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BGL-22
Blue Giant BGL-22 User Manual
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OWNER’S MANU
AL
BGL
-22 W
ALKIE COUNTERBALANCED ST
ACKER
ISSUE DATE:
MAY 5
, 20
20
REV
.0 (PART # 038-926E)
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.
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 Description
5
Introduction
5
General Description
5
Safety Features
5
Name Plate
5
2 Operation
7
General
7
Operating Precautions
7
Load Center
7
Before Operation
8
Lift Truck
8
Sample of Operator Check List
9
General Control Operation
10
Driving and Stopping Procedures
10
2-5.1. Stopping
10
Forward/Reverse Control
10
Pushbutton Switches
10
Belly-Button Switch
11
Steering Arm Gas Spring
11
Lift and Lower Controls
11
Tilt Controls
11
Loading and Unloading
11
Parking
11
Brake Actuation
11
3 Planned Maintenance
13
General
13
Monthly and Quarterly Checks
13
Battery Care
13
3-3.2. Safety Rules
14
3-3.3. Battery Care and Charging
14
3-3.4. Battery Cleaning
14
3-3.5. Maintenance Free Batteries
15
Charging Batteries
15
Lubrication
16
Lift Chain Maintenance
16
Lubrication Diagram
17
4 Troubleshooting
19
General
19
Hydraulic System
20
Controller Troubleshooting
22
4-2.1. Zapi Handset
22
4-2.2. Fault Detection
22
4-2.3. Testing Truck Operation
22
4-2.4. Settings and Adjustments
23
Zapi Handset
23
Zapi Handset
27
Zapi Handset
29
Zapi Controller
31
Zapi Controller Connections
31
5 Steering Arm, Control Head and Compartment
35
Control Head
35
5-1.1. Cap Assembly Removal
35
5-1.2. Cap Assembly Installation
36
Steering Arm
36
5-1.3. Control Head Removal
37
5-1.4. Control Head Installation
37
5-1.5. Speed Potentiometer Replacement
37
5-1.6. Belly-Button Switch Replacement
37
5-1.7. Horn Switch Replacement
37
5-1.8. Lift and Lower Switch
38
Emergency Reverse Switch Assembly
38
Cap Assembly
39
5-1.9. Tilt Switch Replacement
40
Steering Arm
40
5-2.1. Return Spring Replacement
40
5-2.2. Steering Arm Removal
40
5-2.3. Steering Arm Installation
40
Compartment Covers
40
5-3.1. Removal
40
5-3.2. Installation
40
6 Brake Servicing
41
Brakes
41
6-1.1. Brake Assembly Replacement
41
Transmission, Motor, Brake Assembly
42
7 Transmission, Drive Wheel, Load Wheel
43
Drive Wheel
43
Transmission
43
Load Wheel
43
7-3.1. Removal
43
7-3.2. Load Wheel Installation
43
Transmission, Motor, Brake Assembly
44
Load Wheels
45
8 Elevation System Servicing
47
General
47
Lift Chain Length Adjustment
47
8-2.1. Telescopic
47
Chain Assembly
47
Elevation System (Telescopic)
48
8-2.2. Trimast Free Lift Chain
49
8-2.3. Trimast Secondary Lift Chain
49
Lift Chain Wear Inspection
49
Lift Chain Replacement
51
8-4.1. Telescopic
51
8-4.2. Trimast Free Lift Chain
51
8-4.3. Trimast Secondary Lift Chain
51
Lift Cylinders
51
9 Hydraulic System Servicing
53
Lines and Fittings
53
Hydraulic Pump, and Motor Assy
53
9-2.1. Removal
53
9-2.2. Disassembly and Reassembly
53
9-2.3. Installation
55
Lift Cylinder (Telescopic)
57
9-3.1. Removal
57
9-3.2. Repair
57
9-3.3. Installation
57
Elevation System (Telescopic)
58
Lift Cylinder (Telescopic)
59
Lift Cylinder (Trimast Free Lift)
60
9-4.1. Removal
60
9-4.2. Repair
60
9-4.3. Installation
60
Elevation System (Trimast)
61
Lift Cylinder (Trimast Secondary)
63
9-5.1. Removal
63
9-5.2. Repair
63
9-5.3. Installation
63
9-5.4. Tilt Cylinders
65
10 Electrical Components
69
Electrical Control Panel
69
10-1.1.Maintenance
69
10-1.2.Cleaning
69
10-1.3.Panel Removal
69
10-1.4.Panel Disassembly
69
10-1.5.Panel Installation
69
Horn Replacement
69
Pump Motor
72
Drive Motor
72
10-4.1.Motor Removal
72
10-4.2.Motor Installation
72
Deadman Switch
72
10-5.1.Replacement
72
11 Optional Equipment
77
12 Illustrated Parts Breakdown
77
Control Head
80
Free Lift Cylinder (Trimast)
114
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Blue Giant BGL-22 Specifications
General
Brand
Blue Giant
Model
BGL-22
Category
Forklifts
Language
English
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