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Global 989021 Operation, Maintenance, Repair Parts List

Self-propelled, straddle lift truck
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MODEL 989021
SELF-PROPELLED,
STRADDLE LIFT TRUCK
Operation
Maintenance
Repair Parts List
Global Industrial
MANUAL NO. BL-GL22-1119 - 11-20-2019
globalindustrial.com

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Summary of Contents for Global 989021

  • Page 1 MODEL 989021 SELF-PROPELLED, STRADDLE LIFT TRUCK Operation Maintenance Repair Parts List Global Industrial MANUAL NO. BL-GL22-1119 - 11-20-2019 globalindustrial.com...
  • Page 2 WARNING Do not operate this truck unless you have been autho- Do not overload truck. Check nameplate for capacity rized and trained to do so, and have read all warnings and load center information. and instructions in Operator’s Manual and on this When using forks, space forks as far apart as load will truck.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Page Section Page 1 DESCRIPTION ............1-1 5-1.7 HORN SWITCH REPLACEMENT....5-4 INTRODUCTION..........1-1 5-1.8 LIFT AND LOWER SWITCH GENERAL DESCRIPTION......1-1 REPLACEMENT.......... 5-6 SAFETY FEATURES........1-1 STEERING ARM .......... 5-6 5-2.1 RETURN SPRING REPLACEMENT.... 5-6 2 OPERATION ...............2-1 5-2.2 STEERING ARM REMOVAL.
  • Page 4 TABLE OF CONTENTS - Continued Section Page Section Page 10-1.10 KEY SWITCH INSTALLATION....10-3 10-1.18 LIFT LIMIT SWITCH INSTALLATION..10-4 10-1.11 BATTERY INDICATOR REMOVAL... 10-3 10-2 PUMP MOTOR........... 10-4 10-1.12 BATTERY INDICATOR INSTALLATION. .. 10-3 10-3 DRIVE MOTOR.

  • Page 5: Description

    • Dead-man brake to apply the brake and cut off drive power when the steering arm is released. speed range. The 989021 lift truck can be driven with forks raised or lowered; however, the speed is • Emergency brake switch to apply the brake and cut restricted when the platform is raised above a preset off drive power when depressed.
  • Page 6 R8560 Figure 1-2 989021 Lift Truck ITEM COMPONENT ITEM COMPONENT Load wheel Control handle. Power plug Drive wheel Battery indicator display Cover Key switch Battery Lowering button Caster wheel Lift button Hydraulic pump and motor assembly Directional/speed control knob Chassis...

  • Page 7: Operation

    This section gives detailed operating instructions for and loaded. the 989021 lift truck. The instructions are divided into the various phases of operations, such as operating • Be sure that mast is vertical - do not operate on a lift, driving, and stopping.

  • Page 8: Before Operation

    All Table 2-1 covers important inspection points on the service must be performed by a qualified 989021 lift truck which should be checked prior to maintenance technician. operation. Depending on use, some trucks may require additional checks.
  • Page 9 R8549 Figure 2-2 Sample of Operator Check List BL-GL22-1119 - 11-20-2019...

  • Page 10: General Control Operation

    2-4. GENERAL CONTROL OPERATION. Lower the steering arm to a comfortable position above horizontal to disengage the brake and to The speed control (See Figure 2-3) located on each energize the electrical circuits. If the truck is not side of the control head provides fingertip control for moved, the electrical circuits will time out and will driving the truck.

  • Page 11: Belly-Button Switch

    2-7. STEERING ARM GAS SPRING. The steering arm gas spring automatically raises the steering arm to the upright position when the steering arm is released. If the steering arm does not return fully, the steering arm gas spring requires replace- ment.
  • Page 12 NOTES BL-GL22-1119 - 11-20-2019...

  • Page 13: Planned Maintenance

    3-3.1. General A voltage check from battery connector terminal to The 989021 is equipped with maintenance free batter- battery case should indicate near zero volts. Typically, ies. however, the sum of the voltages at both terminals will The care and maintenance of the battery is very equal battery volts.

  • Page 14: 3-3.2 Safety Rules

    3-3.2. Safety Rules Make certain battery used meets weight and size requirements of truck. NEVER operate truck with • Wear protective clothing, such as rubber apron, an undersized battery. gloves, boots and goggles when performing any maintenance on batteries. Do not allow electrolyte to 3-3.4.
  • Page 15 R8561 Figure 3-1 Battery Charging Battery Charging LED Table 3-2 Battery Charging LED Light (2) DISPLAY DESCRIPTION TROUBLESHOOTING Solid Red Battery is charging Normal operation. Solid Green Battery is fully charged Normal operation. The battery voltage is less than 13V or greater than Solid Yellow Battery failure 32.5V.

  • Page 16: Changing Batteries

    R8562 Figure 3-2 Changing Battery pivoting freely. With lift carriage fully lowered, spray or brush on a film of SAE 30 or 40 engine oil. 3-5. CHANGING BATTERIES Table 3-3 Recommended Lubricants Park truck at charging station with carriage lowered (See Table 3-4 for Application)
  • Page 17 R8563 Figure 3-3 Lubrication Diagram Table 3-4 Lubrication Chart FIG 3-2 LOCATION METHOD OF TYPE APPLICATION INDEX APPLICATION (Table 3-3) LUBRICANT Inner & Outer Mast Brush No. 2 Full length of channel where rollers operate. Lift Chain Brush or Spray No.
  • Page 18 NOTES BL-GL22-1119 - 11-20-2019...

  • Page 19: Troubleshooting

    SECTION 4 TROUBLESHOOTING 4-1. GENERAL ate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Lower- Table 4-1 as a guide to determine possible ing, and Miscellaneous malfunctions. causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Oper- BL-GL22-1119 - 11-20-2019...
  • Page 20 Table 4-1 Troubleshooting Chart MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TRUCK AND HYDRAULIC SYSTEM WILL NOT OPERATE Check fuse and replace if a. Fuse blown. necessary. Check fuse and replace if b. Fuse blown. necessary. Check battery connections and c. Battery dead or disconnected. check battery voltage.
  • Page 21 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING Check deadman switch for continuity. If none found when a. Defective deadman switch. the control arm is in the brake Truck does not slow with brake, or position, replace switch.
  • Page 22 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Check the oil level in the reservoir and the oil lines to the lift cylin- der, and repair as required. If Forks do not lift, motor runs. Defect in hydraulic system.

  • Page 23: Controller Troubleshooting

    LED. 4-2.2. Hand Held Programmer (Optional) The hand held programmer is available that is designed specifically for use with the controller. The programmer is available through your Global Industrial dealer. 4-2.3. Fault Recording. R6759 Fault events are recorded in the controller's memory.

  • Page 24: 4-2.5 Diagnostic History

    Put the controller into the diagnostic mode by that the circuit is operational by momentarily dis- pressing the "Menu Navigation Key" (1, Figure 4- connecting one of the emergency reverse wires. 2). Using the Navigation key, select the Faults The vehicle should be disabled and a fault indi- menu.

  • Page 25: 4-2.7 Programmable Parameters

    Leave the key switch on and remove the in-line The programmable parameters are grouped hierarchi- fuse wire. The vehicle status should continue to cally into menus, as shown in Table 4-2. remain off. The MultiMode feature of the controller allows oper- Cycle the key switch off and on.
  • Page 26 Table 4-2 Programmable Parameters Parameter Factory Setting Description DRIVE MENU Sets the rate (in seconds) at which the speed command increases when throttle is applied with the speed limit pot is in its maximum speed position, and the vehicle is traveling Accel Max Speed forward.
  • Page 27 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description DRIVE MENU - Continued Sets the rate (in seconds) that is used to slow down the vehicle when it is traveling in reverse at low speed and throttle is Rev Decel Low reduced.
  • Page 28 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description SPEED MENU During forward operation, defines the requested speed at full throttle when the speed limit pot is in its maximum speed position. M1/M2 Max Speed 100% Note: Allowable range is restricted by the M1/M2 Min Speed setting.
  • Page 29 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU The 1212 controller can accept inputs from both 5k, 3-wire pot throttles and voltage throttles. Set the throttle type param- eter to match the throttle used in your application. 5k, 3-wire pot throttles 0 = wigwag 1 = inverted wigwag...
  • Page 30 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU - Continued The throttle map parameter adjusts the static throttle map. The parameter setting corresponds to the throttle command at half throttle. Throttle Map A setting of 50% provides linear response. Values below 50% reduce the throttle command at low throttle positions, provid- ing enhanced slow speed maneuverability.
  • Page 31 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description INHIBIT MENU The flexible speed input at J1 Pin 6 can be used to limit or to inhibit speed under certain conditions. For example, a switch could be installed under the seat so that if the operator drives the scooter while they are standing the max speed will be lim- ited.
  • Page 32 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description HORN MENU - Continued Sets the reverse beep to be a constant tone (when pro- Beep Constant grammed On) or a 1Hz pulse (when programmed Off). MOTOR MENU Sets the system resistance (motor + brushes + wiring + con- nections) used for load compensation and speed estimation.

  • Page 33: 4-2.8 Diagnostics And Troubleshooting

    Parameter Factory Setting Description BDI MENU - Continued Voltage above which the battery is considered to start charging. Start Charger 28.1 Voltage Note: Allowable range is restricted by the Full Voltage and Full Charge Voltage settings. Voltage at which the BDI calculator will be reset to 100%, after the charger is disconnected and the controller is powered up.

  • Page 34: 4-2.8.1 Led Diagnostics

    The motor controller provides diagnostics information For suggestions about possible causes of the various to assist in troubleshooting drive system problems. faults, refer to Table 4-4 Troubleshooting Chart. The diagnostics information can be obtained in two 4-2.9. Programmer Diagnostics ways: With a programmer, diagnostics and troubleshooting is •...
  • Page 35 Table 4-3 LED Codes LED BLINKS LED BLINKS Error Message digit 1 digit 2 THERMAL FAULT THROTTLE FAULT SPEED POT FAULT UNDERVOLTAGE FAULT OVERVOLTAGE FAULT MAIN OFF FAULT (not used) MAIN FAULT MAIN ON FAULT (not used) WIRING FAULT BRAKE ON FAULT PRECHARGE FAULT Table 4-3 LED Codes- Continued LED BLINKS...
  • Page 36 Table 4-4 Troubleshooting Chart Error Message BLINKS BLINKS EXPLANATION Possible cause Error text digit 1 digit 2 1. Temperature >80°C or < - 10°C. Excessive load on vehicle. Over-/under-temperature THERMAL FAULT Operation in extreme environ- cutback ments. Electromagnetic brake not releasing.
  • Page 37 Table 4-4roubleshooting Chart - Continued Error Message BLINKS BLINKS EXPLANATION Possible cause Error text digit 1 digit 2 1. Misadjusted throttle. WIRING FAULT HPD fault present >10 sec. Broken throttle pot or throttle mechanism. 1. Electromagnetic brake driver shorted. BRAKE ON FAULT Brake On fault Electromagnetic brake coil open.
  • Page 38 NOTES 4-20 BL-GL22-1119 - 11-20-2019...

  • Page 39: Steering Arm, Control Head And Compartment

    SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD Remove four screws, lift up cap assembly and disconnect harness from harness. 5-1.1. Cap Assembly Removal. Engage the emergency stop switch and turn off key switch EF_0006 Figure 5-1 Control Head BL-GL22-1119 - 11-20-2019...

  • Page 40: 5-1.2 Cap Assembly Installation

    5-1.2. Cap Assembly Installation. Position cap assembly on control head and secure with four screws. Hold cap assembly in place and connect harness Disengage the emergency stop switch and turn to harness. on key switch. EF_0005 Figure 5-2 Steering Arm 5-1.3.

  • Page 41: 5-1.4 Control Head Installation

    Remove the cap assembly as described in para- Remove screw, lock washer and flat washer and remove potentiometer from bracket. graph 5-1.1. Disconnect harness from potentiometer and Position new potentiometer in bracket and secure reversing switch. with screw, lock washer and flat washer. Remove two screws, two lock washers and two Install screw, lock washer and flat washer.

  • Page 42: 5-1.7 Horn Switch Replacement

    EF_0006 Figure 5-3 Emergency Reverse Switch Assembly 5-1.7. Horn Switch Replacement. Unsolder harness from defective switch and con- nect it to the new switch. Remove the cap assembly as described in para- Position the new switch in the bracket and secure graph 5-1.1.
  • Page 43 EF_0007 Figure 5-4 Cap Assembly BL-GL22-1119 - 11-20-2019...

  • Page 44: 5-1.8 Lift And Lower Switch Replacement

    5-1.8. Lift and Lower Switch Replacement. Remove the return spring as described in para- graph 5-2.1. Remove the cap assembly as described in para- Disconnect harness from harness. graph 5-1.1. Attach a hoist to steering arm. Remove switch assembly form cap. Remove screw, shaft and the steering arm.

  • Page 45: Brake Servicing

    SECTION 6 BRAKE SERVICING 6-1. BRAKES. Disconnect electric brake from harness. Remove the two mounting screws and the brake. The brake system consists of a drive motor mounted brake. This brake is spring applied and electrically Place the new brake into position and secure with released.
  • Page 46 EF_0004 Figure 6-1 Transmission, Motor, Brake Assembly BL-GL22-1119 - 11-20-2019...

  • Page 47: Transmission, Drive Wheel And Load Wheel

    SECTION 7 TRANSMISSION, DRIVE WHEEL AND LOAD WHEEL 7-1. DRIVE WHEEL. Remove the compartment covers as described in paragraph 5-3. Remove the transmission as described in para- Remove the steering arm as described in para- graph 7-2. graph 5-2. Remove the two mounting screws and brake. Raise the truck off the ground to provide clear- Remove eight screws, eight lock washers and ance for transmission out the bottom.
  • Page 48 EF_0004 Figure 7-1 Transmission, Motor, Brake Mounting BL-GL22-1119 - 11-20-2019...

  • Page 49: Load Wheel

    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.
  • Page 50 NOTES BL-GL22-1119 - 11-20-2019...

  • Page 51: Elevation System Servicing

    SECTION 8 ELEVATION SYSTEM SERVICING 8-1. GENERAL. The elevation system includes the outer mast, inner mast, lift linkage, lift chains, lift cylinder and ram head. 8-2. LIFT CHAIN LENGTH ADJUSTMENT. Fully lower the lift carriage. Engage the emergency stop switchand turn off key switch.

  • Page 52: Lift Chain Wear Inspection

    8-3. LIFT CHAIN WEAR INSPECTION. Engage the emergency stop switch and turn off key switch. The lift chain should be replaced when it is worn enough to increase it’s length by 3% or more. On Tele- WARNING: Before attempting any replacement, cospic trucks, Both chains should be replaced at the make certain power is disconnected.

  • Page 53: Hydraulic System Servicing

    SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS Remove the compartment covers as described in paragraph 5-3. WARNING: When forks are raised, pressure exists in Remove the windshield as described in paragraph the hydraulic system lines and fittings. To 5-4.

  • Page 54: Hydraulic Pump, Motor And Reservoir Assembly

    9-2. HYDRAULIC PUMP, MOTOR AND RESERVOIR Operate the lift and lower buttons to refill the ASSEMBLY cylinder and lines with hydraulic oil. Check level of hydraulic oil. If required, add The hydraulic pump/motor assembly can be disas- hydraulic oil to bring to proper level. Use hydraulic sembled and repaired.
  • Page 55 EF_0016 Figure 9-2 Elevation System (Telescopic) BL-GL22-1119 - 11-20-2019...

  • Page 56: 9-3.2 Repair

    9-3.2. Repair CAUTION: To prevent damage, use proper pipe clamp vise. The cylinder will be distorted if the vise is tightened too much. Secure the lift cylinder in a vise, clamping lightly at the base of the cylinder. Remove gland nut and remove wiper ring and seal from the gland nut.

  • Page 57: Electrical Components

    SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL Tag and disconnect harness from controller. Tag and disconnect remaining leads from the con- 10-1.1.Maintenance troller. NOTE: Erratic operation of the truck may be caused Remove mounting screws, lock washers and by defective controller components. Before remove controller and heat sink.
  • Page 58 EF_0011 Figure 10-1 Electrical System (Telescopic) 10-2 BL-GL22-1119 - 11-20-2019...

  • Page 59: 10-1.7 Buzzer Removal

    10-1.7.Buzzer Removal. 10-1.12.Battery Indicator Installation. Engage the emergency stop switch and turn off Position battery indicator on the bracket and key switch secure with its mounting bracket and nuts. Remove the compartment covers as described in Reconnect harness from battery indicator. paragraph 5-3.

  • Page 60: 10-1.17 Lift Limit Switch Removal

    10-1.17.Lift Limit Switch Removal. 10-3.DRIVE MOTOR. Lower forks fully. The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of Engage the emergency stop switch and turn off motor. Use an air hose to blow dust off of motor sur- key switch.

  • Page 61: Optional Equipment

    SECTION 11 OPTIONAL EQUIPMENT N/ABL-GL22-1119 - 11-20-2019 BL-GL22-1119 - 11-20-2019 11-1...
  • Page 62 NOTES 11-2 BL-GL22-1119 - 11-20-2019...

  • Page 63: Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the 989021 Lift Truck. BL-GL22-1119 - 11-20-2019 12-1...
  • Page 64 EF_0002 Figure 12-1 Frame System - Telescopic Mast 12-2 BL-GL22-1119 - 11-20-2019...
  • Page 65 FRAME SYSTEM - TELESCOPIC MAST Qty. Pos. Part Number Description Notes Reqd. 2101-100016-00 WIRE MESH Lift Height 116” (3000mm) 2101-110000-10-02 FRAME 2101-100006-00 COVER 2101-100007-00 COVER Lift Height 116” (3000mm) 2101-100011-00-02 WIRE MESH 3040-000000-33 FLAT WASHER Ø8 0000-000196-00 NUT M8 0000-000176-00 FLAT WASHER Ø8 0000-000159-00 LOCK WASHER Ø8...
  • Page 66 EF_0003 Figure 12-2 Caster Assembly 12-4 BL-GL22-1119 - 11-20-2019...
  • Page 67 CASTER ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 0000-000294-00 RETAINER RING Ø20 2108-130001-00 BEARING BLOCK 0000-000424-00 BEARING 0000-000420-00 BEARING 0000-000762-00 RETAINER RING Ø62 2101-121000-XK YOKE 2140-142000-00 HINGE PIN 0000-000255-00 BOLT M8×20 2101-145000-XK SHAFT 2105-133002-00-AE PU WHEEL 3090-010000-23 BEARING 6204-2Z 2028-000000-56 FLAT WASHER Ø20 3010-010000-59...
  • Page 68 EF_0004 Figure 12-3 Transmission, Motor and Brake 12-6 BL-GL22-1119 - 11-20-2019...
  • Page 69 TRANSMISSION, MOTOR AND BRAKE Qty. Pos. Part Number Description Notes Reqd. 2108-200000-01 DRIVING ASSEMBLY 1115-520012-10 BRAKE ASSEMBLY 1115-200020-00 PLATE 1115-240001-00 BRAKE 0000-000668-00 BUSHING SCRAPER 1115-240002-0A 2108-200002-0C GEAR BOX CASING 1115-240003-0A SCREW M4×40 1115-200007-00 0000-000386-00 SCREW M6×20 0000-000056-00 LOCK WASHER Ø6 0000-000013-00 GREASE FITTING M8 0000-000704-00...
  • Page 70 EF_0005 Figure 12-4 Steering System 12-8 BL-GL22-1119 - 11-20-2019...
  • Page 71 STEERING SYSTEM Qty. Pos. Part Number Description Notes Reqd. 1115-340000-10-40 CONTROL POD ASSEMBLY With Wire 1127-310000-00 CONTROL HANDLE 1127-310003-00 ROLLER 1127-300101-00 SPRING 1127-300102-00 SPRING TOP ROD 1127-300103-0A SPRING BASE 1116-300001-0A SHAFT 0000-000589-00 RETAINER RING Ø16 2101-300001-00 BRACKET 1127-300002-0A BUFFER BLOCK With Wire 1125-52000Z-10 INCHING SWITCH ASSEMBLY...
  • Page 72 EF_0006 Figure 12-5 Control Head 12-10 BL-GL22-1119 - 11-20-2019...
  • Page 73 CONTROL HEAD Qty. Pos. Part Number Description Notes Reqd. With Wire 1115-341000-00-10 CAP ASSEMBLY SEE 0303 1115-34001X-00 TRAVELLING KNOB 0000-000038-00 LOCKWASHER Ø3 0000-000037-00 SCREW M3×12 0000-000991-00 FLATWASHER Ø3 1114-500007-00 POWER MODULE 1120-340004-00-01 DRIVE SWITCH 0000-000323-00 SCREW M5×16 0000-000390-00 FLATWASHER Ø5 1115-340007-00 WIRE HARNESS COVER 1120-520009-00...
  • Page 74 EF_0007 Figure 12-5 Cap Assembly 12-12 BL-GL22-1119 - 11-20-2019...
  • Page 75 CAP ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 1115-341001-00 UPPER COVER 1120-342203-00 BUTTON FOR LIFTING (R) 1120-342202-00 BUTTON FOR LOWERING (R) 1120-342102-00 SPRING 1120-342201-00 BUTTON BRACKET (R) 1120-342105-00 1120-342104-00 BUTTON FOR LIFTING (L) 1120-342103-00 BUTTON FOR LOWERING (L) 1120-342101-00 BUTTON BRACKET (L) 1120-342300-00 HORN BUTTON ASSEMBLY...
  • Page 76 EF_0008 Figure 12-6 Hydraulic System 12-14 BL-GL22-1119 - 11-20-2019...
  • Page 77 HYDRAULIC SYSTEM Qty. Pos. Part Number Description Notes Reqd. Lift Height 116” (3000mm) 2101-410000-00-04 LIFTING CYLINDER 2101-413000-00 HYDRAULIC PUMP ASSEMBLY 2401-163900-00 BOLT M16×39 0000-000069-00 WASHER Ø16 2101-431000-00 OIL PIPE 0000-000196-00 NUT M8 0000-000159-00 LOCK WASHER Ø8 0000-000176-00 FLAT WASHER Ø8 2108-440000-00 EXPLOSION RELIEF VALVE 3020-000002-23...
  • Page 78 EF_0010 Figure 12-7 Pump and Motor Assembly 12-16 BL-GL22-1119 - 11-20-2019...
  • Page 79 PUMP AND MOTOR ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 2101-41323X-00 RELAY 24VDC 2101-41324X-00 BALANCE VALVE 2101-41325X-00 CHECK VALVE 2101-41326X-00 SOLENOID VALVE 24VDC 3231-74032X-00 PLUG DRAIN 2101-41327X-00 SCREW 2101-41328X-00 WASHER 2101-41329X-00 GEAR PUMPS 2.7CC/R 2101-41330X-00 WASHER Ø8 10 2101-41331X-00 WASHER Ø8 2101-41332X-00 SCREW M8×95...
  • Page 80 EF_0009 Figure 12-8 Lift Cylinder 12-18 BL-GL22-1119 - 11-20-2019...
  • Page 81 LIFT CYLINDER Qty. Pos. Part Number Description Notes Reqd. 2101-410004-01 RING BACK UP Ø45×40×15 ROD PACKING Ø45×35×6 O-RING Ø54×2.4 RING WIPER Ø32×40×5-6.5 2101-410009-00 MUFFLER 2101-QJYG-0A SEAL KIT FOR CYLINDER Incl. Pos. # 2, 3 & 4 BL-GL22-1119 - 11-20-2019 12-19...
  • Page 82 EF_0016 Figure 12-9 Telescopic Mast Lift System 12-20 BL-GL22-1119 - 11-20-2019...
  • Page 83 TELESCOPIC MAST LIFT SYSTEM Qty. Pos. Part Number Description Notes Reqd. Lift Height 116” (3000mm) 2101-620000-00-02 INNER MAST 0000-000374-00 SCREW M12×30 0000-000060-00 LOCK WASHER Ø12 0000-000373-00 FLAT WASHER Ø12 0000-000325-00 SCREW M12×20 2101-140001-00 CONNECTION BLOCK 2101-140005-00 WASHER 0000-000415-00 BOLT M8×16 0000-000159-00 LOCK WASHER Ø8 0000-000176-00...
  • Page 84 EF_0017 Figure 12-10 Telescopic Mast Chain Assembly 12-22 BL-GL22-1119 - 11-20-2019...
  • Page 85 TELESCOPIC MAST CHAIN ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 2108-600002-00 CHAIN ROLLER 2105-600003-00 SHAFT 0000-000756-00 RETAINER RING Ø40 2108-600003-0B WASHER Lift Height 116” (3000mm) 2105-640000-6C-03 CHAIN 2108-640002-0A SHAFT 0000-000188-00 PIN Ø3.2×20 0000-000237-00 NUT M16×1.5 2108-640001-0C BOLT 2105-600002-60 CHAIN ANCHOR 0000-000176-00 FLAT WASHER Ø8 2105-600012-60...
  • Page 86 EF_0018 Figure 12-11 Fork Carriage 12-24 BL-GL22-1119 - 11-20-2019...
  • Page 87 FORK CARRIAGE Qty. Pos. Part Number Description Notes Reqd. 2125-630001-10 SHAFT 2108-630001-10-01 FORK 0000-000374-00 SCREW M12×30 3040-000000-22 LOCK WASHER Ø12 3040-000000-09 FLAT WASHER Ø12 For Telescopic Mast 2101-631000-10 FORK FRAME 2101-65000X-00 ROLLER ASSEMBLY 0000-000434-00 RETAINER RING Ø30 For Telescopic Mast 2125-632000-0A BLOCKING SHELF 3020-010000-67...
  • Page 88 EF_0011 Figure 12-12 Electrical System 12-26 BL-GL22-1119 - 11-20-2019...
  • Page 89 ELECTRICAL SYSTEM Qty. Pos. Part Number Description Notes Reqd. 2101-520000-00 BRACKET 0000-000616-00 SCREW M5×10 1115-510008-00 EMERGENCY STOP SWITCH 0000-000159-00 LOCK WASHER Ø8 1120-500003-0A HORN 0000-000176-00 FLAT WASHER Ø8 0000-000552-00 NUT M8 1115-500009-00 CHARGER HOOP 2108-520014-10 CHARGE ASSEMBLY 1120-540001-00 FUSE STAND 0000-000088-00 SCREW M4×8 0000-000122-00...
  • Page 90 EF_0012 Figure 12-13 Wiring Harness 12-28 BL-GL22-1119 - 11-20-2019...
  • Page 91 WIRING HARNESS Qty. Pos. Part Number Description Notes Reqd. 2101-520001-CF MASTER WIRING HARNESS 1113-520025-00 FUSE 5A 2108-520003-Q0 INTEGRATED BOARD 2101-520003-00 LIMIT SWITCH HARNESS BL-GL22-1119 - 11-20-2019 12-29...
  • Page 92 EF_0013 Figure 12-14 Wiring Cables 12-30 BL-GL22-1119 - 11-20-2019...
  • Page 93 WIRING CABLES Qty. Pos. Part Number Description Notes Reqd. 2105-530003-00 SWITCH-BATTERY CABLE 2101-530002-10 FUSE-SWITCH CABLE 2101-530007-00 BATTERY CONNECTOR CABLE 2101-530004-10 CONTROLLER+ 2101-530005-1A CONTROLLER- 2108-530008-00 C2 CABLE 2101-530011-10 M2 CABLE 2101-530010-10 M1 CABLE BL-GL22-1119 - 11-20-2019 12-31...

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