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OWNER’S MANUAL EPJ-60R RIDER PALLET LIFT TRUCK 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.
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WARNING Do not operate this truck unless you have been autho- Always look in direction of travel. Keep a clear view, rized and trained to do so, and have read all warnings and when load interferes with visibility, travel with load and instructions in Operator’s Manual and on this trailing.
SECTION 1 DESCRIPTION speed range. The EPJ-60R lift truck can be driven 1-1. INTRODUCTION. with forks raised or lowered. The lift truck must be This publication describes the 24 volt transistor pro-tected from the elements. EPJ-60R lift truck distributed by Blue Giant. Included...
1-3. SAFETY FEATURES. • Separately fused control circuits and power circuits. The EPJ-60R is designed and engineered to provide • Readily accessible horn button. max-imum safety for operator and payload. Some of • Handle to provide a firm hand hold for operator.
• Do not overload truck. Check nameplate for load weight and load center information. This section gives detailed operating instructions for the EPJ-60R lift truck. The instructions are divided into • Before lifting, be sure load is centered, forks are the various phases of operations, such as operating...
Table 2-1 Operator Checks ITEM PROCEDURE ITEM PROCEDURE Wheels Check drive wheel for cracks or Transmission Check for signs of fluid leakage. damage. Move truck to check and hydraulic load for freedom of rotation. systems. Hydraulic Check operation of lift and lower Forks Check for cracks and damage.
2-4. TRAVEL. truck is being driven toward the operator, the switch changes the direction of the lift truck. 2-4.1. Brake In an emergency, pull out battery connector, all electri- The brake is fully applied by lowering or raising the cal functions are cut out and the truck automatically steering arm.
R6803 Figure 2-4 Grab Bar 2-7. LOADING AND UNLOADING. 2-5. STEERING ARM GAS SPRING. Move truck to location where load is to be picked The steering arm gas spring automatically raises the steering arm to the upright position when the Move the truck into position so forks are within steering arm is released.
Leakage voltage from battery terminals to battery case accordingly. These procedures must be performed by can cause misleading trouble symptoms with the truck a qualified service technician or your Blue Giant Ser- electrical system. Since components of the truck elec- vice Representative.
Although a leakage voltage reading of zero volts may Charge the battery only in areas designated for not be possible, a cleaner battery will have more that use. usable charge for truck operation and not affect opera- Make certain the charger being used matches the tion of electronic devices on the unit.
3-3.5. MAINTENANCE FREE BATTERIES 3-4. CHARGING BATTERIES Some trucks may be equipped with maintenance free Charging requirements will vary depending on depth batteries. These batteries are completely sealed, will of discharge and temperature. Follow safety rules not require any watering and have a full 80% dis- when placing a battery on charge.
3-5. LUBRICATION. Table 3-2 Recommended Lubricants (See Table 3-3 for Application) Refer to Table 3-2 for the recommended types of No. 1 Transmission oil—EP SAE 80W-90 grease and oil. Table 3-3 in conjunction with Figure 3- Transmission oil—EP SAE 10W-30 (Note) identifies the items requiring lubrication.
SECTION 4 TROUBLESHOOTING 4-1. GENERAL Operate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Table 4-1 as a guide to determine possible Lowering, and Miscellaneous malfunctions. causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Table 4-1 Troubleshooting Chart MALFUNCTION...
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Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING - Continued Brake will not release. a. Air gap more than 0.01 in Adjust (0.25mm). b. Brake temperature above Allow to cool and check air gap. 281°...
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Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch in control head and lowering sole- noid on valve assembly (11, Fig- 12-11).
Console kit contains a Dongle IXXAT Cable and flash On the Device Configuration screen click on OK (See drive containing the computer files required. The kit is available through your Blue Giant dealer. If you Figure 4-3). require dealer location information, contact Blue Giant.
On the Can Hardware screen click on OK (See On the Set Node screen click on NODE 2 Traction Figure and then click on OK (See 4-5). Figure 4-8). Figure 4-5 Can Hardware Screen Figure 4-8 Set Node Screen On the Configuration Can screen click on OK (See On the ZAPI PC Can Console screen click on Config- Figure 4-6).
On the ZAPI PC Can Console screen click on Func- tion. The laptop computer can now be used to access the controller functions. (See Figure 4-11). Figure 4-13 Alarm Logbook Screen The faults may be intermittent faults, faults caused by Figure 4-11 ZAPI PC Can Console Screen loose wires, or faults caused by operator errors.
On the Parameters screen (Figure 4-15) click on If you feel that one of the other parameters has been Receive button. The screen will then list the Parame- changed accedently, check that setting against Table ter Name along with the current Parameter Value. 4-3.
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Table 4-3 Factory Setting-Continued Code Name Position Menu Value Scaled Code Node Value Open STOP BRK SMOOTH 10Hz BACKING SPEED BACKING TIME AUXILIARY TIME HYDRO TIME PUMP IMAX LEVEL=9 PU. ACCELER. DEL PU. DECELER. DEL SPEED LIMIT 100% CREEP SPEED COMPENSATION MIN EVP MAX EVP...
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Table 4-3 Factory Setting-Continued Code Name Position Menu Value Scaled Code Node Value Open AUX OUT FUNCTION PRESENT CONNECTED TO TRACTION SET BATTERY TYPE ADJUST BATTERY 23.66V THROTTLE 0 ZONE THROTTLE X POINT THROTTLE Y POINT BAT. MIN ADJ. LEVEL=0 BAT.
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Table 4-3 Factory Setting-Continued Code Name Position Menu Value Scaled Code Node Value Open BRAKING BOOSTER MOTORRESISTANCE LEVEL=0 SLIP COEFFICIENT LEVEL=0 MAXSLIP RESET 0.60 Hz MAXSLIP 0 2.5 Hz MAXSLIP 1 2.5 Hz MAXSLIP 1 REV 2.5 Hz FREQSLIP 1 30 Hz MAXSLIP 2 3.0 Hz...
SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD Remove two screws (5, Figure 5-2) and two screws (6) and lift up cover (4) and disconnect 5-1.1. Cover Removal. harness (27, Figure 5-1) from switch harness (21, Figure 5-2).
5-1.2. Cover Installation. Position cover (4, Figure 5-2) on control head and secure with two screws (5) and two screws (6). Hold cover (4, Figure 5-2) in place and connect Reconnect the batteries and turn on the key harness (27, Figure 5-1) to switch harness (21, switch (13,...
5-1.3. Control Head Removal Press the new switches (13) into their brackets (8) until they lock in place. Refer to the tags added in Turn off the key switch (13, Figure 12-13) and dis- the remove process. connect the batteries. Install the cover as described in paragraph 5-1.2.
Install cover (21) and secure with three screws Reconnect harness (27, Figure 5-1) to harness (1, (36), three lock washers (2) and three flat wash- Figure 12-15). ers (3). Reconnect brake switch (30, Figure 5-1) from har- Reconnect the batteries and turn on the key ness (1, Figure 12-15).
SECTION 6 BRAKE SERVICING 6-1. BRAKE. 11. Remove load wheel blocks and check operation. 12. Install the compartment covers as described in The brake system consists of a drive motor mounted paragraph 5-3. brake. This brake is spring applied and electrically released.
6-1.2. Stopping Distance Adjustment. Install the compartment covers as described in paragraph 5-3. The stopping distance of the truck should require mini- mal adjustment. However, this distance should be 6-1.3. Brake Assembly Replacement checked with each planned maintenance. Block load wheels. Using an unloaded truck, run truck to its top speed on Remove the compartment covers as described in an even dry concrete surface.
SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL 7-1. Drive Wheel. Turn off the key switch (13, Figure 12-13) and dis- connect the batteries. Remove the compartment covers as described in paragraph 5-3. Loosen but do not remove the six screws (35, Fig- 7-1).
SECTION 8 ELEVATION SYSTEM SERVICING 8-1. LIFT LINKAGE Remove pin (3) and shaft (14). Free roller (16) from bracket (17). 8-1.1. Removal Inspect bushings (15) in roller (16). If necessary, Lift complete truck to height sufficient to permit remove and replace the bushings. access to lift linkage under forks.
SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS Install the compartment covers as described in paragraph 5-3. WARNING: When forks are raised, pressure exists in the hydraulic system lines and fittings. 9-2. HYDRAULIC PUMP, MOTOR, AND RE SER- To ensure release of pressure, forks VOIR ASSY must be fully lowered and the batteries The hydraulic pump/motor assembly can be disas-...
9-2.2. Disassembly and Reassembly 9-2.4. Lift Cylinder Remove the hydraulic pump/motor assembly as 9-2.4.1.Removal described in paragraph 9-2.1. Lower forks fully. Refer to Figure 9-2 for disassembly and reassem- Turn off the key switch (13, Figure 12-13) and dis- bly. connect the batteries.
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9-2.4.2.Repair Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil. Secure the lift cylinder in a vise, clamping lightly Check level of hydraulic oil. If required, add at the base of the cylinder. hydraulic oil to bring to 1 inch below opening. Use Remove gland nut (2, Figure 9-3) from cylinder...
SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL Remove the compartment covers as described in paragraph 5-3. 10-1.1.Maintenance Tag and disconnect all electrical cables which NOTE: Erratic operation of the truck may be caused connect to the control panel (15). by defective controller components. Before Remove four screws (1), four lock washers (2), removing the electrical panel, perform trou- four flat washers (3), and control panel (15).
Click and hold the Acquire button 10-2.HORN REPLACEMENT (Figure 10- 4). Move the control arm to the travel position Turn off the key switch (13, Figure 10-2) and dis- and rotate the speed control (See Figure 10- connect the batteries. 5) located on each side of the control head to the forward position.
10-3.PUMP MOTOR. The pump motor is replaceable but not repairable. Refer to paragraph 9-2. 10-4.DRIVE MOTOR. The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of motor. Use an air hose to blow dust off of motor sur- faces.
10-6.DEADMAN SWITCH Position the new switch (30) on bracket (17) and secure with two screws (14), two lock washers 10-6.1.Replacement (29), two flat washers (15). Disconnect harness (1, Figure 12-15) from the Reconnect harness (1, Figure 12-15) to the dead- deadman switch (30, Figure 12-2).
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000380-00 WASHER, FLAT, M6 1280-000002-00 COVER 0000-000155-00 SCREW, M10 X 40 0000-000368-00 SCREW, M8 X 12 0000-000063-00 WASHER, LOCK, M10 0000-000553-00 NUT, M10 0000-000007-00 WASHER, FLAT, M10 0000-000274-00 BOLT, M6 X 25 2214-150002-00 WASHER 0000-000056-00...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000143-00 WASHER, LOCK, M52 0000-000322-00 SCREW, M8 X 25 0000-000114-00 NUT, M52 X 1.5 0000-000159-00 WASHER, LOCK, M8 1280-300005-00 COVER 0000-000176-00 WASHER, FLAT, M8 0000-000683-00 RETAINING RING, M12 1280-300002-00 PLATE 1280-300003-00 SHAFT 1280-300001-00...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-360012-00 • EMERGENCY REVERS- — 1280-360000-00 CONTROL HEAD ING BUTTON 1280-360001-00 • BRACKET 1280-360009-00 • BUTTON, LOWERING, 1280-360002-00 • HANDLE LEFT 1280-360004-00 • COVER 1280-360007-00 • BUTTON, LIFT, LEFT 1280-360003-00 •...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-141007-00 HORN BUTTON-L 1280-140000-00 GRAB BAR 1280-141008-00 HORN BUTTON-R 0000-000077-00 SCREW, M6 X 12 1280-141004-00 LOWER BUTTON 1280-141002-00 COVER 1280-520004-00 HARNESS ASSY, SWITCH 1280-141001-00 COVER 1280-520003-00 WIRE HARNESS 1280-141005-00 HIGH SPEED BUTTON-L 0000-000032-00 SCREW, M6 X 25 1280-141006-00...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000516-00 SCREW, M12 X 40 0000-000432-00 SCREW, M16 X 80 0000-000060-00 WASHER, LOCK, M12 0000-000191-00 WASHER, LOCK, M16 0000-000373-00 WASHER, FLAT, M12 0000-000220-00 WASHER, FLAT, M16 — TRANSMISSION, MOTOR, 0000-000187-00 NUT, M16 BRAKE ASSEMBLY (FIG-...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-210023-00 • BEARING SEAL, 32019 — 1280-200000-00 TRANSMISSION, MOTOR, BRAKE ASSEMBLY 1280-210024-00 • ELASTIC COLLAR, 1.78 X 18.77 1280-210001-00 • SNAP RING, 10.5 X 16 X 1.5 1280-210025-00 • V-SEAL, V160L 1280-210002-00 •...
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INDEX INDEX PART NO. PART NAME REQD. PART NO. PART NAME REQD. 0000-000692-00 WASHER, FLAT, M22 1280-100003-00 MAT, CUSHION 1280-130001-00 LINK — CASTER ASSEMBLY (FIG- 12-9) 1260-110000-00 FRAME, FORK, 48 INCH 1280-120000-00 FRAME, BACK 1280-110000-00 FRAME, FORK, 96 INCH 0000-000109-00 SCREW, M8 X 16 0000-000630-00 NUT, M12...
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INDEX INDEX PART NO. PART NAME REQD. PART NO. PART NAME REQD. 1280-130008-00 SHAFT 0000-000587-00 GREASE FITTING, M6 1280-130012-00 AXLE 1280-130002-00 SHAFT 0000-000695-00 BUSHING, 162215 0000-000410-00 PIN, M6 X 40 1280-130013-00 ROLLER 0000-000693-00 BUSHING, CSB-20 2225 1280-130010-00 BRACKET, WHEEL 1280-130003-00 SHAFT 1280-130006-00 SHAFT...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000242-00 BOLT, M8 X 15 — 2140-140000-00 CASTER WHEEL 0000-000159-00 • WASHER, LOCK, M8 0000-000093-00 • NUT, M27 X 1.5 2140-142000-00 • HINGE PIN 0000-000094-00 • LOCK RING M27 2140-145000-00 •...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000055-00 SCREW, M6 X 16 2402-384000-00 BOLT, G3/8 X 40 0000-000056-00 WASHER, LOCK, M6 0000-000069-00 SEAL 1280-420000-00 SHAFT 1280-440000-00 HOSE 2701-141600-0A CONNECTOR — PUMP & MOTOR ASSY (FIGURE 12-11) 0000-000044-00 SEAL 0000-000251-00 SCREW, M10 X 25...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1220-430008-00 • ADAPTER — 1220-440000-00 PUMP & MOTOR ASSY 1220-430011-00 • PUMP 1220-430020-00 • SCREW 1220-430012-00 • SCREW 1220-430002-00 • CABLE 1220-420015-00 • TUBE 1220-430005-00 • WIRE ASSEMBLY 1220-430016-00 • TUBE 1220-430021-00 •...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-430003-00 • GUIDE RING — 1280-430000-00 LIFT CYLINDER 0000-000689-00 • YX-SEAL, 70 X 60 X 6 0000-000045-00 • WIPER RING, 63 X 55 X 5-6.5 1280-431000-00 • CYLINDER TUBE 1280-430002-00 •...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-500007-0C BATTERY INDICATOR 0000-000433-00 SCREW, M8 X 12 — ELECTRICAL PANEL 0000-000159-00 WASHER, LOCK, M8 (FIGURE 12-14) 0000-000194-00 WASHER, FLAT, M8 0000-000109-00 SCREW, M8 X 16 1120-500003-00 HORN 0000-000015-00 SCREW, M6 X 10 0000-000499-00 SCREW, M4 X 45 0000-000056-00...
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R6794A Figure 12-14 Electrical Panel INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-510002-00 • BUSS BAR — 1280-520000-00 ELECTRICAL PANEL 1280-510001-00 • BUSS BAR 1280-560001-00 • CONTROLLER 0000-000015-00 • SCREW, M6 X 10 0000-000074-00 • SCREW, M6 X 20 1120-530006-00 •...
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INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1280-531100-00 CONNECTOR BATTERY 1280-531003-00 DRIVE MOTOR CABLE W GRAY 1280-531002-00 DRIVE MOTOR CABLE V 0000-000498-00 SCREW, M6 X 30 1280-531001-00 DRIVE MOTOR CABLE U 0000-000056-00 WASHER, LOCK, M6 1280-531004-00 PUMP POWER CABLE + 1120-112008-00 PLATE 1280-531005-00...
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