Blue Giant BGL-33 Owner'S Manual Download

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TABLE OF CONTENTS

Section

Page

Section

Page

1 DESCRIPTION ............................................................1-1

1-1.

INTRODUCTION..............................................1-1

1-2.

GENERAL DESCRIPTION...............................1-1

1-3.

SAFETY FEATURES. ......................................1-1

2 OPERATION ...............................................................2-1

2-1.

GENERAL. .......................................................2-1

2-2.

OPERATING PRECAUTIONS. ........................2-1

2-3.

BEFORE OPERATION.....................................2-2

2-4.

GENERAL CONTROL OPERATION................2-4

2-4.1. CONTROL ARM...............................................2-4

2-4.2. CONTROL HEAD.............................................2-4

2-5.

DRIVING AND STOPPING PROCEDURES....2-4

2-5.1. STOPPING.......................................................2-4

2-6.

CONTROL ARM GAS SPRING........................2-5

2-7.

LOADING AND UNLOADING. .........................2-5

2-8.

PARKING. ........................................................2-5

3 PLANNED MAINTENANCE ........................................3-1

3-1.

GENERAL. .......................................................3-1

3-2.

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

3-3.

BATTERY CARE.............................................3-1

3-3.1. GENERAL ........................................................3-1

3-3.2. SAFETY RULES ..............................................3-2

3-3.3. BATTERY CARE AND CHARGING.................3-2

3-3.4. BATTERY CLEANING......................................3-2

3-3.5. MAINTENANCE FREE BATTERIES................3-3

3-4.

CHARGING BATTERIES .................................3-3

3-5.

LUBRICATION. ................................................3-4

3-6.

LIFT CHAIN MAINTENANCE...........................3-4

4 TROUBLESHOOTING ................................................4-1

4-1.

GENERAL ........................................................4-1

4-1.1. CONTROLLER TROUBLESHOOTING............4-4

4-1.2. ZAPI HANDSET ...............................................4-4

4-1.3. FAULT DETECTION. .......................................4-4

4-1.4. TESTING TRUCK OPERATION. .....................4-4

4-1.5. SETTINGS AND ADJUSTMENTS ...................4-5

5 STEERING SYSTEM, CONTROL HEAD AND

COMPARTMENT ........................................................5-1

5-1.

CONTROL HEAD.............................................5-1

5-1.1. CAP ASSEMBLY REMOVAL. ..........................5-1

5-1.2. CAP ASSEMBLY INSTALLATION. ..................5-2

5-1.3. CONTROL HEAD REMOVAL. .........................5-3

5-1.4. CONTROL HEAD INSTALLATION. .................5-3

5-1.5. SPEED POTENTIOMETER REPLACEMENT. 5-3

5-1.6. BELLY-BUTTON SWITCH REPLACEMENT. ..5-3

5-1.7. HORN SWITCH REPLACEMENT....................5-3

5-1.8. LIFT AND LOWER SWITCH

REPLACEMENT...............................................5-3

5-1.9. TILT SWITCH REPLACEMENT.......................5-3

5-2.

CONTROL ARM...............................................5-3

5-2.1. GAS RETURN SPRING REPLACEMENT. ......5-3

5-2.2. CONTROL ARM REMOVAL. ...........................5-4

5-2.3. CONTROL ARM INSTALLATION. ...................5-4

5-3.

COMPARTMENT COVERS .............................5-4

5-3.1. REMOVAL........................................................5-4

5-3.2. INSTALLATION................................................5-4

5-4.

STEERING CONTROL.....................................5-4

5-4.1. REMOVAL. ...................................................... 5-4

5-4.2. INSTALLATION. .............................................. 5-4

5-5.

STEERING MOTOR ........................................ 5-5

5-5.1. REMOVAL. ...................................................... 5-5

5-5.2. INSTALLATION. .............................................. 5-5

6 BRAKE SERVICING................................................... 6-1

6-1.

BRAKES. ......................................................... 6-1

6-1.1. BRAKE ASSEMBLY REPLACEMENT ............ 6-1

7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .... 7-1

7-1.

DRIVE WHEEL. ............................................... 7-1

7-2.

TRANSMISSION. ............................................ 7-1

7-3.

LOAD WHEEL. ................................................ 7-1

7-3.1. REMOVAL ....................................................... 7-1

7-3.2. LOAD WHEEL INSTALLATION....................... 7-1

8 ELEVATION SYSTEM SERVICING ........................... 8-1

8-1.

GENERAL........................................................ 8-1

8-2.

LIFT CHAIN LENGTH ADJUSTMENT............. 8-1

8-2.1. TELESCOPIC .................................................. 8-1

8-2.2. THREE STAGE MAST FREE LIFT CHAIN ..... 8-3

8-2.3. THREE STAGE MAST

SECONDARY LIFT CHAIN ............................. 8-3

8-3.

LIFT CHAIN WEAR INSPECTION................... 8-3

8-4.

LIFT CHAIN REPLACEMENT. ........................ 8-5

8-4.1. TELESCOPIC .................................................. 8-5

8-4.2. THREE STAGE MAST FREE LIFT CHAIN ..... 8-5

8-4.3. THREE STAGE MAST

SECONDARY LIFT CHAIN ............................. 8-5

8-5.

LIFT CYLINDERS............................................ 8-5

9 HYDRAULIC SYSTEM SERVICING........................... 9-1

9-1.

LINES AND FITTINGS .................................... 9-1

9-2.

HYDRAULIC PUMP, AND MOTOR ASSY ...... 9-1

9-2.1. REMOVAL ....................................................... 9-1

9-2.2. INSTALLATION ............................................... 9-1

9-3.

LIFT CYLINDER (TELESCOPIC) .................... 9-3

9-3.1. REMOVAL ....................................................... 9-3

9-3.2. REPAIR ........................................................... 9-5

9-3.3. INSTALLATION ............................................... 9-5

9-4.

LIFT CYLINDER

(THREE STAGE MAST FREE LIFT) ............... 9-6

9-4.1. REMOVAL ....................................................... 9-6

9-4.2. REPAIR ........................................................... 9-8

9-4.3. INSTALLATION ............................................... 9-8

9-5.

LIFT CYLINDER

(THREE STAGE MAST SECONDARY) .......... 9-9

9-5.1. REMOVAL ....................................................... 9-9

9-5.2. REPAIR ........................................................... 9-9

9-5.3. INSTALLATION ............................................... 9-9

9-5.4. TILT CYLINDERS.......................................... 9-11

10 ELECTRICAL COMPONENTS ................................. 10-1

10-1. ELECTRICAL CONTROL PANEL ................. 10-1

10-1.1.MAINTENANCE............................................. 10-1

10-1.2.CLEANING .................................................... 10-1

10-1.3.PANEL REMOVAL. ....................................... 10-1

10-1.4.PANEL DISASSEMBLY................................. 10-1

10-1.5.PANEL INSTALLATION. ............................... 10-1

Summary of Contents for BGL-33

Page 1: ...STACKER WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual Failure to do so may result in property damage bodily injury or dea...

Page 2: ...care when operating on ramps travel slowly and do not angle or turn Travel with load downhill Do not overload truck Check nameplate for capacity and load center information When using forks space for...

Page 3: ...RN SPRING REPLACEMENT 5 3 5 2 2 CONTROL ARM REMOVAL 5 4 5 2 3 CONTROL ARM INSTALLATION 5 4 5 3 COMPARTMENT COVERS 5 4 5 3 1 REMOVAL 5 4 5 3 2 INSTALLATION 5 4 5 4 STEERING CONTROL 5 4 5 4 1 REMOVAL 5...

Page 4: ...9 TILT CYLINDER MOUNTING 9 11 9 10 TILT CYLINDER 9 13 10 1 ELECTRICAL SYSTEM 10 2 10 2 ELECTRICAL PANEL 10 3 10 3 TRANSMISSION MOTOR BRAKE ASSEMBLY 10 5 12 1 CONTROL ARM 12 2 12 2 CONTROL HEAD 12 6 1...

Page 5: ...gure 1 2 shows the locations of the truck s main components and controls 1 3 SAFETY FEATURES The BGL 33 is designed and engineered to provide max imum safety for operator and payload Some of the safet...

Page 6: ...R7242 ITEM COMPONENT 1 Chassis 2 Drive wheel 3 Battery Discharge Indicator 4 Key Switch 5 Control Handle 6 Battery Disconnect 7 Controller 8 Mast 9 Back Rest 10 Forks 11 Load Wheel 12 Hydraulic pump...

Page 7: ...ed person on a regular basis Do not exceed the rated capacity Overloading may result in damage to the hydraulic system and struc tural components Be certain that the lifting mechanism is operating smo...

Page 8: ...d to a safe operating condition Do not make any unauthorized repairs or adjustments All service must be performed by a qualified maintenance technician Table 2 1 Operator Checks ITEM PROCEDURE Transmi...

Page 9: ...Figure 2 2 Sample of Operator Check List R6479 9...

Page 10: ...5 DRIVING AND STOPPING PROCEDURES 1 Connect the batteries and turn on the key switch Grasp the grips of the steering head so that the speed control can be comfortably operated by either thumb 2 Lower...

Page 11: ...upright position when the control arm is released If the control arm does not return fully the control arm gas spring requires replacement Return truck to maintenance for repair 2 7 LOADING AND UNLOAD...

Page 12: ...NOTES 12...

Page 13: ...ng soda solution one pound to one gallon of water applied to spilled acid until bub bling stops neutralizes the acid for safe handing and disposal Leakage voltage from battery terminals to battery cas...

Page 14: ...charging is highly explosive and can cause seri ous injury 1 Charge the battery only in areas designated for that use 2 Make certain the charger being used matches the voltage and amperage of the truc...

Page 15: ...regulated battery it never requires watering 3 4 CHARGING BATTERIES Charging requirements will vary depending on depth of discharge and temperature Follow safety rules when placing a battery on charge...

Page 16: ...lift carriage fully lowered spray or brush 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 90 Transmission oil EP S...

Page 17: ...2 Full length of channel where rollers operate 2 Lift Chain Brush or Spray No 4 See Paragraph 3 6 3 Lift Carriage Brush No 2 Light coating where forks slide 4 Hydraulic Reservoir Capacity 1 quarts Ca...

Page 18: ...NOTES 18...

Page 19: ...wiring A loose con nection may be the cause of malfunction Tighten all loose connections before further troubleshooting b Defective deadman switch 40 Figure 12 1 Check and replace switch if defective...

Page 20: ...st 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 hydr...

Page 21: ...g valve Check for leaking fitting in hydrau lic line and repair as required Repack lift cylinder or replace or pump motor assembly Figure 12 21 Truck moves forward when arm is pulled down a Belly butt...

Page 22: ...the latest event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revisited 4 1 3 2 Logbook Access To view the alarm logbook proceed as follow...

Page 23: ...s the ROLL down button 1 or the ROLL up button 2 to find the ADJUSTMENTS display 4 Press the ENTER button 3 to view the adjust ments 5 Press the ROLL down button 2 or the ROLL up button 1 to find the...

Page 24: ...Presence man sensor was active at key on Check the wiring Check the micro switches It could also be an error sequence made by the operator A failure in the logic is possi ble too so when all of the a...

Page 25: ...anently it is necessary to replace the controller If the alarm disap pears the previously stored parameters will have been replaced by the default parame ters with the temperature increases from 85 to...

Page 26: ...c to detect the condition of a bro ken sense diode Check the Voltage on NPOT and the potenti ometer connections 51 TILLER OPEN Warning When the tiller is released after a fixed period of time of stand...

Page 27: ...is a short or a low impedance between the negative of this coil and BAT This warning also occurs if the external load is not present and the parameter EV2 in the Set Options menu is set PRES ENT in t...

Page 28: ...k movement requests Lift Lower are active at the same time Check the wiring of the lift and lower inputs use the readings in the TEST to facilitate the troubleshooting Check the micros witches for fai...

Page 29: ...rough this serial interface It is necessary to replace the controller 13 EEPROM KO It occurs if a test to write and read one location in EEPROM fails The SW expects to read the written value It also o...

Page 30: ...ng the main contactor open 53 STBY I HIGH This alarm occurs two ways 1 In the initial rest state after key on if the outputs of the current amplifiers are not comprised in the window 2 2 to 2 8 Vdc 2...

Page 31: ...sitive arrives to the controller Check the continuity of the wire in the phase U of the motor Otherwise it is necessary to replace the controller 73 POWER FAILURE 1 This alarm occurs when the cur rent...

Page 32: ...or to a minus battery In the first case safety contacts connected to a plus battery when the safety contacts are open CNA 4 is connected to a minus bat tery through a load Only a harness mistake may...

Page 33: ...m occurs if the feedback encoder counting does not change its value even if commanded to change In application with the feedback potentiome ter verify potentiometer is not mechanically loosened Check...

Page 34: ...s necessary to replace the controller 237 WAITING DATA This warning occurs only if CAN BUS is PRESENT At key on the EPS AC0 asks the traction controller to send a list of parameters via CAN BUS From t...

Page 35: ...rong connection between the two encoder channels In this latest case exchange the connections 242 Q LINE SENSOR KO This alarm occurs when the mean voltage of the Quadrature line of the stepper motor c...

Page 36: ...with the one that the slave uC is detecting Furthermore this alarm occurs if the main uC is detecting no steering limitation meanwhile the slave uC is detecting a steering limitation It is necessary t...

Page 37: ...essary to replace the controller 252 KS OPEN This alarm occurs if the slave uC detects the safety contact of the main uC open when expected being closed It is necessary to replace the controller 253 K...

Page 38: ...NOTES 38...

Page 39: ...f the key switch 5 Figure 12 22 and dis connect the batteries 2 Remove two screws 17 Figure 5 2 and two screws 20 As cap 2 is removed cover 6 and spring 16 can be removed 3 Lift up cap 2 tag and disco...

Page 40: ...reconnect harness 34 Figure 5 1 to harnesses 8 9 12 Figure 5 2 2 As cap 2 is installed install cover 6 and spring 16 Secure cap 2 with two screws 17 and two screws 20 3 Reconnect the batteries and tu...

Page 41: ...h Replacement 1 Remove the cap assembly as described in para graph 5 1 1 2 Disconnect harness 34 Figure 5 1 from switch 10 Figure 5 2 3 Remove and replace switch 10 4 Reconnect harness 34 Figure 5 1 t...

Page 42: ...off hinges 6 3 Remove three screws 1 lock washers 11 flat washers 12 and cover 2 4 Remove two screws 3 washers 14 and upper cover 4 5 Remove screw 8 Figure 12 6 lock washer 9 flat washer 10 two screw...

Page 43: ...overs as described in paragraph 5 3 3 Disconnect position switch 2 Figure 12 3 from harness 1 Figure 12 25 4 Remove position switch from the frame 5 Disconnect harness 1 from steering motor 16 Figure...

Page 44: ...NOTES 44...

Page 45: ...batteries 3 Remove the compartment covers as described in paragraph 5 3 4 Disconnect electric brake 2 Figure 6 1 from the harness 1 Figure 12 25 5 Remove three screws 23 Figure 6 1 and remove brake 2...

Page 46: ...Figure 6 1 Drive Assembly R7220 46...

Page 47: ...3 and gear 4 from transmission 5 7 Install new transmission by reversing the steps above 7 3 Load Wheel 7 3 1 Removal 1 Turn off the key switch 5 Figure 12 22 and dis connect the batteries 2 Block th...

Page 48: ...Figure 7 1 Drive Assembly R7220 48...

Page 49: ...Figure 7 2 Load Wheels R7223 49...

Page 50: ...NOTES 50...

Page 51: ...8 2 to allow for adjustment of middle jam nuts 4 Break the lower jam nuts 2 Figure 8 1 located below the mounts on outer mast free from the middle jam nuts 2 5 Take up slack in both lift chains with m...

Page 52: ...Figure 8 2 Elevation System Telescopic R7224 52...

Page 53: ...n jam nuts 2 Figure 8 1 the mount of outer mast 1 Figure 8 3 to allow for adjustment of middle jam nut 4 Break the lower jam nuts 2 Figure 8 1 located below the mount of outer mast free from the mid d...

Page 54: ...Figure 8 3 Mast Three Stage Mast R7225 54...

Page 55: ...n 4 connecting chain 5 to chain anchor 6 at the lift carriage 5 Remove cotter pin 3 and clevis pin 4 connect ing chain 5 to chain anchor 1 at free lift cylinder 9 Figure 8 3 6 Remove chain from sheave...

Page 56: ...NOTES 56...

Page 57: ...em lines and fittings To ensure release of pressure forks must be fully lowered and the batteries discon nected before performing any mainte nance on the hydraulic system 9 2 1 Removal 1 Lower forks f...

Page 58: ...Figure 9 1 Hydraulic System R7228 58...

Page 59: ...ng another lift truck or suitable jack raise mast 16 far enough to remove pressure on the lift cyl inder 15 CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container unde...

Page 60: ...Figure 9 3 Elevation System Telescopic R7224 60...

Page 61: ...n 1 Using another lift truck or suitable jack raise mast 16 Figure 9 3 far enough to allow installation of the lift cylinder 15 2 Slowly lower mast 16 while aligning cylinder 15 with the tap on mast 1...

Page 62: ...ement make certain power is disconnected 3 Using another lift truck or suitable jack raise lift carriage far enough to remove pressure on the free lift cylinder 4 Remove cotter pin and clevis pin conn...

Page 63: ...discon necting 6 Remove chains from sheaves 14 7 Disconnect the tube 9 Figure 9 5 from the bot tom of lift cylinder 8 Support cylinder 9 Figure 9 6 and remove two screws 2 two lock washers 3 and two...

Page 64: ...gure 9 6 on inner mast 20 and secure with two screws 2 two lock washers 3 and two flat washers 17 2 Reconnect the tube 3 Figure 9 5 to the bottom of the cylinder 3 Position ram head 8 Figure 9 6 and b...

Page 65: ...and O ring 2 from gland nut 3 4 Pull out piston rod 4 5 Remove collar 5 and piston 7 from piston rod 4 6 Remove backup ring 6 and packing 8 from pis ton rod 4 7 Coat all parts with hydraulic oil Table...

Page 66: ...Figure 9 8 Secondary Lift Cylinder Three Stage Mast R7234 66...

Page 67: ...ge parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 3 Remove the front compartment covers as described in paragraph 5 3 4 Support the mast in an u...

Page 68: ...seal 8 and O ring 10 in gland nut 9 14 Install gland nut 9 in tube 14 15 Install bearing 2 and retaining rings 3 in clevis 1 16 Install clevis 1 on piston rod 11 and secure with bolt 4 lock washer 5 a...

Page 69: ...Figure 9 10 Tilt Cylinder R7236 69...

Page 70: ...NOTES 70...

Page 71: ...for this task in order to avoid bending the buss bars 10 1 3 Panel Removal 1 Turn off the key switch 5 Figure 12 22 and dis connect the batteries 2 Remove the compartment covers as described in parag...

Page 72: ...Figure 10 1 Electrical System R6478 R7237 72...

Page 73: ...Figure 10 2 Electrical Panel R6478 R7238 73...

Page 74: ...x screws 8 six lock washers 9 and six flat washers 10 to secure the motor to the bearing 3 Position cables as noted in removal and recon nect cables to the drive motor 4 Reinstall the brake as describ...

Page 75: ...Figure 10 3 Transmission Motor Brake Assembly R6879 75...

Page 76: ...NOTES 76...

Page 77: ...SECTION 11 OPTIONAL EQUIPMENT 77...

Page 78: ...NOTES 78...

Page 79: ...SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the BGL 33 Lift Truck 79...

Page 80: ...Figure 12 1 Control Arm R7217 80...

Page 81: ...1 8 0000 000491 00 CLAMP 1 9 1280 300005 00 REVOLVING COVER 1 10 2333 340000 00 B CONTROL HEAD 1 11 0000 000114 00 NUT M53 X 1 5 1 12 0000 000143 00 WASHER LOCK M52 1 13 0000 000681 00 KEY C8 X 7 X 14...

Page 82: ...Figure 12 1 Control Arm Continued R7217 82...

Page 83: ...8 X 20 7 30 2322 300001 00 SUPPORT 1 31 0000 000109 00 SCREW M8 X 16 3 32 1221 300002 00 MOUNTING PLATE 1 33 1221 520007 0A POTENTIOMETER WITH WIRE HARNESS 1 34 2333 520002 10 WIRE HARNESS 1 35 0000 0...

Page 84: ...Figure 12 2 Control Head R7218 84...

Page 85: ...0007 00 TILT BUTTON 1 8 2333 340008 00 LIFT LOWER SWITCH 1 9 2333 520005 10 HORN WIRE HARNESS 1 10 2333 520004 10 BELLY BUTTON SWITCH HARNESS 1 11 2333 520003 10 POTENTIOMETER 1 12 2333 520006 10 TILT...

Page 86: ...Figure 12 3 Drive System R7219 86...

Page 87: ...DRIVE SYSTEM Pos Part Number Description Qty Reqd Notes 1 2333 200000 10 DRIVE ASSEMBLY 1 2 1280 520009 10 POSITION SWITCH WIRE HARNESS 1 87...

Page 88: ...Figure 12 4 Drive Assembly R7220 88...

Page 89: ...REW M8 X 35 6 9 0000 000159 00 WASHER LOCK M8 6 10 0000 000176 00 WASHER FLAT M8 6 11 0000 000516 00 SCREW M12 X 40 6 12 0000 000060 00 WASHER LOCK M12 6 13 0000 000373 00 WASHER FLAT M12 6 14 0000 00...

Page 90: ...Figure 12 5 Compartment R7221 90...

Page 91: ...COVER 1 5 2130 172000 00 HINGE BLOCK L 1 6 2130 182000 00 HINGE BLOCK R 1 7 2333 131000 00 COVER ASSEMBLY L 1 8 2333 141000 00 COVER ASSEMBLY R 1 9 1220 150005 00 NUT M8 2 10 0000 000109 00 SCREW M8 X...

Page 92: ...Figure 12 6 Frame R7222 92...

Page 93: ...00 BOLT M8 X 16 1 9 0000 000159 00 WASHER LOCK M8 10 10 0000 000176 00 WASHER FLAT M8 10 11 0000 000026 00 SCREW M8 X 30 2 12 0000 000015 00 SCREW M6 X 10 1 13 0000 000056 00 WASHER LOCK M6 1 14 0000...

Page 94: ...Figure 12 6 Frame Continued R7222 94...

Page 95: ...FRAME CONTINUED Pos Part Number Description Qty Reqd Notes 23 1280 180001 0A BLOCK 1 24 0000 000279 00 BOLT M8 X 35 1 25 2125 100002 00 BATTERY CLIP 1 26 2140 100001 00 BATTERY BLOCK 1 95...

Page 96: ...Figure 12 7 Load Wheels R7223 96...

Page 97: ...16 2 4 0000 000056 00 WASHER LOCK M6 2 5 0000 000380 00 WASHER FLAT M6 2 6 2320 600002 00 RETAINER 1 7 2320 601100 00 LOAD WHEEL 1 8 2320 600001 00 MOUNTING BASE 1 9 0000 000379 00 WASHER FLAT M14 2 1...

Page 98: ...Figure 12 8 Elevation System Telescopic R7224 98...

Page 99: ...8 4 8 0000 000285 00 BOLT M12 X 35 2 9 0000 000060 00 WASHER LOCK M12 2 10 0000 000283 00 BOLT M10 X 35 4 11 0000 000063 00 WASHER LOCK M10 6 12 2214 600005 00 SHIM A R As Required 13 2214 600004 0A C...

Page 100: ...Figure 12 8 Elevation System Telescopic Continued R7224 100...

Page 101: ...n 19 2214 600007 00 CUSHION BLOCK II 2 20 2130 500002 0A SENSOR BRACKET 1 21 2130 500001 0A SENSOR BRACKET 1 22 2125 520009 26 PROXIMITY SWITCH HARNESS 1 Used for Lift Height 104 22a 2125 520009 29 PR...

Page 102: ...Figure 12 9 Elevation System Three Stage Mast R7225 102...

Page 103: ...R ASSEMBLY 8 7 2125 600007 30 BRACKET 1 8 2125 600001 30 ROLLER BRACKET 1 9 2333 420000 30 01 CYLINDER FREE LIFT 1 Used for Lift Height 157 9a 2333 420000 30 02 CYLINDER FREE LIFT 1 Used for Lift Heig...

Page 104: ...Figure 12 9 Elevation System Three Stage Mast Continued R7225 104...

Page 105: ...1a 2130 410000 30 02 CYLINDER SECONDARY LIFT 2 Used for Lift Height 177 22 2214 600005 00 SHIM A R As Required 23 2125 600006 30 CYLINDER BRACKET 2 24 2125 600005 30 CLIP 2 25 2214 600007 00 CUSHION B...

Page 106: ...Figure 12 9 Elevation System Three Stage Mast Continued R7225 106...

Page 107: ...tes 36 2125 500002 00 PROXIMITY SWITCH 8104 1 Used for Lift Height 157 36a 2125 500003 00 PROXIMITY SWITCH 8104 1 Used for Lift Height 177 37 2125 520009 22 PROXIMITY SWITCH HARNESS 1 Used for Lift He...

Page 108: ...Figure 12 10 Lift Carriage Telescopic R7226 108...

Page 109: ...4 00 BOLT M12 X 30 4 2 0000 000060 00 WASHER LOCK M12 4 3 0000 000373 00 WASHER FLAT M12 4 4 2320 631000 00 BACKREST 1 5 2130 631000 00 LIFT CARRIAGE 1 6 2125 630001 00 FORK 2 7 2125 630001 10 PIN ASS...

Page 110: ...Figure 12 11 Lift Carriage Three Stage Mast R7227 110...

Page 111: ...0221 00 BOLT M12 X 30 4 2 0000 000060 00 WASHER LOCK M12 4 3 0000 000373 00 WASHER FLAT M12 4 4 2320 631000 00 BACKREST 1 5 2125 641000 30 LIFT CARRIAGE 1 6 2125 630001 00 FORK 2 7 2125 630001 10 PIN...

Page 112: ...Figure 12 12 Chain Assembly R6818 112...

Page 113: ...1 Used for Lift Height 126 Telescopic Mast 5b 2125 651000 30 01 CHAIN I MOUNTS TO FREE LIFT CYL 1 Used for Lift Height 157 Three Stage Mast 5c 2125 651000 30 02 CHAIN I MOUNTS TO FREE LIFT CYL 1 Used...

Page 114: ...Figure 12 13 Hydraulic System R7228 114...

Page 115: ...16 4 9 2125 420001 00 MAGNET 1 10 0000 000635 00 PLUG M18 X 1 5 1 11 0000 000510 00 WASHER M20 1 12 2130 423000 00 FILTER 1 13 2333 420000 00 HOSE 2 14 2333 430000 00 HOSE 2 15 3218 711000 00 HOSE TI...

Page 116: ...Figure 12 14 Tilt System R7235 116...

Page 117: ...on Qty Reqd Notes 1 0000 000255 00 BOLT M8 X 20 2 2 0000 000159 00 WASHER LOCK M8 4 3 0000 000176 00 WASHER FLAT M8 4 4 2333 400001 00 SHAFT 2 5 2333 440000 00 TILT CYLINDER 2 6 0000 000321 00 SCREW M...

Page 118: ...Figure 12 15 Lift System Telescopic R7230 118...

Page 119: ...00069 00 SEAL M16 6 2 2706 161600 00 CONNECTOR M16 x 1 5 x M16 x 1 5 2 3 2130 470000 00 TUBE ASEMBLY 2 4 2125 400002 3A MANIFOLD 1 5 2712 141300 00 PLUG G1 4 1 6 0000 000169 00 SCREW M8 X 30 2 7 2701...

Page 120: ...Figure 12 16 Lift System Three Stage Mast R7231 120...

Page 121: ...SCREW M8 X 30 2 7 2702 142000 00 CONNECTOR G1 4 X M20 X 1 5 1 8 0000 000044 00 SEAL M14 1 9 2125 430000 3B TUBE ASSEMBLY 1 10 2125 450000 3A TUBE ASSEMBLY 1 11 2706 162000 10 CONNECTOR M16 X 1 5 X M2...

Page 122: ...Figure 12 17 Lift Cylinder Telescopic R7232 122...

Page 123: ...0 RING WIPER 35 X 43 X 5 6 5 1 2 0000 000370 00 O RING 40 X 3 1 1 3 1220 420001 0A GLAND NUT 1 4 2130 410001 00 01 PISTON ROD 1 4a 2130 410001 00 02 PISTON ROD 5 2130 410003 00 COLLAR 1 6 2130 410004...

Page 124: ...Figure 12 18 Free Lift Cylinder Three Stage Mast R7233 124...

Page 125: ...X 5 6 5 1 2 0000 000690 00 O RING 60 X 3 1 1 3 2130 420002 30 GLAND NUT 1 4 2130 420001 30 01 PISTON ROD 1 Used for Lift Height 157 Three Stage Mast 4a 2130 420001 30 02 PISTON ROD 1 Used for Lift He...

Page 126: ...Figure 12 19 Secondary Lift Cylinder Three Stage Mast R7234 126...

Page 127: ...5 1 2 0000 000370 00 O RING 40 X 3 1 1 3 1220 420001 0A GLAND NUT 1 4 2130 410001 30 01 PISTON ROD 1 Used for Lift Height 157 Three Stage Mast 4a 2130 410001 30 02 PISTON ROD 1 Used for Lift Height 1...

Page 128: ...Figure 12 20 Tilt Cylinder R7236 128...

Page 129: ...T M14 X 55 1 5 0000 000233 00 WASHER LOCK M14 1 6 0000 001014 00 NUT M14 1 7 0000 001017 00 DUST SEAL LYO 30 X 47 X 10 1 8 0000 001016 00 SEAL 30 X 43 X 7 1 9 2320 440001 00 GUIDE RING 1 10 0000 00096...

Page 130: ...Figure 12 21 Pump and Motor R7229 130...

Page 131: ...ASSEMBLY 1 1 2130 470002 40 MOTOR 1 2 2320 421008 00 PUMP SOLENOID 1 3 2320 421016 00 SOLENOID VALVE 3 Lift Tilt 4 2333 460001 10 PROPORTIONAL SOLENOID VALVE 1 Lower 5 2320 421002 00 PUMP 1 6 2320 42...

Page 132: ...Figure 12 22 Electrical System R7237 132...

Page 133: ...220 520002 1C KEY SWITCH 1 6 1115 510006 20 HOUR METER 1 7 1220 520007 0D METER WIRING HARNESS 1 8 0000 000170 00 SCREW M6 X 30 2 9 0000 000056 00 WASHER LOCK M6 3 10 2333 531000 00 BATTERY CONNECTOR...

Page 134: ...Figure 12 23 Electrical Panel R7238 134...

Page 135: ...10 00 WASHER FLAT M8 4 7 1120 540002 00 FUSE 200A 2 8 0000 000126 00 SCREW M6 X 16 4 9 1280 560002 00 CONTROLLER AC 1 10 1120 540001 00 B FUSE BLOCK 2 11 1280 510002 00 BUSS BAR 1 12 1280 510001 00 BU...

Page 136: ...Figure 12 24 Battery Assembly Optional R7001A 136...

Page 137: ...1145 553001 20 M1 CABLE 1 13 1145 533003 2L M3 CABLE 1 14 1145 553100 20 GREY BATT CONNECTOR ASSY 1 15 0000 000102 00 SCREW M6 45 2 16 005450 HANDLE UPPER 1 17 0000 000166 00 NUT M6 2 18 1145 551000 2...

Page 138: ...Figure 12 25 Wire Harness R7240 138...

Page 139: ...WIRE HARNESS Pos Part Number Description Qty Reqd Notes 1 2333 520001 00 WIRE HARNESS 1 2 1120 500010 00 FUSE 10A 2 139...

Page 140: ...Figure 12 26 Wiring Cables R7241 140...

Page 141: ...BLE V 1 3 2333 530003 00 DRIVE MOTOR CABLE W 1 4 2333 530004 00 PUMP MOTOR CABLE 1 5 2333 530005 00 PUMP MOTOR CABLE 1 6 2333 530006 10 STREEING MOTOR CABLE U 1 7 2333 530007 10 STREEING MOTOR CABLE V...

Page 142: ...uga ON Canada L5T 2N6 t 905 457 3900 f 905 457 2313 USA 6350 Burnt Poplar Road Greensboro NC 27409 www bluegiant com If calling within North America t 1 800 668 7078 f 1 888 378 5781 Copyright Blue Gi...

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