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9-2
BL-GL22-1119 - 11-20-2019
9-2. HYDRAULIC PUMP, MOTOR AND RESERVOIR
ASSEMBLY
The hydraulic pump/motor assembly can be disas-
sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo-
nent.
WARNING:
When forks are raised, pressure exists in
the hydraulic system 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 fully.
2.
Engage the emergency stop switch (and turn off
key switch.
3.
Remove the compartment covers as described in
paragraph
4.
Tag and disconnect electrical leads from motor
and solenoid of pump/motor assembly.
NOTE:
The reservoir and hose will be filled with
hydraulic oil. Place a container under the
pump assembly to catch any hydraulic oil.
5.
Disconnect hose from pump/motor assembly.
6.
While supporting pump/motor assembly, remove
four screws and four lock washers.
7.
Remove the pump/motor assembly.
9-2.2. Disassembly and Reassembly
1.
Remove the hydraulic pump/motor assembly as
described in paragraph
2.
sembly.
9-2.3. Installation
1.
While supporting the pump/motor assembly (,
install four screws and four lock washers.
2.
Reconnect hose to pump/motor assembly.
3.
Connect electrical leads to motor and solenoid of
pump/motor assembly.
4.
Fill the hydraulic reservoir. Use hydraulic oil listed
in
.
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
8.
Install the compartment covers as described in
paragraph
9-3. LIFT CYLINDER
9-3.1. Removal
1.
With the lift truck wheels securely blocked, raise
the forks approximately three feet from floor and
position blocks or strong supports under 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.
CAUTION:
Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
4.
Remove the compartment covers as described in
paragraph
5.
Remove the windshield as described in paragraph
6.
Remove the lift chain as described in paragraph
7.
Disconnect the hose from the top of lift cylinder.
8.
Disconnect the hose from the bottom of lift cylin-
der and remove connector and seal.
9.
Manually push the cylinder rod down as far as
possible.
10. Remove screw, lock washer, flat washer and ram
head from cylinder.
WARNING: Support lift cylinder before performing
the following steps to prevent cylinder
from falling.
11. Remove two bolts, two lock washers, two flat
washers and clip.
12. Raise lift cylinder assembly up and out of truck.
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: ......