C22 PDF
C22 PDF
C22 PDF
SELF-PROPELLED,
COUNTERBALANCED LIFT TRUCK
Operation
Maintenance
Repair Parts List
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.
permit. Before lifting, be sure load is centered, forks
Do not operate this truck until you have checked its are completely under load, and load is as far back as
condition. Give special attention to tires, horn, battery, possible against load backrest.
controller, lift system (including forks or attachments, Do not handle unstable or loosely stacked loads. Use
chains, cables and limit switches), brakes, steering special care when handling long, high or wide loads, to
mechanism, guards and safety devices. avoid losing the load, striking bystanders, or tipping
Operate truck only from designated operating position. the truck.
Never place any part of your body into the mast struc-
Do not handle loads which are higher than the load
ture or between the mast and the truck. Do not carry backrest or load backrest extension unless load is
passengers. Keep feet clear of truck and wear foot secured so that no part of it could fall backward.
protection.
Elevate forks or other lifting mechanism only to pick up
Observe applicable traffic regulations. Yield right of
or stack a load. Watch out for obstructions, especially
way to pedestrians. Slow down and sound horn at
overhead.
cross aisles and wherever vision is obstructed.
Do not lift personnel except on a securely attached
Start, stop, travel, steer and brake smoothly. Slow
specially designed work platform. USE EXTREME
down for turns and on uneven or slippery surfaces that
CARE WHEN LIFTING PERSONNEL. Make sure
could cause truck to slide or overturn. Use special
mast is vertical, place truck controls in neutral and
care when traveling without load as the risk of overturn
apply brakes. Lift and lower smoothly. Remain in oper-
may be greater.
ating position or immediate vicinity as long as person-
Travel with lifting mechanism as low as possible. nel are on the work platform. Never transport
Always look in direction of travel. Keep a clear view, personnel on forks or work platform.
and when load interferes with visibility, travel with load Do not allow anyone to stand or pass under load or lift-
trailing. ing mechanism.
Use special care when operating on ramps travel
When leaving truck, neutralize travel control, fully
slowly, and do not angle or turn. Travel with load
lower lifting mechanism and set brake. When leaving
downhill.
truck unattended, also shut off power.
TABLE OF CONTENTS
BL-C22-1010 i
TABLE OF CONTENTS - Continued
ii BL-C22-1010
SECTION 1
DESCRIPTION
1-1. INTRODUCTION.
This publication describes the 24 volt transistor
C22 lift truck distributed by Big Lift LLC. Included are MODEL NO. SERIAL NO.
Users shall comply with all requirements indicated in TRUCK WT LESS BATTERY LB/ KG BATTERY MIN WT LB/ KG
The self-propelled C22 truck, Figure 1-2, lifts and U.S. PATENT NO. 4,444,284
AUSTRALIAN PATENT NO. 537,987
R6209
The forward and reverse motion is controlled by either
of two controller levers mounted on the control head. Figure 1-1 Name Plate
Stopping and turning is controlled by the steering arm. • High speed limit switch to restrict speed when lift
Lift, Lower and Tilt are controlled by pushbuttons on carriage is raised above the preset limit.
the control head. The battery powered lift truck is quiet
and without exhaust fumes. • All control functions automatically return to “OFF”
when released.
The reversible AC motor propels the lift truck in for-
ward or reverse direction throughout the available • Externally accessible quick-disconnect battery plug
speed range. The C22 lift truck can be driven with within operator's reach.
forks raised or lowered; however, the speed is • Separately fused control circuits and power circuits.
restricted when the platform is raised above a preset
limit. • Readily accessible horn button.
The model number will be found on the name plate • Lift carriage backrest to help stabilize the load.
(Figure 1-1) along with the serial number, lifting capac- • Handle to provide a firm hand hold for operator.
ity, and load center. Figure 1-2 shows the locations of
• Flow control valve regulates maximum lowering
the truck’s main components and controls.
speed within prescribed limits.
1-3. SAFETY FEATURES. • Relief valve maintains hydraulic pressure within pre-
scribed limits.
The C22 is designed and engineered to provide maxi-
mum safety for operator and payload. Some of the • High visibility color scheme of truck provides visual
safety features incorporated into the design are: alert of truck’s presence.
• Dead-man brake to apply the brake and cut off drive • Battery Indicator.
power when the steering arm is released. • Casters.
• Belly-button switch to reverse truck should the oper-
ator accidentally pin himself against a wall or
obstruction when backing up in slow speed.
BL-C22-1010 1-1
R6685
1-2 BL-C22-1010
SECTION 2
OPERATION
R3814
BL-C22-1010 2-1
2-3. BEFORE OPERATION proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
Table 2-1 covers important inspection points on the
and other areas specified in the SEC-
C22 lift truck which should be checked prior to opera-
TION 3.
tion. Depending on use, some trucks may require
additional checks. WARNING: If the truck is found to be unsafe and in
Figure 2-2 shows a sample format for an Operator need of repair, or contributes to an
Checklist, which can be modified as necessary to fit unsafe condition, report it immediately to
your operation. the designated authority. Do not operate
it until it has been restored to a safe
WARNING: Periodic maintenance of this truck by a operating condition. Do not make any
QUALIFIED TECHNICIAN is required. unauthorized repairs or adjustments. All
service must be performed by a qualified
CAUTION: A QUALIFIED SERVICE TECHNICIAN
maintenance technician.
should check the truck monthly for
2-2 BL-C22-1010
Electric Truck
Big Joe Manufacturing Company Daily Operator Check-Off List
Date Operator
Dept. Shift
Hour Meter
Reading Drive Hoist
Steering
Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.
R6479
BL-C22-1010 2-3
2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-3) located on each
side of the control head provides fingertip control for
driving the truck. Rotate the control in the direction you
want to travel. The farther you rotate the control from
the neutral position, the faster the truck will travel.
R6688
2-4 BL-C22-1010
lower or the fast lower button and hold until forks
descend to desired height.
BL-C22-1010 2-5
NOTES
2-6 BL-C22-1010
SECTION 3
PLANNED MAINTENANCE
The C22 may be equipped with maintenance free or A voltage check from battery connector terminal to
industrial wet cell batteries. battery case should indicate near zero volts. Typically,
however, the sum of the voltages at both terminals will
The care and maintenance of the battery is very equal battery volts. This leakage voltage will discharge
important to obtain efficient truck operation and maxi- the battery. As battery cleanliness deteriorates, the
mum battery life. usable charge of the battery decreases due to this self
discharge.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check mechanical brake for proper operation.
Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch
of hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4 inch
of hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contactors for proper operation.
Monthly Check deadman brake switch for proper operation.
Monthly Check lift chain tension, lubrication & operation (see paragraph 3-6.)
Quarterly Check lift and tilt cylinders for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.
Semi-annually Inspect for chain wear (See SECTION 8)
BL-C22-1010 3-1
Although a leakage voltage reading of zero volts may 1. Charge the battery only in areas designated for
not be possible, a cleaner battery will have more that use.
usable charge for truck operation and not affect opera- 2. Make certain the charger being used matches the
tion of electronic devices on the unit. voltage and amperage of the truck battery.
3-3.2. Safety Rules 3. Before disconnecting or connecting batteries to a
charger, make sure the charger is “OFF”. If an
• Wear protective clothing, such as rubber apron,
attempt is made to do this while the charger is
gloves, boots and goggles when performing any
“ON”, serious injury to you, the battery and the
maintenance on batteries. Do not allow electrolyte to
charger could result.
come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush immedi- 4. Before connecting the battery cable to the trucks
ately and thoroughly with clean water. Obtain medi- receptacle, make sure the key switch is off. The
cal attention immediately. Should electrolyte be battery cable must be fully connected before the
spilled on skin, rinse promptly with clean water and truck is used. If the plug is not making good con-
wash with soap. A baking soda solution (one pound tact, heat will weld the two parts of the battery
to one galleon of water) will neutralize acid spilled on connector together, making it difficult to remove
clothing, floor or any other surface. Apply solution and necessary to replace.
until bubbing stops and rinse with clean water. 5. Battery terminals should be checked and cleaned
• If truck is equipped with wet cell batteries, keep vent of corrosion regularly. Good battery terminal con-
plugs firmly in place at all times except when adding tact is essential not only for operation, but also for
water or taking hydrometer readings. Do not allow proper charging of the battery.
dirt, cleaning solution or other foreign material to 6. The charging requirements will vary depending on
enter cells. Impurities in electrolyte has a neutraliz- the use of the truck. The battery should be given
ing effect reducing available charge. as equalizing charge on a weekly basis. This
• Do not bring any type of flame, spark, etc., near the charge should normally be an additional three
battery. Gas formed while the battery is charging, is hours at the finish rate.
highly explosive. This gas remains in the cells long 7. Make certain battery used meets weight and size
after charging has stopped. requirements of truck. NEVER operate truck with
• Do not lay metallic or conductive objects on battery. an undersized battery.
Arcing will result. 3-3.4. Battery Cleaning
• Do not touch non-insulated parts of DC output con- Always keep vent plugs tightly in place when cleaning
nector or battery terminals to avoid possible electri- battery. When properly watered and charged, the bat-
cal shock. tery will remain clean and dry. All that is necessary is
• De-energize all AC and DC power connections to brush or blow off any dust or dirt that may accumu-
before servicing battery. late on them. However, if electrolyte is spilled or over-
flows from a cell, it should be neutralized with a
• Do not charge a frozen battery.
solution of baking soda and water, brushing the soda
• Do not use charger if it has been dropped or other- solution beneath the connectors and removing grime
wise damaged. from the covers. Then rinse the battery with cool water
from a low pressure supply to remove the soda and
3-3.3. Battery Care and Charging loosen dirt. If batteries stay wet consistently, they may
CAUTION: Never smoke or bring open flame near be either overcharged or over filled. This condition
the battery. Gas formed during charging should be investigated and corrected.
is highly explosive and can cause seri-
ous injury.
3-2 BL-C22-1010
3-3.5. MAINTENANCE FREE BATTERIES 3-4. CHARGING BATTERIES
Some trucks may be equipped with maintenance free Charging requirements will vary depending on depth
batteries. These batteries are completely sealed, will of discharge and temperature. Follow safety rules
not require any watering and have a full 80% dis- when placing a battery on charge.
charge available.
Proceed as follows:
Sealed Maintenance Free batteries contain a pressure 1. Park truck at charging station with carriage low-
release valve and under normal operating conditions ered and turn the key switch off.
do not require any special ventilation.
2. Check the condition of the AC cord, the battery
CAUTION: Do not try to open this battery or remove connector and battery cables. If there are any
the pressure release valve. cuts in the cable, any exposed wires, loose plugs
or connectors, DO NOT attempt to charge the
Only under severe overcharging, such as connected
batteries. Contact appropriate personnel for
to an improperly sized charger, will any significant
repairs to be made.
amount of gasses be released from the battery. Also,
being a valve regulated battery, it never requires 3. Disconnect the batteries from the truck and con-
watering. nect the batteries to the charger. Make sure con-
nectors are mated properly.
4. Connect the charger to the appropriate power
supply.
5. Follow the instructions for the charger being used.
BL-C22-1010 3-3
3-5. LUBRICATION. Table 3-2 Recommended Lubricants
(See Table 3-3 for Application)
Refer to Table 3-2 for the recommended types of
grease and oil. Table 3-3 in conjunction with Figure 3- No. 1 Transmission oil—EP SAE 80W-90
1 identifies the items requiring lubrication. Transmission oil—EP SAE 10W-30 (Note)
3-4 BL-C22-1010
R6690
BL-C22-1010 3-5
NOTES
3-6 BL-C22-1010
SECTION 4
TROUBLESHOOTING
BL-C22-1010 4-1
Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING -
Continued
Brake will not release. a. Air gap more than 0.01 in Adjust.
(0.25mm).
b. Brake temperature above Allow to cool and check air gap.
281° F (140° C).
c. Open brake circuitry or wiring. Make voltage checks.
Brake drags. a. Air gap less than 0.01 in Adjust.
(0.25mm).
b. Defective electric brake (3, Fig- Replace.
ure 12-5).
Brake grabs. a. Incorrect stopping distance Adjust (refer to Table 4-2).
adjustment.
b. Defective electric brake (3, Fig- Replace.
ure 12-5).
Abnormal noise and chatter when Defective electric brake (3, Figure Replace.
brake is applied. 12-5).
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of Defective packing in lift cylinder Repair lift cylinder.
the lift cylinder.
Squealing sounds when lifting a. Oil level too low. Identify oil leak.
forks. b. Dry channels in mast. Apply grease.
c. Defective mast or carriage roll- Replace rollers
ers
Forks do not lift to top. a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to I.D.plate for capacity.
Weak, slow or uneven action of a. Defective pump or relief valve. Check pressure. Adjust as
hydraulic system. necessary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.plate for capacity.
d. Defective lift motor solenoid. Replace coil (20, Figure 12-19).
e. Battery charge low. Charge battery.
Forks do not lift, pump motor does a. Battery is dead or discon- Check and recharge if required.
not run. nected.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for Check lift switch in control head,
operating pump motor. as well as the coil (20, Figure
12-19).
4-2 BL-C22-1010
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. If
normal, check the hydraulic
pump, and relief valve. Repair,
or adjust.
Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in
control head and lowering coils
(7, Figure 12-18). Replace as
required.
Load will not hold a. Oil bypassing internally in con- Replace or repair valve assembly
trol valve (3, Figure 12-16).
b. Worn lift cylinder. Replace cylinder.
Platform does not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs. b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capac-
ity.
c. Batteries need charging. Change batteries.
Forks creep downward under load Leak in hydraulic system, lift cylin- Check for leaking fitting in hydrau-
when in a raised position. der or lowering valve. lic line and repair as required.
Repack lift cylinder or replace
or repair valve assembly (3,
Figure 12-16).
MISCELLANEOUS
Steering arm does not return to a. Week return spring. Replace spring.
the upright position.
b. Binding. Check and free the binding item.
Verify that the cable has not
been damaged. Repair or
replace as needed.
Truck moves forward when arm is a. Belly-button switch defective. Check for short, and repair or
pulled down. replace as necessary.
b. Short in control head. Check wiring and repair as
required.
Steering arm jerks excessively Drive wheel worn. Replace drive wheel if worn to
starting or stopping the truck. within 3/8 inch of hub.
Drive motor is jerky. Motor internally damaged or worn. Replace motor.
BL-C22-1010 4-3
4-2. CONTROLLER TROUBLESHOOTING 4-2.2. Hand Held Programmer (Optional)
4-4 BL-C22-1010
1. Connect the programmer to the programmer con- side of the Navigation key again to display the list
nector (Figure 4-2) on the controller. of System Faults. The display should indicate "No
Known Faults."
BL-C22-1010 4-5
4-2.6. Diagnostic History 6. Cycle the key switch off and on. Release the
brake and apply the throttle. The vehicle should
The handheld programmer can be used to access the
now operate normally.
controller's diagnostic history file. When the program-
mer is connected to the unit, the error log file is auto- 4-2.8. Programmable Parameters
matically uploaded into the handheld programmer.
The controller has a number of parameters that can be
To see the present status of the unit, use the Menu programmed using the handheld programmer. These
Navigation Key (1, Figure 4-3) to select: programmable parameters allow the vehicle’s perfor-
Faults->System Faults. mance characteristics to be customized to fit the
needs of individual vehicles or vehicle applications.
To access this log, use the Menu Navigation Key to
select: The OEM can specify the default value for each
parameter and can also designate whether a parame-
Faults->Fault History
ter will have User or OEM access rights. Accordingly,
The faults are shown as a code and descriptive text. If programmers are available in User and OEM versions.
there are multiple faults, you have to scroll through the The User programmer can adjust only those parame-
list using the Up and Down Buttons on the Menu Navi- ter with User access rights, whereas the OEM pro-
gation Key grammer can adjust all the parameters.
The faults may be intermittent faults, faults caused by The MultiModeTM feature of the controller allows oper-
loose wires, or faults caused by operator errors. Faults ation in four distinct modes. These modes can be pro-
such as HPD or over-temperature may be caused by grammed to provide four different sets of operating
operator habits or by overloading. characteristics, which can be useful for operating in
After a problem has been diagnosed and corrected, different conditions, such as slow precise indoor
clearing the diagnostic history file is recommended. maneuvering in Mode 1; faster, long distance, outdoor
This allows the controller to accumulate a new file of travel in Mode 4; and application-specific special con-
faults. By checking the new diagnostic history file at a ditions in Modes 2 and 3. Eight parameters can be
later date, you can quickly determine whether the configured independently in each of the four modes:
problem has been completely fixed. • acceleration rate (M1-M4)
To clear the diagnostic history file, select: • braking current limit (M1-M4)
Faults->Clear Fault History. • braking rate (M1-M4)
You will be asked to confirm your actions. Use the • deceleration rate (M1-M4)
"plus" arrow (+) for yes to clear the menu and the
"minus" arrow (-) (3) to cancel your selection and not • drive current limit (M1-M4)
clear the Fault History. • maximum forward speed (M1-M4)
4-2.7. Test the Fault Detection Circuitry • maximum reverse speed (M1-M4)
1. Put the vehicle up on blocks to get the drive wheel • restraint (M1-M4)
off the ground. To change a parameter (Table 4-2) using the program-
2. Disconnect the battery and make sure the key- mer, use the Navigation key (1, Figure 4-3) to select
switch is in the "OFF" position. the "PROGRAM" menu. Press the Right key to display
a listing of program settings. Scroll down the Program
3. Using an inline fuse holder fitted with a 10 amp
Listing until the desired parameter is highlighted on the
fuse and alligator clips, connect the controller's M
display. Press the Right key to display the settings for
and B- terminals.
the item selected. Press the Increase/Decrease key
4. Reconnect the battery and turn the key switch to ("+" or "-") (3) until the desired value setting is
the "ON" position. Release the brake and apply reached. The parameter is now set at the desired
the throttle. The motor should not operate. value. All programming occurs in real time. That
5. Leave the key switch on and remove the in-line means the parameter can be changed while the vehi-
fuse wire. The vehicle status should continue to cle is in operation.
remain off.
4-6 BL-C22-1010
Table 4-2 Programmable Parameters
Parameter Factory Setting Description
VOLTAGE 2 Normal battery voltage, in volts.
2 = 24V
M1 DRIVE C/L 150 Mode 1 drive current limit, in amps.
BL-C22-1010 4-7
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
M1 DECEL RATE 25 Mode 1 deceleration rate, in seconds.
4-8 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
INT BRAKE RATE 0.3 Interlock braking rate, in seconds
The interlock braking rate defines the time it takes the con-
troller to increase from 0% to 100% braking output (as
determined by the max regen current setpoints) when inter-
lock braking is initiated. The interlock braking rate is adjust-
able from 0.1 to 3.0 seconds.
QUICK START 1 Quick-start throttle factor
BL-C22-1010 4-9
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
M1 MAX REV SPD 100 Mode 1 maximum reverse speed, as % drive output
1 = 5kW - 0 potentiometer
2 = single-ended 0 - 5V, 3-wire pot, current sources, and
electronic throttles
3 = 0 - 5kW potentiometers
4 = wigwag 0 - 5V and 3-wire pot throttles
4-10 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
THRTL DEADBAND 12 Throttle neutral deadband, as %
BL-C22-1010 4-11
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
THROTTLE MAP 45 Drive output at 50% throttle input, as %
4-12 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
FLD MAP START 50 Armature current at which field map takes effect, in amp
BL-C22-1010 4-13
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
CURRENT RATIO 1 Current ratio: factor of 1, 2, 4, or 8
For example, with the current ratio set at 1 with 20% throttle
requested, 20% of the battery voltage and 20% of the drive
current will be allowed to flow in the motor (assuming a 50%
throttle map setting). If the current ratio is set at 2 under
these same conditions, 40% of the current will be available;
if it is set at 3, 80%. The controller will not allow more than
the programmed drive current to flow in the motor. If the cur-
rent ratio is set at 4 with 20% throttle requested, the control-
ler will allow only 100% of the drive current and not 160%.
4-14 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
M1 RESTRAINT 10 Mode 1 restraint braking, in amps
BL-C22-1010 4-15
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
HPD 2 High pedal disable (HPD)
The high pedal disable (HPD) feature prevents the vehicle from
driving if greater than 25% throttle is already applied upon
startup. In addition to providing routine smooth starts, HPD
also prevents accidental sudden starts if problems in the
throttle linkage (e.g., bent parts, broken return spring) give a
throttle input signal to the controller even with the throttle
released.
HPD fault detection can be turned off by setting the HPD Type
to 0. To meet EEC requirements, HPD must be pro-
grammed to Type 1 or Type 2.
4-16 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
SRO 3 Static return to off (SRO)
BL-C22-1010 4-17
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
SEQUENCING DLY 0 Sequencing delay, in seconds
4-18 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
CONT DIAG ON Contactor diagnostic: On or Off
For Aux Type 5, the device connected to Pin 8 will be off when
the Pin 8 driver is open, and on when the driver is closed.
The aux delay could be used to allow the auxiliary device to
keep running for a short while after the vehicle reaches the
neutral state.
EMR REV C\L 150 Emergency reverse current limit, in amps
BL-C22-1010 4-19
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
EMR REV CHECK Off Emergency reverse wiring check: On or Off
4-20 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
ANTI-TIEDOWN Off Anti-tiedown: On or Off
The pot low fault parameter allows the controller’s pot low
fault detection to be disabled. This is useful when single-
wire, ground (B-) referenced voltage throttle inputs are
used. Setting the pot low fault parameter to Off disables the
fault detection at the pot low input (Pin 7). It is recom-
mended that the pot low fault parameter be set to On in any
application where a resistive throttle is used. This will pro-
vide the most comprehensive throttle fault detection and
provide the safest possible vehicle operation.
Note: The programmer’s display name for the pot low fault is
“Throttle Wiper Lo.”
FULL VOLTS Voltage considered 100% state of charge, in volts
The full voltage parameter sets the battery voltage that will be
considered 100% state-of-charge. When a loaded battery
drops below this voltage, it begins to lose charge. The full
voltage value can be set from the programmed Empty Volts
value up to the programmed Reset Volts value, in 0.01 VPC
increments.
After adjusting Full Volts, KSI must be cycled for the new set-
ting to take effect.
EMPTY VOLTS Voltage considered 0% state of charge, in volts
The empty voltage parameter sets the battery voltage that will
be considered 0% state-of-charge. When the battery
remains under this voltage consistently, the battery dis-
charge indicator will read 0% state of charge. The empty
voltage value can be set from 1.50 up to the programmed
Full Volts value, in 0.01 VPC increments.
After adjusting Empty Volts, KSI must be cycled for the new
setting to take effect.
BL-C22-1010 4-21
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
RESET VOLTS Voltage at which state of charge resets to 100%, in volts
4-22 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
SET TOTL HRS Off Apply preset values to total hourmeter: On or Off
Once the preset values have been loaded, the Set Total Hours
parameter should be programmed Off.
SET TRAC HRS Off Apply preset values to traction hourmeter: On or Off
The total service hours parameter is used to set the timer for the
next scheduled overall maintenance. The service interval
can be up to 5,000 hours. The total service timer is adjust-
able between 0.0 and 50.0, in 0.5 increments, with 25.0
being equivalent to 2,500 hours (25.0 X 100).
BL-C22-1010 4-23
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
SRVC TOTL Off Reset total service timer: On or Off
The total disable hours parameter is used to set the total dis-
able timer; it can be adjusted between 0 and 250 hours, in 1
hour increments. If the total disable timer expires, the trac-
tion fault speed goes into effect.
4-24 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
DIS TRAC HRS Total traction timer setting, in hours
BL-C22-1010 4-25
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
MOT HOT X10 mΩ Field resistance at which no drive output, in 10-milliohm units
Note: If the load sensor’s voltage is out of range (less than 0.2
V or greater than 4.8 V) during interlock braking while the
vehicle is driving in reverse, the regen current will default to
the programmed Max Rev Regen value.
4-26 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
MIN FWD REGEN 150 Max. intk braking regen current fr. fwd., min. load, in amps
Note: If the load sensor’s voltage is out of range (less than 0.2
V or greater than 4.8 V) during interlock braking while the
vehicle is driving forward, the regen current will default to
the programmed Max Fwd Regen value.
MAX LOAD VOLTS Voltage on load sensor for max. regen current, in volts
For Aux Type 5, the interlock braking delay does not apply.
BL-C22-1010 4-27
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
FAULT CODE Off Fault code: On or Off
The controller has two fault outputs, at Pins 2 and 3, which can
be used to transmit signals to LEDs located on the display
panel or on any remote panel. The fault outputs can be con-
figured to display faults in two different formats: Fault Code
format or Fault Category format. The fault code parameter
is used to select the preferred format.
In Fault Code format (fault code parameter On), the two fault
outputs operate independently. When a fault is present, the
Fault 1 driver (Pin 2) provides a pulsed signal equivalent to
the fault code flashed by the controller’s built-in Status LED;
the fault codes are listed in Table 4-5. The Fault 2 driver
(Pin 3) will steadily pull low (to B-) when any fault is present,
and can be used to drive a fault/no-fault LED. When no
faults are present, the Fault 1 and Fault 2 outputs will both
be high.
4-28 BL-C22-1010
Table 4-2 Programmable Parameters - Continued
Parameter Factory Setting Description
PUMP METER Off Enables use of pin 2 as input for a pump hourmeter: On or Off
BL-C22-1010 4-29
Table 4-4 Configuration Options:
Auxiliary Driver (Pin 8)
4-30 BL-C22-1010
4-2.9.1. LED Diagnostics 4-2.10.Programmer Diagnostics
During normal operation with no faults present, the With a programmer, diagnostics and troubleshooting is
Status LED flashes a single flash at approximately 1 more direct than with the LED alone. The programmer
flash/second. If the controller detects a fault, a 2-digit presents complete diagnostic information in plain lan-
fault identification code is flashed continuously until guage - no code to decipher. Faults are displayed in
the fault is corrected. For example, three flashes fol- the Diagnostic Menu, and the status of the controller
lowed by two flashes is code "3,2" appears in the LED inputs/outputs is displayed in the Test Menu.
code table as:
The following 4-step process is generally used for
000 00 000 00 000 00 diagnosing and troubleshooting an inoperative vehicle
using the programmer:
(3,2) (3,2) (3,2)
1. Visually inspect the vehicle for obvious problems:
The codes are listed in Table 4-5. The "0" 's in Table 4-
5 indicate an illuminated LED. For suggestions about 2. Diagnose the problem:
possible causes of the various faults, refer to Table 4- 3. Test the circuitry with the programmer:
6 Troubleshooting Chart.
4. Correct the problem.
Operational faults, such as an over-temperature situa- Repeat the last three steps as necessary until the
tion, are cleared as soon as the operation is brought vehicle is operational.
within range. Non-operational faults, such as a throttle
fault, usually requires the brake or key switch to be Refer to the Table 4-6 for suggestions covering a
cycled after the problem is remedied. wide range of possible faults.
Table 4-5 LED Codes
NOTE: Only one fault is indicated at a time and faults are not queued up.
BL-C22-1010 4-31
Table 4-6 Troubleshooting Chart
LED PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE
CODE LCD DISPLAY
0,1 NO KNOWN FAULTS
1,1 CURRENT SHUNT 1. Abnormal vehicle operation causing Cycle KSI. If problem persists, replace
FAULT high current spikes. controller.
2. Current sensor out of range.
3. Controller failure.
1,2 HW FAILSAFE 1. Noisy environment. Cycle KSI. If problem persists, replace
2. Self-test or watchfault. controller.
3. Controller failure.
1,3 M- SHORTED 1. Internal or external short of M- to B-. Check wiring; cycle KSI. If problem per-
2. Incorrect motor wiring. sists, replace controller.
3. Controller failure.
1,4 SRO 1. Improper sequence of KSI, brake, Follow proper sequence; adjust throttle if
interlock, and direction inputs. necessary; adjust programmable
2. Interlock or direction switch circuit parameters
open. if necessary.
4-32 BL-C22-1010
Table 4-5 Troubleshooting Chart - Continued
LED PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE
CODE LCD DISPLAY
3,1 FIELD SHORT 1. Main contactor soil shorted. Check contactor soil and field winding;
2. Field winding shorted to B+ or B-. cycle KSI.
BL-C22-1010 4-33
NOTES
4-34 BL-C22-1010
SECTION 5
STEERING ARM, CONTROL HEAD AND COMPARTMENT
5-1.1. Control Head Removal 1. Remove the control head as described in para-
graph 5-1.1.
1. Turn off the key switch (6, Figure 5-5) and discon-
nect the batteries. 2. Place the control head on a clean work bench.
3. Trace the belly-button switch leads down to the
2. Remove the six outer screws (10, Figure 5-1) and
control head connector and remove the leads
lift off cover (11).
from the connector.
NOTE: The seventh inner screw (10) and nut (14) 4. Remove two screws (5, Figure 5-1) and two screw
secure support plate (13) to cover (11). (6).
3. Remove the six screws (17, Figure 5-2) and cover 5. Lift button (1) with mounting bracket (4) out of the
(16) to gain access to electrical connectors. control head.
6. Remove button (1) from mounting bracket (4)
WARNING: Once cover (16) is removed, air spring
being careful not to loose springs (2).
(11) can fall free of socket (9) if the con-
trol arm (7) is lowered and raised. 7. Install button (1) with springs (2) on mounting
bracket (4) and check for proper operation.
NOTE: When removing the control head in the fol-
8. Position button (1) with mounting bracket (4) in
lowing step, be sure to hold it in place until
the control head.
the control cable is disconnected.
9. Install two screws (5) and two screw (6).
4. Working inside the control head, remove two
screws (2) and two washers (3), being careful not 10. Install the switch leads in the control head con-
to drop control head (1). nector.
11. Install the control head as described in paragraph
5. Lift up control head (1) and unplug the electrical
5-1.6.
connector.
R6654
BL-C22-1010 5-1
R6653
5-1.3. Lift, Lower and Horn Switch Replacement. 7. Place plate (13) into position and temporariy
secure with a clamp. Install nut (14) and screw
1. Remove the control head as described in para-
(10). Then remove the clamp.
graph 5-1.1.
2. Place the control head on a clean work bench. 8. Check buttons for proper operation.
9. Install the switch leads in the control head con-
3. Trace the leads of the defective switch down to
nector.
the control head connector and remove the leads
from the connector. 10. Install the control head as described in paragraph
5-1.6.
NOTE: When center screw (10, Figure 5-1) and nut
(14) are removed, springs (8) will fall out. 5-1.4. Directional Switch Removal and Adjust-
ment.
4. Use a small clamp to hold plate (13) and cover
(11) together. Remove screw (10) and nut (14). 1. Remove the control head as described in para-
Slowly remove the clamp and separate plate (13) graph 5-1.1.
from cover (11) being careful not to lose springs 2. Place the control head on a clean work bench.
(8).
3. Remove two screws (11, Figure 5-3) and lift
5. Remove the button with the defective switch. mounting bracket (8) out of the control head.
6. Place buttons (7, 9 and 12) with springs (8) in 4. Remove two nuts (10) and two washers (9) from
position in cover (11). two screws (5).
5-2 BL-C22-1010
R6655
BL-C22-1010 5-3
5-1.6. Control Head Installation. 2. Remove two screws (23) and two washers (24)
and plate (25).
1. Position control head (1, Figure 5-2) on arm (7)
and feed the electrical harness into arm (7). 3. Remove two screws (14) and move switch (20)
2. Working inside the control head, install two with mounting plate (17) out of the way. Steel ball
screws (2) and two washers (3). (19) will fall free.
4. Secure the steering arm (1) in the upright posi-
3. Connect the electrical harness and position it
tion.
along side the air return spring (11)
5. Remove screw (16), shaft (11) and rubber sleeve
4. Install cover (16) and secure with six screws (17).
(12).
5. Install cover (11, Figure 5-1) and secure with six
screws (10) 6. Remove the six screws (17, Figure 5-2) and cover
(16).
6. Reconnect the batteries and turn on the keyswitch
(6, Figure 12-7) and switch (4). WARNING: Once cover (16) is removed, air spring
(11) can fall free of socket (9) if the con-
5-2. STEERING ARM trol arm (7) is lowered and raised.
5-2.1. Return Air Spring Replacement. 7. Tilt the steering arm (7) forward to free air return
spring (11) to free it from socket (9).
The steering arm air return spring (11, Figure 5-2) is
replaced while the steering arm (7) is in the upright 8. Remove snap ring (12) and free air return spring
position. (11) from screw (14).
1. Remove two screws (4, Figure 5-4), two washers 9. Position the new air return spring (11) on screw
(3) and plate (2). (14) and secure with snap ring (12).
R6629
5-4 BL-C22-1010
10. While moving the steering arm (7) back, position 4. Remove the steering arm from socket (26).
the air return spring (11) inside socket (9).
5-2.3. Steering Arm Installation.
11. Install cover (16) and secure with six screws (17).
1. Position the steering arm from socket (26, Figure
12. Install shaft (11, Figure 5-4) and rubber sleeve
5-4).
(12) and secure with screw (16).
2. Install shaft (9) and roll pin (8).
13. Reposition switch (20) with mounting plate (17)
and steel ball (19) and install two screws (14). 3. Install the steering arm air return spring (11, Fig-
ure 5-2) as described in paragraph 5-2.1.
14. Check for proper operation of switch (20).
4. Install the control head as described in paragraph
15. Tuck in wires of switch (20) to prevent pinching
5-1.6.
and install plate (25), two screws (23) and two
washers (24).
5-3. COMPARTMENT COVERS
16. Install plate (2) and secure with two screws (4)
and two washers (3). 5-3.1. Forward Compartment.
R6658
BL-C22-1010 5-5
5-3.1.2.Installation. 2. Remove two screws (22) and two screws (20) and
lift off cover (19) with panel (2).
1. Position front covers (25 and 26, Figure 5-5) on
the frame. 3. Remove two screws (22) and two screws (20) lift
2. Install eight screws (27). off cover (21) with panel (3).
4. Remove nuts (17) and washers (18) to separate
3. Install top cover (28) and secure with four screws
panels (2 and 3) from covers (19 and 21).
(27).
4. Reconnect the batteries and turn on the keyswitch 5-3.3. Installation.
(6) and switch (4).
1. Position panels (2 and 3, Figure 5-5) on covers
5-3.2. Rear Compartment. (19 and 21) and secure with nuts (17) and wash-
ers (18).
5-3.2.1.Removal. 1. Position front covers (19 and 21) on the frame.
1. Turn off the key switch (6, Figure 5-5) and discon- 2. Install four screws (22) and four screws (20).
nect the batteries.
3. Reconnect the batteries and turn on the keyswitch
(6) and switch (4).
5-6 BL-C22-1010
SECTION 6
BRAKE SERVICING
BL-C22-1010 6-1
6-1.2. Stopping Distance Adjustment. 16. Position new bushings (7) and shims (4) over the
three brake mounting holes in the motor.
The stopping distance of the truck should require mini-
mal adjustment. However, this distance should be 17. Place magnet body (1) on bushings (7) and
checked with each planned maintenance. secure with the three screws (1, Figure 6-2) and
three washers (2).
Using an unloaded truck, run truck to its top speed on
an even dry concrete surface. Move control handle 18. Finally tighten the three mounting screws to 52 in-
into the lower braking position. Measure length of lb (6 Nm).
braking path from the actuation point of the brakes 19. Reconnect electric brake to the harness.
until the truck has stopped. The actual length of the
20. Install socket (35, Figure 6-3) and secure with
braking path should be between approximately 1.5 -
three screws (36).
2.5 ft (0.5-0.7 m).
21. Install pressure block (34) and secure with four
To adjust stopping distance, proceed as follows:
screws (33)
1. Block load wheels. 22. Install the steering arm as described in paragraph
2. Remove the rear compartment covers as 5-2.3.
described in paragraph 5-3. 23. Remove load wheel blocks and check operation.
3. Adjust the brake (Refer to Table 4-2). 24. Install the rear compartment covers as described
4. Remove load wheel blocks and check operation. in paragraph 5-3.
5. Install the rear compartment covers as described 25. Reconnect the batteries and turn on the keyswitch
in paragraph 5-3. (6, Figure 12-7).
6-2 BL-C22-1010
R6629
BL-C22-1010 6-3
NOTES
6-4 BL-C22-1010
SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL
7-1. Drive Wheel. 8. Remove screw (4, Figure 7-2) and remove plate
1. Turn off the key switch (6, Figure 12-7) and dis- (5) with tension spring (13).
connect the batteries. 9. Remove the screws securing forcing cylinder (Fig-
ure 12-22) to bracket (10, Figure 7-1).
2. Remove the rear compartment covers as
described in paragraph 5-3. 10. Remove two nuts (32, Figure 7-2) two washers
(33) and two screws (36) securing bracket (35) to
3. Loosen but do not remove the five nuts (28, Fig-
bottom of bracket (10).
ure 7-1).
4. Jack up the truck so the drive wheel is off the 11. Disconnect the two links (20) on each side of the
ground; then securely block the truck to prevent transmission by remove screws (22) and pins (21)
from frame (10).
movement.
12. Slowly lower the transmission out the bottom of
5. Remove the five nuts (28) and drive wheel (27)
the frame.
from the transmission (25).
6. Install new drive wheel in reverse order of 13. Install new transmission by reversing the steps
removal. above.
7-2. Transmission.
The transmission floats on bracket (35, Figure 7-2)
and two links (20). Two springs (13, Figure 7-1) supply
a downward pressure for maintaining traction. A forc-
ing cylinder (Figure 12-22) is mounted between
bracket (10, Figure 7-1) and bracket (35, Figure 7-2) to
provide additional traction when carrying heaver loads.
The heavier the load, the greater the hydraulic pres-
sure to the forcing cylinder.
1. Remove the rear compartment covers as
described in paragraph 5-3.
2. Remove the steering arm as described in para-
graph 5-2.2.
3. Remove the brake (3, Figure 7-1) as described in
paragraph 6-1.3.
4. Remove four screws (33, Figure 7-3) and pres-
sure block (34).
5. Remove the drive motor (6, Figure 7-1) as
described in paragraph 10-4.1.
6. Remove the drive wheel (27) as described in R6656
paragraph 7-1.
Figure 7-1 Transmission, Motor, Brake Assembly
7. Support the transmission (25).
BL-C22-1010 7-1
R6660
R6629
7-2 BL-C22-1010
7-3. Load Wheel. 7-3.2. Repair
7-3.1. Removal 6. Remove snap rings (3, Figure 7-4) and bearings
(4) from wheels (5).
1. Raise forks.
7. Inspect bearings (4) and replace if necessary.
2. Turn off the key switch (6, Figure 12-7) and dis-
connect the batteries. 8. Reassemble bearings (4) and snap rings (3) in
wheels (5).
3. Block the drive wheel to prevent the truck from
rolling. 7-3.3. Load Wheel Installation
4. Jack up the frame to raise the load wheels off the 1. Position load wheel assembly (5, Figure 7-4) in
floor. Securely block the frame in the raised posi- frame.
tion.
2. Install shaft (2) and secure with snap rings (1).
NOTE: When shaft (2, Figure 7-4) is removed, load 3. Remove blocking from under the truck.
wheel assembly (5) will drop free.
4. Lower the truck.
5. Remove snap rings (1) securing shaft (2) and 5. Reconnect the batteries and turn on the keyswitch
remove shaft (2) and load wheel assembly (5). (6, Figure 12-7).
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.
This ensures level and safe operation of the
lift truck.
R6662
BL-C22-1010 7-3
NOTES
7-4 BL-C22-1010
SECTION 8
ELEVATION SYSTEM SERVICING
8-1. GENERAL. 4. Thread the top jam nut (12, Figure 8-2) up adjust-
The elevation system includes the outer mast, inner ing bolt (8) to allow for adjustment of middle jam
mast, lift linkage, lift chains, lift cylinder and tilt cylin- nut (12).
der. 5. Take up slack in both lift chains with middle jam
nut (12). Strive for equal tension on both chains.
8-2. LIFT CHAIN LENGTH ADJUSTMENT. 6. Align adjusting bolts (8) so each clevis pin (10) is
1. Fully lower the lift carriage. parallel to the mast.
2. Turn off the key switch (6, Figure 12-7) and dis- CAUTION: At least 3 full threads must be present
connect the batteries. below lower nut (12) after adjustment.
WARNING: Before attempting any adjustment, make 7. Tighten jam nuts securely while maintaining align-
certain power is disconnected. ment of clevis pin (10).
3. Loosen the bottom jam nut (12, Figure 8-2) on 8. Reconnect the batteries and turn on the keyswitch
adjusting bolt (8) located at the top crossmember (6, Figure 12-7).
of the outer mast (8, Figure 8-1). 9. Test chain by operating carriage. If slack is still
apparent, repeat above procedure.
R6663
BL-C22-1010 8-1
8-3. LIFT CHAIN WEAR INSPECTION. 8-4. LIFT CHAIN REPLACEMENT.
Both lift chains should be replaced when either chain 1. With the lift truck wheels securely blocked, raise
is worn enough to increase it’s length by 3% or more. the forks approximately three feet from floor and
To make this determination proceed as follows. position blocks or strong supports under the lift
carriage.
Using a section of chain that sees the most frequent
operation over the chain sheaves, isolate a vertical 2. Lower the carriage onto the support. Check that
portion under tension from the weight of carriage and arrangement is secure before proceeding and the
forks. lift chains are slack.
Measure the distance between pin centers on 20 verti- 3. Turn off the key switch (6, Figure 12-7) and dis-
cal links. If the section measures 12.88” or more, the connect the batteries.
chain should be replaced.
WARNING: Before attempting any replacement,
New chain anchor pins should be installed when make certain power is disconnected.
chains are replaced. Never replace a partial section of
chain and never repair chain. Refer to paragraph 8-4. 4. Remove cotter pin (9, Figure 8-2) and clevis pin
when installing new chain. (13) connecting chain (5) to the lift carriage.
R6664
8-2 BL-C22-1010
5. Remove cotter pin (9) and clevis pin (10) connect- 10. Adjust the chains according to paragraph 8-2.
ing chain (5) to adjusting bolt (8) at the outer 11. Reconnect the batteries and turn on the keyswitch
mast. (6, Figure 12-7).
6. Remove chain from sheave (6).
7. Position new chain on sheave (6). 8-5. LIFT CYLINDER.
8. Secure chain to adjusting bolt (8) at the outer NOTE: Removal and repair of lift cylinder is covered
mast with clevis pin (10) and cotter pin (9). in SECTION 9.
9. Connect the opposite end of chain to the lift car-
riage with clevis pin (10) and cotter pin (9).
BL-C22-1010 8-3
NOTES
8-4 BL-C22-1010
SECTION 9
HYDRAULIC SYSTEM SERVICING
9-1. LINES AND FITTINGS CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
WARNING: When forks are raised, pressure exists in under the line or fitting before discon-
the hydraulic system lines and fittings. necting.
To ensure release of pressure, forks
must be fully lowered and the batteries 4. Refer to Figure 9-1 and remove leaking line or fit-
disconnected before performing any ting and replace it with a new line or fitting.
maintenance on the hydraulic system. 5. Check level of hydraulic oil. If required, add
NOTE: Leaking hydraulic fittings may be remedied by hydraulic oil to bring to proper level. Use hydraulic
simply tightening fittings. If this does not rem- oil listed in Table 3-2.
edy the leak, the fittings or line must be 6. Reconnect the batteries and turn on the keyswitch
replaced. (6, Figure 12-7).
1. Lower forks fully. 7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
2. Turn off the key switch (6, Figure 12-7) and dis-
connect the batteries. 8. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
3. Remove the front compartment covers as oil listed in Table 3-2.
described in paragraph 5-3.
9. Install the front compartment covers as described
in paragraph 5-3.
R6666
BL-C22-1010 9-1
9-2. HYDRAULIC PUMP, AND MOTOR ASSY 2. Install tube assy (17) with two fittings (18) and
four washers (20)
WARNING: When forks are raised. pressure exists in
the hydraulic system lines and fittings. 3. Connect electrical leads to motor (1, Figure 9-2).
To ensure release of pressure, forks 4. Fill the hydraulic reservoir. Use hydraulic oil listed
must be fully lowered and the batteries in Table 3-2.
disconnected before performing any 5. Reconnect the batteries and turn on the keyswitch
maintenance on the hydraulic system. (6, Figure 12-7).
9-2.1. Removal 6. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
1. Lower forks fully.
7. Check level of hydraulic oil. If required, add
2. Turn off the key switch (6, Figure 12-7) and dis-
hydraulic oil to bring to proper level. Use hydraulic
connect the batteries.
oil listed in Table 3-2.
3. Remove the front compartment covers as
8. Install the front compartment covers as described
described in paragraph 5-3.
in paragraph 5-3.
4. Tag and disconnect electrical leads from motor (1,
Figure 9-2).
9-2 BL-C22-1010
9-2.4. Lift Cylinders WARNING: Before attempting any replacement,
make certain power is disconnected.
9-2.4.1.Removal
CAUTION: Hydraulic oil can damage parts. Wipe off
1. With the lift truck wheels securely blocked, raise
any oil immediately. Provide a container
the forks approximately three feet from floor and
under the line or fitting before discon-
position blocks or strong supports under inner
necting.
mast
2. Lower inner mast onto the support. Check that 4. Disconnect hoses (4 and 6, Figure 9-1) from the
arrangement is secure before proceeding and bottom of the lift cylinders.
that the lift cylinders are free of the inner mast. 5. Remove two screws (4, Figure 9-3), clamp (5) and
3. Turn off the key switch (6, Figure 12-7) and dis- plate (6).
connect the batteries. 6. Carefully raise lift cylinder (3) from the outer mast
(8).
7. Repeat steps 5. and 6. for the remaining cylinder.
R6663
BL-C22-1010 9-3
9-2.4.2.Repair 11. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
CAUTION: To prevent damage, use proper pipe
clamp vise. The cylinder will be distorted 12. Check level of hydraulic oil. If required, add
if the vise is tightened too much. hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2.
1. Secure the lift cylinder in a vise, clamping lightly 13. Install the front compartment covers as described
at the base of the cylinder. in paragraph 5-3.
2. Remove bolt (5, Figure 9-4) and washer (4).
3. Remove snap ring (7).
4. Pull out piston rod (6).
5. Remove dust seal (1) and seal (2) from cylinder
body (3).
6. Coat all parts with hydraulic oil (Table 3-2).
7. Install new seal (2) and dust seal (1) in cylinder
body (3).
8. Insert rod (6) in cylinder body (3).
9. Reinstall snap ring (7).
10. Reinstall bolt (5, Figure 9-4) and washer (4).
9-2.4.3.Installation
1. Position one cylinder (3, Figure 9-3) on outer
mast (8).
2. Secure the cylinder with plate (6), clamp (5) and
two screws (4).
3. Repeat steps 1. and 2. for the opposite cylinder.
4. Reconnect hoses (4 and 6, Figure 9-1) to the bot-
tom of the cylinders.
5. Using a suitable lifting device, raise the inner
mast and remove the supports.
6. Slowly lower the inner mast while lining up the lift
cylinders with the top of the inner mast.
7. Adjust the chains according to paragraph 8-2.
8. Remove the front compartment covers as
described in paragraph 5-3.
9. Fill the hydraulic reservoir. Use hydraulic oil listed R6670
in Table 3-2.
Figure 9-4 Lift Cylinder
10. Reconnect the batteries and turn on the keyswitch
(6, Figure 12-7).
9-4 BL-C22-1010
9-2.5. Tilt Cylinders 4. Disconnect hoses (3 and 26, Figure 9-1) from the
bottom of the tilt cylinders.
9-2.5.1.Removal
5. Support the tilt cylinder and remove pin (20, Fig-
WARNING: Mast must be supported by a hoist ure 9-5) and shaft (19) from the cylinder.
before removing the tilt cylinders. 6. Carefully raise tilt cylinder from the truck.
1. Secure mast with a hoist. 7. Repeat steps 5. and 5. for the remaining cylinder.
2. Turn off the key switch (6, Figure 12-7) and dis- 9-2.5.2.Repair
connect the batteries.
CAUTION: To prevent damage, use proper pipe
WARNING: Before attempting any replacement, clamp vise. The cylinder will be distorted
make certain power is disconnected. if the vise is tightened too much.
CAUTION: Hydraulic oil can damage parts. Wipe off 1. Remove snap ring (10, Figure 9-5).
any oil immediately. Provide a container
under the line or fitting before discon- 2. Pull out piston rod (4).
necting. 3. Remove nut (9), washer (8), piston (6), O-ring (5)
and cover (13) from rod (4).
3. Remove the front compartment covers as
described in paragraph 5-3. 4. Remove seals (7) from piston (6).
R6671
BL-C22-1010 9-5
5. Remove O-ring (15), seal (14), ring (12) and wear 9-2.5.3.Installation
ring (11) from cover (13).
1. Position one cylinder between the outer mast and
6. Remove snap rings (17) and bearing (21) from the truck frame.
cylinder body (16). 2. Secure the cylinder with two shafts (19, Figure 9-
7. While holding clevis (1), loosen nut (3). 5) and two pins (20).
8. Remove clevis (1), washer (2) and nut (3) from 3. Secure the opposite cylinder to the truck frame
rod (4). with one shaft (19) and pin (20).
9. Remove snap rings (17) and bearing (21) from 4. Adjust clevis (1) so that the mounting hole aligns
clevis (1). with the mounting hole of the outer mast.
10. Coat all parts with hydraulic oil (Table 3-2). 5. Secure the cylinder to the mast with one shaft
11. Install bearing (21) in clevis (1) and secure with (19) and pin (20).
two snap rings (17). 6. Secure nuts (3) against clevises (1).
12. Install nut (3), washer (2) and clevis (1) on rod (4). 7. Reconnect hoses (3 and 26, Figure 9-1) to the
The clevis will be adjusted during installation of bottom of the tilt cylinders.
the cylinder.
8. Fill the hydraulic reservoir. Use hydraulic oil listed
13. Install bearing (21) in cylinder body (16) and in Table 3-2.
secure with two snap rings (17).
9. Reconnect the batteries and turn on the keyswitch
14. Install O-ring (15), seal (14), ring (12) and wear (6, Figure 12-7).
ring (11) on cover (13). 10. Operate the tilt buttons to refill the cylinder and
15. Install seals (7) on piston (6). lines with hydraulic oil.
16. Install cover (13) on rod (4). 11. Check level of hydraulic oil. If required, add
17. Install O-ring (5), piston (6), washer (8), and nut hydraulic oil to bring to proper level. Use hydraulic
(9) on rod (4). oil listed in Table 3-2.
18. Install piston rod (4) in cylinder body (16). 12. Install the front compartment covers as described
in paragraph 5-3.
19. Remove snap ring (10).
9-6 BL-C22-1010
SECTION 10
ELECTRICAL COMPONENTS
10-1.ELECTRICAL CONTROL PANEL moist rag. Allow it to dry before reconnecting the
battery.
10-1.1.Maintenance
4. Make sure the connections to the buss bars are
NOTE: Erratic operation of the truck may be caused tight. Use two well insulated wrenches for this
by defective controller components. Before task in order to avoid steering the buss bars.
removing the electrical panel, perform trou-
bleshooting procedures per SECTION 4, to 10-1.3.Panel Removal.
determine corrective action to be taken. 1. Turn off the key switch (6, Figure 12-7) and dis-
connect the batteries.
There are no user-serviceable parts inside the control-
ler. No attempt should be made to open the controller. 2. Remove the front compartment covers as
Opening the controller may damage it and will void the described in paragraph 5-3.
warranty. 3. Tag and disconnect all electrical cables which
The controller is programmed at the factory specifi- connect to the control panel (37, Figure 10-1).
cally for the truck model on which it is equipped. It is 4. Remove four screws (38) and control panel (37).
important to replace the controller with the correct pre-
programmed unit to assure proper performance set- 10-1.4.Panel Disassembly.
tings intended for that particular truck. See Figure 12- Refer to Figure 10-2 for location and identity of the
23 for the preprogrammed controller number. major replacement components mounted on the panel
It is recommended that the controller exterior be and remove defective parts.
cleaned periodically, and if a Handset is available, this NOTE: Contactors (6 and 7) are not repairable and
periodic cleaning provides a good opportunity to check must be replaced if defective.
the controller’s diagnostic history file. It is also recom-
mended that the controller’s fault detection circuitry be 10-1.5.Panel Installation.
checked whenever the vehicle is serviced.
1. Install the control panel (37, Figure 10-1) and
10-1.2.Cleaning secure with four screws (38).
1. Turn off the key switch (6, Figure 12-7) and dis- 2. Connect all electrical cables to the control panel
connect the batteries. as noted during removal.
2. Remove the front compartment covers as 3. Install the front compartment covers as described
described in paragraph 5-3. in paragraph 5-3.
3. Remove any dirt or corrosion from the buss bar 4. Reconnect the batteries and turn on the keyswitch
area. The controller should be wiped clean with a (6, Figure 12-7).
BL-C22-1010 10-1
R6478
R6660
10-2 BL-C22-1010
R6478
R6674
BL-C22-1010 10-3
10-3.PUMP MOTOR. 7. Install the brake as described in paragraph 6-1.3.
Refer to paragraph 9-2. 8. Install the steering arm as described in paragraph
5-2.3.
10-4.DRIVE MOTOR. 9. Remove the rear compartment covers as
The drive motor exposed surfaces should be cleaned described in paragraph 5-3.
at least once a month to assure proper cooling of
motor. Use an air hose to blow bust off of motor sur- 10-5.LIMITATION SWITCH
faces. 1. Disconnect harness from the limitation switch (17,
Figure 12-12).
10-4.1.Motor Removal
2. Remove switch (17) from socket (18).
1. Remove the rear compartment covers as
described in paragraph 5-3. NOTE: The switch must be positioned so that it is
2. Remove the steering arm as described in para- operated when the lift carriage is up.
graph 5-2.2.
3. Secure the new switch (17) on socket (18).
3. Remove the brake as described in paragraph
4. Reconnect harness to switch.
6-1.3.
4. Remove four screws (33, Figure 10-4) and pres-
sure block (34).
5. Note routing of cables to ensure proper installa-
tion.
6. Tag the cables connected to the drive motor; then
disconnect these cables from the drive motor.
7. Remove the ten screws (4 Figure 10-3) and lock
washers (5).
8. Lift motor (6) from bearing (7).
9. Remove nut (24), gear (23), and key (22) from
motor (6).
10. Remove snap rings (20 and 21), sleeve (18),
bearing (17) and seal (16) from the motor (6).
10-4.2.Motor Installation
1. Position seal (16, Figure 10-3), bearing (17),
sleeve (18) and on motor (6) and secure with
snap rings (20 and 21).
2. Position key (22) and gear (23) on the shaft of
motor (1) and secure with nut (24).
3. Install drive motor onto transmission. Make sure
to align gear (23) with the gear inside the trans-
mission.
4. Reinstall the ten screws (4) and lock washers (5)
to secure the motor to the transmission.
5. Position cables as noted in removal and recon-
nect cables to the drive motor. Make sure to
match the cable label to the terminal.
R6656
6. Reinstall pressure block (34) and secure with four
screws (33).
Figure 10-3 Transmission, Motor, Brake Assembly
10-4 BL-C22-1010
10-6.DEADMAN SWITCH 5. Position the new switch (20), sheet (18) and ball
(19) on bracket (17) and secure with the two
10-6.1.Replacement screws (20) and washers (21).
1. Remove two screws (4, Figure 10-4), two wash- 6. Reconnect the deadman switch wiring.
ers (3) and plate (2).
7. Check for proper operation of switch (20).
2. Remove two screws (23) and two washers (24)
8. Tuck in wires of switch (20) to prevent pinching
and plate (25).
and install plate (25), two screws (23) and two
3. Disconnect wiring for deadman switch (20). washers (24).
4. Remove the two screws (22), washers (21), 9. Install plate (2) and secure with two screws (4)
switch (20) and sheet (18) from bracket (17). Ball and two washers (3).
(19) will drop out.
R6629
BL-C22-1010 10-5
NOTES
10-6 BL-C22-1010
SECTION 11
OPTIONAL EQUIPMENT
BL-C22-1010 11-1
NOTES
11-2 BL-C22-1010
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
Following is an illustrated parts breakdown of assemblies and parts associated with the C22 Lift Truck.
BL-C22-1010 12-1
R6629
12-2 BL-C22-1010
R6653
BL-C22-1010 12-3
R6654
12-4 BL-C22-1010
R6655
BL-C22-1010 12-5
R6656
12-6 BL-C22-1010
R6657
BL-C22-1010 12-7
R6658
12-8 BL-C22-1010
R6659
BL-C22-1010 12-9
R6660
12-10 BL-C22-1010
R6661
BL-C22-1010 12-11
R6662
12-12 BL-C22-1010
R6633
BL-C22-1010 12-13
R6664
12-14 BL-C22-1010
R6665
BL-C22-1010 12-15
R6666
12-16 BL-C22-1010
R6667
BL-C22-1010 12-17
R6669
12-18 BL-C22-1010
R6668
BL-C22-1010 12-19
R6673
12-20 BL-C22-1010
R6670
BL-C22-1010 12-21
R6671
12-22 BL-C22-1010
R6672
BL-C22-1010 12-23
R6674
12-24 BL-C22-1010
R6677
BL-C22-1010 12-25
R6675
12-26 BL-C22-1010
R6676
BL-C22-1010 12-27
R6678
12-28 BL-C22-1010
Big Lift LLC