Blue Giant BG ZERO, Owner'S Manual

Page 1: ...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 RE...

Page 2: ...mps and obstructions Before and during all vehicle operations ensure that adequate clearance is maintained from overhead obstructions and energized electrical conductors and parts Before elevating pla...

Page 3: ...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...

Page 4: ...4...

Page 5: ...pounds capacity including load and operator The vehicle enables general maintenance work and efficient selection and moving of materials in any area or at any level of the warehouse or storeroom This...

Page 6: ...nnect switch Disconnects the supply current deactivates all electrical functions causing the order picker to brake automatically 9 Travel switch Select the required driving direction 10 Right Deadman...

Page 7: ...the data plate or warning decals are lost or damaged they MUST be replaced immediately Have your supervisor or the designated authority contact Blue Giant Authorized Dealer for replacement The data p...

Page 8: ...ption of Fault Nature of Fault Corrective Procedure Full Details Required Incomplete Information will Delay Process Blue Giant Part Part Description QTY Blue Giant Replacement Part s Invoice Number s...

Page 9: ...nd user are required by ANSI A92 6 to ensure annual inspections of the BG Zero Electric Access Vehicle occur and are performed no later than 13 months from the date of prior annual inspection or every...

Page 10: ...serviced or replaced by trained personnel This manual and the manufacturer s instructions concerning batteries and charging stations must be observed when carrying out the work 2 5 4 Battery Care and...

Page 11: ...batteries out of the vehicle 6 for installation please reverse step 1 5 Replace only with original OEM batteries or batteries approved by an authorized Blue Giant dealer Contact your authorized Blue...

Page 12: ...oting freely With lift carriage fully lowered spray on a film of Moly Chain Lube For more information see SECTION 7 Table 2 2 Recommended Lubricants See Table 2 3 for Application Table 2 3 Lubrication...

Page 13: ...d to perform service on the BG Zero Task Support Vehicle All service records must be maintained N O I T A M R O F N I R E S U D N E R E N W O N O I T A M R O F N I R E L A E D COMPANY ADDRESS Annual I...

Page 14: ...s that this machine has been inspected per each area of inspec on and any and all discrepancies have been brought to the a en on of the Owner User and that all discrepancies have been corrected prior...

Page 15: ...mergency power disconnect switch pressed or defective e Deadman footswitch not pressed or defective f Battery charge too low g Faulty fuse Check battery charge charge battery if necessary Test fuses V...

Page 16: ...iscon nected Check and recharge if required b Defective wiring Check and repair as required c Defect in electrical system for operating pump motor Check lift switch on platform as well as the relay Pl...

Page 17: ...loose connections before further troubleshooting Check and replace potentiometer if defective Check for proper operation and replace if necessary a Faulty fuse b Check all wiring A loose connection m...

Page 18: ...nection on the harness next to the Zapi controllers 1 Push press the Power On Button for 3s the display will showow 2 Press the button until CAN CONSOLE shows on the display 3 The display will show Pr...

Page 19: ...for 3s the display will show 2 Press the button until CAN CONSOLE shows on the display 3 The display will show Press OK to go into the CANCOSOLE Menu 4 The display will show Press OK to go into the Tr...

Page 20: ...Table 3 3 Troubleshooting Chart Traction Lift Controller 20...

Page 21: ...Figure 3 2 Troubleshooting Chart Traction Lift Controller Continued 21...

Page 22: ...Table 3 3Troubleshooting Chart Traction Lift Controller Continued 22...

Page 23: ...Figure 3 2 Troubleshooting Chart Traction Lift Controller Continued 23...

Page 24: ...Figure 3 2 Troubleshooting Chart Traction Lift Controller Continued 24...

Page 25: ...isconnect switch Figure 4 1 and turn off key switch 2 Remove screw and separate lower cover from the arm rest 3 Disconnect harness from potentiometer 4 Remove screw from steering wheel 5 Remove four s...

Page 26: ...vehicle 2 Install five screws 3 Disengage the emergency power disconnect switch and turn on key switch Figure 4 2 Front Compartment Cover Figure 4 3 Rear Compartment Cover 4 3 REAR COMPARTMENT COVER 4...

Page 27: ...screws flat washers and lock washers that secures the steering motor to the bracket 7 Remove the screw and key from the chain gear and then remove the chain gear from the steering motor 4 4 2 Motor I...

Page 28: ...NOTES 28...

Page 29: ...switch 2 Block load wheels 3 Remove the compartment cover as described in paragraph 4 2 1 4 Disconnect electric brake from harness 5 Remove the mounting screws and brake 6 Place the new brake into po...

Page 30: ...Figure 5 1 Drive System EC_0003 30...

Page 31: ...agraph 4 4 1 4 Raise the vehicle off the ground to provide clearance for drive assembly out the bottom Securely block the vehicle to prevent movement 5 Disconnect electric brake from harness 6 Disconn...

Page 32: ...cover and secure with three screws 4 Remove the blocking from under the vehicle and lower it to the ground 5 Disengage the emergency power disconnect switch and turn on key switch 6 3 DRIVE WHEEL 1 En...

Page 33: ...Figure 6 2 Frame EC_0001 33...

Page 34: ...Figure 6 3 Transmission Motor Brake Assembly EC_0004 34...

Page 35: ...nut Figure 7 1 to allow for adjustment 4 Break the lower jam nut free from the top nut 5 Take up slack in the lift chain with top nut 6 Align anchor so the clevis pin is parallel to the mast 7 Ensure...

Page 36: ...blocked raise the inner mast Figure 7 3 approximately three feet and position blocks or strong supports under the inner mast 2 Lower inner mast onto the support Check that arrangement is secure before...

Page 37: ...Figure 7 2 Elevation System Overview EC_0013 37...

Page 38: ...Figure 7 3 Elevation System Breakdown EC_0014 38...

Page 39: ...Figure 7 4 Platform EC_0017 39...

Page 40: ...40...

Page 41: ...r buttons to refill the cylinder and lines with hydraulic oil 8 Check level of hydraulic oil If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 2 2 9 Install the...

Page 42: ...Figure 8 1 Hydraulic System EC_0007 42...

Page 43: ...WARNING Relieve pressure off the system prior to opening any lines Before attempting any replacement make certain power is disconnected CAUTION Hydraulic oil can damage parts Wipe off any oil immediat...

Page 44: ...ecting from cylinder 2 Raise the platform high enough to remove the six screws and remove the front lower cover 3 Remove eight screws and remove the front upper cover WARNING Support cylinder before p...

Page 45: ...Figure 8 4 Elevation System Overview EC_0013 45...

Page 46: ...Figure 8 5 Elevation System Breakdown EC_0014 46...

Page 47: ...bed in paragraph 4 2 1 3 Remove any dirt or corrosion from the bus bar area The controller should be wiped clean with a moist rag Allow it to dry before reconnecting the battery 9 1 3 Panel Removal 1...

Page 48: ...Figure 9 1 Electrical System EC_0009 48...

Page 49: ...nting plate with sensor 6 Remove four screws four lock washers and four flat washers and separate sensor from mounting plate 7 Position new sensor on mounting plate and secure with four screws 8 Insta...

Page 50: ...s and harness from control panel 4 Remove four screws four lock washers four flat washers and panel 5 Remove the Control Panel Assembly out of the way 6 Disconnect cables and harnesses from charger 7...

Page 51: ...the screws and disconnect mount from bracket s 6 Disconnect protective chain from the mount s 7 Remove the harness es from protective chain s 8 Lift harness with protective chain from sheave 9 Remove...

Page 52: ...Figure 9 3 Elevation System Breakdown EC_0014 52...

Page 53: ...Figure 9 4 Platform EC_0017 53...

Page 54: ...Figure 9 5 Operating Control Assembly Left EC_0005 54...

Page 55: ...Figure 9 6 Operating Control Assembly Right EC_0006 55...

Page 56: ...NOTES 56...

Page 57: ...SECTION 10 OPTIONAL EQUIPMENT 10 1 INDUSTRIAL BATTERY Contact you authorized Blue Giant dealer for information on optional batteries and battery chargers 57...

Page 58: ...NOTES 58...

Page 59: ...SECTION 11 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the BG Zero Electric Access Vehicle 59...

Page 60: ...Figure 11 1 Frame EC_0001 60...

Page 61: ...6 16 0000 000123 00 FLAT WASHER 6 4 17 2320 600002 00 BAFFLE 2 18 0000 000700 00 SCREW M8 16 6 19 2140 140005 00 WASHER 4 20 CK10 170000 00 CASTER ASSEMBLY 2 21 0000 000322 00 SCREW M8 25 8 22 1600 10...

Page 62: ...Figure 11 2 Caster Assembly EC_0002 62...

Page 63: ...ARING 1 4 0000 000758 00 ELASTIC COLLAR 52 1 5 1115 032300 AA CASTER SUPPORT 1 6 0000 000281 00 BOLT M8 80 1 7 0000 000373 00 FLAT WASHER 12 1 8 CK10 171004 00 BUFFER BLOCK 1 9 1115 032001 A0 ROD 1 10...

Page 64: ...Figure 11 3 Drive System EC_0003 64...

Page 65: ...0 000109 00 SCREW M8 16 2 13 3020 050000 17 SCREW M5 8 1 14 0000 001253 00 KEY 6X6X25 1 15 1600 200002 00 CHAIN GEAR 1 16 1600 200003 00 PLATE 1 17 0000 000151 00 SCREW M8 25 4 18 0000 000210 00 FLAT...

Page 66: ...Figure 11 4 Transmission Motor Brake Assembly EC_0004 66...

Page 67: ...15 0000 000659 00 CLIP 15 2 16 0000 000667 00 BEARING 1 17 1600 GSX 10 GEAR KIT 1 18 0000 000680 00 BEARING 1 19 1115 GSX 20 GEAR KIT 1 20 0000 001020 00 PARALLEL KEY 5 5 16 1 21 0000 000026 00 SCREW...

Page 68: ...Figure 11 5 Operating Control Assembly Left EC_0005 68...

Page 69: ...ARMREST 1 6 0000 000278 00 BOLT M8 30 3 7 0000 000159 00 LOCK WASHER 8 3 8 0000 000105 00 FLAT WASHER 8 3 9 1600 513000 00 STEPPING MOTOR 1 10 3712 420004 00 MOTOR WIRE HARNESS 1 11 0000 000004 00 SCR...

Page 70: ...Figure 11 6 Operating Control Assembly Right EC_0006 70...

Page 71: ...0992 00 SCREW M3 12 2 9 0000 001410 00 SCREW M12 30 1 10 0000 000060 00 LOCK WASHER 12 1 11 1600 520008 00 SWITCH 1 12 1600 511000 00 ACCELERATOR ASSEMBLY 1 13 1600 300303 0A BRACKET 1 14 1600 300300...

Page 72: ...Figure 11 7 Hydraulic System EC_0007 72...

Page 73: ...56 00 LOCK WASHER 6 2 7 1600 431000 00 OIL PIPE I 1 8 2402 143500 00 BOLT G1 4 35 3 9 0000 000044 00 WASHER 14 8 10 CK11 450000 00 ACCUMULATOR 1 11 2701 141400 00 JOINT M14 1 5 M14 1 5 1 12 2112 44000...

Page 74: ...Figure 11 8 Hydraulic Pump Assembly EC_0008 74...

Page 75: ...L 1 7 ECK 421007 00 FLAT WASHER 5 4 8 ECK 421008 00 BOLT M5X10 4 9 ECK 421022 00 AIR FILTER 1 10 ECK 421021 00 OIL PLUG 1 11 ECK 421011 00 SUCTION PIPE 1 12 ECK 421012 00 OIL FILTER 1 13 ECK 421013 00...

Page 76: ...Figure 11 9 Electrical System EC_0009 76...

Page 77: ...T WASHER 6 12 19 1600 510001 10 00 CONTROLLER DUALPMX 1 20 1220 500001 00 EMERGENCY STOP SWITCH 1 21 0000 000009 00 SCREW M4 12 2 22 0000 000122 00 LOCK WASHER 4 9 23 0000 000702 00 FLAT WASHER 4 9 24...

Page 78: ...Figure 11 10 Wiring Harness 1 EC_0010 78...

Page 79: ...Wire Harness 1 POS PART NUMBER DESCRIPTION QTY REQD NOTES 1 1600 520001 1A MAIN WIRING HARNESS 1 2 1600 520002 10 MULTI CORE CABLE HARNESS 1 3 LB00 200094 00 RELAY 24V 1 79...

Page 80: ...Figure 11 11 Wiring Harness 2 EC_0011 80...

Page 81: ...Wire Harness 2 POS PART NUMBER DESCRIPTION QTY REQD NOTES 1 1600 520003 1A PLATFORM HARNESS 1 2 1600 510004 00 CONTROLLER CAN TILLER 1 81...

Page 82: ...Figure 11 12 Wiring Cables EC_0012 82...

Page 83: ...2002 00 B CABLE 1 4 1600 530008 00 PUMP POWER CABLE 1 5 1600 530009 00 PUMP POWER CABLE 1 6 1600 530001 00 E F CABLE 1 7 1600 530004 00 EPS CABLE 1 8 1600 530005 00 EPS CABLE 1 9 1600 530002 10 STEERI...

Page 84: ...Figure 11 13 Elevation System Overview EC_0013 84...

Page 85: ...600010 60 PLUGGING 4 11 0000 000434 00 RETAINER RING 30 4 12 1600 600010 00 ROLLER 4 13 0000 001525 00 SCREW M12X10 4 14 0000 000761 00 SCREW M12X20 4 15 1600 600007 A0 FRONT COVER 1 16 1600 60000X 0...

Page 86: ...Figure 11 14 Elevation System Breakdown EC_0014 86...

Page 87: ...00 000761 00 SCREW M12X20 12 16 0000 000151 00 SCREW M8X25 4 17 0000 000384 00 SCREW M6X40 4 18 1600 600200 00 PLATE 2 19 1600 600003 00 CHAIN WHEEL 2 20 1600 600009 00 CHAIN ROLLER 4 21 1600 600400 A...

Page 88: ...Figure 11 14Elevation System Breakdown Continued EC_0014 88...

Page 89: ...2 39 1120 500006 00 MICRO SWITCH 4 40 1600 520006 10 SWITCH HARNESS 1 41 0000 000617 00 SCREW M4 20 6 42 1600 600001 00 DRAG BRACKET 1 43 1600 600015 A0 BRACKET 1 44 1600 520012 1A SWITCH WIRE HARNESS...

Page 90: ...Figure 11 15 Lift Cylinder EC_0015 90...

Page 91: ...SEAL KIT FOR CYLINDER 1 Includes pos 4 11 1 2125 416000 00 SNAP RING 26 5 2 2 1 2 CK10 414000 30 BUFFER SLEEVE 1 3 1600 411001 00 RING 30 40 6 1 4 1600 411002 00 SEAL 30 40 2 1 5 1600 411003 00 SUPPO...

Page 92: ...Figure 11 16 Lift Cylinder Assembly Tray EC_0019 92...

Page 93: ...600 660012 00 DUST RING 1 13 1600 660013 00 SEAL 19 1 9 1 14 1600 660014 00 COPPER SLEEVE 1 15 1600 660015 00 SEAL 24 2 4 1 16 1600 660016 00 OIL SEAL DZ24 16 5 1 17 1600 660017 00 COVER 1 18 1600 660...

Page 94: ...Chain Assembly Figure 11 17 Chain Assembly EC_0016 94...

Page 95: ...1 1600 600302 A0 CHAIN JOINT 1 2 1600 600301 A0 CHAIN JOINT 1 3 1600 600304 A0 SHAFT 2 4 1600 600303 A0 CHAIN 1 4 1600 600403 A0 CHAIN 1 5 307001000023 COTTER 1 6X20 2 6 0000 000553 00 NUT M10 2 7 000...

Page 96: ...Figure 11 18 Operator Platform EC_0017 96...

Page 97: ...DOOR 1 13 1600 702000 0B RIGHT DOOR 1 14 1600 703000 00 PIN MECHANISM 2 15 2028 019000 04 SLEEVE 1612 2 16 0000 000322 00 SCREW M8X25 4 17 0000 000159 00 LOCK WASHER 8 4 18 0000 000026 00 SCREW M8X30...

Page 98: ...Figure 11 18Operator Platform Continued EC_0017 98...

Page 99: ...38 1600 520015 00 BRAKE SWITCH 1 39 0000 000028 00 SCREW M4 10 2 40 0000 000122 00 LOCK WASHER 4 2 41 0000 000702 00 FLAT WASHER 4 2 36 1600 520010 00 CONNECTING LINE 2 37 3030 220000 06 NUT M2 4 38...

Page 100: ...ica t 1 800 872 2583 f 1 888 378 5781 Copyright Blue Giant Equipment Corporation 2020 Corporate 410 Admiral Blvd Mississauga ON L5T 2N6 t 905 457 3900 f 905 457 2313 USA 6350 Burnt Poplar Rd Greensbor...