MSA22

MANUAL STACKER

Used from Serial Number 526130065

Operation
Maintenance
Repair Parts List

Big Lift LLC MANUAL NO. BL-MSA22-0917 - 09-21-2017

www.bigjoeforklifts.com
 WARNING

Do not operate this truck unless you have been autho- Use special care when operating on ramps travel
rized and trained to do so, and have read all warnings slowly, and do not angle or turn. Travel with load
and instructions in Operator’s Manual and on this downhill.
truck.
Do not overload truck. Check nameplate for capacity
Do not operate this truck until you have checked its and load center information.
condition. Give special attention to wheels, lift system
When using forks, space forks as far apart as load will
(including forks or attachments, chains, and cables),
permit. Before lifting, be sure load is centered, forks
steering, guards and safety devices.
are completely under load, and load is as far back as
Operate truck only from designated operating position. possible against load backrest.
Never place any part of your body into the mast struc-
Do not handle unstable or loosely stacked loads. Use
ture or between the mast and the truck. Do not carry
special care when handling long, high or wide loads, to
passengers. Keep feet clear of truck and wear foot
avoid losing the load, striking bystanders, or tipping
protection.
the truck.
Observe applicable traffic regulations. Yield right of
Do not handle loads which are higher than the load
way to pedestrians. Slow down at cross aisles and
backrest unless load is secured so that no part of it
wherever vision is obstructed.
could fall backward.
Start, stop, travel, and steer smoothly. Slow down for
Elevate forks or other lifting mechanism only to pick up
turns and on uneven or slippery surfaces that could
or stack a load. Watch out for obstructions, especially
cause truck to slide or overturn. Use special care
overhead.
when traveling without load as the risk of overturn may
be greater. Do not allow anyone to stand or pass under load or lift-
ing mechanism.
Travel with lifting mechanism as low as possible.
Always look in direction of travel. Keep a clear view, When leaving truck, neutralize travel control, and fully
and when load interferes with visibility, travel with load lower lifting mechanism.
trailing.

BL-MSA22-0917 - 09-21-2017
 TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................... 1 6 HYDRAULIC SYSTEM SERVICING.............................17
1-1 INTRODUCTION ................................................... 1 6-1 GENERAL ............................................................17
1-2 GENERAL DESCRIPTION .................................... 1 6-2 HYDRAULIC UNIT (NON-TEL)............................17
1-3 SAFETY FEATURES............................................. 1 6-2.1 REMOVAL ...................................................17
6-2.2 INSTALLATION ...........................................17
2 OPERATION .................................................................. 3 6-3 HYDRAULIC UNIT (TELESCOPIC).....................18
2-1 GENERAL.............................................................. 3 6-3.1 REMOVAL ...................................................18
2-2 OPERATING PRECAUTIONS............................... 3 6-3.2 INSTALLATION ...........................................18
2-3 BEFORE OPERATION.......................................... 3 6-4 CONTROL HANDLE AND FOOT PEDAL............20
2-4 OPERATING INSTRUCTIONS.............................. 5 6-4.1 REMOVAL ...................................................20
2-4.1 FOOT ACTUATED CASTER BRAKE ........... 5 6-4.2 REASSEMBLY ............................................20
2-4.2 OPERATOR MAST HANDLES ..................... 5 6-5 HYDRAULIC PUMP .............................................21
2-4.3 SPRING LOADED STEERING HANDLE...... 5 6-5.1 DISASSEMBLY ...........................................21
2-5 TRANSPORT......................................................... 6 6-5.2 REASSEMBLY ............................................21
2-5.1 MOVING, (POSITIONING) 6-6 CYLINDER, TELESCOPIC ..................................22
AND STOPPING ........................................... 6 6-6.1 DISASSEMBLY ...........................................22
2-5.2 TURNING...................................................... 6 6-6.2 REASSEMBLY ............................................22
2-6 LOADING AND UNLOADING................................ 6
7 FRAME AND RELATED PARTS SERVICING .............25
3 PLANNED MAINTENANCE ........................................... 7 7-1 GENERAL ............................................................25
3-1 GENERAL.............................................................. 7 7-2 LOAD WHEEL REPLACEMENT..........................25
3-2 MONTHLY AND QUARTERLY CHECKS.............. 7 7-3 CASTER REPLACEMENT...................................25
3-3 LUBRICATION....................................................... 7 7-4 CASTER WHEEL REPLACEMENT.....................25
3-4 LIFT CHAIN MAINTENANCE ................................ 7
8 ILLUSTRATED PARTS BREAKDOWN ........................29
4 TROUBLESHOOTING ................................................... 9
4-1 GENERAL.............................................................. 9

5 LIFT SYSTEM SERVICING.......................................... 11

5-1 GENERAL............................................................ 11
5-2 LIFT CHAIN WEAR INSPECTION ...................... 11
5-3 LIFT CHAINS ADJUSTMENT.............................. 11
5-4 LIFT CHAINS REPLACEMENT........................... 11
5-5 FORK CARRIAGE ............................................... 11
5-5.1 NON-TEL .................................................... 11
5-5.2TELESCOPIC....................................................... 14
5-6 FORKS ................................................................ 14
5-6-1 REMOVAL .................................................. 14
5-6.2 INSTALLATION........................................... 14

BL-MSA22-0917 - 09-21-2017 i
 NOTES

ii BL-MSA22-0917 - 09-21-2017
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION. The model number will be found on the name plate
This publication describes the MSA22 Series Manual along with the serial number, lifting capacity, and load
Stackers distributed by Big Lift LLC. Included are oper- center. Figure 1-1 shows the locations of the truck’s
ating instructions, planned maintenance instructions, main components and controls.
lubrication procedures, corrective maintenance proce-
dures and a complete parts list with part location illus- 1-3. SAFETY FEATURES.
trations. The MSA Series Manual Stackers are designed and
Users shall comply with all requirements indicated in engineered to provide maximum safety for operator
applicable OSHA standards and current edition of and payload. Some of the safety features incorporated
A.N.S.I. B56.1 Part II. By following these requirements into the design are:
and the recommendations contained in this manual, • Steer casters.
you will receive many years of dependable service
• Foot actuated brake on casters.
from your MSA22 lift truck.
• Control handle automatically returns to raised posi-
1-2. GENERAL DESCRIPTION. tion when released.
The manually-propelled MSA22 Series Manual Stack- • Mast handles and steering handle to provide a firm
ers, Figure 1-1, lift and transport payloads up to 2200 hand hold for operator.
on adjustable forks. • High visibility color scheme of truck provides visual
The mast handles are used to help control the lift alert of truck’s presence.
truck. The control handle is used to propel and steer
the lift truck. Lift and Lower are controlled by the con-
trol handle and foot pedal.

BL-MSA22-0917 - 09-21-2017 1
 R8474

Figure 1-1. MSA22 Manual Stacker

2 BL-MSA22-0917 - 09-21-2017
 SECTION 2
OPERATION

2-1. GENERAL. 6. Lower the load before traveling. If it is necessary

The following paragraphs describe the controls and to move the load while raised, travel cautiously
procedures involved in proper operation of the manual and use extra care when turning.
stacker.
2-3. BEFORE OPERATION.
2-2. OPERATING PRECAUTIONS. Table 2-1 covers important inspection points on the
MSA22 Series Manual Stackers which should be
WARNING: Improper operation of the manual checked prior to operation. Depending on use some
stacker may result in operator injury, or trucks may require additional checks.
load and/or truck damage. Observe the
following precautions when operating the Figure 2-2 shows a sample format for an Operator
MSA22 Series Manual Stackers. Checklist, which can be modified as necessary to fit
your operation.
The following safety precautions must be adhered to
at all times. WARNING: Periodic maintenance of this truck by a
QUALIFIED SERVICE TECHNICIAN is
1. Leave the load in the full down position for over- required.
night storage.
2. Engage the brake on the casters before leaving CAUTION: A QUALIFIED SERVICE TECHNICIAN
the stacker. should check the truck monthly for
proper lubrication, proper fluid levels,
3. Center the load as far as possible toward the back brake maintenance, motor maintenance
rest. Never lift a load on the fork tips or on one and other areas specified in the SEC-
fork blade. TION 3.
4. Do not attempt to lift a load heavier than the rated
capacity of the truck. Check that the center of WARNING: If the truck is found to be unsafe and in
gravity of the load is not beyond the load center need of repair, or contributes to an
listed on the name plate. See Figure 2-1 for an unsafe condition, report it immediately to
explanation of load center. the designated authority. Do not operate
it until it has been restored to a safe
5. Check for obstructions before raising or lowering operating condition. Do not make any
a load. unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.

Figure 2-1 Load Center

BL-MSA22-0917 - 09-21-2017 3
 Table 2-1 Operator Checks
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 that the load wheels
and casters can rotate freely.
Caster brake Check that the brake holds the truck stationary.
Lift and Lower Check operation of lift and lower to their maximum positions.

R7122

Figure 2-2 Sample of Operator Check List

4 BL-MSA22-0917 - 09-21-2017
2-4. OPERATING INSTRUCTIONS. 2-4.2. Operator Mast Handles
1. To raise the load, pump steering handle or foot The operator mast handles located on each side of the
pedal just a few strokes to raise the load from the mast are used to help control the truck.
floor.
2-4.3. Spring Loaded Steering Handle
2. To lower the load, pull flinger tip control lever
toward the operator or push the lowering pedal. The spring loaded steering handle is used to raise the
load, propel and steer the lift truck.
2-4.1. Foot Actuated Caster Brake
The foot actuated caster brake is used to hold the
truck stationary.

R8474

Figure 2-3. M22 Lift Truck

BL-MSA22-0917 - 09-21-2017 5
2-5. TRANSPORT. 3. Raise the forks to the desired height for entry
under the load.
2-5.1. Moving, (Positioning) and Stopping
4. Move the lift truck into position so that the forks
1. Check that the load is in the down position leaving are centered under the load.
enough floor clearance to maneuver the truck
5. Move the lift truck forward to place the load as far
before traveling.
back as possible toward the fork carriage. Raise
2. Release the caster brake. the forks to lift the load.
3. Apply pressure to the steering handle and mast
CAUTION: To avoid spilling the load, move slowly
handles to move the truck forward. Pull evenly on
and use extra caution when turning.
the steering handle to move the truck backward.
4. To stop the lift truck, hand restraint against the 6. Move the lift truck backward from the loading
steering handle and mast handles is usually ade- position.
quate. 7. When the load is clear of its rack, lower the load,
5. Pull flinger tip control lever toward the operator to leaving enough floor clearance to maneuver the
lower the load to the floor and engage the caster truck.
brake. 8. Push or pull the truck carefully to the area where
the load is to be placed.
2-5.2. Turning
9. Align the lift truck with its new position.
NOTE: Turning and maneuvering the lift truck is
10. Raise the forks to the desired height and slowly
made easier if the truck is in motion.
move the lift truck into position for off-loading.
Begin rolling the truck and simultaneously apply side CAUTION: The load must rest squarely on its rack
pressure to the steering handle to cause the caster when it is lowered into position.
wheels to swivel.
11. When the load is in position, lower the forks until
2-6. LOADING AND UNLOADING. the pallet rest on its rack and the forks are free.
1. Move the truck to the location where the load is to 12. Slowly move the lift truck backward, checking that
be picked up. the forks do not catch on the pallet or rack.
2. Adjust the forks to the maximum practical width to 13. Lower the forks when they are clear.
support the load. 14. Proceed to move the next load.

6 BL-MSA22-0917 - 09-21-2017
 SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. 3-2. MONTHLY AND QUARTERLY CHECKS.

Planned maintenance consists of periodic visual and Table 3-1 is a monthly and quarterly inspection and
operational checks, parts inspection, lubrication, and service chart based on normal usage of equipment
scheduled maintenance designed to prevent or dis- eight hours per day, five days per week. If the stacker
cover malfunctions and defective parts. The operator is used in excess of forty hours per week, the fre-
performs the checks in SECTION 2, and refers any quency of inspection and service should be increased
required servicing to a qualified maintenance techni- accordingly. These procedures must be performed by
cian who performs the scheduled maintenance and a qualified service technician or your Big Lift LLC Ser-
any required servicing. vice Representative.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
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)

3-3. LUBRICATION.
Refer to Table 3-2 for the recommended types of Table 3-2 Recommended Lubricants
grease and oil. Table 3-3 in conjunction with Figure 3-1 (See Table 3-3 for Application)
identifies the items requiring lubrication. No. 1 Grease—Lithium base, general purpose.

3-4. LIFT CHAIN MAINTENANCE.

No. 2 SAE 30 or 40 Engine lubricating oil
Fully raise and lower fork carriage while observing No. 3 Hydraulic oil-Heavy duty with a foam sup-
chains as they move over chain sheaves. Ensure pressing agent and rust and oxidation
chain is aligned and tracking properly and all links are inhibitors.
pivoting freely. With fork carriage fully lowered, spray
or brush on a film of SAE 30 or 40 engine oil.

BL-MSA22-0917 - 09-21-2017 7
 R8475

Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) 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.

8 BL-MSA22-0917 - 09-21-2017
 SECTION 4
TROUBLESHOOTING

4-1. GENERAL
This section gives fixes for some common problems lists these malfunctions, their causes, probable and
that may arise while operating the lift truck. Table 4-1 corrective action that will resolve the problem.
Table 4-1 Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Oil sprays or flows from the top of Defective packing in lift cylinder. Overhaul lift cylinder and install
lift cylinder. 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- Replace bearing.
ings.
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 a. Foreign particles. Clean system.
to neutral. b. Defective pump. Repair pump assembly.
Weak, slow or uneven action of a. Defective pump Repair pump assembly.
hydraulic system. b. Defective lift cylinder Repair lift cylinder.
c. Load exceeds capacity. See data plate.
Forks creep down with or without a. Oil bypassing in pump. Repair pump assembly.
load. b. Worn lift cylinder packing Repair lift cylinder.

BL-MSA22-0917 - 09-21-2017 9
 NOTES

10 BL-MSA22-0917 - 09-21-2017
 SECTION 5
LIFT SYSTEM SERVICING

5-1. GENERAL 5. Tighten the bottom two jam nuts together.

This section covers maintenance and repair proce- 6. Tighten the jam nuts while maintaining alignment
dures for the lift system. The lift system consists of: of the adjusting bolts.
Inner mast assembly (Telescopic)
5-4. LIFT CHAINS REPLACEMENT.
Fork carriage
NOTE: The 2200 lb 62 inch Non-Tel only has one lift
Forks chain (Figure 5-1). All others have two lift
Lift chain chains and both chains must be replaced at
the same time.
The lift cylinder, pump and handle assembly is consid-
ered part of the hydraulic system and is covered in 1. Place a solid support on the floor under the verti-
SECTION 6. cal members nearest the center of fork carriage.
2. Lower the carriage until it is supported by the sup-
5-2. LIFT CHAIN WEAR INSPECTION.
port and the chains are slack.
Both lift chains should be replaced when either chain
3. Remove the two cotter pins (Figure 5-2) and pin
is worn enough to increase it’s length by 3% or more.
securing chain to the fork carriage.
To make this determination proceed as follows.
4. Remove the two cotter pins and pin securing
Using a section of chain that sees the most frequent chain to adjusting bolt.
operation over the chain sheaves, isolate a vertical
portion under tension from the weight of carriage and 5. Remove the chain from the sheave.
forks. 6. Position new chain in place on sheave.
Measure the distance between pin centers on 20 verti- 7. Connect chain to adjusting bolt with pin and two
cal links. If the section measures 12.88” or more, the cotter pins.
chain should be replaced. 8. Connect the opposite end chain to the fork car-
New chain anchor pins should be installed when riage with pin and two cotter pins.
chains are replaced. Never replace a partial section of 9. Replace the remaining chain is the same manner.
chain and never repair a damaged chain. Refer to
10. Adjust chains according to paragraph 5-3.
paragraph 5-4. when installing new chain.
5-5. FORK CARRIAGE.
5-3. LIFT CHAINS ADJUSTMENT.
5-5.1. Non-Tel
NOTE: The 2200 lb 62 inch Non-Tel only has one lift
chain (Figure 5-1). All others have two lift 1. Completely lower the carriage until the chains are
chains and both chains must be adjusted at slack, then disconnect battery.
the same time. 2. Remove the lift chains as described in paragraph
1. Lower the carriage fully, then disconnect battery. 5-4.
3. Using a suitable lifting device attached to the fork
CAUTION: At least 3 full threads must be present carriage, slowly raise the carriage out of the mast.
below bottom hex nuts (Figure 5-2) after
completion of adjustment. 4. Remove snap ring (Figure 5-3) and roller (4) from
carriage (2).
2. Loosen the top jam nuts on the adjusting bolts. 5. Remove snap ring (6) and bearing (5) from roller
3. Break the bottom most jam nuts free from the (4).
remaining jam nuts and take up slack in the 6. Install the fork carriage in the reverse order of
chains by turning the remaining jam nuts. removal.
4. Align adjusting bolt so that it is parallel to the
mast.

BL-MSA22-0917 - 09-21-2017 11
 DZ_0007

Figure 5-1 Chain, Non-Tel (2200 lb 62 Inch Lift)

12 BL-MSA22-0917 - 09-21-2017
 DZ_0010

Figure 5-2. Chain Telescopic (2200 lb 96 inch Lift

BL-MSA22-0917 - 09-21-2017 13
5-5.2. Telescopic 5-6. FORKS.
1. Place a solid support on the floor under the verti- Check the forks periodically for cracks and other dam-
cal members nearest the center of the fork car- age.
riage.
CAUTION: The forks are very heavy make sure that
2. Lower the carriage until it is supported by the sup- you have the right equipment to lift the
port and the chains are slack, then disconnect forks off/on to the carriage.
battery.
3. Remove the lift chains as described in paragraph 5-6.1. Removal
5-4. 1. Completely lower the carriage until the chains are
4. Remove the lift cylinder as described in para- slack.
graph SECTION 6 2. Position the forks in the center of the fork carriage
5. Using a suitable lifting device attached to the so that the forks are lined up with the “cut out” on
inner mast, slowly raise the inner mast until the the bottom rail of the fork carriage.
fork carriage is free. 3. While supporting the forks, lift up the fork locking
6. Remove the fork carriage from the inner mast. pin and tilt the fork tip up. Make sure that you
have the fork secured so that it does not fall down
7. Remove snap ring (Figure 5-3) and roller from
since it’s very heavy.
carriage.
8. Remove snap ring and bearing from roller. 5-6.2. Installation
9. Install the fork carriage in the reverse order of 1. Lift the fork and place the top fork hook onto the
removal. top rail and make sure that you have the fork cen-
tered on the fork carriage so that it lines up with
the “cut out” on the bottom rail.
2. Now tilt the fork tip down so that the fork is hori-
zontal and hanging on the fork carriage.
3. You can now lift the fork locking pin and position
the forks where you want them.

14 BL-MSA22-0917 - 09-21-2017
 DZ_0009

Figure 5-3 Fork carriage Telescopic (2200 lb 96 inch Lift Shown)

BL-MSA22-0917 - 09-21-2017 15
 NOTES

16 BL-MSA22-0917 - 09-21-2017
 SECTION 6
HYDRAULIC SYSTEM SERVICING

6-1. GENERAL. 5. Remove the bolts that holds the hydraulic assem-
This section covers the maintenance and repair proce- bly to the frame.
dures for the lift cylinder, pump and handle assembly. 6. Remove the cylinder hoop that holds the cylinder
This assembly can be removed as an assembly or the in place on the chassis by removing the nuts and
individual components can be repaired individually. washers.
7. Remove the hydraulic assembly.
6-2. HYDRAULIC UNIT (NON-TEL).
6-2.2. Installation
6-2.1. Removal
1. Position the assembly on the frame and secure it
1. Chock all wheels and engage the caster brake. with the screws.
2. Raise the forks approximately three feet from the 2. Install the cylinder hoop that holds the cylinder in
floor and position blocks or other strong supports place on the chassis with the nuts and washers.
under the fork carriage. Keep supports in place
3. Install the lift chains as described in paragraph
during the entire procedure.
SECTION 5
3. Lower the carriage onto the supports. Check that
4. Raise the carriage and remove the supports.
the supports are supporting the carriage.
5. With fork carriage fully lowered, remove plug from
4. Remove the lift chains as described in paragraph
top of cylinder and fill with hydraulic oil. Use
5-4.
hydraulic oil listed in Table 3-2.
6. Adjust the lift chains according to SECTION 5

BL-MSA22-0917 - 09-21-2017 17
 DZ_0001

Figure 6-1 Frame, Non-Tel (2200 lb 62 Inch Lift)).

6-3. HYDRAULIC UNIT (TELESCOPIC). 6-3.2. Installation

6-3.1. Removal 1. Position the lift cylinder on the frame (Figure 6-2).
2. Using a suitable lifting device, support the inner
1. Chock all wheels and engage the caster brake.
mast and remove the supports.
2. Raise the forks approximately three feet from the
3. Slowly lower the inner mast while lining up the lift
floor and position blocks or other strong supports
cylinder with the inner mast cross member.
under the fork carriage. Keep supports in place
during the entire procedure. 4. Secure the top of the cylinder with screw, spring
washer and flat washer.
3. Lower the carriage onto the supports. Check that
the supports are supporting the carriage. 5. Secure the hydraulic assembly to the frame with
bolts.
4. Remove the bolts that holds the hydraulic assem-
bly to the frame (16, Figure 6-2). 6. With fork carriage fully lowered, remove plug from
top of cylinder and fill with hydraulic oil. Use
5. Support the cylinder and remove bolt, spring
hydraulic oil listed in Table 3-2.
washer and flat washer securing the top of the
cylinder to inner mast. 7. Adjust the lift chains according to paragraph 5-3.
6. Using a suitable lifting device, raise the inner mast
and remove the assembly from frame. Position
blocks or other strong supports under inner mast.

18 BL-MSA22-0917 - 09-21-2017
 DZ_0002 DZ_0008

Figure 6-2. Frame Telescopic (2200 lb 96 Inch Lift Shown)

BL-MSA22-0917 - 09-21-2017 19
6-4. CONTROL HANDLE AND FOOT PEDAL. 3. Remove the nut and the rod that holds the foot
pedal in place (Figure 6-4).
6-4.1. Removal
6-4.2. Reassembly
1. Fully lower the fork carriage.
2. Remove cotter pins from the shaft that hold the 1. Install the rod and the nut that holds the foot pedal
handle in place (Figure 6-3) and disconnect the in place (Figure 6-4).
chain from the foot pedal. 2. Line up the handle and install the shaft and the
cotter pins that hold the handle in place (Figure 6-
3) and reconnect the chain to the foot pedal.

DZ_0003

Figure 6-3 Hydraulic Unit

20 BL-MSA22-0917 - 09-21-2017
 DZ_0004

Figure 6-4 Hydraulic Assembly

6-5. HYDRAULIC PUMP. 6-5.2. Reassembly

6-5.1. Disassembly 1. Reassemble and Install the right valve and the
foot pedal (Figure 6-3).
1. Fully lower the fork carriage.
2. Reassemble and Install left valve (Figure 6-4).
2. Remove the control handle and foot pedal as
3. Install new seal and wiper ring on the plunger.
described in paragraph 6-4.
4. Install the plunger in the pump body.
3. Remove the spring cover from the top of the
pump. 5. Install the spring cover on top of the pump.
4. Lift plunger from pump body. 6. Install the control handle and foot pedal as
described in paragraph 6-4.
5. Remove the seal and the wiper ring from the
plunger. 7. With fork carriage fully lowered, remove plug from
top of cylinder and fill with hydraulic oil. Use
6. Remove and disassemble left valve. Refer to Fig-
hydraulic oil listed in Table 3-2.
ure 6-4.
7. Remove the foot pedal and right valve. Refer to
Figure 6-4.

BL-MSA22-0917 - 09-21-2017 21
6-6. CYLINDER, TELESCOPIC 6-6.2. Reassembly

6-6.1. Disassembly 1. Install the o-ring between the hydraulic assembly

and the cylinder body.
1. Fully lower the fork carriage.
CAUTION: Use the proper tube pipe clamp vise in
2. Remove the hydraulic unit as described in para-
the following steps to prevent damage to
graph 6-2.
the lift cylinder.
3. Remove the control handle and foot pedal as
described in paragraph 6-4. 2. Install the packing on the piston rod.
3. Insert the piston rod into cylinder body..
CAUTION: Use the proper tube pipe clamp vise in
the following steps to prevent damage to 4. Install the wiper ring and o-rings on the gland nut
the lift cylinder. (Figure 6-5).
5. Install gland nut on the cylinder body.
4. Secure the hydraulic body assembly in a vise and
remove the gland nut. 6. Remove lift cylinder from vise.
5. Remove the wiper ring and o-rings from the gland 7. Install the control handle and foot pedal as
nut (Figure 6-5). described in paragraph 6-4.
6. Pull piston rod out of cylinder body. 8. Install the cylinder, pump handle assembly as
described in paragraph 6-2.
7. Remove the packing from the piston rod.
9. With fork carriage fully lowered, remove plug from
8. Remove the cylinder body from the hydraulic
top of cylinder and fill with hydraulic oil. Use
assembly.
hydraulic oil listed in Table 3-2.
9. Remove the o-ring between the hydraulic assem-
bly and the cylinder body.

22 BL-MSA22-0917 - 09-21-2017
 DZ_0004
Figure 6-5 Hydraulic Assembly

BL-MSA22-0917 - 09-21-2017 23
 NOTES

24 BL-MSA22-0917 - 09-21-2017
 SECTION 7
FRAME AND RELATED PARTS SERVICING

7-1. GENERAL. 7-3. CASTER REPLACEMENT.

This section covers load wheels and casters replace- 1. Fully lower the carriage.
ment. 2. Chock the load wheels.

7-2. LOAD WHEEL REPLACEMENT. 3. Raise the rear of the lift truck with a suitable jack
or another lift truck. Place strong supports approx-
1. Fully lower the carriage. imately six inches in front of the caster to be
1. Chock both caster wheels and the load wheel that replaced.
is not being replaced. 4. Lower the lift truck so that the body of the truck is
2. Raise the front of the lift truck with a suitable jack resting on the supports. Remove the jack.
or another lift truck. Place strong supports under 5. Check that the caster wheel is not touching the
the straddle leg just in back of the wheel housing floor and is free to turn.
so that the load wheel being replaced is approxi-
6. Remove four nuts (Figure 7-1), spring washers,
mately one inch above the floor.
flat washers, bolts and caster assembly.
3. Remove the screw (Figure 7-1) and the shaft.
7. Install a new caster in the reverse order of
4. Remove the washers and bearings from load removal.
wheel.
5. Install a new load wheel in the reverse order of 7-4. CASTER WHEEL REPLACEMENT
removal. 1. Follow step 1-5 in paragraph 7-3.
2. Remove the bolt and nut that holds the caster
wheel in place.
3. Remove the washers, shaft and bearings from the
caster wheel.
4. Install a new caster wheel in the reverse order of
removal.

BL-MSA22-0917 - 09-21-2017 25
DZ_0001
Non Telescopic DZ_0002 Telescopic

Figure 7-1 Frame

26 BL-MSA22-0917 - 09-21-2017
 SECTION 8
ILLUSTRATED PARTS BREAKDOWN

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

BL-MSA22-0917 - 09-21-2017 29
 DZ_0001

Figure 8-1 Frame, Non-Tel (2200 lbs 62 inch Lift)

30 BL-MSA22-0917 - 09-21-2017
 FRAME, NON-TEL (2200 LBS 62 INCH LIFT)

Qty.
Pos. Part Number Description Notes
Reqd.
1 2009-110000-00 FRAME 1
2 2009-010000-00 CASTER 2
3 2010-130000-10 END FRAME R 1
4 2010-120000-10 END FRAME L 1
5 2010-141000-10 SHAFT 4
6 0000-000090-00 SCREW M6×12 4
7 2125-101003-00 WASHER 8
8 0000-000424-00 BEARING 8
9 2010-140001-10 LOAD WHEEL 4
10 2009-100000-00-01 HYDRAULIC UNIT 1
11 0000-000372-00 SCREW M8×40 2
12 0000-000771-00 BOLT M16×40 6
13 0000-000191-00 LOCK WASHER Ø16 6
14 0000-000541-00 FLAT WASHER Ø16 6
15 0000-000251-00 BOLT M10×25 8
16 0000-000063-00 LOCK WASHER Ø10 8
17 0000-000007-00 FLAT WASHER Ø10 8
18 0000-001245-00 NUT M10 8
19 0000-000868-00 SCREW M6×16 4
20 2214-150003-00 WASHER 8
21 2009-600001-00 WINDSHIELD 1
22 0000-000550-00 NUT M8 4
23 0000-000159-00 LOCK WASHER Ø8 4
24 0000-000176-00 FLAT WASHER Ø8 4
25 2009-640000-00 CYLINDER HOOP 1
26 0000-000284-00 BOLT M12×30 4
27 0000-000060-00 LOCK WASHER Ø12 4
28 0000-000630-00 NUT M12 4
29 2009-011000-00 BRAKE 1
30 0000-000495-01 BOLT M12×85 1
31 2009-010001-00 NYLON WASHER 2
32 2009-010002-00 SHAFT 1
33 0000-001795-00 BEARING 2
34 2009-010003-00 NYLON WHEEL 1
35 0000-001334-00 NUT M12 1

BL-MSA22-0917 - 09-21-2017 31
 DZ_0002

Figure 8-2 Frame, Telescopic (2200 lbs 96 Inch Lift)

32 BL-MSA22-0917 - 09-21-2017
 FRAME, TELESCOPIC (2200 LBS 96 INCH LIFT)

Qty.
Pos. Part Number Description Notes
Reqd.
1 2009-110000-10 FRAME 1
2 2009-010000-00 CASTER 2
3 2010-130000-10 END FRAME R 1
4 2010-120000-10 END FRAME L 1
5 2010-141000-10 SHAFT 4
6 0000-000090-00 SCREW M6×12 4
7 2125-101003-00 WASHER 8
8 0000-000424-00 BEARING 8
9 2010-140001-10 LOAD WHEEL 4
10 2009-100000-00-02 HYDRAULIC UNIT 1
11 0000-000372-00 SCREW M8×40 2
12 0000-000771-00 BOLT M16×40 6
13 0000-000191-00 LOCK WASHER Ø16 6
14 0000-000541-00 FLAT WASHER Ø16 6
15 0000-000251-00 BOLT M10×25 8
16 0000-000063-00 LOCK WASHER Ø10 8
17 0000-000007-00 FLAT WASHER Ø10 8
18 0000-001245-00 NUT M10 8
19 0000-000868-00 SCREW M6×16 4
20 2214-150003-00 WASHER 8
21 2009-600001-10 WINDSHIELD 1
22 2009-011000-00 BRAKE 1
23 0000-000495-01 BOLT M12×85 1
24 2009-010001-00 NYLON WASHER 2
25 2009-010002-00 SHAFT 1
26 0000-001795-00 BEARING 2
27 2009-010003-00 NYLON WHEEL 1
28 0000-001334-00 NUT M12 1

BL-MSA22-0917 - 09-21-2017 33
 DZ_0003

Figure 8-3 Hydraulic Unit

34 BL-MSA22-0917 - 09-21-2017
 HYDRAULIC UNIT

Qty.
Pos. Part Number Description Notes
Reqd.
1 2009-170000-00 CONTROL HANDLE 1 Includes pos. # 12-21
2 2009-101000-00-01 HYDRAULIC BODY ASSEMBLY 1 Lift Height: 62” (1575mm”)
2 2009-101000-00-02 HYDRAULIC BODY ASSEMBLY 1 Lift Height: 96” (2438mm)
3 2009-100002-00 SHAFT II 1
4 0000-000686-00 COTTER PIN Ø3.2×32 4
5 2009-180000-00 SPRING 1
6 2009-100004-00 SHAFT I 1
7 2009-100003-00 SHAFT III 1
8 0000-000683-00 RETAINER RING Ø12 2
9 2009-100001-00 PRESSURE RELEASE LEVER 1
10 2009-141000-00 PRESSURE RELEASE PEDAL 1
11 2009-142000-00 ROLLER 1
12 2009-170001-00 LEAF SPRING 1
13 2009-170002-00 TORSION SPRING 1
14 0000-000679-00 ROUND PIN Ø4×30 1
15 2009-172000-00 LEVER 1
16 0000-001235-10 ROUND PIN Ø6×30 1
17 0000-001236-10 ROUND PIN Ø4×12 1
18 2009-173000-00 ROD 1
19 2009-171000-00 CONTROL HANDLE 1
20 0000-000108-00 NUT M6 1
21 0000-000923-00 LOCK NUT M6 1

BL-MSA22-0917 - 09-21-2017 35
 DZ_0004

Figure 8-4 Hydraulic Assembly

36 BL-MSA22-0917 - 09-21-2017
 HYDRAULIC ASSEMBLY

Qty.
Pos. Part Number Description Notes
Reqd.
-- 2009-101000-00-01 HYDRAULIC ASSEMBLY 1 Lift Height: 62” (1575mm”)
-- 2009-101000-00-02 HYDRAULIC ASSEMBLY 1 Lift Height: 96” (2438mm)
Includes pos. #:
KIT 2009-ZZG-0A SEAL KIT FOR HYDRAULIC ASSEMBLY 1
5,6,17,18,19,20,22
1 2009-120000-00-01 CYLINDER 1 Lift Height: 62” (1575mm”)
1a 2009-120000-00-02 CYLINDER 1 Lift Height: 96” (2438mm)
2 2009-111000-00-01 PISTON ROD 1 Lift Height: 62” (1575mm”)
2a 2009-111000-00-02 PISTON ROD 1 Lift Height: 96” (2438mm)
3 2009-160000-00-01 CYLINDER BODY 1 Lift Height: 62” (1575mm”)
3a 2009-160000-00-02 CYLINDER BODY 1 Lift Height: 96” (2438mm)
4 2009-113000-00 CAP 1
5 0000-000978-00 RING WIPER 32×40×5-6.5 1
6 0000-000971-00 O-RING 37×3.1 1
7 2009-131000-00 PRESSURE BAR 1
8 2009-132000-00 SPRING COVER 1
9 2009-130001-00 SPRING 1
10 2009-150000-00 PRESSURE RELEASE LEVER 1
11 0000-001606-10 PIN 8×50 1
12 2009-153000-00 ROD 1
13 0000-000108-00 NUT M6 1
14 1113-422000-00 UNLOADING VALVE 1
15 1113-423000-00 RELIEF VALVE 1
16 1113-421000-00 CONTROL VALVE 1
17 0000-001152-00 RING WIPER 22×31×3.7-7.6 1
18 0000-001153-00 YX-SEAL 22×30×5 1
19 0000-000346-00 O-RING 70×3.1 1
20 0000-000967-00 O-RING 80×3.1 1
21 2009-101001-00 RING BACK UP 40×35×20 1
22 0000-000132-00 ROD PACKING 30×40×6 1
23 2009-133000-00 BLOCK 1

BL-MSA22-0917 - 09-21-2017 37
 DZ_0005

Figure 8-5 Cylinder Head Assembly, Non-Tel (2200lbs 62 Inch Lift)

38 BL-MSA22-0917 - 09-21-2017
 CYLINDER HEAD ASSEMBLY, NON-TEL (2200LBS 62 INCH LIFT)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000756-00 RETAINER RING Ø40 2
2 2108-600001-00 SHAFT 1
3 2108-600003-00 WASHER 2
4 2108-600002-00 CHAIN ROLLER 1
5 2009-620000-00 CHAIN BRACKET 1
6 0000-000943-00 BOLT M12×40 1
7 0000-000060-00 LOCK WASHER Ø12 1
8 0000-000373-00 FLAT WASHER Ø12 1

BL-MSA22-0917 - 09-21-2017 39
 DZ_0006

Figure 8-6 Fork Carriage, Non-Tel (2200lbs 62 Inch Lift)

40 BL-MSA22-0917 - 09-21-2017
 FORK CARRIAGE, NON-TEL (2200LBS 62 INCH LIFT)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000284-00 BOLT M12×30 4
2 0000-000060-00 LOCK WASHER Ø12 4
3 0000-000373-00 FLAT WASHER Ø12 4
4 2125-632000-00 BLOCKING SHELF 1
5 2009-631000-00 FORK FRAME 1
6 2108-632000-70 ROLLER ASSEMBLY 4
7 2108-630001-10 FORK 2
8 2125-630001-10 SHAFT 2
9 0000-001525-00 SCREW M12×10 4
10 0000-000761-00 SCREW M12×20 4
11 2108-650000-60 ROLLER 4
12 0000-000434-00 RETAINER RING Ø30 4
13 0000-000777-00 STEEL BALL 12.0000 G100 B 4

BL-MSA22-0917 - 09-21-2017 41
 DZ_0007

Figure 8-7 Lift Chain, Non-Tel (2200lbs 62 inch Lift)

42 BL-MSA22-0917 - 09-21-2017
 LIFT CHAIN, NON-TEL (2200LBS 62 INCH LIFT)

Qty.
Pos. Part Number Description Notes
Reqd.
1 2108-640004-00 CHAIN LH1234 ，65 1
2 2108-640001-00 BOLT 1
3 0000-000237-00 NUT M16×1.5 3
4 2108-640002-00 PIN SHAFT 2
5 0000-000188-00 PIN Ø3.2×20 3
6 0000-000176-00 FLAT WASHER Ø8 2

BL-MSA22-0917 - 09-21-2017 43
 DZ_0008

Figure 8-8 Cylinder Head Assembly, Telescopic (2200lb 96 Inch Lift)

44 BL-MSA22-0917 - 09-21-2017
 CYLINDER HEAD ASSEMBLY, TELESCOPIC (2200lb 96 inch Lift)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000761-00 SCREW M12×20 6
2 2108-600002-60 BOLT 2
3 0000-000757-00 NUT M20X1.5 2
4 2108-600003-60 SPRING 2
5 2108-600004-60 POSITIONING ROD 2
6 2108-600005-60 CHAIN ROLLER Ø84/Ø52X33 2
7 0000-000100-00 BEARING 2
8 0000-000294-00 RETAINER RING Ø25 4
9 0000-000758-00 ELASTIC COLLAR Φ52 2
10 0000-000374-00 SCREW M12×30 1
11 0000-000060-00 LOCK WASHER Ø12 1
12 0000-000373-00 FLAT WASHER Ø12 1
13 2009-600002-00 FIXED PLATE 1
14 2108-632000-70 ROLLER ASSEMBLY 2
15 0000-000109-00 SCREW M8×16 2
16 2009-620000-10 INNER MAST 1
17 0000-001525-00 SCREW M12×10 6
18 0000-000777-00 STEEL BALL 12.0000 G100 B 4
19 2108-600008-60-B ROLLER ASSEMBLY 2
20 2108-600009-60 BEARING BLOCK 2
21 0000-000007-00 FLAT WASHER Ø10 6
22 0000-000063-00 LOCK WASHER Ø10 6
23 0000-000760-00 BOLT M10×30 6
24 2108-600011-60 CYLINDER HOOP 1
25 0000-000550-00 NUT M8 4
26 0000-000159-00 LOCK WASHER Ø8 4
27 0000-000176-00 FLAT WASHER Ø8 4
28 2108-650000-60 ROLLER 2
29 0000-000434-00 RETAINER RING Ø30 2

BL-MSA22-0917 - 09-21-2017 45
 DZ_0009

Figure 8-9 Fork Carriage, Telescopic (2200lb 96 inch Lift)

46 BL-MSA22-0917 - 09-21-2017
 FORK CARRIAGE, TELESCOPIC (2200lb 96 inch Lift)

Qty.
Pos. Part Number Description Notes
Reqd.
1 0000-000284-00 BOLT M12×30 4
2 0000-000060-00 LOCK WASHER Ø12 4
3 0000-000373-00 FLAT WASHER Ø12 4
4 2125-632000-00 BLOCKING SHELF 1
5 2111-631000-10 FORK FRAME 1
6 2108-632000-70 ROLLER ASSEMBLY 4
7 2108-630001-10 FORK 2
8 2125-630001-10 SHAFT 2
9 0000-001525-00 SCREW M12×10 4
10 0000-000761-00 SCREW M12×20 4
11 2108-650000-60 ROLLER 4
12 0000-000434-00 RETAINER RING Ø30 4
13 0000-000777-00 STEEL BALL 12.0000 G100 B 4

BL-MSA22-0917 - 09-21-2017 47
 DZ_0010

Figure 8-10 Lift Chain, Telescopic (2200lb 96 inch Lift)

48 BL-MSA22-0917 - 09-21-2017
 LIFT CHAIN, TELESCOPIC (2200lb 96 Inch Lift)

Qty.
Pos. Part Number Description Notes
Reqd.
1 2010-640000-00 CHAIN LH0844, 132 2
2 2108-640002-60 BOLT 2
3 0000-000237-00 NUT M16×1.5 6
4 0000-000220-00 WASHER Ø16 4
5 0000-000188-00 PIN Ø3.2×20 8
6 0000-000779-00 PIN Ø6×30 4

BL-MSA22-0917 - 09-21-2017 49
Big Lift LLC