Global 989021 Use and care manual

Global Industrial MANUAL NO. BL-GL22-1119 - 11-20-2019
globalindustrial.com
MODEL 989021
SELF-PROPELLED,
STRADDLE LIFT TRUCK
Operation
Maintenance
Repair Parts List

WARNING
Do not operate this truck unless you have been autho-
rized 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 tires, horn, battery,
controller, lift system (including forks or attachments,
chains, cables and limit switches), brakes, steering
mechanism, guards and safety devices.
Operate truck only from designated operating position.
Never place any part of your body into the mast struc-
ture or between the mast and the truck. Do not carry
passengers. Keep feet clear of truck and wear foot
protection.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.
Start, stop, travel, steer and brake smoothly. Slow
down for turns and on uneven or slippery surfaces that
could cause truck to slide or overturn. Use special
care when traveling without load as the risk of overturn
may be greater.
Travel with lifting mechanism as low as possible.
Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with load
trailing.
Use special care when operating on ramps travel
slowly, and do not angle or turn. Travel with load
downhill.
Do not overload truck. Check nameplate for capacity
and load center information.
When using forks, space forks as far apart as load will
permit. Before lifting, be sure load is centered, forks
are completely under load, and load is as far back as
possible against load backrest.
Do not handle unstable or loosely stacked loads. Use
special care when handling long, high or wide loads, to
avoid losing the load, striking bystanders, or tipping
the truck.
Do not handle loads which are higher than the load
backrest or load backrest extension unless load is
secured so that no part of it could fall backward.
Elevate forks or other lifting mechanism only to pick up
or stack a load. Watch out for obstructions, especially
overhead.
Do not lift personnel except on a securely attached
specially designed work platform. USE EXTREME
CARE WHEN LIFTING PERSONNEL. Make sure
mast is vertical, place truck controls in neutral and
apply brakes. Lift and lower smoothly. Remain in oper-
ating position or immediate vicinity as long as person-
nel are on the work platform. Never transport
personnel on forks or work platform.
Do not allow anyone to stand or pass under load or lift-
ing mechanism.
When leaving truck, neutralize travel control, fully
lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.

TABLE OF CONTENTS
BL-GL22-1119 - 11-20-2019 1
Section Page Section Page
1 DESCRIPTION ............................................................1-1
1-1 INTRODUCTION. .........................................1-1
1-2 GENERAL DESCRIPTION. ..........................1-1
1-3 SAFETY FEATURES....................................1-1
2 OPERATION ...............................................................2-1
2-1 GENERAL.....................................................2-1
2-2 OPERATING PRECAUTIONS......................2-1
2-3 BEFORE OPERATION.................................2-2
2-4 GENERAL CONTROL OPERATION............2-4
2-5 DRIVING AND STOPPING PROCEDURES 2-4
2-5.1 STOPPING ...................................................2-4
2-6 BELLY-BUTTON SWITCH............................2-5
2-7 STEERING ARM GAS SPRING. ..................2-5
2-8 LIFT AND LOWER CONTROLS...................2-5
2-9 LOADING AND UNLOADING.......................2-5
2-10 PARKING......................................................2-5
3 PLANNED MAINTENANCE ........................................3-1
3-1 GENERAL.....................................................3-1
3-2 MONTHLY AND QUARTERLY CHECKS.....3-1
3-3 BATTERY CARE. .........................................3-1
3-3.1 GENERAL.....................................................3-1
3-3.2 SAFETY RULES...........................................3-2
3-3.3 BATTERY CARE AND CHARGING .............3-2
3-3.4 MAINTENANCE FREE BATTERIES ............3-2
3-4 CHARGING BATTERIES..............................3-2
3-5 CHANGING BATTERIES..............................3-4
3-6 LUBRICATION..............................................3-4
3-7 LIFT CHAIN MAINTENANCE. ......................3-4
4 TROUBLESHOOTING ................................................4-1
4-1 GENERAL.....................................................4-1
4-2 CONTROLLER TROUBLESHOOTING ........4-5
4-2.1 FAULT DETECTION.....................................4-5
4-2.2 HAND HELD PROGRAMMER (OPTIONAL) 4-5
4-2.3 FAULT RECORDING....................................4-5
4-2.4 GENERAL CHECKOUT................................4-5
4-2.5 DIAGNOSTIC HISTORY...............................4-6
4-2.6 TEST FAULT DETECTION CIRCUITRY ......4-6
4-2.7 PROGRAMMABLE PARAMETERS .............4-7
4-2.8 DIAGNOSTICS AND
TROUBLESHOOTING................................4-16
4-2.8.1 LED DIAGNOSTICS ...................................4-16
4-2.9 PROGRAMMER DIAGNOSTICS................4-16
5 STEERING ARM, CONTROL HEAD AND
COMPARTMENT ........................................................5-1
5-1 CONTROL HEAD .........................................5-1
5-1.1 CAP ASSEMBLY REMOVAL........................5-1
5-1.2 CAP ASSEMBLY INSTALLATION................5-2
5-1.3 CONTROL HEAD REMOVAL.......................5-2
5-1.4 CONTROL HEAD INSTALLATION...............5-3
5-1.5 SPEED POTENTIOMETER
REPLACEMENT...........................................5-3
5-1.6 BELLY-BUTTON SWITCH REPLACEMENT5-3
5-1.7 HORN SWITCH REPLACEMENT................ 5-4
5-1.8 LIFT AND LOWER SWITCH
REPLACEMENT. ......................................... 5-6
5-2 STEERING ARM.......................................... 5-6
5-2.1 RETURN SPRING REPLACEMENT............ 5-6
5-2.2 STEERING ARM REMOVAL. ...................... 5-6
5-2.3 STEERING ARM INSTALLATION. .............. 5-6
5-3 COMPARTMENT COVERS......................... 5-6
5-3.1 REMOVAL....................................................5-6
5-3.2 INSTALLATION............................................ 5-6
5-4 WINDSHIELD............................................... 5-6
5-4.1 REMOVAL....................................................5-6
5-4.2 INSTALLATION............................................ 5-6
6 BRAKE SERVICING................................................... 6-1
6-1 BRAKES.......................................................6-1
6-1.1 BRAKE ASSEMBLY REPLACEMENT......... 6-1
7 TRANSMISSION, DRIVE WHEEL AND
LOAD WHEEL ............................................................ 7-1
7-1 DRIVE WHEEL. ........................................... 7-1
7-2 TRANSMISSION.......................................... 7-1
7-3 LOAD WHEEL.............................................. 7-3
7-3.1 REMOVAL....................................................7-3
7-3.2 REPAIR ........................................................ 7-3
7-3.3 LOAD WHEEL INSTALLATION ................... 7-3
8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1 GENERAL. ................................................... 8-1
8-2 LIFT CHAIN LENGTH ADJUSTMENT......... 8-1
8-3 LIFT CHAIN WEAR INSPECTION............... 8-2
8-4 LIFT CHAIN REPLACEMENT...................... 8-2
8-4 LIFT CYLINDERS. ....................................... 8-2
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1 LINES AND FITTINGS................................. 9-1
9-2 HYDRAULIC PUMP, MOTOR AND
RESERVOIR ASSEMBLY............................ 9-2
9-2.1 REMOVAL....................................................9-2
9-2.2 DISASSEMBLY AND REASSEMBLY.......... 9-2
9-2.3 INSTALLATION............................................ 9-2
9-3 LIFT CYLINDER........................................... 9-2
9-3.1 REMOVAL....................................................9-2
9-3.2 REPAIR........................................................ 9-4
9-3.3 INSTALLATION............................................ 9-4
10 ELECTRICAL COMPONENTS ................................. 10-1
10-1 ELECTRICAL CONTROL PANEL.............. 10-1
10-1.1 MAINTENANCE ......................................... 10-1
10-1.2 CLEANING................................................. 10-1
10-1.3 CONTROLLER REMOVAL ........................ 10-1
10-1.4 CONTROLLER INSTALLATION. ............... 10-1
10-1.5 CHARGER REMOVAL............................... 10-1
10-1.6 CHARGER INSTALLATION....................... 10-1
10-1.7 BUZZER REMOVAL .................................. 10-3
10-1.8 BUZZER INSTALLATION. ......................... 10-3
10-1.9 KEY SWITCH REMOVAL. ......................... 10-3

TABLE OF CONTENTS - Continued
1-2 BL-GL22-1119 - 11-20-2019
Section Page Section Page
10-1.10 KEY SWITCH INSTALLATION. ................. 10-3
10-1.11 BATTERY INDICATOR REMOVAL. .......... 10-3
10-1.12 BATTERY INDICATOR INSTALLATION. .. 10-3
10-1.13 LED INDICATOR REMOVAL. .................... 10-3
10-1.14 LED INDICATOR INSTALLATION ............. 10-3
10-1.15 EMERGENCY STOP SWITCH REMOVAL 10-3
10-1.16 EMERGENCY STOP SWITCH
INSTALLATION.......................................... 10-3
10-1.17 LIFT LIMIT SWITCH REMOVAL ................ 10-4
10-1.18 LIFT LIMIT SWITCH INSTALLATION. .......10-4
10-2 PUMP MOTOR...........................................10-4
10-3 DRIVE MOTOR. .........................................10-4
10-4 DEADMAN SWITCH...................................10-4
11 OPTIONAL EQUIPMENT..........................................11-1
12 ILLUSTRATED PARTS BREAKDOWN ....................12-1

BL-GL22-1119 - 11-20-2019 1-1
SECTION 1
DESCRIPTION
1-1. INTRODUCTION.
This publication describes the 24 volt 989021 lift truck
distributed by Global Industrial. Included are operating
instructions, planned maintenance instructions, lubri-
cation procedures, corrective maintenance procedures
and a complete parts list with part location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your 989021 lift truck.
1-2. GENERAL DESCRIPTION.
The self-propelled 989021 truck (Figure 1-2) lifts and
transports payloads up to 2200 pounds on adjustable
forks.
The forward and reverse motion is controlled by either
of two controller levers mounted on the control head.
Stopping and turning is controlled by the steering arm.
Lift and Lower is controlled by pushbuttons on the con-
trol head. The battery powered lift truck is quiet and
without exhaust fumes.
The reversible DC motor propels the lift truck in for-
ward or reverse direction throughout the available
speed range. The 989021 lift truck can be driven with
forks raised or lowered; however, the speed is
restricted when the platform is raised above a preset
limit.
The model number will be found on the name plate
(Figure 1-1) along with the serial number, lifting capac-
ity, and load center. (Figure 1-2) shows the locations of
the truck’s main components and controls.
1-3. SAFETY FEATURES.
The 989021 is designed engineered to provide maxi-
mum safety for operator and payload. Some of the
safety features incorporated into the design are:
Figure 1-1 Name Plate
• Dead-man brake to apply the brake and cut off drive
power when the steering arm is released.
• Emergency brake switch to apply the brake and cut
off drive power when depressed.
• Belly-button switch to reverse truck should the oper-
ator accidentally pin himself against a wall or
obstruction when backing up in slow speed.
• High speed limit switch to restrict speed when lift
carriage is raised above the preset limit.
• All control functions automatically return to “OFF”
when released.
• Externally accessible emergency stop switch within
operator's reach.
• Separately fused control circuits and power circuits.
• Readily accessible horn button.
• Lift carriage backrest to help stabilize the load.
• Handle to provide a firm hand hold for operator.
• Flow control valve regulates maximum lowering
speed within prescribed limits.
• Relief valve maintains hydraulic pressure within pre-
scribed limits.
• High visibility color scheme of truck provides visual
alert of truck’s presence.
• Battery Indicator
•Caster.
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1-2 BL-GL22-1119 - 11-20-2019
Figure 1-2 989021 Lift Truck
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ITEM COMPONENT
1 Control handle.
2 Drive wheel
3 Cover
4 Battery
5Caster wheel
6 Hydraulic pump and motor assembly
7Chassis
8 Emergency stop switch
9Forks
10 Lift cylinder
11 Load wheel
12 Power plug
13 Battery indicator display
14 Key switch
15 Lowering button
16 Lift button
17 Directional/speed control knob
18 Horn button
19 Emergency reverse button
ITEM COMPONENT

BL-GL22-1119 - 11-20-2019 2-1
SECTION 2
OPERATION
2-1. GENERAL.
This section gives detailed operating instructions for
the 989021 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 989021
lift truck.
The following safety precautions must be adhered to
at all times.
• Do not operate this truck unless you have been
trained and authorized to do so.
• All warnings and instructions must be read and
understood before using the equipment.
• Equipment must not be altered in any way.
• Equipment must be inspected by a qualified person
on a regular basis.
• Do not exceed the rated capacity. Overloading may
result in damage to the hydraulic system and struc-
tural components.
• Be certain that the lifting mechanism is operating
smoothly throughout its entire height, both empty
and loaded.
• Be sure that mast is vertical - do not operate on a
side slope.
• Be sure the truck has a firm and level footing.
• Avoid overhead wires and obstructions.
• Check for obstructions when raising or lowering the
lift carriage.
• Do not handle unstable or loosely stacked loads.
Use special care when handling long, high, or wide
loads to avoid tipping, loss of load, or striking
bystanders.
• Center and carry the load as far back as possible
toward the lift carriage back rest. The center of grav-
ity of the load must not exceed the load center listed
on the nameplate. See Figure 2-1 for load center
limitations.
• Pick up loads on both forks. Do not pick up on only
one fork.
• When traveling, always lower the load as far as pos-
sible.
Figure 2-1 Load Center
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2-2 BL-GL22-1119 - 11-20-2019
• When stacking pallets in racks and it is necessary to
move the load in a raised position, use caution.
Operate truck smoothly.
• Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.
• Operate truck only from designated operation posi-
tion. Never place any part of your body between the
mast uprights. Do not carry passengers.
• Do not allow anyone to stand or pass under load or
lifting mechanism.
• When leaving truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When leaving
truck unattended, turn off key switch, remove key
and disengage the emergency stop switch.
2-3. BEFORE OPERATION
Table 2-1 covers important inspection points on the
989021 lift truck which should be checked prior to
operation. Depending on use, some trucks may
require additional checks.
Figure 2-2 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit
your operation.
WARNING: Periodic maintenance of this truck by a
QUALIFIED TECHNICIAN is required.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
should check the truck monthly for
proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
and other areas specified in the SEC-
TION 3.
WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
unsafe condition, report it immediately to
the designated authority. Do not operate
it until it has been restored to a safe
operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.
Table 2-1 Operator Checks
ITEM PROCEDURE
Transmission
and hydraulic
systems.
Check for signs of fluid leakage.
Forks Check for cracks and damage;
and, that they are properly
secured.
Chains, cables
and hoses
Check that they are in place,
secured correctly, functioning
properly and free of binding or
damage.
Windshield and
load backrest
Check that the windshield and
load backrest are in place,
properly secured and not dam-
aged.
Safety signs Check that warning labels,
nameplate, etc., are in good
condition and legible.
Horn Check that horn sounds when
operated.
Steering Check for binding or looseness in
steering arm when steering.
Travel controls Check that speed controls on
control head operate in all
speed ranges in forward and
reverse and that belly button
switch functions.
Wheels Check drive wheel for cracks or
damage. Move truck to check
load for freedom of rotation.
Hydraulic
controls
Check operation of lift and lower
to their maximum positions.
Brakes Check that brakes actuate when
steering arm is raised to upright
position, and when lowered to
horizontal position.
Deadman/
Parking brake
Check that steering arm raises to
upright position when released
and brake applies.
Emergency Stop
Switch
Check that emergency stop
switch can be disengaged and
reengaged.
Battery charge Check the battery indicator.
High speed limit
switch
Allow for enough space to oper-
ate truck in high speed. Elevate
forks approximately two feet,
then test drive truck to check if
high speed is cut out.
ITEM PROCEDURE

BL-GL22-1119 - 11-20-2019 2-3
Figure 2-2 Sample of Operator Check List
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2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-3) located on each
side of the control head provides fingertip control for
driving the truck. Rotate the control in the direction you
want to travel. The farther you rotate the control from
the neutral position, the faster the truck will travel.
Figure 2-3 Forward/Reverse Control
The pushbutton switches (See Figure 2-4), located on
the front of the control head activate the lift-lower con-
trols and the horn.
Figure 2-4 Pushbutton Switches
2-5. DRIVING AND STOPPING PROCEDURES.
1. Disengage the emergency stop switch and turn
on the key switch. Grasp the grips of the steering
head so that the speed control can be comfortably
operated by either thumb.
2. Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
energize the electrical circuits. If the truck is not
moved, the electrical circuits will time out and will
deenergize. See Figure 2-5.
3. To move forward (with load in back), slowly press
the speed control forward. See Figure 2-3. Press
the forward speed control farther to increase
speed.
4. To slow down or stop, release the speed control
and lower or raise the steering arm to the horizon-
tal or vertical position. See Figure 2-5. In those
positions, the brake engages, slowing or stopping
the truck.
5. Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
3.
2-5.1. Stopping
The stopping distance of the truck depends on the
ground conditions. The driver must take this into
account when operating the truck.
The driver must be looking ahead when traveling. If
there is no hazard, brake moderately to avoid moving
the load.
There are four different ways to stop the truck:
1. Plugging: This electrical braking function con-
sists of rotating the speed control lever in the
opposite direction of travel and then releasing it
when the truck stops. Plugging is a convenient
way to slow down the truck during normal opera-
tion. If the control is not released, the truck will
accelerate in the opposite direction.
2. Steering arm (See Figure 2-5): The brake is fully
applied by lowering or raising the steering arm.
(See Figure 2-5) All traction control power is shut
off when the brake is engaged. When the steering
arm is in the upright position, the brake acts as a
parking brake. Deadman braking occurs when the
handle is released and spring action raises steer-
ing arm to the upright position.
3. Emergency braking: Press the emergency brake
switch, all electrical functions are cut out and the
truck automatically brakes.
4. Regenerative braking: If the speed control lever
is released, the truck automatically brakes regen-
eratively. When the speed is below 0.5 MPH, the
brake applies.
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