Blue Giant BGN-40 Owner's Manual
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Blue Giant BGN-40 Owner's Manual

Power drive straddle truck
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OWNER'S MANUAL
BGN-40 POWER DRIVE STRADDLE TRUCK
WARNING
Do not operate or service this product unless you have
read and fully understand the entire contents of this
manual. Failure to do so may result in property damage,
bodily injury or death.
ISSUE DATE: MAY 5, 2020 REV.0 (PART # 038-XXXE)

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  • Page 1 OWNER’S MANUAL BGN-40 POWER DRIVE STRADDLE TRUCK WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual. Failure to do so may result in property damage, bodily injury or death.
  • 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 6 BRAKE SERVICING ........... 6-1 1-1. INTRODUCTION..........1-1 6-1. BRAKES............6-1 1-2. GENERAL DESCRIPTION.......1-1 6-1.1. AIR GAP ADJUSTMENT......... 6-1 1-3. SAFETY FEATURES........1-1 6-1.2. STOPPING DISTANCE ADJUSTMENT..6-2 6-1.3.
  • Page 4 LIST OF ILLUSTRATIONS Figure Page Figure Page NAME PLATE ............1-1 10-3 TRANSMISSION, MOTOR, BRAKE PDS LIFT TRUCK..........1-2 ASSEMBLY............10-5 LOAD CENTER ............ 2-1 12-1 STEERING SYSTEM .......... 12-2 SAMPLE OF OPERATOR CHECK LIST....2-3 12-2 CONTROL HEAD ..........12-4 FORWARD/REVERSE CONTROL ......

  • Page 5: Description

    SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the 24 volt transistor PDS lift truck distributed by Blue Giant. Included are MODEL NO. SERIAL NO. operating instructions, planned maintenance instruc- MAX CAP LB/ MAX CAP LB/ LOAD CTR IN/ LOAD CTR IN/...
  • Page 6 R6765 Figure 1-2. PDS Lift Truck...

  • Page 7: Operation

    SECTION 2 OPERATION 2-1. GENERAL. • Be certain that the lifting mechanism is operating smoothly throughout its entire height, both empty This section gives detailed operating instructions for and loaded. the PDS lift truck. The instructions are divided into the various phases of operations, such as operating lift, •...

  • Page 8: Before Operation

    • When stacking pallets in racks and it is necessary to Figure 2-2 shows a sample format for an Operator move the load in a raised position, use caution. Checklist, which can be modified as necessary to fit Operate truck smoothly. your operation.
  • Page 9 Electric Truck Daily Operator Check-Off List Operator Date Truck No. Model No. Dept. Shift Hour Meter Reading Drive Hoist Check O.K. ( ) Need Maintenance Tires Load Wheels Horn Lift Lower Control Attachment Operation Forward & Reverse Controls Steering Brakes Hydraulic Leaks, Cylinders, Valves, Hoses, Etc.

  • Page 10: General Control Operation

    2-4. GENERAL CONTROL OPERATION. The speed control (See Figure 2-3) located on each side of the control head provides fingertip control for driving the truck. Rotate the control in the direction you want to travel. The farther you rotate the control from the neutral position, the faster the truck will travel.

  • Page 11: Steering Arm Gas Spring

    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. Move truck to location where load is to be picked Move the truck into position so forks are within pallet or skid, and the load is centered over the forks and as far back as possible.
  • Page 12 NOTES...

  • Page 13: Planned Maintenance

    Leakage voltage from battery terminals to battery case accordingly. These procedures must be performed by can cause misleading trouble symptoms with the truck a qualified service technician or your Blue Giant Ser- electrical system. Since components of the truck elec- vice Representative.

  • Page 14: 3-3.2. Safety Rules

    Although a leakage voltage reading of zero volts may Charge the battery only in areas designated for not be possible, a cleaner battery will have more that use. usable charge for truck operation and not affect opera- Make certain the charger being used matches the tion of electronic devices on the unit.

  • Page 15: 3-3.5. Maintenance Free Batteries

    3-3.5. MAINTENANCE FREE BATTERIES 3-4. CHARGING BATTERIES Some trucks may be equipped with maintenance free Charging requirements will vary depending on depth batteries. These batteries are completely sealed, will of discharge and temperature. Follow safety rules not require any watering and have a full 80% dis- when placing a battery on charge.

  • Page 16: Lubrication

    3-5. LUBRICATION. Table 3-2 Recommended Lubricants (See Table 3-3 for Application) Refer to Table 3-2 for the recommended types of No. 1 Transmission oil—EP SAE 80W-90 grease and oil. Table 3-3 in conjunction with Transmission oil—EP SAE 10W-30 (Note) Figure 3-1 identifies the items requiring lubrication.
  • Page 17 R6836 Figure 3-1 Lubrication Diagram Table 3-3 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...

  • Page 19: Troubleshooting

    SECTION 4 TROUBLESHOOTING 4-1. GENERAL Operate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Table 4-1 as a guide to determine possible Lowering, and Miscellaneous malfunctions. causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Table 4-1 Troubleshooting Chart MALFUNCTION...
  • Page 20 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING - a. Air gap less than 0.01 in Adjust. Continued (0.25mm). Brake drags. b. Defective electric brake (15, Replace. Figure 12-5). Brake grabs. a. Incorrect stopping distance Adjust.
  • Page 21 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Load will not hold a. Oil bypassing internally in con- Replace valve assembly (Figure trol valve 12-16). b. Worn lift cylinder or packing. Repack cylinder.

  • Page 22: Controller Troubleshooting

    The Zapi Handset is avail- 4-2.2.2. Logbook Access able through your Blue Giant dealer. If you require dealer location information, contact Blue Giant. To view the alarm logbook proceed as follows:...

  • Page 23: 4-2.4. Settings And Adjustments

    4-2.4. Settings and Adjustments 4-2.4.1. Set Options To set options proceed as follows and refer to Table 4- Connect the Zapi Handset, refer to paragraph 4-2.1. Press the ROLL up button (1, Figure 4-2) and the SET up button (5) at the same time to enter the CONFIG MENU.
  • Page 24 Table 4-2 Set Options - Continued Parameter Factory Setting Description SET INPUT #2 PRESENT It can be can be set as: • PRESENT: CNA#14 (Table 4-5) is managed as a cutback speed input (SR#2). • OPTION #1: CNA#14 (Table 4-5) is managed as an inching back- ward.
  • Page 25 Table 4-2 Set Options - Continued Parameter Factory Setting Description AUX OUTPUT #1 BRAKE This option handles output CNA#3 (Table 4-5). It can be used as: • BRAKE: CNA#3 (Table 4-5) drives an electromechanical Brake. • HYDROCOMNT: CNA#3 (Table 4-5) drives the contractor for a hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detected.
  • Page 26 Table 4-2 Set Options - Continued Parameter Factory Setting Description AUX VOLTAGE #1 100% This option specifies the percentage of the keyswitch controlled voltage to be applied to the loads on CNA#1 (Table 4-5) (main contactor coil) and CNA#3 (Table 4-5) (electromechanical brake).
  • Page 27 4-2.4.2. Adjustments To change an adjustment proceed as follows and refer Table 4-3: Connect the Zapi Handset, refer to paragraph 4-2.1. Press the ROLL up button (1, Figure 4-3) and the SET up button (5) at the same time to enter the CONFIG MENU.
  • Page 28 Table 4-3 Adjustments - Continued Parameter Factory Setting Description THROTTLE X POINT This parameter together with the THROTTLE Y POINT, changes the characteristic of the accelerator input curve: when the acceler- ator is de-pressed to X point percent, the corresponding truck speed is Y point percent of the Maximum truck speed.
  • Page 29 4-2.4.3. Parameter Change To change a parameter proceed as follows and refer Table 4-4: Connect the Zapi Handset, refer to paragraph 4-2.1. Press the ROLL down button (1, Figure 4-5) and the ENTER button (3) at the same time to enter the MAIN MENU.
  • Page 30 Table 4-4 Parameter Adjustments - Continued Parameter Factory Setting Description CUTBACK SPEED 100% Typically from 10% to 100%. It determines the percentage of the max speed applied when the cutback switch 1 (SR#1 on CNA#15 (Table 4-5) is active. When set to 100% the speed reduction is ineffective.
  • Page 31 R6628 Figure 4-6 Zapi Controller Connectors Table 4-5 Zapi Controller Connector Pins CNA Connector ABBREVATION DESCRIPTION CNA#1 Negative of main contactor coil. CNA#2 Positive of main contactor coil. CNA#3 Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current: 3 A. CNA#4 Negative of pump contactor soil.
  • Page 32 Table 4-5 Zapi Controller Connector Pins - Continued CNA Connector - Continued ABBREVATION DESCRIPTION CNA#12 -BATT -Batt. CNA#13 MOT TH Motor thermal sensor input. The internal pull-up is a fixed 2mA (Max 5V) source current. CNA#14 Speed reduction 2 input. Active low (switch opened). CNA#15 Speed reduction 1 input.
  • Page 33 Table 4-5 Zapi Controller Connector Pins - Continued CNC Connector CONNECTOR ABBREVATION DESCRIPTION CNC#1 PCLRXD Positive serial reception. CNC#2 NCLRXD Negative serial reception. CNC#3 PCLTXD Positive serial transmission. CNC#4 NCLTXD Negative serial transmission. CNC#5 Negative console power supply. CNC#6 +12V Positive console power supply.
  • Page 34 NOTES...

  • Page 35: Steering Arm, Control Head And Compartment

    SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD Remove four screws (17, Figure 5-1), lift up cap assembly (21) and disconnect harness (23) from 5-1.1. Cap Assembly Removal. harness (41, Figure 5-2). Turn off the key switch (1, Figure 12-24) and dis- connect the batteries.

  • Page 36: 5-1.2. Cap Assembly Installation

    5-1.2. Cap Assembly Installation. Position cap assembly (21, Figure 5-1) on control head and secure with four screws (17). Hold cap assembly (21, Figure 5-1) in place and Reconnect the batteries and turn on the key connect harness (23) to harness (41, Figure 5-2).

  • Page 37: 5-1.3. Control Head Removal

    5-1.3. Control Head Removal Position new potentiometer (15) in bracket (20) and secure with screw (16), lock washer (6) and Remove the cap assembly as described in para- flat washer (7). graph 5-1.1. Install screw (1), lock washer (6) and flat washer Disconnect harness (41, Figure 5-2) from potenti-...

  • Page 38: 5-1.7. Horn Switch Replacement

    R6810 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 bracket (14) and graph 5-1.1.
  • Page 39 R6809 Figure 5-4 Cap Assembly...

  • Page 40: 5-1.8. Lift And Lower Switch Replacement

    5-1.8. Lift and Lower Switch Replacement. Reconnect the batteries and turn on the key switch (1, Figure 12-24). Remove the cap assembly as described in para- graph 5-1.1. 5-2.2. Steering Arm Removal. Remove switch assembly (1 or 1A, Figure 5-4) Turn off the key switch (1, Figure 12-24) and dis-...

  • Page 41: Brake Servicing

    SECTION 6 BRAKE SERVICING 6-1. BRAKES. Recheck the gap. The brake system consists of a drive motor mounted 11. Remove load wheel blocks and check operation. brake. This brake is spring applied and electrically 12. Install the compartment covers as described in released.

  • Page 42: 6-1.2. Stopping Distance Adjustment

    6-1.2. Stopping Distance Adjustment. Install the compartment covers as described in paragraph 5-3. The stopping distance of the truck should require mini- mal adjustment. However, this distance should be 6-1.3. Brake Assembly Replacement checked with each planned maintenance. Block load wheels. Using an unloaded truck, run truck to its top speed on Remove the compartment covers as described in an even dry concrete surface.

  • Page 43: Transmission, Drive Wheel, Load Wheel

    SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL 7-1. Drive Wheel. 7-3. Load Wheel. Turn off the key switch (1, Figure 12-24) and dis- 7-3.1. Removal connect the batteries. Raise forks. Remove the compartment covers as described in Turn off the key switch (1, Figure 12-24) and dis- paragraph...
  • Page 44 R6811 Figure 7-1 Transmission, Motor, Brake Assembly...
  • Page 45 R6814 Figure 7-2 Adjustable Straddle...
  • Page 46 NOTES...

  • Page 47: 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. 8-2.1. Telescopic Fully lower the lift carriage. Turn off the key switch (1, Figure 12-24) and dis- connect the batteries.
  • Page 48 R6816 Figure 8-2 Elevation System (Telescopic)

  • Page 49: 8-2.2. Trimast Free Lift Chain

    8-2.2. TRIMAST Free Lift Chain Loosen jam nuts (2, Figure 8-1), the mount of outer mast (1, Figure 8-3), to allow for adjustment Fully lower the lift carriage. of middle jam nut. Turn off the key switch (1, Figure 12-24) and dis- Break the lower jam nuts (2, Figure 8-1), located...
  • Page 50 R6817 Figure 8-3 Mast (TRIMAST)

  • Page 51: Lift Chain Replacement

    8-4. LIFT CHAIN REPLACEMENT. Remove cotter pin (3) and clevis pin (4) connect- ing chain (5) to chain anchor (1) at free lift cylinder 8-4.1. Telescopic (29, Figure 8-3). With the lift truck wheels securely blocked, raise Remove chain from sheave (14). the forks approximately three feet from floor and Position new chain on sheave (14).
  • Page 52 NOTES...

  • Page 53: Hydraulic System Servicing

    SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS Install the compartment covers as described in paragraph 5-3. WARNING: When forks are raised, pressure exists in the hydraulic system lines and fittings. 9-2. HYDRAULIC PUMP, M OTOR, AND RE SER- To ensure release of pressure, forks VOIR ASSY must be fully lowered and the batteries...

  • Page 54: 9-2.3. Installation

    R6819 Figure 9-1 Hydraulic System 9-2.3. Installation Reconnect the batteries and turn on the keyswitch Figure 12-24). While supporting the pump/motor assembly (1, Operate the lift and lower buttons to refill the Figure 9-1), install four screws (2) and four lock cylinder and lines with hydraulic oil.

  • Page 55: 9-2.4. Lift Cylinder (Telescopic)

    9-2.4. Lift Cylinder (Telescopic) Remove piston (7) and O-ring (5) from rod (4). Remove guide ring (6) and seal (8) from piston 9-2.4.1.Removal (7). With the lift truck wheels securely blocked, raise Coat all parts with hydraulic oil (Table 3-2). the forks approximately three feet from floor and position blocks or strong supports under inner Install guide ring (6) and new seal (8) on piston...
  • Page 56 R6816 Figure 9-2 Mast (Telescopic)
  • Page 57 R6825 Figure 9-3 Lift Cylinder (Telescopic)

  • Page 58: 9-2.5. Lift Cylinder (Trimast Free Lift)

    9-2.5. Lift Cylinder (TRIMAST Free Lift) Pull out piston rod (4). Remove guide ring (5), snap ring (6) and inner 9-2.5.1.Removal collar (7) from piston rod (4). Fully lower the lift carriage. Coat all parts with hydraulic oil (Table 3-2). Turn off the key switch (1, Figure 12-24) and dis-...
  • Page 59 R6817 Figure 9-4 Mast (TRIMAST)
  • Page 60 R6826 Figure 9-5Free Lift Cylinder (TRIMAST)

  • Page 61: 9-2.6. Lift Cylinder (Trimast Secondary)

    9-2.6. Lift Cylinder (TRIMAST Secondary) Remove piston (7) and O-ring (5) from piston rod (4). 9-2.6.1.Removal Remove ring (6) and seal (8) from piston (7). Fully lower the lift carriage. Coat all parts with hydraulic oil (Table 3-2). Turn off the key switch (1, Figure 12-24) and dis- Install ring (6) and seal (8) on piston (7).
  • Page 62 R6827 Figure 9-6 Secondary Lift Cylinder (TRIMAST)

  • Page 63: Electrical Components

    SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL Make sure the connections to the buss bars are tight. Use two well insulated wrenches for this 10-1.1.Maintenance task in order to avoid steering the buss bars. NOTE: Erratic operation of the truck may be caused 10-1.3.Panel Removal.
  • Page 64 R6478 R6828A Figure 10-1 Electrical System...

  • Page 65: Horn Replacement

    10-2.HORN REPLACEMENT Remove screw (17), lock washer (7), flat washer (8), and horn (9). Turn off the key switch (1, Figure 10-1) and dis- Install horn (9) and secure with screw (17), lock connect the batteries. washer (7), flat washer (8). Remove the compartment covers as described in Install the compartment covers as described in paragraph...

  • Page 66: Pump Motor

    10-3.PUMP MOTOR. Install plate (33, Figure 12-1) on the motor and secure with three screws (28) and three lock The pump motor is replaceable but not repairable. washer (29). Refer to paragraph 9-2. Install drive motor onto transmission. Make sure 10-4.DRIVE MOTOR.
  • Page 67 R6811 Figure 10-3 Transmission, Motor, Brake Assembly...
  • Page 68 NOTES...

  • Page 69: Optional Equipment

    SECTION 11 OPTIONAL EQUIPMENT 11-1.LOAD BACKREST A load backrest is available for addition to the lift truck to allow handling of high loads.
  • Page 70 NOTES...

  • Page 71: Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the PDS Lift Truck.
  • Page 72 R6807 Figure 12-1 Steering System...
  • Page 73 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000060-00 WASHER, LOCK, M12 — CONTROL HEAD (FIGURE 12-2) 0000-000222-00 WASHER, FLAT, M12 2130-340000-00 STEERING ARM 0000-000109-00 SCREW, M8 x 16 0000-000029-00 • BUSHING 0000-000159-00 WASHER, LOCK, M8 0000-000490-00 CLAMP 1220-300007-00 PLATE, WIRING HARNESS 0000-000010-00...
  • Page 74 R6808 Figure 12-2 Control Head...
  • Page 75 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000004-00 • SCREW, M5 X 12 — 2125-340000-00-B CONTROL HEAD 0000-000035-00 • SCREW, M5 X 20 0000-000010-00 • SCREW, M5 X 6 1120-340002-00 • COVER 1120-340005-00 • CONTROL KNOB 1120-341000-00 •...
  • Page 76 R6809 Figure 12-3 Cap Assembly...
  • Page 77 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-342103-10 • • BUTTON, LOWERING, — 2125-342000-00 CAP ASSEMBLY LEFT, TWO SPEED 1120-342200-00 • LIFT/LOWERING SWITCH 1120-342101-00 • • BUTTON BRACKET, ASSY, RIGHT LEFT 2125-342100-00 • LIFT/LOWERING SWITCH 1120-342002-00 • HORN BUTTON ASSY, LEFT, TWO SPEED 0000-000039-00 •...
  • Page 78 R6810 Figure 12-4 Emergency Reverse Switch Assembly INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-342005-00 • PIN — 1120-343000-00 EMERGENCY REVERSE SWITCH ASSY 1120-343001-0A • BRACKET 1120-343002-00 • EMERGENCY REVERSE 1120-343004-00 • PIN BUTTON 1120-343003-00 • SPRING...
  • Page 79 NOTES...
  • Page 80 R6811 Figure 12-5 Transmission, Motor, Brake Assembly...
  • Page 81 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-230000-00 BEARING 0000-000070-00 SCREW, M10 X 25 0000-000013-00 GREASE FITTING 0000-000157-00 1120-240000-00 TRANSMISSION — DRIVE MOTOR (FIGURE 12-26) 1120-200001-00 DRIVE WHEEL 0000-000169-00 SCREW, M8 X 30 0000-000025-00 WASHER 0000-000159-00 WASHER, LOCK, M8 1120-210000-00 BRAKE 0000-000176-00...
  • Page 82 R6813 Figure 12-6 Compartment...
  • Page 83 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-181000-00 COVER, RIGHT 0000-000433-00 SCREW, M8 X 12 1220-150005-00 NUT, M8 2130-190002-00 MIDDLE COVER 0000-000322-00 SCREW, M8 X 25 0000-000649-00 SCREW, M8 X 20 0000-000159-00 WASHER, LOCK, M8 2130-190001-00 UPPER COVER 0000-000194-00 WASHER, FLAT, M8 2130-172000-00...
  • Page 84 R6814 Figure 12-7 Adjustable Straddle...
  • Page 85 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-140000-00 LOAD WHEEL ASSEMBLY 2130-130000-00 STRADDLE, RIGHT (USED WITH SHAFT 14) 2130-140000-0A LOAD WHEEL ASSEMBLY 2130-130000-0A STRADDLE, RIGHT (USED 0000-000181-00 • BEARING, 6205-Z WITH SHAFT 14A) 2130-140001-00 • LOAD WHEEL 2130-120000-00 STRADDLE, LEFT (USED 0000-000015-00...
  • Page 86 R6844 Figure 12-8 Fixed Straddle (PDS 40 ONLY)
  • Page 87 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000159-00 WASHER, LOCK, M8 2140-110000-00 FRAME ASSEMBEY 0000-000176-00 WASHER, FLAT, M8 2140-140005-OA SHIM 0000-000181-00 BEARING, 6205-Z — CASTER ASSEMBLY (FIGURE 12-9) 2130-140001-00 LOAD WHEEL 2130-140004-00 SHIM, PDS 40 2130-140003-00 WASHER 0000-000432-00 SCREW, M16 X 80 2130-140002-00...
  • Page 88 R6834 Figure 12-9 Caster (Adjustable Straddle)
  • Page 89 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-143001-00 • SHAFT — 1120-140000-00 CASTER ASSEMBLY 0000-000020-00 • BEARING, 6204 1120-140002-00 • SCREW, M10 X 25 1120-143003-00 • CASTER WHEEL 1120-140001-00 • CASTER HOUSING 0000-000057-00 • NUT, M12 0000-000164-00 •...
  • Page 90 R6845 Figure 12-10 Caster (Fixed Straddle)
  • Page 91 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000242-00 • BOLT, M8 X 16 — 2140-140000-00 CASTER ASSEMBLY 0000-000159-00 • WASHER, LOCK, M8 0000-000093-00 • NUT, M27 X 1.5 2140-142000-00 • HINGE PLATE 0000-000094-00 • WASHER, M27 2140-145000-00 •...
  • Page 92 R6816 Figure 12-11 Elevation System (Telescopic)
  • Page 93 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — CARRIAGE (FIGURE 12-13) 2125-612000-00 ROLLER ASSEMBLY 2214-600001-00 CHAIN SHEAVES 2125-612004-00 • SCREW 0000-000244-00 BOLT, M10 X 30 2125-612007-00 • SNAP RING 0000-000071-00 WASHER, FLAT, M10 2125-612002-00 • BRACKET 0000-000109-00 SCREW, M8 X 16 2125-612001-00 •...
  • Page 94 R6817 Figure 12-12 Elevation System (TRIMAST)
  • Page 95 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2125-612001-00 • ROLLER OUTER MAST 2125-612005-00 • WIPER 2125-610000-30-01 (158 IN LIFT) 0000-000183-00 • SNAP RING 2125-610000-30-02 (177 IN LIFT) 2125-600001-30 RAM HEAD 2125-610000-30-03 (189 IN LIFT) — FREE LIFT CYLINDER 0000-000285-00 BOLT, M12 X 30 (FIGURE...
  • Page 96 R6815 Figure 12-13 Lift Carriage...
  • Page 97 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000183-00 • RETAINING RING, M35 0000-000221-00 BOLT, M12 X 30 2130-631000-00 CARRIAGE (TELESCOPIC) 0000-000060-00 WASHER, LOCK, M12 2130-631000-30 CARRIAGE (TRIMAST) 0000-000373-00 WASHER, FLAT, M12 2125-630001-00 FORK 2125-631100-00 ROLLER ASSEMBLY 2125-630001-10 2125-631104-00 •...
  • Page 98 INDEX PART PART NAME REQD. 0000-000188-00 PIN, COTTER 2125-640002-00 CHAIN, TELESCOPIC 2125-640000-01 (104 IN LIFT) (91 LINKS) 2125-640000-02 (126 IN LIFT) (105 LINKS) 2125-640000-03 (142 IN LIFT) (115 LINKS) CHAIN, TRIMAST FREE LIFT 2125-651000-30-01 (158 IN LIFT) (55 LINKS) 2125-651000-30-02 (177 IN LIFT) (63 LINKS) 2125-651000-30-03 (189 IN LIFT) (69 LINKS)
  • Page 99 R6819 Figure 12-15 Hydraulic System INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. HOSE ASSEMBLY, BGN40 2130-460000-00 — PUMP & MOTOR ASSY (FIGURE 12-16) 2140-410000-00 HOSE ASSEMBLY, PDS 40 0000-000710-00 SCREW, M6 X 45 0000-000044-00 • SEAL 0000-000056-00 WASHER, LOCK, M6 2402-143500-00 •...
  • Page 100 R6820 Figure 12-16 Pump & Motor Assy...
  • Page 101 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-430009-00 • FLANGE — 2130-430000-00 PUMP & MOTOR ASSY 2130-430010-00 • PUMP 2130-410001-00 • MOTOR 2130-430011-00 • TUBE 2130-430002-00 • SOLENOID 2130-430012-00 • FILTER 2130-430003-00 • CARTRIDGE 2130-430013-00 • VALVE, FLOW CONTROL, 2130-430004--00 •...
  • Page 102 R6821A Figure 12-17 Hydraulic System (Telescopic)
  • Page 103 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2125-450000-00 RELIEF VALVE 2130-400002-00-B TUBE 2702-141600-00 UNION 2801-161601-00 • CONNECTOR 0000-000069-00 O-RING 2802-141601-00 • CONNECTOR 0000-000044-00 O-RING 2130-400001-00 MANIFOLD 0000-000154-00 SCREW, M8 X 35...
  • Page 104 R6822A Figure 12-18 Hydraulic System (Telescopic)
  • Page 105 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2125-450000-00 RELIEF VALVE 2130-400002-0A-B TUBE ASSEMBLY 2702-141600-00 UNION 2805-160010-20 • BOLT, M16 X 1.5 0000-000044-00 O-RING 0000-000069-00 • O-RING 0000-000169-00 SCREW, M8 X 30 2801-161601-00 • CONNECTOR 0000-000069-00 O-RING 2130-400002-30 MANIFOLD...
  • Page 106 R6823A Figure 12-19 Hydraulic System (TRIMAST)
  • Page 107 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. TUBE 2125-400001-30-B TUBE 2125-440000-30-01 (158 IN LIFT) 2801-161601-00 • CONNECTOR 2125-440000-30-02 (177 IN LIFT) 2802-141601-00 • CONNECTOR 2125-440000-30-03 (189 IN LIFT) 2125-450000-00 RELIEF VALVE 0000-000109-00 SCREW, M8 X 16 2125-400002-30 MANIFOLD 0000-000159-00 WASHER, LOCK, M8...
  • Page 108 R6824 Figure 12-20 Hydraulic System (TRIMAST)
  • Page 109 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000044-00 O-RING 2130-400002-0A-B TUBE ASSEMBLY 2130-430000-3A-B TUBE ASSEMBLY 2805-160010-20 • BOLT, M16 X 1.5 0000-000069-00 • O-RING 0000-000069-00 • O-RING 2805-160014-00 • BOLT, M16 X 1.5 2125-400002-30 • MANIFOLD 2125-450000-00 RELIEF VALVE TUBE 0000-000109-00...
  • Page 110 R6825 Figure 12-21 Lift Cylinder (Telescopic)
  • Page 111 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-410003-00 • O-RING — LIFT CYLINDER 2130-410004-00 • GUIDE RING 2130-410000-00-01 (104 IN LIFT) 2130-410002-00 • PISTON 2130-410000-00-02 (126 IN LIFT) 0000-000132-00 • SEAL 2130-410000-00-03 (142 IN LIFT) — • CYLINDER TUBE 0000-000084-00 •...
  • Page 112 R6826 Figure 12-22 Free Lift Cylinder (TRIMAST)
  • Page 113 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-420002-30 • GLAND NUT — FREE LIFT CYLINDER — • PISTON ROD — 2130-420000-30-01 (158 IN LIFT) 2130-420003-00 • GUIDE RING — 2130-420000-30-02 (177 IN LIFT) 0000-000698-00 • SNAP RING —...
  • Page 114 R6827 Figure 12-23 Secondary Lift Cylinder (TRIMAST)
  • Page 115 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — • PISTON ROD — SECONDARY LIFT CYLINDER 2130-410003-30 • O-RING — 2130-410000-30-01 (158 IN LIFT) 2130-410004-30 • GUIDE RING 2130-410002-30 • PISTON — 2130-410000-30-02 (177 IN LIFT) 0000-000132-00 • SEAL —...
  • Page 116 R6828A Figure 12-24 Electrical System...
  • Page 117 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-520003-3A HARNESS FOR 1120-520002-0C KEY SWITCH MECHANICAL SWITCH) 1120-500016-00 • KEY (TRIMAST) — ELECTRICAL PANEL — — SWITCH, LIMIT (TRIMAST) (FIGURE 12-25) (ELECTRICAL SENSOR) 0000-000498-00 SCREW, M6 X 30 2125-500003-00 SWITCH, LIMIT (TRIMAST) 2130-531000-00 CONNECTOR, BATTERY...
  • Page 118 R6829 Figure 12-25 Electrical Panel INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-500005-00 CONTACTOR 2125-510001-00 BOARD 0000-000077-00 SCREW, M6 X 12 0000-000128-00 WASHER, FLAT, M5 1120-540001-00-B FUSE HOLDER 0000-000206-00 WASHER, LOCK, M5 0000-000077-00 SCREW, M6 X 12 0000-000004-00 SCREW, M5 X 12 0000-000196-00...
  • Page 119 NOTES...
  • Page 120 R6830 Figure 12-26 Drive Motor...
  • Page 121 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000056-00 • WASHER, LOCK, M6 — 1120-220000-00 MOTOR ASSEMBLY 1120-220002-00 • BEARING 0000-000293-00 • RETAINING RING 0000-000204-00 • KEY 0000-000226-00 • KEY, 6 X 6 X 16 0000-000409-00 • O-RING 1120-220001-00 •...
  • Page 122 R6831 Figure 12-27 Wiring Harness INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-500010-00 FUSE, 10A 2130-520001-00 HARNESS, MAIN...
  • Page 123 R6832 Figure 12-28 Wiring Cables INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2130-530007-00 PUMP POWER CABLE - 2130-530004-00 MOTOR CABLE V 2130-530006-00 PUMP POWER CABLE + 2130-530005-00 MOTOR CABLE U 2130-530003-00 MOTOR CABLE W...
  • Page 124 R6833 Figure 12-29 Battery Compartment INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2125-102200-00 ROLLER 0000-000322-00 SCREW, M8 X 25 2130-151000-00 FRAME 0000-000159-00 WASHER, LOCK, M8 0000-000321-00 SCREW, M8 X 20 0000-000176-00 WASHER, FLAT, M8 0000-000194-00 WASHER, FLAT, M8 2130-160001-00 PLATE 2130-160002-00...
  • Page 126 Corporate 410 Admiral Blvd USA 6350 Burnt Poplar Road Mississauga, ON, Canada L5T 2N6 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.bluegiant.com If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2020...

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