Blue Giant BGL-22, Owner'S Manual

Page: 63 / 130

9-5. Lift Cylinder (TRIMAST Secondary)
9-5.1. Removal
1. Fully lower the lift carriage.
2. Turn off the key switch (6, Figure 12-22 ) and dis-
connect the batteries.
WARNING: Before attempting any replacement,
make certain power is disconnected.
3. Remove screw (1, Figure 9-6 ), lock washer (2)
and flat washer (3) securing the top of cylinder
(30) to mast (22).
4. Using another lift truck or suitable jack, raise mid-
dle mast (22) far enough to remove pressure on
the secondary lift cylinder (30).
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
5. Disconnect the tube (1, Figure 9-3 ) from the bot-
tom of lift cylinder.
6. Support cylinder (30) and remove two bolts (24),
two lock washers (2), two flat washers (2), shims
(27), bracket (28), clip (20) and nut (31).
7. Raise lift cylinder assembly up and out of truck.
9-5.2. Repair
CAUTION: To prevent damage, use proper pipe
clamp vise. The cylinder will be distorted
if the vise is tightened too much.
1. Secure the lift cylinder in a vise, clamping lightly
at the base of the cylinder.
2. Remove gland nut (3, Figure 9-8 ).
3. Remove wiper (1), packing (2) and O-rings (4 and
11) from gland nut (3).
4. Pull out piston rod (5).
5. Remove backup ring (8), retaining ring (7) and
bushing (6) from piston rod (5).
6. Coat all parts with hydraulic oil ( Table 3-2 ).
7. Install backup ring (8), retaining ring (7) and bush-
ing (6) on piston rod (5).
8. Insert rod (5) in cylinder tube (9).
9. Install wiper (1), packing (2) and O-rings (4 and
11) on gland nut (3).
10. Install gland nut (3) in cylinder tube (9).
9-5.3. Installation
1. Using another lift truck or suitable jack, raise mid-
dle mast (22,
Figure 9-6 ) far enough to allow
installation of the secondary lift cylinder (30).
2. Slowly lower mast (22) while aligning cylinder (30)
with the tap on mast (22).
3. Secure the top of cylinder (30) with flat washer
(3), lock washer (2) and screw (1)
4. Install clip (29), bracket (28), shims (27), two flat
washers (3), two lock washers (2), two bolts (24)
and two nuts (31).
5. Reconnect the tube (1, Figure 9-3 ) to the bottom
of the lift cylinder.
6. Fill the hydraulic reservoir. Use hydraulic oil listed
in
Table 3-2 .
7. Reconnect the batteries and turn on the keyswitch
(6,
Figure 12-22 ).
8. Operate the lift and lower buttons to refill the
cylinders and lines with hydraulic oil.
9. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in
Table 3-2 .
10. Install the compartment covers as described in
paragraph 5-3.
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