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TABLE OF CONTENTS
BL-GL22-1119 - 11-20-2019
1
1 DESCRIPTION ............................................................1-1
INTRODUCTION. .........................................1-1
GENERAL DESCRIPTION. ..........................1-1
1-3
SAFETY FEATURES....................................1-1
2 OPERATION ...............................................................2-1
GENERAL.....................................................2-1
2-2
OPERATING PRECAUTIONS......................2-1
2-3
BEFORE OPERATION.................................2-2
GENERAL CONTROL OPERATION. ...........2-4
DRIVING AND STOPPING PROCEDURES 2-4
STOPPING ...................................................2-4
BELLY-BUTTON SWITCH............................2-5
STEERING ARM GAS SPRING. ..................2-5
LIFT AND LOWER CONTROLS...................2-5
LOADING AND UNLOADING.......................2-5
PARKING......................................................2-5
3 PLANNED MAINTENANCE ........................................3-1
GENERAL.....................................................3-1
MONTHLY AND QUARTERLY CHECKS.....3-1
BATTERY CARE. .........................................3-1
GENERAL.....................................................3-1
SAFETY RULES ...........................................3-2
BATTERY CARE AND CHARGING .............3-2
MAINTENANCE FREE BATTERIES ............3-2
3-4
CHARGING BATTERIES..............................3-2
CHANGING BATTERIES..............................3-4
LUBRICATION..............................................3-4
3-7
LIFT CHAIN MAINTENANCE. ......................3-4
4 TROUBLESHOOTING ................................................4-1
GENERAL.....................................................4-1
CONTROLLER TROUBLESHOOTING ........4-5
FAULT DETECTION.....................................4-5
HAND HELD PROGRAMMER (OPTIONAL) 4-5
FAULT RECORDING....................................4-5
GENERAL CHECKOUT................................4-5
DIAGNOSTIC HISTORY...............................4-6
TEST FAULT DETECTION CIRCUITRY ......4-6
PROGRAMMABLE PARAMETERS .............4-7
DIAGNOSTICS AND
TROUBLESHOOTING................................4-16
4-2.8.1 LED DIAGNOSTICS ...................................4-16
4-2.9
PROGRAMMER DIAGNOSTICS................4-16
5 STEERING ARM, CONTROL HEAD AND
COMPARTMENT ........................................................5-1
5-1
CONTROL HEAD .........................................5-1
CAP ASSEMBLY REMOVAL........................5-1
CAP ASSEMBLY INSTALLATION................5-2
CONTROL HEAD REMOVAL.......................5-2
CONTROL HEAD INSTALLATION...............5-3
SPEED POTENTIOMETER
REPLACEMENT...........................................5-3
BELLY-BUTTON SWITCH REPLACEMENT5-3
HORN SWITCH REPLACEMENT................ 5-4
LIFT AND LOWER SWITCH
REPLACEMENT. ......................................... 5-6
STEERING ARM.......................................... 5-6
RETURN SPRING REPLACEMENT............ 5-6
STEERING ARM REMOVAL. ...................... 5-6
STEERING ARM INSTALLATION. .............. 5-6
COMPARTMENT COVERS ......................... 5-6
REMOVAL.................................................... 5-6
INSTALLATION............................................ 5-6
WINDSHIELD............................................... 5-6
REMOVAL.................................................... 5-6
5-4.2
INSTALLATION............................................ 5-6
6 BRAKE SERVICING ................................................... 6-1
BRAKES....................................................... 6-1
BRAKE ASSEMBLY REPLACEMENT......... 6-1
7 TRANSMISSION, DRIVE WHEEL AND
LOAD WHEEL ............................................................ 7-1
7-1
DRIVE WHEEL. ........................................... 7-1
7-2
TRANSMISSION.......................................... 7-1
7-3
LOAD WHEEL.............................................. 7-3
REMOVAL.................................................... 7-3
REPAIR........................................................ 7-3
LOAD WHEEL INSTALLATION ................... 7-3
8 ELEVATION SYSTEM SERVICING ........................... 8-1
GENERAL. ................................................... 8-1
LIFT CHAIN LENGTH ADJUSTMENT. ........ 8-1
LIFT CHAIN WEAR INSPECTION. .............. 8-2
8-4
LIFT CHAIN REPLACEMENT...................... 8-2
LIFT CYLINDERS. ....................................... 8-2
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
LINES AND FITTINGS................................. 9-1
HYDRAULIC PUMP, MOTOR AND
RESERVOIR ASSEMBLY............................ 9-2
REMOVAL.................................................... 9-2
DISASSEMBLY AND REASSEMBLY .......... 9-2
INSTALLATION............................................ 9-2
LIFT CYLINDER........................................... 9-2
REMOVAL.................................................... 9-2
REPAIR........................................................ 9-4
INSTALLATION............................................ 9-4
10 ELECTRICAL COMPONENTS ................................. 10-1
ELECTRICAL CONTROL PANEL.............. 10-1
MAINTENANCE ......................................... 10-1
CLEANING................................................. 10-1
CONTROLLER REMOVAL ........................ 10-1
CONTROLLER INSTALLATION. ............... 10-1
CHARGER REMOVAL............................... 10-1
CHARGER INSTALLATION....................... 10-1
BUZZER REMOVAL .................................. 10-3
Summary of Contents for 989021
Page 9: ...BL GL22 1119 11 20 2019 2 3 Figure 2 2 Sample of Operator Check List R8549 ...
Page 12: ...2 6 BL GL22 1119 11 20 2019 NOTES ...
Page 18: ...3 6 BL GL22 1119 11 20 2019 NOTES ...
Page 38: ...4 20 BL GL22 1119 11 20 2019 NOTES ...
Page 43: ...BL GL22 1119 11 20 2019 5 5 Figure 5 4 Cap Assembly EF_0007 ...
Page 46: ...6 2 BL GL22 1119 11 20 2019 Figure 6 1 Transmission Motor Brake Assembly EF_0004 ...
Page 48: ...7 2 BL GL22 1119 11 20 2019 Figure 7 1 Transmission Motor Brake Mounting EF_0004 ...
Page 50: ...7 4 BL GL22 1119 11 20 2019 NOTES ...
Page 55: ...BL GL22 1119 11 20 2019 9 3 Figure 9 2 Elevation System Telescopic EF_0016 ...
Page 58: ...10 2 BL GL22 1119 11 20 2019 Figure 10 1 Electrical System Telescopic EF_0011 ...
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 64: ...12 2 BL GL22 1119 11 20 2019 Figure 12 1 Frame System Telescopic Mast EF_0002 ...
Page 66: ...12 4 BL GL22 1119 11 20 2019 Figure 12 2 Caster Assembly EF_0003 ...
Page 68: ...12 6 BL GL22 1119 11 20 2019 Figure 12 3 Transmission Motor and Brake EF_0004 ...
Page 70: ...12 8 BL GL22 1119 11 20 2019 Figure 12 4 Steering System EF_0005 ...
Page 72: ...12 10 BL GL22 1119 11 20 2019 Figure 12 5 Control Head EF_0006 ...
Page 74: ...12 12 BL GL22 1119 11 20 2019 Figure 12 5 Cap Assembly EF_0007 ...
Page 76: ...12 14 BL GL22 1119 11 20 2019 Figure 12 6 Hydraulic System EF_0008 ...
Page 78: ...12 16 BL GL22 1119 11 20 2019 Figure 12 7 Pump and Motor Assembly EF_0010 ...
Page 80: ...12 18 BL GL22 1119 11 20 2019 Figure 12 8 Lift Cylinder EF_0009 ...
Page 82: ...12 20 BL GL22 1119 11 20 2019 Figure 12 9 Telescopic Mast Lift System EF_0016 ...
Page 84: ...12 22 BL GL22 1119 11 20 2019 Figure 12 10 Telescopic Mast Chain Assembly EF_0017 ...
Page 86: ...12 24 BL GL22 1119 11 20 2019 Figure 12 11 Fork Carriage EF_0018 ...
Page 88: ...12 26 BL GL22 1119 11 20 2019 Figure 12 12 Electrical System EF_0011 ...
Page 90: ...12 28 BL GL22 1119 11 20 2019 Figure 12 13 Wiring Harness EF_0012 ...
Page 92: ...12 30 BL GL22 1119 11 20 2019 Figure 12 14 Wiring Cables EF_0013 ...
Page 94: ......