self-propelled, counterbalanced lift … counterbalanced lift truck operation ... drive motor. ......

Big Lift LLC MANUAL NO. BL-C22-1010 - 06-19-2017www.bigjoeforklifts.com 06/19/2017

C22SELF-PROPELLED,

COUNTERBALANCED LIFT TRUCK

Operation

Maintenance

Repair Parts List

WARNING

Do not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator’s Manual and on thistruck.

Do not operate this truck until you have checked itscondition. Give special attention to tires, horn, battery,controller, lift system (including forks or attachments,chains, cables and limit switches), brakes, steeringmechanism, guards and safety devices.

Operate truck only from designated operating position.Never place any part of your body into the mast struc-ture or between the mast and the truck. Do not carrypassengers. Keep feet clear of truck and wear footprotection.

Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be greater.

Travel with lifting mechanism as low as possible.Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loadtrailing.

Use special care when operating on ramps travelslowly, and do not angle or turn. Travel with loaddownhill.

Do not overload truck. Check nameplate for capacityand load center information.

When using forks, space forks as far apart as load willpermit. Before lifting, be sure load is centered, forksare completely under load, and load is as far back aspossible against load backrest.

Do not handle unstable or loosely stacked loads. Usespecial care when handling long, high or wide loads, toavoid losing the load, striking bystanders, or tippingthe truck.

Do not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall backward.

Elevate forks or other lifting mechanism only to pick upor stack a load. Watch out for obstructions, especiallyoverhead.

Do not lift personnel except on a securely attachedspecially designed work platform. USE EXTREMECARE WHEN LIFTING PERSONNEL. Make suremast is vertical, place truck controls in neutral andapply brakes. Lift and lower smoothly. Remain in oper-ating position or immediate vicinity as long as person-nel are on the work platform. Never transportpersonnel on forks or work platform.

Do not allow anyone to stand or pass under load or lift-ing mechanism.

When leaving truck, neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off power.

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION............................................................1-11-1. INTRODUCTION..............................................1-11-2. GENERAL DESCRIPTION...............................1-11-3. SAFETY FEATURES. ......................................1-1

2 OPERATION ...............................................................2-12-1. GENERAL. .......................................................2-12-2. OPERATING PRECAUTIONS. ........................2-12-3. BEFORE OPERATION.....................................2-22-4. GENERAL CONTROL OPERATION................2-42-5. DRIVING AND STOPPING PROCEDURES. ...2-42-6. BELLY-BUTTON SWITCH. ..............................2-42-7. STEERING ARM GAS SPRING.......................2-52-8. LIFT, LOWER AND FAST LOWER

CONTROLS. ....................................................2-52-9. LOADING AND UNLOADING. .........................2-52-10. PARKING. .......................................................2-5

3 PLANNED MAINTENANCE ........................................3-13-1. GENERAL. .......................................................3-13-2. MONTHLY AND QUARTERLY CHECKS. .......3-13-3. BATTERY CARE.............................................3-13-3.1. GENERAL ........................................................3-13-3.2. SAFETY RULES ..............................................3-23-3.3. BATTERY CARE AND CHARGING.................3-23-3.4. BATTERY CLEANING......................................3-23-3.5. MAINTENANCE FREE BATTERIES................3-33-4. CHARGING BATTERIES .................................3-33-5. LUBRICATION. ................................................3-43-6. LIFT CHAIN MAINTENANCE...........................3-4

4 TROUBLESHOOTING ................................................4-14-1. GENERAL ........................................................4-14-2. CONTROLLER TROUBLESHOOTING............4-44-2.1. FAULT DETECTION. .......................................4-44-2.2. HAND HELD PROGRAMMER (OPTIONAL)....4-44-2.3. FAULT RECORDING. ......................................4-44-2.4. FAULT RECOVERY. ........................................4-44-2.5. GENERAL CHECKOUT. ..................................4-44-2.6. DIAGNOSTIC HISTORY ..................................4-64-2.7. TEST THE FAULT DETECTION CIRCUITRY .4-64-2.8. PROGRAMMABLE PARAMETERS.................4-64-2.9. DIAGNOSTICS AND TROUBLESHOOTING. 4-304-2.10.PROGRAMMER DIAGNOSTICS ...................4-31

5 STEERING ARM, CONTROL HEAD AND COMPARTMENT ........................................................5-15-1. CONTROL HEAD.............................................5-15-1.1. CONTROL HEAD REMOVAL ..........................5-15-1.2. BELLY-BUTTON SWITCH REPLACEMENT. ..5-15-1.3. LIFT, LOWER AND HORN SWITCH

REPLACEMENT...............................................5-25-1.4. DIRECTIONAL SWITCH REMOVAL AND

ADJUSTMENT. ................................................5-25-1.5. POTENTIOMETER REMOVAL TESTING

AND ADJUSTMENT.........................................5-35-1.6. CONTROL HEAD INSTALLATION. .................5-4

5-2. STEERING ARM ............................................. 5-45-2.1. RETURN AIR SPRING REPLACEMENT. ....... 5-45-2.2. STEERING ARM REMOVAL........................... 5-55-2.3. STEERING ARM INSTALLATION................... 5-55-3. COMPARTMENT COVERS............................. 5-55-3.1. FORWARD COMPARTMENT. ........................ 5-55-3.2. REAR COMPARTMENT.................................. 5-65-3.3. INSTALLATION. .............................................. 5-6

6 BRAKE SERVICING................................................... 6-16-1. BRAKES. ......................................................... 6-16-1.1. AIR GAP ADJUSTMENT. ................................ 6-16-1.2. STOPPING DISTANCE ADJUSTMENT. ......... 6-26-1.3. BRAKE ASSEMBLY REPLACEMENT ............ 6-2

7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-17-1. DRIVE WHEEL. ............................................... 7-17-2. TRANSMISSION. ............................................ 7-17-3. LOAD WHEEL. ................................................ 7-37-3.1. REMOVAL ....................................................... 7-37-3.2. REPAIR .......................................................... 7-37-3.3. LOAD WHEEL INSTALLATION....................... 7-3

8 ELEVATION SYSTEM SERVICING ........................... 8-18-1. GENERAL........................................................ 8-18-2. LIFT CHAIN LENGTH ADJUSTMENT............. 8-18-3. LIFT CHAIN WEAR INSPECTION................... 8-28-4. LIFT CHAIN REPLACEMENT. ........................ 8-28-5. LIFT CYLINDER. ............................................. 8-3

9 HYDRAULIC SYSTEM SERVICING........................... 9-19-1. LINES AND FITTINGS .................................... 9-19-2. HYDRAULIC PUMP, AND MOTOR ASSY ...... 9-29-2.1. REMOVAL ....................................................... 9-29-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-29-2.3. INSTALLATION ............................................... 9-29-2.4. LIFT CYLINDERS............................................ 9-39-2.5. TILT CYLINDERS............................................ 9-5

10 ELECTRICAL COMPONENTS................................. 10-110-1. ELECTRICAL CONTROL PANEL ................. 10-110-1.1.MAINTENANCE............................................. 10-110-1.2.CLEANING .................................................... 10-110-1.3.PANEL REMOVAL. ....................................... 10-110-1.4.PANEL DISASSEMBLY................................. 10-110-1.5.PANEL INSTALLATION. ............................... 10-110-2. HORN REPLACEMENT ................................ 10-210-3. PUMP MOTOR. ............................................. 10-410-4. DRIVE MOTOR. ............................................ 10-410-4.1.MOTOR REMOVAL....................................... 10-410-4.2.MOTOR INSTALLATION............................... 10-410-5. LIMITATION SWITCH ................................... 10-410-6. DEADMAN SWITCH...................................... 10-510-6.1.REPLACEMENT............................................ 10-5

11 OPTIONAL EQUIPMENT ......................................... 11-1

12 ILLUSTRATED PARTS BREAKDOWN.................... 12-1

BL-C22-1010 - 06-19-2017 i

TABLE OF CONTENTS - Continued

Figure Page Figure Page

1-1 NAME PLATE..................................................... 1-11-2 PDS LIFT TRUCK .............................................. 1-22-1 LOAD CENTER.................................................. 2-12-2 SAMPLE OF OPERATOR CHECK LIST............ 2-32-3 FORWARD/REVERSE CONTROL .................... 2-42-4 PUSHBUTTON SWITCHES............................... 2-42-5 BRAKE ACTUATION.......................................... 2-42-6 BELLY-BUTTON SWITCH ................................. 2-53-1 LUBRICATION DIAGRAM.................................. 3-54-1 CONTROLLER LED........................................... 4-44-2 CONTROLLER TERMINALS ............................. 4-54-3 HAND HELD PROGRAMMER ........................... 4-55-1 STEERING ARM ................................................ 5-15-2 CONTROL HEAD............................................... 5-25-3 SWITCH BOX..................................................... 5-35-4 STEERING SYSTEM ......................................... 5-45-5 COMPARTMENT ............................................... 5-56-1 BRAKE ASSEMBLY........................................... 6-16-2 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY ........................................................ 6-26-3 STEERING SYSTEM ......................................... 6-37-1 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY ........................................................ 7-17-2 FRAME............................................................... 7-27-3 STEERING SYSTEM ......................................... 7-27-4 LOAD WHEEL.................................................... 7-38-1 OUTER MAST.................................................... 8-18-2 INNER MAST ..................................................... 8-29-1 HYDRAULIC SYSTEM ....................................... 9-19-2 PUMP AND MOTOR ASSEMBLY...................... 9-29-3 OUTER MAST.................................................... 9-39-4 LIFT CYLINDER................................................. 9-49-5 TILT CYLINDER................................................. 9-5

10-1 FRAME ............................................................. 10-210-2 ELECTRICAL PANEL....................................... 10-310-3 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY....................................................... 10-410-4 STEERING SYSTEM........................................ 10-512-1 STEERING SYSTEM........................................ 12-212-2 HANDLE ASSEMBLY....................................... 12-312-3 SWITCH BOX ASSEMBLY............................... 12-412-4 SWITCH BOX ................................................... 12-512-5 TRANSMISSION, MOTOR, BRAKE

ASSEMBLY....................................................... 12-612-6 TRANSMISSION, ASSEMBLY ......................... 12-712-7 COMPARTMENT.............................................. 12-812-8 COVER ASSEMBLY......................................... 12-912-9 FRAME ........................................................... 12-1012-10 CASTER ......................................................... 12-1112-11 LOAD WHEEL ................................................ 12-1212-12 OUTER MAST ................................................ 12-1312-13 INNER MAST.................................................. 12-1412-14 LIFT CARRIAGE............................................. 12-1512-15 HYDRAULIC SYSTEM ................................... 12-1612-16 PUMP & MOTOR ASSY ................................. 12-1712-17 PUMP ASSEMBLY ......................................... 12-1812-18 VALVE ASSEMBLY........................................ 12-1912-19 VALVE -B ASSEMBLY ................................... 12-2012-20 LIFT CYLINDER ............................................. 12-2112-21 TILT CYLINDER ............................................. 12-2212-22 FORCING CYLINDER .................................... 12-2312-23 ELECTRICAL SYSTEM.................................. 12-2412-24 BRAKE ASSEMBLY ....................................... 12-2512-25 DRIVE MOTOR............................................... 12-2612-26 HYDRAULIC MOTOR..................................... 12-2712-27 BATTERY ....................................................... 12-28

Table Page Table Page

2-1 OPERATOR CHECKS......................................... 2-23-1 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART ....................................... 3-13-2 RECOMMENDED LUBRICANTS ........................ 3-43-3 LUBRICATION CHART ....................................... 3-54-1 TROUBLESHOOTING CHART ........................... 4-14-2 PROGRAMMABLE PARAMETERS .................... 4-7

4-3 FAULT CATEGORIES .......................................4-294-4 CONFIGURATION OPTIONS: AUXILIARY

DRIVER (PIN 8) .................................................4-304-5 LED CODES.......................................................4-314-6 TROUBLESHOOTING CHART..........................4-32

ii BL-C22-1010 - 06-19-2017

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the 24 volt transistor C22 lift truck distributed by Big Lift LLC. Included areoperating instructions, planned maintenance instruc-tions, lubrication procedures, corrective maintenanceprocedures and a complete parts list with part locationillustrations.

Users shall comply with all requirements indicated inapplicable OSHA standards and current edition ofA.N.S.I. B56.1 Part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your C22 lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled C22 truck, Figure 1-2, lifts andtransports payloads up to 2200 pounds on adjustableforks.

The forward and reverse motion is controlled by eitherof two controller levers mounted on the control head.Stopping and turning is controlled by the steering arm.Lift, Lower and Tilt are controlled by pushbuttons onthe control head. The battery powered lift truck is quietand without exhaust fumes.

The reversible AC motor propels the lift truck in for-ward or reverse direction throughout the availablespeed range. The C22 lift truck can be driven withforks raised or lowered; however, the speed isrestricted when the platform is raised above a presetlimit.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe truck’s main components and controls.

1-3. SAFETY FEATURES.

The C22 is designed and engineered to provide maxi-mum safety for operator and payload. Some of thesafety features incorporated into the design are:

• Dead-man brake to apply the brake and cut off drivepower when the steering arm is released.

• Belly-button switch to reverse truck should the oper-ator accidentally pin himself against a wall orobstruction when backing up in slow speed.

Figure 1-1 Name Plate

• High speed limit switch to restrict speed when liftcarriage is raised above the preset limit.

• All control functions automatically return to “OFF”when released.

• Externally accessible quick-disconnect battery plugwithin operator's reach.

• Separately fused control circuits and power circuits.

• Readily accessible horn button.

• Lift carriage backrest to help stabilize the load.

• Handle to provide a firm hand hold for operator.

• Flow control valve regulates maximum loweringspeed within prescribed limits.

• Relief valve maintains hydraulic pressure within pre-scribed limits.

• High visibility color scheme of truck provides visualalert of truck’s presence.

• Battery Indicator.

• Casters.

R6209

COMPLIES WITH THE APPLICABLE REQUIRE-COMPLIES WITH THE APPLICABLE REQUIRE-

MENTS OF ANSI B56.1 AND OSHA STANDARDSMENTS OF ANSI B56.1 AND OSHA STANDARDS

BIG LIFT LLCBIG LIFT LLC

WISCONSIN DELLS, WISCONSIN 53965WISCONSIN DELLS, WISCONSIN 53965

AUSTRALIAN PATENT NO. 537,987AUSTRALIAN PATENT NO. 537,987

U.S. PATENT NO. 4,444,284U.S. PATENT NO. 4,444,284

TRUCK

TYPE

MODEL NO. SERIAL NO.

VOLTAGEBATTERY

TYPETYPECERTIFIED

MAX CAP LB/MAX CAP LB/ LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/

LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/ALT CAP LB/

BATTERY MIN WT LB/BATTERY MIN WT LB/TRUCK WT LESS BATTERY LB/TRUCK WT LESS BATTERY LB/

BATTERY MAX WT LB/BATTERY MAX WT LB/TRUCK WT WITH BATTERY LB/TRUCK WT WITH BATTERY LB/

KG MM MM

MM MMKG

KGKG

KGKG

BL-C22-1010 - 06-19-2017 1-1

Figure 1-2. C22 Lift Truck

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SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forthe C22 lift truck. The instructions are divided into thevarious phases of operations, such as operating lift,driving, and stopping. Routine precautions areincluded for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the C22 lifttruck.

The following safety precautions must be adhered toat all times.

• Do not operate this truck unless you have beentrained and authorized to do so.

• All warnings and instructions must be read andunderstood before using the equipment.

• Equipment must not be altered in any way.

• Equipment must be inspected by a qualified personon a regular basis.

• Do not exceed the rated capacity. Overloading mayresult in damage to the hydraulic system and struc-tural components.

• Be certain that the lifting machine is operatingsmootly throughout its entire height, both empty andloaded.

• Be sure that mast is vertical - do not operate on aside slope.

• Be sure the truck has a firm and level footing.

• Avoid overhead wires and obstructions.

• Check for obstructions when raising or lowering thelift carriage.

• Do not handle unstable or loosely stacked loads.Use special care when handling long, high, or wideloads to avoid tipping, loss of load, or strikingbystanders.

• Center and carry the load as far back as possibletoward the lift carriage back rest. The center-of-grav-ity of the load must not exceed the load center listedon the nameplate. See Figure 2-1 for load centerlimitations.

• Pick up loads on both forks. Do not pick up on onlyone fork.

• When traveling, always lower the load as far as pos-sible.

• When stacking pallets in racks and it is necessary tomove the load in a raised position, use caution.Operate truck smoothly.

• Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

• Operate truck only from designated operation posi-tion. Never place any part of your body between themast uprights. Do not carry passengers.

• Do not allow anyone to stand or pass under load orlifting mechanism.

• When leaving truck, neutralize travel control. Fullylower lifting mechanism and set brake. When leavingtruck unattended, turn off key switch, remove keyand disconnect battery.

Figure 2-1 Load Center

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2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on theC22 lift truck which should be checked prior to opera-tion. Depending on use, some trucks may requireadditional checks.

Figure 2-2 shows a sample format for an OperatorChecklist, which can be modified as necessary to fityour operation.

WARNING: Periodic maintenance of this truck by aQUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIANshould check the truck monthly for

proper lubrication, proper fluid levels,brake maintenance, motor maintenanceand other areas specified in the SEC-TION 3.

WARNING: If the truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority. Do not operateit until it has been restored to a safeoperating condition. Do not make anyunauthorized repairs or adjustments. Allservice must be performed by a qualifiedmaintenance technician.

Table 2-1 Operator Checks

ITEM PROCEDURE

Transmission and hydraulic systems.

Check for signs of fluid leakage.

Forks Check for cracks and damage; and, that they are properly secured.

Chains, cables and hoses

Check that they are in place, secured correctly, functioning properly and free of binding or damage.

Guards and load backrest

Check that safety guards are in place, properly secured and not damaged.

Safety signs Check that warning labels, nameplate, etc., are in good condition and legible.

Horn Check that horn sounds when operated.

Steering Check for binding or looseness in steering arm when steering.

Travel controls Check that speed controls on control head operate in all speed ranges in forward and reverse and that belly button switch functions.

Wheels Check drive wheel for cracks or damage. Move truck to check load for freedom of rotation.

Hydraulic controls

Check operation of lift and lower to their maximum positions.

Brakes Check that brakes actuate when steering arm is raised to upright position, and when lowered to horizontal position.

Deadman/Parking brake

Check that steering arm raises to upright position when released and brake applies.

Battery disconnect

Check that battery can be disconnected and recon-nected. Check for connector damage.

Battery charge Check the battery indicator.

High speed limit switch

Allow for enough space to oper-ate truck in high speed. Elevate forks approximately two feet, then test drive truck to check if high speed is cut out.

ITEM PROCEDURE

2-2 BL-C22-1010 - 06-19-2017

Figure 2-2 Sample of Operator Check List

R6479

Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Load Wheels

Horn

Lift Lower Control

Need MaintenanceO.K. ( )

Shift

Hour Meter

Reading Drive Hoist

Attachment Operation

Forward & Reverse Controls

Steering

Brakes

Hydraulic Leaks, Cylinders,

Valves, Hoses, Etc.

BL-C22-1010 - 06-19-2017 2-3

2-4. GENERAL CONTROL OPERATION.

The speed control (See Figure 2-3) located on eachside of the control head provides fingertip control fordriving the truck. Rotate the control in the direction youwant to travel. The farther you rotate the control fromthe neutral position, the faster the truck will travel.

Figure 2-3. Forward/Reverse Control

The pushbutton switches (See Figure 2-4), located onthe front of the control head activate the lift, lower, fastlower, tilt, and horn.

Figure 2-4. Pushbutton Switches

The brake is fully applied by lowering or raising thesteering arm. (See Figure 2-5) All traction controlpower is shut off when the brake is engaged. Whenthe steering arm is in the upright position, the brakeacts as a parking brake. Deadman braking occurswhen the handle is released and spring action raisessteering arm to the upright position.

Figure 2-5. Brake Actuation

2-5. DRIVING AND STOPPING PROCEDURES.

1. Be sure the emergency stop button is up.

2. Connect the batteries and turn on the key switch.Grasp the grips of the steering head so that thespeed control can be comfortably operated byeither thumb.

3. Lower the steering arm to a comfortable positionabove horizontal to disengage the brake and toenergize the electrical circuits. If the truck is notmoved, the electrical circuits will time out and willdeenergize. See Figure 2-5.

4. To move forward (with load in front), slowly pressthe speed control forward. See Figure 2-3. Pressthe forward speed control farther to increasespeed.

5. To slow down or stop, release the speed controland lower or raise the steering arm to the horizon-tal or vertical position. See Figure 2-5. In thosepositions, the brake engages, slowing or stoppingthe truck.

6. Procedures for movement in reverse are thesame as in the forward direction except slowlypress the speed control backward. See Figure 2-3.

2-6. BELLY-BUTTON SWITCH.

The belly-button switch (Figure 2-6) minimizes thepossibility of the driver being pinned by the steeringarm while driving the lift truck in slow speed. If theswitch presses against the operator while the lift truckis being driven toward the operator, the switchchanges the direction of the lift truck.

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2-4 BL-C22-1010 - 06-19-2017

Figure 2-6. Belly-Button Switch

2-7. STEERING ARM GAS SPRING.

The steering arm gas spring automatically raises thesteering arm to the upright position when the steeringarm is released. If the steering arm does not returnfully, the steering arm gas spring requires replace-ment. Return truck to maintenance for repair.

2-8. LIFT, LOWER AND FAST LOWER CONTROLS.

Lift, lower and fast lower control buttons are located onthe steering control head. (Figure 2-4)

To lift forks, push in the lift button and hold until forksreach desired height. To lower forks, push in either the

lower or the fast lower button and hold until forksdescend to desired height.

2-9. LOADING AND UNLOADING.

1. Approach the load slowly.

2. Stop truck when the forks are just in front of theload.

3. Adjust the forks to the maximum practical width tosupport the load.

4. Raise or lower and tilt the forks until they areproperly aligned with the pallet opening.

5. Move the truck slowly into position so forks arewithin pallet or skid, and the load is centered overthe forks and as far back as possible.

6. Raise forks to lift load.

7. Drive to area where load is to be placed.

8. Move truck to align load with its new position.

9. Lower and tilt the load until it rests squarely inplace and the forks are free.

10. Slowly move the truck out from under the load.

2-10. PARKING.

When finished with moving loads, return the truck to itsmaintenance or storage area. Turn off the key switchand disconnect the batteries. Charge batteries as nec-essary. Refer to battery care instructions, SECTION 3.

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BL-C22-1010 - 06-19-2017 2-5

NOTES

2-6 BL-C22-1010 - 06-19-2017

SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

Planned maintenance consists of periodic visual andoperational checks, parts inspection, lubrication, andscheduled maintenance designed to prevent or dis-cover malfunctions and defective parts. The operatorperforms the checks in SECTION 2, and refers anyrequired servicing to a qualified maintenance techni-cian who performs the scheduled maintenance andany required servicing.

3-2. MONTHLY AND QUARTERLY CHECKS.

Table 3-1 is a monthly and quarterly inspection andservice chart based on normal usage of equipmenteight hours per day, five days per week. If the lift truckis used in excess of forty hours per week, the fre-quency of inspection and service should be increasedaccordingly. These procedures must be performed bya qualified service technician or your Big Lift LLC Ser-vice Representative.

3-3. BATTERY CARE.

3-3.1. General

The C22 may be equipped with maintenance free orindustrial wet cell batteries.

The care and maintenance of the battery is veryimportant to obtain efficient truck operation and maxi-mum battery life.

CAUTION: Gases produced by a battery can beexplosive. Do not smoke, use an openflame, create an arc or sparks in thevicinity of the battery. Ventilate anenclosed area well when charging.

CAUTION: Batteries contain sulfuric acid which maycause severe burns. Avoid contact witheyes, skin or clothing. In case of contact,flush immediately and thoroughly withclean water. Obtain medical attentionwhen eyes are affected. A baking sodasolution (one pound to one gallon ofwater) applied to spilled acid until bub-bling stops, neutralizes the acid for safehanding and disposal.

Leakage voltage from battery terminals to battery casecan cause misleading trouble symptoms with the truckelectrical system. Since components of the truck elec-trical system are insulated from truck frame, leakagevoltage will not normally affect truck operation unless ashort circuit or breakdown of circuit wire insulation totruck frame occurs.

A voltage check from battery connector terminal tobattery case should indicate near zero volts. Typically,however, the sum of the voltages at both terminals willequal battery volts. This leakage voltage will dischargethe battery. As battery cleanliness deteriorates, theusable charge of the battery decreases due to this selfdischarge.

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 - 06-19-2017 3-1

Although a leakage voltage reading of zero volts maynot be possible, a cleaner battery will have moreusable charge for truck operation and not affect opera-tion of electronic devices on the unit.

3-3.2. Safety Rules

• Wear protective clothing, such as rubber apron,gloves, boots and goggles when performing anymaintenance on batteries. Do not allow electrolyte tocome in contact with eyes, skin, clothing or floor. Ifelectrolyte comes in contact with eyes, flush immedi-ately and thoroughly with clean water. Obtain medi-cal attention immediately. Should electrolyte bespilled on skin, rinse promptly with clean water andwash with soap. A baking soda solution (one poundto one galleon of water) will neutralize acid spilled onclothing, floor or any other surface. Apply solutionuntil bubbing stops and rinse with clean water.

• If truck is equipped with wet cell batteries, keep ventplugs firmly in place at all times except when addingwater or taking hydrometer readings. Do not allowdirt, cleaning solution or other foreign material toenter cells. Impurities in electrolyte has a neutraliz-ing effect reducing available charge.

• Do not bring any type of flame, spark, etc., near thebattery. Gas formed while the battery is charging, ishighly explosive. This gas remains in the cells longafter charging has stopped.

• Do not lay metallic or conductive objects on battery.Arcing will result.

• Do not touch non-insulated parts of DC output con-nector or battery terminals to avoid possible electri-cal shock.

• De-energize all AC and DC power connectionsbefore servicing battery.

• Do not charge a frozen battery.

• Do not use charger if it has been dropped or other-wise damaged.

3-3.3. Battery Care and Charging

CAUTION: Never smoke or bring open flame nearthe battery. Gas formed during chargingis highly explosive and can cause seri-ous injury.

1. Charge the battery only in areas designated forthat use.

2. Make certain the charger being used matches thevoltage and amperage of the truck battery.

3. Before disconnecting or connecting batteries to acharger, make sure the charger is “OFF”. If anattempt is made to do this while the charger is“ON”, serious injury to you, the battery and thecharger could result.

4. Before connecting the battery cable to the trucksreceptacle, make sure the key switch is off. Thebattery cable must be fully connected before thetruck is used. If the plug is not making good con-tact, heat will weld the two parts of the batteryconnector together, making it difficult to removeand necessary to replace.

5. Battery terminals should be checked and cleanedof corrosion regularly. Good battery terminal con-tact is essential not only for operation, but also forproper charging of the battery.

6. The charging requirements will vary depending onthe use of the truck. The battery should be givenas equalizing charge on a weekly basis. Thischarge should normally be an additional threehours at the finish rate.

7. Make certain battery used meets weight and sizerequirements of truck. NEVER operate truck withan undersized battery.

3-3.4. Battery Cleaning

Always keep vent plugs tightly in place when cleaningbattery. When properly watered and charged, the bat-tery will remain clean and dry. All that is necessary isto brush or blow off any dust or dirt that may accumu-late on them. However, if electrolyte is spilled or over-flows from a cell, it should be neutralized with asolution of baking soda and water, brushing the sodasolution beneath the connectors and removing grimefrom the covers. Then rinse the battery with cool waterfrom a low pressure supply to remove the soda andloosen dirt. If batteries stay wet consistently, they maybe either overcharged or over filled. This conditionshould be investigated and corrected.

3-2 BL-C22-1010 - 06-19-2017

3-3.5. MAINTENANCE FREE BATTERIES

Some trucks may be equipped with maintenance freebatteries. These batteries are completely sealed, willnot require any watering and have a full 80% dis-charge available.

Sealed Maintenance Free batteries contain a pressurerelease valve and under normal operating conditionsdo not require any special ventilation.

CAUTION: Do not try to open this battery or removethe pressure release valve.

Only under severe overcharging, such as connectedto an improperly sized charger, will any significantamount of gasses be released from the battery. Also,being a valve regulated battery, it never requireswatering.

3-4. CHARGING BATTERIES

Charging requirements will vary depending on depth ofdischarge and temperature. Follow safety rules whenplacing a battery on charge.

Proceed as follows:

1. Park truck at charging station with carriage low-ered and turn the key switch off.

2. Check the condition of the AC cord, the batteryconnector and battery cables. If there are any cutsin the cable, any exposed wires, loose plugs orconnectors, DO NOT attempt to charge the bat-teries. Contact appropriate personnel for repairsto be made.

3. Disconnect the batteries from the truck and con-nect the batteries to the charger. Make sure con-nectors are mated properly.

4. Connect the charger to the appropriate powersupply.

5. Follow the instructions for the charger being used.

BL-C22-1010 - 06-19-2017 3-3

3-5. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil. Table 3-3 in conjunction with Figure 3-1identifies the items requiring lubrication.

3-6. LIFT CHAIN MAINTENANCE.

Fully raise and lower lift carriage while observingchains as they move over chain sheaves. Ensurechain is aligned and tracking properly and all links arepivoting freely. With lift carriage fully lowered, spray orbrush on a film of SAE 30 or 40 engine oil.

Table 3-2 Recommended Lubricants(See Table 3-3 for Application)

No. 1 Transmission oil—EP SAE 80W-90Transmission oil—EP SAE 10W-30 (Note)

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS foam suppressing agent and rust and oxidation inhibitors

Hydraulic oil-Heavy duty with a viscosity of 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

3-4 BL-C22-1010 - 06-19-2017

Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart

FIG 3-2 INDEX

NO.

LOCATION METHOD OF APPLICATION

TYPE (Table 3-3)

APPLICATION OF

LUBRICANT

1 TransmissionCapacity 2 pints

Can No. 1 Fill to level plug opening

2 Lift Chain Brush or Spray No. 4 See Paragraph 3-6.

3 Mast Brush No. 2 Full length of channel where rollers operate.

4 Lift Carriage Brush No. 2 Light coating where forks slide

5 Hydraulic ReservoirCapacity-1 quarts

Can No. 3 With lift carriage fully lowered, fill reservoir with hydraulic oil to 1 inch below opening

R6690

BL-C22-1010 - 06-19-2017 3-5

NOTES

3-6 BL-C22-1010 - 06-19-2017

SECTION 4TROUBLESHOOTING

4-1. GENERAL

Use Table 4-1 as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck and Hydraulic System Will Not Oper-

ate: Truck Does Not Operate Forward orReverse:Trouble With Braking: Trouble With Lifting Or Lower-ing, and Miscellaneous malfunctions.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK AND HYDRAULIC SYSTEM WILL NOT OPER-ATE

Truck will not travel nor will lift sys-tem operate.

a. Fuse (8 or 13, Figure 12-23) blown.

Check fuse and replace if necessary.

b. Battery dead or disconnected. Check battery quick-disconnect plug and check battery voltage.

c. Keyswitch (6, Figure 12-7) defective.

Bypass keyswitch to determine if it is malfunctioning.

d. Defective wiring. Check for open circuit. Repair as required.

TRUCK DOES NOT OPERATE FORWARD OR REVERSE

Truck does not travel forward or reverse. All other functions operate normally.

a. Check all wiring. A loose con-nection may be the cause of malfunction.

Tighten all loose connections before further troubleshooting.

b. Defective deadman switch (20, Figure 12-1).

Check and replace switch if defective.

c. Defective main contactor (4, Figure 12-23).

Check for proper operation and replace if necessary.

d. Defective potentiometer (14, Figure 12-4).

Check and replace potentiometer if defective.

Truck travels forward but not in reverse.

Defective potentiometer (14, Fig-ure 12-4) in control head.


Truck travels reverse but not in forward.



Truck travels forward and in reverse at lower speeds; will not travel at high speed.



TROUBLE WITH BRAKING

Truck does not slow with brake, or brake does not engage.

a. Defective deadman switch (20, Figure 12-1).

Check deadman switch for continuity. If none found when the control arm is in the brake position, replace switch.

b. Defective electric brake (3, Fig-ure 12-5).

Adjust or replace brake.

BL-C22-1010 - 06-19-2017 4-1

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH BRAKING - Continued

Brake will not release. a. Air gap more than 0.01 in (0.25mm).

Adjust.

b. Brake temperature above 281F (140 C).

Allow to cool and check air gap.

c. Open brake circuitry or wiring. Make voltage checks.

Brake drags. a. Air gap less than 0.01 in (0.25mm).

Adjust.


Replace.

Brake grabs. a. Incorrect stopping distance adjustment.

Adjust (refer to Table 4-2).


Replace.

Abnormal noise and chatter when brake is applied.

Defective electric brake (3, Figure 12-5).

Replace.

TROUBLE WITH LIFTING OR LOWERING

Oil sprays or flows from the top of the lift cylinder.

Defective packing in lift cylinder Repair lift cylinder.

Squealing sounds when lifting forks.

a. Oil level too low. Identify oil leak.

b. Dry channels in mast. Apply grease.

c. Defective mast or carriage roll-ers

Replace rollers

Forks do not lift to top. a. Oil level too low. Add oil to reservoir.

b. Load larger than capacity. Refer to I.D.plate for capacity.

Weak, slow or uneven action of hydraulic system.

a. Defective pump or relief valve. Check pressure. Adjust as 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 not run.

a. Battery is dead or discon-nected.

Check and recharge if required.

b. Defective wiring. Check and repair as required.

c. Defect in electrical system for operating pump motor.

Check lift switch in control head, as well as the coil (20, Figure 12-19).

4-2 BL-C22-1010 - 06-19-2017



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-trol valve

Replace or repair valve assembly (3, Figure 12-16).

b. Worn lift cylinder. Replace cylinder.

Platform does not lift to top. Pump motor runs.

a. Oil level too low. Add oil to reservoir.

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 when in a raised position.

Leak in hydraulic system, lift cylin-der or lowering valve.

Check for leaking fitting in hydrau-lic line and repair as required. Repack lift cylinder or replace or repair valve assembly (3, Figure 12-16).

MISCELLANEOUSSteering arm does not return to

the upright position.a. Week return spring. Replace spring.

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 pulled down.

a. Belly-button switch defective. Check for short, and repair or replace as necessary.

b. Short in control head. Check wiring and repair as required.

Steering arm jerks excessively starting or stopping the truck.

Drive wheel worn. Replace drive wheel if worn to within 3/8 inch of hub.

Drive motor is jerky. Motor internally damaged or worn. Replace motor.

BL-C22-1010 - 06-19-2017 4-3

4-2. CONTROLLER TROUBLESHOOTING

4-2.1. Fault Detection.

The controller provides diagnostics information toassist technicians in troubleshooting drive systemproblems. When a fault is detected, the appropriatefault code is signaled via the LED, externally visible onthe side of controller (See Figure 4-1 for LED locationon controller). The diagnostic codes flashed by theLED are listed in Table 4-5.

Figure 4-1. Controller LED

If the fault is critical, the controller is automatically dis-abled. Faults can be caused internally (e.g. shortedtransistors) or externally (e.g., wrench or hardwaredropped across controller terminals).

To recover from a fault, the F/R switch must be turnedoff and back on again. If the fault has been corrected,the controller will turn back on.

The automatic fault detection system includes:

• Contactor coil open / shorted driver

• Contactor driver over-current / contactor coil short

• Contactor welded

• Emergency reverse circuit check

• M- output fault

• Memory checks upon start-up

• Over-voltage cutback

• Power supply out of range (internal)

• Throttle fault

• Under-voltage cutback

• Watchdog (external and internal)

4-2.2. Hand Held Programmer (Optional)

The hand held programmer is available that isdesigned specifically for use with the controller. Itserves dual functions of reading diagnostic data pro-vided by the controller and adjusting certain perfor-mance values of the controller. There are twoversions, User and OEM. The User version can adjustonly those parameters with User access rights. TheOEM programmer can adjust all the parameters. Theprogrammer is available through your Big Lift LLCdealer.

4-2.3. Fault Recording.

Fault events are recorded in the controller's memory.However, multiple occurrences of the same fault arerecorded as one occurrence.

The fault event list can be loaded into the programmerfor readout. The Special Diagnostics mode providesaccess to the controller's diagnostic history file. Thehistory file contains the entire fault event list createdsince the diagnostic history file was last cleared. Thestandard Diagnostics mode provides information aboutonly the currently active faults.

4-2.4. Fault Recovery.

Almost all faults require a cycling of the KSl (KeySwitch Input) or brake input to reset the controller andenable operation. Refer to Table 4-6 for fault clearancerequirements.

4-2.5. General Checkout.

Carefully complete the following checkout procedure.If you find a problem during the checkout, refer toparagraph 4-2.9. for further information.

The checkout can be conducted with or without thehandheld programmer (See Paragraph 4-2.2.). How-ever, the checkout procedure is easier with a program-mer. To evaluate the system without a programmer,observe the LED and note the flashing pattern andrefer to Table 4-5 for the code description.

CAUTION: Put the vehicle up on blocks to get thedrive wheel off the ground before begin-ning these tests.

Turn the keyswitch off and make sure thebrake is applied, the throttle is in neutral,and the forward/reverse switches areopen.

Do not stand, or allow anyone else tostand directly in front of or behind thevehicle during the tests.

R6691

4-4 BL-C22-1010 - 06-19-2017

1. Connect the programmer to the programmer con-nector (Figure 4-2) on the controller.

Figure 4-2. Controller Terminals

2. Turn the lift truck key switch to the ON position.The programmer should "power up" with an initialdisplay (2, Figure 4-3), and the controllers StatusLED should begin steadily blinking a single flash.If neither happens, check for continuity in the keyswitch circuit and controller ground.

Figure 4-3. Hand Held Programmer

3. Put the controller into the diagnostic mode bypressing the "Menu Navigation Key" (1, Figure 4-3). Using the Navigation key, select the Faultsmenu. Display the Faults menu by pressing theRight side of the Navigation key. Press the Right

side of the Navigation key again to display the listof System Faults. The display should indicate "NoKnown Faults."

Release the brake by pulling down the steeringarm into the operating position. The controllersLED should continue blinking a single flash andthe programmer should continue to indicate nofaults. If there is a problem, the LED will flash adiagnostic code and the programmer will display adiagnostic message. If you are conducting thecheckout without a programmer, look up the LEDdiagnostic code in Table 4-5.

When the problem has been corrected, it may benecessary to cycle the brake in order to clear thefault code.

4. With the brake released, select a direction andoperate the throttle. The motor should begin toturn in the selected direction. If it does not, verifythe wiring to the forward/reverse switches andmotor. The motor should run proportionally fasterwith increasing throttle. If not, refer to Paragraph4-2.9.

5. Put the controller into the test mode by using theNavigation key (1) to select the "Monitor" menu.Select the Monitor mode by pressing the "Right"arrow on the Navigation key. Press the Navigationkey "Down" arrow to scroll down to observe thestatus of the forward, reverse, brake, emergencyreverse, and mode switches. Cycle each switch inturn, observing the programmer. Each inputshould show the correct state on the programmer.

6. Check the controller's fault detection circuitry asdescribed in Paragraph 4-2.6.

7. Take the vehicle off the blocks and drive it in aclear area. It should have smooth accelerationand good top speed.

8. Test the plug braking of the vehicle. The vehicleshould smoothly slow to a stop and reverse direc-tion, with the audible plugging tone.

9. Verify that all options, such as high pedal disable(HPD), static return to off (SRO), and anti-tie-down, are as desired.

10. Check to see whether the emergency reverse(belly button) feature is working correctly. Verifythat the circuit is operational by momentarily dis-connecting one of the emergency reverse wires.The vehicle should be disabled and a fault indi-cated.

R6491

I7090

BL-C22-1010 - 06-19-2017 4-5

4-2.6. Diagnostic History

The handheld programmer can be used to access thecontroller's diagnostic history file. When the program-mer is connected to the unit, the error log file is auto-matically uploaded into the handheld programmer.

To see the present status of the unit, use the MenuNavigation Key (1, Figure 4-3) to select:

Faults->System Faults.

To access this log, use the Menu Navigation Key toselect:

Faults->Fault History

The faults are shown as a code and descriptive text. Ifthere are multiple faults, you have to scroll through thelist using the Up and Down Buttons on the Menu Navi-gation Key

The faults may be intermittent faults, faults caused byloose wires, or faults caused by operator errors. Faultssuch as HPD or over-temperature may be caused byoperator habits or by overloading.

After a problem has been diagnosed and corrected,clearing the diagnostic history file is recommended.This allows the controller to accumulate a new file offaults. By checking the new diagnostic history file at alater date, you can quickly determine whether theproblem has been completely fixed.

To clear the diagnostic history file, select:

Faults->Clear Fault History.

You will be asked to confirm your actions. Use the"plus" arrow (+) for yes to clear the menu and the"minus" arrow (-) (3) to cancel your selection and notclear the Fault History.

4-2.7. Test the Fault Detection Circuitry

1. Put the vehicle up on blocks to get the drive wheeloff the ground.

2. Disconnect the battery and make sure the key-switch is in the "OFF" position.

3. Using an inline fuse holder fitted with a 10 ampfuse and alligator clips, connect the controller's Mand B- terminals.

4. Reconnect the battery and turn the key switch tothe "ON" position. Release the brake and applythe throttle. The motor should not operate.

5. Leave the key switch on and remove the in-linefuse wire. The vehicle status should continue toremain off.

6. Cycle the key switch off and on. Release thebrake and apply the throttle. The vehicle shouldnow operate normally.

4-2.8. Programmable Parameters

The controller has a number of parameters that can beprogrammed using the handheld programmer. Theseprogrammable parameters allow the vehicle’s perfor-mance characteristics to be customized to fit theneeds of individual vehicles or vehicle applications.

The OEM can specify the default value for eachparameter and can also designate whether a parame-ter will have User or OEM access rights. Accordingly,programmers are available in User and OEM versions.The User programmer can adjust only those parame-ter with User access rights, whereas the OEM pro-grammer can adjust all the parameters.

The MultiModeTM feature of the controller allows oper-ation in four distinct modes. These modes can be pro-grammed to provide four different sets of operatingcharacteristics, which can be useful for operating indifferent conditions, such as slow precise indoormaneuvering in Mode 1; faster, long distance, outdoortravel in Mode 4; and application-specific special con-ditions in Modes 2 and 3. Eight parameters can beconfigured independently in each of the four modes:

• acceleration rate (M1-M4)

• braking current limit (M1-M4)

• braking rate (M1-M4)

• deceleration rate (M1-M4)

• drive current limit (M1-M4)

• maximum forward speed (M1-M4)

• maximum reverse speed (M1-M4)

• restraint (M1-M4)

To change a parameter (Table 4-2) using the program-mer, use the Navigation key (1, Figure 4-3) to selectthe "PROGRAM" menu. Press the Right key to displaya listing of program settings. Scroll down the ProgramListing until the desired parameter is highlighted on thedisplay. Press the Right key to display the settings forthe item selected. Press the Increase/Decrease key("+" or "-") (3) until the desired value setting isreached. The parameter is now set at the desiredvalue. All programming occurs in real time. Thatmeans the parameter can be changed while the vehi-cle is in operation.

4-6 BL-C22-1010 - 06-19-2017

Table 4-2 Programmable Parameters

Parameter Factory Setting Description

VOLTAGE 2 Normal battery voltage, in volts.

The battery voltage parameter sets the overvoltage and undervoltage protection thresholds for the controller and battery. Overvoltage protection cuts back regenerative brak-ing to prevent damage to batteries and other electrical sys-tem components due to overvoltage; undervoltage protection prevents systems from operating at voltages below their design thresholds. The battery voltage parame-ter can be set at 2 or 3, and should always be set to the sys-tem’s nominal battery pack voltage:

2 = 24V

M1 DRIVE C/L 150 Mode 1 drive current limit, in amps.

The drive current limit parameter allows adjustment of the maximum current the controller will supply to the motor during drive operation. This parameter can be limited to reduce the maximum torque applied to the drive system by the motor in any reduced performance mode. The drive cur-rent limit is adjustable from 50 amps up to the controller’s full rated armature current.

M2 DRIVE C/L Not Used

M3 DRIVE C/L Not Used

M4, DRIVE C/L Not Used

M1 BRAKE C/L 150 Mode 1 braking current limit, in amps.

The braking current limit parameter adjusts the maximum current the controller will supply to the motor during regen braking. The braking current limit is adjustable from 50 amps up to the controller’s full rated braking current.

M2 BRAKE C/L Not Used



M1 ACCEL RATE 2 Mode 1 acceleration rate, in seconds.

The acceleration rate defines the time it takes the controller to accelerate from 0% drive output to 100% drive output. A larger value represents a longer acceleration time and a gentler start. Fast starts can be achieved by reducing the acceleration time, i.e., by adjusting the accel rate to a smaller value. The acceleration rate is adjustable from 0.1 to 3.0 seconds.

M2 ACCEL RATE Not Used



BL-C22-1010 - 06-19-2017 4-7

Table 4-2 Programmable Parameters - Continued


M1 DECEL RATE 25 Mode 1 deceleration rate, in seconds.

The deceleration rate defines the time it takes the controller to reduce its output to the new throttle request when the throttle is reduced or released. A lower value represents a faster deceleration and thus a shorter stopping distance. The decel rate defines the vehicle’s braking characteristic for any reduction in throttle, including to neutral, that does not include a request for the opposite direction. The decel rate is adjustable from 0.1 to 10.0 seconds.

M2 DECEL RATE Not Used



THROTTLE DECEL 04 Time for transition to braking mode, in seconds

The throttle deceleration rate parameter adjusts the rate at which the vehicle transitions to braking when throttle is first reduced. If the throttle decel rate is set low, deceleration is initiated abruptly. The transition is smoother if the throttle decel rate is higher; however, setting the throttle decel parameter too high can cause the vehicle to feel uncontrol-lable when the throttle is released, as it will continue to drive for a short period. The throttle decel rate is adjustable from 0.1 to 1.0 second, with a value of 0.3 or 0.4 working well for most vehicles.

When the armature current goes negative (i.e., at the point when positive torque transitions to negative torque), the normal decel rate goes into effect.

M1 BRAKE RATE 2 Mode 1 braking rate, in seconds.

The braking rate defines the time it takes the controller to increase from 0% braking output to 100% braking output (as defined by the corresponding mode specific brake current limit) when a new direction is selected. A larger value rep-resents a longer time and consequently gentler braking. Faster braking is achieved by adjusting the braking rate to a smaller value. The braking rate is adjustable from 0.1 sec-ond to 3.0 seconds.

Note: The variable braking parameter must be programmed Off for the braking rate parameter to apply; if variable brak-ing is On, the braking rate will be determined by throttle position rather than the programmed braking rate.

M2 BRAKE RATE 2 Not Used



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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

Upon receiving a sudden high throttle demand from neutral, the quick start function causes the controller to momentar-ily exceed its normal acceleration rate, in order to overcome vehicle inertia. The quick start algorithm is applied each time the throttle passes through neutral and the controller is not in braking mode. If the controller is in braking mode, the quick start function is disabled, allowing normal braking to occur. Quick start is adjustable from 0 to 10. Increasing the value will “liven” the vehicle’s acceleration response to fast throttle movements.

NOTE: Quick start is not a MultiMode TM parameter, and its value will therefore affect all four operating modes.

TAPER RATE 1 Threshold affecting end of regen during direction reversal: 1 to 20

The taper rate affects direction-reversal at the very end of braking, just before the vehicle stops moving in the original direction. Low taper rate values result in faster, more abrupt direction transitions. Higher taper rate values result in slower and smoother direction transitions. The taper rate is adjustable from 1 to 20.

M1 MAX FWD SPD 100 Mode 1 maximum forward speed, as % drive output

The maximum forward speed parameter defines the maximum controller voltage output at full throttle, in the forward direc-tion. The maximum forward speed parameter is adjustable from the programmed creep speed up to 100%.

M2 MAX FWD SPD Not Used



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M1 MAX REV SPD 100 Mode 1 maximum reverse speed, as % drive output

The maximum reverse speed parameter defines the maxi-mum controller voltage output at full throttle, in the reverse direction. The maximum reverse speed parameter is adjust-able from 0% to 100%.




CREEP SPEED 5 Creep speed, as % drive output

The creep speed parameter defines the initial controller output generated when a direction is first selected. No applied throttle is necessary for the vehicle to enter the creep mode, only a direction signal. The controller maintains creep speed until the throttle is rotated out of the throttle dead-band (typically 10% of throttle).

Creep speed is adjustable from 0% to 25% of the controller output; it cannot be set higher than the lowest programmed M1–M4 maximum forward speed. The specified creep speed is not displayed as the throttle percent in the pro-grammer’s Test Menu when a direction is selected and zero throttle is applied; only the 0% throttle command is dis-played.

THROTTLE TYPE 1 Type of throttle input

The controller accepts a variety of throttle inputs. The throttle type parameter can be programmed to 1, 2, 3, or 4. The standard throttle input signal type options are:

1 = 5kW - 0 potentiometer2 = single-ended 0 - 5V, 3-wire pot, current sources, and electronic throttles3 = 0 - 5kW potentiometers 4 = wigwag 0 - 5V and 3-wire pot throttles

4-10 BL-C22-1010 - 06-19-2017



THRTL DEADBAND 12 Throttle neutral deadband, as %

The throttle deadband parameter defines the throttle pot wiper voltage range that the controller interprets as neutral. Increasing the throttle deadband setting increases the neu-tral range. This parameter is especially useful with throttle assemblies that do not reliably return to a well-defined neu-tral point, because it allows the deadband to be defined wide enough to ensure that the controller goes into neutral when the throttle mechanism is released.

The throttle deadband parameter is adjustable from 0% to 40% of the nominal throttle wiper range; the default setting is 10%. The nominal throttle wiper voltage range depends on the throttle type selected.

THROTTLE MAX 95 Throttle input req’d for 100% drive output, as %

The throttle max parameter sets the wiper voltage or resis-tance required to produce 100% controller output. Decreas-ing the throttle max setting reduces the wiper voltage or resistance and therefore the full stroke necessary to pro-duce full controller output. This feature allows reduced-range throttle assemblies to be accommodated.

The programmer displays the throttle max parameter as a per-centage of the active throttle range. The active throttle range is not affected by the throttle deadband setting. The throttle max parameter can be adjusted from 100% to 60%; the default setting is 90%. The nominal throttle wiper range depends of the throttle type selected.

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THROTTLE MAP 45 Drive output at 50% throttle input, as %

The throttle map parameter modifies the vehicle’s response to the throttle input. The throttle map parameter’s default setting of 50% provides a linear output response to throttle position. Values below 50% reduce the controller output at low throttle, providing enhanced slow speed maneuverabil-ity. Values above 50% give the vehicle a faster, more responsive feel at low throttle.

The throttle map setting can be programmed between 20% and 80%. The setting refers to the PWM output at half throt-tle, as a percentage of the throttle’s full active range. The throttle’s active range is the voltage or resistance between the 0% modulation point (the throttle deadband threshold) and the 100% modulation point (the throttle max threshold).

With creep speed set at 0 and maximum speed set 100%, a 50% throttle map setting will give 50% output at half throttle. A throttle map setting of 80% will give 80% output at half throttle.

Changing either of the speed parameters changes the charac-teristics of the controller output relative to the throttle input and hence the throttle response. Controller output is always a percentage of the range defined by the speed parameters (the range between the creep speed and maximum speed settings). This means that controller output will begin to increase above the set creep speed as soon as the throttle exceeds the neutral deadband threshold. Controller output will continue to increase as the throttle input increases and will reach maximum output when the throttle input reaches the throttle max threshold. The maximum controller output at this point is defined by the value of the maximum speed parameter.

FIELD MIN 3 Minimum field current, in amps

The minimum field current limit parameter defines the mini-mum allowed field current, thus determining the vehicle’s maximum speed. Field Min can be adjusted from 1.6 amps up to the lowest programmed M1–M4 Restraint value.

FIELD MAX 13 Maximum field current, in amps

The maximum field current limit parameter defines the max-imum allowed field current. The maximum field current limit setting determines the vehicle’s maximum torque and the maximum power that the field winding will have to dissipate. Field Max can be adjusted from the programmed Field Min value up to the controller’s full rated field current.

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FLD MAP START 50 Armature current at which field map takes effect, in amp

The field map start parameter defines the armature current at which the field map starts to increase from the programmed Field Min value. This parameter is adjustable from 25 amps up to the full rated armature current value.

The field map start parameter is used to equalize the vehicle’s maximum speed when loaded and unloaded. Increasing the field map start parameter value will increase the maximum load weight that the vehicle can carry while maintaining maximum speed on a level surface.

FIELD MAP 50 Field current map setting, as %

The field map defines the relationship between armature cur-rent and field current under steady-state drive conditions. The shape of the field map is determined by the pro-grammed Field Min, Field Max, Field Map, Field Map Start, and M1-M4 Drive C/L settings.

The field map parameter adjusts the field current at the Field Map Midpoint, which is located halfway between the pro-grammed Field Map Start and the programmed M1-M4 Drive C/L. With the field map parameter set at 50%, the motor’s field current increases linearly with increasing armature current—thus emulating a series wound motor.

Decreasing the field map parameter reduces the field current at a given armature current. As the field current is reduced, the motor will be able to maintain speeds closer to the max-imum speed value as its load increases; however, the motor’s capability to produce torque at these higher speeds will decrease. With the Field Map reduced to 20%, the field current at the Field Map Midpoint will exceed Field Min by 20% of the range between Field Min and Field Max.

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CURRENT RATIO 1 Current ratio: factor of 1, 2, 4, or 8

The current ratio parameter defines how much of the pro-grammed drive current will be available to the motor at reduced throttle requests. The current ratio parameter can be set to 1, 2, 3, or 4. These settings correspond to the fol-lowing ratios:1 = 1:12 = 2:13 = 4:14 = 8:1

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%.

High current ratio values will allow quicker startup response and improved ramp climbing with partial throttle, but may cause too much jumpiness.

Note: Current ratio is only effective in drive; it does not affect regen.

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M1 RESTRAINT 10 Mode 1 restraint braking, in amps

Because the controller is configured to provide regenerative braking, overspeed causes the controller to create a braking current and thus limit or “restrain” the overspeed condition. The restraint parameter determines how strongly the con-troller tries to limit the vehicle speed to the existing throttle setting. It is applicable when throttle is reduced or when the vehicle begins to travel downhill.

At zero throttle, the restraint function tries to keep the motor at zero speed, which helps hold the vehicle from running away down ramps. The higher the restraint parameter value, the stronger the braking force applied to the motor and the slower the vehicle will creep down ramps. This creeping speed depends on the restraint setting, the steepness of the ramp, and the vehicle load weight. The restraint feature can never hold a vehicle perfectly stationary on a ramp and is not intended to replace a mechanical or electromagnetic brake for this purpose.

The restraint parameter establishes a linear mapping of field current to braking current, and is adjustable from the pro-grammed minimum field (Field Min) up to the controller’s full rated field current. It is limited by the programmed maximum field (Field Max). Setting the restraint parameter to a high value will cause strong braking, in an effort to bring the vehi-cle speed down to the requested speed. Extremely high val-ues may cause the vehicle speed to oscillate (“hunt”) while in ramp restraint.

M2 RESTRAINT Not Used



LOAD COMP 0 Load compensation: 0 to 25% drive output

The load compensation parameter actively adjusts the applied motor voltage as a function of motor load current. This results in more constant vehicle speeds over variations in driving surface (ramps, rough terrain, etc.) without the vehicle operator constantly adjusting the throttle position; it also helps equalize loaded and unloaded vehicle speeds. The load compensation parameter is adjustable from 0% to 25% of the controller’s PWM output. High values will cause the controller to be more aggressive in attempting to main-tain vehicle speed. However, too much load compensation can result in jerky vehicle starts and speed oscillation (“hunting”) when the vehicle is unloaded.

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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 requires the controller to receive a KSI input and an inter-lock input (HPD Type 1)—or simply a KSI input (HPD Type 2)—before receiving a throttle input greater than 25%; if the inputs are not received in the proper sequence, the control-ler will inhibit output to the motor. An HPD fault can be cleared by reducing the throttle demand to less than 25%.

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.

Note: The conditions for HPD faults are not affected by whether the main contactor interlock parameter is On or Off.

HPD Type 0: No HPD fault detection

HPD Type 1: KSI+interlock

To drive the vehicle, the controller must receive both a KSI input and an interlock input before receiving a >25% throttle input. Any other sequence will result in an HPD fault that will prevent the vehicle from being driven.

With HPD Type 1, the sequencing delay parameter can be used to prevent HPD faults that would otherwise occur from momentary opening of the interlock switch while driving. If the interlock switch is opened and then quickly closed before the programmed sequencing delay elapses, no HPD fault will be declared and operation will not be interrupted.

HPD Type 2: KSI only

To drive the vehicle, the controller must receive a KSI input before receiving a throttle input greater than 25%. Violation of this sequence will result in an HPD fault that will prevent the vehicle from being driven. With HPD Type 2, if throttle is applied after the KSI input has been received but before the interlock switch is closed, the vehicle will accelerate to the requested speed as soon as the interlock switch is closed.

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SRO 3 Static return to off (SRO)

The static return to off (SRO) feature prevents the vehicle from being started when “in gear,” i.e., with a direction already selected. SRO checks the sequencing of the KSI and interlock inputs relative to a direction input. SRO faults can result from using an incorrect sequence, or from using a correct sequence with less than 50 msec between steps. If an SRO fault is declared, the controller will inhibit output to the motor until the fault is cleared by using an acceptable sequence.

The sequencing delay can be used to prevent SRO faults that would otherwise occur from momentary opening of the interlock switch while driving. If the interlock switch is opened and then quickly closed before the programmed delay time elapses, no SRO fault will be declared and oper-ation will not be interrupted.

Note: The conditions for SRO faults are not affected by whether the main contactor interlock parameter is On or Off.

Three types of SRO are available, along with a “no SRO” option.

SRO Type 0: No SRO fault detection

SRO Type 1: KSI and Interlock before direction input

To drive the vehicle, the controller must receive both a KSI input and an interlock input before receiving an input from either direction switch. The order in which the KSI and inter-lock inputs are received does not matter, only that they are both received before a direction input.

SRO Type 2: KSI before Interlock before direction input

To drive the vehicle, the controller must receive a KSI input and then an interlock input before receiving an input from either direction switch.

SRO Type 3: KSI before Interlock before forward input

Type 3 SRO is useful for walkie vehicles that frequently oper-ate on ramps. To drive the vehicle in the forward direction, the controller must receive the KSI, interlock, and forward inputs in that order, as in SRO Type 2. However, this sequence is not required for operation in reverse. With SRO Type 3, a reverse input is allowed at any place in the sequence: i.e., before interlock, or even before KSI.

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SEQUENCING DLY 0 Sequencing delay, in seconds

The sequencing delay feature allows the interlock switch to be cycled within a set time—the sequencing delay—without activating HPD or SRO. This feature is useful in applications where the interlock switch may bounce or be momentarily cycled during operation. However, it is important to bear in mind that the same sequencing delay also delays the initia-tion of interlock braking.

The sequencing delay can be programmed from 0.0 to 3.0 seconds, with 0.0 corresponding to no delay.

MAIN CONT INTR ON Main contactor uses interlock input: On or Off

The main contactor interlock parameter allows the OEM to define a dual switch requirement to operate the vehicle. When this parameter is programmed On, the controller requires that both KSI (Pin 16) and the interlock input (Pin 15) be pulled high (to B+) before the controller will engage the main contactor. The main contactor will open after the interlock switch is opened and the sequencing delay expires. If this parameter is programmed Off, only the KSI input is required for the main contactor to be engaged.

After changing the main contactor interlock setting, KSI must be cycled for the new setting to take effect.

MAIN OPEN DLY 5 Main contactor open delay: On or Off

The main contactor open delay parameter is applicable only if the main contactor driver interlock has been programmed On. The delay can then be set to allow the contactor to remain engaged for a period of time after the interlock switch is opened. The delay is useful for preventing unnec-essary cycling of the contactor and for maintaining power to auxiliary functions, such as a steering pump motor, that may be used for a short time after the interlock switch has opened. The main contactor open delay is programmable from 0 to 40 seconds.

After the interlock switch is opened, the programmed sequenc-ing delay must expire before the main contactor open delay timer starts counting. Therefore, the time between the inter-lock switch opening and the main contactor disengaging is the sum of the sequencing delay and the main contactor open delay.

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CONT DIAG ON Contactor diagnostic: On or Off

The main contactor diagnostics parameter, when pro-grammed On, enables two checks to verify that the main contactor is present and that it has not welded closed. Each time the main contactor is commanded to engage, the con-troller first performs a main contactor welded test to verify that it is not already closed. The controller then engages the contactor and performs a missing contactor test to confirm that the contactor successfully engaged.

These checks are not performed if the main contactor diagnos-tics parameter is programmed Off. The main contactor driver, however, is always protected from overcurrents, short circuits, and overheating.

AUX TYPE 1 Auxiliary driver type

The auxiliary driver type parameter configures the low side driver at Pin 8. The auxiliary driver can be programmed to operate in any of the configurations (i.e., Types 1 through 5) described in Table 4-4. Types 1 through 4 are various ways of configuring the driver for an electromagnetic brake; Type 5 is a non-EM-brake option. If no auxiliary device will be connected to Pin 8, the auxiliary driver should be pro-grammed to Type 0.

AUX DELAY 0.2 Auxiliary driver open delay, in seconds

The auxiliary driver delay parameter allows a delay before the electromagnetic brake is engaged (Pin 8 driver opened) after the vehicle reaches the neutral state (throttle in neu-tral, both direction switches open, motor speed approxi-mately zero). The Aux Delay is adjustable from 0 to 30 seconds. When set to zero, there is no delay and the brake is engaged as soon as the vehicle reaches the neutral state. This parameter does not apply to Aux Type 1 (see Table 4-4).

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

When emergency reverse is activated, the emergency reverse current limit parameter defines the maximum braking current during deceleration and the maximum drive current after the vehicle switches direction. The emergency reverse current limit is adjustable from 50 amps up to the controller’s full rated braking current.

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EMR REV CHECK Off Emergency reverse wiring check: On or Off

The emergency reverse check parameter is applicable only when the emergency reverse feature is being used in the application. If emergency reverse is not being used, this parameter should be set to Off.

When enabled (programmed On), the emergency reverse check tests for continuity from the emergency reverse check output (Pin 10) to the emergency reverse input (Pin 13). Therefore, the emergency reverse wiring should be connected as closely as possible to the controller side of the emergency reverse switch.

EMR DIR INTR Off Emergency reverse direction interlock: On or Off

In applications that use the emergency reverse feature, the emergency reverse direction interlock parameter defines the requirements for resuming normal operation after using emergency reverse. After emergency reverse has been used, the controller sets the output drive to zero regardless of whether a direction or throttle is being requested. With the emergency reverse direction interlock parameter set to On, the operator can either open both direction switches or cycle the interlock switch to enable normal operation. With the emergency reverse direction interlock parameter set to Off, the only way for the operator to resume normal opera-tion is by cycling the interlock switch.

VARIABLE BRAKE Off Variable braking: On or Off

The variable braking parameter defines how the controller will apply braking force when direction-reversal braking is requested. If the variable braking parameter is programmed On, the amount of braking current applied by the controller will be a function of the throttle’s position when braking is requested. With variable braking, the operator can use the throttle to control the amount of braking force applied to a moving vehicle. Increasing throttle in the direction opposite to the vehicle’s motion will apply increasing amounts of regen braking current to the motor, slowing the vehicle more quickly.

If a fixed amount of braking force is preferred, the variable braking parameter should be programmed Off. With vari-able braking Off, the controller applies the full braking cur-rent specified as soon as braking is requested.

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ANTI-TIEDOWN Off Anti-tiedown: On or Off

The anti-tiedown feature prevents operators from taping or “tying down” the mode select switches in order to operate permanently in Mode 2 or Mode 4 (which are typically the higher speed modes). Each time the interlock switch closes, the anti-tiedown feature checks which mode is selected. If the mode select switches are requesting Mode 2 or Mode 4 (Mode Select 1 switch closed), the controller will default to Mode 1 or Mode 3, depending on the position of the Mode Select 2 switch, and an anti-tiedown fault will be declared. The controller will then remain in Mode 1 or Mode 3 until the Mode Select 1 switch is released and reactivated. The anti-tiedown feature can be programmed On or Off.

POT LOW FAULT Off Pot Low Fault: 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.

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RESET VOLTS Voltage at which state of charge resets to 100%, in volts

The reset voltage parameter sets the battery voltage used to detect the 100% state-of-charge point on a battery with no load. Whenever the programmed Reset Voltage is present for 2 seconds (except during regenerative braking), the bat-tery discharge indicator % will automatically reset to 100%. The reset voltage value can be set from the programmed Full Volts value up to 3.00 VPC, in 0.01 VPC increments.

BATTERY ADJUST Battery discharge indicator algorithm adjustment to compen-sate for battery capacity, in secs

The battery adjustment parameter is used to adjust the bat-tery discharge indicator algorithm to compensate for battery capacity. Higher capacity batteries can spend more time below the Full Volts setting before beginning to lose charge. The battery adjustment parameter sets the number of sec-onds of droop required before the battery state of charge is decremented by 1%. It is adjustable from 0.1 to 20.0 sec-onds.

BDI LOCKOUT Off Fault 2 output high when battery discharge indicator (BDI) %=0: On or Off

When the BDI lockout parameter is programmed On, the Fault 2 output (at Pin 3) can be used as an interface to an external auxiliary enable circuit. When BDI%=0, the Fault 2 output will be high; when BDI%.1, the Fault 2 output will be low.

When BDI lockout is programmed Off, the Fault 2 output is determined by the setting of the Fault Code parameter.

BDI DISABLE Off Battery s-o-c <1% invokes battery discharge indicator (BDI) Limit Speed: On or Off

The BDI disable parameter, when programmed On, limits the vehicle’s maximum speed to the BDI Limit Speed when the battery state-of-charge is 0%.

ADJ HRS LOW Hourmeter preset low byte: 0-99

The adjust hours low parameter is used to adjust the lowest two digits, from 00 to 99. It is not possible to set tenths.

ADJ HRS MID Hourmeter preset middle byte: 0-99

The adjust hours middle parameter is used to adjust the mid-dle two digits, from 00 to 99.

ADJ HRS HIGH Hourmeter preset high byte: 0-99

The adjust hours high parameter is used to set the highest two digits, from 00 to 99.

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SET TOTL HRS Off Apply preset values to total hourmeter: On or Off

The set total hours parameter is used to apply the preset high, middle, and low values to the total (i.e., KSI on-time) hourmeter. First, adjust the preset values as desired for the total hourmeter. Then, program the Set Total Hours parame-ter On, which automatically loads the preset values.

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 set traction hours parameter is used to apply preset high, middle, and low values to the traction hourmeter. First, adjust the preset values as desired for the traction hourme-ter. Then, program the Set Traction Hours parameter On, which automatically loads the preset values. Once they have been loaded, the Set Traction Hours parameter should be programmed Off.

HOURMETER TYPE Off Total hourmeter is default display: On or Off

The Spyglass gauge displays hourmeter data for 5 seconds each time the keyswitch is turned on. The hourmeter type parameter defines whether the total hourmeter or traction hourmeter data will be displayed. When this parameter is programmed On, the total hourmeter is displayed; when programmed Off, the traction hourmeter is displayed.

SRVC TOTL HRS Total service timer setting, in hundreds of hours

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).

Setting the parameter to 0 means that the timer will never expire - i.e., there will be no overall maintenance reminder.

SRVC TRAC HRS Traction service timer setting, in hundreds of hours

The traction service hours parameter is used to set the timer for the next scheduled traction motor maintenance. The ser-vice interval can be up to 5,000 hours. The traction service timer is adjustable between 0.0 and 50.0, in 0.5 increments, with 25.0 being equivalent to 2,500 hours (25.0 X 100).

Setting the parameter to 0 means that the timer will never expire - i.e., there will be no motor maintenance reminder.

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SRVC TOTL Off Reset total service timer: On or Off

When the total service timer expires, the controller automati-cally sets the service total parameter On. The Service Total parameter must then be programmed Off to indicate the appropriate service has been performed.

If a vehicle is brought in for service before a service warning is issued, you can check the accumulated total service hours. Plug in the hand held programmer and go to the Monitor menu. Multiply the “Tot Srvc X25” value by 25 and add the “+Tot Srvc” value; this is how many total hours have elapsed since the total service timer was last reset.

When service is performed before the total service timer expires, the Service Total parameter must be programmed On and then Off to reset it.

SRVC TRAC Off Reset traction service timer: On or Off

When the traction service timer expires, the controller auto-matically sets the service traction parameter On. The Ser-vice Traction parameter must then be programmed Off to indicate the appropriate service has been performed.

If a vehicle is brought in for service before a service warning is issued, you can check the accumulated traction service hours. Plug in the hand held programmer and go to the Monitor menu. Multiply the “Trac Srvc X25” value by 25 and add the “+Trac Srvc” value; this is how many traction hours have elapsed since the traction service timer was last reset.

When service is performed before the traction service timer expires, the Service Traction parameter must be pro-grammed On and then Off to reset it.

DIS TOTL HRS Total disable timer setting, in hours

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.

Setting the parameter to 0 means that the total disable timer will never expire and therefore never invoke the traction fault speed.

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DIS TRAC HRS Total traction timer setting, in hours

The traction disable hours parameter is used to set the trac-tion disable timer; it can be adjusted between 0 and 250 hours, in 1 hour increments. If the traction disable timer expires, the traction fault speed goes into effect.

Setting the parameter to 0 means that the traction disable timer will never expire and therefore never invoke the trac-tion fault speed.

TRAC FAULT SPD Max. drive speed if disable timer expires, as %

The traction fault speed parameter sets the maximum drive speed in the event the traction disable timer expires or the total disable timer expires; it can be adjusted between 0–100% of drive output, and applies to all modes.

BDI LIMIT SPD Max. drive speed upon battery discharge indicator (BDI) dis-able, as %

The BDI limit speed parameter sets the vehicle’s maximum allowed speed when the BDI disable parameter is pro-grammed On and the battery state of charge is 0%. The BDI limit speed is adjustable from 0 to 100% of drive output.

If the BDI disable parameter is programmed Off, the BDI limit speed will not be in effect.

WARM SPEED Max. drive speed if Mot Wrm resistance exceeds setpoint, as %

The warm speed parameter defines the maximum drive speed output when the motor field resistance is at or above the Motor Warm Resistance setpoint. The warm speed is adjustable from 0 to 100% of drive output.

MOT WRM X10 m Field resistance setpoint for Warm Speed, in 10-milliohm units

The motor warm resistance parameter defines the field resis-tance setpoint at which a motor warm fault will occur and the maximum speed will be controlled by the Warm Speed setting.

Note: The parameter value is in ten-milliohm units. If you want to program the Motor Warm Resistance setpoint to 900 m (0.9 ), you would enter 90 for the MOT WRM x10 m value. The Motor Warm Resistance setpoint is adjustable from 100 m (MOT WRM x10 m =10) up to the Motor Hot Resistance setpoint.

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MOT HOT X10 m Field resistance at which no drive output, in 10-milliohm units

The motor hot resistance parameter defines the field resis-tance setpoint at which a motor hot fault will occur and no drive output will be allowed. It is adjustable from the Motor Warm Resistance setpoint up to 2500 m (2.5 ). The value entered is in ten-milliohm units, which means the maximum Motor Hot Resistance value is one-tenth of 2500 (i.e., MOT HOT x10 m =250).

MOTOR COMP Off Enable cutback/cutoff response to motor overtemp.: On or Off

The motor resistance compensation parameter is used (pro-grammed On) to enable the motor overtemperature protec-tion feature.

MAX REV REGEN 150 Max. intk braking regen current fr. rev., max. load, in amps

The maximum reverse regen parameter defines the maxi-mum regenerative current at maximum load while traveling in the reverse direction. The max reverse regen current is adjustable from 100 amps up to the controller’s full rated current.

If a load sensor is not used, this will be the single maximum regen current in the reverse direction.

MAX FWD REGEN 150 Max. intk braking regen current fr. fwd., max. load, in amps

The maximum forward regen parameter defines the maxi-mum regenerative current at maximum load while traveling in the forward direction. The max forward regen current is adjustable from 100 amps up to the controller’s full rated current.

If a load sensor is not used, this will be the single maximum regen current in the forward direction.

MIN REV REGEN 150 Max. intk braking regen current fr. rev., min. load, in amps

The minimum reverse regen parameter defines the maxi-mum regenerative current at minimum load while traveling in the reverse direction. The Min Rev Regen current is adjustable from 25 amps up to the controller’s full rated cur-rent. The reverse regen current increases linearly from Min Rev Regen to Max Rev Regen as the load sensor input var-ies from Min Load Volts to Max Load Volts.

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.

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MIN FWD REGEN 150 Max. intk braking regen current fr. fwd., min. load, in amps

The minimum forward regen parameter defines the maxi-mum regenerative current at minimum load while traveling in the forward direction. The Min Fwd Regen current is adjustable from 25 amps up to the controller’s full rated cur-rent. The forward regen current increases linearly from Min Fwd Regen to Max Fwd Regen as the load sensor input var-ies from Min Load Volts to Max Load Volts.

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

The maximum load volts parameter defines the load sensor input voltage at the maximum load. It is adjustable from 0.2 V to 4.8 V.

MIN LOAD VOLTS Voltage on load sensor for min. regen current, in volts

The minimum load volts parameter defines the load sensor input voltage at the minimum load. It is adjustable from 0.2 V up to the programmed Max Load Volts.

INT BRAKE DLY Delay before E-M brake applied after intk switch opens, in secs

The interlock brake delay parameter allows a delay before the electromagnetic brake is engaged after the interlock switch opens; during this time, interlock braking is in effect. The electromagnetic brake is engaged when the delay has expired or when the motor speed approaches zero, which-ever occurs first. The Interlock Brake Delay is adjustable from 0.0 to 8.0 seconds. When set to zero, there is no delay and the brake is engaged as soon as the interlock switch opens. Interlock braking will still occur until the motor speed hits zero.

For Aux Type 5, the interlock braking delay does not apply.

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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.

In Fault Category format (fault code parameter Off), each com-bination of the two fault outputs defines one of four fault cat-egories. Table 4-3 lists the possible faults included in each category.

Note: Alternatively, Pin 2 can be used as a pump meter input, and Pin 3 can be used to interface an external auxiliary enable circuit.

EM BRAKE PWM On Enables modulation of brake driver output: On or Off

The auxiliary driver output (at Pin 8) can be modulated if you are using an EM brake (or other auxiliary device) whose coil voltage rating is lower than the battery voltage. If the elec-tromagnetic brake PWM parameter is programmed On, the brake will pull in at 100% PWM (full current up to 3 amps) for 500 ms and then pull back to 62.5% PWM (.2 amps max) at a frequency of about 250 Hz and continue at this level until released. If programmed Off, the auxiliary driver output will remain steadily at 100% PWM.

FIELD CHECK Off Fault will register if open detected in field: On or Off

The field check parameter determines whether the field diag-nostics will be active. When programmed On, the controller checks for field open and field shorted faults. This parame-ter is typically programmed On except in series motor appli-cations, or where the motor resistance is too high to provide valid fault data.

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Table 4-3 Fault Categories



PUMP METER Off Enables use of pin 2 as input for a pump hourmeter: On or Off

The pump meter parameter, when programmed On, config-ures the Fault Output 1 line (at Pin 2) to function as an input to measure the hours a pump is running. The pump is con-sidered to be running when Pin 2 is at the battery voltage. When the pump meter parameter is programmed On, the traction hourmeter serves as a combination traction/pump hourmeter, and all the above “TRAC” hourmeter parameters apply to both traction hours and pump hours. The traction/pump hourmeter counts the hours when a direction is selected and the hours when the pump is running.

FaultCategory

Fault 1Output

Fault 2Output

Possible Existing Faults

0 HIGH HIGH (no faults present)

1 LOW HIGH Current Shunt, HW Failsafe, M- Shorted, Throttle Wiper High or Low, Emergency Reverse Wiring Fault, Field Winding Open, Contactor Coil or Field Shorted, Main Contractor Welded or Missing

2 HIGH LOW Low Battery Voltage, Overvoltage, Thermal Cutback

3 LOW LOW Anti-Tiedown, HPD, SRO, Expired Service Timer or Disable Timer, Motor Too Hot

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Table 4-4 Configuration Options:Auxiliary Driver (Pin 8)

4-2.9. Diagnostics and Troubleshooting.

The motor controller provides diagnostics informationto assist in troubleshooting drive system problems.The diagnostics information can be obtained in twoways:

• Reading the appropriate display on the programmer

• Observing the fault codes issued by the Status LED.The Status LED is located on the side of the control-ler. See Figure 4-1 for location of the LED on thecontroller.

TYPE Description of Operation

0 Aux driver disabled

1 Electromagnetic brake used like a parking brake.• The brake is released when the interlock switch closes.• The brake is engaged as follows:Interlock The aux driver engages the brake when the interlock switch opens and (a) the programmed Sequencing Delay and Interlock Brake Delay expire or (b) the motor speed nears zero, whichever happens first. Neutral State * The aux driver does not respond to neutral state; there is no therefore no Aux Delay. Emerg. Rev. The aux driver does not respond to emergency reverse.

2 Electromagnetic brake used to prevent rolling when stopping on a hill.• The brake is released when the interlock switch closes and either a direction switch or the emergency reverse switch closes.• The brake is engaged as follows:Interlock Same as Type 1.Neutral State * When the vehicle reaches the neutral state, the aux driver engages the brake as soon as the programmed Aux Delay expires.Emerg. Rev. After the emergency reverse switch has been applied and released, the aux driver engages the brake as soon as the programmed Aux Delay has expired. The Aux Delay timer starts when motor speed nears zero.

3 Electromagnetic brake functions as in Type 2 except during Emerg. Rev.Emerg. Rev. (a) If both direction switches are open when the emergency reverse switch is released, same as Type 2. (b) If a direction switch is closed when the emer-gency reverse switch is released, the Aux Delay timer starts when the emergency reverse switch is released.

4 Electromagnetic brake functions as in Type 1 except during Emerg. Rev.Emerg. Rev. Same as Type 3, except in situation (a), where the aux driver does not respond, and the brake therefore remains released.

5 Auxiliary device other than an electromagnetic brake.This option is appropriate if the aux driver will be used for a brush or pump motor con-tactor, for example, or for hydraulic steering assist. The aux driver will be energized when the interlock switch and either a direction switch or the emergency reverse switch are closed. The aux driver will turn off when the programmed Aux Delay has expired after the interlock switch opens, or both direction switches are opened while the vehicle is driving, or the emergency reverse switch is released. The Aux Delay timer starts when motor speed nears zero.

* The neutral state is reached when, during normal operation, the throttle is in neutral, no direction is selected (both direction switches open), and motor speed is approximately zero.

4-30 BL-C22-1010 - 06-19-2017

4-2.9.1. LED Diagnostics

During normal operation with no faults present, theStatus LED flashes a single flash at approximately 1flash/second. If the controller detects a fault, a 2-digitfault identification code is flashed continuously untilthe fault is corrected. For example, three flashes fol-lowed by two flashes is code "3,2" appears in the LEDcode table as:

000 00 000 00 000 00

(3,2) (3,2) (3,2)

The codes are listed in Table 4-5. The "0" 's in Table 4-5 indicate an illuminated LED. For suggestions aboutpossible causes of the various faults, refer to Table 4-6Troubleshooting Chart.

Operational faults, such as an over-temperature situa-tion, are cleared as soon as the operation is broughtwithin range. Non-operational faults, such as a throttlefault, usually requires the brake or key switch to becycled after the problem is remedied.

4-2.10.Programmer Diagnostics

With a programmer, diagnostics and troubleshooting ismore direct than with the LED alone. The programmerpresents complete diagnostic information in plain lan-guage - no code to decipher. Faults are displayed inthe Diagnostic Menu, and the status of the controllerinputs/outputs is displayed in the Test Menu.

The following 4-step process is generally used fordiagnosing and troubleshooting an inoperative vehicleusing the programmer:

1. Visually inspect the vehicle for obvious problems:

2. Diagnose the problem:

3. Test the circuitry with the programmer:

4. Correct the problem.

Repeat the last three steps as necessary until thevehicle is operational.

Refer to the Table 4-6 for suggestions covering awide range of possible faults.

Table 4-5 LED Codes

NOTE: Only one fault is indicated at a time and faults are not queued up.

LED Code Explanation

LED Off Not illuminated No power or defective controller

Solid On Always on Defective controller

Single Flash 0 Controller operational, no faults

1 - 2 0 00 Hardware fail-safe error

1 - 3 0 000 M- fault or motor output short

1 - 4 0 0000 Sequencing fault (SRO)

2 - 1 00 0 Throttle wiper high

2 - 2 00 00 Emergency reverse circuit check fault (BB wiring)

2 - 3 00 000 High-pedal-disable fault (HPD) or expired timer

2 - 4 00 0000 Throttle wiper low

3 - 1 000 0 Contactor driver over current or field winding short

3 - 2 000 00 Welded main contactor

3 - 3 000 000 Field winding open

3 - 4 000 0000 Missing contactor

4 - 1 0000 0 Low battery voltage

4 - 2 0000 00 Overvoltage

4 - 3 0000 000 Thermal cutback, due to over/under temp

4 - 4 0000 0000 anti-tiedown fault, or overheated motor

BL-C22-1010 - 06-19-2017 4-31

Table 4-6 Troubleshooting Chart

LED CODE

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE FAULT CLEARANCE

0,1 NO KNOWN FAULTS

1,1 CURRENT SHUNT FAULT

1. Abnormal vehicle operation causing high current spikes.

Cycle KSI. If problem persists, replace controller.

2. Current sensor out of range.

3. Controller failure.

1,2 HW FAILSAFE 1. Noisy environment. Cycle KSI. If problem persists, replace controller.2. Self-test or watchfault.


1,3 M- SHORTED 1. Internal or external short of M- to B-. Check wiring; cycle KSI. If problem per-sists, replace controller.2. Incorrect motor wiring.


1,4 SRO 1. Improper sequence of KSI, brake, interlock, and direction inputs.

Follow proper sequence; adjust throttle if necessary; adjust programmable parameters if necessary.

2. Interlock or direction switch circuit open.

3. Sequencing delay too short.

4. Wrong SRO or throttle type selected.

5. Misadjusted throttle pot.

2,1 THROTTLE WIPER HI 1. Throttle input wire open or shorted to B+.

When Throttle Wiper High input returns to valid range.

2. Defective throttle pot.

3. Wrong throttle type selected.

2,2 EMR REV WIRING 1. Emergency reverse wire or check wire open.

Re-apply emergency reverse or cycle interlock.

2,3 HPD 1. Improper sequence of KSI, interlock, and throttle inputs

Follow proper sequence; adjust throttle if necessary; adjust programmable parameters if necessary.


3. Sequencing delay too short.

4. Wrong HPD or throttle type selected.


SRVC TOTAL 1. Total maintenance timer expired. Reset with programmer.

SRVC TRAC 1. Traction maintenance timer expired. Reset with programmer.

TOTAL DISABLED 1. Total disable timer expired. Reset with programmer.

TRAC DISABLED 1. Traction disable timer expired. Reset with programmer.

2,4 THROTTLE WIPER LO 1. Throttle pot wire open or shorted to B+.

When Throttle Wiper Low input returns to valid range.

2. Wrong throttle type selected.

3. Defective throttle pot.

4-32 BL-C22-1010 - 06-19-2017


LED CODE

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE FAULT CLEARANCE

3,1 FIELD SHORT 1. Main contactor soil shorted. Check contactor soil and field winding; cycle KSI.2. Field winding shorted to B+ or B-.

3. Field resistance too low.

3,2 MAIN CONT WELDED 1. Main contactor stuck closed. Check wiring and contactor; cycle KSI.

2. Main contactor driver shorted.

3,3 FIELD OPEN 1. Field winding connection open. Check wiring and cycle KSI.

2. Field winding open.

3,4 MISSING CONTAC-TOR

1. Main contactor coil open. Check wiring and cycle KSI.

2. Main contactor missing.

3.Wire to main contactor open.

4,1 LOW BATTERY VOLT-AGE

1. Battery voltage < undervoltage cut-back.

When voltage rises above undervoltage cutoff point.

2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2 OVERVOLTAGE 1. Battery voltage > overvoltage shut-down limit.

When voltage falls below overvoltage cutoff point.

4,3 THERMAL CUTBACK 1. Temperature >85C or <-25C. Clears when heatsink temperature returns to within acceptable range.2. Excessive load on vehicle.

3. Improper mounting of controller.

4,4 ANTI-TIEDOWN 1. Mode switches shorted to B+. Release Mode Select 1.

2. Mode Select 1:”tied down” to select Mode 2 or Mode 4 permanently.

MOTOR HOT 1. Field resistance > motor hot setpoint. When resistance < setpoint.

MOTOR WARM 1. Field resistance > motor warm set-point.

When resistance < setpoint.

BL-C22-1010 - 06-19-2017 4-33

NOTES

4-34 BL-C22-1010 - 06-19-2017

SECTION 5STEERING ARM, CONTROL HEAD AND COMPARTMENT

5-1. CONTROL HEAD

5-1.1. Control Head Removal

1. Turn off the key switch (6, Figure 5-5) and discon-nect the batteries.

2. Remove the six outer screws (10, Figure 5-1) andlift off cover (11).

NOTE: The seventh inner screw (10) and nut (14)secure support plate (13) to cover (11).

3. Remove the six screws (17, Figure 5-2) and cover(16) to gain access to electrical connectors.

WARNING: Once cover (16) is removed, air spring(11) can fall free of socket (9) if the con-trol arm (7) is lowered and raised.

NOTE: When removing the control head in the fol-lowing step, be sure to hold it in place untilthe control cable is disconnected.

4. Working inside the control head, remove twoscrews (2) and two washers (3), being careful notto drop control head (1).

5. Lift up control head (1) and unplug the electricalconnector.

5-1.2. Belly-Button Switch Replacement.

1. Remove the control head as described in para-graph 5-1.1.

2. Place the control head on a clean work bench.

3. Trace the belly-button switch leads down to thecontrol head connector and remove the leadsfrom the connector.

4. Remove two screws (5, Figure 5-1) and two screw(6).

5. Lift button (1) with mounting bracket (4) out of thecontrol head.

6. Remove button (1) from mounting bracket (4)being careful not to loose springs (2).

7. Install button (1) with springs (2) on mountingbracket (4) and check for proper operation.

8. Position button (1) with mounting bracket (4) inthe control head.

9. Install two screws (5) and two screw (6).

10. Install the switch leads in the control head con-nector.

11. Install the control head as described in paragraph5-1.6.

Figure 5-1. Steering Arm

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Figure 5-2. Control Head

5-1.3. Lift, Lower and Horn Switch Replacement.



3. Trace the leads of the defective switch down tothe control head connector and remove the leadsfrom the connector.

NOTE: When center screw (10, Figure 5-1) and nut(14) are removed, springs (8) will fall out.

4. Use a small clamp to hold plate (13) and cover(11) together. Remove screw (10) and nut (14).Slowly remove the clamp and separate plate (13)from cover (11) being careful not to lose springs(8).

5. Remove the button with the defective switch.

6. Place buttons (7, 9 and 12) with springs (8) inposition in cover (11).

7. Place plate (13) into position and temporariysecure with a clamp. Install nut (14) and screw(10). Then remove the clamp.

8. Check buttons for proper operation.



5-1.4. Directional Switch Removal and Adjust-ment.



3. Remove two screws (11, Figure 5-3) and liftmounting bracket (8) out of the control head.

4. Remove two nuts (10) and two washers (9) fromtwo screws (5).

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5-2 BL-C22-1010 - 06-19-2017

Figure 5-3. Switch Box

5. Remove the two screws (5) with switches (6) andblock (7).

6. Remove the switch leads from the control headconnector.

7. Position the new switches (6) and block (7) onmounting bracket (8) and secure with two screws(5), two washers (9) and two nuts (10).

8. Position mounting bracket (8) in the control headand install two screws (11).

9. Check that rollers on both switches (6) contact thesurface of cam (4) but do not engage the switchesin the neutral position. If required, loosen screw(11) and adjust position of bracket (8) to obtainproper operation.



5-1.5. Potentiometer Removal Testing and Adjust-ment.



3. Remove two screws (11, Figure 5-3) and liftmounting bracket (13) out of the control head.

4. Remove gear (12) from potentiometer (14).

5. Remove the potentiometer mounting nut andremove potentiometer (14) from mounting bracket(13).

6. Remove the potentiometer leads from the controlhead connector.

7. Position the new potentiometer (14) on mountingbracket (13) and secure with potentiometermounting nut.

8. Position mounting bracket (13) in the control headand install two screws (11).

9. Set an ohmmeter to the RX1K (1000) scale andconnect across the potentiometer leads.

10. Slowly press the control knob (18) in the forwarddirection until a click indicating forward switch clo-sure is heard and record the ohmmeter reading.

11. Repeat step 10. while pressing control lever inreverse direction. Meter readings should be thesame as for the forward direction (±200 ohms). Ifmeter readings are not the same, adjust positionof bracket (13) as necessary to obtain the samevalues. Adjust the potentiometer again if neces-sary.

12. Install the potentiometer leads in the control headconnector.


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5-1.6. Control Head Installation.

1. Position control head (1, Figure 5-2) on arm (7)and feed the electrical harness into arm (7).

2. Working inside the control head, install twoscrews (2) and two washers (3).

3. Connect the electrical harness and position italong side the air return spring (11)

4. Install cover (16) and secure with six screws (17).

5. Install cover (11, Figure 5-1) and secure with sixscrews (10)

6. Reconnect the batteries and turn on the keyswitch(6, Figure 12-7) and switch (4).

5-2. STEERING ARM

5-2.1. Return Air Spring Replacement.

The steering arm air return spring (11, Figure 5-2) isreplaced while the steering arm (7) is in the uprightposition.

1. Remove two screws (4, Figure 5-4), two washers(3) and plate (2).

2. Remove two screws (23) and two washers (24)and plate (25).

3. Remove two screws (14) and move switch (20)with mounting plate (17) out of the way. Steel ball(19) will fall free.

4. Secure the steering arm (1) in the upright posi-tion.

5. Remove screw (16), shaft (11) and rubber sleeve(12).

6. Remove the six screws (17, Figure 5-2) and cover(16).

WARNING: Once cover (16) is removed, air spring(11) can fall free of socket (9) if the con-trol arm (7) is lowered and raised.

7. Tilt the steering arm (7) forward to free air returnspring (11) to free it from socket (9).

8. Remove snap ring (12) and free air return spring(11) from screw (14).

9. Position the new air return spring (11) on screw(14) and secure with snap ring (12).

Figure 5-4 Steering System

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5-4 BL-C22-1010 - 06-19-2017

10. While moving the steering arm (7) back, positionthe air return spring (11) inside socket (9).

11. Install cover (16) and secure with six screws (17).

12. Install shaft (11, Figure 5-4) and rubber sleeve(12) and secure with screw (16).

13. Reposition switch (20) with mounting plate (17)and steel ball (19) and install two screws (14).

14. Check for proper operation of switch (20).

15. Tuck in wires of switch (20) to prevent pinchingand install plate (25), two screws (23) and twowashers (24).

16. Install plate (2) and secure with two screws (4)and two washers (3).

5-2.2. Steering Arm Removal.


2. Remove the steering arm air return spring (11,Figure 5-2) as described in paragraph 5-2.1.

3. Remove roll pin (8, Figure 5-4) and shaft (9).

4. Remove the steering arm from socket (26).

5-2.3. Steering Arm Installation.

1. Position the steering arm from socket (26, Figure5-4).

2. Install shaft (9) and roll pin (8).

3. Install the steering arm air return spring (11, Fig-ure 5-2) as described in paragraph 5-2.1.


5-3. COMPARTMENT COVERS

5-3.1. Forward Compartment.

5-3.1.1.Removal.


2. Remove four screws (27) and top cover (28).

3. Remove four screws (27) and front covers (25).

4. Remove four screws (27) and front covers (26).

Figure 5-5 Compartment

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5-3.1.2.Installation.

1. Position front covers (25 and 26, Figure 5-5) onthe frame.

2. Install eight screws (27).

3. Install top cover (28) and secure with four screws(27).

4. Reconnect the batteries and turn on the keyswitch(6) and switch (4).

5-3.2. Rear Compartment.

5-3.2.1.Removal.


2. Remove two screws (22) and two screws (20) andlift off cover (19) with panel (2).

3. Remove two screws (22) and two screws (20) liftoff cover (21) with panel (3).

4. Remove nuts (17) and washers (18) to separatepanels (2 and 3) from covers (19 and 21).

5-3.3. Installation.

1. Position panels (2 and 3, Figure 5-5) on covers(19 and 21) and secure with nuts (17) and wash-ers (18).

1. Position front covers (19 and 21) on the frame.

2. Install four screws (22) and four screws (20).

3. Reconnect the batteries and turn on the keyswitch(6) and switch (4).

5-6 BL-C22-1010 - 06-19-2017

SECTION 6BRAKE SERVICING

6-1. BRAKES.

The brake system consists of a drive motor mountedbrake. This brake is spring applied and electricallyreleased. Should it become necessary to move a deadtruck, the brake is equipped with an adjusting nut (Fig-ure 6-1) that may be manually loosened to release thebrake.

WARNING: Before returning the truck to operation,be sure to return the brake adjusting nutto its original position and check forproper braking function. Failure to returnadjusting nut to its original positionresults in truck having no braking ability.

6-1.1. Air Gap Adjustment.

The “air gap” is the distance between the magnet bodyand the rotor plate with the brake applied. As the brakepads and rotor wear normally, the air gap will increaseand should be readjusted when it measures more than0.25 mm.

NOTE: If the air gap measures more than 0.25 mm,the brake may not release properly. Air gapadjustment can be performed as long as thebrake pads and rotor function properly or untilthe adjustable spacer threads are fullyengaged (adjustment limit reached).

1. Block load wheels.

2. Remove the rear compartment covers asdescribed in paragraph 5-3.

3. Using low pressure air, remove any dirt betweenarmatures and magnet body.

4. Using standard feeler gauges, check the gapbetween the rotor plate (6, Figure 6-1) and rotor(11). The gap should be 0.25 mm.

5. If necessary, refer to Figure 6-1 and adjust thegap as follows:

a. Remove the three mounting screws.

f. Lift magnetic body (1) with rotor plateattached and adjust shims (4) to obtain theproper gap.

g. Install the three mounting screws.

h. Recheck the gap.

9. Remove load wheel blocks and check operation.

10. Install the rear compartment covers as describedin paragraph 5-3.

Figure 6-1 Brake Assembly

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6-1.2. Stopping Distance Adjustment.

The stopping distance of the truck should require mini-mal adjustment. However, this distance should bechecked with each planned maintenance.

Using an unloaded truck, run truck to its top speed onan even dry concrete surface. Move control handleinto the lower braking position. Measure length ofbraking path from the actuation point of the brakesuntil the truck has stopped. The actual length of thebraking path should be between approximately 1.5 -2.5 ft (0.5-0.7 m).

To adjust stopping distance, proceed as follows:



3. Adjust the brake (Refer to Table 4-2).



6-1.3. Brake Assembly Replacement


2. Turn off the key switch (6, Figure 12-7) and dis-connect the batteries.


4. Remove the steering arm as described in para-graph 5-2.2.

5. Remove four screws (33, Figure 6-3) and pres-sure block (34).

6. Remove three screws (36) and remove socket(35).

7. Disconnect electric brake from the harness.

8. Remove three screws (1, Figure 6-2), three wash-ers (2).

9. Lift off magnet body (1, Figure 6-1) with rotor plate(6) attached.

10. Remove bushings (7) and shims (4).

11. Remove rotor (11) from hub (9).

12. Remove snap ring (8), hub (9), key (10) and bush-ing (12) from the drive motor.

13. Install new bushing (12), key (10), hub (9) andsnap ring (8) on the drive motor.

14. Install new rotor (11) on hub (9).

15. Assembly magnet body (1), springs (5), rotor (6),and install two screws (3) and nuts (2).

16. Position new bushings (7) and shims (4) over thethree brake mounting holes in the motor.

17. Place magnet body (1) on bushings (7) andsecure with the three screws (1, Figure 6-2) andthree washers (2).

18. Finally tighten the three mounting screws to 52 in-lb (6 Nm).

19. Reconnect electric brake to the harness.

20. Install socket (35, Figure 6-3) and secure withthree screws (36).

21. Install pressure block (34) and secure with fourscrews (33)

22. Install the steering arm as described in paragraph5-2.3.



25. Reconnect the batteries and turn on the keyswitch(6, Figure 12-7).

Figure 6-2 Transmission, Motor, Brake Assembly

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6-2 BL-C22-1010 - 06-19-2017


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NOTES

6-4 BL-C22-1010 - 06-19-2017

SECTION 7TRANSMISSION, DRIVE WHEEL, LOAD WHEEL

7-1. Drive Wheel.



3. Loosen but do not remove the five nuts (28, Fig-ure 7-1).

4. Jack up the truck so the drive wheel is off theground; then securely block the truck to preventmovement.

5. Remove the five nuts (28) and drive wheel (27)from the transmission (25).

6. Install new drive wheel in reverse order ofremoval.



7-2. Transmission.

The transmission floats on bracket (35, Figure 7-2)and two links (20). Two springs (13, Figure 7-1) supplya downward pressure for maintaining traction. A forc-ing cylinder (Figure 12-22) is mounted betweenbracket (10, Figure 7-1) and bracket (35, Figure 7-2) toprovide additional traction when carrying heaver loads.The heavier the load, the greater the hydraulic pres-sure to the forcing cylinder.



3. Remove the brake (3, Figure 7-1) as described inparagraph 6-1.3.


5. Remove the drive motor (6, Figure 7-1) asdescribed in paragraph 10-4.1.

6. Remove the drive wheel (27) as described inparagraph 7-1.

7. Support the transmission (25).

8. Remove screw (4, Figure 7-2) and remove plate(5) with tension spring (13).

9. Remove the screws securing forcing cylinder (Fig-ure 12-22) to bracket (10, Figure 7-1).

10. Remove two nuts (32, Figure 7-2) two washers(33) and two screws (36) securing bracket (35) tobottom of bracket (10).

11. Disconnect the two links (20) on each side of thetransmission by remove screws (22) and pins (21)from frame (10).

12. Slowly lower the transmission out the bottom ofthe frame.

13. Install new transmission by reversing the stepsabove.


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Figure 7-2 Frame


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7-2 BL-C22-1010 - 06-19-2017

7-3. Load Wheel.

7-3.1. Removal

1. Raise forks.


3. Block the drive wheel to prevent the truck fromrolling.

4. Jack up the frame to raise the load wheels off thefloor. Securely block the frame in the raised posi-tion.

NOTE: When shaft (2, Figure 7-4) is removed, loadwheel assembly (5) will drop free.

5. Remove snap rings (1) securing shaft (2) andremove shaft (2) and load wheel assembly (5).

NOTE: Inspect the load wheel assembly. If the loadwheel is worn within 1/8" of the metal sleeve,or is cracked or damaged, replace the entireload wheel and bearing assembly. Big LiftLLC recommends that both load wheelassemblies be replaced at the same time.This ensures level and safe operation of thelift truck.

7-3.2. Repair

6. Remove snap rings (3, Figure 7-4) and bearings(4) from wheels (5).

7. Inspect bearings (4) and replace if necessary.

8. Reassemble bearings (4) and snap rings (3) inwheels (5).

7-3.3. Load Wheel Installation

1. Position load wheel assembly (5, Figure 7-4) inframe.

2. Install shaft (2) and secure with snap rings (1).

3. Remove blocking from under the truck.

4. Lower the truck.


Figure 7-4. Load Wheel

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NOTES

7-4 BL-C22-1010 - 06-19-2017

SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL.

The elevation system includes the outer mast, innermast, lift linkage, lift chains, lift cylinder and tilt cylin-der.

8-2. LIFT CHAIN LENGTH ADJUSTMENT.

1. Fully lower the lift carriage.


WARNING: Before attempting any adjustment, makecertain power is disconnected.

3. Loosen the bottom jam nut (12, Figure 8-2) onadjusting bolt (8) located at the top crossmemberof the outer mast (8, Figure 8-1).

4. Thread the top jam nut (12, Figure 8-2) up adjust-ing bolt (8) to allow for adjustment of middle jamnut (12).

5. Take up slack in both lift chains with middle jamnut (12). Strive for equal tension on both chains.

6. Align adjusting bolts (8) so each clevis pin (10) isparallel to the mast.

CAUTION: At least 3 full threads must be presentbelow lower nut (12) after adjustment.

7. Tighten jam nuts securely while maintaining align-ment of clevis pin (10).


9. Test chain by operating carriage. If slack is stillapparent, repeat above procedure.

Figure 8-1 Outer Mast

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8-3. LIFT CHAIN WEAR INSPECTION.

Both lift chains should be replaced when either chainis worn enough to increase it’s length by 3% or more.To make this determination proceed as follows.

Using a section of chain that sees the most frequentoperation over the chain sheaves, isolate a verticalportion under tension from the weight of carriage andforks.

Measure the distance between pin centers on 20 verti-cal links. If the section measures 12.88” or more, thechain should be replaced.

New chain anchor pins should be installed whenchains are replaced. Never replace a partial section ofchain and never repair chain. Refer to paragraph 8-4.when installing new chain.

8-4. LIFT CHAIN REPLACEMENT.

1. With the lift truck wheels securely blocked, raisethe forks approximately three feet from floor andposition blocks or strong supports under the liftcarriage.

2. Lower the carriage onto the support. Check thatarrangement is secure before proceeding and thelift chains are slack.


WARNING: Before attempting any replacement,make certain power is disconnected.

4. Remove cotter pin (9, Figure 8-2) and clevis pin(13) connecting chain (5) to the lift carriage.

Figure 8-2 Inner Mast

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8-2 BL-C22-1010 - 06-19-2017

5. Remove cotter pin (9) and clevis pin (10) connect-ing chain (5) to adjusting bolt (8) at the outermast.

6. Remove chain from sheave (6).

7. Position new chain on sheave (6).

8. Secure chain to adjusting bolt (8) at the outermast with clevis pin (10) and cotter pin (9).

9. Connect the opposite end of chain to the lift car-riage with clevis pin (10) and cotter pin (9).

10. Adjust the chains according to paragraph 8-2.


8-5. LIFT CYLINDER.

NOTE: Removal and repair of lift cylinder is coveredin SECTION 9.

BL-C22-1010 - 06-19-2017 8-3

NOTES

8-4 BL-C22-1010 - 06-19-2017

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

NOTE: Leaking hydraulic fittings may be remedied bysimply tightening fittings. If this does not rem-edy the leak, the fittings or line must bereplaced.

1. Lower forks fully.


3. Remove the front compartment covers asdescribed in paragraph 5-3.

CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting.

4. Refer to Figure 9-1 and remove leaking line or fit-ting and replace it with a new line or fitting.

5. Check level of hydraulic oil. If required, addhydraulic oil to bring to proper level. Use hydraulicoil listed in Table 3-2.


7. Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil.


9. Install the front compartment covers as describedin paragraph 5-3.

Figure 9-1 Hydraulic System

R6666

BL-C22-1010 - 06-19-2017 9-1

9-2. HYDRAULIC PUMP, AND MOTOR ASSY

WARNING: When forks are raised. pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

9-2.1. Removal

1. Lower forks fully.



4. Tag and disconnect electrical leads from motor (1,Figure 9-2).

NOTE: Place a container under the pump assemblyto catch any hydraulic oil.

5. Remove two fittings (18, Figure 9-1), four washers(20) and tube assy (17).

6. Remove four screws (24) and four washers (23).

7. Remove the pump and motor assembly (25).

8. Remove all material of gasket (4, Figure 9-2) fromthe mating surfaces.

9-2.2. Disassembly and Reassembly

1. Remove two screws (7, Figure 9-2) and removemotor (1) and sleeve (2) from valve assy (3).

2. Remove two screws (6) and remove pump (5)from valve assy (3).

3. Refer to Figure 12-16 for disassembly and reas-sembly of the pump.

4. Refer to Figure 12-18 for disassembly and reas-sembly of the valve.

5. Refer to Figure 12-26 for disassembly and reas-sembly of the motor.

6. Position pump (5) on valve assy (3) and securewith two screws (6).

7. Position sleeve (2) and motor (1) on valve assy(3) and secure with two screws (7).

9-2.3. Installation

1. Install pump and motor assy (25, Figure 9-1), withnew gasket (4, Figure 9-2) on reservoir (12, Fig-ure 9-1) and secure with four screws (24) and fourwashers (23).

2. Install tube assy (17) with two fittings (18) andfour washers (20)

3. Connect electrical leads to motor (1, Figure 9-2).

4. Fill the hydraulic reservoir. Use hydraulic oil listedin Table 3-2.





Figure 9-2 Pump and Motor Assembly

R6667

9-2 BL-C22-1010 - 06-19-2017

9-2.4. Lift Cylinders

9-2.4.1.Removal

1. With the lift truck wheels securely blocked, raisethe forks approximately three feet from floor andposition blocks or strong supports under innermast

2. Lower inner mast onto the support. Check thatarrangement is secure before proceeding andthat the lift cylinders are free of the inner mast.




4. Disconnect hoses (4 and 6, Figure 9-1) from thebottom of the lift cylinders.

5. Remove two screws (4, Figure 9-3), clamp (5) andplate (6).

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 - 06-19-2017 9-3

9-2.4.2.Repair

CAUTION: To prevent damage, use proper pipeclamp vise. The cylinder will be distortedif the vise is tightened too much.

1. Secure the lift cylinder in a vise, clamping lightlyat the base of the cylinder.

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 cylinderbody (3).

6. Coat all parts with hydraulic oil (Table 3-2).

7. Install new seal (2) and dust seal (1) in cylinderbody (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 outermast (8).

2. Secure the cylinder with plate (6), clamp (5) andtwo 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 mastand remove the supports.

6. Slowly lower the inner mast while lining up the liftcylinders with the top of the inner mast.

7. Adjust the chains according to paragraph 8-2.







Figure 9-4 Lift Cylinder

R6670

9-4 BL-C22-1010 - 06-19-2017

9-2.5. Tilt Cylinders

9-2.5.1.Removal

WARNING: Mast must be supported by a hoistbefore removing the tilt cylinders.

1. Secure mast with a hoist.





4. Disconnect hoses (3 and 26, Figure 9-1) from thebottom of the tilt cylinders.

5. Support the tilt cylinder and remove pin (20, Fig-ure 9-5) and shaft (19) from the cylinder.

6. Carefully raise tilt cylinder from the truck.

7. Repeat steps 5. and 5. for the remaining cylinder.

9-2.5.2.Repair

CAUTION: To prevent damage, use proper pipeclamp vise. The cylinder will be distortedif the vise is tightened too much.

1. Remove snap ring (10, Figure 9-5).

2. Pull out piston rod (4).

3. Remove nut (9), washer (8), piston (6), O-ring (5)and cover (13) from rod (4).

4. Remove seals (7) from piston (6).

Figure 9-5 Tilt Cylinder

R6671

BL-C22-1010 - 06-19-2017 9-5

5. Remove O-ring (15), seal (14), ring (12) and wearring (11) from cover (13).

6. Remove snap rings (17) and bearing (21) fromcylinder body (16).

7. While holding clevis (1), loosen nut (3).

8. Remove clevis (1), washer (2) and nut (3) fromrod (4).

9. Remove snap rings (17) and bearing (21) fromclevis (1).

10. Coat all parts with hydraulic oil (Table 3-2).

11. Install bearing (21) in clevis (1) and secure withtwo snap rings (17).

12. Install nut (3), washer (2) and clevis (1) on rod (4).The clevis will be adjusted during installation ofthe cylinder.

13. Install bearing (21) in cylinder body (16) andsecure with two snap rings (17).

14. Install O-ring (15), seal (14), ring (12) and wearring (11) on cover (13).

15. Install seals (7) on piston (6).

16. Install cover (13) on rod (4).

17. Install O-ring (5), piston (6), washer (8), and nut(9) on rod (4).

18. Install piston rod (4) in cylinder body (16).

19. Remove snap ring (10).

9-2.5.3.Installation

1. Position one cylinder between the outer mast andthe truck frame.

2. Secure the cylinder with two shafts (19, Figure 9-5) and two pins (20).

3. Secure the opposite cylinder to the truck framewith one shaft (19) and pin (20).

4. Adjust clevis (1) so that the mounting hole alignswith the mounting hole of the outer mast.

5. Secure the cylinder to the mast with one shaft(19) and pin (20).

6. Secure nuts (3) against clevises (1).

7. Reconnect hoses (3 and 26, Figure 9-1) to thebottom of the tilt cylinders.



10. Operate the tilt buttons to refill the cylinder andlines with hydraulic oil.



9-6 BL-C22-1010 - 06-19-2017

SECTION 10ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL

10-1.1.Maintenance

NOTE: Erratic operation of the truck may be causedby defective controller components. Beforeremoving the electrical panel, perform trou-bleshooting procedures per SECTION 4, todetermine corrective action to be taken.

There are no user-serviceable parts inside the control-ler. No attempt should be made to open the controller.Opening the controller may damage it and will void thewarranty.

The controller is programmed at the factory specifi-cally for the truck model on which it is equipped. It isimportant to replace the controller with the correct pre-programmed unit to assure proper performance set-tings intended for that particular truck. See Figure 12-23 for the preprogrammed controller number.

It is recommended that the controller exterior becleaned periodically, and if a Handset is available, thisperiodic cleaning provides a good opportunity to checkthe controller’s diagnostic history file. It is also recom-mended that the controller’s fault detection circuitry bechecked whenever the vehicle is serviced.

10-1.2.Cleaning



3. Remove any dirt or corrosion from the buss bararea. The controller should be wiped clean with a

moist rag. Allow it to dry before reconnecting thebattery.

4. Make sure the connections to the buss bars aretight. Use two well insulated wrenches for thistask in order to avoid steering the buss bars.

10-1.3.Panel Removal.



3. Tag and disconnect all electrical cables whichconnect to the control panel (37, Figure 10-1).

4. Remove four screws (38) and control panel (37).

10-1.4.Panel Disassembly.

Refer to Figure 10-2 for location and identity of themajor replacement components mounted on the paneland remove defective parts.

NOTE: Contactors (6 and 7) are not repairable andmust be replaced if defective.

10-1.5.Panel Installation.

1. Install the control panel (37, Figure 10-1) andsecure with four screws (38).

2. Connect all electrical cables to the control panelas noted during removal.



BL-C22-1010 10-1

Figure 10-1 Frame

10-2.HORN REPLACEMENT



3. Tag and disconnect all electrical connections fromhorn.

4. Remove the mounting hardware and horn.

5. Install horn and secure with the mounting hard-ware.



R6478

R6660

10-2 BL-C22-1010

Figure 10-2 Electrical Panel

R6478

R6674

BL-C22-1010 10-3

10-3.PUMP MOTOR.

Refer to paragraph 9-2.

10-4.DRIVE MOTOR.

The drive motor exposed surfaces should be cleanedat least once a month to assure proper cooling ofmotor. Use an air hose to blow bust off of motor sur-faces.

10-4.1.Motor Removal



3. Remove the brake as described in paragraph 6-1.3.


5. Note routing of cables to ensure proper installa-tion.

6. Tag the cables connected to the drive motor; thendisconnect these cables from the drive motor.

7. Remove the ten screws (4 Figure 10-3) and lockwashers (5).

8. Lift motor (6) from bearing (7).

9. Remove nut (24), gear (23), and key (22) frommotor (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 withsnap rings (20 and 21).

2. Position key (22) and gear (23) on the shaft ofmotor (1) and secure with nut (24).

3. Install drive motor onto transmission. Make sureto 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 tomatch the cable label to the terminal.

6. Reinstall pressure block (34) and secure with fourscrews (33).

7. Install the brake as described in paragraph 6-1.3.

8. Install the steering arm as described in paragraph5-2.3.


10-5.LIMITATION SWITCH

1. Disconnect harness from the limitation switch (17,Figure 12-12).

2. Remove switch (17) from socket (18).

NOTE: The switch must be positioned so that it isoperated when the lift carriage is up.

3. Secure the new switch (17) on socket (18).

4. Reconnect harness to switch.


R6656

10-4 BL-C22-1010

10-6.DEADMAN SWITCH

10-6.1.Replacement

1. Remove two screws (4, Figure 10-4), two wash-ers (3) and plate (2).

2. Remove two screws (23) and two washers (24)and plate (25).

3. Disconnect wiring for deadman switch (20).

4. Remove the two screws (22), washers (21),switch (20) and sheet (18) from bracket (17). Ball(19) will drop out.

5. Position the new switch (20), sheet (18) and ball(19) on bracket (17) and secure with the twoscrews (20) and washers (21).

6. Reconnect the deadman switch wiring.

7. Check for proper operation of switch (20).

8. Tuck in wires of switch (20) to prevent pinchingand install plate (25), two screws (23) and twowashers (24).

9. Install plate (2) and secure with two screws (4)and two washers (3).


R6629

BL-C22-1010 10-5

NOTES

10-6 BL-C22-1010

SECTION 11OPTIONAL EQUIPMENT

BL-C22-1010 - 06-19-2017 11-1

NOTES

11-2 BL-C22-1010 - 06-19-2017

SECTION 12ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the C22 Lift Truck.

BL-C22-1010 - 06-19-2017 12-1


R6629

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — HANDLE ASSEMBLY (FIGURE 12-2)

REF

2 2000-508001 OUTER COVER PLATE 1

3 2000-537002 WASHER 4

4 2000-541002 SCREW 2

5 2000-534004 RUBBER SLEEVE 2


7 2000-512002 BUSHING, LUBRICATED 2

8 2000-536001 ROLL PIN 1

9 2000-513001 SHAFT 1

10 2000-534003 RUBBER WASHER 1

11 2000-513003 SHAFT 1


13 2000-231001 SCREW 2

14 2000-541004 SCREW 2

15 2000-334001 PLUG 1

16 2000-525004 SCREW 1

17 2000-535004 MOUNTING PLATE 1

18 2000-509002 FASTENING SHEET 1

19 2000-504001 STEEL BALL 1

20 2000-517004 DEADMAN SWITCH 1

21 2000-537003 WASHER 2

22 2000-541001 SCREW 2

23 2000-541003 SCREW 2

24 2000-537001 WASHER 2

25 2000-508002 INNER COVER PLATE 1

26 2300-502001 HANDLE SOCKET 1

27 2700-513001 CONNECTING SHAFT 1

28 4000-536001 ROLL PIN 1

29 4001-220001 BEARING 2

30 4000-231002 SCREW 4

31 4000-502004 BLOCK, POSITIONING 1

32 4000-534001 PROTECTION SLEEVE 1

33 1000-741001 SCREW 4

34 4001-102001 PRESSURE BLOCK 1

35 4000-501001 LINK SOCKET 1

36 1000-342001 SCREW 3

37 4000-525003 SCREW 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-2 BL-C22-1010 - 06-19-2017

Figure 12-2 Handle Assembly

R6653

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-500001 HANDLE ASSEMBLY 1

1 — • SWITCH BOX ASSEMBLY(FIGURE 12-3)

REF

2 2000-931008 • SCREW 2

3 2000-537001 • WASHER 2

4 2000-517001 • HANDLE 1

5 1000-536001 • ROLL PIN 1

6 1000-538002 • SCREW 1

7 2000-501006 • CONTROL ARM 1

8 2000-442001 • SCREW 4

9 6000-502002 • AIR SPRING SOCKET 1

— 4000-500007 • AIR SPRING ASSEMBLY 1

10 2000-525012 • • HEAD 1

11 6000-519001 • • AIR SPRING 1

12 2000-527002 • • SNAP RING 1

13 2000-525008 • • JOINT 1

14 2000-525006 • • SCREW 1

15 1000-527001 • • SNAP RING 1

16 2000-502001 • COVER 1

17 2000-542001 • SCREW 6

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-3

Figure 12-3 Switch Box Assembly

R6654

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-500002 SWITCH BOX ASSEMBLY 1

— 1000-540001 • EMERGENCY REVERSE SWITCH ASSEMBLY

1

1 2000-540007 • • EMERGENCY REVERSE BUTTON

1

2 2000-519002 • • SPRING 4

3 2000-540001 • • RUBBER CONTACT 1

4 2000-518001 • • FASTENING PLATE 1

5 2000-542003 • • SCREW 2

6 2001-141005 • SCREW 2

7 3200-540001 • LIFT/LOWER BUTTON 1

8 2000-519003 • SPRING 6

9 3200-540002 • FAST LOWER/HORN BUTTON

1

10 2000-542003 • SCREW 7

11 2000-509003 • COVER 1

12 2700-502001 • TILT BUTTON 1

13 3200-518001 • SUPPORT PLATE 1

14 2000-539001 • NUT 1

15 — • SWITCH BOX(FIGURE 12-4)

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-4 BL-C22-1010 - 06-19-2017

Figure 12-4 Switch Box

R6655

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2000-501004 RACK 1

2 2000-519004 SPRING 1

3 2000-536011 ROLL PIN 1

4 2000-501005 CAM 1

— 1000-500003 SWITCH ASSEMBLY 1

5 2000-538005 • SCREW 2

6 2000-507003 • SWITCH 2

7 2000-535001 • ISOLATE BLOCK 1

8 2000-518003 • MOUNTING BRACKET 1

9 1000-504001 • WASHER 4

10 2000-539002 • NUT 2

11 2001-141005 SCREW 4

— 1000-500004 POTENTIOMETER ASSY 1

12 2000-521001 • GEAR 1

13 2000-518004 • MOUNTING BRACKET 1

14 2000-507007 • POTENTIOMETER 1

15 1000-529001 SWITCH BOX 1

16 2000-512001 COPPER BUSHING 2

17 2000-513002 CAM SHAFT 1

18 2000-540005 CONTROL KNOB 2

19 2000-535003 CONNECTING WASHER 2

20 2000-534001 COVER 2

21 2000-536012 ROLL PIN 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-5


R6656

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2001-031001 SCREW 3

2 2001-437001 WASHER, LOCK 3

3 4001-000001 BRAKE (FIGURE 12-24) 1

4 2000-131002 SCREW 10

5 2001-037001 WASHER, LOCK 4

6 1201-400005 DRIVE MOTOR(FIGURE 12-25)

1

7 4000-220001 BEARING 1

8 4000-231002 SCREW 6

9 4000-812001 BEARING 2

10 4000-318001 BRACKET 1

11 4000-325001 BOLT 2

12 2700-313002 SPRING SOCKET 2

13 2700-319001 SPRING 2

14 2700-312001 TUBE 2

15 2700-313001 SPRING SOCKET 2

16 2001-405001 SEAL WASHER 1

17 2001-420001 BEARING 1

18 2001-212003 POSITION SLEEVE 1

19 2001-228001 O-RING 1

20 2001-227003 SNAP RING 1

21 2001-427001 SNAP RING 1

22 2001-435001 KEY 1

23 2000-121005 GEAR 1

24 2001-425002 NUT 1

25 — TRANSMISSION(FIGURE 12-6)

REF

26 2000-325001 STUD 5

27 4000-332001 DRIVE WHEEL 1

28 2000-325002 NUT 5

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-6 BL-C22-1010 - 06-19-2017

Figure 12-6 Transmission, Assembly

R6657

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2300-200001 TRANSMISSION 1

1 2000-120002 • SCREW 4

2 4000-111001 • TOP COVER 1

3 2000-125001 • NUT 1

4 2000-121001 • GEAR 1

5 2000-120003 • BEARING 2

6 2000-141001 • SCREW 8

7 2000-625001 • BOLT 2

8 2000-603010 • WASHER 2

9 2000-111002 • SIDE COVER 1

10 2000-128002 • O-RING 1

11 2000-130001 • BOLT 1

12 2000-135001 • WASHER 1

13 2000-121002 • GEAR 1

14 2000-120002 • BEARING 1

15 2000-137001 • WASHER 2

16 2000-137002 • WASHER 2

17 2000-121004 • GEAR 1

18 2001-037001 • WASHER, LOCK 8

19 2000-731003 • SCREW 8

20 2000-120001 • BEARING 1

21 2000-105001 • SEAL 1

22 2000-121003 • SPLINE SHAFT 1

23 2000-126001 • HOUSING 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-7

Figure 12-7 Compartment

R6658

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — COVER ASSEMBLY(FIGURE 12-8)

REF

2 2000-908001 RIGHT PANEL 1

3 2000-908002 LEFT PANEL 1

4 2000-407001 EMERGENCY STOP BUTTON

1

5 2001-116002 BATTERY INDICATOR(BDI W. HOURMETER)

1

6 2000-507008 KEY SWITCH 1

7 2000-908003 MIDDLE PANEL 1

8 2000-931001 SCREW 2

9 2000-937001 WASHER 6

10 2000-941001 SCREW 4

11 2302-013021 SUPPORT 1

12 2000-937002 WASHER 2

13 2000-937003 WASHER, LOCK 2

14 2000-931003 SCREW 2

15 2000-913001 SHAFT 2

16 2000-931004 SCREW 2

17 2000-939001 NUT 8

18 2000-935001 WASHER 8

19 2300-900002 RIGHT COMPARTMENT COVER

1

20 2000-925001 SCREW 4

21 2300-900001 LEFT COMPARTMENT COVER

1

22 2000-924001 SCREW 4

23 2301-129002 RIGHT BATTERY COVER 1

24 2301-129001 LEFT BATTERY COVER 1

25 2700-909002 LEFT FRONT COVER 1

26 2700-909002 RIGHT FRONT COVER 1

27 1000-441002 SCREW 12

28 2700-909003 TOP FRONT COVER 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-8 BL-C22-1010 - 06-19-2017

Figure 12-8 Cover Assembly

R6659

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2301-100001 COVER ASSEMBLY 1

1 2001-108001 • PLASTIC COVER 1

2 2001-137001 • WASHER 4

3 2001-141005 • SCREW 4

4 2001-118001 • COVER FRAMEWORK 1

5 2000-939001 • NUT 2

6 2000-937001 • WASHER 2

7 2701-118001 • COVER FRAMEWORK 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-9

Figure 12-9 Frame

R6660

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 6000-642001 SCREW 8

2 2300-700001 COVER PLATE 1

3 2700-418001 LEFT BALANCING WEIGHT 1

4 4000-730002 BOLT 1

5 4000-702001 PRESSURE PLATE 1

6 1000-139001 NUT 1

7 2000-725001 PIN 2

8 4000-231002 SCREW 8

9 2300-902001 SUPPORT SEAT 1

10 2700-724001 FRAME 1

11 2700-704002 SCREW 4

12 2000-937002 WASHER 2

13 2000-931004 SCREW 2

14 2700-709001 HOOK 2

15 2700-709001 SUPPORT 1

16 2700-718002 RIGHT BALANCING WEIGHT

1

17 — CASTER (FIGURE 12-10) REF

18 4000-737001 WASHER 2

19 1001-036001 ROLL PIN 2

20 2300-701001 LINK 2

21 6000-813001 PIN 2

22 6001-442001 SCREW 2

23 2301-112001 ROLLER 7

24 2301-113001 ROLLER SHAFT 7

25 2300-713002 PIN SHAFT 2

26 2300-702003 PLATE 2

27 2300-713003 PIN SHAFT 2

28 — LOAD WHEEL ASSY (FIGURE 12-11)

REF

29 2001-427001 SNAP RING 2

30 2000-827001 SNAP RING 4

31 2700-513003 SHAFT 2

32 2000-839001 NUT 2

33 4000-837001 WASHER 2

34 2300-713001 SHAFT 1

35 2700-202001 BRACKET 1

36 4000-825001 BOLT 2

37 — ELECTRIC PANEL ASSY (FIGURE 12-23)

REF

38 1001-031003 SCREW 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-10 BL-C22-1010 - 06-19-2017

Figure 12-10 Caster

R6661

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-300001 CASTER 2

1 4000-227001 • SNAP RING 1

2 4000-320001 • BEARING 1

3 4000-320002 • BEARING 1

4 2300-302001 • WHEEL BRACKET 1

5 2300-330001 • BOLT 1

6 2000-305001 • SEAL 2

7 2300-312001 • BUSHING 2

8 1000-320002 • BEARING 2

9 2700-332001 • WHEEL 1

10 4000-312002 • SLEEVE 1

11 2000-737003 • WASHER, LOCK 1

12 2001-239001 • NUT 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-11

Figure 12-11 Load Wheel

R6662

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-300001 LOAD WHEEL ASSY 2

1 2000-827001 • SNAP RING 2

2 2701-213001 • SHAFT 1

3 2700-327001 • SNAP RING 2

4 2700-304001 • BEARING 2

5 2700-332002 • LOAD WHEEL 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-12 BL-C22-1010 - 06-19-2017


R6633

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2000-820001 ROLLER 2

2 2000-837001 WASHER 4

3 — LIFT CYLINDER ASSY(FIGURE 12-20)

REF

4 2000-800001 SCREW 4

5 2000-835002 CLAMP 2

6 2000-835001 PLATE 2

7 2700-812001 BEARING 2

8 2700-824001 OUTER MAST (3.3m) 1

8 2700-824002 OUTER MAST (3.0m) 1

9 2000-834001 PROTECTIVE SCREEN 1



12 2000-937001 WASHER 4

13 2001-437001 WASHER, LOCK 4

14 2000-939001 NUT 4

15 2000-742001 SCREW 4

16 2000-824003 LIMITATION BLOCK 2

17 2000-407005 LIMITATION SWITCH 1

18 2000-809001 SWITCH SOCKET 1

19 2000-941001 SCREW 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-13

Figure 12-13 Inner Mast

R6664

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2000-827001 SNAP RING 4

2 2000-837002 RING 4

3 2000-827002 SNAP RING 4

4 2000-820002 BEARING 4

5 2000-804001 LIFT CHAIN 2

6 2000-801001 CHAIN SHEAVE 2

7 2000-812001 SHAFT 2

8 2000-825001 ADJUSTING BOLT 2

9 2000-804002 COTTER PIN 6

10 2000-813001 CONNECTING PIN 2

11 2000-804003 COTTER PIN 2

12 2000-839001 NUT 6

13 2000-825002 PIN 2

14 2000-809002 SPACER 2

15 2000-834003 BUMPER BLOCK 2

16 2000-831001 SCREW 2

17 2000-820001 ROLLER 2

18 2000-837001 WASHER 12

19 2000-834004 LIMITATION BLOCK 2

20 2000-837003 WASHER 2

21 2001-037001 WASHER, LOCK 2

22 2000-931005 SCREW 2

23 2000-835005 BLOCK 2

24 2000-442001 SCREW 1

25 2000-800013 INNER MAST (3.3M) 1

25 2000-800014 INNER MAST (3.0M) 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-14 BL-C22-1010 - 06-19-2017

Figure 12-14 Lift Carriage

R6665

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2701-318001 BACKREST 1

2 2000-830002 BOLT 1

3 2000-820001 ROLLER 4

4 2701-300001 CARRIAGE 1

5 2001-302002 FORK 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-15

Figure 12-15 Hydraulic System

R6666

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — TILT CYLINDER (FIGURE 12-21)

REF

2 1000-628002 O-RING 11

3 2700-614003 HOSE ASSEMBLY 2

4 2700-603004 TUBE ASSEMBLY 1

5 2000-603014 T-FITTING 1


7 2000-603010 WASHER 2

8 2300-614001 FITTING 1


10 — VALVE ASSEMBLY(FIGURE 12-18)

REF

11 1001-031003 SCREW 4

12 2700-609001 OIL RESERVOIR 1

13 2000-625001 SCREW 1


15 1000-603004 WASHER 1

16 — FORCING CYLINDER ASSY(FIGURE 12-22)

REF


18 2000-603016 FITTING 2

19 2000-615001 FITTING 1

20 2500-612001 WASHER 4

21 2000-612008 PIPE 1

22 2000-600019 PIPE COVER 1

23 2001-037001 WASHER, LOCK 4

24 2000-631003 SCREW 4

25 — PUMP AND MOTOR ASSY(FIGURE 12-16)

REF


27 2800-631003 SCREW 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-16 BL-C22-1010 - 06-19-2017

Figure 12-16 Pump & Motor Assy

R6667

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2800-600001 PUMP & MOTOR ASSY 1

1 — • HYDRAULIC MOTOR(FIGURE 12-26)

REF

2 2000-612004 • CONNECTING SLEEVE 1

3 — • VALVE ASSEMBLY(FIGURE 12-18)

REF

4 2000-605005 • GASKET 1

5 — • OIL PUMP(FIGURE 12-17)

REF

6 2800-631002 • SCREW 2

7 2800-631001 • SCREW 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-17

Figure 12-17 Pump Assembly

R6669

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2800-600002 PUMP ASSEMBLYY 1

1 2000-628001 • O-RING 1

2 2000-605001 • SEAL 1

3 2000-628002 • O-RING 1

4 2000-611005 • COVER 1

5 2000-628016 • O-RING 2

6 2000-628017 • O-RING 2

7 2000-605002 • BACKUP RING 2

8 2000-612007 • DISCHARGE BLOCK 2

9 2800-621001 • DRIVE GEAR 1

10 2800-621002 • DRIVEN GEAR 1

11 2000-633001 • PIN 4

12 2800-629001 • PUMP BODY 1

13 2000-611006 • COVER 1

14 2000-628019 • O-RING 1

15 2000-614009 • OIL SUCTION TUBE 1

16 2000-603020 • SIEVE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-18 BL-C22-1010 - 06-19-2017

Figure 12-18 Valve Assembly

R6668

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2800-600004 VALVE ASSEMBLY 1

1 2800-603001 • VALVE BODY 1

2 2000-609001 • SPRING 2

3 2000-603003 • CORE 2

4 2000-628007 • O-RING 4

5 2000-603002 • SLEEVE 2

6 2000-628008 • O-RING 2

7 2000-603018 • ELECTROMAGNETIC COIL

2

8 2000-630001 • BOLT 2

9 2000-637001 • WASHER 2

10 2000-625002 • PLUG 1

11 2000-628013 • O-RING 1

12 2000-637005 • WASHER 1

13 2000-634002 • FILTER 1

14 2000-603005 • CAP 1

15 2000-628009 • O-RING 1

16 2000-619003 • SPRING 1

17 2000-613001 • SPRING SOCKET 1

18 2000-604001 • STEEL BALL 2

19 2000-603004 • VALVE SLEEVE 1

20 2000-628010 • O-RING 1

21 2000-634001 • BACKUP RING 1

22 2000-603009 • SPRING SOCKET 1

23 2000-619002 • SPRING 1

24 2000-603007 • PRESSURE ADJUSTING BOLT

1

25 2000-637002 • WASHER 1

26 2000-603008 • NUT 1

27 2000-628014 • O-RING 1

28 2000-625003 • PLUG 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-19

Figure 12-19 Valve -B Assembly

R6673

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-603002 VALVE-B, ASSEMBLY 1


1

2 2300-614001 • FITTING 5

3 2000-603010 • WASHER 7

4 2000-637002 • WASHER 3

5 2000-603007 • PRESSURE ADJUSTING BOLT

3

6 2000-603008 • NUT 3

7 2700-602001 • VALVE SLEEVE 1

8 2000-628014 • O-RING 1

9 2000-604001 • STEEL BALL 1

10 2000-603009 • SPRING SOCKET 1

11 2000-619002 • SPRING 1

12 2900-603001 • FITTING 2

13 2000-628010 • SEAL 1

14 2700-628001 • SEAL 1

15 2700-603006 • VALVE BODY 1

16 2000-637001 • WASHER 9

17 2000-630001 • BOLT 9

18 1000-304002 • STEEL BALL 3

19 2700-609001 • SPRING 2


1

21 6000-131006 • BOLT 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-20 BL-C22-1010 - 06-19-2017

Figure 12-20 Lift Cylinder

R6670

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2000-600005 LIFT CYLINDER (3.3M) 1

— 2000-600010 LIFT CYLINDER (3.0M) 1

1 2000-605003 • DUST SEAL 1

2 2000-605004 • SEAL 1

3 2000-614007 • CYLINDER BODY (3.3M) 1

3 2000-614013 • CYLINDER BODY (3.0M) 1

4 2000-637003 • WASHER 1

5 2000-630002 • BOLT 1

6 2000-613002 • PISTON ROD (3.3M) 1

6 2000-613006 • PISTON ROD (3.0M) 1

7 2000-627001 • SNAP RING 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-21

Figure 12-21 Tilt Cylinder

R6671

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-600002 TILT CYLINDER 2

1 2701-201001 • CLEVIS 1

2 2700-604003 • WASHER 1

3 2700-604004 • NUT 1

4 2700-613001 • PISTON ROD 1

5 2700-604002 • O-RING 1

6 2700-603007 • PISTON 1

7 2700-605001 • SEAL 2

8 2700-604005 • WASHER 1

9 2700-604006 • NUT 1

10 2700-604007 • SNAP RING 1

11 2700-612001 • WEAR RING 1

12 2700-612003 • RING 1

13 2700-612003 • CYLINDER BODY 1

14 2700-605002 • SEAL 1

15 2700-628002 • O-RING 1

16 2700-614005 • CYLINDER BODY 1

17 2700-604001 • SNAP RING 2

18 1000-312008 • GREASE FITTING 2

19 2700-513002 • SHAFT 2

20 2700-604008 • PIN 2

21 2700-620001 • BEARING 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-22 BL-C22-1010 - 06-19-2017

Figure 12-22 Forcing Cylinder

R6672

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 2700-600003 FORCING CYLINDER 1

1 2300-718001 • BRACKET 1

2 4000-619001 • SPRING 1

3 4000-630001 • BOLT 1

4 2300-600004 • CYLINDER BODY 1

5 4000-605004 • SEAL 1

6 4000-605003 • DUST SEAL 2

7 2000-731002 • SCREW 3

8 2000-737003 • WASHER, LOCK 3

9 4000-613002 • PISTON ROD 1

10 2300-602002 • TOP PLATE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-23

Figure 12-23 Electrical System

R6674

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 3500-400002 BOARD 1

2 2000-406002 CONTROLLER 1

3 2000-507006 HORN 1

4 1000-400025 BOARD 1

5 2000-407010 FUSE 1

6 4300-407002 DRIVE CONTACTOR 1

7 4300-407001 HYDRAULIC CONTACTOR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-24 BL-C22-1010 - 06-19-2017

Figure 12-24 Brake Assembly

R6677

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 4001-000001 BRAKE ASSEMBLY 1

1 2001-010006 • MAGNET BODY 1

2 2001-439001 • NUT 2

3 2001-431001 • SCREW 2

4 4301-037001 • SHIM 6

5 2001-019001 • SPRING 7

6 2001-010005 • ROTOR 1

7 4301-035001 • BUSHING 3

8 4000-227001 • SNAP RING 1

9 2001-021001 • HUB 1

10 4001-404001 • FLAT KEY 1

11 2001-010008 • ROTOR 1

12 2001-012001 • BUSHING 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-25

Figure 12-25 Drive Motor

R6675

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 1201-400005 DRIVE MOTOR 1

1 2001-400009 • DUST SHIELD 1

2 2001-430001 • SCREW 8

3 2001-437001 • WASHER, LOCK 8

4 2001-400008 • TOP COVER 1

5 2001-420001 • BEARING 1

6 2001-427002 • SNAP RING 1

7 2001-419001 • SPRING 4

8 2001-407001 • CARBON BRUSH 4

9 2001-400003 • STATOR 1

10 2001-400002 • ROTOR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-26 BL-C22-1010 - 06-19-2017

Figure 12-26 Hydraulic Motor

R6676

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 1001-400001 HYDRAULIC MOTOR 1

1 2001-409002 • DUST SHIELD 1

2 2001-430003 • SCREW 4

3 2014-37006 • WASHER, LOCK 12

4 2001-439001 • NUT 4

5 2000-537002 • WASHER 4

6 2001-411003 • REAR COVER 1

7 2001-437007 • WAVE WASHER 1

8 2001-420002 • BEARING 1

9 2001-100005 • BRUSH SOCKET 1

10 2001-419002 • SPRING 8

11 2001-407002 • CARBON BRUSH 8

12 2001-430004 • SCREW 4

13 2001-400006 • STATOR 1

14 2001-400007 • ROTOR 1

15 2001-402001 • FAN 1

16 2001-420003 • BEARING 1

17 2001-437008 • WASHER 1

18 2001-411004 • MOTOR COVER 1

19 2001-430005 • SCREW 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

BL-C22-1010 - 06-19-2017 12-27

Figure 12-27 Battery

R6678

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 2001-100004 CHARGER (110V) 1

1 2001-100005 CHARGER (220V) 1

2 2001-100006 BATTERY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-28 BL-C22-1010 - 06-19-2017

Big Lift LLC

self-propelled, counterbalanced lift … counterbalanced lift truck operation ... drive motor. ......

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