Blue Giant EPJ-30 Owner'S Manual Download

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Figure 5-3 Emergency Reverse Switch Assembly

R6754

Summary of Contents for EPJ-30

Page 1: ...TRUCK ISSUE DATE MAY 5 2020 REV 0 PART 038 XXXE WARNING 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...

Page 2: ...on 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 l...

Page 3: ...3 5 1 7 HORN SWITCH REPLACEMENT 5 5 5 1 8 LIFT AND LOWER SWITCH REPLACEMENT 5 6 5 2 UPPER COMPARTMENT COVERS 5 7 5 2 1 REMOVAL 5 7 5 2 2 INSTALLATION 5 7 5 3 LOWER COMPARTMENT COVERS 5 8 5 3 1 REMOVA...

Page 4: ...UNTING 6 2 7 1 TRANSMISSION MOTOR BRAKE MOUNTING 7 2 7 2 WHEEL ASSEMBLY 7 3 8 1 FRAME 8 1 8 2 LIFT LINKAGE ASSEMBLY 8 2 9 1 COMPARTMENT COVER 9 1 9 2 HYDRAULIC SYSTEM 9 3 9 3 PUMP MOTOR ASSY 9 4 9 4 L...

Page 5: ...pushbuttons on the con trol head The battery powered lift truck is quiet and without exhaust fumes The reversible AC motor propels the lift truck in for ward or reverse direction throughout the avail...

Page 6: ...r accidentally pin himself against a wall or obstruction when backing up in slow speed All control functions automatically return to OFF when released Emergency Disconnect within operator s reach Read...

Page 7: ...when traveling without load as the risk of overturn may be greater Always look in direction of travel Keep a clear view and when load interferes with visibility travel with load or lifting mechanism t...

Page 8: ...s 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 lif...

Page 9: ...rator Check Off List Date Operator Truck No Model No Dept Check Tires Load Wheels Horn Lift Lower Control Need Maintenance O K Shift Hour Meter Reading Drive Hoist Attachment Operation Forward Reverse...

Page 10: ...ps of the steering head so that the speed control can be comfortably oper ated by either thumb 2 Lower the steering arm to a comfortable position above horizontal to disengage the brake and to energiz...

Page 11: ...tton and hold until forks descend to desired height 2 9 LOADING AND UNLOADING 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 a...

Page 12: ...NOTES 12...

Page 13: ...clean water Obtain medical attention when eyes are affected A baking soda solution one pound to one gallon of water applied to spilled acid until bub bling stops neutralizes the acid for safe handing...

Page 14: ...is highly explosive and can cause seri ous injury 1 Charge the battery only in areas designated for that use 2 Battery terminals should be checked and cleaned of corrosion regularly Good battery termi...

Page 15: ...ith 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 c...

Page 16: ...ve four screws 1 Figure 3 3 four washers 2 Figure 3 3 Screw Removal c Tag and disconnecct the three battery cables Figure 3 4 d Rotate control arm to the extreme position as shown in Figure 3 5 e Pull...

Page 17: ...No 1 Transmission oil EP SAE 80W 90 Transmission oil EP SAE 10W 30 Note No 2 Grease Lithium base general purpose No 3 Hydraulic oil Heavy duty with a viscosity of 150 SUS foam suppressing agent and r...

Page 18: ...F LUBRICANT 1 Transmission Capacity 2 pints Can No 1 Fill to level plug opening 2 Hydraulic Reservoir Capacity 1 quarts Can No 3 With lift carriage fully lowered fill reservoir with hydraulic oil to 1...

Page 19: ...all loose connections before further troubleshooting b Defective deadman switch 16 Figure 12 1 Check and replace switch if defective c Defective controller 3 Figure 12 16 Check for proper operation a...

Page 20: ...to reservoir Weak slow or uneven action of hydraulic system a Defective pump or relief valve Check pressure Adjust as necessary b Worn lift cylinder Replace cylinder c Load larger than capacity Refer...

Page 21: ...ange batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylin der or lowering valve Check for leaking fitting in hydrau lic line and repair as required R...

Page 22: ...g checkout procedure If you find a problem during the checkout refer to paragraph 4 2 7 for further information The checkout can be conducted with or without the handheld programmer See Paragraph 4 2...

Page 23: ...rse switches and motor The motor should run proportionally faster with increasing throttle If not refer to Paragraph 4 2 7 5 Put the controller into the test mode by using the Navigation key 1 to sele...

Page 24: ...cuitry 1 Put the vehicle up on blocks to get the drive wheel off the ground 1 Turn off the key switch 23 Figure 12 16 and emergency disconnect 20 2 Using an inline fuse holder fitted with a 10 amp fus...

Page 25: ...4 Correct the problem Repeat the last three steps as necessary until the vehicle is operational Refer to the Table 4 3 for suggestions covering a wide range of possible faults Table 4 2 LED Codes LED...

Page 26: ...not correspond to throttle request 2 Short in motor or in motor wiring 3 Controller failure 6 HPD Fault HPD High Pedal Disable 1 Improper sequence of throttle and KSI push or inhibit pot 2 Misadjusted...

Page 27: ...tWiper out of range 1 Throttle input wire open or shorted 2 Throttle pot defective 3 Wrong throttle type selected 2 Undervoltage Fault Battery voltage too low 1 Battery voltage 17 volts 2 Bad connecti...

Page 28: ...NOTES 28...

Page 29: ...5 1 1 Control Head Removal 1 Turn off the key switch 23 Figure 12 16 and emergency disconnect 20 2 Remove the cap assembly 1 Figure 5 2 as described in paragraph 5 1 3 3 Disconnect harness 15 Figure 5...

Page 30: ...wo washers 7 and two flat washers 6 WARNING When removing the control head in the following steps be sure to hold it in place until the control harness is disconnected 6 Remove two screws 11 two washe...

Page 31: ...eter 21 4 Remove screw 4 washer 3 and control knob 14 from other side of potentiometer 21 5 Remove two screws 16 lock washers 6 and flat washers 7 and remove potentiometer 21 from bracket 20 6 Positio...

Page 32: ...Figure 5 3 Emergency Reverse Switch Assembly R6754 32...

Page 33: ...move two pins 10 and switch 6 from bracket 7 4 Unsolder harness 13 from switch 6 5 Solder harness 13 to new switch 6 6 Position new switch 6 in bracket 7 and secure with two pins 10 7 Position bracket...

Page 34: ...o pins 3 two switches 2 and four springs 5 from bracket 4 5 Unsolder harness 13 Figure 5 4 from defective switch 2 Figure 5 5 6 Solder the harness to new switch 2 7 Position switches 2 and four spring...

Page 35: ...cover 6 4 Disconnect cable 3 from the battery charger 5 Remove two side covers 7 5 2 2 Installation 1 Install two side covers 7 Figure 5 6 2 Reconnect cable 3 to the battery charger 3 Feed cable 3 thr...

Page 36: ...cover 9 3 Remove four screws 8 cover 9 and skids 5 and 6 from transmission 11 5 3 2 Installation 1 Position skids 5 and 6 Figure 5 7 and cover 9 on transmission 11 and secure with four screws 8 2 Posi...

Page 37: ...eering arm being sure it fully engages its seat 5 Position the opposite end of the gas return spring 8 on bracket 5 and install screw 1 5 4 2 Steering Arm Removal 1 Remove steering arm gas return spri...

Page 38: ...NOTES 38...

Page 39: ...compartment covers as described in paragraph 5 3 3 Disconnect electric brake 6 Figure 12 17 from harness 4 4 Remove the three mounting screws 39 Figure 6 1 and the brake 5 Place the new brake into pos...

Page 40: ...Figure 6 1 Transmission Motor Brake Mounting R6742 40...

Page 41: ...wheel 33 9 Install new drive wheel in reverse order of removal 10 Install the lower compartment covers as described in paragraph 5 3 11 Turn on the key switch 23 Figure 12 16 and emergency disconnect...

Page 42: ...Figure 7 1 Transmission Motor Brake Mounting R6742 42...

Page 43: ...embly If the load wheel is worn within 1 8 of the metal sleeve or is cracked or damaged replace the entire load wheel and bearing assembly Blue Giant recommends that both load wheel assemblies be repl...

Page 44: ...NOTES 44...

Page 45: ...under frame 8 Figure 8 1 transmission 13 and at tips of the forks 2 Turn off the key switch 23 Figure 12 16 and emergency disconnect 20 3 Remove pins 10 Figure 8 1 and remove shafts 11 4 Remove clips...

Page 46: ...racket 12 in the fork and install pin 9 8 Install reassemble by reversing the steps above 8 1 3 Installation 1 Position link assembly 14 Figure 8 1 under frame 8 2 Raise each link assembly 14 into pos...

Page 47: ...e performing any maintenance on the hydraulic sys tem NOTE Leaking hydraulic fittings may be remedied by simply tightening fittings If this does not rem edy the leak the fittings or line must be repla...

Page 48: ...1 and four washers 2 2 Turn on the key switch 23 Figure 12 16 and emergency disconnect 20 3 Install the upper compartment cover as described in paragraph 5 2 9 3 HYDRAULIC PUMP MOTOR AND RESER VOIR A...

Page 49: ...draulic oil 7 Check level of hydraulic oil Hydraulic oil must be 1 inch below opening If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 8 Install the compart...

Page 50: ...Figure 9 3 Pump Motor Assy R6747 50...

Page 51: ...oist carefully raise frame 8 slightly so the cylinder can be removed 9 3 4 2 Repair 1 Secure the lift cylinder in a vise clamping lightly at the base of the cylinder 2 Unscrew gland nut 4 Figure 9 4 f...

Page 52: ...ning If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 4 Turn on the key switch 23 Figure 12 16 and emergency disconnect 20 5 Operate the lift and lower butt...

Page 53: ...Make sure the connections to the buss bars are tight Use two well insulated wrenches for this task in order to avoid steering the buss bars 10 1 3 Controller Removal 1 Turn off the key switch 23 Figu...

Page 54: ...Figure 10 1 Electrical System R6750 54...

Page 55: ...ect 20 2 Remove the upper compartment covers as described in paragraph 5 2 3 Tag and disconnect harness 2 Figure 10 2 from key switch 23 Figure 10 1 4 Remove mounting nut and key switch 23 from bracke...

Page 56: ...cure with its mounting nut 2 Install the knob on the emergency disconnect 20 3 Reconnect harness 2 Figure 10 2 to emergency disconnect 20 Figure 10 1 4 Install upper compartment covers as described in...

Page 57: ...Figure 10 3 Wiring Cables R6752 57...

Page 58: ...2 from limit switch 10 Figure 12 9 5 Remove two screws 1 and limit switch 10 from bracket 2 10 1 18 Lift Limit Switch Installation 1 Position limit switch 10 Figure 12 9 on bracket 2 and secure with t...

Page 59: ...nt 1 Turn off the key switch 23 Figure 10 1 and emergency disconnect 20 2 Remove the upper compartment covers as described in paragraph 5 2 1 Disconnect wiring from the deadman switch 16 Figure 12 1 2...

Page 60: ...NOTES 60...

Page 61: ...SECTION 11 OPTIONAL EQUIPMENT 61...

Page 62: ...NOTES 62...

Page 63: ...SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the EPJ 30 Lift Truck 63...

Page 64: ...Figure 12 1 Steering Arm R6740 64...

Page 65: ...0000 000016 00 SCREW M6 X 8 1 7 0000 000030 00 SCREW M10 X 16 1 8 1120 3 0000 00 GAS SPRING 1 9 1115 300002 00 SHAFT 1 10 CONTROL HEAD FIGURE 12 2 REF 11 1115 500001 00 BRACKET 1 12 0000 000120 00 SCR...

Page 66: ...Figure 12 2 Control Head R6741 66...

Page 67: ...88 00 SCREW M4 X 8 2 9 0000 000122 00 WASHER LOCK M4 2 10 0000 000005 00 WASHER FLAT M4 2 11 0000 000322 00 SCREW M8 X 25 2 12 0000 000159 00 WASHER LOCK M8 2 13 0000 000176 00 WASHER FLAT 2 14 1120 3...

Page 68: ...2002 00 HORN BUTTON 1 4 LIFT LOWERING SWITCH ASSY LEFT FIGURE 12 4 REF 5 0000 000040 00 NUT 4 6 1120 310001 00 HORN SWITCH 1 7 1120 342004 00 HORN SWITCH BRACKET 1 8 0000 000039 00 SCREW 3 9 1120 3420...

Page 69: ...E NO REQD 1120 342100 00 LIFT LOWERING SWITCH ASSY LEFT 1 1 1120 342103 00 BUTTON LOWERING 1 2 1120 310001 00 SWITCH 2 3 1120342105 00 PIN 3 4 1120 342101 00 BUTTON BRACKET LEFT 1 5 1120 342102 00 SPR...

Page 70: ...O REQD 1120 342200 00 LIFT LOWERING SWITCH ASSY RIGHT 1 1 1120 342203 00 BUTTON LOWERING 1 2 1120 310001 00 SWITCH 2 3 1120342105 00 PIN 3 4 1120 342201 00 BUTTON BRACKET RIGHT 1 5 1120 342102 00 SPRI...

Page 71: ...T NAME NO REQD 1120 343000 00 EMERGENCY REVERSE SWITCH ASSY 1 1 1120 343002 00 EMERGENCY REVERSE BUTTON 1 2 1120 343003 00 SPRING 2 3 1120342005 00 PIN 2 4 1120 343001 0A BRACKET 1 5 1120 343004 00 PI...

Page 72: ...Figure 12 7 Transmission Motor Brake Mounting R6742 72...

Page 73: ...0 000667 00 BEARING 61905 1 19 1115 200004 00 GEAR 1 20 0000 000680 00 BEARING 16003 1 21 1115 200003 00 GEAR 1 22 0000 000660 00 KEY 5 X 5 X 18 1 23 0000 000154 00 SCREW M8 X 35 5 24 0000 000159 00 W...

Page 74: ...SCREW M6 X 16 4 2 0000 000123 00 WASHER FLAT M6 4 3 1115 500006 10 CABLE CHARGER 1 4 1115 120002 00 CAP 1 5 1120 150004 00 SCREW M6 X 25 2 6 1115 120001 00 COVER 1 7 1115 120003 00 COVER 2 8 HYDRAULIC...

Page 75: ...3 0000 000179 00 SCREW M6 X 10 2 4 0000 000123 00 WASHER FLAT M6 2 5 1115 140000 00 SKID LEFT 1 6 1115 150000 00 SKID RIGHT 1 7 1115 121000 00 COVER 1 8 0000 000655 00 SCREW M10 X 25 4 9 1115 121100...

Page 76: ...0016 00 SCREW M6 X 8 2 5 1115 400001 00 SHAFT 1 6 1115 130004 0A SHAFT 2 7 0000 000652 00 PIN M5 X 30 4 8 1115 110000 40 FRAME 1 9 1115 130002 0A SHAFT 1 10 0000 000654 00 PIN M4 X 45 2 11 1115 130001...

Page 77: ...S 2 4 0000 000675 00 BUSHING 2525 2 5 0000 000101 00 NUT M22 X 1 5 2 6 1115 132100 00 TENSION BAR 2 7 0000 000011 00 BUSHING 2015 4 8 1115 130005 40 WHEEL BRACKET ASSY 2 9 0000 000029 00 BUSHING 2012...

Page 78: ...Figure 12 12 Load Wheel R6607 INDEX NO PART NO PART NAME NO REQD 1120 13300 40 LOAD WHEEL 2 1 0000 000020 00 BEARING 2 2 1115 133002 40 LOAD WHEEL 1 INDEX NO PART NO PART NAME NO REQD 78...

Page 79: ...NOTES 79...

Page 80: ...Figure 12 13 Outer Mast R6746 80...

Page 81: ...1115 400050 00 BLOCK 1 4 CYLINDER FIGURE 12 15 REF 5 0000 000011 00 BUSHING 2015 2 6 1150 420000 00 HOSE ASSY 1 7 0000 000044 00 WASHER M14 4 8 2401 146000 00 BOLT 1 9 2401 143500 00 BOLT 1 10 0000 00...

Page 82: ...Figure 12 14 Pump Motor Assy R6747 82...

Page 83: ...ETURN PIPE 1 10 1115 560010 00 CONNECTING SHAFT 1 11 1115 560011 00 GEAR PUMP 1 12 1115 560012 00 WASHER M5 2 13 1115 560013 00 SCREW M5 X 70 2 14 1115 560014 00 SUCTION PIPE 1 15 1115 560015 00 OIL F...

Page 84: ...0000 0A LIFT CYLINDER 1 1 1115 410001 0A PISTON ROD 1 2 0000 000672 00 WIPER RING 1 3 0000 000673 00 O RING 1 4 1115 410002 0A GLAND NUT 1 5 1115 411000 0A CYLINDER BODY 1 6 1115 410003 00 GUIDE RING...

Page 85: ...NOTES 85...

Page 86: ...Figure 12 16 Electrical System R6750 86...

Page 87: ...000196 00 NUT M8 4 12 0000 000194 00 WASHER FLAT M8 4 13 0000 000126 00 SCREW M6 X 16 2 14 1120 540001 00 STAND FUSE 1 15 0000 000297 00 BOLT M8 X 35 2 16 1115 510003 00 FUSE 1 17 1115 520014 00 CHAR...

Page 88: ...Figure 12 17 Wiring Harness R6751 88...

Page 89: ...IGURE 12 1 REF 6 BRAKE ASSEMBLY FIGURE 12 7 REF 7 SWITCH ASSY LIMIT FIGURE 12 9 REF 8 KEY SWITCH ASSEMBLY FIGURE 12 16 REF 9 BATTERY INDICATOR FIGURE 12 16 REF 10 LED INDICATOR FIGURE 12 16 REF 11 BUZ...

Page 90: ...Figure 12 18 Wiring Cables R6752 90...

Page 91: ...5 00 CABLE P 1 8 1115 530006 00 CABLE P 1 9 1115 500005 00 BATTERY 2 10 1115 100001 00 BLOCK EPE 2 11 1115 231000 00 BRACKET 1 12 0000 000646 00 SCREW M4 X 10 2 13 0000 0001089 00 NUT M6 2 14 0000 000...

Page 92: ...EPJ 30 WIRING DIAGRAM WIRING DIAGRAM 92...

Page 93: ...93...

Page 94: ...sauga ON Canada L5T 2N6 t 905 457 3900 f 905 457 2313 USA 6350 Burnt Poplar Road Greensboro NC 27409 www bluegiant com If calling within North America t 1 800 668 7078 f 1 888 378 5781 Copyright Blue...

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