Blue Giant EPJ-40, Owner'S Manual

Page: 54 / 124

9-2 B
G-D40-0131
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under the line or fitting before discon-
necting.
4. Refer to Figure 9-1 and remove leaking line or fit-
ting and replace it with a new line or fitting. Check
level of hydraulic oil. With lift carriage fully low-
ered, fill reservoir with hydraulic oil to 1 inch below
opening. Use hydraulic oil listed in
Table 3-2 .
5. Turn on key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
6. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic 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 compartment covers as described in
paragraph
5-2.
9-2. HYDRAULIC AND ELECTRICAL ASSEMBLY
REMOVAL
The hydraulic system and electrical system can be
removed as an assembly to provide additional clear-
ance for various maintenance procedures.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-2.1. Removal
1. Lower forks fully.
2. Turn off key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
3. Remove the compartment covers as described in
paragraph
5-2.
4. Disconnect hose (3, Figure 9-1 ) from pump and
motor assembly (4).
5. Tag and disconnect all harnesses and cables from
electrical components on board (4,
Figure 12-17 ).
6. Support board (4) and remove four screws (1, Fig-
ure 12-17 ), four lock washers (2) and four flat
washers (3).
7. Remove board (4).
9-2.2. Installation
1. Position board (4, Figure 12-17 ) on frame and
secure with four screws (1, Figure 12-17 ), four
lock washers (2) and four flat washers (3).
2. Reconnect hose (3, Figure 9-1 ) to pump and
motor assembly (4).
3. Reconnect all harnesses and cables to electrical
components on board (4,
Figure 12-17 ).
4. Turn on key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
5. Install the compartment covers as described in
paragraph
5-2.
9-3. HYDRAULIC PUMP, MOTOR, AND RESER-
VOIR ASSY
The hydraulic pump/motor assembly can be disas-
sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo-
nent.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-3.1. Removal
1. Lower forks fully.
2. Turn off key switch (21, Figure 12-20 ) and emer-
gency disconnect (2, Figure 12-19 ).
3. Remove the hydraulic and electrical assembly as
described in paragraph
9-2.
NOTE: The reservoir will be filled with hydraulic oil.
Place a container under the pump assembly
to catch any hydraulic oil.
4. Remove two screws (5, Figure 9-1 ), lock washers
(6) and flat washers (7) and remove pump and
motor (4).
9-3.2. Disassembly and Reassembly
1. Remove the hydraulic pump/motor assembly as
described in paragraph
9-3.1.
2. Refer to Figure 9-2 for disassembly and reassem-
bly.