Page 1 CB22 SELF-PROPELLED, COUNTERBALANCED LIFT TRUCK Operation Maintenance Repair Parts List NOTE: For the most current parts information and service updates, please refer to the Big Joe Support site at www.bigjoesupport.com Big Lift LLC MANUAL NO. BL-CB22-1214 - 04-11-2019 www.bigjoeforklifts.com...
Page 2 WARNING Do not operate this truck unless you have been autho- Do not overload truck. Check nameplate for capacity rized and trained to do so, and have read all warnings and load center information. and instructions in Operator’s Manual and on this When using forks, space forks as far apart as load will truck.
Page 3: Table Of Contents
CONTROL HEAD INSTALLATION ..5-3 9-5.3 INSTALLATION ........9-11 5-1.5 SPEED POTENTIOMETER 9-5.4 TILT CYLINDERS....... 9-13 REPLACEMENT ........5-3 9-5.4.1 REMOVAL .......... 9-13 5-1.6 BELLY-BUTTON SWITCH 9-5.4.2 REPAIR ..........9-14 REPLACEMENT ........5-3 9-5.4.3 INSTALLATION ........9-14 5-1.7 HORN SWITCH REPLACEMENT..5-3 BL-CB22-1214 - 04-11-2019...
Page 4 PANEL REMOVAL ......10-1 10-5.1 REPLACEMENT ......... 10-5 10-1.4 PANEL DISASSEMBLY...... 10-1 10-1.5 PANEL INSTALLATION...... 10-1 11 OPTIONAL EQUIPMENT ......... 11-1 10-2 HORN REPLACEMENT ........ 10-1 10-3 PUMP MOTOR ..........10-5 12 ILLUSTRATED PARTS BREAKDOWN ....12-1 BL-CB22-1214 - 04-11-2019...
Page 5: Description
This publication describes the 24 volt obstruction. CB22 lift truck distributed by Big Lift LLC. Included are operating instructions, planned maintenance instruc- tions, lubrication procedures, corrective maintenance procedures and a complete parts list with part location illustrations.
Page 6 R6898 Figure 1-2. CB22 Lift Truck ITEM COMPONENT ITEM COMPONENT Mast Chassis Back Rest Cover Forks Drive wheel Load Wheel Cover Hydraulic pump Control Handle Battery Battery Indicator Battery Disconnect Key Switch Front cover BL-CB22-1214 - 04-11-2019...
Page 7: Operation
This section gives detailed operating instructions for and loaded. the CB22 lift truck. The instructions are divided into the various phases of operations, such as operating lift, • Be sure that mast is vertical - do not operate on a driving, and stopping.
Page 8: Before Operation
Table 2-1 covers important inspection points on the maintenance technician. CB22 lift truck which should be checked prior to opera- tion. Depending on use, some trucks may require additional checks. Table 2-1 Operator Checks...
Page 9 R6479 Figure 2-2 Sample of Operator Check List BL-CB22-1214 - 04-11-2019...
Page 10: General Control Operation
Regenerative braking: If the speed control lever is Grasp the grips of the steering head so that the released, the truck automatically brakes regener- speed control can be comfortably operated by atively. When the speed is below .5 MPH, the either thumb. brake applies BL-CB22-1214 - 04-11-2019...
Page 11: Belly-Button Switch
When finished with moving loads, return the truck to its Figure 2-6. Belly-Button Switch maintenance or storage area. Turn off the key switch and disconnect the batteries. Charge batteries as nec- essary. Refer to battery care instructions, SECTION 3. BL-CB22-1214 - 04-11-2019...
Page 12 NOTES BL-CB22-1214 - 04-11-2019...
Page 13: Planned Maintenance
Leakage voltage from battery terminals to battery case accordingly. These procedures must be performed by can cause misleading trouble symptoms with the truck a qualified service technician or your Big Lift LLC Ser- electrical system. Since components of the truck elec- vice Representative.
Page 14: 3-3.2 Safety Rules
If batteries stay wet consistently, they may be either overcharged or over filled. This condition CAUTION: Never smoke or bring open flame near should be investigated and corrected. the battery. Gas formed during charging is highly explosive and can cause seri- ous injury. BL-CB22-1214 - 04-11-2019...
Page 15: 3-3.5 Maintenance Free Batteries
Make sure con- watering. nectors are mated properly. Connect the charger to the appropriate power supply. Follow the instructions for the charger being used. R7005 BL-CB22-1214 - 04-11-2019...
Page 16: Lubrication
SAE 30 or 40 engine oil. 100 SUS foam suppressing agent and rust and oxidation inhibitors (Note) No. 4 SAE 30 or 40 Engine lubricating oil NOTE: USED ON COLD CONDITIONED TRUCKS BL-CB22-1214 - 04-11-2019...
Page 17 Light coating where forks slide Hydraulic Reservoir No. 3 With lift carriage fully lowered, fill Capacity-1 quarts reservoir with hydraulic oil to 1 inch below opening Transmission No. 1 Fill to level plug opening Capacity 2 pints BL-CB22-1214 - 04-11-2019...
Page 18 NOTES BL-CB22-1214 - 04-11-2019...
Page 19: Troubleshooting
TROUBLE WITH BRAKING Truck does not slow with brake, or a. Defective deadman switch (29, Check deadman switch for brake does not engage. Figure 12-1). continuity. If faulty, replace switch. b. Defective electric brake (2, Fig- Replace brake. 12-5). BL-CB22-1214 - 04-11-2019...
Page 20 Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir and the oil lines to the lift cylinder, and repair as required. If normal, check the hydraulic pump, and relief valve. Repair, or adjust. BL-CB22-1214 - 04-11-2019...
Page 21 Check wiring and repair as required. Steering arm jerks excessively Drive wheel worn. Replace drive wheel if worn to within starting or stopping the truck. 3/8 inch of hub. Drive motor is jerky. Motor internally damaged or worn. Replace motor. BL-CB22-1214 - 04-11-2019...
Page 22: Controller Troubleshooting
This function permits a deeper diagnosis of problems changes of the controller. The Zapi Handset is avail- as the recent history can be revisited. able through your Big Lift LLC dealer. If you require 4-2.2.2. Logbook Access dealer location information, contact Big Lift LLC.
Page 23: 4-2.4 Settings And Adjustments
This input must be connected to a Keyswitch controlled voltage. The SR#1 becomes active when CNA#15 (Table 4-5) is open. The inching backward becomes active when the CNA#15 (Table 4- 5) is closed to a Keyswitch controlled voltage. BL-CB22-1214 - 04-11-2019...
Page 24 ON/OFF: If this options is programmed ON the traction Inverter manages a hydraulic steering function when the keyswitch is switched ON (only if the AUX OUTPUT #1 option is programmed as HYDRO CONTACT or as WXCLUSIVE HYDRO). STOP ON RAMP Not used. BL-CB22-1214 - 04-11-2019...
Page 25 INPUT #4 is set BELLY. It can be set as: • NONE: The quick inversion function is not managed (no effect when CNB#7 (Table 4-5) switches over). • TIMED: The quick inversion function is timed. • BELLY: The quick inversion function is managed but not timed. BL-CB22-1214 - 04-11-2019...
Page 26 Bus: the handling of the Hydraulics is specified on the TRUCK TYPE setting. • ABSENT: The MDI-PRC is not connected to the ACO: the TRUCK TYPE disappears from the SET OPTIONS function list. MOT SET-UP Not used. BL-CB22-1214 - 04-11-2019...
Page 27: 4-2.4.2 Adjustments
SET BATTERY TYPE Selects the nominal battery voltage. ADJUST BATTERY XX V Do not modify - Factory adjusted (Fine adjustment of the battery voltage measured by the controller.) THROTTLE 0 ZONE Establishes a deadband in the accelerator input curve. BL-CB22-1214 - 04-11-2019...
Page 28 • OPTION#1: CHECK UP NEEDED warning on the handset and MDIPRC after 300 hours. • OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours. • OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380 hours. R6642 Figure 4-4Throttle Regulation 4-10 BL-CB22-1214 - 04-11-2019...
Page 29: 4-2.4.3 Parameter Change
100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed in forward direction. MAX SPEED BACK 100 Hz Typically from 90 Hz to 160 Hz. It determines the maximum speed in backward direction. BL-CB22-1214 - 04-11-2019 4-11...
Page 30 It is used to push up, in feedforward way, the torque when it is not possible to control the flux, in feedback way, because of the low frequency. 4-12 BL-CB22-1214 - 04-11-2019...
Page 31 Encoder Positive Supply (+5 or +12 Vdc) CNA#10 ENC- Encoder Negative Supply (GND to minus battery) CNA#11 HM(+B) Output for driving an hourmeter; when the hourmeter is active this output provides a +Batt signal; 3 maximum current. BL-CB22-1214 - 04-11-2019 4-13...
Page 32 Lowering request input, active high. CNB#9 LIFTING SW Lifting request input, active high. CNB#10 CPOT Lifting request input, active high. CNB#11 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis. CNB#12 PPOT Potentiometer positive: 10V output; keep load >1k 4-14 BL-CB22-1214 - 04-11-2019...
Page 33 Negative console power supply. CNC#6 +12V Positive console power supply. CNC#7 FLASH Must be connected to C8 for the Flash memory programming (if used). CNC#8 FLASH Must be connected to C7 for the Flash memory programming (If used). BL-CB22-1214 - 04-11-2019 4-15...
Page 34 NOTES 4-16 BL-CB22-1214 - 04-11-2019...
Page 35: Steering Arm, Control Head And Compartment
(1) and disconnect harness (15, Figure 5-1.1. Cap Assembly Removal. 5-4) from harness (28, Figure 5-2). Turn off the key switch (12, Figure 12-29 or 12, Figure 12-30) and disconnect the batteries. R6877A Figure 5-1 Control Head BL-CB22-1214 - 04-11-2019...
Page 36: 5-1.2 Cap Assembly Installation
Hold cap assembly (1, Figure 5-1) in place and Reconnect the batteries and turn on the key connect harness to harness (28, Figure 5-2). switch (12, Figure 12-29 or 12, Figure 12-30). R6876A Figure 5-2 Steering Arm BL-CB22-1214 - 04-11-2019...
Page 37: 5-1.3 Control Head Removal
(16), lock washer (6) and flat washer (7). Remove two pins (10) and defective switch from bracket (10). Install screw (22), lock washer (6) and flat washer (7). Connect harness to the new switch. BL-CB22-1214 - 04-11-2019...
Page 38: 5-1.8 Lift And Lower Switch Replacement
Install the cap assembly as described in para- Remove pin (6, Figure 5-4) securing bracket (5) graph 5-1.2. and remove the bracket. Remove two pins (6), two switches and four 5-1.8. Lift and Lower Switch Replacement. springs (4) from bracket (5). BL-CB22-1214 - 04-11-2019...
Page 39 R6878A Figure 5-4 Cap Assembly BL-CB22-1214 - 04-11-2019...
Page 40: 5-1.9 Tilt Switch Replacement
Position the opposite end of the gas return spring Reconnect the batteries and turn on the key (3) on bracket (17) and install screw (4). switch (12, Figure 12-29 or 12, Figure 12-30). Install middle cover (5, Figure 12-7) and secure with two screws (4). BL-CB22-1214 - 04-11-2019...
Page 41: Brake Servicing
10. Install the rear compartment covers as described Remove the steering arm as described in para- in paragraph 5-3. graph 5-2.2. 11. Reconnect the batteries and turn on the keyswitch (12, Figure 12-29 or 12, Figure 12-30). BL-CB22-1214 - 04-11-2019...
Page 42 R6879A Figure 6-1 Transmission, Motor, Brake Assembly BL-CB22-1214 - 04-11-2019...
Page 43: Transmission, Drive Wheel, Load Wheel
Remove the drive wheel (13) as described in or is cracked or damaged, replace the entire paragraph 7-1. load wheel and bearing assembly. Big Lift Remove the brake (2, Figure 7-1) as described in LLC recommends that both load wheel paragraph 6-1.1.
Page 44 R6879A Figure 7-1 Transmission, Motor, Brake Assembly BL-CB22-1214 - 04-11-2019...
Page 45 R6882A Figure 7-2 Load Wheels BL-CB22-1214 - 04-11-2019...
Page 46 NOTES BL-CB22-1214 - 04-11-2019...
Page 47: Elevation System Servicing
(4). Reconnect the batteries and turn on the keyswitch (12, Figure 12-29 or 12, Figure 12-30). Test chain by operating carriage. If slack is still apparent, repeat above procedure. R6818 Figure 8-1 Chain Assembly BL-CB22-1214 - 04-11-2019...
Page 48 R6883 Figure 8-2 Elevation System (Telescopic) BL-CB22-1214 - 04-11-2019...
Page 49: 8-2.2 Trimast Free Lift Chain
New chain anchor pins should be installed when chains are replaced. Never replace a partial section of WARNING: Before attempting any adjustment, make chain and never repair chain. Refer to paragraph 8-4. certain power is disconnected. when installing new chain. BL-CB22-1214 - 04-11-2019...
Page 50 R6884A Figure 8-3 Mast (TRIMAST) BL-CB22-1214 - 04-11-2019...
Page 51: Lift Chain Replacement
12-30). Remove cotter pin (3, Figure 8-1) and clevis pin 8-5. LIFT CYLINDERS. (4) connecting chain (5) to chain anchor (6) at the lift carriage. NOTE: Removal and repair of lift cylinders are cov- ered in SECTION BL-CB22-1214 - 04-11-2019...
Page 52 NOTES BL-CB22-1214 - 04-11-2019...
Page 53: Hydraulic System Servicing
5-3. 9-1) as described in paragraph 9-2.1. Refer to Figure 12-18 for disassembly and reas- sembly of the pump and motor. Install the pump and motor assembly (5, Figure 9- 1) as described in paragraph 9-2.3. BL-CB22-1214 - 04-11-2019...
Page 54 R8009 Figure 9-1 Hydraulic System BL-CB22-1214 - 04-11-2019...
Page 55: 9-2.3 Installation
9-1). oil listed in Table 3-2. Install the front compartment covers as described TRIMAST Trucks: Reconnect hose (5, Figure 9- in paragraph 5-3. 3) to pump and motor (5, Figure 9-1) R6887A Figure 9-2 Hydraulic System (Telescopic) BL-CB22-1214 - 04-11-2019...
Page 56 R6888A Figure 9-3 Hydraulic System (TRIMAST) BL-CB22-1214 - 04-11-2019...
Page 57: Lift Cylinder (Telescopic)
13. Check level of hydraulic oil. If required, add Remove wiper ring (8) and O-ring (9) from gland hydraulic oil to bring to proper level. Use hydraulic nut (7). oil listed in Table 3-2. Pull out piston rod (1). BL-CB22-1214 - 04-11-2019...
Page 58 R6883A Figure 9-4 Elevation System (Telescopic) BL-CB22-1214 - 04-11-2019...
Page 59 R6889A Figure 9-5 Lift Cylinder (Telescopic) BL-CB22-1214 - 04-11-2019...
Page 60: Lift Cylinder (Trimast Free Lift)
Secure the lift cylinder in a vise, clamping lightly at the base of the cylinder. Check level of hydraulic oil. If required, add hydraulic oil to bring to proper level. Use hydraulic Remove gland nut (4, Figure 9-7). oil listed in Table 3-2. BL-CB22-1214 - 04-11-2019...
Page 61 R6884A Figure 9-6 Elevation System (TRIMAST) BL-CB22-1214 - 04-11-2019...
Page 62 R6890A Figure 9-7 Free Lift Cylinder (TRIMAST) 9-10 BL-CB22-1214 - 04-11-2019...
Page 63: Lift Cylinder (Trimast Secondary)
Table 3-2. Remove gland nut (3, Figure 9-8). 10. Install the compartment covers as described in Remove wiper (1), packing (2) and O-rings (4 and paragraph 5-3. 11) from gland nut (3). BL-CB22-1214 - 04-11-2019 9-11...
Page 64 R6891 Figure 9-8 Secondary Lift Cylinder (TRIMAST) 9-12 BL-CB22-1214 - 04-11-2019...
Page 65: 9-5.4 Tilt Cylinders
WARNING: Before attempting any replacement, 9-9), lock washers (2), flat washers (3) and make certain power is disconnected. pins (4) and shaft from the cylinder. Carefully raise tilt cylinder from the truck. R6892 Figure 9-9 Tilt Cylinder Mounting BL-CB22-1214 - 04-11-2019 9-13...
Page 66: 9-5.4.2 Repair
Install the front compartment covers as described 12. Install piston rod (14) in cylinder body (17). in paragraph 5-3. 13. Install dust seal (7), O-ring (8), snap ring (9), seal (10), O-ring (13) and bearing (12) in gland nut (11). 9-14 BL-CB22-1214 - 04-11-2019...
Page 67 R6893 Figure 9-10 Tilt Cylinder BL-CB22-1214 - 04-11-2019 9-15...
Page 68 NOTES 9-16 BL-CB22-1214 - 04-11-2019...
Page 69: Electrical Components
Install the compartment covers as described in 10-1.3.Panel Removal. paragraph 5-3. Turn off the key switch (12, Figure 12-29 or 12, Reconnect the batteries and turn on the keyswitch Figure 12-30) and disconnect the batteries. (12, Figure 12-29 or 12, Figure 12-30). BL-CB22-1214 - 04-11-2019 10-1...
Page 70 R6478 R6894A Figure 10-1Electrical System - Used up to Serial # S2320148 10-2 BL-CB22-1214 - 04-11-2019...
Page 71 R6478 R6894A Figure 10-2 Electrical System - Used from Serial # S2320149 BL-CB22-1214 - 04-11-2019 10-3...
Page 72 R6478 R6895A Figure 10-3 Electrical Panel 10-4 BL-CB22-1214 - 04-11-2019...
Page 73: Pump Motor
Install middle cover (5) and secure with two Install drive motor onto transmission. Make sure screws (4, Figure 12-7). the gears align. Reconnect the batteries and turn on the keyswitch (12, Figure 12-29 or 12, Figure 12-30). BL-CB22-1214 - 04-11-2019 10-5...
Page 74 R6879A Figure 10-4 Transmission, Motor, Brake Assembly 10-6 BL-CB22-1214 - 04-11-2019...
Page 75: Optional Equipment
SECTION 11 OPTIONAL EQUIPMENT BL-CB22-1214 - 04-11-2019 11-1...
Page 76 NOTES 11-2 BL-CB22-1214 - 04-11-2019...
Page 77: Illustrated Parts Breakdown
SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the CB22 Lift Truck. BL-CB22-1214 - 04-11-2019 12-1...
Page 78 R6876A Figure 12-1 Steering System 12-2 BL-CB22-1214 - 04-11-2019...
Page 79 Used up to Serial # 2320-520002-00 STEER ARM HARNESS S2320148 Used from Serial # 2320-520002-40 STEER ARM HARNESS S2320149 2112-520003-0C WIRE HARNESS -DEADMAN SWITCH 0000-000010-00 SCREW M5×6 0000-000490-00 HARNESS CLAMP 0000-000063-00 LOCKWASHER Ø10 1220-560001-00 INCHING SWITCH I BL-CB22-1214 - 04-11-2019 12-3...
Page 80 R6877A Figure 12-2 Control Head - Used up to Serial Number 327120792 12-4 BL-CB22-1214 - 04-11-2019...
Page 81 0000-000010-00 SCREW M5×6 1120-343000-00-B EMERGENCY REVERSE SWITCH ASSY. With Wire Harness Used up to Serial # 2320-311000-00-B CAP ASSEMBLY WITH WIRE HARNESS S2320148 Used between Serial # 2320-311000-40-B CAP ASSEMBLY WITH WIRE HARNESS S2320149 - 327120792 BL-CB22-1214 - 04-11-2019 12-5...
Page 82 DE_0048 Figure 12-3 Control Head - Used from Serial Number 327120793 12-6 BL-CB22-1214 - 04-11-2019...
Page 83 SCREW M5×16 0000-000390-00 FLATWASHER Ø5 1115-340007-00 WIRE HARNESS COVER 1120-520009-00 REVERSING SWITCH WIRE 0000-000989-00 SCREW M2×12 1115-340003-00 COVER 1121-310004-00 SPRING 1115-340002-00 COVER 0000-000322-00 SCREW M8×25 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 1115-340001-00 WASHER 0000-000035-00 SCREW M5×20 BL-CB22-1214 - 04-11-2019 12-7...
Page 84 R6878A Figure 12-4 Cap Assembly - Used up to Serial Number 327120792 12-8 BL-CB22-1214 - 04-11-2019...
Page 85 LIFT AND LOWER BOX(R) ASSEMBLY 2320-311100-00 TILTING BOX ASSEMBLY Used up to Serial # 2320-520003-00 BUTTONS ASSEMBLY S2320148 Used on Serial # S2221176, S2317016, 2320-520003-40 BUTTONS ASSEMBLY S2320149 and between Serial # S2321082 and 327120792 1220-560002-00 INCHING SWITCH II BL-CB22-1214 - 04-11-2019 12-9...
Page 86 DE_0049 Figure 12-5 Cap Assembly - Used from Serial Number 327120793 12-10 BL-CB22-1214 - 04-11-2019...
Page 87 1120-342300-00 HORN BUTTON ASSEMBLY 0000-000039-00 SCREW ST3.5×9.5 0000-000490-00 HARNESS CLAMP 1120-342200-00 LIFT AND LOWER BOX(R) ASSEMBLY 2320-311100-00 TILTING BOX ASSEMBLY 2320-520003-40 BUTTONS ASSEMBLY 1220-560002-00 INCHING SWITCH II 1120-342002-00 HORN BUTTON 1120-342005-00 1120-342003-00 SPRING 1120-342004-00 BUTTON BRACKET BL-CB22-1214 - 04-11-2019 12-11...
Page 88 R6810A Figure 12-6 Emergency Reverse Switch Assembly - Used up to Serial Number 327120792 12-12 BL-CB22-1214 - 04-11-2019...
Page 89 PART NUMBER DESCRIPTION NOTES REQD. 1120-343000-00-B EMERGENCY REVERSE SWITCH ASSY. Includes Pos. # 1 - 6 1120-343002-00 COVER 1120-343003-00 SPRING 1120-342005-00 1120-343001-0A BRACKET 1120-343004-00 EMERGENCY REVERSE SWITCH WIRE With Switch 1220-520005-0C HARNESS 1220-560002-00 INCHING SWITCH II BL-CB22-1214 - 04-11-2019 12-13...
Page 90 R6879A Figure 12-7 Transmission, Motor, Brake Assembly 12-14 BL-CB22-1214 - 04-11-2019...
Page 91 Box I 4230-210000-10 0000-000070-00 SCREW M10×25 1120-210002-00 BRAKE LINING Used on Non-Serviceable gearbox 4230-210001-00 DRIVE WHEEL STUD part # 4230-210000-00 Pos. # 12 Used on Serviceable gearbox 1120-240014-30 DRIVE WHEEL STUD part # 4230-210000-10 Pos. # 12a BL-CB22-1214 - 04-11-2019 12-15...
Page 92 R8018 Figure 12-8 Transmission - Used between Serial # S2214169 - 327121134 12-16 BL-CB22-1214 - 04-11-2019...
Page 93 4230-GB10-00 GEAR SET (z1/z2=26/100) This set includes 2 gears 0000-000379-00 FLATWASHER Ø14 0000-001055-00 WASHER Ø14 0000-001056-00 NUT M14×1.5 0000-000211-00 O-RING 150×3.1 1120-240010-30 COVER 1120-240011-30 GAS PLUG 0000-000055-00 SCREW M6×16 1120-240017-30 SEAL WASHER TC80×65×8 1120-240013-30 OUTPUT SHAFT BL-CB22-1214 - 04-11-2019 12-17...
Page 94 DE_0050 Figure 12-9 Transmission - Used from Serial # 327121134 12-18 BL-CB22-1214 - 04-11-2019...
Page 95 ZK12-GB30-A0 GEAR SET (Z1/Z2=26/100) This set includes 2 gears 0000-000379-00 FLATWASHER Ø14 ZK12-240020-00 WASHER Ø14 3030-070000-04 NUT M14 0000-000211-00 O-RING 150×3.1 ZK12-240005-00 COVER ZK12-240019-00 VENT PLUG 0000-000055-00 SCREW M6×16 3060-030000-17 SEAL WASHER TC80×55×8 ZK12-240007-00 OUTPUT SHAFT BL-CB22-1214 - 04-11-2019 12-19...
Page 96 R6880 Figure 12-10 Compartment 12-20 BL-CB22-1214 - 04-11-2019...
Page 97 2125-140002-00 UPPER COVER number 326110893 Used from serial 2125-140002-50 UPPER COVER number 326110894 0000-000126-00 SCREW M6×16 1120-150002-00 MIDDLE COVER 2125-140001-00 LOWER COVER 1146-151002-30 MANUAL HOLDER Used from serial 0000-000119-00 SCREW M5x12 number 326110894 0000-000546-00 NUT M5 BL-CB22-1214 - 04-11-2019 12-21...
Page 98 R6881 Figure 12-11 Frame 12-22 BL-CB22-1214 - 04-11-2019...
Page 99 Used up to 07/15/12 2320-120000-10 COUNTER WEIGHT (LOWER) I Used from 07/15/12 2320-100003-00 BRACKET 2320-130000-00 COUNTER WEIGHT (LOWER) II Used up to 07/15/12 2320-130000-10 COUNTER WEIGHT (LOWER) II Used from 07/15/12 2125-100002-00 BATTERY CLAMP 2214-150002-00 WASHER 0000-000242-00 BOLT M8×16 BL-CB22-1214 - 04-11-2019 12-23...
Page 100 R6882A Figure 12-12 Load Wheels 12-24 BL-CB22-1214 - 04-11-2019...
Page 101 REQD. 0000-000700-00 SCREW M8×16 2320-600003-00 BAFFLE 0000-000620-00 BOLT M6×16 0000-000056-00 LOCKWASHER Ø6 0000-000380-00 FLATWASHER Ø6 2320-600002-00 BAFFLE 2320-601100-00 LOADING WHEEL 2320-600001-00 BRACKET 0000-000379-00 FLATWASHER Ø14 0000-000233-00 LOCKWASHER Ø14 0000-001028-00 BOLT M14×90 0000-000858-00 BUSHING 50×60×30 0000-000857-00 BEARING BL-CB22-1214 - 04-11-2019 12-25...
Page 102 Figure 12-13 Elevation System (Telescopic) 12-26 BL-CB22-1214 - 04-11-2019...
Page 103 Lift Height 128” This Is Used For 2320-610000-00-02 OUTER MAST ASSEMBLY Lift Height 104” This Is Used For 2320-610000-00-04 OUTER MAST ASSEMBLY Lift Height 128” 0000-000001-00 SCREW M6×20 2125-600005-00 BUFFER BLOCK 0000-000075-00 SCREW M12×30 0000-000630-00 NUT M12 BL-CB22-1214 - 04-11-2019 12-27...
Page 104 R6883A Figure 12-14 Elevation System (Telescopic) - Continued 12-28 BL-CB22-1214 - 04-11-2019...
Page 105 LOCKWASHER Ø5 S2120004 Used from Serial # 0000-000390-00 FLATWASHER Ø5 S2120004 Used from Serial # 2125-500004-00 SENSOR BRACKET S2120004 Used from Serial # 2125-500002-00 PROXIMITY SWITCH 8104 S2120004 Used from Serial # 2130-520003-0A PROXIMITY SWITCH WIRING S2120004 BL-CB22-1214 - 04-11-2019 12-29...
Page 106 R6884A Figure 12-15 Elevation System (Three Stage) 12-30 BL-CB22-1214 - 04-11-2019...
Page 107 OUTER MAST ASSEMBLY Used from serial number 324170307 0000-000026-00 SCREW M8×30 2214-600005-00 BLOCK A.R. As Required 2125-600006-30 CYLINDER SUPPORTING 2125-600005-30 TUBING CLAMP 2125-410000-30-01 LIFT CYLINDER ASSEMBLY Used up to 091513 2125-410000-3A-01 LIFT CYLINDER ASSEMBLY Used from 091613 BL-CB22-1214 - 04-11-2019 12-31...
Page 108 R6884A Figure 12-16 Elevation System (Three Stage) - Continued 12-32 BL-CB22-1214 - 04-11-2019...
Page 109 Used from serial number 2333-500001-30 SENSOR BRACKET 324170307 2125-520003-3A LOWER PROXIMITY SWITCH WIRE 2125-520009-22 LIFTING PROXIMITY SWITCH WIRE Used from 113011 2125-500003-00 PROXIMITY SWITCH 0000-000546-00 NUT M5 0000-000206-00 LOCKWASHER Ø5 0000-000390-00 FLATWASHER Ø5 2125-500002-00 PROXIMITY SWITCH BL-CB22-1214 - 04-11-2019 12-33...
Page 110 R6815A Figure 12-17 Lift Carriage (Two Stage) 12-34 BL-CB22-1214 - 04-11-2019...
Page 111 LOAD BACKREST Used from 051612 2125-631104-00 SCREW 2125-612007-00 SNAP RING 2125-612002-00 ASSISTANT ROLLER 2125-612001-00 MAIN ROLLER 2125-612005-00 DUST SNAP 0000-000183-00 RETAINER RING Ø35 2125-631000-00 FORK FRAME 2125-630001-00 FORK 2125-630001-10 PIN ASSEMBLY 2125-631100-00 ROLLER ASSEMBLY 0000-000030-00 SCREW M10×16 BL-CB22-1214 - 04-11-2019 12-35...
Page 112 R8008 Figure 12-18 Lift Carriage (Three Stage) 12-36 BL-CB22-1214 - 04-11-2019...
Page 113 SCREW M10×16 number 324170307 and 324200418 Used between serial 0000-000109-00 SCREW M10×16 number 324170307 and 324200418 Used between serial 0000-000159-00 SCREW M10×16 number 324170307 and 324200418 Used between serial 0000-000176-00 SCREW M10×16 number 324170307 and 324200418 BL-CB22-1214 - 04-11-2019 12-37...
Page 114 R6818 Figure 12-19 Chain Assembly 12-38 BL-CB22-1214 - 04-11-2019...
Page 115 Used on Three Stage 2125-652000-30-01 CHAIN ASSEMBLY Mast Lift Height 157” Used on Free Lift 2125-651000-30-01 CHAIN ASSEMBLY Cylinder - Three Stage Mast Lift Height 157” 2125-640003-00 CHAIN ANCHOR 0000-000686-00 COTTER PIN Ø3.2×32 0000-000176-00 FLATWASHER Ø8 BL-CB22-1214 - 04-11-2019 12-39...
Page 116 R8009 Figure 12-20 Hydraulic System - Used up to serial number 324200458 12-40 BL-CB22-1214 - 04-11-2019...
Page 117 BOLT M 6×16 Used up to Serial # 2320-422000-00 TANK S2121004 Used between Serial # 2320-422000-0A TANK S2121005 and 324200458 2112-410005-00 RUBBER CUSHION 2707-141401-A0 CONNECTOR G1/4-M14×1.5 0000-000044-00 WASHER Ø14 3130-730800-00 OIL PIPE ASSEMBLY 2402-143700-A0 BOLT G1/4×37 BL-CB22-1214 - 04-11-2019 12-41...
Page 118 R8216 Figure 12-21 Hydraulic System - Used from serial number 324200459 12-42 BL-CB22-1214 - 04-11-2019...
Page 119 PART NUMBER DESCRIPTION NOTES REQD. 0000-000155-00 SCREW M10×40 0000-000063-00 LOCKWASHER Ø10 0000-000007-00 FLATWASHER Ø10 2112-410004-00 WASHER 2320-470000-00 PUMP MOTOR ASSEMBLY 2707-141401-A0 CONNECTOR G1/4-M14×1.5 0000-000044-00 WASHER Ø14 3130-730800-00 OIL PIPE ASSEMBLY 2402-143700-A0 BOLT G1/4×37 2112-410005-00 RUBBER CUSHION BL-CB22-1214 - 04-11-2019 12-43...
Page 120 R6886A Figure 12-22 Pump & Motor - Used up to serial number 324200458 12-44 BL-CB22-1214 - 04-11-2019...
Page 121 2130-430009-0A FILTER , STEEL 2320-421014-00 MANIFOLD 2320-421015-00 O-RING 0000-000159-00 LOCKWASHER Ø8 0000-000110-00 SCREW M8×65 2320-421016-00 SOLENOLD VALVE I For Lifting and Tilting 2320-421017-00 SOLENOLD VALVE II For Lowering 2320-421018-00 RELIEF VALVE 2125-430023-00 BRUSH 2130-430012-0A VALVE 12L/MIN BL-CB22-1214 - 04-11-2019 12-45...
Page 122 R8217 Figure 12-23 Pump & Motor - Used from serial number 324200459 12-46 BL-CB22-1214 - 04-11-2019...
Page 123 WASHER 5 1115-560024-00 FILTER 2320-470020-00 O-RING 100X3.55 2320-470021-00 RETURN TUBE 2320-470022-00 VALVE 2320-470023-00 BRUSH 2320-470024-00 MANIFOLD 2320-470025-00 SOLENOLD VALVE I For Lowering For Lifting 2320-470026-00 SOLENOLD VALVE II and Tilting 2320-470027-00 WASHER 8 2320-470028-00 SCREW M8×70 BL-CB22-1214 - 04-11-2019 12-47...
Page 124 R6887A Figure 12-24 Hydraulic System (Telescopic) 12-48 BL-CB22-1214 - 04-11-2019...
Page 125 S2213250 Used from Serial # 2320-400002-00 ACCUMULATOR HOOP S2213250 Used from Serial # 0000-000109-00 SCREW M8×16 S2213250 Used from Serial # 0000-000159-00 LOCKWASHER Ø8 S2213250 Used from Serial # 0000-000176-00 FLATWASHER Ø8 S2213250 2402-143700-00 BOLT G1/4×37 BL-CB22-1214 - 04-11-2019 12-49...
Page 126 R6888A Figure 12-25 Hydraulic System (Three Stage) - Used up to 12/26/12 12-50 BL-CB22-1214 - 04-11-2019...
Page 127 WASHER Ø14 2125-430000-3A-B METALLIC OIL PIPE ASSEMBLY 2125-450000-30-B METALLIC OIL PIPE ASSEMBLY ? 2805-160014-00 BOLT M16×1.5 2125-440000-3A-01 HOSE 2702-141400-0A BOLT G1/4X35 Used from 12/07/12 to 2702-141400-00 CONNECTOR 12/26/12 0000-000109-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 BL-CB22-1214 - 04-11-2019 12-51...
Page 128 R8010 Figure 12-26 Hydraulic System (Three Stage) - Used from 12/27/12 12-52 BL-CB22-1214 - 04-11-2019...
Page 129 0000-000176-00 FLATWASHER Ø8 2701-161600-00 CONNECTOR M16×1.5-M16×1.5 2702-142000-00 CONNECTOR G1/4-M20×1.5 2214-423000-00 ACCUMULATOR Used from 06/14/13 2320-400002-00 ACCUMULATOR HOOP Used from 06/14/13 2320-450000-00 METALLIC OIL PIPE Used from 06/14/13 2701-141400-00 CONNECTOR M14X1.5-M14X1.5 Used from 06/14/13 2402-143700-00 BOLT G1/4×37 BL-CB22-1214 - 04-11-2019 12-53...
Page 130 R6892 Figure 12-27 Tilt Cylinder Mounting 12-54 BL-CB22-1214 - 04-11-2019...
Page 131 POS. PART NUMBER DESCRIPTION NOTES REQD. 0000-000255-00 BOLT M8×20 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 3218-840000-00 SHAFT Used up to Serial # 2320-430000-00 TILTING CYLINDER ASSEMBLY S2118062 Used from Serial # 2320-440000-00 TILTING CYLINDER ASSEMBLY S2118063 BL-CB22-1214 - 04-11-2019 12-55...
Page 132 R6889A Figure 12-28 Lift Cylinder (Telescopic) 12-56 BL-CB22-1214 - 04-11-2019...
Page 133 Used on Lift Height 96” 2110-411000-00-06 CYLINDER TUBE Used on Lift Height 104” 2110-411000-00-05 CYLINDER TUBE Used on Lift Height 128” 2125-410004-0A 0000-000084-00 RING WIPER Ø35×43×5-6.5 0000-000370-00 O-RING Ø40×3.1 2125-410005-00 RING BACK UP Ø50×20×2.5 0000-000512-00 ROD PACKING Ø40×50×6 BL-CB22-1214 - 04-11-2019 12-57...
Page 134 R6890 Figure 12-29 Free Lift Cylinder (Three Stage) 12-58 BL-CB22-1214 - 04-11-2019...
Page 135 SEAL KIT FOR CYLINDER Includes Pos. # 1, 3 & 5 0000-000045-00 RING WIPER 55×63×5-6.5 0000-000684-00 COLLAR 55×65×3 0000-000046-00 ROD PACKING 55×65×6 2125-420002-30 0000-000685-00 O-RING 65×3.1 2125-420001-30-01 PISTON ROD 2125-420003-30 RING BACK UP 70×65×25 2125-421000-30-01 CYLINDER TUBE BL-CB22-1214 - 04-11-2019 12-59...
Page 136 R6891 Figure 12-30 Secondary Lift Cylinder (Three Stage Mast) - Used up to 09/15/13 12-60 BL-CB22-1214 - 04-11-2019...
Page 137 Incl. Pos. # 1, 2, 4 & 11) 0000-000084-00 RING WIPER 35×43×5-6.5 0000-000085-00 ROD PACKING 35×45×6 2125-410004-30 0000-000519-00 O-RING 48×3.1 2125-410001-30-01 PISTON ROD 2125-410005-30 BUSHING 0000-000520-00 COLLAR Ø24 2125-410002-30 RING BACK UP 2125-411000-30-01 CYLINDER 2125-410006-30 0000-000609-00 O-RING 52.5×3.1 BL-CB22-1214 - 04-11-2019 12-61...
Page 138 R8011 Figure 12-31 Secondary Lift Cylinder (Three Stage Mast) - Used from 09/16/13 12-62 BL-CB22-1214 - 04-11-2019...
Page 139 RING WIPER 35×43×5-6.5 0000-000085-00 ROD PACKING 35×45×6 2125-410004-30 0000-000519-00 O-RING 48×3.1 2125-410001-3A-01 PISTON ROD 2125-410003-00 COLLAR 38×33×2.5 2125-410007-30 PISTON 2125-410002-30 RING BACK UP 2125-411000-30-01 CYLINDER TUBE 2125-410006-30 0000-001137-00 SCREW M6×5 0000-000133-00 WASHER Ø6 0000-000609-00 O-RING 52.5×3.1 BL-CB22-1214 - 04-11-2019 12-63...
Page 140 R6893A Figure 12-32 Tilt Cylinder - Used up to Serial # S2118062 12-64 BL-CB22-1214 - 04-11-2019...
Page 141 NUT M14×1.5 3218-810002-00 DUST SEAL 3218-810006-00 O-SING 58605-15T11 SNAP RING 3218-810005-00 SEAL 58602-15T11 GUIDE RING 3218-810001-00 BEARING 3218-810003-00 O-RING 2320-430001-00 PISTON ROD 58604-15T11 WEAR RING 3218-810004-00 SEAL 58607-15T11 CYLINDER BODY 3218-810007-00 BEARING 0000-000588-00 GREASE CUP M10×1 BL-CB22-1214 - 04-11-2019 12-65...
Page 142 R8012 Figure 12-33 Tilt Cylinder - Used from Serial # S2118063 12-66 BL-CB22-1214 - 04-11-2019...
Page 143 NUT M14 0000-001017-00 DUST SEAL LYO 30×47×10 0000-001016-00 SEAL 30×43×7 2320-440001-00 GUIDE RING 0000-000967-00 O-SING 80×3.1 2320-442000-00 PISTON ROD 0000-001015-00 SEAL YX70×80×6 2320-440003-00 WEAR RING 20×2.5 2320-441000-00 CYLINDER BODY 3218-810007-00 BUSHING 3040 0000-000588-00 GREASE CUP M10×1 BL-CB22-1214 - 04-11-2019 12-67...
Page 144 R6894A Figure 12-34 Electrical System - Used up to Serial # S2320148 12-68 BL-CB22-1214 - 04-11-2019...
Page 145 FAN ASSEMBLY Serial # S2216117 & S2216118) Used from Serial # S2216061 (Except 1220-500004-00 FAN COVER Serial # S2216117 & S2216118) Used from Serial # S2216061 (Except 2320-520007-00 FAN WIRING HARNESS Serial # S2216117 & S2216118) BL-CB22-1214 - 04-11-2019 12-69...
Page 146 R8013 Figure 12-35 Electrical System - Used from Serial # S2320149 12-70 BL-CB22-1214 - 04-11-2019...
Page 147 1220-520007-0D BDI WRING HARNESS 3 PIN 0000-000170-00 SCREW M6×30 0000-000056-00 LOCKWASHER Ø6 2320-531000-00 CONNECTOR BATTERY 1120-112008-00 PLATE 1220-520002-1C POWER SWITCH ASSEMBLY 0000-000121-00 SCREW M4×35 0000-000122-00 LOCKWASHER Ø4 0000-000702-00 FLATWASHER Ø4 1220-520010-0C FAN ASSEMBLY 1220-500004-00 FAN COVER BL-CB22-1214 - 04-11-2019 12-71...
Page 148 R6895A Figure 12-36 Electrical Panel - Used up to Serial # S2320148 12-72 BL-CB22-1214 - 04-11-2019...
Page 149 CONTROLLER 1120-530007-00 BUS BAR 0000-000123-00 FLATWASHER Ø6 0000-000056-00 LOCKWASHER Ø6 0000-000166-00 NUT M6 1120-500005-10 CONTACTOR 0000-000077-00 SCREW M6×12 1120-540001-00-B FUSE HOLDER 0000-000090-00 SCREW M6×12 0000-000196-00 NUT M8 0000-000210-00 FLATWASHER Ø8 1120-540002-00 FUSE 200A 1120-530006-00 BUS BAR BL-CB22-1214 - 04-11-2019 12-73...
Page 150 R8014 Figure 12-37 Electrical Panel - Used from Serial # S2320149 12-74 BL-CB22-1214 - 04-11-2019...
Page 151 2110-500007-00-0A CONTROLLER Used from 02-2015 0000-000123-00 FLATWASHER Ø6 0000-000056-00 LOCKWASHER Ø6 0000-000015-00 SCREW M6×10 1120-530007-00 BUS BAR 2110-510002-0A BUS BAR 1120-500005-10 CONTACTOR 0000-000196-00 NUT M8 0000-000210-00 FLATWASHER Ø8 1120-540002-00 FUSE 200A 0000-000074-00 SCREW M6×20 1120-540001-00-B STAND BL-CB22-1214 - 04-11-2019 12-75...
Page 152 R8015 Figure 12-38 Drive Motor 12-76 BL-CB22-1214 - 04-11-2019...
Page 153 REQD. 0000-000293-00 RETAINING RING 0000-000226-00 KEY 6×6×16 1120-220001-00 TERMINAL BLOCK 0000-000206-00 LOCKWASHER Ø5 0000-000117-00 SCREW M5×10 0000-000166-00 NUT M6 0000-000056-00 LOCKWASHER Ø6 1120-220002-00 BEARING 0000-000204-00 KEY 3×5×13 0000-000409-00 O-RING 63×3.55 0000-000436-00 NUT M12×1.5 0000-000323-00 SCREW M5×16 BL-CB22-1214 - 04-11-2019 12-77...
Page 154 R6896A Figure 12-39 Wiring Harness - Used up to Serial # S2320148 12-78 BL-CB22-1214 - 04-11-2019...
Page 155 Wiring Harness - Used up to Serial # S2320148 QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2320-520001-00 MAIN WIRE HARNESS 1120-500010-00 FUSE 10A 2320-520004-00 SOLENOID VALVE WIRE HARNESS BL-CB22-1214 - 04-11-2019 12-79...
Page 156 R8016 Figure 12-40 Wiring Harness - Used from Serial # S2320149 12-80 BL-CB22-1214 - 04-11-2019...
Page 157 Wiring Harness - Used from Serial # S2320149 QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2320-520001-40 MAIN WIRE HARNESS 1120-500010-00 FUSE 10A 2320-520004-40 SOLENOID VALVE WIRE HARNESS BL-CB22-1214 - 04-11-2019 12-81...
Page 158 R6897A Figure 12-41 Wiring Cables - Used up to Serial # S2320148 12-82 BL-CB22-1214 - 04-11-2019...
Page 159 - Used up to Serial # S2320148 QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2320-530007-00 Pump Power Cable + 2320-530006-00 Pump Power Cable - 2320-530004-00 Motor Cable V 2320-530003-00 Motor Cable U 2320-530005-00 Motor Cable W BL-CB22-1214 - 04-11-2019 12-83...
Page 160 R8017 Figure 12-42 Wiring Cables - Used from Serial # S2320149 12-84 BL-CB22-1214 - 04-11-2019...
Page 161 - Used from Serial # S2320149 QTY. POS. PART NUMBER DESCRIPTION NOTES REQD. 2320-530001-40 MOTOR CABLE U 2320-530002-40 MOTOR CABLE V 2320-530003-40 MOTOR CABLE W 2320-530004-40 PUMP POWER CABLE - 2320-530005-40 PUMP POWER CABLE + 2320-531000-40 CONNECTOR BATTERY BL-CB22-1214 - 04-11-2019 12-85...
Page 162 R7001A Figure 12-43 Battery Pack Assembly - Used up to serial number S2410120 12-86 BL-CB22-1214 - 04-11-2019...
Page 163 Used from serial # S2221331 0000-000700-00 SCREW M8 x 16 Used up to serial # S2221330 0000-000206-00 LOCK WASHER Ø5 Used from serial # S2221331 0000-000159-00 LOCK WASHER Ø8 Used from serial # S2221331 0000-000176-00 FLAT WASHER Ø8 BL-CB22-1214 - 04-11-2019 12-87...
Page 164 R8077 Figure 12-44 Battery Pack Assembly - Used between S2410121 to D24140007 12-88 BL-CB22-1214 - 04-11-2019...
Page 165 1145-550002-20 INSERTION 1120-560002-00 CHARGER CABLE USA 1115-500009-00 CHARGER HOOP 0000-000390-00 FLATWASHER Ø5 0000-000700-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 0000-000117-00 SCREW M5×10 1120-112008-00 PLATE Charger pos. 19 not 1145-EP25-20 KIT FOR CHARGER INSTALLATION included BL-CB22-1214 - 04-11-2019 12-89...
Page 166 R8078 Figure 12-45 Battery Pack Assembly - Used from serial number D24140008 12-90 BL-CB22-1214 - 04-11-2019...
Page 167 PULLER HANDLE 0000-000166-00 NUT M6 1145-551000-2E BATTERY FRAME 1120-560000-00-01 CHARGER, 25A 110V 1145-550002-20 INSERTION 1120-560002-00 CHARGER CABLE USA 1115-500009-00 CHARGER HOOP 0000-000390-00 FLATWASHER Ø5 0000-000700-00 SCREW M8×16 0000-000159-00 LOCKWASHER Ø8 0000-000176-00 FLATWASHER Ø8 0000-000117-00 SCREW M5×10 BL-CB22-1214 - 04-11-2019 12-91...
Page 168 Big Lift LLC...

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