Blue Giant BGN-40, Owner'S Manual

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9-2.4. Lift Cylinder (Telescopic)
9-2.4.1.Removal
1. With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and
position blocks or strong supports under inner
mast
2. Lower inner mast onto the support. Check that
arrangement is secure before proceeding.
3. Turn off the key switch (1, Figure 12-24 ) and dis-
connect the batteries.
WARNING: Before attempting any replacement,
make certain power is disconnected.
CAUTION:
Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
4. Disconnect the hose from the bottom of lift cylin-
der.
5. Manually push the cylinder rod down as far as
possible.
WARNING: Support lift cylinder before performing
the following steps to prevent cylinder
from falling.
6. Remove two bolts (10, Figure 9-2 ), two lock wash-
ers (11), two flat washers (24), clip (14), bracket
(13) and shims (12).
7. Raise lift cylinder assembly (15) up and out of
truck.
9-2.4.2.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 9-3 ).
3. Remove wiper ring (1) and O-ring (2) from gland
nut (3).
4. Pull out piston rod (4).
5. Remove piston (7) and O-ring (5) from rod (4).
6. Remove guide ring (6) and seal (8) from piston
(7).
7. Coat all parts with hydraulic oil ( Table 3-2 ).
8. Install guide ring (6) and new seal (8) on piston
(7).
9. Install new O-ring (5) on rod (4).
10. Install piston (7) on rod (4).
11. Insert rod (4) in cylinder tube (9).
12. Install wiper ring (1) and O-ring (2) on gland nut
(3).
13. Install gland nut (3) in cylinder tube (9).
9-2.4.3.Installation
1. Position the cylinder on outer mast (20, Figure 9-
2 ).
2. Install clip (14), bracket (13) and shims (12) and
secure with two bolts (10), two lock washers (11),
two flat washers (24).
3. Using a suitable lifting device, support the inner
mast (34) and remove the supports.
4. Slowly lower the inner mast while lining up the lift
cylinder with its mounting taps.
5. Secure the top of the cylinder with screw (23),
lock washer (11) and flat washer (24).
6. Reconnect the hose to the bottom of lift cylinder.
7. Adjust the chains according to paragraph 8-2.
8. Fill the hydraulic reservoir. Use hydraulic oil listed
in
Table 3-2 .
9. Reconnect the batteries and turn on the keyswitch
(1,
Figure 12-24 ).
10. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
11. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in
Table 3-2 .
12. Install the compartment covers as described in
paragraph 5-3.
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