MSA - Only available models · 2016-11-14 · 2-2 BL-MSA-0114 - 11-14-2016 Table 2-1 Operator...

Big Lift LLC MANUAL NO. BL-MSA-0114 - 11-14-2016www.bigjoeforklifts.com

MSAMANUAL STACKER

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 wheels, lift system(including forks or attachments, chains, and cables),steering, 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 at cross aisles andwherever vision is obstructed.

Start, stop, travel, and steer smoothly. Slow down forturns and on uneven or slippery surfaces that couldcause truck to slide or overturn. Use special carewhen traveling without load as the risk of overturn maybe 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 unless load is secured so that no part of itcould fall backward.

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

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

When leaving truck, neutralize travel control, and fullylower lifting mechanism.

TABLE OF CONTENTS

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.....................................2-12-4 OPERATING INSTRUCTIONS ........................2-32-4.1 Foot Actuated Caster Brake ..................2-32-4.2 Operator Mast Handles .........................2-32-4.3 Spring Loaded Steering Handle ............2-32-5 TRANSPORT ...................................................2-42-5.1 Moving, (Positioning) and Stopping.......2-42-5.2 Turning ..................................................2-42-6 LOADING AND UNLOADING ..........................2-4

3 PLANNED MAINTENANCE ........................................3-13-1 GENERAL ........................................................3-13-2 MONTHLY AND QUARTERLY CHECKS ........3-13-3 LUBRICATION .................................................3-13-4 LIFT CHAIN MAINTENANCE...........................3-1

4 TROUBLESHOOTING ................................................4-14-1 GENERAL ........................................................4-1

5 LIFT SYSTEM SERVICING.........................................5-15-1 GENERAL ........................................................5-15-2 LIFT CHAIN WEAR INSPECTION ...................5-15-3 LIFT CHAINS ADJUSTMENT ..........................5-15-4 LIFT CHAINS REPLACEMENT........................5-15-5 FORK CARRIAGE............................................5-15-5.1 Non-Tel..................................................5-15-5.2 Telescopic .............................................5-55-6 FORKS .............................................................5-55-6.1 Removal ................................................5-55-6.2 Installation .............................................5-5

Section Page

6 HYDRAULIC SYSTEM SERVICING........................... 6-16-1 GENERAL........................................................ 6-16-2 CYLINDER, PUMP AND HANDLE

ASSEMBLY (NON-TEL) .................................. 6-16-2.1 Removal................................................ 6-16-2.2 Installation............................................. 6-26-3 CYLINDER, PUMP AND HANDLE

ASSEMBLY (TELESCOPIC) ........................... 6-26-3.1 Removal................................................ 6-26-3.2 Installation............................................. 6-36-4 CONTROL HANDLE AND FOOT PEDAL ....... 6-46-4.1 Removal................................................ 6-46-42 Reassembly .......................................... 6-46-5 HYDRAULIC PUMP......................................... 6-56-5.1 Disassembly ......................................... 6-56-5.2 Reassembly .......................................... 6-56-6 CYLINDER, NON-TEL (2200lb 63 Inch Lift) .... 6-56-6.1 Disassembly ......................................... 6-56-6.2 Reassembly .......................................... 6-56-7 CYLINDER, TELESCOPIC

(2200lb 98 Inch Lift) ......................................... 6-76-7.1 Disassembly ......................................... 6-76-7.2 Reassembly .......................................... 6-7

7 FRAME AND RELATED PARTS SERVICING ........... 7-17-1 GENERAL........................................................ 7-17-2 LOAD WHEEL REPLACEMENT ..................... 7-17-3 CASTER REPLACEMENT .............................. 7-1

8 ILLUSTRATED PARTS BREAKDOWN...................... 8-1

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TABLE OF CONTENTS - Continued

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SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the MSA Series ManualStackers distributed by Big Lift LLC. Included are oper-ating instructions, planned maintenance instructions,lubrication procedures, corrective maintenance proce-dures and a complete parts list with part location illus-trations.

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 M22 lift truck.

1-2. GENERAL DESCRIPTION.

The manually-propelled MSA Series Manual Stackers,Figure 1-1, lift and transport payloads up to 2200 onadjustable forks.

The mast handles are used to help control the lifttruck. The control handle is used to propel and steerthe lift truck. Lift and Lower are controlled by the con-trol handle and foot pedal.

The model number will be found on the name platealong with the serial number, lifting capacity, and loadcenter. Figure 1-1 shows the locations of the truck’smain components and controls.

1-3. SAFETY FEATURES.

The MSA Series Manual Stackers are designed andengineered to provide maximum safety for operatorand payload. Some of the safety features incorporatedinto the design are:

• Steer casters.

• Foot actuated brake on casters.

• Control handle automatically returns to raised posi-tion when released.

• Mast handles and steering handle to provide a firmhand hold for operator.

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

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Figure 1-1. MSA Manual Stacker

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SECTION 2OPERATION

2-1. GENERAL.

The following paragraphs describe the controls andprocedures involved in proper operation of the manualstacker.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the manualstacker may result in operator injury, orload and/or truck damage. Observe thefollowing precautions when operating theMSA Series Manual Stackers.

The following safety precautions must be adhered toat all times.

1. Leave the load in the full down position for over-night storage.

2. Engage the brake on the casters before leavingthe stacker.

3. Center the load as far as possible toward the backrest. Never lift a load on the fork tips or on onefork blade.

4. Do not attempt to lift a load heavier than the ratedcapacity of the truck. Check that the center ofgravity of the load is not beyond the load centerlisted on the name plate. See Figure 2-1 for anexplanation of load center.

5. Check for obstructions before raising or loweringa load.

6. Lower the load before traveling. If it is necessaryto move the load while raised, travel cautiouslyand use extra care when turning.

2-3. BEFORE OPERATION.

Table 2-1 covers important inspection points on theMSA Series Manual Stackers which should bechecked prior to operation. Depending on use sometrucks may require additional 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 forproper 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.

Figure 2-1 Load Center

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Table 2-1 Operator Checks

Figure 2-2 Sample of Operator Check List

ITEM PROCEDURE

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

Chains Check that they are in place, properly secured and not damaged.

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

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

Wheels Check wheels for cracks or damage. Move the truck to check load wheel and cast-ers for freedom of rotation.

Caster brake Check that the brake holds the truck stationary.

Lift and Lower Check operation of lift and lower to their maximum positions.

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2-4. OPERATING INSTRUCTIONS.

1. To raise the load, pump steering handle or footpedal just a few strokes to raise the load from thefloor.

2. To lower the load, pull flinger tip control levertoward the operator.

2-4.1. Foot Actuated Caster Brake

The foot actuated caster brake is used to hold thetruck stationary.

2-4.2. Operator Mast Handles

The operator mast handles located on each side of themast are used to help control the truck.

2-4.3. Spring Loaded Steering Handle

The spring loaded steering handle is used to raise theload, propel and steer the lift truck.

Figure 2-3. M22 Lift Truck

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2-5. TRANSPORT.

2-5.1. Moving, (Positioning) and Stopping

1. Check that the load is in the down position leavingenough floor clearance to maneuver the truckbefore traveling.

2. Release the caster brake.

3. Apply pressure to the steering handle and masthandles to move the truck forward. Pull evenly onthe steering handle to move the truck backward.

4. To stop the lift truck, hand restraint against thesteering handle and mast handles is usually ade-quate.

5. Pull flinger tip control lever toward the operator tolower the load to the floor and engage the casterbrake.

2-5.2. Turning

NOTE: Turning and maneuvering the lift truck ismade easier if the truck is in motion.

Begin rolling the truck and simultaneously apply sidepressure to the steering handle to cause the casterwheels to swivel.

2-6. LOADING AND UNLOADING.

1. Move the truck to the location where the load is tobe picked up.

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

3. Raise the forks to the desired height for entryunder the load.

4. Move the lift truck into position so that the forksare centered under the load.

5. Move the lift truck forward to place the load as farback as possible toward the fork carriage. Raisethe forks to lift the load.

CAUTION: To avoid spilling the load, move slowlyand use extra caution when turning.

6. Move the lift truck backward from the loadingposition.

7. When the load is clear of its rack, lower the load,leaving enough floor clearance to maneuver thetruck.

8. Push or pull the truck carefully to the area wherethe load is to be placed.

9. Align the lift truck with its new position.

10. Raise the forks to the desired height and slowlymove the lift truck into position for off-loading.

CAUTION: The load must rest squarely on its rackwhen it is lowered into position.

11. When the load is in position, lower the forks untilthe pallet rest on its rack and the forks are free.

12. Slowly move the lift truck backward, checking thatthe forks do not catch on the pallet or rack.

13. Lower the forks when they are clear.

14. Proceed to move the next load.

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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 stackeris 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.

Table 3-1 Monthly and Quarterly Inspection and Service Chart

3-3. 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.

3-4. LIFT CHAIN MAINTENANCE.

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

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

VISUAL CHECKS

INTERVAL INSPECTION OR SERVICE

Daily Observe performance of truck. Check any improper operation.

Monthly Check load wheels for wear.

Monthly Check caster wheels for wear.

Monthly Check lift chain tension, lubrication & operation (see paragraph 3-4.)

Quarterly Check lift cylinder for leakage.

Semi-annually Inspect for chain wear (See SECTION 7)

No. 1 Grease—Lithium base, general purpose.

No. 2 SAE 30 or 40 Engine lubricating oil

No. 3 Hydraulic oil-Heavy duty with a foam sup-pressing agent and rust and oxidation inhibitors.

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

2 Fork Carriage Brush No. 1 Light coating where forks slide

3 Mast Brush No. 1 Full length of channel where rollers operate.

4 Lift Cylinder can No. 3 With fork carriage fully lowered, remove plug from top of cylinder and fill with hydraulic oil.

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SECTION 4TROUBLESHOOTING

4-1. GENERAL

This section gives fixes for some common problemsthat may arise while operating the lift truck. Table 4-1

lists these malfunctions, their causes, probable andcorrective action that will resolve the problem.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

Oil sprays or flows from the top of lift cylinder.

Defective packing in lift cylinder. Overhaul lift cylinder and install new packing, seal, and wiper ring.

Squealing sound when lifting. a. Oil level low. Add oil as necessary.

b. Dry mast channels. Apply grease.

c. Defective mast or carriage bear-ings.

Replace bearing.

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

Oil leaks at hydraulic pump Defective pump. Repair pump assembly.

Foot pedal control does not return to neutral.

a. Foreign particles. Clean system.

b. Defective pump. Repair pump assembly.

Weak, slow or uneven action of hydraulic system.

a. Defective pump Repair pump assembly.

b. Defective lift cylinder Repair lift cylinder.

c. Load exceeds capacity. See data plate.

Forks creep down with or without load.

a. Oil bypassing in pump. Repair pump assembly.

b. Worn lift cylinder packing Repair lift cylinder.

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NOTES

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SECTION 5LIFT SYSTEM SERVICING

5-1. GENERAL

This section covers maintenance and repair proce-dures for the lift system. The lift system consists of:

Inner mast assembly (Telescopic)

Fork carriage

Forks

Lift chain

The lift cylinder, pump and handle assembly is consid-ered part of the hydraulic system and is covered inSECTION 6.

5-2. 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 a damaged chain. Refer toparagraph 5-4. when installing new chain.

5-3. LIFT CHAINS ADJUSTMENT.

NOTE: The 2200 lb 63 inch Non-Tel only has one liftchain (Figure 5-1). All others have two liftchains and both chains must be adjusted atthe same time.

1. Lower the carriage fully, then disconnect battery.

CAUTION: At least 3 full threads must be presentbelow bottom hex nuts (7, Figure 5-2)after completion of adjustment.

2. Loosen the top jam nuts (7) on the adjusting bolts(59).

3. Break the bottom most jam nuts (7) free from theremaining jam nuts (7) and take up slack in thechains by turning the remaining jam nuts (7).

4. Align adjusting bolt (4) so that it is parallel to themast.

5. Tighten the bottom two jam nuts (7) together.

6. Tighten the jam nuts (7) while maintaining align-ment of the adjusting bolts.

5-4. LIFT CHAINS REPLACEMENT.

NOTE: The 2200 lb 63 inch Non-Tel only has one liftchain (Figure 5-1). All others have two liftchains and both chains must be replaced atthe same time.

1. Place a solid support on the floor under the verti-cal members nearest the center of fork carriage.

2. Lower the carriage until it is supported by the sup-port and the chains are slack.

3. Remove the two cotter pins (5, Figure 5-2) andpin (6) securing chain (3) to the fork carriage.

4. Remove the two cotter pins (5) and pin (6) secur-ing chain (3) to adjusting bolt (4).

5. Remove the chain from the sheave (46).

6. Position new chain in place on sheave (46).

7. Connect chain (3) to adjusting bolt (4) with pin (6)and two cotter pins (5).

8. Connect the opposite end chain (4) to the forkcarriage with pin (6) and two cotter pins (5).

9. Replace the remaining chain is the same manner.

10. Adjust chains according to paragraph 5-3.

5-5. FORK CARRIAGE.

5-5.1. Non-Tel

1. Completely lower the carriage until the chains areslack, then disconnect battery.

2. Remove the lift chains as described in paragraph5-4.

3. Using a suitable lifting device attached to the forkcarriage, slowly raise the carriage out of the mast.

4. Remove snap ring (7, Figure 5-3) and roller (4)from carriage (2).

5. Remove snap ring (6) and bearing (5) from roller(4).

6. Install the fork carriage in the reverse order ofremoval.

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Figure 5-1 Frame, Non-Tel (2200 lb 63 Inch Lift)

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Figure 5-2. Frame Telescopic (2200 lb 98 Inch Lift Shown)

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5-5.2. Telescopic

1. Place a solid support on the floor under the verti-cal members nearest the center of the fork car-riage.

2. Lower the carriage until it is supported by the sup-port and the chains are slack, then disconnectbattery.


4. Remove the lift cylinder as described in para-graph SECTION 6

5. Using a suitable lifting device attached to theinner mast (55, Figure 5-2), slowly raise the innermast until the fork carriage is free.

6. Remove the fork carriage from the inner mast.

7. Remove snap ring (7, Figure 5-3) and roller (4)from carriage (2).

8. Remove snap ring (6) and bearing (5) from roller(4).

9. Install the fork carriage in the reverse order ofremoval.

5-6. FORKS.

Check the forks periodically for cracks and other dam-age.

5-6.1. Removal

1. Completely lower the carriage until the chains areslack.

2. Remove snap ring (1, Figure 5-3).

3. While supporting the forks (13), remove shaft (9).

4. Remove bolts (10), wear plates (11) and shims(12).

5-6.2. Installation

1. Install wear plates (1, Figure 5-3), shims (12) andbolts (10).

2. Position the forks (13) in carriage (2).

3. Install shaft (9) through carriage (2) while aligningthe mounting holes of forks (13).

4. Install snap ring (1).

5. If necessary, adjust the amount of shims (12) thealign the forks.

Figure 5-3 Fork carriage Telescopic (2200 lb 98 Inch Lift Shown)

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SECTION 6HYDRAULIC SYSTEM SERVICING

6-1. GENERAL.

This section covers the maintenance and repair proce-dures for the lift cylinder, pump and handle assembly.This assembly can be removed as an assembly or theindividual components can be repaired individually.

6-2. CYLINDER, PUMP AND HANDLE ASSEMBLY (NON-TEL).

6-2.1. Removal

1. Chock all wheels and engage the caster brake.

2. Raise the forks approximately three feet from thefloor and position blocks or other strong supportsunder the fork carriage. Keep supports in placeduring the entire procedure.

3. Lower the carriage onto the supports. Check thatthe supports are supporting the carriage.


5. 2200 lb 63 Inch Lift: Remove sheave (7, Figure6-1).

6.Remove two bolts (28), spring washer (25) andflat washers (26) securing the bottom of the cylin-der to frame (2).

7. Support the cylinder and remove two nuts (20),spring washers (21), flat washers (22) and clevisbolt (23).

8. Lift the assembly from frame (2).


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6-2.2. Installation

1. Position the assembly on the mast and securewith clevis bolt (23, Figure 6-2), flat washers (22),spring washers (21) and nuts (20).

2. Secure the bottom of the cylinder to frame (2) withtwo bolts (28), spring washer (25) and flat wash-ers (26).

3. 2200 lb 63 Inch Lift: Install sheave (7, Figure 6-1).

4. Install the lift chains as described in paragraphSECTION 5

5. Raise the carriage and remove the supports.

6. With fork carriage fully lowered, remove plug fromtop of cylinder and fill with hydraulic oil. Usehydraulic oil listed in Table 3-2.

7. Adjust the lift chains according to SECTION 5


6-3. CYLINDER, PUMP AND HANDLE ASSEMBLY (TELESCOPIC).

6-3.1. Removal

1. Chock all wheels and engage the caster brake.

2. Raise the forks approximately three feet from thefloor and position blocks or other strong supportsunder the fork carriage. Keep supports in placeduring the entire procedure.

3. Lower the carriage onto the supports. Check thatthe supports are supporting the carriage.

4. Remove two bolts (16, Figure 6-3), spring washer(15) and flat washers (23) securing the bottom ofthe cylinder to frame (2).

5. Support the cylinder and remove bolt (16), springwasher (15), flat washer (23) securing the top ofthe cylinder to inner mast (55).

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6. Using a suitable lifting device, raise the inner mast(55) and remove the assembly from frame (2).Position blocks or other strong supports underinner mast (5).

6-3.2. Installation

1. Position the lift cylinder on the frame (2, Figure 6-3).

2. Using a suitable lifting device, support the innermast (55) and remove the supports.

3. Slowly lower the inner mast while lining up the liftcylinder with the inner mast cross member.

4. Secure the top of the cylinder with screw (16),spring washer (15) and flat washer (23).

5. Secure the bottom of the cylinder to frame (2) withtwo bolts (16), spring washers (15) and flat wash-ers (23).


7. Adjust the lift chains according to paragraph 5-3.

Figure 6-3. Frame Telescopic (2200 lb 98 Inch Lift Shown)

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6-4. CONTROL HANDLE AND FOOT PEDAL.

6-4.1. Removal

1. Fully lower the fork carriage.

2. Remove pin (54, Figure 6-4) and disconnect chain(55) from bracket (35).

3. Remove axle (42), handle (52) and pedal (36)from body (1).

4. Free the pad (37) from pedal (36).

5. Remove pin (40) and roller (38) from pedal (36).

6. Remove bearing (39) from roller (38).

6-4.2. Reassembly

1. Install bearing (39, Figure 6-4) in roller (38).

2. Position roller (38) in pedal (36) and install pin(40).

3. Install new pad (37) on pedal (36).

4. Position handle (52) and pedal (36) on body (1)and install axle (42).

5. Reconnect chain (55) to bracket (35) and installpin (54).

Figure 6-4 Lift Cylinder, Non-Tel (2200lb 63 Inch Lift Shown)

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6-5. HYDRAULIC PUMP.

6-5.1. Disassembly


2. Remove the control handle and foot pedal asdescribed in paragraph 6-4.

3. Lift plunger (15, Figure 6-4) from body (1).

4. Remove upper snap ring (12), cup (13), spring(14) from plunger (15).

5. Remove lower snap ring (12), seal (17) and seat(18) from plunger (15).

6. Remove and disassemble left valve (7). Refer toFigure 6-4.

7. Remove bracket (35) and right valve housing(29). Refer to Figure 6-4.

6-5.2. Reassembly

1. Reassemble and Install right valve housing (29)and bracket (35). Refer to Figure 6-4.

2. Reassemble and Install left valve (7, Figure 6-4).Refer to Figure 6-4.

3. Install seat (18), seal (17) and lower snap ring(12) on plunger (15).

4. Install spring (14), cup (13) and upper snap ring(12) on plunger (15).

5. Install plunger (15) in body (1).

6. Install the control handle and foot pedal asdescribed in paragraph 6-4.


6-6. CYLINDER, NON-TEL (2200lb 63 Inch Lift)

6-6.1. Disassembly


2. Remove the cylinder, pump handle assembly asdescribed in paragraph 6-2.


CAUTION: Use the proper tube pipe clamp vise inthe following steps to prevent damage tothe lift cylinder.

4. Secure cylinder body in the vise and removegland nut (48, Figure 6-4).

5. Remove dust seal (50), and O-ring (49) and sealring (47) from gland nut (48).

6. Pull piston rod (46) out of cylinder body (1).

7. Remove snap ring (12), washer (43), seal (44)and bushing (45) from piston rod (46).

6-6.2. Reassembly

1. Install bushing (45, Figure 6-4), seal (44), washer(43) and snap ring (12) on piston rod (46).

2. Install O-ring (7), piston (8) and snap ring (10) onpiston rod (6).


3. Secure cylinder body (1) in the vise.

4. Install piston rod (46) in body (1).

5. Install seal ring (47), O-ring (49) and dust seal(50) on gland nut (48).

6. Install gland nut (48) on body (1).

7. Remove lift cylinder from vise.


9. Install the cylinder, pump handle assembly asdescribed in paragraph 6-2.


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6-7. CYLINDER, TELESCOPIC (2200lb 98 Inch Lift)

6-7.1. Disassembly


2. Remove the cylinder, pump handle assembly asdescribed in paragraph 6-2.



4. Secure cylinder body (1) in the vise and removegland nut (51, Figure 6-5).

5. Remove dust seal (53), and O-ring (52), O-ring(48), seal (49) and seal ring (50) from gland nut(51).

6. Pull piston rod (47) out of cylinder body (1).

7. Remove seal (46) from piston rod (47).

6-7.2. Reassembly

1. Install seal (46, Figure 6-5) on piston rod (47).


2. Secure cylinder body (1) in the vise.

3. Install piston rod (47) in body (1).

4. Install seal ring (50), seal (49), O-ring (48), O-ring(52) and dust seal (53) on gland nut (51).

5. Install gland nut (51) on body (1).

6. Remove lift cylinder from vise.


8. Install the cylinder, pump handle assembly asdescribed in paragraph 6-2.


Figure 6-5 Lift Cylinder, Telescopic (2200lb 98 Inch Lift)

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6-6 BL-MSA-0114 - 11-14-2016

SECTION 7FRAME AND RELATED PARTS SERVICING

7-1. GENERAL.

This section covers load wheels and casters replace-ment.

7-2. LOAD WHEEL REPLACEMENT.

1. Fully lower the carriage.

1. Chock both caster wheels and the load wheel thatis not being replaced.

2. Raise the front of the lift truck with a suitable jackor another lift truck. Place strong supports underthe straddle leg just in back of the wheel housingso that the load wheel being replaced is approxi-mately one inch above the floor.

3. Remove screws (47, Figure 7-1) and plate (46).

4. Remove axle (44), bushing (41 and 45) and loadwheel (43).

5. Remove bearings (42) from load wheel (43).

6. Install a new load wheel in the reverse order ofremoval.

7-3. CASTER REPLACEMENT.

1. Fully lower the carriage.

2. Chock the load wheels.

3. Raise the rear of the lift truck with a suitable jackor another lift truck. Place strong supports approx-imately six inches in front of the caster to bereplaced.

4. Lower the lift truck so that the body of the truck isresting on the supports. Remove the jack.

5. Check that the caster wheel is not touching thefloor and is free to turn.

6. Remove four nuts (24, Figure 7-1), spring wash-ers (25), flat washers (26), bolts (28) and casterassembly.

7. Remove nut (29), spring washer (10), bolt (34)and caster (32) from caster and brake housing(27).

8. Remove push covers (30), axle cover (33) andbearings (31) from caster wheel (32).

9. Install a new caster in the reverse order ofremoval.

Figure 7-1 Frame, Non-Tel (2200 lb 63 Inch Lift Shown)

R7109

BL-MSA-0114 - 11-14-2016 7-1

NOTES

7-2 BL-MSA-0114 - 11-14-2016

SECTION 8ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the MSA Manual Stacker.

BL-MSA-0114 - 11-14-2016 8-1


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FRAME, NON-TEL (2200 LB 63 INCH LIFT)

Pos. Part Number DescriptionQty.

Reqd.Notes

1 2310-160101 GUARD 1

2 2310-160102 TRUCK FRAME 1

3 2310-161010 SNAP RING, M30 2

4 2310-160104 AXLE 1

5 2310-160105 SNAP RING, M72 1

6 2310-161071 BEARING 1

7 2310-160107 SHEAVE 1

8 2310-160108 NUT, CARRIER WHEEL 1

9 2310-161067 FLAT WASHER M12 4

10 2310-161066 SPRING WASHER 12 5

11 2310-161065 BOLT, M12 x 35 4

12 2310-160112 LIFT CHAIN 1

13 2310-161064 WASHER 4

14 2310-161063 BOLT, M6 X 16 4

15 2310-251019 COTTER PIN, 1.2 X 16 2

16 2310-160116 CHAIN PIN, 8 X 33 1

17 2310-160117 ADJUSTING BOLT 1

18 2310-160118 NUT, M18 x 1.5 3

19 2310-160119 FLAT WASHER, M18 2

20 2310-161004 NUT, M8 2

21 2310-161005 SPRING WASHER, M8 2

22 2310-161006 FLAT WASHER, M8 2

23 2310-161056 CLEVIS BOLT 1

24 2310-161076 NUT, M10 8

25 2310-161007 SPRING WASHER, M10 10

26 2310-161041 FLAT WASHER, M10 10

27 2310-160127 CASTER HOUSING 2

27a 2310-NY CASTER WHEEL ASSEMBLY (NYLON) 2

27b 2310-PU CASTER WHEEL ASSEMBLY (POLY) 2

28 2310-160128 BOLT, M10 X 25 8

29 2310-161020 NUT, M12 2

30 2310-160130 PUSH COVER 4

31 2310-161023 BEARING 4

32 2310-160132 REAR WHEEL, 150 (NYLON) 2

33 2310-160133 AXLE COVER 2

34 2310-160134 BOLT, M12 X 85 2

BL-MSA-0114 - 11-14-2016 8-3

Figure 8-1 Frame, Non-Tel (2200 lb 63 Inch Lift) - Continued

8-4 BL-MSA-0114 - 11-14-2016

P

th -

3

2 ’s

-

th -

4

2 ’s

-

** N n M1

FRAME, NON-TEL (2200 LB 63 INCH LIFT) - CONTINUED

os. Part Number DescriptionQty.

Reqd.Notes

35 2310-161045 NUT, M20 ** 4 See Notes below.

36 2310-161047 FLAT WASHER, M20 ** 1 See Notes below.

37 2310-161048 BOLT, M20 X 100 ** 4 See Notes below.

38 2310-161044 BOLT, M20 X 1.5 X 45 ** 2 See Notes below.

39 2310-161046 RIGHT STRADDLE LEG ** 1

Used up to serial # M14020001 and on trucks wiserial # between M14020020M14020034. See Straddle Section for trucks with higherserial numbers listed above.

9a 2310-161078 RIGHT STRADDLE LEG 1

Used from serial # M1402000but not on trucks with serial #betweenM14020020 - M14020034. See Adjustable Straddle Section.

40 2310-161003 LEFT STRADDLE LEG ** 1


0a 2310-161077 LEFT STRADDLE LEG 1

Used from serial # M1402000but not on trucks with serial #betweenM14020020 - M14020034. See Adjustable Straddle Section.

41 2310-161049 SPACING BUSH ** 2 See Notes below.

42 2310-161050 BEARING ** 4 See Notes below.

43 2310-161051 FRONT WHEEL, (NYLON) ** 2 See Notes below.

44 2310-161052 AXLE ** 2 See Notes below.


46 2310-161054 PUSH PLATE ** 2 See Notes below.


OTE For items Pos. # 35-38, 39a, 40a, 41 - 47: Used up to serial # M14020001 and on trucks with serial # betwee4020020-M14020034. See Adjustable Straddle Section for trucks with higher serial numbers then listed above.

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Figure 8-2 Frame, Telescopic (2200 lb 98 Inch Lift)

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FRAME, TELESCOPIC (2200 LB 98 INCH LIFT)


Reqd.Notes

1 2310-250101 GUARD 1

2 2310-250102 TRUCK FRAME 1

3 2310-251020 LIFT CHAIN (2.5 M) 2


5 2310-251019 COTTER PIN, 1.2 X 16 4

6 2310-251018 CHAIN PIN 2

7 2310-161058 NUT, M16 x 1.5 6

8 2310-161057 FLAT WASHER, M16 4

9 2310-161033 SNAP RING, M25 4

10 2310-250110 ROLLER 2

11 2310-161065 BEARING 2

12 2310-251016 STEEL BALL, 12 2

13 2310-250113 BEARING SEAT 2

14 2310-251007 SCREW, M12 X 20 10

15 2310-161007 SPRING WASHER, M10 17

16 2310-161040 BOLT, M10 X 30 9


18 2310-251010 NUT, M20 X 1.5 2

19 2310-251011 SPRING 2

20 2310-251012 LIFT PIN 2

21 2310-161064 WASHER 4

22 2310-161063 BOLT, M6 x 16 4

23 2310-161041 FLAT WASHER, M10 10

24 2310-161076 NUT, M10 8

25 2310-160127 CASTER HOUSING 2

25a 2310-NY CASTER WHEEL ASSEMBLY (NYLON) 2

25b 2310-PU CASTER WHEEL ASSEMBLY (POLY) 2

26 2310-161020 NUT, M12 2

27 2310-161066 SPRING WASHER, M12 2

28 2310-160130 PUSH COVER 2

29 2310-161023 BEARING 4

30 2310-160132 REAR WHEEL, 150 (NYLON) 2

31 2310-160133 AXLE COVER 2

32 2310-160134 BOLT, M12 X 85 2

33 2310-161045 NUT, M20 ** 4 See Notes below.

34 2310-161047 FLAT WASHER, M20 ** 1 See Notes below.

BL-MSA-0114 - 11-14-2016 8-7

Figure 8-2 Frame, Telescopic (2200 lb 98 Inch Lift) - Continued

R7111

8-8 BL-MSA-0114 - 11-14-2016

P

th -

3

2 ’s

th -

3

2 ’s

** N n M1

FRAME, TELESCOPIC (2200 LB 98 INCH LIFT) - CONTINUED

os. Part Number DescriptionQty.

Reqd.Notes


36 2310-161044 BOLT, M20 X 1.5 X 45 ** 2 See Notes below.

37 2310-161046 RIGHT STRADDLE LEG ** 1



Used from serial # M1402000but not on trucks with serial #between M14020020 - M14020034. See Adjustable Straddle Section.

38 2310-161003 LEFT STRADDLE LEG ** 1


8a 2310-161077 LEFT STRADDLE LEG 1

Used from serial # M1402000but not on trucks with serial #between M14020020 - M14020034. See Adjustable Straddle Section.


40 2310-161050 BEARING ** 4 See Notes below.

41 2310-161051 FRONT WHEEL, (NYLON) ** 2 See Notes below.

42 2310-161052 AXLE ** 2 See Notes below.


44 2310-161054 PUSH PLATE ** 2 See Notes below.


46 2310-251021 SHEAVE 2

47 2310-161030 BEARING 2

48 2310-251022 SNAP RING, M52 2

49 2310-251008 PLUG 2

50 2310-250150 ROLLER 2

51 2310-251005 BEARING 2

52 2310-161010 SNAP RING, M30 2

53 2310-161069 SNAP RING, M62 2

54 2310-251003 STEEL BALL, M13.5 2

55 2310-250154 INNER MAST 1

OTE For items Pos. # 33-36, 37a, 38a, 39 - 45: Used up to serial # M14020001 and on trucks with serial # betwee4020020-M14020034. See Adjustable Straddle Section for trucks with higher serial numbers then listed above.

BL-MSA-0114 - 11-14-2016 8-9

Figure 8-3 Adjustable Straddles (starting S/N M14020002 (except M14020020-M14020034)R8000

8-10 BL-MSA-0114 - 11-14-2016

Adjustable Straddles (starting S/N M14020002 (except M14020020-M14020034)


Reqd.Notes

1 2310-161079 AXLE 2

2 2310-161080 SCREW 2

3 2310-161081 WASHER 4

4 2310-161051 LOAD WHEEL (NYLON) 2

5 2310-161050 BEARING 4

6 2310-161077 LEFT STRADDLE LEG 1


7 2310-161096 BOLT M16 x 50 3

8 2310-161097 WASHER 3

9 2310-161098 WASHER 3

NOTE:The above mentioned quantities is for one straddle (pos. 1-5 & 7-9) so you have to take it times 2 if doing both left and right side.

BL-MSA-0114 - 11-14-2016 8-11

Figure 8-4 Fork carriage, Non-Tel (2200 lb 63 Inch Lift)R7115

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FORK CARRIAGE, NON-TEL (2200 LB 63 INCH LIFT)


Reqd.Notes

1 2310-161010 SNAP RING, M30 2

2 2310-160302 FORK CARRIAGE 1

3 2310-163003 SCREW, M12 X 20 4

4 2310-250150 ROLLER 4

5 2310-251005 BEARING 4

6 2310-161069 SNAP RING, M62 4

7 2310-161010 SNAP RING, M30 4

8 2310-251003 STEEL BALL, M13.5 4

9 2310-162006 AXLE 1

10 2310-162005 BOLT, M8 X 20 4

11 2310-162004 PLATE 2

12 2310-162003 SHIM 2

13 2310-162002 FORK 2

BL-MSA-0114 - 11-14-2016 8-13

Figure 8-5 Fork carriage, Telescopic (2200lb / 98 Inch Lift)

8-14 BL-MSA-0114 - 11-14-2016

FORK CARRIAGE, TELESCOPIC (2200lb / 98 Inch Lift)


Reqd.Notes

1 2310-161010 SNAP RING, M30 2

2 2310-250302 FORK CARRIAGE 1

3 2310-163003 SCREW, M12 X 20 4

4 2310-250150 ROLLER 4

5 2310-251005 BEARING 4

6 2310-161069 SNAP RING, M62 4

7 2310-161010 SNAP RING, M30 4

8 2310-251003 STEEL BALL, M13.5 4

9 2310-162006 AXLE 1

10 2310-162005 BOLT, M8 X 20 4

11 2310-162004 PLATE 2

12 2310-162003 SHIM 2

13 2310-162002 FORK 2

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Figure 8-6 Lift Cylinder, Non-Tel (2200lb 63 Inch Lift)

8-16 BL-MSA-0114 - 11-14-2016

LIFT CYLINDER, NON-TEL (2200LB 63 INCH LIFT)


Reqd.Notes

-- 2310-160256 HYDRAULIC UNIT ASSEMBLY 1 Includes pos.# 1 - 55

1 2310-160201 CYLINDER BODY 1

2 2310-160202 SCREW 1

3 2310-160203 COPPER LINER 1

4 2310-160204 SPRING 1

5 2310-160205 LIFT PIN 1

6 2310-160206 STEEL BALL 1

7 2310-160207 LEFT VALVE BUSH 1

8 2310-160208 COPPER LINER 3

9 2310-160209 FLAT SPRING 1

10 2310-160210 O-RING, 11.8 X 2.65 2

11 2310-160211 STOP PIN, 3 X 17.8 1

12 2310-160212 SNAP RING, M12 2

13 2310-160213 SPRING CUP 1

14 2310-160214 SPRING 1

15 2310-160215 PUMP PLUNGER 1

16 2310-160216 O-RING, 11.2 X 2.65 1

17 2310-160217 YX-SEAL RING 1

18 2310-160218 SPRING SEAT 1

19 2310-160219 SEAL RING, M16 1

20 2310-160220 COTTER PIN,8 X 40 1

21 2310-160221 O-RING, 14 X 1.8 1

22 2310-160222 VALVE HOUSING 1

23 2310-160223 STEEL BALL 1

24 2310-160224 LIFT PIN 2

25 2310-160225 SPRING 1

26 2310-160226 SAFETY VALVE BOLT 1

27 2310-160227 O-RING, 8 X 1.8 1

28 2310-160228 STEEL BALL 1

29 2310-160229 RIGHT VALVE HOUSING 1

30 2310-160230 O-RING, 45 X 1.8 2

31 2310-160231 SPRING 1

32 2310-160232 RETURN OIL RAM 1

33 2310-160233 BOLT, M6 X 35 1

34 2310-160234 NUT, M6 2

BL-MSA-0114 - 11-14-2016 8-17

Figure 8-6 Lift Cylinder, Non-Tel (2200lb 63 Inch Lift) - ContinuedR7118

8-18 BL-MSA-0114 - 11-14-2016

LIFT CYLINDER, NON-TEL (2200LB 63 INCH LIFT) - CONTINUED


Reqd.Notes

35 2310-160235 BRACKET 1

36 2310-160236 FOOT PEDAL 1

37 2310-160237 PEDAL PAD 1

38 2310-160238 ROLLER 1

39 2310-160239 OILLESS BEARING 1

40 2310-160240 PIN 1

41 2310-160241 OILLESS BEARING,26/20 X 18 X 11 4

42 2310-160242 HANDLE AXLE 1

43 2310-160243 FLAT WASHER, M16 1

44 2310-160244 OIL SEAL UN27 1

45 2310-160245 BUSHING 1

46 2310-160246 PISTON ROD 1

47 2310-160247 SEAL RING 1

48 2310-160248 GLAHD NUT 1

49 2310-160249 O-RING, 31.5 X 3.55 1

50 2310-160250 DUST SEAL, 32 X 45 X 8 1

51 2310-160251 OIL PLUG 1

52 2310-160252 HANDLE 1

53 2310-160253 RETURN SPRING 1

54 2310-160254 COTTER PIN, 4 X 30 1

55 2310-160255 HANDLE CHAIN 1

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Figure 8-7 Lift Cylinder, Telescopic (2200lb 98 Inch Lift)

8-20 BL-MSA-0114 - 11-14-2016

LIFT CYLINDER, TELESCOPIC (2200lb 98 Inch Lift)


Reqd.Notes

-- 2310-250258 HYDRAULIC UNIT ASSEMBLY 1 Includes pos.# 1 - 59

1 2310-250201 CYLINDER BODY 1 Lift height 98” (2500mm)

2 2310-160202 SCREW 1

3 2310-160203 COPPER LINER 1

4 2310-160204 SPRING 1

5 2310-160205 LIFT PIN 1

6 2310-160206 STEEL BALL 1

7 2310-160207 LEFT VALVE BUSH 1

8 2310-160208 COPPER LINER 3

9 2310-160209 FLAT SPRING 1

10 2310-160210 O-RING, 11.8 X 2.65 2

11 2310-160211 STOP PIN, 3 X 17.8 1

12 2310-160212 SNAP RING, M12 2

13 2310-160213 SPRING CUP 1

14 2310-160214 SPRING 1

15 2310-160215 PUMP PLUNGER 1

16 2310-160216 O-RING, 11.2 X 2.65 1

17 2310-160217 YX-SEAL RING 1

18 2310-160218 SPRING SEAT 1

19 2310-160219 SEAL RING, M16 1

20 2310-160220 SPRING PIN,8 X 40 1

21 2310-160221 O-RING, 14 X 1.8 1

22 2310-160222 VALVE HOUSING 1

23 2310-160223 STEEL BALL 1

24 2310-160224 LIFT PIN 2

25 2310-160225 SPRING 1

26 2310-160226 SAFETY VALVE BOLT 1

27 2310-160227 O-RING, 8 X 1.8 1

28 2310-160228 STEEL BALL 1

29 2310-160229 RIGHT VALVE HOUSING 1

30 2310-160230 O-RING, 45 X 1.8 2

31 2310-160231 SPRING 1

32 2310-160232 RETURN OIL RAM 1

33 2310-160233 BOLT, M6 X 35 1

BL-MSA-0114 - 11-14-2016 8-21

Figure 8-7 Lift Cylinder, Telescopic (2200lb 98 Inch Lift) - Continued

8-22 BL-MSA-0114 - 11-14-2016

LIFT CYLINDER, TELESCOPIC (2200lb 98 Inch Lift) - CONTINUED


Reqd.Notes

34 2310-160234 NUT, M6 2

35 2310-160235 BRACKET 1

36 2310-160236 FOOT PEDAL 1

37 2310-160237 PEDAL PAD 1

38 2310-160238 ROLLER 1

39 2310-160239 OILLESS BEARING 1

40 2310-160240 PIN 1

41 2310-160241 OILLESS BEARING, 26/20 X 18 X 11 4

42 2310-250242 AXLE COVER 2

43 2310-250243 TORSIONAL SPRING 1

44 2310-250244 HANDLE AXLE 1

45 2310-250245 TORSIONAL SPRING 1

46 2310-250246 PISTON 1

46a 2315-250246 BOTTOM SEAL 1

47 2310-250247 PISTON ROD 1

48 2310-250248 O-RING, 43.7 X 3.5 1

49 2310-250249 YX-SEAL 1

50 2310-160247 SEAL RING 1

51 2310-250251 GLAND NUT 1

52 2310-250252 O-RING, 34.5 X 3.55 1

53 2310-250253 DUST SEAL, 35 1

54 2310-250254 COMPOSITE WASHER, 10 1

55 2310-250255 BOLT 1

56 2310-250256 SCREW, M5 X 16 1

57 2310-250257 HANDLE 1

58 2310-160254 COTTER PIN, 4 X 30 1

59 2310-160255 HANDLE CHAIN 1

BL-MSA-0114 - 11-14-2016 8-23

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