Blue Giant EPJ-60R, Owner'S Manual

Page: 45 / 94

SECTION 9
HYDRAULIC SYSTEM SERVICING
9-1. LINES AND FITTINGS
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
disconnected before performing any
maintenance on the hydraulic system.
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
replaced.
1. Lower forks fully.
2. Turn off the key switch (13, Figure 12-13 ) and dis-
connect the batteries.
3. Remove the compartment covers as described in
paragraph
5-3.
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.
5. Check level of hydraulic oil. If required, add
hydraulic oil to bring to 1 inch below opening. Use
hydraulic oil listed in
Table 3-2 .
6. Reconnect the batteries and turn on the keyswitch
(13,
Figure 12-13 ).
7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
8. Check level of hydraulic oil. If required, add
hydraulic oil to bring to 1 inch below opening. Use
hydraulic oil listed in
Table 3-2 .
9. Install the compartment covers as described in
paragraph
5-3.
9-2. HYDRAULIC PUMP, MOTOR, AND RE SER-
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
disconnected before performing any
maintenance on the hydraulic system.
9-2.1. Removal
1. Lower forks fully.
2. Turn off the key switch (13, Figure 12-13 ) and dis-
connect the batteries.
3. Remove the compartment covers as described in
paragraph
5-3.
4. Tag and disconnect electrical leads from pump/
motor assembly (6,
Figure 9-2 ) and solenoid (5).
NOTE:
The reservoir and hose will be filled with
hydraulic oil. Place a container under the
pump assembly to catch any hydraulic oil.
5. Disconnect hose (3, Figure 9-1 ) from pump/motor
assembly (4).
6. While supporting the pump/motor assembly (4),
remove two screws (5), two lock washers (6) and
two flat washers (7).
7. Remove the pump/motor assembly (4).