Blue Giant EPJ-40, Owner'S Manual

Page: 4 / 124

TABLE OF CONTENTS - Continued
ii B
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10-1.6. CHARGER INSTALLATION....................... 10-1
10-1.7. EMERGENCY DISCONNECT REMOVAL. 10-2
10-1.8. EMERGENCY DISCONNECT INSTALLATION.
10-2
10-1.9. CONTACTOR REMOVAL.......................... 10-2
10-1.10. CONTACTOR INSTALLATION.................. 10-2
10-1.11. FUSE REMOVAL. ...................................... 10-2
10-1.12. FUSE INSTALLATION. .............................. 10-2
10-1.13. COOLING FAN REMOVAL........................ 10-4
10-1.14. COOLING FAN INSTALLATION................ 10-4
10-1.15. BUZZER REMOVAL. ................................. 10-4
10-1.16. BUZZER INSTALLATION. ......................... 10-4
10-1.17. KEY SWITCH REMOVAL. ......................... 10-4
10-1.18. KEY SWITCH INSTALLATION. ................. 10-4
10-1.19. BATTERY INDICATOR REMOVAL............10-4
10-1.20. BATTERY INDICATOR INSTALLATION....10-4
10-1.21. LIFT LIMIT SWITCH REMOVAL. ...............10-6
10-1.22. LIFT LIMIT SWITCH INSTALLATION. .......10-6
10-2.
PUMP MOTOR...........................................10-7
10-3. DRIVE MOTOR. .........................................10-7
10-4. DEADMAN SWITCH ..................................10-7
10-4.1. REPLACEMENT.........................................10-7
11
OPTIONAL EQUIPMENT11-1
12
ILLUSTRATED PARTS BREAKDOWN12-1
LIST OF ILLUSTRATIONS
Figure Page Figure Page
1-1 NAME PLATE ..................................................... 1-1
1-2 D40 LIFT TRUCK................................................. 1-1
2-1 SAMPLE OF OPERATOR CHECK LIST ............. 2-3
2-2 FORWARD/REVERSE CONTROL...................... 2-4
2-3 PUSHBUTTON SWITCHES ................................ 2-4
2-4 BRAKE ACTUATION ........................................... 2-4
2-5 BELLY-BUTTON SWITCH................................... 2-5
3-1 CHARGING BATTERY ........................................ 3-3
3-2 COVER REMOVAL.............................................. 3-4
3-3 CONTROLLER BOARD REMOVAL .................... 3-4
3-4 LUBRICATION DIAGRAM ................................... 3-6
4-1 ZAPI CONTROLLER ........................................... 4-4
4-2 ZAPI HANDSET................................................... 4-5
4-3 ZAPI HANDSET................................................... 4-9
4-4 THROTTLE REGULATION................................ 4-10
4-5 ZAPI HANDSET................................................. 4-11
4-6 ZAPI CONTROLLER CONNECTIONS .............. 4-13
5-1 STEERING ARM.................................................. 5-1
5-2 CONTROL HEAD ................................................ 5-2
5-3 EMERGENCY REVERSE SWITCH ASSEMBLY 5-4
5-4 CAP ASSEMBLY ................................................. 5-5
5-5 COMPARTMENT COVER ................................... 5-6
6-1 BRAKE ASSEMBLY ............................................ 6-1
7-1 WHEEL ASSEMBLY............................................ 7-2
7-2 TRANSMISSION MOTOR, BRAKE MOUNTING. 7-4
8-1 FRAME ................................................................ 8-1
8-2 LIFT LINKAGE ASSEMBLY................................. 8-2
9-1 HYDRAULIC SYSTEM ........................................ 9-1
9-2 PUMP & MOTOR ASSY....................................... 9-3
9-3 LIFT CYLINDER................................................... 9-5
10-1 ELECTRICAL COMPONENTS (SHEET 1) ........ 10-3
10-2 ELECTRICAL COMPONENTS (SHEET 2) ........ 10-5
10-3 ELECTRIC SYSTEM.......................................... 10-6
12-1 STEERING ARM ................................................ 12-2
12-2 CONTROL HEAD............................................... 12-4
12-3 CAP ASSEMBLY................................................ 12-8
12-4 EMERGENCY REVERSE SWITCH
ASSEMBLY ...................................................... 12-10
12-5 TRANSMISSION MOTOR, BRAKE
MOUNTING...................................................... 12-12
12-6 TRANSMISSION .............................................. 12-14
12-7 COMPARTMENT COVERS ............................. 12-18
12-8 LOAD BACKREST ........................................... 12-20
12-9 FRAME............................................................. 12-24
12-10 LIFT LINK ASSEMBLY..................................... 12-26
12-11 LOAD WHEEL.................................................. 12-28
12-12 CASTER........................................................... 12-30
12-13 HYDRAULIC SYSTEM..................................... 12-32
12-14 PUMP & MOTOR ASSY................................... 12-34
12-15 LIFT CYLINDER............................................... 12-36
12-16 ELECTRICAL SYSTEM ................................... 12-38
12-17 MOTOR ASSEMBLY........................................ 12-40
12-18 ELECTRICAL COMPONENTS (SHEET 1) ...... 12-42
12-19 ELECTRICAL COMPONENTS (SHEET 2) ...... 12-44
12-20 WIRING HARNESS.......................................... 12-48
12-21 WIRING CABLES............................................. 12-50
LIST OF TABLES
Table Page Table Page
2-1 OPERATOR CHECKS ........................................... 2-2
3-1 MONTHLY AND QUARTERLY INSPECTION AND
SERVICE CHART .................................................. 3-1
3-2 RECOMMENDED LUBRICANTS........................... 3-5
3-3 LUBRICATION CHART .......................................... 3-6
4-1 TROUBLESHOOTING CHART ..............................4-1
4-2 SET OPTIONS........................................................4-5
4-3 ADJUSTMENTS .....................................................4-9
4-4 PARAMETER ADJUSTMENTS ............................4-11
4-5 ZAPI CONTROLLER CONNECTOR PINS...........4-13