Blue Giant BG ZERO - Default Chapter; Table of Contents

TABLE OF CONTENTS
Section Page Section Page
1 DESCRIPTION............................................................1-1
1-1 INTRODUCTION ..........................................1-1
1-2 GENERAL DESCRIPTION ...........................1-1
1-3 DATA PLATE AND WARNING DECAL ........1-3
1-4 INSTALLATION / WARRANTY
CHECK LIST.................................................1-3
2 PLANNED MAINTENANCE ........................................2-1
2-1 GENERAL.....................................................2-1
2-2 MONTHLY AND QUARTERLY CHECKS.....2-1
2-3 FREQUENT INSPECTIONS.........................2-1
2-4 ANNUAL INSPECTIONS..............................2-1
2-5 BATTERY CARE ..........................................2-1
2-5.1 General.....................................................2-1
2-5.2 Safety Rules .............................................2-2
2-5.3 Maintenance Personnel............................2-2
2-5.4 Battery Care and Charging.......................2-2
2-5.5 Battery Cleaning .......................................2-2
2-5.6 Maintenance Free Batteries .....................2-2
2-6 CHARGING BATTERIES..............................2-3
2-7 REPLACING BATTERIES ............................2-3
2-7.1 Battery disposal ........................................2-3
2-8 LUBRICATION..............................................2-4
2-9 LIFT CHAIN MAINTENANCE .......................2-4
3 TROUBLESHOOTING ................................................3-1
3-1 GENERAL.....................................................3-1
3-2 CONTROLLER TROUBLESHOOTING ........3-4
3-2.1 Zapi Handset ............................................3-4
3-2.2 Fault Detection .........................................3-4
3-2.2.1 General.................................................3-4
3-2.2.2 Logbook Access...................................3-4
3-2.3 Testing Vehicle Operation ........................3-4
3-2.4 Factory Settings........................................3-5
4 STEERING SYSTEM ..................................................4-1
4-1 CONTROL ARM ...........................................4-1
4-1.1 Steering Control Removal ........................4-1
4-1.2 Steering Control Installation .....................4-2
4-2 FRONT COMPARTMENT COVER...............4-2
4-2.1 Cover Removal.........................................4-2
4-2.2 Cover Installation......................................4-2
4-3 REAR COMPARTMENT COVER.................4-2
4-3.1 Cover Removal.........................................4-2
4-3.2 Cover Installation......................................4-2
4-4 STEERING MOTOR .....................................4-3
4-4.1 Motor Removal .........................................4-3
4-4.2 Motor Installation ......................................4-3
5 BRAKE SERVICING....................................................5-1
5-1 BRAKES .......................................................5-1
5-1.1 Brake Assembly Replacement .................5-1
6 TRANSMISSION, DRIVE WHEEL,
LOAD WHEEL AND CASTERS.................................. 6-1
6-1 TRANSMISSION AND DRIVE MOTOR....... 6-1
6-2 LOAD WHEEL.............................................. 6-2
6-2.1 Removal................................................... 6-2
6-2.2 Installation................................................ 6-2
6-3 DRIVE WHEEL ............................................ 6-2
6-4 CASTER....................................................... 6-2
7 ELEVATION SYSTEM SERVICING............................ 7-1
7-1 GENERAL .................................................... 7-1
7-2 LIFT CHAIN LENGTH ADJUSTMENT......... 7-1
7-3 LIFT CHAIN WEAR INSPECTION............... 7-2
7-4 LIFT CHAIN REPLACEMENT...................... 7-2
7-4.1 Three Stage Mast .................................... 7-2
7-4.1.1 Mast Lifting Chain................................ 7-2
7-5 LIFT CYLINDERS ........................................ 7-2
8 HYDRAULIC SYSTEM SERVICING........................... 8-1
8-1 LINES AND FITTINGS................................. 8-1
8-2 HYDRAULIC PUMP, MOTOR,
AND RESERVOIR ASSEMBLY ................... 8-1
8-2.1 Removal................................................... 8-1
8-2.2 Installation................................................ 8-3
8-2.3 Disassembly and Reassembly................. 8-3
8-3 LIFT CYLINDER - MAIN .............................. 8-3
8-3.1 Removal................................................... 8-3
8-3.2 Repair ...................................................... 8-4
8-3.3 Installation................................................ 8-4
8-4 LIFT CYLINDER - TRAY.............................. 8-4
8-4.1 Removal................................................... 8-4
8-4.2 Repair ...................................................... 8-4
8-4.3 Installation................................................ 8-4
9 ELECTRICAL COMPONENTS................................... 9-1
9-1 ELECTRICAL CONTROL PANEL................ 9-1
9-1.1 Maintenance ............................................ 9-1
9-1.2 Cleaning................................................... 9-1
9-1.3 Panel Removal......................................... 9-1
9-1.4 Panel disassembly ................................... 9-1
9-1.5 Panel Installation...................................... 9-1
9-2 HORN REPLACEMENT............................... 9-1
9-3 LOWERING BUZZER REPLACEMENT ...... 9-3
9-4 LEVEL SENSOR BUZZER
REPLACEMENT .......................................... 9-3
9-5 LEVEL SENSOR REPLACEMENT.............. 9-3
9-6 WARNING LIGHT REPLACEMENT ............ 9-3
9-7 BLUE LIGHT REPLACEMENT .................... 9-3
9-8 BATTERY REPLACEMENT......................... 9-4
9-9 BATTERY CHARGER.................................. 9-4
9-9.1 Removal................................................... 9-4
9-9.2 Installation................................................ 9-4
9-10 PLATFORM CABLE REPLACEMENT......... 9-5
9-10.1 Three Stage Mast .................................... 9-5
10 OPTIONAL EQUIPMENT ......................................... 10-1
10-1 INDUSTRIAL BATTERY ........................... 10-1
11 ILLUSTRATED PARTS BREAKDOWN......................11-1
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