Blue Giant BGL-33 Owner's Manual

Blue Giant BGL-33 Owner's Manual

Walkie counterbalanced stacker
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OWNER'S MANUAL
BGL-33 WALKIE COUNTERBALANCED STACKER
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 # 038-943E)

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Summary of Contents for Blue Giant BGL-33

  • Page 1 OWNER’S MANUAL BGL-33 WALKIE COUNTERBALANCED STACKER 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 5-4.1. REMOVAL............5-4 1-1. INTRODUCTION..........1-1 5-4.2. INSTALLATION..........5-4 1-2. GENERAL DESCRIPTION.......1-1 5-5. STEERING MOTOR ........5-5 1-3. SAFETY FEATURES........1-1 5-5.1. REMOVAL............5-5 5-5.2. INSTALLATION..........5-5 2 OPERATION ...............2-1 2-1.
  • Page 4 Page Figure Page NAME PLATE ............1-1 10-3 TRANSMISSION, MOTOR, BRAKE ASSEMBLY 10-5 BGL-33 LIFT TRUCK ..........1-2 12-1 CONTROL ARM........... 12-2 LOAD CENTER ............. 2-1 12-2 CONTROL HEAD..........12-6 SAMPLE OF OPERATOR CHECK LIST ....2-3 12-3 DRIVE SYSTEM ..........12-8 CONTROL ARM ............
  • Page 5: Description

    The reversible AC motor propels the lift truck in for- carriage is raised above the preset limit. ward or reverse direction throughout the available • All control functions automatically return to “OFF” speed range. The BGL-33 lift truck can be driven when released. with forks raised lowered;...
  • Page 6 R7242 Figure 1-2. BGL-33 Lift Truck ITEM COMPONENT ITEM COMPONENT Mast Chassis Back Rest Drive wheel Forks Battery Discharge Indicator Load Wheel Key Switch Hydraulic pump Control Handle Battery Battery Disconnect Controller...
  • Page 7: Operation

    This section gives detailed operating instructions for and loaded. the BGL-33 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, stopping.
  • 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: Sample Of Operator Check List

    R6479 Figure 2-2 Sample of Operator Check List...
  • Page 10: General Control Operation

    2-4. GENERAL CONTROL OPERATION. 2-4.1. Control Arm The control arm is used to steer and to control speed and braking of the truck. Slow Speed: Move the control arm down to the slow speed range and move the travel lever to forward or reverse.
  • Page 11: Control Arm Gas Spring

    way to slow down the truck during normal opera- 2-7. LOADING AND UNLOADING. tion. If the control is not released, the truck will Move truck to location where load is to be picked accelerate in the opposite direction. Figure 2-3): The brake is fully Control arm (See Move the truck into position so forks are within applied by lowering or raising the control arm.
  • 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 of batteries. These batteries are completely sealed, will discharge and temperature. Follow safety rules when not require any watering and have a full 80% dis- 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 Figure 3-1 Transmission oil—EP SAE 10W-30 (Note) identifies the items requiring lubrication.
  • Page 17: Lubrication Diagram

    R7245 Figure 3-1 Lubrication Diagram Table 3-3 Lubrication Chart FIG 3-1 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 ate: Truck Does Not Operate Forward or Reverse: 4-1. GENERAL 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- Table 4-1 Troubleshooting Chart MALFUNCTION...
  • Page 20 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING - Continued Brake will not release. a. Defective electric brake (2, Fig- Replace brake. 12-4). b. Brake temperature above Allow to cool. 281F (140 C). c. Open brake circuitry or wiring. Make voltage checks.
  • Page 21 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in control head, & lowering sole- noid (4, Figure 12-21).
  • Page 22: 4-1.1. Controller Troubleshooting

    The Zapi Handset is avail- 4-1.4. Testing Truck Operation. able through your Blue Giant dealer. If you require The Zapi Handset can be used to test certain truck dealer location information, contact Blue Giant. operations as follows:...
  • Page 23: 4-1.5. Settings And Adjustments

    Press the ENTER button (3) to view the adjust- 4-1.5. Settings and Adjustments ments. 4-1.5.1. Set Options Press the ROLL down button (2) or the ROLL up To set options proceed as follows: button (1) to find the adjustment to be changed. Connect the Zapi Handset, refer to paragraph Press the SET up button (5) or the SET down but- 4-1.2.
  • Page 24 Table 4-2 TRACTION CONTROLLER Error Message Possible Cause Fault Elimination Code Error Text SLIP PROFILE This is an error on the choice of Check the value of the parameters in the hard- the parameters of the slip pro- ware setting menu. file.
  • Page 25 Table 4-2 TRACTION CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text BATTERY LOW This occurs when the battery Charge the battery. If charging does not help, charge is calculated being less using a voltmeter, measure the battery volt- than or equal to 10% of the full age and compare the reading with the charge and the BATTERY...
  • Page 26 Table 4-2 TRACTION CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text PEDAL WIRE The SW continuously checks for Check the Voltage on NPOT and the potenti- the connection of the two sup- ometer connections. ply ends of the potentiometer in the accelerator.
  • Page 27 Table 4-2 TRACTION CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text DEAD MAN This warning (present only in At the next travel request with dead man ABSENT trucks with “Dead Man” switch) switch closed, the warning disappears. appears when the “Dead Man”...
  • Page 28 Table 4-2 TRACTION CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text EVP DRIVER KO The EVP valve driver is not able The device or its driving circuit is damaged, to drive the load (cannot replace the controller. close).
  • Page 29 Table 4-2 TRACTION CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text PUMP VACC The minimum of the lift potentiom- It is suggested to repeat a “PROGRAM VACC” NOT OK eter is not correctly set. procedure. SENS. MOT. •...
  • Page 30 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text LOGIC This alarm occurs when the real It is necessary to replace the controller. FAILURE #1 voltage between phases W and U of the motor is different from the desired voltage.
  • Page 31 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text HIGH CURRENT This alarm occurs if the circuit to Check the motor is suited to work with the limit via hardware the current in EPS-AC0 (not oversized). Otherwise it is the motor is either always necessary to replace the controller.
  • Page 32 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text CLOCK PAL The main uC sends an analog It is necessary to replace the controller. NOT OK signal towards trhe slave uC to reset the slave uC on demand. When the slave uC detects the analog signal external to a win- dow from 2.2 to 2.8 and not in...
  • Page 33 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text MICRO SLAVE It occurs in one or the following It is necessary to replace the controller. conditions: (Open loop application only) If the slave uC detects the stator voltage phasor rotates in the opposite direction respect to the sign of the stepper motor...
  • Page 34 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text NO SYNC Every 16msec, inside the code It is necessary to replace the controller. cycle, the main uC rises and then lowers an input for the slave uC (SYNC).
  • Page 35 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text EPS NOT This is a real alarm that cuts off ALIGNED the traction. It occurs at the ini- tial alignment if the straight- ahead condition is not matched within 6 sec.
  • Page 36 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text GAIN EEPROM The parameters to compensate It is necessary to send the controller to Zapi to for the gain of the current execute the maximum current regulation. amplifiers (ADJUSTMENT #03 and ADJUSTMENT #04 are recorded in a not volatile mem-...
  • Page 37 Table 4-3 STEERING CONTROLLER - Continued Error Message Possible Cause Fault Elimination Code Error Text F.B OUT OF This alarm occurs for a fault on Check the connections of the feedback poten- RANGE the feedback potentiometer tiomerter. This alarm occurs when one con- (CPOT on CNB#6).
  • Page 38 NOTES...
  • Page 39: Steering System, Control Head And Compartment

    SECTION 5 STEERING SYSTEM, CONTROL HEAD AND COMPARTMENT Remove two screws (17, Figure 5-2) and two 5-1. CONTROL HEAD screws (20). As cap (2) is removed, cover (6) and 5-1.1. Cap Assembly Removal. spring (16) can be removed. Turn off the key switch (5, Figure 12-22) and dis- Lift up cap (2), tag and disconnect harness (34,...
  • Page 40: 5-1.2. Cap Assembly Installation

    As cap (2) is installed, install cover (6) and spring 5-1.2. Cap Assembly Installation. (16). Secure cap (2) with two screws (17) and two Hold cap (2, Figure 5-2) in place and reconnect screws (20). harness (34, Figure 5-1) to harnesses (8, 9, 12, Reconnect the batteries and turn on the key Figure 5-2).
  • Page 41: 5-1.3. Control Head Removal

    Reconnect harness (34, Figure 5-1) to switch (10, 5-1.3. Control Head Removal. Figure 5-2). Remove the cap assembly as described in para- Install the cap assembly as described in para- graph 5-1.1. graph 5-1.2. Tag and disconnect harness (34, Figure 5-1) from switch (10, Figure...
  • Page 42: 5-2.2. Control Arm Removal

    Remove screw (1) and free the gas return spring Remove screw (8, Figure 12-6), lock washer (9), (16) from bracket (15). flat washer (10), two screws (11), lock washers (9) and cover (2). Pull downward on the gas return spring (16) to free it from its seat inside control arm (23).
  • Page 43: Steering Motor

    Install cam (42) and secure with two screws (31), Disconnect position switch (2, Figure 12-3) from lock washers (2). harness (1, Figure 12-25). Position potentiometer (33) on mounting plate Remove position switch from the frame. (32) and secure with plate (39), two screws (41), Disconnect harness (1) from steering motor (16, lock washers (19), and flat washers (20).
  • Page 44 NOTES...
  • Page 45: Brake Servicing

    SECTION 6 BRAKE SERVICING Disconnect electric brake (2, Figure 6-1) from the 6-1. BRAKES. harness (1, Figure 12-25). The brake system consists of a drive motor mounted Remove three screws (23, Figure 6-1) and brake. This brake is spring applied and electrically remove brake (2).
  • Page 46 R7220 Figure 6-1 Drive Assembly...
  • Page 47: 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 (5, Figure 12-22) and dis- 7-3.1. Removal connect the batteries. Turn off the key switch (5, Figure 12-22) and dis- Remove the compartment covers as described in connect the batteries.
  • Page 48 R7220 Figure 7-1 Drive Assembly...
  • Page 49 R7223 Figure 7-2 Load Wheels...
  • Page 50 NOTES...
  • 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. 8-2.1. Telescopic Fully lower the lift carriage. Turn off the key switch (5, Figure 12-22) and dis- connect the batteries.
  • Page 52 R7224 Figure 8-2 Elevation System (Telescopic)
  • Page 53: 8-2.2. Three Stage Mast Free Lift Chain

    Loosen jam nuts (2, Figure 8-1), the mount of 8-2.2. Three Stage Mast Free Lift Chain outer mast (1, Figure 8-3), to allow for adjustment Fully lower the lift carriage. of middle jam nut. Turn off the key switch (5, Figure 12-22) and dis- Break the lower jam nuts (2,...
  • Page 54 R7225 Figure 8-3 Mast (Three Stage Mast)
  • Page 55: Lift Chain Replacement

    Remove cotter pin (3) and clevis pin (4) connect- 8-4. LIFT CHAIN REPLACEMENT. ing chain (5) to chain anchor (1) at free lift cylinder 8-4.1. Telescopic 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 56 NOTES...
  • Page 57: Hydraulic System Servicing

    SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS 9-2.1. Removal Lower forks fully. WARNING: When forks are raised, pressure exists in the hydraulic system lines and fittings. To Turn off the key switch (5, Figure 12-22) and dis- ensure release of pressure, forks must connect the batteries.
  • Page 58 R7228 Figure 9-1 Hydraulic System...
  • Page 59: Lift Cylinder (Telescopic)

    Using another lift truck or suitable jack, raise mast 9-3. Lift Cylinder (Telescopic) (16) far enough to remove pressure on the lift cyl- 9-3.1. Removal inder (15). Fully lower the lift carriage. Hydraulic oil can damage parts. Wipe off CAUTION: Turn off the key switch (5, Figure 12-22) and dis-...
  • Page 60 R7224 Figure 9-3 Elevation System (Telescopic)
  • Page 61: 9-3.3. Installation

    Operate the lift and lower buttons to refill the 9-3.2. Repair cylinders and lines with hydraulic oil. CAUTION: To prevent damage, use proper pipe Check level of hydraulic oil. If required, add clamp vise. The cylinder will be distorted hydraulic oil to bring to proper level. Use hydraulic if the vise is tightened too much.
  • Page 62: Lift Cylinder (Three Stage Mast Free Lift)

    Using another lift truck or suitable jack, raise lift 9-4. Lift Cylinder (Three Stage Mast Free Lift) carriage far enough to remove pressure on the 9-4.1. Removal free lift cylinder Fully lower the lift carriage. Remove cotter pin and clevis pin connecting the lift chain to the anchor at cylinder (9, Figure 9-6).
  • Page 63 Hydraulic oil can damage parts. Wipe off Disconnect the tube (9, Figure 9-5) from the bot- CAUTION: any oil immediately. Provide a container tom of lift cylinder. under the line or fitting before discon- Support cylinder (9, Figure 9-6) and remove two necting.
  • Page 64: 9-4.2. Repair

    Operate the lift and lower buttons to refill the 9-4.2. Repair cylinder and lines with hydraulic oil. CAUTION: To prevent damage, use proper pipe Check level of hydraulic oil. If required, add clamp vise. The cylinder will be distorted hydraulic oil to bring to proper level. Use hydraulic if the vise is tightened too much.
  • Page 65: Lift Cylinder (Three Stage Mast Secondary)

    Remove backup ring (6) and packing (8) from pis- 9-5. Lift Cylinder (Three Stage Mast Secondary) ton rod (4). 9-5.1. Removal Coat all parts with hydraulic oil (Table 3-2). Fully lower the lift carriage. Install packing (8) and backup ring (6) on piston Turn off the key switch (5, Figure 12-22) and dis-...
  • Page 66: Secondary Lift Cylinder (Three Stage Mast)

    R7234 Figure 9-8 Secondary Lift Cylinder (Three Stage Mast)
  • Page 67: 9-5.4. Tilt Cylinders

    under the line or fitting before discon- 9-5.4. Tilt Cylinders necting. 9-5.4.1.Removal Remove the front compartment covers as WARNING: Mast must be supported by a hoist described in paragraph 5-3. before removing the tilt cylinders. Support the mast in an upright position. Secure mast with a hoist and safety chains and Disconnect hoses (13 &...
  • Page 68 15. Install bearing (2) and retaining rings (3) in clevis 9-5.4.2.Repair (1). CAUTION: To prevent damage, use proper pipe 16. Install clevis (1) on piston rod (11) and secure with clamp vise. The cylinder will be distorted bolt (4), lock washer (5) and nut (6). if the vise is tightened too much.
  • Page 69 R7236 Figure 9-10 Tilt Cylinder...
  • Page 70 NOTES...
  • Page 71: Electrical Components

    SECTION 10 ELECTRICAL COMPONENTS Tag and disconnect all electrical cables which 10-1.ELECTRICAL CONTROL PANEL connect to the control panel (4, Figure 10-1). 10-1.1.Maintenance Remove four screws (1), four lock washers (2), four flat washers (3) and control panel (4). NOTE: Erratic operation of the truck may be caused by defective controller.
  • Page 72 R6478 R7237 Figure 10-1 Electrical System...
  • Page 73 R6478 R7238 Figure 10-2 Electrical Panel...
  • Page 74: Pump Motor

    Position cables as noted in removal and recon- 10-3.PUMP MOTOR. nect cables to the drive motor. Refer to paragraph 9-2. Reinstall the brake as described in paragraph 6-1.1. 10-4.DRIVE MOTOR. Reinstall the drive wheel (6) as described in para- The drive motor exposed surfaces should be cleaned graph 7-1.
  • Page 75 R6879 Figure 10-3 Transmission, Motor, Brake Assembly...
  • Page 76 NOTES...
  • Page 77: Optional Equipment

    SECTION 11 OPTIONAL EQUIPMENT...
  • Page 78 NOTES...
  • Page 79: Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the BGL-33 Lift Truck.
  • Page 80 R7217 Figure 12-1 Control Arm...
  • Page 81 CONTROL ARM Qty. Pos. Part Number Description Notes Reqd. 0000-000322-00 SCREW, M8 X 25 0000-000159-00 WASHER, LOCK, M8 0000-000176-00 WASHER, FLAT, M8 0000-000283-00 BOLT, M10 X 35 0000-000063-00 WASHER, LOCK, M10 0000-000007-00 WASHER, FLAT, M10 0000-000004-00 SCREW, M5 X 12 0000-000491-00 CLAMP 1280-300005-00...
  • Page 82 R7217 Figure 12-1 Control Arm - Continued...
  • Page 83: Control Arm

    CONTROL ARM - CONTINUED Qty. Pos. Part Number Description Notes Reqd. 2333-330000-10 CONTROL ARM 2322-300002-00 SLEEVE 0000-000142-00 BEARING 6011-2Z 0000-000321-00 SCREW, M8 X 20 2333-310000-00 HANDLE BRACKET 1280-370000-10 DAMPING STEERING BOX 0000-000321-00 SCREW, M8 X 20 2322-300001-00 SUPPORT 0000-000109-00 SCREW, M8 X 16 1221-300002-00 MOUNTING PLATE POTENTIOMETER WITH WIRE...
  • Page 84 R7218 Figure 12-2 Control Head...
  • Page 85: Control Head

    CONTROL HEAD Qty. Pos. Part Number Description Notes Reqd. — 2333-340000-00-B CONTROL HEAD ASSEMBLY 2333-340001-00 COVER 2333-340002-00 2333-340003-00 TRAVEL LEVER R 2333-340004-00 TRAVEL LEVER L 2333-340005-00 HORN BUTTON 2333-340006-00 BELLY BUTTON COVER 2333-340007-00 TILT BUTTON 2333-340008-00 LIFT LOWER SWITCH 2333-520005-10 HORN WIRE HARNESS BELLY BUTTON SWITCH 2333-520004-10...
  • Page 86 R7219 Figure 12-3 Drive System...
  • Page 87: Drive Assembly

    DRIVE SYSTEM Qty. Pos. Part Number Description Notes Reqd. 2333-200000-10 DRIVE ASSEMBLY 1280-520009-10 POSITION SWITCH WIRE HARNESS...
  • Page 88 R7220 Figure 12-4 Drive Assembly...
  • Page 89: Drive Assembly

    DRIVE SYSTEM Qty. Pos. Part Number Description Notes Reqd. — 2333-200000-00 DRIVE ASSEMBLY 2333-240000-10 DRIVE MOTOR 2333-210000-00 BRAKE ASSEMBLY 2333-200002-10 BEARING 2333-200003-10 GEAR 2333-220000-10 TRANSMISSION 2333-230000-10 DRIVE WHEEL 0000-000869-00 BOLT, M8 X 40 0000-000154-00 SCREW, M8 X 35 0000-000159-00 WASHER, LOCK, M8 0000-000176-00 WASHER, FLAT, M8 0000-000516-00...
  • Page 90 R7221 Figure 12-5 Compartment...
  • Page 91: Compartment

    COMPARTMENT Qty. Pos. Part Number Description Notes Reqd. 0000-000433-00 SCREW, M8 X 12 2130-190002-00 MIDDLE COVER 0000-000649-00 SCREW, M8 X 20 2130-190001-00 UPPER COVER 2130-172000-00 HINGE BLOCK L 2130-182000-00 HINGE BLOCK R 2333-131000-00 COVER ASSEMBLY L 2333-141000-00 COVER ASSEMBLY R 1220-150005-00 NUT, M8 0000-000109-00...
  • Page 92 R7222 Figure 12-6 Frame...
  • Page 93: Frame

    FRAME Qty. Pos. Part Number Description Notes Reqd. 2333-100002-00 COVER 2333-120000-00 BATTERY COVER 2333-100001-10 CABLE BAFFLE 2333-150000-00 COUNTER WEIGHT L 2333-160000-00 COUNTER WEIGHT R 0000-000368-00 SCREW, M8 X 12 2214-150002-00 WASHER 0000-000242-00 BOLT, M8 X 16 0000-000159-00 WASHER, LOCK, M8 0000-000176-00 WASHER, FLAT, M8 0000-000026-00...
  • Page 94 R7222 Figure 12-6 Frame - Continued...
  • Page 95 FRAME - CONTINUED Qty. Pos. Part Number Description Notes Reqd. 1280-180001-0A BLOCK 0000-000279-00 BOLT, M8 X 35 2125-100002-00 BATTERY CLIP 2140-100001-00 BATTERY BLOCK...
  • Page 96 R7223 Figure 12-7 Load Wheels...
  • Page 97: Load Wheels

    LOAD WHEELS Qty. Pos. Part Number Description Notes Reqd. 0000-000700-00 SCREW, M8 X 16 2320-600003-00 COVER 0000-000620-00 BOLT, M6 X 16 0000-000056-00 WASHER, LOCK, M6 0000-000380-00 WASHER, FLAT, M6 2320-600002-00 RETAINER 2320-601100-00 LOAD WHEEL 2320-600001-00 MOUNTING BASE 0000-000379-00 WASHER, FLAT, M14 0000-000233-00 WASHER, LOCK, M14 0000-001028-00...
  • Page 98 R7224 Figure 12-8 Elevation System (Telescopic)
  • Page 99: Elevation System (Telescopic)

    ELEVATION SYSTEM (TELESCOPIC) Qty. Pos. Part Number Description Notes Reqd. 2125-612000-00 ROLLER ASSEMBLY 2214-600001-00 CHAIN ROLLER 0000-000244-00 BOLT, M10 X 30 0000-000071-00 WASHER, FLAT, M10 0000-000109-00 SCREW, M8 X 16 0000-000159-00 WASHER, LOCK, M8 0000-000176-00 WASHER, FLAT, M8 0000-000285-00 BOLT, M12 X 35 0000-000060-00 WASHER, LOCK, M12 0000-000283-00...
  • Page 100 R7224 Figure 12-8 Elevation System (Telescopic) - Continued...
  • Page 101: Elevation System (Telescopic)

    ELEVATION SYSTEM (TELESCOPIC) - CONTINUED Qty. Pos. Part Number Description Notes Reqd. Used for 2333-610000-00-01 OUTER MAST Lift Height 104” Used for 2333-610000-00-03 OUTER MAST Lift Height 126” See Lift Carriage LIFT CARRIAGE — Section 2214-600007-00 CUSHION BLOCK II 2130-500002-0A SENSOR BRACKET 2130-500001-0A SENSOR BRACKET...
  • Page 102 R7225 Figure 12-9 Elevation System (Three Stage Mast)
  • Page 103: Elevation System (Three Stage Mast)

    ELEVATION SYSTEM (THREE STAGE MAST) Qty. Pos. Part Number Description Notes Reqd. Used for 2333-610000-30-01 OUTER MAST Lift Height 157” Used for 2333-610000-30-02 OUTER MAST Lift Height 177” 0000-000285-00 BOLT, M12 X 35 0000-000060-00 WASHER, LOCK, M12 0000-000283-00 BOLT, M10 X 35 0000-000063-00 WASHER, LOCK, M10 2125-612000-00...
  • Page 104 R7225 Figure 12-9 Elevation System (Three Stage Mast) - Continued...
  • Page 105: Elevation System (Three Stage Mast)

    ELEVATION SYSTEM (THREE STAGE MAST) - CONTINUED Qty. Pos. Part Number Description Notes Reqd. 0000-000222-00 WASHER, FLAT, M12 2125-600002-30 HOSE ROLLER 2125-600003-00 BUSHING Used for 2333-630000-30-01 INNER MAST Lift Height 157” Used for 2333-630000-30-02 INNER MAST Lift Height 177” Used for 2130-410000-30-01 CYLINDER, SECONDARY LIFT Lift Height 157”...
  • Page 106 R7225 Figure 12-9 Elevation System (Three Stage Mast) - Continued...
  • Page 107 ELEVATION SYSTEM (THREE STAGE MAST) - CONTINUED Qty. Pos. Part Number Description Notes Reqd. Used for 2125-500002-00 PROXIMITY SWITCH, 8104 Lift Height 157” Used for 2125-500003-00 PROXIMITY SWITCH, 8104 Lift Height 177” Used for 2125-520009-22 PROXIMITY SWITCH HARNESS Lift Height 157” Used for 2125-520009-24 PROXIMITY SWITCH HARNESS...
  • Page 108 R7226 Figure 12-10 Lift Carriage (Telescopic)
  • Page 109: Lift Carriage (Telescopic)

    LIFT CARRIAGE (TELESCOPIC) Qty. Pos. Part Number Description Notes Reqd. 0000-000284-00 BOLT, M12 X 30 0000-000060-00 WASHER, LOCK, M12 0000-000373-00 WASHER, FLAT, M12 2320-631000-00 BACKREST 2130-631000-00 LIFT CARRIAGE 2125-630001-00 FORK 2125-630001-10 PIN ASSEMBLY 2125-612000-00 ROLLER ASSEMBLY 0000-000030-00 SCREW, M10 X 16...
  • Page 110 R7227 Figure 12-11 Lift Carriage (Three Stage Mast)
  • Page 111: Lift Carriage (Three Stage Mast)

    LIFT CARRIAGE (Three Stage Mast) Qty. Pos. Part Number Description Notes Reqd. 0000-000221-00 BOLT, M12 X 30 0000-000060-00 WASHER, LOCK, M12 0000-000373-00 WASHER, FLAT, M12 2320-631000-00 BACKREST 2125-641000-30 LIFT CARRIAGE 2125-630001-00 FORK 2125-630001-10 PIN ASSEMBLY 2125-612000-00 ROLLER ASSEMBLY 0000-000030-00 SCREW, M10 X 16...
  • Page 112 R6818 Figure 12-12 Chain Assembly...
  • Page 113: Chain Assembly

    CHAIN ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 2125-640001-00 ADJUSTING BOLT 0000-000187-00 NUT, M16 X 1.5 0000-000188-00 COTTER PIN, M3.2 X 20 2125-640002-00 Used for CHAIN I 2125-640000-00-02 Lift Height 104”, (MOUNTS TO FREE LIFT CYL) Telescopic Mast Used for CHAIN I 2125-640000-00-04 Lift Height 126”,...
  • Page 114 R7228 Figure 12-13 Hydraulic System...
  • Page 115: Hydraulic System

    HYDRAULIC SYSTEM Qty. Pos. Part Number Description Notes Reqd. 0000-000155-00 SCREW, M10 X 40 0000-000063-00 WASHER, LOCK, M10 0000-000007-00 WASHER, FLAT, M10 2112-410004-00 WASHER 2333-460000-10 PUMP AND MOTOR ASSEMBLY 2333-411000-00 RESERVOIR 0000-000056-00 WASHER, LOCK, M6 0000-000620-00 BOLT, M6 X 16 2125-420001-00 MAGNET 0000-000635-00...
  • Page 116 R7235 Figure 12-14 Tilt System...
  • Page 117: Tilt Cylinder

    TILT SYSTEM Qty. Pos. Part Number Description Notes Reqd. 0000-000255-00 BOLT, M8 X 20 0000-000159-00 WASHER, LOCK, M8 0000-000176-00 WASHER, FLAT, M8 2333-400001-00 SHAFT 2333-440000-00 TILT CYLINDER 0000-000321-00 SCREW, M8 X 20 3218-840000-00 SHAFT...
  • Page 118 R7230 Figure 12-15 Lift System (Telescopic)
  • Page 119: Lift System (Telescopic)

    LIFT SYSTEM (TELESCOPIC) Qty. Pos. Part Number Description Notes Reqd. 0000-000069-00 SEAL, M16 CONNECTOR, 2706-161600-00 M16 x 1.5 x M16 x 1.5 2130-470000-00 TUBE ASEMBLY 2125-400002-3A MANIFOLD 2712-141300-00 PLUG, G1/4 0000-000169-00 SCREW, M8 X 30 CONECTOR, 2701-161600-00 M16 X 1.5 X M16 X 1.5 0000-000044-00 SEAL, M14...
  • Page 120 R7231 Figure 12-16 Lift System (Three Stage Mast)
  • Page 121: Lift System (Three Stage Mast)

    LIFT SYSTEM (Three Stage Mast) Qty. Pos. Part Number Description Notes Reqd. 0000-000069-00 SEAL, M16 CONNECTOR, 2706-161600-00 M16 x 1.5 x M16 x 1.5 2130-430000-30 TUBE ASEMBLY 2125-400002-30 MANIFOLD CONECTOR, 2701-161600-00 M16 X 1.5 X M16 X 1.5 0000-000169-00 SCREW, M8 X 30 2702-142000-00 CONNECTOR, G1/4 X M20 X 1.5 0000-000044-00...
  • Page 122 R7232 Figure 12-17 Lift Cylinder (Telescopic)
  • Page 123: Lift Cylinder (Telescopic)

    LIFT CYLINDER (TELESCOPIC) Qty. Pos. Part Number Description Notes Reqd. Used for 2130-410000-00-01 LIFT CYLINDER Lift Height 104”, — Telescopic Mast Used for 2130-410000-00-02 LIFT CYLINDER Lift Height 126”, — Telescopic Mast 2130-2BG SEAL KIT Includes 1,2,8 — 0000-000084-00 RING, WIPER, 35 X 43 X 5-6.5 0000-000370-00 O-RING, 40 X 3.1 1220-420001-0A...
  • Page 124 R7233 Figure 12-18 Free Lift Cylinder (Three Stage Mast)
  • Page 125: Free Lift Cylinder (Three Stage Mast)

    FREE LIFT CYLINDER (Three Stage Mast) Qty. Pos. Part Number Description Notes Reqd. Used for 2333-420000-30-01 FREE LIFT CYLINDER Lift Height 157”, — Three Stage Mast Used for 2333-420000-30-02 FREE LIFT CYLINDER Lift Height 177”, — Three Stage Mast 2333-ZZG-3A SEAL KIT Includes 1,2,7 —...
  • Page 126 R7234 Figure 12-19 Secondary Lift Cylinder (Three Stage Mast)
  • Page 127 SECONDARY LIFT CYLINDER (Three Stage Mast) Qty. Pos. Part Number Description Notes Reqd. Used for 2130-410000-30-01 SECONDARY LIFT CYLINDER Lift Height 157”, — Three Stage Mast Used for 2130-410000-30-02 SECONDARY LIFT CYLINDER Lift Height 177”, — Three Stage Mast 2130-2BG SEAL KIT Includes 1,2,3 —...
  • Page 128 R7236 Figure 12-20 Tilt Cylinder...
  • Page 129: Tilt Cylinder

    TILT CYLINDER Qty. Pos. Part Number Description Notes Reqd. 2333-440000-00 TILT CYLINDER — 2320-QXG-0A SEAL KIT Includes 7,8,9,10 — 2333-440001-00 CLEVIS 0000-001012-00 BEARING, GE30ES 0000-000849-00 SEAL, M47 0000-001013-00 BOLT, M14 X 55 0000-000233-00 WASHER, LOCK, M14 0000-001014-00 NUT, M14 0000-001017-00 DUST SEAL, LYO 30 X 47 X 10 0000-001016-00 SEAL, 30 X 43 X 7...
  • Page 130 R7229 Figure 12-21 Pump and Motor...
  • Page 131: Pump And Motor

    PUMP AND MOTOR Qty. Pos. Part Number Description Notes Reqd. 2333-460000-10 PUMP & MOTOR ASSEMBLY — 2130-470002-40 MOTOR 2320-421008-00 PUMP SOLENOID 2320-421016-00 SOLENOID VALVE Lift & Tilt PROPORTIONAL SOLENOID 2333-460001-10 Lower VALVE 2320-421002-00 PUMP 2320-421012-00 PLASTIC TUBE 2320-421013-00 FILTER, STEEL 2130-470003-40 BRUSH...
  • Page 132 R7237 Figure 12-22 Electrical System...
  • Page 133: Electrical System

    ELECTRICAL SYSTEM Qty. Pos. Part Number Description Notes Reqd. 0000-000321-00 SCREW, M8 X 20 0000-000159-00 WASHER, LOCK, M8 0000-000194-00 WASHER, FLAT, M8 See Electrical ELECTRICAL PANEL — Panel Section 1220-520002-1C KEY SWITCH 1115-510006-20 HOUR METER 1220-520007-0D METER WIRING HARNESS 0000-000170-00 SCREW, M6 X 30 0000-000056-00 WASHER, LOCK, M6...
  • Page 134 R7238 Figure 12-23 Electrical Panel...
  • Page 135 ELECTRICAL PANEL Qty. Pos. Part Number Description Notes Reqd. 2333-510001-00 CONTROLLER 0000-000074-00 SCREW, M6 X 20 0000-000056-00 WASHER, LOCK, M6 0000-000380-00 WASHER, FLAT, M6 0000-000196-00 NUT, M8 0000-000210-00 WASHER, FLAT, M8 1120-540002-00 FUSE, 200A 0000-000126-00 SCREW, M6 X 16 1280-560002-00 CONTROLLER, AC 1120-540001-00-B FUSE BLOCK 1280-510002-00...
  • Page 136 R7001A Figure 12-24 Battery Assembly (Optional)
  • Page 137 BATTERY ASSEMBLY (OPTIONAL) Qty. Pos. Part Number Description Notes Reqd. 0000-000055-00 SCREW M6×16 0000-000056-00 LOCK WASHER Ø6 0000-000023-00 FLAT WASHER Ø6 1145-550003-20 WASHER RUBBER 1145-550001-20 BLOCK 0000-000119-00 SCREW M5×8 0000-000206-00 LOCK WASHER Ø5 1145-552000-2D BATTERY COVER 003232 BATTERY 1120-560000-00 CHARGER 1145-553002-2L M2 CABLE 1145-553001-20...
  • Page 138 R7240 Figure 12-25 Wire Harness...
  • Page 139: Wire Harness

    WIRE HARNESS Qty. Pos. Part Number Description Notes Reqd. 2333-520001-00 WIRE HARNESS 1120-500010-00 FUSE, 10A...
  • Page 140 R7241 Figure 12-26 Wiring Cables...
  • Page 141 WIRE CABLES Qty. Pos. Part Number Description Notes Reqd. 2333-530001-00 DRIVE MOTOR CABLE U 2333-530002-00 DRIVE MOTOR CABLE V 2333-530003-00 DRIVE MOTOR CABLE W 2333-530004-00 PUMP MOTOR CABLE + 2333-530005-00 PUMP MOTOR CABLE - 2333-530006-10 STREEING MOTOR CABLE U 2333-530007-10 STREEING MOTOR CABLE V 2333-530008-10 STREEING MOTOR CABLE W...
  • Page 142 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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