 4 step process is generally used for diagnosing and troubleshooting an inoperative vehicle using the programmer 1 Visually inspect the vehicle for obvi...

Страница 34: ...e does not correspond to throttle request 2 Short in motor or in motor wiring 3 Controller failure 6 HPD Fault HPD High Pedal Disable 1 Improper sequence of throttle and KSI push or inhibit pot 2 Misadjusted throttle pot 9 Main Fault Main contactor fault 1 Main contractor welded or stuck open 2 Main contactor driver fault 9 Main OFF Fault Main contactor driver Off fault Main contactor driver faile...

Страница 35: ...d or PotWiper out of range 1 Throttle input wire open or shorted 2 Throttle pot defective 3 Wrong throttle type selected 2 Undervoltage Fault Battery voltage too low 1 Battery voltage 17 volts 2 Bad connection at battery or control ler 6 Wiring Fault HPD fault present 10 sec 1 Misadjusted throttle 2 Broken throttle pot or throttle mecha nism ...

Страница 36: ...4 18 B 6 NOTES ...

Страница 37: ...p Assembly Removal 1 Engage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn off key switch 4 Figure 12 22 or 3 Figure 12 23 2 Remove four screws 17 Figure 5 1 lift up cap assembly 21 and disconnect harness 23 from harness 15 Figure 5 2 Figure 5 1 Control Head R6808 ...

Страница 38: ... connect harness 23 to harness 15 Figure 5 2 2 Position cap assembly 21 Figure 5 1 on control head and secure with four screws 17 1 Disengage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 Figure 5 2 Steering Arm R6846 ...

Страница 39: ...and flat washer 7 6 Remove screw 16 lock washer 6 and flat washer 7 and remove potentiometer 15 from bracket 20 7 Position new potentiometer 15 in bracket 20 and secure with screw 16 lock washer 6 and flat washer 7 8 Install screw 1 lock washer 6 and flat washer 7 9 Install control knob 14 on potentiometer 15 and secure with screw 4 and washer 3 10 Install control knob 2 on the other side of poten...

Страница 40: ...Figure 5 4 bracket 14 and springs 13 3 Remove two pins 12 and defective switch from bracket 14 4 Unsolder harness from defective switch and con nect it to the new switch 5 Position the new switch in bracket 14 and secure with two pins 12 6 Position bracket 14 in cover 17 and secure with three screws 11 7 Install the cap assembly as described in para graph 5 1 2 R6810 ...

Страница 41: ...B 6 5 5 Figure 5 4 Cap Assembly R6847 ...

Страница 42: ...posite end of the gas return spring 12 on bracket 5 and install screw 1 8 Install rotating cover 6 Figure 12 6 and secure with three screws 5 9 Disengage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 5 2 2 Steering Arm Removal 1 Engage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn off key switch 4 Figure...

Страница 43: ...tch 4 Figure 12 22 or 3 Figure 12 23 2 Remove six screws 1 Figure 12 6 and six wash ers 2 and remove cover 3 5 4 2 Installation 3 Install cover 3 Figure 12 6 and secure with six screws 1 and six washers 2 4 Disengage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 ...

Страница 44: ...5 8 B 6 NOTES ...

Страница 45: ...s to the brake then securely block the truck to prevent move ment 3 Disconnect electric brake from harness 1 Figure 12 24 or Figure 12 25 4 Remove the two mounting screws 2 Figure 6 1 and the brake 5 Place the new brake into position and secure with the two mounting screws 6 Reconnect electric brake to harness 1 Figure 12 24 or Figure 12 25 7 Remove the blocking and lower the truck to the ground 8...

Страница 46: ...6 2 B 6 Figure 6 1 Transmission Motor Brake Assembly R6848 ...

Страница 47: ...urn off key switch 4 Figure 12 22 or 3 Figure 12 23 2 Remove the compartment covers as described in paragraph 5 3 3 Remove the steering arm as described in para graph 5 2 4 Raise the truck off the ground to provide clear ance for transmission out the bottom Securely block the truck to prevent movement 5 Remove two screws 5 Figure 12 6 and bracket 7 6 Disconnect electric brake 1 Figure 7 1 from har...

Страница 48: ...7 2 B 6 Figure 7 1 Transmission Motor Brake Mounting R6848 ...

Страница 49: ...pect 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 This ensures level and safe operation of the lift truck 7 3 2 Repair 1 Remove bearings 8 Figure 12 8 or Figure 12 9 from wheels 9 2 Inspect bearings 8 an...

Страница 50: ...7 4 B 6 NOTES ...

Страница 51: ...cated the above either the frame or the lift carriage to allow for adjustment of middle jam nut 4 Break the lower jam nut 3 free from the middle jam nut 3 5 Take up slack in the lift chain with middle jam nut 3 6 Align anchor 2 so the clevis pin 4 is parallel to the mast CAUTION At least 3 full threads must be present below lower nut 3 after adjustment 7 Tighten jam nuts securely while maintaining...

Страница 52: ...stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 9 Test chain by operating carriage If slack is still apparent repeat above procedure 8 3 LIFT CHAIN WEAR INSPECTION The lift chain should be replaced when it is worn enough to increase it s length by 3 or more On Tele cospic trucks Both chains should be replaced at the same time To make this dete...

Страница 53: ... Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 8 4 2 Telescopic 1 With the lift truck wheels securely blocked raise the forks approximately three feet from floor and position blocks or strong supports under the inner mast 2 Lower inner mast onto the support Check that arrangement is secure before proceeding 3 Engage the emergency stop switch 31 Figure 12 2...

Страница 54: ...8 4 B 6 NOTES ...

Страница 55: ...r forks fully 2 Engage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn off key switch 4 Figure 12 22 or 3 Figure 12 23 3 Remove the compartment covers as described in paragraph 5 3 4 Remove the mono mast cover as described in paragraph 5 3 CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 5 ...

Страница 56: ...Use hydraulic oil listed in Table 3 2 10 Install the compartment covers as described in paragraph 5 3 11 Install the mono mast cover as described in para graph 5 3 9 2 HYDRAULIC PUMP MOTOR AND RESER VOIR ASSY The hydraulic pump motor assembly can be disas sembled and repaired However a defective pump valve or motor requires replacement of that compo nent WARNING When forks are raised pressure exis...

Страница 57: ... to refill the cylinder and lines with hydraulic oil 7 Check level of hydraulic oil If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 8 Install the compartment covers as described in paragraph 5 3 9 3 Lift Cylinder Mono 9 3 1 Removal 1 With the lift truck wheels securely blocked raise the forks approximately three feet from floor and position blocks or st...

Страница 58: ...9 4 B 6 Figure 9 3 Elevation System Mono R6854 ...

Страница 59: ...st 2 Install clip 10 Figure 9 3 and secure with two bolts 9 two lock washers 12 two flat washers 13 3 Install ram head 5 on top of cylinder 11 and secure with screw 6 lock washer 7 and flat washer 8 4 Install the lift chain as described in paragraph 8 4 5 Install connector 12 Figure 9 1 and seal 11 6 Reconnect the hose 13 to the bottom of lift cylin der 7 Reconnect the hose 10 to the top of lift c...

Страница 60: ...r from falling 7 Remove screw 10 lock washer 11 and flat washer 12 securing the top of the cylinder 8 Remove screw 32 lock washer 11 and flat washer 12 securing the bottom of the cylinder 9 Manually push the cylinder rod down as far as possible 10 Raise lift cylinder assembly 15 up and out of truck 9 4 2 Repair CAUTION To prevent damage use proper pipe clamp vise The cylinder will be distorted if ...

Страница 61: ...B 6 9 7 Figure 9 6 Elevation System Telescopic R6855 ...

Страница 62: ...ct the hose 10 to the top of lift cylinder 6 Fill the hydraulic reservoir Use hydraulic oil listed in Table 3 2 7 Disengage the emergency stop switch 31 Figure 12 22 or 28 Figure 12 23 and turn on key switch 4 Figure 12 22 or 3 Figure 12 23 8 Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil 9 Check level of hydraulic oil If required add hydraulic oil to bring ...

Страница 63: ...f key switch 4 Figure 10 1 or 3 Figure 10 2 2 Remove the compartment covers as described in paragraph 5 3 3 Tag and disconnect harness 1 Figure 12 24 or Figure 12 25 from controller 13 Figure 10 1 or 9 Figure 10 2 4 Tag and disconnect remaining leads from the controller Refer to Figure 12 26 or Figure 12 27 5 Remove mounting screws lock washers and remove controller 13 Figure 10 1 or 9 Figure 10 2...

Страница 64: ...10 2 BG S22 0812 Figure 10 1 Electrical System Mono R6865 ...

Страница 65: ...BG S22 0812 10 3 Figure 10 2 Electrical System Telescopic R6866 ...

Страница 66: ...gure 12 25 to buzzer 10 Figure 10 1 or 2 Figure 10 2 3 Install upper compartment covers as described in paragraph 5 3 4 Disengage the emergency stop switch 31 Figure 10 1 or 28 Figure 10 2 and turn on key switch 4 Figure 10 1 or 3 Figure 10 2 10 1 11 Key Switch Removal 1 Engage the emergency stop switch 31 Figure 10 1 or 28 Figure 10 2 and turn off key switch 4 Figure 10 1 or 3 Figure 10 2 2 Remov...

Страница 67: ...the emer gency disconnect from the bracket 10 1 18 Emergency Disconnect Installation 1 Position emergency disconnect 31 Figure 10 1 or 28 Figure 10 2 on the bracket and secure with two screws 2 Install the knob on the emergency disconnect 3 Reconnect cables 3 and 4 Figure 12 26 or Fig ure 12 27 to emergency disconnect 31 Figure 10 1 or 28 Figure 10 2 4 Install compartment covers as described in pa...

Страница 68: ...dman switch 16 Figure 12 1 4 Remove the two screws 9 and bracket 8 from bracket 5 5 Remove two screws 7 and switch 16 from bracket 8 6 Position the new switch 16 on bracket 8 and secure with the two screws 7 7 Position bracket 8 on bracket 5 and secure with two screws 9 8 Install compartment covers as described in para graph 5 3 9 Disengage the emergency stop switch 31 Figure 10 1 or 28 Figure 10 ...

Страница 69: ...BG S22 0812 11 1 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 ...

Страница 70: ...11 2 BG S22 0812 NOTES ...

Страница 71: ...BG S22 0812 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the S22 Lift Truck ...

Страница 72: ...12 2 BG S22 0812 Figure 12 1 Steering System R6846 ...

Страница 73: ...00016 00 SCREW M5 x 8 1 7 0000 000120 00 SCREW M2 x 8 2 8 1115 500001 00 BRACKET 1 9 0000 000651 00 SCREW M4 x 8 2 10 CONTROL HEAD FIGURE 12 2 REF 11 2108 300002 00 SHAFT 1 12 1120 320000 00 GAS SPRING 1 13 1115 310000 00 STEERING ARM 1 14 0000 000677 00 BUSHING 1610 2 15 1115 520010 00 WIRING HARNESS 1 16 1115 520009 0A DEADMAN SWITCH 1 17 1115 520017 00 POTENTIOMETER WIRING HARNESS 1 INDEX NO PA...

Страница 74: ...12 4 BG S22 0812 Figure 12 2 Control Head R6808 ...

Страница 75: ... 0000 000322 00 SCREW M8 X 25 2 12 0000 000159 00 WASHER LOCK M8 2 13 0000 000176 00 WASHER FLAT M8 2 14 1120 340003 00 CONTROL KNOB 1 15 1220 520008 00 POTENTIOMETER 1 16 0000 000004 00 SCREW M5 X 12 1 17 0000 000035 00 SCREW M5 X 20 4 18 1120 340002 00 COVER 1 19 1120 341000 00 HANDLE 1 20 1120 340001 00 CONNECTOR BRACKET 1 21 2125 342000 00 B CAP ASSEMBLY 2 SPEED LOWERING 1 22 CAP ASSEMBLY FIGU...

Страница 76: ...12 6 BG S22 0812 Figure 12 3 Cap Assembly R6847 ...

Страница 77: ...20 342102 00 SPRING 8 5 1120 342201 00 BUTTON BRACKET RIGHT 1 6 1120 342105 00 PIN 6 7 1120 342104 00 BUTTON LIFT LEFT 1 8 1120 342103 00 BUTTON LOWERING LEFT TWO SPEED 1 9 1120 342101 00 BUTTON BRACKET LEFT 1 10 1120 342002 00 HORN BUTTON 1 11 0000 000039 00 SCREW 3 12 1120 342005 00 PIN 2 13 1120 342003 00 SPRING 2 14 1120 342004 00 HORN SWITCH BRACKET 1 15 0000 000490 00 CLAMP 3 16 0000 000039 ...

Страница 78: ...R6810 INDEX NO PART NO PART NAME NO REQD 1120 343000 00 EMERGENCY REVERSE SWITCH ASSY 1 1 1120 343002 00 EMERGENCY REVERSE BUTTON 1 2 1120 343003 00 SPRING 2 3 1120 342005 00 PIN 2 4 1120 343001 0A BRACKET 1 5 1120 343004 00 PIN 1 INDEX NO PART NO PART NAME NO REQD ...

Страница 79: ...BG S22 0812 12 9 NOTES ...

Страница 80: ...12 10 BG S22 0812 Figure 12 5 Transmission Motor Brake Assembly R6848 ...

Страница 81: ...0659 00 CLIP M15 2 16 0000 000667 00 BEARING 61905Z 1 17 GEAR SET REPLACE BOTH 1 17A 1115 200004 00 GEAR 1 17B 1115 200005 00 GEAR 1 18 0000 000680 00 BEARING 16003Z 1 19 GEAR SET REPLACE BOTH 1 19A 1115 200002 00 GEAR LOOP 1 19B 1115 200003 00 GEAR 1 20 0000 000660 00 KEY 5 X 5 X 18 1 21 0000 000154 00 SCREW M8 X 35 5 22 0000 000159 00 WASHER LOCK M8 5 23 0000 000670 00 SEAL M155 X 172 X 10 1 24 ...

Страница 82: ...12 12 BG S22 0812 Figure 12 6 Compartment Mono R6849 ...

Страница 83: ...100006 00 SCREW M6 X 10 8 2 2214 150002 00 WASHER M6 8 3 2108 100001 00 01 COVER 1 4 2108 100002 00 COVER 1 5 0000 000179 00 SCREW M6 X 10 5 6 2108 100004 00 ROTATION COVER 1 7 2108 100005 00 BRACKET 1 8 2108 100003 00 COVER 1 INDEX NO PART NO PART NAME NO REQD ...

Страница 84: ...12 14 BG S22 0812 Figure 12 7 Compartment Telescopic R6850 ...

Страница 85: ...O REQD 1 2108 100006 00 SCREW M6 X 10 8 2 2214 150002 00 WASHER M6 8 3 2108 100002 00 COVER 1 4 0000 000179 00 SCREW M6 X 10 5 5 2108 100004 00 ROTATION COVER 1 6 2108 100005 00 BRACKET 1 7 2108 100003 00 COVER 1 INDEX NO PART NO PART NAME NO REQD ...

Страница 86: ...12 16 BG S22 0812 Figure 12 8 Adjustable Straddle Mono R6851 ...

Страница 87: ... 10 5 2130 110000 00 FRAME 1 6 0000 000218 00 SCREW M6 X 16 4 7 2125 101003 00 WASHER 8 8 0000 000424 00 BEARING 6205 2Z 8 9 2125 101001 00 LOAD WHEEL 4 10 2125 101002 00 SHAFT 4 11 2108 130000 10 STRADDLE RIGHT 1 12 2108 120000 10 STRADDLE LEFT 1 13 0000 000703 00 SCREW M16 X 45 6 14 0000 000191 00 WASHER LOCK M16 6 15 0000 000541 00 WASHER FLAT M16 6 INDEX NO PART NO PART NAME NO REQD ...

Страница 88: ...12 18 BG S22 0812 Figure 12 9 Adjustable Straddle Telescopic R6852 ...

Страница 89: ... 10 5 2108 110000 60 FRAME 1 6 0000 000218 00 SCREW M6 X 16 4 7 2125 101003 00 WASHER 8 8 0000 000424 00 BEARING 6205 2Z 8 9 2125 101001 00 LOAD WHEEL 4 10 2125 101002 00 SHAFT 4 11 2108 130000 10 STRADDLE RIGHT 1 12 2108 120000 10 STRADDLE LEFT 1 13 0000 000703 00 SCREW M16 X 45 6 14 0000 000191 00 WASHER LOCK M16 6 15 0000 000541 00 WASHER FLAT M16 6 INDEX NO PART NO PART NAME NO REQD ...

Страница 90: ...12 20 BG S22 0812 Figure 12 10 Caster R6853 ...

Страница 91: ...ARING BLOCK 1 6 0000 000421 00 BEARING 6306 2RZ 1 7 2108 140001 10 SPRING 2 8 2140 141000 00 HOUSING 1 9 0000 000242 00 SCREW M8 X 16 2 10 0000 000159 00 WASHER LOCK M8 2 11 2140 142000 00 HINGE PIN 1 12 2140 145000 00 SHAFT 1 13 2140 140003 00 SHAFT 2 14 2140 143000 00 CASTER HOUSING 1 15 2140 144002 00 CASTER WHEEL 1 16 0000 000424 00 BEARING 6205 2Z 2 17 0000 000249 00 WASHER FLAT M24 2 INDEX N...

Страница 92: ...12 22 BG S22 0812 Figure 12 11 Elevation System Mono R6854 ...

Страница 93: ... CHAIN SHEAVES 1 5 2108 620000 00 RAM HEAD 1 6 0000 000374 00 SCREW M12 X 30 1 7 0000 000060 00 WASHER LOCK M12 1 8 0000 000373 00 WASHER FLAT M12 1 9 0000 000321 00 SCREW M8 X 20 4 10 2108 600004 00 CLIP CYLINDER 1 11 LIFT CYLINDER FIGURE 12 20 REF 12 0000 000159 00 WASHER LOCK M8 4 13 0000 000176 00 WASHER FLAT M8 4 INDEX NO PART NO PART NAME NO REQD ...

Страница 94: ...12 24 BG S22 0812 Figure 12 12 Elevation System Telescopic R6855 ...

Страница 95: ...0001 60 BUSHING 1 15 LIFT CYLINDER FIGURE 12 21 REF 16 2108 632000 60 ROLLER ASSEMBLY 8 17 2108 600006 60 COLUMN 2 18 0000 000777 00 STEEL BALL 4 19 2108 600007 60 ROLLER 2 20 0000 000420 00 BEARING 6206 2 21 0000 000434 00 RETAINING RING 2 22 0000 000762 00 SNAP RING 8 23 0000 000761 00 SCREW M12 X 20 2 24 2108 600008 60 ROLLER 2 25 0000 000759 00 BEARING 3205 2 26 2108 600009 60 BEARING BLOCK 2 ...

Страница 96: ...12 26 BG S22 0812 Figure 12 13 Lift Carriage Mono R6856 ...

Страница 97: ...EW M10 X 20 1 4 0000 000063 00 WASHER LOCK M10 1 5 2125 631100 00 ROLLER ASSEMBLY 4 6 2125 612007 00 SNAP RING 4 7 2125 612002 00 BRACKET 4 8 2125 612001 00 ROLLER 4 9 2125 612005 00 DUST SEAL 4 10 0000 000183 00 RETAINING RING M35 4 11 2125 631104 00 SCREW 4 12 2108 631000 10 CARRIAGE 1 INDEX NO PART NO PART NAME NO REQD ...

Страница 98: ...12 28 BG S22 0812 Figure 12 14 Lift Carriage Telescopic R6857 ...

Страница 99: ...CK SUPPORT 1 5 2108 632000 60 ROLLER ASSEMBLY 4 6 2108 600006 60 COLUMN 4 7 0000 000761 00 SCREW M12 X 20 4 8 0000 000777 00 STEEL BALL 4 9 2108 600007 60 ROLLER 2 10 0000 000420 00 BEARING 6206 2 11 0000 000434 00 RETAINING RING 2 12 0000 000762 00 SNAP RING 8 13 2108 631000 60 CARRIAGE 1 14 2125 630001 00 FORK 2 15 2125 630001 10 LOCK 2 INDEX NO PART NO PART NAME NO REQD ...

Страница 100: ... 12 15 Chain Assembly Mono R6858 INDEX NO PART NO PART NAME NO REQD 1 2108 640000 00 01 CHAIN 63 LINKS 1 2 2108 640001 00 ADJUSTING SCREW 2 3 0000 000237 00 NUT M16 X 1 5 6 4 2108 640002 00 PIN 2 5 0000 000188 00 PIN COTTER 4 ...

Страница 101: ...ART NO PART NAME NO REQD 1 2125 640001 60 01 CHAIN 96 IN LIFT 131 LINKS 2 1 2125 640001 60 02 CHAIN 116 IN LIFT 143 LINKS 2 2 2108 640002 60 ADJUSTING SCREW 2 3 0000 000237 00 NUT M16 X 1 5 6 4 0000 000220 00 WASHER M16 4 5 0000 000188 00 PIN COTTER 8 6 0000 000779 00 PIN 4 ...

Страница 102: ...000176 00 WASHER FLAT M8 3 5 2112 410004 00 SPACER 3 6 0000 000056 00 WASHER LOCK M6 4 7 0000 000259 00 SCREW M6 X 16 4 8 2108 411000 00 OIL RESERVOIR 1 9 0000 000472 00 CLAMP 2 10 2108 400002 00 01 HOSE 1 11 0000 000069 00 SEAL 1 12 2701 161600 00 CONNECTOR 1 13 2108 400001 00 HOSE 1 14 2112 410002 00 BREATHER 1 15 2702 381600 00 CONNECTOR 1 16 0000 000634 00 SEAL 1 INDEX NO PART NO PART NAME NO ...

Страница 103: ...M8 3 5 2112 410004 00 SPACER 3 6 0000 000056 00 WASHER LOCK M6 4 7 0000 000259 00 SCREW M6 X 16 4 8 2108 411000 60 OIL RESERVOIR 1 9 0000 000472 00 CLAMP 2 10 2108 400002 00 03 HOSE 96 IN LIFT 1 10 2108 400002 00 04 HOSE 116 IN LIFT 1 11 0000 000634 00 SEAL 1 12 2702 381400 00 CONNECTOR 1 13 2112 410002 00 BREATHER 1 14 2108 400001 60 HOSE 1 15 0000 000069 00 SEAL 1 16 2108 400001 60 CONNECTOR 1 I...

Страница 104: ...12 34 BG S22 0812 Figure 12 19 Pump Motor Assy R6862 ...

Страница 105: ...LVE 1 6 2108 422006 00 PLUG PLASTIC 1 7 2108 422007 00 PLUG CHECK VALVE 1 8 2108 422008 00 PLUG 1 9 2108 422009 00 PLUG PLASTIC 1 10 2108 422010 00 SOLENOID VALVE 1 11 2108 422011 00 CHECK VALVE 1 12 2108 422012 00 CONNECTOR 1 13 0000 000763 00 O RING 1 14 2108 422013 00 PUMP GEAR 1 15 2108 422014 SUCTION HOSE 1 16 2108 422015 00 SUCTION FILTER 1 17 2108 422016 00 ESCAPE VALVE 1 INDEX NO PART NO P...

Страница 106: ...ER 1 1 PISTON ROD 1 2 2125 410002 00 PISTON 1 3 2125 410003 00 O RING 1 4 2125 410006 00 BUSHING 1 5 0000 000711 00 BEARING 3530 1 6 CYLINDER TUBE 1 7 2125 410004 0A GLAND NUT 1 8 0000 000084 00 WIPER RING 1 9 0000 000370 00 O RING 1 10 2125 410005 00 GUIDE RING 2 11 0000 000512 00 SEAL 1 2110 2Bg SEAL KIT INCLUDES 3 4 9 ...

Страница 107: ...0 60 02 LIFT CYLINDER 116 IN LIFT 1 1 PISTON ROD 1 2 2125 410002 00 PISTON 1 3 2125 410003 00 O RING 1 4 2125 410006 00 BUSHING 1 5 0000 000711 00 bearing 3530 1 6 CYLINDER TUBE 1 7 2125 410004 0A GLAND NUT 1 8 0000 000084 00 WIPER RING 1 9 0000 000370 00 O RING 1 10 2125 410005 00 GUIDE RING 2 11 0000 000512 00 SEAL 1 2110 2Bg SEAL KIT INCLUDES 3 4 9 ...

Страница 108: ...12 38 BG S22 0812 Figure 12 22 Electrical System Mono R6865 ...

Страница 109: ... 1115 510004 00 CONTROLLER 1 14 1115 510005 00 HEATSINK 1 15 0000 000159 00 WASHER LOCK M8 6 16 0000 000176 00 WASHER FLAT M8 6 17 0000 000378 00 SCREW M4 X 16 2 18 1120 500005 00 TERMINAL 1 19 0000 000010 00 SCREW M5 X 6 4 20 2108 520006 00 SWITCH LIMIT 1 21 0000 000109 00 SCREW M8 X 16 6 22 0000 000702 00 WASHER FLAT M4 6 23 BATTERY 2 24 0000 000088 00 SCREW M4 X 8 4 25 2108 520014 00 CHARGER AS...

Страница 110: ...12 40 BG S22 0812 Figure 12 23 Electrical System Telescopic R6866 ...

Страница 111: ...1 11 0000 000010 00 SCREW M5 X 6 4 12 2108 520006 00 SWITCH LIMIT 1 13 0000 000378 00 SCREW M4 X 16 2 14 1120 500005 00 TERMINAL 1 15 0000 000196 00 NUT M8 2 16 0000 000194 00 WASHER FLAT M8 2 17 1115 510003 00 FUSE 100A 1 18 0000 000126 00 SCREW M6 X 16 2 19 1120 540001 00 FUSE HOLDER 1 20 0000 000109 00 SCREW M8 X 16 6 21 0000 000159 00 WASHER LOCK M8 6 22 0000 000176 00 WASHER FLAT M8 6 23 BATT...

Страница 112: ...12 42 BG S22 0812 Figure 12 24 Wiring Harness Mono R6831 INDEX NO PART NO PART NAME NO REQD 1 2108 520001 00 HARNESS MAIN 1 2 1120 500010 00 FUSE 10A INDEX NO PART NO PART NAME NO REQD ...

Страница 113: ...BG S22 0812 12 43 Figure 12 25 Wiring Harness Telescopic R6868 INDEX NO PART NO PART NAME NO REQD 1 2108 520001 60 HARNESS MAIN 1 2 1120 500010 00 FUSE 10A INDEX NO PART NO PART NAME NO REQD ...

Страница 114: ...BLE C1 1 7 2108 530001 00 CABLE B 1 8 2108 530004 00 CABLE M2 1 9 2108 530003 00 CABLE M1 1 10 2108 530002 00 CABLE B 1 11 1115 231000 00 BRACKET 1 12 0000 000004 00 SCREW M5 X 12 2 13 0000 000108 00 NUT M6 2 14 0000 000056 00 WASHER LOCK M6 2 15 0000 000380 00 WASHER FLAT M6 2 16 0000 000646 00 SCREW M4 X 10 2 17 0000 000277 00 BOLT M8 X 25 4 18 0000 000159 00 WASHER LOCK M8 4 19 0000 000176 00 W...

Страница 115: ... CABLE C1 1 7 2108 530001 60 CABLE B 1 8 2108 530004 60 CABLE M2 1 9 2108 530003 60 CABLE M1 1 10 2108 530002 60 CABLE B 1 11 1115 231000 00 BRACKET 1 12 0000 000004 00 SCREW M5 X 12 2 13 0000 000108 00 NUT M6 2 14 0000 000056 00 WASHER LOCK M6 2 15 0000 000380 00 WASHER FLAT M6 2 16 0000 000646 00 SCREW M4 X 10 2 17 0000 000277 00 BOLT M8 X 25 4 18 0000 000159 00 WASHER LOCK M8 4 19 0000 000176 0...

Страница 116: ...12 46 BG S22 0812 ...

Страница 117: ......

Страница 118: ... Brampton ON Canada L6W 3K2 t 905 457 3900 f 905 457 2313 USA 6350 Burnt Poplar Road Greensboro NC 27409 www BlueGiant com If calling within North America t 1 800 668 7078 f 1 888 378 5781 Copyright Blue Giant Equipment Corporation 2014 ...

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