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Blue Giant EPJ-60R, Owner'S Manual

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Blue Giant EPJ-60R Owner'S Manual Download Page 69

INDEX

NO.

PART

NO.

PART NAME

NO.

REQD.

1

0000-000432-00

SCREW, M16 X 80

4

2

0000-000191-00

WASHER, LOCK, M16

4

3

0000-000220-00

WASHER, FLAT, M16

4

4

0000-000187-00

NUT, M16

4

5

1280-200002-00

BUSHING

4

6

1280-200001-00

MOUNT, TRANSMISSION

1

7

0000-000516-00

SCREW, M12 X 40

6

8

0000-000060-00

WASHER, LOCK, M12

6

9

0000-000373-00

WASHER, FLAT, M12

4

10

      —

TRANSMISSION, MOTOR, 

BRAKE ASSEMBLY (

FIG-

URE 12-6

)

REF

INDEX

NO.

PART

NO.

PART NAME

NO.

REQD.

Summary of Contents for EPJ-60R

Page 1: ...RUCK 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 in property damage bodily injury or death I...

Page 2: ...r 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 load as the risk of overturn may be grea...

Page 3: ...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 S...

Page 4: ...1 TRANSMISSION MOTOR BRAKE ASSEMBLY 7 1 7 2 DRIVE SYSTEM 7 2 8 1 FRAME 8 2 8 2 LIFT LINKAGE 8 3 9 1 HYDRAULIC SYSTEM 9 2 9 2 PUMP MOTOR ASSY 9 4 9 3 LIFT CYLINDER 9 5 10 1 SCREEN 11 10 1 10 2 ELECTRIC...

Page 5: ...ersible AC motor propels the lift truck in for ward or reverse direction throughout the available speed range The EPJ 60R lift truck can be driven with forks raised or lowered The lift truck must be p...

Page 6: ...obstruction when backing up in slow speed All control functions automatically return to OFF when released Externally accessible quick disconnect battery plug within operator s reach Separately fused c...

Page 7: ...g 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 trailing Do no...

Page 8: ...es 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 li...

Page 9: ...erator 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 Revers...

Page 10: ...ingertip control for driving the truck Rotate the control in the direction you want to travel The farther you rotate the control from the neu tral position the faster the truck will travel 2 4 3 Belly...

Page 11: ...er LOWER button and hold until forks descend to desired height 2 7 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 palle...

Page 12: ...NOTES...

Page 13: ...th 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 handi...

Page 14: ...arging is highly explosive and can cause seri ous injury 1 Charge the battery only in areas designated for that use 2 Make certain the charger being used matches the voltage and amperage of the truck...

Page 15: ...e regulated battery it never requires watering 3 4 CHARGING BATTERIES Charging requirements will vary depending on depth of discharge and temperature Follow safety rules when placing a battery on char...

Page 16: ...on 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...

Page 17: ...on 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 inch below opening 3 Li...

Page 18: ...NOTES...

Page 19: ...ing A loose con nection may be the cause of malfunction Tighten all loose connections before further troubleshooting b Defective deadman switch 30 Figure 12 2 Check and replace switch if defective c D...

Page 20: ...forks a Oil level too low Identify oil leak b Lift linkage binding Apply grease Forks do not lift to top Oil level too low Add oil to reservoir Weak slow or uneven action of hydraulic system a Defecti...

Page 21: ...Change 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...

Page 22: ...ontroller The Zapi Can Console kit contains a Dongle IXXAT Cable and flash drive containing the computer files required The kit is available through your Blue Giant dealer If you require dealer locati...

Page 23: ...button See Figure 4 7 Figure 4 7 ZAPI PC Can Console Screen On the Set Node screen click on NODE 2 Traction and then click on OK See Figure 4 8 Figure 4 8 Set Node Screen On the ZAPI PC Can Console sc...

Page 24: ...ermittent faults faults caused by loose wires or faults caused by operator errors Faults such as HPD or over temperature may be caused by operator habits or by overloading After a problem has been dia...

Page 25: ...31 MAX SPEED BACK 69 Code Name Position Menu Value Scaled Value Code Open Node 0 ACCELER DELAY 0 0 24 2 4 0 2 165 BACKING ACCEL 1 0 10 1 0 2 11 RELEASE BRAKING 2 0 20 2 0 2 220 TILLER BRAKING 3 0 3 0...

Page 26: ...EVP2 37 0 249 97 6 0 2 250 EVP OPEN DELAY 38 0 16 0 8 0 2 249 EVP CLOSE DELAY 39 0 16 0 8 0 2 248 EVP OPEN DELAY2 40 0 16 0 8 0 2 247 EVP CLOSE DELAY2 41 0 16 0 8 0 2 190 TILLER SWITCH 0 1 1 SEAT 0 2...

Page 27: ...1 ON 0 2 189 PWM ON AUX OUT 13 3 1 ON 0 2 159 ADJUSTMENT 01 0 131 56 90 0 2 158 ADJUSTMENT 02 1 131 57 91 0 2 142 SET CURRENT 2 131 32 320A 0 2 141 SET TEMPERATURE 3 131 107 38 0 2 157 ADJUSTMENT 3 4...

Page 28: ...55 55 Hz 0 2 194 MAXSLIP 3 23 129 47 4 7 Hz 0 2 168 MAXSLIP 3 REV 24 129 22 2 2 Hz 0 2 198 FREQSLIP 3 25 129 80 80 Hz 0 2 195 MAXSLIP 4 26 129 47 4 7 Hz 0 2 169 MAXSLIP 4 REV 27 129 22 2 2 Hz 0 2 199...

Page 29: ...AD 5 1 1 Cover Removal 1 Turn off the key switch 13 Figure 12 13 and dis connect the batteries 2 Remove two screws 5 Figure 5 2 and two screws 6 and lift up cover 4 and disconnect harness 27 Figure 5...

Page 30: ...and connect harness 27 Figure 5 1 to switch harness 21 Figure 5 2 2 Position cover 4 Figure 5 2 on control head and secure with two screws 5 and two screws 6 3 Reconnect the batteries and turn on the...

Page 31: ...on the switch 4 Replace switch harness as an assembly 5 Press the new switches 13 into their brackets 8 until they lock in place Refer to the tags added in the remove process 6 Install the cover as de...

Page 32: ...teering arm assembly on the transmis sion and secure with eight screws 4 Figure 12 1 lock washers 5 and flat washers 6 2 Secure the steering arm assembly to the frame with four screws 7 lock washers 8...

Page 33: ...Figure 5 3 Steering System R6776A...

Page 34: ...NOTES...

Page 35: ...wheels 2 Remove the compartment covers as described in paragraph 5 3 3 Using low pressure air remove any dirt between armatures and magnet body 4 Using standard feeler gauges check the gap between the...

Page 36: ...raph 5 3 3 Rotate the adjusting nut Figure 6 1 clockwise to SHORTEN the stopping distance or counterclock wise to LENGTHEN the stopping distance 4 Remove load wheel blocks and check operation 5 Instal...

Page 37: ...batteries and turn on the keyswitch 13 Figure 12 13 7 2 Transmission 1 Turn off the key switch 13 Figure 12 13 and dis connect the batteries 2 Block the load wheels securely 3 Remove the compartment c...

Page 38: ...Figure 7 2 Drive System R6781...

Page 39: ...aged replace the entire load wheel and bearing assembly Blue Giant recommends that both load wheel assemblies be replaced at the same time This ensures level and safe operation of the lift truck 7 3 2...

Page 40: ...NOTES...

Page 41: ...8 2 and shaft 13 Free bracket 17 from bar end 12 2 Inspect bushings 4 in bar end 12 If necessary remove and replace the bushings 3 Remove pin 3 and shaft 14 Free roller 16 from bracket 17 4 Inspect bu...

Page 42: ...Figure 8 1 Frame R6786A...

Page 43: ...Figure 8 2 Lift Linkage R6787A...

Page 44: ...NOTES...

Page 45: ...ns 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...

Page 46: ...Figure 9 1 Hydraulic System R6789...

Page 47: ...raulic oil to bring to 1 inch below opening Use hydraulic oil listed in Table 3 2 8 Install the compartment covers as described in paragraph 5 3 9 2 4 Lift Cylinder 9 2 4 1 Removal 1 Lower forks fully...

Page 48: ...Figure 9 2 Pump Motor Assy R6790...

Page 49: ...10 Install gland nut 2 on cylinder tube 7 9 2 4 3 Installation 1 Position the cylinder in the frame and secure the bottom of the cylinder with shaft 10 Figure 9 1 screw 8 and lock washer 9 2 Secure to...

Page 50: ...NOTES...

Page 51: ...compartment cover as described in paragraph 5 3 3 Remove any dirt or corrosion from the bus bar area The controller should be wiped clean with a moist rag Allow it to dry before reconnecting the batte...

Page 52: ...Figure 10 2 Electrical System R6478 R6792A...

Page 53: ...Figure 10 3 Electrical Panel R6478 R6794A...

Page 54: ...Acquire button Figure 10 4 and then press the Save button to store these settings 8 Install the compartment covers as described in paragraph 5 3 9 Reconnect the batteries and turn on the keyswitch 13...

Page 55: ...e motor 8 Reinstall the brake as described in paragraph 6 1 3 10 5 LIFT LIMIT SWITCH 10 5 1 Replacement 1 Disconnect wiring from the lift limit switch 21 Fig ure 10 2 2 Remove the two screws 17 two lo...

Page 56: ...30 Figure 12 2 2 Remove the two screws 14 two lock washers 29 two flat washers 15 and switch 30 from bracket 17 3 Position the new switch 30 on bracket 17 and secure with two screws 14 two lock washe...

Page 57: ...SECTION 11 OPTIONAL EQUIPMENT 11 1 LOAD BACKREST A load backrest is available for addition to the lift truck to allow handling of high loads...

Page 58: ...NOTES...

Page 59: ...SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the EPJ 60R Lift Truck...

Page 60: ...Figure 12 1 Steering System R6776A...

Page 61: ...3 0000 000553 00 NUT M10 4 4 0000 000274 00 BOLT M6 X 25 8 5 0000 000056 00 WASHER LOCK M6 8 6 0000 000380 00 WASHER FLAT M6 8 7 0000 000155 00 SCREW M10 X 40 4 8 0000 000063 00 WASHER LOCK M10 4 9 00...

Page 62: ...Figure 12 2 Steering Arm R6778B...

Page 63: ...30 00 SCREW M10 X 16 1 17 2130 300001 00 BRACKET STEERING 1 18 0000 000681 00 KEY C8 X 7 X 14 1 19 0000 000143 00 WASHER LOCK M52 1 20 0000 000114 00 NUT M52 X 1 5 1 21 1280 300005 00 COVER 1 22 0000...

Page 64: ...Figure 12 3 Control Head R6780A...

Page 65: ...08 0C POTENTIOMETER 1 11 1120 343003 00 SPRING 2 12 1280 360005 00 CONTROL KNOB RIGHT 1 13 1220 520005 0C SWITCH ASSEMBLY REVERSING 1 14 1280 360012 00 EMERGENCY REVERS ING BUTTON 1 15 1280 360009 00...

Page 66: ...Figure 12 4 Grab Bar Assembly R6785A...

Page 67: ...06 00 HIGH SPEED BUTTON R 1 7 1280 141003 00 LIFT BUTTON 1 8 1280 141009 00 SPRING 8 9 1280 141007 00 HORN BUTTON L 1 10 1280 141008 00 HORN BUTTON R 1 11 1280 141004 00 LOWER BUTTON 1 12 1280 520004...

Page 68: ...Figure 12 5 Drive System R6781...

Page 69: ...00220 00 WASHER FLAT M16 4 4 0000 000187 00 NUT M16 4 5 1280 200002 00 BUSHING 4 6 1280 200001 00 MOUNT TRANSMISSION 1 7 0000 000516 00 SCREW M12 X 40 6 8 0000 000060 00 WASHER LOCK M12 6 9 0000 00037...

Page 70: ...Figure 12 6 Transmission Motor Brake Assembly R6783...

Page 71: ...TIC COLLAR M150 1 21 1280 210021 00 BEARING SEAL 30 X 62 X 7 1 22 1280 210022 00 BEARING SEAL 100 X 150 X 13 1 23 1280 210023 00 BEARING SEAL 32019 1 24 1280 210024 00 ELASTIC COLLAR 1 78 X 18 77 1 25...

Page 72: ...Figure 12 7 Frame R6786A...

Page 73: ...131000 00 SHAFT 2 11 1280 132000 00 SHAFT 2 12 0000 000694 00 BUSHING 4 13 0000 000692 00 WASHER FLAT M22 4 14 1280 130001 00 LINK 2 15 1260 110000 00 FRAME FORK 48 INCH 1 15 1280 110000 00 FRAME FOR...

Page 74: ...Figure 12 8 Lift Linkage R6787A...

Page 75: ...48 INCH 1 9 1280 133000 00 TENSION BAR 96 INCH 1 10 0000 000691 00 NUT M22 X 1 5 10 11 1280 130014 00 BAR 2 12 1280 130007 00 END TENSION BAR 2 13 1280 130008 00 SHAFT 2 14 1280 130012 00 AXLE 2 15 0...

Page 76: ...Figure 12 9 Caster Wheel R6788...

Page 77: ...ARINGBLOCK 1 6 0000 000421 00 BEARING 6306 2RZ 1 7 2140 140004 00 SPRING 2 8 2140 141000 00 YOKE 1 9 0000 000242 00 BOLT M8 X 15 2 10 0000 000159 00 WASHER LOCK M8 2 11 2140 142000 00 HINGE PIN 1 12 2...

Page 78: ...Figure 12 10 Hydraulic System R6789...

Page 79: ...REF 5 0000 000251 00 SCREW M10 X 25 2 6 0000 000063 00 WASHER LOCK M10 2 7 0000 000007 00 WASHER FLAT M10 2 8 0000 000055 00 SCREW M6 X 16 2 9 0000 000056 00 WASHER LOCK M6 2 10 1280 420000 00 SHAFT...

Page 80: ...Figure 12 11 Pump Motor Assy R6790...

Page 81: ...TOR 1 7 1220 430009 00 VALVE SOLENOID 1 8 1220 430010 00 CARTRIDGE 1 9 1220 430006 00 RELIEF VALVE 1 10 1220 430022 00 PLUG 1 11 1220 430008 00 ADAPTER 1 12 1220 430011 00 PUMP 1 13 1220 430012 00 SCR...

Page 82: ...Figure 12 12 Lift Cylinder R6791A...

Page 83: ...5 1 2 1280 430002 00 GLAND NUT 1 3 0000 000690 00 O RING 60 X 3 1 1 4 1280 430001 00 PISTON ROD 1 5 1280 430003 00 GUIDE RING 1 6 0000 000689 00 YX SEAL 70 X 60 X 6 1 7 1280 431000 00 CYLINDER TUBE 1...

Page 84: ...Figure 12 13 Electrical System R6792A...

Page 85: ...1280 100001 00 COVER 1 12 1120 500016 00 KEY 1 13 1115 500002 0C KEY SWITCH 3 WAY 1 14 1120 500007 0C BATTERY INDICATOR 1 15 ELECTRICAL PANEL FIGURE 12 14 REF 16 0000 000109 00 SCREW M8 X 16 2 17 0000...

Page 86: ...R FLAT M8 8 7 1120 540002 00 FUSE 200A 2 8 0000 000126 00 SCREW M6 X 16 4 9 0000 000206 00 WASHER LOCK M5 4 10 1120 540001 00 B FUSE BLOCK 2 11 1280 510002 00 BUSS BAR 1 12 1280 510001 00 BUSS BAR 1 1...

Page 87: ...NOTES...

Page 88: ...Figure 12 15 Wiring Harness R6796A...

Page 89: ...INDEX NO PART NO PART NAME NO REQD 1 1280 520001 00 WIRING HARNESS MAIN 1 2 1120 500010 00 FUSE 10A 1...

Page 90: ...Figure 12 16 Wiring Cables R6798A...

Page 91: ...MOTOR CABLE V 1 3 1280 531001 00 DRIVE MOTOR CABLE U 1 4 1280 531004 00 PUMP POWER CABLE 1 5 1280 531005 00 PUMP POWER CABLE 1 6 1280 531100 00 CONNECTOR BATTERY GRAY 1 7 0000 000498 00 SCREW M6 X 30...

Page 92: ...NOTES...

Page 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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