Blue Giant EPJ-60R, Owner'S Manual

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TABLE OF CONTENTS
Section Page Section Page
1 DESCRIPTION ............................................................1-1
1-1.
INTRODUCTION. .............................................1-1
1-2. GENERAL DESCRIPTION...............................1-1
1-3. SAFETY FEATURES. ......................................1-2
2 OPERATION ...............................................................2-1
2-1.
GENERAL. .......................................................2-1
2-2. OPERATING PRECAUTIONS. ........................2-1
2-3. BEFORE OPERATION.....................................2-1
2-4. TRAVEL. ..........................................................2-4
2-4.1. BRAKE .............................................................2-4
2-4.2. TRAVEL ...........................................................2-4
2-4.3. BELLY-BUTTON SWITCH ...............................2-4
2-5.
STEERING ARM GAS SPRING.......................2-5
2-6. LIFT AND LOWER CONTROLS. .....................2-5
2-7. LOADING AND UNLOADING. .........................2-5
2-8. 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. BATTERY CLEANING......................................3-2
3-3.5. MAINTENANCE FREE BATTERIES................3-3
3-4.
CHARGING BATTERIES .................................3-3
3-5. LUBRICATION. ................................................3-4
4 TROUBLESHOOTING ................................................4-1
4-1.
GENERAL ........................................................4-1
4-2. CONTROLLER TROUBLESHOOTING............4-4
4-2.1. ZAPI CAN CONSOLE KIT................................4-4
4-2.2. DIAGNOSTIC HISTORY ..................................4-6
4-2.3. ADJUISTMENT. ...............................................4-6
5 STEERING ARM, CONTROL HEAD AND
COMPARTMENT ........................................................5-1
5-1.
CONTROL HEAD .............................................5-1
5-1.1. COVER REMOVAL. .........................................5-1
5-1.2. COVER INSTALLATION. .................................5-2
5-1.3. CONTROL HEAD REMOVAL ..........................5-3
5-1.4. CONTROL HEAD INSTALLATION ..................5-3
5-1.5. BELLY-BUTTON SWITCH REPLACEMENT. ..5-3
5-1.6. HORN, LIFT AND LOWER SWITCH
REPLACEMENT...............................................5-3
5-1.7. SPEED POTENTIOMETER REPLACEMENT. 5-3
5-2.
STEERING ARM ..............................................5-3
5-2.1. RETURN SPRING REPLACEMENT................5-3
5-2.2. STEERING ARM REMOVAL............................5-4
5-2.3. STEERING ARM INSTALLATION....................5-4
5-3.
COMPARTMENT COVERS .............................5-4
5-3.1. REMOVAL. .......................................................5-4
5-3.2. INSTALLATION. ...............................................5-4
6 BRAKE SERVICING ................................................... 6-1
6-1.
BRAKE............................................................. 6-1
6-1.1. AIR GAP ADJUSTMENT. ................................ 6-1
6-1.2. STOPPING DISTANCE ADJUSTMENT. ......... 6-2
6-1.3. BRAKE ASSEMBLY REPLACEMENT ............ 6-2
7 TRANSMISSION, DRIVE WHEEL, 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
7-4.
CASTERS ........................................................ 7-3
8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1.
LIFT LINKAGE ................................................. 8-1
8-1.1. REMOVAL ....................................................... 8-1
8-1.2. REPAIR ........................................................... 8-1
8-1.3. INSTALLATION ............................................... 8-1
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1.
LINES AND FITTINGS .................................... 9-1
9-2. HYDRAULIC PUMP, MOTOR, AND
RESERVOIR ASSY ......................................... 9-1
9-2.1. REMOVAL ....................................................... 9-1
9-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-3
9-2.3. INSTALLATION ............................................... 9-3
9-2.4. LIFT CYLINDER .............................................. 9-3
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.PANEL REMOVAL. ....................................... 10-1
10-1.4.PANEL DISASSEMBLY................................. 10-1
10-1.5.PANEL INSTALLATION. ............................... 10-1
10-2. HORN REPLACEMENT ................................ 10-4
10-3. PUMP MOTOR. ............................................. 10-5
10-4. DRIVE MOTOR. ............................................ 10-5
10-4.1.MOTOR REMOVAL....................................... 10-5
10-4.2.MOTOR INSTALLATION............................... 10-5
10-5. LIFT LIMIT SWITCH ...................................... 10-5
10-5.1.REPLACEMENT............................................ 10-5
10-5.2.ADJUSTMENT............................................... 10-5
10-6. DEADMAN SWITCH...................................... 10-6
10-6.1.REPLACEMENT............................................ 10-6
11 OPTIONAL EQUIPMENT ......................................... 11-1
11-1. LOAD BACKREST......................................... 11-1
12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1