OPERATOR’S MANUALEPJ-40 ELECTRIC PALLET TRUCK

WARNINGDo 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.

ISSUE DATE: MAY 5, 2020 REV.0 (PART # 038-928EO)

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FOREWORD

As a lift truck operator, you are responsible for a machine that is use-ful, powerful, and can be hazardous if not operated as described. Your Blue Giant truck may weigh more than some cars, depending on the model. Observing and practicing the safety warnings in this manual cannot be overemphasized. Just knowing the warnings, however, is no substitute for common sense. Using your common sense will, in almost all cases, prevent accidents. Think of the truck as your own. In this way you will learn its capabilities and limitations.

This manual is intended to remain with the truck at all times as a handy

reference guide to operation. Detailedmaintenance procedures are found inthe parts and service manual for thespecific truck model, and are to beperformed only by a qualified techni-cian. For further information onobtaining a complete parts and ser-vice manual, see page 21 of this man-ual.

The operator who knows his truck willlearn to spot problems as theydevelop. This is accomplished by per-forming the Daily Checks and report-ing any problems to the designatedauthority.

TABLE OF CONTENTS

SAFETY SYMBOLS ..............................................................................................2

GENERAL DESCRIPTION ....................................................................................2

NAME PLATE AND WARNING DECAL................................................................2

LOAD CAPACITY ..................................................................................................4

BEFORE OPERATION ..........................................................................................5Optional Features....................................................................................8

INSTRUMENTS AND CONTROLS .......................................................................7Optional Features....................................................................................8

OPERATION ..........................................................................................................9Forward and Reverse Travel and Speed Control ..................................9Steering ....................................................................................................9Stopping.................................................................................................10Parking ...................................................................................................10Battery Charging ...................................................................................11Load Handling .......................................................................................11Moving a Disabled Truck ......................................................................11

NOTICE - OBTAINING A PARTS AND SERVICE MANUAL ..............................21

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SAFETY SYMBOLS

WARNING and CAUTIONS are both signal words intended to alert the viewer tothe existence and relative degree of a hazard. They are both preceded by a safetyalert symbol consisting of an exclamation mark enclosed by a triangle.

A Warning indicates a hazard which could result in injury or death if proper pre-cautions are not taken.

A Caution indicates a reminder of routine safety practices.

A prohibition slash (circle with diagonal slash through it) indicates a procedure oraction that should not be performed under any circumstances, as both personalinjury and/or damage to equipment will result.

GENERAL DESCRIPTION

Blue Giant Pallet trucks lift and transport loads on rigid forks.

Control for steering, braking, forward and reverse travel, horn, lift, lower and speed control are all located on the control handle.

Trucks in this series may vary in loadcapacity, battery arrangement, andinstrumentation, depending on modeland options.

NAME PLATE AND WARNING DECAL

Name plate and warning decal loca-tions may vary between models, but they are always near the steering arm within sight of the operator.

If the name plate or warning deal are lost or damaged they should be replaced immediately. Have your supervisor or the designated authority contact Blue Giant Authorized Dealer for replacement.

The name plate shows the modelnumber; serial number; truck type;battery type, voltage and minimumweight. It also contains information onthe load capacity and load center. Thewarning decal contains warningswhich also appear, with illustrations, inthe Operating Precautions section ofthis manual.

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Name Plate and Warning Decal Locations - Typical

This truck is equipped with a battery. Read and heed the warning decal locatednear the battery. An example is shown here:

WARNING:

R4906

4

LOAD CAPACITY

Do not overload truck. Check capacityplate for load weight and load centerinformation.

The load capacity depends on theload center. The load maximumcapacity listed on the capacity plateassumes a uniform load whose centeris at 1/2 the length of the fork and cen-tered between the forks. The maxi-mum load capacity is reduced when

the load center exceeds 1/2 the lengthof the forks or is not centered betweenthe forks. The fork length and wheel-base must be adequate for the skid orbin to be handled.

Note that a truck undergoing speedchanges is less stable than a standingtruck. If you are not sure that the truckcan lift a certain load, consult yoursupervisor or the designated authority.

Load Center

R5060

5

BEFORE OPERATION

The table on page 6 covers importantinspection points on trucks whichshould be checked prior to operation.Depending on use, some trucks mayrequire additional checks.

The illustration below shows a sampleformat for a Operator Checklist, whichcan be modified as necessary to fityour operation.

Periodic maintenance of thistruck by a QUALIFIED TECH-NICIAN is required.

A QUALIFIED SERVICETECHNICIAN should check the

truck monthly for proper lubrica-tion, proper fluid levels, brakemaintenance, motor mainte-nance and other areas speci-fied in the parts and servicemanual maintenance section.

If the truck is found to be unsafeand in need of repair, or con-tributes to an unsafe condition,report it immediately to the des-ignated authority. Do not oper-ate it until it has been restoredto a safe operating condition.Do not make any unauthorizedrepairs or adjustments. All ser-vice must be performed by aqualified maintenance techni-cian.

Sample of Operator Check List

WARNING:

WARNING:

WARNING:

R6235

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Operator Checks

ITEM PROCEDURETransmission and hydraulic systems

Check for signs of fluid leakage.

Forks Check for cracks and damage.Guards and load backrest Check that safety guards are properly secured

and not damaged.Safety signs Check that warning labels, nameplate, etc.,

are in good condition and legible.Horn Check that horn sounds when operated.Steering Check for binding or looseness in steering

arm when steering.Travel controls Check that speed controls on control handle

operate in all speed ranges in forward and reverse and that belly button switch functions.

Wheels Check drive wheel for cracks or damage. Move truck to check load wheels for freedom of rotation.

Hydraulic controls Check operation of lift and lower, and tilt to their maximum positions.

Brakes Check that brakes actuate when steering arm is raised to upright position, and when lowered to horizontal position.

Deadman/Parking brake Check that steering arm raises to upright posi-tion when released and brake applies.

Battery disconnect Check that battery can be disconnected and reconnected. Check for connector damage.

High speed limit switch Allow for enough space to operate truck in high speed. Disengage third speed using the high speed cut-out switch, then test drive truck to check if high speed is cut out.

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INSTRUMENTS AND CONTROLS

The steering arm and control handleprovide controls for steering, forwardand reverse speed control, braking,raising and lowering the forks, andhorn. Control handles on some mod-els have the high speed cut-outswitch. Control handles on all modelshave a “belly-button” reversing switchwhich reverses the direction of thetruck upon contact with the operator.

Detailed operating instructions are inthe Operation section of this manual.

A battery disconnect is mounted nearthe steering arm. Pulling the discon-nect removes all power from truck cir-cuits in the event of an emergency.

Control Handle

R4070

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Walkie/Rider Pallet Trucks have agrab handle which also contains lift,lower and horn controls.

Optional Features

The optional battery capacity indica-tor, hour meter and keyswitch mounton the panel near the control handle.The battery capacity indicator moni-

tors the battery discharge rate to indi-cate the remaining battery capacity.The hour meter records the accumu-lated hours that electrical energy isbeing drawn from the battery to runthe pump and drive motors. The key-switch provides added security to thetruck, preventing unauthorized per-sonnel from operating the machine.

Grab Handle

R4907

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OPERATION

Forward and Reverse Travel andSpeed Control

Control Handle

All directional and speed controls arelocated on the control handle.

Forward and reverse are controlled byrotating the speed control lever asshown. The lever is spring loaded toreturn to neutral when released. Fur-ther rotation in either direction willprogress the truck from slow to maxi-mum travel speed.

To change directions or to stop thetruck, rotate the speed control lever inthe opposite direction. The truck will

come to a stop and then, unless thecontrols are returned to the centerneutral position, accelerate in theopposite direction.

Steering

Moving the control handle (which con-nects to the steering arm) right or leftwill turn the truck right or left. Whenmaneuvering around corners, makesquare turns and be sure there is adequate clearance.

R4070

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Stopping

Stop the truck as gradually as possi-ble. Unnecessary rapid stopping couldbe hazardous. Load could becomeunstable.

There are four possible ways to stopthe truck:

1. Plugging: This electrical brakingfunction consists of rotating thespeed control lever in the oppo-site direction of travel and thenreleasing it when the truck stops.Plugging is a convenient way tostop the truck during normaloperation. If the control is notreleased, the truck will acceleratein the opposite direction.

2. Steering arm in horizontalposition: Lowering the steeringarm to the horizontal positionapplies brake pad pressure to thebrake disc. Lowering the steeringarm below the horizontal position

increases the braking force andde-energizes the controls.

3. Steering arm in vertical posi-tion: Raising the steering arm tonear vertical position appliesbrake pad pressure to the brakedisc. Further vertical positioningincreases the braking force andde-energizes the controls. Thisposition services as a parkingbrake. As a safety precaution, thesteering arm is spring loaded toreturn to the vertical position inthe event the driver releases thecontrol handle during operation.This is known as deadman brak-ing.

Parking

When parking the truck, do notobstruct traffic lanes or aisles.

1. Park the truck in its designatedparking area.

Steering Arm Braking Positions

R3629

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2. Raise the steering arm until verti-cal to apply the parking brake.

3. Fully lower forks.

4. Turn keyswitch (if so equipped) tooff position. Remove key foradded security.

5. Pull out battery disconnect.

Battery Charging

Refer to DOC 245 for battery safetyand maintenance.

NOTE: Battery charging instructionsare contained in the servicemanual.

Load Handling

Handle only loads arranged forstability and always use cau-tion. Raise and lower the loadsmoothly to prevent the loadfrom falling.

Always be sure the load andload center are within thecapacity of the truck. If in doubtcheck the nameplate.

1. Approach the load slowly.

2. Move the truck slowly into posi-tion so that the forks are centeredabout the load.

3. Make sure the load is against thebackrest and then raise the forksuntil the pallet clears the rack.

4. Lead the truck by the control han-dle with the load trailing exceptwhen in confined areas. Rampsshould be traveled with operatoruphill of truck when empty, oroperator downhill of truck withload on forks.

5. Always look in the direction oftravel. Move slowly and checkclearances when approachingobstructions.

6. Do not make sudden starts andstops. Operate truck smoothlyand gradually.

7. Travel slowly and squarelyaround corners. Remember thatthe trailing load wheels do not fol-low the turn path of the drivewheel. Instead they tend to cutthe corner.

8. Line up the truck with the unload-ing area.

9. Stop the truck and check the loadalignment with surroundingobjects.

10. Be careful not to damage ormove adjacent loads and objects.

11. Lower the forks until the load isresting on its own.

12. Move the truck back until theforks are clear of the pallet.

Moving a Disabled Truck

Do not attempt to move a disabledtruck; notify your supervisor or properauthority.

WARNING:

WARNING:

12

The following operating instructions appear on the truck warning decal, which islocated near the steering arm.

R4071

Do not operate this truck unless you havebeen trained and authorized to do so,and have read and understand all warn-ings and instructions contained in thisoperator’s manual and on this truck.

R4072

Do not operate this truck untilyou have checked its condition.Give special attention to tires,horn, battery, controller, lift sys-tems, brakes, steering mecha-nism, guards and safetydevices. If you have any ques-tions, notify your supervisor orproper authority.

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R4073

Walkie Pallet Trucks: Operatetruck only from walking position.

R4905

Walkie/Rider Pallet Trucks:Keep feet within limits of truck.

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R4074

Wear foot protection andkeep feet clear of truck.

R4075

Do not carry passengers.

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R4076

Observe applicable traffic regulations. Yield right-of-way to pedestrians.Slow down and sound horn at cross aisles and wherever vision isobstructed.

R4077

Start, stop, travel, steer and brake smoothly. Slow down for turns and onuneven or slippery surfaces that could cause truck to slide or overturn. Usespecial care when traveling without load as the risk of overturn may begreater.

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R4078

Always look in direction of travel. Keep aclear view, and when load interferes withvisibility, travel with load or lifting mecha-nism trailing (except when climbingramps.

R4079

Use special care when operating on ramps; travel slowly, and do not angleor turn. Travel unloaded with lifting mechanism downhill, and travel loadedwith load uphill.

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R4081

Do not handle loads which are higherthan load backrest or load backrestextension unless load is secured so thatno part of it could fall backward.

R4082

Before lifting, be sure load is centered,forks are completely under load, andload is as far back as possible againstload backrest.

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R4904

Keep hands out of lifting mechanism.

R4083

When leaving truck neutralize travel con-trol. Fully lower lifting mechanism andset brake. When leaving truck unat-tended also shut off power.

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NOTICE - OBTAINING A PARTS AND SERVICE MANUAL

A complete parts and service manual covering this truck is available from Blue Giant Manufacturing Company. To order, obtain the serial number of your truckand con-tact your Blue Giant Authorized Dealer.

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NOTES

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NOTES

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If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2020