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BG ZERO
Blue Giant BG ZERO - User Manual
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OWNER’S MANU
AL
BG ZERO T
ASK SUPPORT VEHICLE
W
ARNING
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:
DECEMBER 7
, 2020 REV
.
1.
0 (PART # 038-XXXXE)
ACTUAL PRODUCT MA
Y NOT APPEAR EXACTL
Y AS SHOWN
2
Table of Contents
Main Page
Default Chapter
3
Table of Contents
3
1 Description
5
Introduction
5
General Description
5
Data Plate and Warning Decal
7
Installation / Warranty Check List
7
2 Planned Maintenance
9
General
9
Monthly and Quarterly Checks
9
Frequent Inspections
9
Annual Inspections
9
Battery Care
9
2-5.2 Safety Rules
10
2-5.3 Maintenance Personnel
10
2-5.4 Battery Care and Charging
10
2-5.5 Battery Cleaning
10
2-5.6 Maintenance Free Batteries
10
Charging Batteries
11
Replacing Batteries
11
2-7.1 Battery Disposal
11
Lubrication
12
Lift Chain Maintenance
12
3 Troubleshooting
15
General
15
Controller Troubleshooting
18
3-2.1 Zapi Handset
18
3-2.2 Fault Detection
18
3-2.2.1 General
18
3-2.2.2 Logbook Access
18
3-2.3 Testing Vehicle Operation
18
3-2.4 Factory Settings
19
4 Steering System
25
Control Arm
25
4-1.1 Steering Control Removal
25
4-1.2 Steering Control Installation
26
Front Compartment Cover
26
4-2.1 Cover Removal
26
4-2.2 Cover Installation
26
Rear Compartment Cover
26
Steering Motor
27
4-4.1 Motor Removal
27
4-4.2 Motor Installation
27
5 Brake Servicing
29
Brakes
29
5-1.1 Brake Assembly Replacement
29
6 Transmission, Drive Wheel, Load Wheel and Casters
31
Transmission and Drive Motor
31
Load Wheel
32
6-2.1 Removal
32
6-2.2 Installation
32
Drive Wheel
32
Caster
32
7 Elevation System Servicing
35
General
35
Lift Chain Length Adjustment
35
Lift Chain Wear Inspection
36
Lift Chain Replacement
36
7-4.1 Three Stage Mast
36
7-4.1.1 Mast Lifting Chain
36
Lift Cylinders
36
8 Hydraulic System Servicing
41
Lines and Fittings
41
Hydraulic Pump, Motor
41
8-2.1 Removal
41
8-2.3 Disassembly and Reassembly
43
Lift Cylinder - Main
43
8-3.1 Removal
43
8-3.2 Repair
44
8-3.3 Installation
44
Lift Cylinder - Tray
44
8-4.1 Removal
44
9 Electrical Components
47
Electrical Control Panel
47
9-1.1 Maintenance
47
9-1.2 Cleaning
47
9-1.3 Panel Removal
47
9-1.4 Panel Disassembly
47
9-1.5 Panel Installation
47
Horn Replacement
47
Lowering Buzzer Replacement
49
Level Sensor Buzzer Replacement
49
Level Sensor Replacement
49
Warning Light Replacement
49
Blue Light Replacement
49
Battery Replacement
50
Battery Charger
50
9-9.1 Removal
50
9-9.2 Installation
50
Platform Cable Replacement
51
9-10.1 Three Stage Mast
51
10 Optional Equipment
57
Industrial Battery
57
11 Illustrated Parts Breakdown
59
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Blue Giant BG ZERO Specifications
General
Brand
Blue Giant
Model
BG ZERO
Category
Utility Vehicle
Language
English
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