989068 SELF-PROPELLED, MANUAL LIFT PALLET LIFT TRUCK Operation Maintenance Repair Parts List Global Industrial www.globalindustrial.com MANUAL NO.
WARNING Do not operate this truck unless you have been authorized and trained to do so, and have read all warnings and instructions in Operator’s Manual and on this truck. Do not operate this truck until you have checked its condition. Give special attention to wheels, horn, battery, controller, lift system, brakes, steering mechanism, guards and safety devices. Operate truck only from designated operating position. Do not carry passengers. Keep feet clear of truck and wear foot protection.
TABLE OF CONTENTS Section 1 3 4 . Section Page DESCRIPTION .......................................................................1-1 1-1. 1-2. 1-3. 2 Page 5-2. 5-2.1. 5-2.2. 5-3. 5-3.1. 5-3.2. 5-3.3. 5-3.4. INTRODUCTION. ..................................................1-1 GENERAL DESCRIPTION. ...................................1-1 SAFETY FEATURES. ............................................1-1 OPERATION...........................................................................2-1 2-1.
TABLE OF CONTENTS - Continued LIST OF ILLUSTRATIONS Figure 1-1 1-2 2-1 2-2 2-3 2-4 2-5 3-1 3-2 3-3 4-1 4-2 5-1 5-2 5-3 6-1 7-1 Page NAME PLATE ................................................................ 989068 PALLET LIFT TRUCK ....................................... SAMPLE OF OPERATOR CHECK LIST ....................... 989068 PALLET LIFT TRUCK ....................................... BATTERY INDICATOR.................................................. 989068 PALLET LIFT TRUCK ..........................
SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the 24 volt 989068 lift truck distributed by Global Industrial. Included are operating instructions, planned maintenance instructions, lubrication procedures, corrective maintenance procedures and a complete parts list with part location illustrations. • Dead-man brake to apply the brake and cut off drive power when the steering arm is released.
R7159 Figure 1-2 989068 Pallet Lift Truck ITEM 1 2 3 4 5 1-2 COMPONENT Control Head Control Handle Controller Cover Pump Drive Wheel ITEM 6 7 8 9 10 COMPONENT Balance Block Batteries Battery Disconnect Control Lever Forks BL-GP33-0321 - 03-26-2021
SECTION 2 OPERATION 2-1. GENERAL. This section gives detailed operating instructions for the 989068 lift truck. The instructions are divided into the various phases of operations, such as operating lift, driving, and stopping. Routine precautions are included for safe operation. 2-2. OPERATING PRECAUTIONS. WARNING: Improper operation of the lift truck may result in operator injury, or load and/or lift truck damage. Observe the following precautions when operating the 989068 lift truck.
2-4. DURING BREAK-IN • Avoid sudden stop, starts or turns. During the first 100 hours of operation, operate the truck under light load conditions: • Perform oil changes and lubrication earlier than specified. • Prevent the new battery from over discharging. • Limit load to 70-80% of the rated load. • Perform specified preventive maintenance services carefully and completely. Table 2-1 Operator Checks ITEM Transmission and hydraulic systems.
R8754 Figure 2-1 Sample of Operator Check List BL-GP33-0321 - 03-26-2021 2-3
2-5. CONTROLS R7160 Figure 2-2 989068 Pallet Lift Truck 2-5.1. Power Button The power button (1, Figure 2-2) is used to switch control current on and off. • The first LED lights when the battery is properly charged. As the battery charge decreases, additional LEDs will light. 2-5.2. Key Switch (Optional) • When the second to the last LED flashes, the battery is 70% discharged. The optional key switch is (2, Figure 2-2) has two positions, ON and OFF.
2-6. OPERATION 2-6.2. Braking. 2-6.1. Forward and Reverse Travel. Emergency Stop 1. Pull out the battery disconnect (8, Figure 2-4). All electrical functions are cut out and the brake is applied. 2. Turn on the power switch (1, Figure 2-2) and the optional key switch (2). Grasp the grips of the steering head so that the forward and reverse controls can be comfortably operated by either thumb.
2-6.3. LIFT AND LOWER. 2-7. LOADING AND UNLOADING. Lift 1. Move truck to location where load is to be picked up. 2. Move the truck into position so forks are within pallet or skid, and the load is centered over the forks and as far back as possible. Lower 3. Raise forks to lift load. Pull up on control lever (2, Figure 2-5) until the desired lower height is achieved. Reset lever (2) to the neutral position. 4. Drive to area where load is to be placed. 5.
SECTION 3 PLANNED MAINTENANCE 3-1. GENERAL. Planned maintenance consists of periodic visual and operational checks, parts inspection, lubrication, and scheduled maintenance designed to prevent or discover malfunctions and defective parts. The operator performs the checks in SECTION 2, and refers any required servicing to a qualified maintenance technician who performs the scheduled maintenance and any required servicing. 3-2. MONTHLY AND QUARTERLY CHECKS.
• Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in cell long after charging has stopped. • Do not lay metallic or conductive objects on battery. Arcing will result. • Do not touch non-insulated parts of DC output connector or battery terminals to avoid possible electrical shock. • De-energize all AC and DC power connections before servicing battery. • Do not charge a frozen battery. 3-3.3.
3-4. CHARGING BATTERIES Charging requirements will vary depending on depth of discharge and temperature. Follow safety rules when placing a battery on charge. Proceed as follows: 1. Park truck at charging station with forks lowered and turn the key switch off. 2. Check the condition of the AC cord and battery cables. If there are any cuts in the cable, any exposed wires, loose plugs or connectors, DO NOT attempt to charge the batteries. Contact appropriate personnel for repairs to be made. 3.
3-5. BATTERIES REPLACEMENT 3-6. LUBRICATION. 1. Park the truck and turn off the power. 2. Lift the forks to the highest position by moving control handle (1, Figure 3-2) up and down and rotate handle (1) a few degrees to the left or right. Refer to Table 3-2 for the recommended types of grease and oil. Table 3-3 in conjunction with Figure 3-3 identifies the items requiring lubrication. 3. Remove two screws (2) and remove cover (3). 4. Tag and disconnect the battery cables. 5. Replace batteries.
R7165 Figure 3-3 Lubrication Diagram Table 3-3 Lubrication Chart FIG 3-2 INDEX NO. 1 LOCATION Hydraulic oil filler neck 2 3 METHOD OF APPLICATION Can Lift Linkage Fittings* Brush Transmission oil filler Can neck * Raise lift carriage to gain access to grease fittings. BL-GP33-0321 - 03-26-2021 TYPE (Table 3-3) No. 1 No. 2 No. 2 APPLICATION OF LUBRICANT With lift carriage fully lowered, fill with hydraulic oil Lubricate contact surfaces Fill with grease.
NOTES 3-6 BL-GP33-0321 - 03-26-2021
SECTION 4 TROUBLESHOOTING 4-1. GENERAL Use Table 4-1 as a guide to determine possible causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Oper- ate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Lowering, and Miscellaneous malfunctions. Table 4-1 Troubleshooting Chart MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TRUCK AND HYDRAULIC SYSTEM WILL NOT OPERATE Truck will not travel nor will lift system operate. a.
Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE TROUBLE WITH LIFTING OR LOWERING . Oil sprays or flows from the top of the hydraulic assembly. Defective hydraulic assembly Repair or replace hydraulic assembly. Squealing sounds when lifting forks. a. Oil level too low. Identify oil leak. b. Lift linkage binding. Apply grease. Forks do not lift to top. Oil level too low. Add oil to reservoir. Forks lift, but will not go down. Control rod out of adjustment.
4-2. CONTROLLER TROUBLESHOOTING 4-2.1. Fault Detection. The controller provides diagnostics information to assist technicians in troubleshooting drive system problems. When a fault is detected it is stored inside the controller. 4-2.2. Hand Held Programmer (Optional) The hand held programmer is available that is designed specifically for use with the controller. The programmer is available through your Global Industrial dealer. R6759 4-2.3. Fault Recording.
4. 5. 4-4 With the brake released, select a direction and operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the forward/reverse switches and motor. The motor should run proportionally faster with increasing throttle. If not, refer to Paragraph 4-2.7. Put the controller into the test mode by using the Navigation key (1) to select the "Monitor" menu. Select the Monitor mode by pressing the "Right" arrow on the Navigation key.
4-2.5. Diagnostic History The handheld programmer can be used to access the controller's diagnostic history file. When the programmer is connected to the unit, the error log file is automatically uploaded into the handheld programmer. To see the present status of the unit, use the Menu Navigation Key (1, Figure 4-2) to select: 3. Using an inline fuse holder fitted with a 10 amp fuse and alligator clips, connect the controller's M and B- terminals. 4. Turn on the power switch (9) and key switch (8).
NOTES 4-6 BL-GP33-0321 - 03-26-2021
SECTION 5 CONTROL HANDLE, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD 5-1.2. Control Head Installation 5-1.1. Control Head Removal 1. Reconnect harness to switches. 2. Position cover and cap on control handle and secure with three screws. 3. Turn on the power switch or key switch depending what is on the truck. 1. Turn off the power switch or key switch depending what is on the truck. 2. Remove three screws and separate cover and cap from control handle . 3.
R7145 Figure 5-2 Control Handle 5-2 BL-GP33-0321 - 03-26-2021
5-1.3. Belly-Button Switch Replacement. 4. Install the control head as described in paragraph 5-1.2. 1. Remove the control head as described in paragraph 5-1.1. 5-1.6. Power Switch Replacement. 2. Remove button and springs from cover. 3. Remove bracket from cover and remove switch. 1. Remove the control head as described in paragraph 5-1.1. 4. Unsolder harness from switch. 2. Remove power switch from the back of cover. 5. Solder harness to new switch. 3.
5-2. TRANSMISSION COVERS 5-2.2. Installation. 5-2.1. Removal. 1. Place cover into position. 2. Secure with four screws, four lock washers and four flat washers. 3. Turn on the power switch or key switch depending what is on the truck. 1. Turn off the power switch or key switch (8) depending what is on the truck. 2. Remove cover. 3. Remove four screws, four lock washers and four flat washers 4. Remove cover.
5-3. CONTROL HANDLE 5-3.3. Control Handle Removal. 5-3.1. Control Rod Removal. 1. Remove switch as described in paragraph 10-3. 2. Remove control rod as described in paragraph 53.1. 3. Attach a hoist to control handle. 4. Remove pins from shaft. 5. Remove shaft from control handle and lift the handle from the hydraulic assembly. 6. Remove bushings from control handle. 7. Remove pin remove shaft, roller and bushing from control handle. 8. Remove two screws and remove bumper from handle. 1.
NOTES 5-6 BL-GP33-0321 - 03-26-2021
SECTION 6 BRAKE SERVICING 6-1. BRAKES. 4. The brake system consists of a transmission mounted brake. This brake is spring applied and electrically released. Remove the three mounting screws and the brake. 5. Place the new brake into position and secure with the three mounting screws. 6. Reconnect electric brake to harness. 7. Remove load wheel blocks and check operation. 8. Install the transmission covers as described in paragraph 5-2. 6-1.1. Brake Assembly Replacement 1. Block load wheels. 2.
R7148 Figure 6-1 Transmission, Motor, Brake Mounting 6-2 BL-GP33-0321 - 03-26-2021
SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL 7-1. DRIVE WHEEL. 1. Turn off the power switch or key switch depending what is on the truck. 2. Remove transmission covers as described in paragraph 5-2. 3. 11. Turn on the power switch (or key switch depending what is on the truck. 7-2. TRANSMISSION. 1. Jack up the truck so the drive wheel is off the ground; then securely block the truck to prevent movement. Turn off the power switch or key switch depending what is on the truck. 2.
R7148 Figure 7-1 Transmission, Motor, Brake Mounting 7-2 BL-GP33-0321 - 03-26-2021
SECTION 8 ELEVATION SYSTEM SERVICING 8-1. Lift Linkage (SINGLE WHEEL) 8-1.1. Removal 1. 2. Lift complete truck to height sufficient to permit access to lift linkage under forks. Provide blocking under frame, transmission and at tips of the forks. 3. Remove pins and remove shafts. 4. Remove pins from each side of frame. Support link assembly and remove shaft. 5. Remove pins and remove shafts and washers. 6. Lower link assembly to the floor.
8-1.2. Repair 8-1.3. Installation 1. Remove pins, shafts and load wheels from brackets. 1. Position link assembly under frame. 2. 2. Remove pins and shafts. Free brackets from tension bars. Raise link assembly into position and install shaft through frame Secure shaft with pins. 3. 3. Remove bushings from brackets if replacement is necessary, Position wheel brackets in frame and install shafts. Secure shafts with pins). 4. 4. Remove pins from tension bars and free tension bars from link.
R7152 Figure 8-2 Lift Linkage Assembly (Single Wheel) BL-GP33-0321 - 03-26-2021 8-3
NOTES 8-4 BL-GP33-0321 - 03-26-2021
SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. HYDRAULIC ASSEMBLY REMOVAL 9-1.1. Removal The hydraulic system and electrical system can be removed as an assembly to provide additional clearance for various maintenance procedures. 1. Fully lower forks. 2. Turn off power switch or key switch depending what is on the truck. WARNING: When forks are raised, pressure exists in the hydraulic system lines and fittings.
7. Remove the control handle as described in paragraph 5-3.3. 9-2. HYDRAULIC PUMP SPRING REPLACEMENT 8. Remove four screws, four lock washers, four flat washers and assembly. 1. Fully lower forks. 2. Turn off power switch or key switch depending what is on the truck. 3. Remove the control handle as described in paragraph 5-3.3. 4. Remove piston rod, seat, wiper, seal and spring. 5. Replace the spring and reassembly in reverse order. 9-1.2. Installation 1.
SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL 6. 10-1.1.Maintenance NOTE: Erratic operation of the truck may be caused by defective controller components. Before removing the electrical panel, perform troubleshooting procedures per SECTION 4, to determine corrective action to be taken. Remove two nuts, two lock washers, two screws and separate controller from cover. 10-1.3.Controller Installation. 1.
R7156 Figure 10-1 Electrical System 10-2 BL-GP33-0321 - 03-26-2021
10-1.6.Battery Disconnect Removal. 10-2.DRIVE MOTOR. 1. Turn off power switch or key switch depending what is on the truck. 2. Remove battery disconnect from connector. 3. Tag and disconnect connector from the battery and controller. The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of motor. Use an air hose to blow dust off of motor surfaces. 4. Remove two screws, two flat washers and bracket. 5.
NOTES 10-4 BL-GP33-0321 - 03-26-2021
SECTION 11 OPTIONAL EQUIPMENT BL-GP33-0321 - 03-26-2021 11-1
NOTES 11-2 BL-GP33-0321 - 03-26-2021
SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the 989068 Lift Truck.
R7145 Figure 12-1 Steering Arm 12-2 BL-GP33-0321 - 03-26-2021
STEERING ARM Pos. Part Number Description Qty. Reqd.
R7145 Figure 12-1 Steering Arm - Continued 12-4 BL-GP33-0321 - 03-26-2021
STEERING ARM - CONTINUED Pos. Part Number Description Qty. Reqd.
R7146 Figure 12-2 Control Head - Used up to Serial # E2410609 12-6 BL-GP33-0321 - 03-26-2021
CONTROL HEAD - Used up to Serial # E2410609 Pos. Part Number Description Qty. Reqd. Notes — 1121-310000-00-B CONTROL HEAD 1 1 1121-310002-00 COVER 1 2 1121-310001-00 CAP 1 3 1121-310003-00 BUTTON, REVERSE 1 4 1280-360013-00 BUTTON BRACKET 1 5 1121-522000-00 FOR, REV & HORN SWITCHES 3 6 1121-310004-00 SPRING 1 7 1121-521000-00 BELLY-BUTTON SWITCH ASSY 1 8 1121-523000-00 POWER SWITCH 1 Used up to serial number E2319422 8a 1115-520019-0A KEY SWITCH 1 Std.
R7166 Figure 12-3 Control Head - Used from Serial # E2410610 12-8 BL-GP33-0321 - 03-26-2021
CONTROL HEAD - Used from Serial # E2410610 Pos. Part Number Description Qty. Reqd. Notes — 1121-310000-0A-B CONTROL HEAD 1 1 1121-310002-0A-B COVER 1 2 1121-310001-0A-B CAP 1 3 0000-000004-00 SCREW M5×12 3 4 1121-310003-00 BUTTON REVERSER COVER 1 5 1121-310004-00 SPRING 1 6 0000-001243-00 SCREW M3×6 3 7 1121-520013-00 INTEGRATED MODULE 1 8 0000-001133-00 O-RING Ø3.15×1.
R7147 Figure 12-4 Compartment Cover 12-10 BL-GP33-0321 - 03-26-2021
COMPARTMENT COVER Pos. 1 Part Number 1121-141000-00 Description LOWER COVER Qty. Reqd. Notes 1 Used up to serial number 424210520 - After that replaced by Pos. # 14 2 1121-140001-00 UPPER COVER 1 Used up to serial number 424210520 - After that Replaced by Pos.
DM_0004 Figure 12-5 Transmission Motor, Brake Mounting - Used up to serial number 426150000 12-12 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING - USED UP TO SERIAL NUMBER 426150000 Pos. Part Number Description Qty. Reqd.
DM_0004 Figure 12-5 Transmission Motor, Brake Mounting - Continued - Used up to serial number 426150000 12-14 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING - CONTINUED - USED UP TO SERIAL NUMBER 426150000 Pos. Part Number Description Qty. Reqd.
DM_0019 Figure 12-6 Transmission Motor, Brake Mounting Used between serial number 426150001 - 427202925 12-16 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING USED BETWEEN SERIAL NUMBER 426150001 - 427202925 Pos. Part Number Description Qty. Reqd. Notes 1 1121-200000-A0 DRIVE UNIT 1 Includes pos.
DM_0019 Figure 12-6 Transmission Motor, Brake Mounting Used between serial number 426150001 - 427202925 - Continued 12-18 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING USED BETWEEN SERIAL NUMBER 426150001 - 427202925 - CONTINUED Pos. Part Number Description Qty. Reqd.
DM_0020 Figure 12-7 Transmission Motor, Brake Mounting Used from serial number 427202926 12-20 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING USED FROM SERIAL NUMBER 427202926 Pos. Part Number Description Qty. Reqd. Notes Includes pos.
DM_0020 Figure 12-7 Transmission Motor, Brake Mounting Used from serial number 427202926 - Continued 12-22 BL-GP33-0321 - 03-26-2021
TRANSMISSION MOTOR, BRAKE MOUNTING USED FROM SERIAL NUMBER 427202926 - CONTINUED Pos. Part Number Description Qty. Reqd.
R7150 Figure 12-8 Frame (Single Wheel) 12-24 BL-GP33-0321 - 03-26-2021
FRAME (SINGLE WHEEL) Pos. Part Number Description Qty. Reqd.
R7152 Figure 12-9 Lift Link Assembly (Single Wheel) 12-26 BL-GP33-0321 - 03-26-2021
LIFT LINK ASSEMBLY (SINGLE WHEEL) Pos. Part Number Description Qty. Reqd. Notes Frame Width 27" (685mm) 1 1121-131000-10 DOWN LINK, FRAME WIDTH 27" 1 2 1115-130008-00 LOAD WHEEL SHAFT ROLLER 4 3 1121-130003-00 SHAFT 2 4 1121-132010-00 NUT M22×1.
R7154 Figure 12-10 Load Wheel (Single Wheel) 12-28 BL-GP33-0321 - 03-26-2021
LOAD WHEEL (SINGLE WHEEL) Pos. Part Number Description Qty. Reqd.
R7155A Figure 12-11 Hydraulic System 12-30 BL-GP33-0321 - 03-26-2021
HYDRAULIC SYSTEM Pos. Part Number Description Qty. Reqd.
R7156 Figure 12-12 Electrical System 12-32 BL-GP33-0321 - 03-26-2021
ELECTRICAL SYSTEM Pos. Part Number Description Qty. Reqd.
R7156 Figure 12-12 Electrical System - Continued 12-34 BL-GP33-0321 - 03-26-2021
ELECTRICAL SYSTEM - CONTINUED Pos. Part Number Description Qty. Reqd.
R8076 Figure 12-13 Wiring Harness - Used up to serial number E2410609 12-36 BL-GP33-0321 - 03-26-2021
WIRING HARNESS - USED UP TO SERIAL NUMBER E2410609 Pos. Part Number Description Qty. Reqd.
R7157 Figure 12-14 Wiring Harness - Used from serial number E2410610 12-38 BL-GP33-0321 - 03-26-2021
WIRING HARNESS - USED FROM SERIAL NUMBER E2410610 Pos. Part Number Description Qty. Reqd.
R7158 Figure 12-15 Wiring Cables 12-40 BL-GP33-0321 - 03-26-2021
WIRING CABLES Pos. Part Number Description Qty. Reqd. Notes 1 1121-530002-00 CABLE, BATTERY CONNECTOR 1 2 1121-530001-0A CABLE, B- 1 3 1121-530003-00 CABLE, M1 1 4 1121-530004-00 CABLE, M2 1 5 1121-500001-00 BATTERY 2 Used up to serial number 427153349 Used from serial number 427153350. Battery has a strap.
NOTES 12-42 BL-GP33-0321 - 03-26-2021
