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Global 989021, Operation, Maintenance, Repair Parts List

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Global 989021 Operation, Maintenance, Repair Parts List Download Page 21

BL-GL22-1119 - 11-20-2019

4-3

Table 4-1 Troubleshooting Chart - Continued

MALFUNCTION

PROBABLE CAUSE

CORRECTIVE ACTION

TROUBLE WITH BRAKING

Truck does not slow with brake, or 

brake does not engage.

a. Defective deadman switch.

Check deadman switch for 

continuity. If none found when 
the control arm is in the brake 
position, replace switch.

b. Defective electric brake.

Adjust or replace brake.

Brake will not release.

a. Air gap more than 0.01 in 

(0.25mm).

Adjust.

b. Brake temperature above 

281



F (140

 C).

Allow to cool and check air gap.

c. Open brake circuitry or wiring.

Make voltage checks.

Brake drags.

Defective electric brake.

Replace.

Brake grabs.

a. Incorrect stopping distance 

adjustment.

Adjust.

b. Defective electric brake.

Replace.

Abnormal noise and chatter when 

brake is applied.

Defective electric brake.

Replace.

TROUBLE WITH LIFTING OR 
LOWERING

Oil sprays or flows from the top of 

the lift cylinder.

Defective packing in lift cylinder

Repair lift cylinder.

Squealing sounds when lifting 

forks.

a. Oil level too low.

Identify oil leak and fill reservoir.

b. Dry channels in mast.

Apply grease.

c. Defective mast 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 

hydraulic system.

a. Defective pump or relief valve.

Check pressure. Adjust as 

necessary.

b. Worn lift cylinder.

Replace cylinder.

c. Load larger than capacity.

Refer to I.D.plate for capacity.

d. Defective lift motor solenoid.

Replace solenoid on pump motor.

e. Battery charge low.

Charge battery.

Forks do not lift, pump motor does 

not run.

a. Battery is dead or discon-

nected.

Check and recharge if required.

b. Defective wiring.

Check and repair as required.

c. Defect in electrical system for 

operating pump motor.

Check lift switch in control head, 

as well as the solenoid.

Summary of Contents for 989021

Page 1: ...Global Industrial MANUAL NO BL GL22 1119 11 20 2019 globalindustrial com MODEL 989021 SELF PROPELLED STRADDLE LIFT TRUCK Operation Maintenance Repair Parts List ...

Page 2: ...al 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 forks as far apart as load will permit Before lifting be sure load is centered forks are completely under load and load is as far back as possible against load backrest Do not handle unstable or loosel...

Page 3: ...Y INSTALLATION 5 2 5 1 3 CONTROL HEAD REMOVAL 5 2 5 1 4 CONTROL HEAD INSTALLATION 5 3 5 1 5 SPEED POTENTIOMETER REPLACEMENT 5 3 5 1 6 BELLY BUTTON SWITCH REPLACEMENT5 3 5 1 7 HORN SWITCH REPLACEMENT 5 4 5 1 8 LIFT AND LOWER SWITCH REPLACEMENT 5 6 5 2 STEERING ARM 5 6 5 2 1 RETURN SPRING REPLACEMENT 5 6 5 2 2 STEERING ARM REMOVAL 5 6 5 2 3 STEERING ARM INSTALLATION 5 6 5 3 COMPARTMENT COVERS 5 6 5 ...

Page 4: ...LATION 10 3 10 1 13 LED INDICATOR REMOVAL 10 3 10 1 14 LED INDICATOR INSTALLATION 10 3 10 1 15 EMERGENCY STOP SWITCH REMOVAL 10 3 10 1 16 EMERGENCY STOP SWITCH INSTALLATION 10 3 10 1 17 LIFT LIMIT SWITCH REMOVAL 10 4 10 1 18 LIFT LIMIT SWITCH INSTALLATION 10 4 10 2 PUMP MOTOR 10 4 10 3 DRIVE MOTOR 10 4 10 4 DEADMAN SWITCH 10 4 11 OPTIONAL EQUIPMENT 11 1 12 ILLUSTRATED PARTS BREAKDOWN 12 1 ...

Page 5: ...ver the speed is restricted when the platform is raised above a preset limit The model number will be found on the name plate Figure 1 1 along with the serial number lifting capac ity and load center Figure 1 2 shows the locations of the truck s main components and controls 1 3 SAFETY FEATURES The 989021 is designed engineered to provide maxi mum safety for operator and payload Some of the safety ...

Page 6: ... 4 Battery 5 Caster wheel 6 Hydraulic pump and motor assembly 7 Chassis 8 Emergency stop switch 9 Forks 10 Lift cylinder 11 Load wheel 12 Power plug 13 Battery indicator display 14 Key switch 15 Lowering button 16 Lift button 17 Directional speed control knob 18 Horn button 19 Emergency reverse button ITEM COMPONENT ...

Page 7: ...d by a qualified 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 smoothly throughout its entire height both empty and loaded Be sure that mast is vertical do not operate on a side slope Be sure the truck has a firm and level footing Avoid overhead wires ...

Page 8: ...l it has been restored 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 Transmission and hydraulic systems Check for signs of fluid leakage Forks Check for cracks and damage and that they are properly secured Chains cables and hoses Check that they are in pl...

Page 9: ...BL GL22 1119 11 20 2019 2 3 Figure 2 2 Sample of Operator Check List R8549 ...

Page 10: ...gages slowing or stopping the truck 5 Procedures for movement in reverse are the same as in the forward direction except slowly press the speed control backward See Figure 2 3 2 5 1 Stopping The stopping distance of the truck depends on the ground conditions The driver must take this into account when operating the truck The driver must be looking ahead when traveling If there is no hazard brake m...

Page 11: ...trol buttons are located on the steering control head Figure 2 4 To lift forks push in either LIFT button and hold until forks reach desired height To lower forks push in either LOWER button and hold until forks descend to desired height 2 9 LOADING AND UNLOADING 1 Move truck to location where load is to be picked up 2 Move the truck into position so forks are within pallet or skid and the load is...

Page 12: ...2 6 BL GL22 1119 11 20 2019 NOTES ...

Page 13: ...illed acid until bub bling stops neutralizes the acid for safe handing and disposal Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system Since components of the truck elec trical system are insulated from truck frame leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire i...

Page 14: ...rging requirements will vary depending on the use of the truck The battery should be given as equalizing charge on a weekly basis This charge should normally be an additional three hours at the finish rate 4 Make certain battery used meets weight and size requirements of truck NEVER operate truck with an undersized battery 3 3 4 MAINTENANCE FREE BATTERIES Trucks are equipped with maintenance free ...

Page 15: ...y charged Normal operation Solid Yellow Battery failure The battery voltage is less than 13V or greater than 32 5V Flashing Yellow Charger failure a Output current or output voltage is too large b The temperature of charger is too high Flashing Red Charger without output current a Charger failure b The battery is not connected battery failure No Light Charger failure a Charger failure b The input ...

Page 16: ...ble 3 4 in conjunction with Figure 3 3 identifies the items requiring lubrication 3 7 LIFT CHAIN MAINTENANCE Fully raise and lower lift carriage while observing chains as they move over chain sheaves Ensure chain is aligned and tracking properly and all links are pivoting freely With lift carriage fully lowered spray or brush on a film of SAE 30 or 40 engine oil Table 3 3 Recommended Lubricants Se...

Page 17: ...ter Mast Brush No 2 Full length of channel where rollers operate 2 Lift Chain Brush or Spray No 4 See Paragraph 3 7 3 Lift Carriage Brush No 2 Light coating where forks slide 4 Transmission Capacity 2 pints Can No 1 Fill to level plug 5 Hydraulic Reservoir Capacity 1 quarts Can No 3 With lift carriage fully lowered fill reservoir with hydraulic oil to level on breather dip stick R8563 ...

Page 18: ...3 6 BL GL22 1119 11 20 2019 NOTES ...

Page 19: ...e 4 1 as a guide to determine possible causes of trouble The table is divided into five main categories Truck and Hydraulic System Will Not Oper ate Truck Does Not Operate Forward or Reverse Trouble With Braking Trouble With Lifting Or Lower ing and Miscellaneous malfunctions ...

Page 20: ...ERSE Truck does not travel forward or reverse All other functions oper ate normally a Check all wiring A loose con nection may be the cause of malfunction Tighten all loose connections before further troubleshooting b Defective deadman switch Check and replace switch if defective c Defective controller Check for proper operation and replace if necessary d Defective potentiometer Check and replace ...

Page 21: ... OR LOWERING Oil sprays or flows from the top of the lift cylinder Defective packing in lift cylinder Repair lift cylinder Squealing sounds when lifting forks a Oil level too low Identify oil leak and fill reservoir b Dry channels in mast Apply grease c Defective mast 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 ...

Page 22: ...ir b Load larger than capacity Refer to nameplate on side of mast for maximum load capacity c Batteries need charging Change batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylin der or lowering valve Check for leaking fitting in hydrau lic line and repair as required Repack lift cylinder or replace valve assembly MISCELLANEOUS Steering arm does no...

Page 23: ...omplete the following checkout procedure If you find a problem during the checkout refer to paragraph 4 2 8 for further information The checkout can be conducted with or without the handheld programmer See Paragraph 4 2 2 How ever the checkout procedure is easier with a program mer To evaluate the system without a programmer observe the LED and note the flashing pattern and refer to Table 4 3 for ...

Page 24: ... stop and reverse direc tion with the audible plugging tone 9 Verify that all options such as high pedal disable HPD static return to off SRO and anti tie down are as desired 10 Check to see whether the emergency reverse belly button feature is working correctly Verify that the circuit is operational by momentarily dis connecting one of the emergency reverse wires The vehicle should be disabled an...

Page 25: ...ameters The programmable parameters are grouped hierarchi cally into menus as shown in Table 4 2 The MultiModeTM feature of the controller allows oper ation in two distinct modes Mode 1 and M2 These modes can be programmed to provide four different sets of operating characteristics which can be useful for operating in different conditions Mode 1 could be programmed such that the vehicle moves slow...

Page 26: ... Low Speed setting Decel Low Speed 8 Sets the rate in seconds that is used to slow down the vehicle when it s traveling forward at low speed and throttle is reduced Larger values represent slower response Note Allowable range is restricted by the Decel High Speed setting Rev Accel Max Speed 1 5 Sets the rate in seconds at which the speed command increases when throttle is applied while the speed l...

Page 27: ...ciated with gear slack in the transaxle when throttle is applied from the neutral state Larger values provide a softer slack take up Gear Soften 100 This parameter is intended to soften the bump associated with gear slack in the transaxle when throttle is released and then reapplied while the vehicle is still moving Larger values pro vide a softer slack take up Creep Speed 10 Creep Speed helps to ...

Page 28: ... to apply a speed limit pot must be installed in parallel with the throttle and the Speed Limit Pot parameter must be programmed On see Throttle menu M1 M2 Rev Max Speed 100 During reverse operation defines the requested speed at full throttle when he speed limit pot is in its maximum speed posi tion Note Allowable range is restricted by M1 M2 Rev Min Speed setting M1 M2 Rev Min Speed M1 100 M2 60...

Page 29: ...he throttle itself Neutral Deadband 30 Sets the throttle range the controller interprets as neutral Increasing the parameter setting increases the neutral range This parameter allows the neutral deadband to be defined wide enough to ensure the controller goes into neutral when the throttle is released Throttle Max 100 Sets the pot wiper voltage required to produce 100 controller output Increasing ...

Page 30: ...n inhibits driving and puts the controller into throttle autocalibration mode Setting the parameter Off returns the controller to normal oper ation CURRENT MENU Main Current Limit 70 Sets the maximum current the controller will supply to the motor during normal driving By limiting the current supplied this parameter can be used to protect the motor from poten tially damaging currents or to reduce ...

Page 31: ... Voltage 24 A high initial voltage is applied to the brake coil when the brake is first released After approximately 1 second this peak volt age drops to the programmed Hold Voltage The parameter should be set high enough to hold the brake released under all the shock and vibration conditions the vehicle will be sub jected to Brake Light OFF When set to On the horn output J1 Pin 3 will act as a br...

Page 32: ...ns in maximum speed that would otherwise result when driving with a fully charged battery vs a partially discharged battery If Speed Scaler is set to 23 volts for example the maximum vehicle speed will be the same whether the actual battery voltage is 27 volts or 23 volts or any value in between Current Rating 70 This parameter should be set to the current rating provided by the motor 0 70 A manuf...

Page 33: ... vehicle speed when the battery charge falls below the programmed Low BDI Level COMPENSATION MENU IR Comp 90 Sets the motor load compensation Higher values provide stronger disturbance rejection while lower values provide smoother operation Note Allowable range is restricted by the Anti Rollback Comp setting Anti Rollback Comp 125 Sets the motor load compensation after the throttle is released to ...

Page 34: ...ses the fault codes listed in Table 4 3 Six sin gle digit codes are used 2 3 5 6 7 and 9 For suggestions about possible causes of the various faults refer to Table 4 4 Troubleshooting Chart 4 2 9 Programmer Diagnostics With a programmer diagnostics and troubleshooting is more direct than with the LED alone The programmer presents complete diagnostic information in plain lan guage no code to deciph...

Page 35: ... OVERVOLTAGE FAULT 1 5 MAIN OFF FAULT 2 1 not used 2 2 MAIN FAULT 2 3 MAIN ON FAULT 2 4 not used 2 5 WIRING FAULT 3 1 BRAKE ON FAULT 3 2 PRECHARGE FAULT 3 3 Table 4 3 LED Codes Continued Error Message LED BLINKS digit 1 LED BLINKS digit 2 BRAKE OFF FAULT 3 4 HPD FAULT 3 5 CURRENT SENSE FAULT 4 1 HARDWARE FAILSAFE 4 2 EE CHECKSUM FAULT 4 3 not used 4 4 BATTERY DISCONNECT FAULT 4 5 ...

Page 36: ...lected 1 3 SPEED POT FAULT Speed limit pot wiper out of range 1 Speed limit pot wire s broken or shorted 2 Broken speed limit pot 1 4 UNDERVOLTAGE FAULT Battery voltage too low 1 Battery voltage 17 volts 2 Bad connection at battery or controller 1 5 OVERVOLTAGE FAULT Battery voltage too high 1 Battery voltage 31 volts 2 Vehicle operating with charger attached 3 Intermittent battery connection 2 1 ...

Page 37: ... 4 BRAKE OFF FAULT Brake Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil shorted 3 5 HPD FAULT HPD High Pedal Disable 1 Improper sequence of throt tle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 CURRENT SENSE FAULT Current sense out of range 1 Short in motor or in motor wir ing 2 Controller failure 4 2 HARDWARE FAILSAFE Motor voltage out of range 1 Moto...

Page 38: ...4 20 BL GL22 1119 11 20 2019 NOTES ...

Page 39: ...G ARM CONTROL HEAD AND COMPARTMENT 5 1 CONTROL HEAD 5 1 1 Cap Assembly Removal 1 Engage the emergency stop switch and turn off key switch 2 Remove four screws lift up cap assembly and disconnect harness from harness Figure 5 1 Control Head EF_0006 ...

Page 40: ...lation 1 Hold cap assembly in place and connect harness to harness 2 Position cap assembly on control head and secure with four screws 1 Disengage the emergency stop switch and turn on key switch Figure 5 2 Steering Arm 5 1 3 Control Head Removal EF_0005 ...

Page 41: ...ock washer and flat washer 6 Remove screw lock washer and flat washer and remove potentiometer from bracket 7 Position new potentiometer in bracket and secure with screw lock washer and flat washer 8 Install screw lock washer and flat washer 9 Install control knob on potentiometer and secure with screw and washer 10 Install control knob on the other side of potentiom eter and secure with screw and...

Page 42: ...s 11 Figure 5 4 bracket and springs from button 10 3 Remove two pins and defective switch from the bracket 4 Unsolder harness from defective switch and con nect it to the new switch 5 Position the new switch in the bracket and secure with the two pins 6 Position button 10 in cover 1 and secure with three screws 11 7 Install the cap assembly as described in para graph 5 1 2 EF_0006 ...

Page 43: ...BL GL22 1119 11 20 2019 5 5 Figure 5 4 Cap Assembly EF_0007 ...

Page 44: ...at 7 Position the opposite end of the gas return spring on bracket and install screw 8 Install rotating cover and secure with three screws 9 Disengage the emergency stop switch and turn on key switch 5 2 2 Steering Arm Removal 1 Engage the emergency stop switch and turn off key switch 2 Remove the return spring as described in para graph 5 2 1 3 Disconnect harness from harness 4 Attach a hoist to ...

Page 45: ...k load wheels 2 Jack up the truck to gain access to the brake then securely block the truck to prevent move ment 3 Disconnect electric brake from harness 4 Remove the two mounting screws and the brake 5 Place the new brake into position and secure with the two mounting screws 6 Reconnect electric brake to harness 7 Remove the blocking and lower the truck to the ground 8 Remove load wheel blocks an...

Page 46: ...6 2 BL GL22 1119 11 20 2019 Figure 6 1 Transmission Motor Brake Assembly EF_0004 ...

Page 47: ...l 7 2 TRANSMISSION 1 Engage the emergency stop switch and turn off key switch 2 Remove the compartment covers as described in paragraph 5 3 3 Remove the steering arm as described in para graph 5 2 4 Raise the truck off the ground to provide clear ance for transmission out the bottom Securely block the truck to prevent movement 5 Remove two screws and bracket 6 Disconnect electric brake from harnes...

Page 48: ...7 2 BL GL22 1119 11 20 2019 Figure 7 1 Transmission Motor Brake Mounting EF_0004 ...

Page 49: ...eel assembly NOTE Inspect the load wheel assembly If the load wheel is worn within 1 8 of the metal sleeve or is cracked or damaged replace the entire load wheel and bearing assembly Global Industrial recommends that both load wheel assemblies be replaced at the same time This ensures level and safe operation of the lift truck 7 3 2 Repair 1 Remove bearings from wheels 2 Inspect bearings and repla...

Page 50: ...7 4 BL GL22 1119 11 20 2019 NOTES ...

Page 51: ...cated the above either the frame or the lift carriage to allow for adjustment of middle jam nut 4 Break the lower jam nut free from the middle jam nut 5 Take up slack in the lift chain with middle jam nut 6 Align anchor so the clevis pin is parallel to the mast CAUTION At least 3 full threads must be present below lower nut after adjustment 7 Tighten jam nuts securely while maintaining align ment ...

Page 52: ...N REPLACEMENT 1 With the lift truck wheels securely blocked raise the forks approximately three feet from floor and position blocks or strong supports under the lift carriage 2 Lower lift carriage onto the support Check that arrangement is secure before proceeding 3 Engage the emergency stop switch and turn off key switch WARNING Before attempting any replacement make certain power is disconnected...

Page 53: ... windshield as described in paragraph 5 4 CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 5 Refer to Figure 9 1 and remove leaking line or fit ting and replace it with a new line or fitting 6 Check level of hydraulic oil If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 ...

Page 54: ...c reservoir Use hydraulic oil listed in Table 3 3 5 Disengage the emergency stop switch and turn on key switch 6 Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil 7 Check level of hydraulic oil If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 3 8 Install the compartment covers as described in paragraph 5 3 9 3 LIFT CYLI...

Page 55: ...BL GL22 1119 11 20 2019 9 3 Figure 9 2 Elevation System Telescopic EF_0016 ...

Page 56: ...o lock washers two flat washers 3 Install ram head on top of cylinder and secure with screw lock washer and flat washer 4 Install the lift chain as described in paragraph 8 4 5 Install connector and seal 6 Reconnect the hose to the bottom of lift cylinder 7 Reconnect the hose to the top of lift cylinder 8 Fill the hydraulic reservoir Use hydraulic oil listed in Table 3 3 9 Disengage the emergency ...

Page 57: ... Remove any dirt or corrosion from the bus bar area The controller should be wiped clean with a moist rag Allow it to dry before reconnecting the battery 10 1 3 Controller Removal 1 Engage the emergency stop switch and turn off key switch 2 Remove the compartment covers as described in paragraph 5 3 3 Tag and disconnect harness from controller 4 Tag and disconnect remaining leads from the con trol...

Page 58: ...10 2 BL GL22 1119 11 20 2019 Figure 10 1 Electrical System Telescopic EF_0011 ...

Page 59: ...10 1 12 Battery Indicator Installation 1 Position battery indicator on the bracket and secure with its mounting bracket and nuts 2 Reconnect harness from battery indicator 3 Install upper compartment covers as described in paragraph 5 3 4 Disengage the emergency stop switch and turn on key switch 10 1 13 LED Indicator Removal 1 Engage the emergency stop switch and turn off key switch 2 Remove the ...

Page 60: ... on key switch 10 2 PUMP MOTOR The pump motor is replaceable but not repairable Refer to paragraph 9 2 10 3 DRIVE MOTOR The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of motor Use an air hose to blow dust off of motor sur faces The drive motor is replaceable but not repairable Refer to paragraph 7 2 10 4 DEADMAN SWITCH 1 Engage the emergency stop ...

Page 61: ...BL GL22 1119 11 20 2019 11 1 SECTION 11 OPTIONAL EQUIPMENT N ABL GL22 1119 11 20 2019 ...

Page 62: ...11 2 BL GL22 1119 11 20 2019 NOTES ...

Page 63: ...BL GL22 1119 11 20 2019 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the 989021 Lift Truck ...

Page 64: ...12 2 BL GL22 1119 11 20 2019 Figure 12 1 Frame System Telescopic Mast EF_0002 ...

Page 65: ...76 00 FLAT WASHER Ø8 4 9 0000 000159 00 LOCK WASHER Ø8 14 10 1115 150004 0C SCREW M6 16 2 11 2125 101002 0A SHAFT 2 12 2101 600003 00 WASHER 2 13 0000 000055 00 SCREW M6 16 2 14 0000 000380 00 FLAT WASHER Ø6 2 15 2108 100001 10 01 WASHER A R As Required THK 1mm 15 2108 100001 10 02 WASHER A R As Required THK 3mm 16 2101 120000 XK CASTER ASSEMBLY SEE 0103 1 17 0000 000026 00 SCREW M8 30 3 18 0000 0...

Page 66: ...12 4 BL GL22 1119 11 20 2019 Figure 12 2 Caster Assembly EF_0003 ...

Page 67: ...00 BEARING 1 5 0000 000762 00 RETAINER RING Ø62 1 6 2101 121000 XK YOKE 1 7 2140 142000 00 HINGE PIN 1 8 0000 000255 00 BOLT M8 20 2 9 2101 145000 XK SHAFT 1 10 2105 133002 00 AE PU WHEEL 1 11 3090 010000 23 BEARING 6204 2Z 2 12 2028 000000 56 FLAT WASHER Ø20 2 13 3010 010000 59 BOLT M10 100 2 14 2101 123000 XK YOKE 1 15 2140 140004 00 SPRING 2 16 2101 120009 XK PLATE 2 17 3030 000000 24 NUT M10 2...

Page 68: ...12 6 BL GL22 1119 11 20 2019 Figure 12 3 Transmission Motor and Brake EF_0004 ...

Page 69: ...0 CLIP Ø42 1 15 0000 000659 00 CLIP Ø15 2 16 0000 000667 00 BEARING 1 17 1115 GSX 10 GEAR KIT 1 18 0000 000680 00 BEARING 1 19 1115 GSX 20 GEAR KIT 1 20 0000 000660 00 PARALLEL KEY 5 5 18 1 21 0000 000026 00 SCREW M8 30 11 22 0000 000159 00 LOCK WASHER Ø8 5 23 0000 000670 00 OIL SEAL Ø155 172 10 1 24 1115 200021 D0 SCREW M5 30 6 25 1115 200022 D0 SCREW M6 25 6 26 0000 000662 00 PARALLEL KEY 5 5 12...

Page 70: ...12 8 BL GL22 1119 11 20 2019 Figure 12 4 Steering System EF_0005 ...

Page 71: ... 310003 00 ROLLER 1 4 1127 300101 00 SPRING 1 5 1127 300102 00 SPRING TOP ROD 1 6 1127 300103 0A SPRING BASE 1 7 1116 300001 0A SHAFT 2 8 0000 000589 00 RETAINER RING Ø16 4 9 2101 300001 00 BRACKET 1 10 1127 300002 0A BUFFER BLOCK 1 11 1125 52000Z 10 INCHING SWITCH ASSEMBLY 1 With Wire 12 0000 000677 00 BEARING 1610F 2 13 0000 000004 00 SCREW M5 12 1 14 0000 000120 00 SCREW M2 8 2 ...

Page 72: ...12 10 BL GL22 1119 11 20 2019 Figure 12 5 Control Head EF_0006 ...

Page 73: ...WITCH 1 8 0000 000323 00 SCREW M5 16 1 9 0000 000390 00 FLATWASHER Ø5 1 10 1115 340007 00 WIRE HARNESS COVER 1 11 1120 520009 00 REVERSING SWITCH WIRE 1 12 0000 000989 00 SCREW M2 12 2 13 1115 340003 00 COVER 1 14 1121 310004 00 SPRING 2 15 1115 340002 10 COVER 1 16 0000 000322 00 SCREW M8 25 4 17 0000 000159 00 LOCKWASHER Ø8 4 18 0000 000176 00 FLATWASHER Ø8 4 19 1115 340001 00 WASHER 2 20 1115 5...

Page 74: ...12 12 BL GL22 1119 11 20 2019 Figure 12 5 Cap Assembly EF_0007 ...

Page 75: ...L 1 8 1120 342103 00 BUTTON FOR LOWERING L 1 9 1120 342101 00 BUTTON BRACKET L 1 10 1120 342300 00 HORN BUTTON ASSEMBLY 1 11 0000 000039 00 SCREW ST3 5 9 5 3 12 1220 56003X 00 INCHING SWITCH 1 13 1120 342200 00 LIFT AND LOWER BOX R ASSEMBLY 1 14 1120 342100 00 LIFT AND LOWER BOX L ASSEMBLY 1 15 1220 520006 0C BUTTONS ASSEMBLY 1 16 1220 560002 00 INCHING SWITCH II 5 17 1120 342002 00 HORN BUTTON 1 ...

Page 76: ...12 14 BL GL22 1119 11 20 2019 Figure 12 6 Hydraulic System EF_0008 ...

Page 77: ...INDER 1 Lift Height 116 3000mm 2 2101 413000 00 HYDRAULIC PUMP ASSEMBLY 1 3 2401 163900 00 BOLT M16 39 2 4 0000 000069 00 WASHER Ø16 4 5 2101 431000 00 OIL PIPE 1 6 0000 000196 00 NUT M8 2 7 0000 000159 00 LOCK WASHER Ø8 2 8 0000 000176 00 FLAT WASHER Ø8 2 9 2108 440000 00 EXPLOSION RELIEF VALVE 1 10 3020 000002 23 BOLT 2 ...

Page 78: ...12 16 BL GL22 1119 11 20 2019 Figure 12 7 Pump and Motor Assembly EF_0010 ...

Page 79: ... 41331X 00 WASHER Ø8 2 11 2101 41332X 00 SCREW M8 95 2 12 2101 41333X 00 FILTER 1 13 2101 41334X 00 INLET TUBE 1 14 2101 41335X 00 MAGNET SHEET 1 15 2101 41336X 00 BOLT M5X12 4 16 2101 41337X 00 TANK 4L 1 17 2101 41338X 00 TANK TOP 1 18 3231 74022X 00 CLAMP 80 100MM 1 19 2101 41339X 00 WASHER 4 20 2101 41340X 00 RETURN PIPE 1 21 2101 41341X 00 RETURN PIPE 1 22 2101 41342X 00 CONNECTOR 1 23 2101 41...

Page 80: ...12 18 BL GL22 1119 11 20 2019 Figure 12 8 Lift Cylinder EF_0009 ...

Page 81: ...ER Pos Part Number Description Qty Reqd Notes 1 2101 410004 01 RING BACK UP Ø45 40 15 1 2 ROD PACKING Ø45 35 6 1 3 O RING Ø54 2 4 1 4 RING WIPER Ø32 40 5 6 5 1 5 2101 410009 00 MUFFLER 1 KIT 2101 QJYG 0A SEAL KIT FOR CYLINDER 1 Incl Pos 2 3 4 ...

Page 82: ...12 20 BL GL22 1119 11 20 2019 Figure 12 9 Telescopic Mast Lift System EF_0016 ...

Page 83: ... Ø12 1 4 0000 000373 00 FLAT WASHER Ø12 1 5 0000 000325 00 SCREW M12 20 1 6 2101 140001 00 CONNECTION BLOCK 2 7 2101 140005 00 WASHER 1 8 0000 000415 00 BOLT M8 16 2 9 0000 000159 00 LOCK WASHER Ø8 4 10 0000 000176 00 FLAT WASHER Ø8 4 11 2101 140003 00 SHAFT 2 12 2101 140002 00 ROLLER 2 13 0000 001101 00 SCREW M8 20 4 14 2101 600018 00 PLATE 1 15 0000 001444 00 RETAINER RING Ø8 2 16 2101 65000X 00...

Page 84: ...12 22 BL GL22 1119 11 20 2019 Figure 12 10 Telescopic Mast Chain Assembly EF_0017 ...

Page 85: ...G Ø40 2 4 2108 600003 0B WASHER 2 5 2105 640000 6C 03 CHAIN 1 Lift Height 116 3000mm 6 2108 640002 0A SHAFT 1 7 0000 000188 00 PIN Ø3 2 20 3 8 0000 000237 00 NUT M16 1 5 2 9 2108 640001 0C BOLT 1 10 2105 600002 60 CHAIN ANCHOR 1 11 0000 000176 00 FLAT WASHER Ø8 2 12 2105 600012 60 PLATE 1 13 3020 010000 91 SCREW M5 25 1 14 0000 000206 00 LOCK WASHER Ø5 1 15 0000 000390 00 FLAT WASHER Ø5 1 ...

Page 86: ...12 24 BL GL22 1119 11 20 2019 Figure 12 11 Fork Carriage EF_0018 ...

Page 87: ...1 10 01 FORK 2 3 0000 000374 00 SCREW M12 30 4 4 3040 000000 22 LOCK WASHER Ø12 4 5 3040 000000 09 FLAT WASHER Ø12 5 6 2101 631000 10 FORK FRAME 1 For Telescopic Mast 7 2101 65000X 00 ROLLER ASSEMBLY 4 8 0000 000434 00 RETAINER RING Ø30 4 9 2125 632000 0A BLOCKING SHELF 1 For Telescopic Mast 10 3020 010000 67 SCREW M12 25 1 ...

Page 88: ...12 26 BL GL22 1119 11 20 2019 Figure 12 12 Electrical System EF_0011 ...

Page 89: ...00 SCREW M6 16 2 17 1120 500006 00 LIMIT SWITCH 1 18 2101 100003 50 PLATE 1 19 0000 000121 00 SCREW M4 35 2 20 1115 510004 00 20 CONTROLLER 1 21 2112 410005 00 RUBBER CUSHION 2 22 2101 100005 00 LONG SCREW 1 23 2101 100004 00 BRACKET 1 24 1121 100004 00 RUBBER CUSHION 2 25 1115 500005 00 07 BATTERY 2 26 3020 000000 05 SCREW M6 15 2 27 0000 000056 00 LOCK WASHER Ø6 4 28 0000 000380 00 FLAT WASHER Ø...

Page 90: ...12 28 BL GL22 1119 11 20 2019 Figure 12 13 Wiring Harness EF_0012 ...

Page 91: ... 20 2019 12 29 WIRING HARNESS Pos Part Number Description Qty Reqd Notes 1 2101 520001 CF MASTER WIRING HARNESS 1 2 1113 520025 00 FUSE 5A 1 3 2108 520003 Q0 INTEGRATED BOARD 1 4 2101 520003 00 LIMIT SWITCH HARNESS 1 ...

Page 92: ...12 30 BL GL22 1119 11 20 2019 Figure 12 14 Wiring Cables EF_0013 ...

Page 93: ...y Reqd Notes 1 2105 530003 00 SWITCH BATTERY CABLE 1 2 2101 530002 10 FUSE SWITCH CABLE 1 3 2101 530007 00 BATTERY CONNECTOR CABLE 2 4 2101 530004 10 CONTROLLER 1 5 2101 530005 1A CONTROLLER 1 6 2108 530008 00 C2 CABLE 1 7 2101 530011 10 M2 CABLE 1 8 2101 530010 10 M1 CABLE 1 ...

Page 94: ......

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