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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.
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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.
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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 ............
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;...
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.
• 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.
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.
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.
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.
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.
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.
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.
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...
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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. 281F (140 C). c. Open brake circuitry or wiring. Make voltage checks.
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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).
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:...
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.
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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.
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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...
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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.
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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”...
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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).
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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. •...
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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.
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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.
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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...
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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...
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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).
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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.
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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-...
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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).
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,...
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).
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...
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).
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).
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).
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.
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.
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R7224 Figure 8-2 Elevation System (Telescopic)
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,...
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).
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.
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-...
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R7224 Figure 9-3 Elevation System (Telescopic)
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.
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).
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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.
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.
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-...
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 &...
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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.
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.
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.
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...
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...
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...
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...
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R7225 Figure 12-9 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”...
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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...
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”,...
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...
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R7231 Figure 12-16 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...
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...
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 —...
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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 —...
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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...
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