Blue Giant EPJ-30 User manual

OPERATOR’S MANUAL
EPJ-30 ELECTRIC POWER PALLET 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.
ISSUE DATE:MAY 5, 2020 REV.0 (PART # 038-927EO)

1
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 Big
Lift LLC 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. Focusing on the
task at hand 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. Detailed
maintenance procedures are found in
the parts and service manual for the
specific truck model, and are to be
performed only by a qualified techni-
cian. For further information on
obtaining a complete parts and ser-
vice manual, see page 21 of this man-
ual.
The operator who knows his truck will
learn to spot problems as they
develop. This is accomplished by per-
forming the Daily Checks and report-
ing any problems to the designated
authority.
TABLE OF CONTENTS
SAFETY SYMBOLS..............................................................................................2
GENERAL DESCRIPTION....................................................................................2
NAME PLATE AND WARNING DECAL...............................................................2
LOAD CAPACITY..................................................................................................5
BEFORE OPERATION..........................................................................................6
INSTRUMENTS AND CONTROLS .......................................................................8
OPERATION........................................................................................................10
Forward and Reverse Travel and Speed Control ...............................10
Steering..................................................................................................10
Stopping.................................................................................................11
Parking...................................................................................................11
Battery Charging...................................................................................12
Load Handling .......................................................................................12
Moving a Disabled Truck......................................................................12
NOTICE - OBTAINING A PARTS AND SERVICE MANUAL .............................21

2
SAFETY SYMBOLS
WARNING and CAUTIONS are both signal words intended to alert the viewer to
the existence and relative degree of a hazard. They are both preceded by a safety
alert 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 or
action that should not be performed under any circumstances, as both personal
injury and/or damage to equipment will result.
GENERAL DESCRIPTION
Big Lift LLC Pallet trucks lift and trans-
port 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 load
capacity, battery arrangement, and
instrumentation, depending on model
and 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 decal are
lost or damaged they should be
replaced immediately. Have your
supervisor or the designated author-
ity contact Big Lift LLC Authorized
Dealer for replacement.
The name plate shows the model
number, serial number, and truck
type. Battery type, with voltage and
minimum weight, is shown along with
information on the load capacity and
load center.
The warning decal contains warnings
which also appear, with illustrations,
in the Operating Precautions section
of this manual.

3
EPJ-30 Name Plate and Warning Decal Locations - Typical
WPT Name Plate and Warning Decal Locations - Typical
R6837
R6692

4
WRT Name Plate and Warning Decal Locations - Typical
This truck is equipped with a battery. Read and heed the warning decal located
near the battery. An example is shown here:
WARNING:
R6838

5
LOAD CAPACITY
Do not overload truck. Check capacity
plate for load weight and load center
information.
The load capacity depends on the
load center. The load maximum
capacity listed on the capacity plate
assumes a uniform load whose center
is 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 length
of the forks or is not centered between
the forks. The fork length and wheel-
base must be adequate for the skid or
bin to be handled.
Note that a truck undergoing speed
changes is less stable than a standing
truck. If you are not sure that the truck
can lift a certain load, consult your
supervisor or the designated author-
ity.
Load Center
R6693

6
BEFORE OPERATION
The table on page 7 covers important
inspection points on trucks which
should be checked prior to operation.
Depending on use, some trucks may
require additional checks.
The illustration below shows a sample
format for an Operator Checklist,
which can be modified as necessary
to fit your operation.
Periodic maintenance of this
truck by a QUALIFIED TECH-
NICIAN is required.
A QUALIFIED SERVICE
TECHNICIAN should check the
truck monthly for proper lubri-
cation, proper fluid levels,
brake maintenance, motor
maintenance and other areas
specified in the parts and ser-
vice manual maintenance sec-
tion.
If the truck is found to be
unsafe and in need of repair, or
contributes to an unsafe condi-
tion, report it immediately to the
designated authority. Do not
operate it until it has been
restored to a safe operating
condition. Do not make any
unauthorized repairs or adjust-
ments. All service must be per-
formed by a qualified
maintenance technician.
Sample of Operator Check List
WARNING:
WARNING:
WARNING:
R6235
Electric Truck
Daily Operator Check-Off List
Date
Operator
Truck No. Model No.
Dept.
Check
Tires
Load Wheels
Horn
Lift Lower Control
Need MaintenanceO.K.( )
Shift
Hour Meter
Reading Drive Hoist
Attachment Operation
Forward & Reverse Controls
Steering
Electrical Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.

7
Operator Checks
ITEM PROCEDURE
Transmission 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 to their maxi-
mum 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.

8
INSTRUMENTS AND CONTROLS
The steering arm and control handle
provide controls for steering, forward
and reverse speed control, braking,
raising and lowering the forks, and
horn. Control handles on all models
have a “belly-button” reversing switch
which reverses the direction of the
truck upon contact with the operator.
Control Handle
R6694

9
Walkie/Rider Pallet Trucks have a
grab bar which also contains lift, lower
and horn controls.
Detailed operating instructions are in
the Operation section of this manual.
A battery disconnect is mounted near
the steering arm. Pulling the discon-
nect removes all power from truck cir-
cuits in the event of an emergency.
Grab Bar
R6803

10
OPERATION
Forward and Reverse Travel and
Speed Control
Control Handle
All directional and speed controls are
located on the control handle.
Forward and reverse are controlled by
rotating the speed control lever as
shown. The lever is spring loaded to
return to neutral when released. Fur-
ther rotation in either direction will
progress the truck from slow to maxi-
mum travel speed.
To change directions or to stop the
truck, rotate the speed control lever in
the opposite direction. The truck will
come to a stop and then, unless the
controls are returned to the center
neutral position, accelerate in the
opposite direction.
Steering
Moving the control handle (which con-
nects to the steering arm) right or left
will turn the truck right or left. When
maneuvering around corners, make
square turns and be sure there is
adequate clearance.
R6694

11
Stopping
Stop the truck as gradually as possi-
ble. Unnecessary rapid stopping could
be hazardous. Load could become
unstable.
To stop the tucks movement (forward
or reverse), raise the control handle to
the up position or push the control
handle all the way down. In both posi-
tions, the electric brake will deactivate
and the bake will apply. To release
the brake, just move the control han-
dle to the operating position.
NOTE: The steering arm gas spring
automatically raises the
steering arm to the upright
position when the steering
arm is released.
CAUTION: If the control handle does
not raise immediately to
the vertical position when
released, the truck should
be placed “OUT OF SER-
VICE” until it can be
inspected by a qualified
repair technician.
Parking
When parking the truck, do not
obstruct traffic lanes or aisles.
1. Park the truck in its designated
parking area.
2. Raise the steering arm until verti-
cal to apply the parking brake.
3. Fully lower forks.
4. Turn keyswitch to off position.
Remove key for added security.
5. Pull out battery disconnect.
Steering Arm Braking Positions
R6620

12
Battery Charging
Refer to DOC 245 for battery safety
and maintenance.
NOTE: Battery charging instructions
are contained in the service
manual.
Load Handling
Handle only loads arranged for
stability and always use cau-
tion. Raise and lower the load
smoothly to prevent the load
from falling.
Always be sure the load and
load center are within the
capacity of the truck. If in doubt
check the nameplate.
1. Approach the load slowly.
2. Move the truck slowly into posi-
tion so that the forks are within
pallet or skid, and the load is cen-
tered over the forks and as far
back as possible.
3. Raise the forks to lift load.
4. Lead the truck by the control han-
dle with the load trailing except
when in confined areas. Ramps
should be traveled with operator
uphill of truck when empty, or
operator downhill of truck with
load on forks.
5. Always look in the direction of
travel. Move slowly and check
clearances when approaching
obstructions.
6. Do not make sudden starts and
stops. Operate truck smoothly
and gradually.
7. Travel slowly and squarely
around corners. Remember that
the trailing load wheels do not fol-
low the turn path of the drive
wheel. Instead they tend to cut
the corner.
8. Line up the truck with the unload-
ing area.
9. Stop the truck and check the load
alignment with surrounding
objects.
10. Be careful not to damage or
move adjacent loads and objects.
11. Lower the forks until the load is
resting on its own.
12. Move the truck back until the
forks are clear of the pallet.
Moving a Disabled Truck
Do not attempt to move a disabled
truck; notify your supervisor or proper
authority.
WARNING:
WARNING:

13
The following operating instructions appear on the truck warning decal, which is
located near the steering arm.
Do not operate this truck unless you
have been trained and authorized to do
so, and have read and understand all
warnings and instructions contained in
this operator’s manual and on this truck.
R6695
R6696
Do not operate this truck until
you have checked its condi-
tion. Give special attention to
wheels, horn, battery, control-
ler, lift systems, brakes, steer-
ing mechanism, guards and
safety devices. If you have any
questions, notify your supervi-
sor or proper authority.

14
R6697
Walkie Pallet Trucks: Operate
truck only from walking position.
R6839
Walkie/Rider Pallet Trucks:
Keep feet within limits of truck.

15
R6699
Wear foot protection and
keep feet clear of truck.
R6701
Do not carry passengers.

16
R6702
Observe applicable traffic regulations. Yield right-of-way to pedestrians.
Slow down and sound horn at cross aisles and wherever vision is
obstructed.
R6703
Start, stop, travel, steer 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
greater.

17
R6704
Always look in direction of travel. Keep a
clear view, and when load interferes with
visibility, travel with load or lifting mecha-
nism trailing (except when climbing
ramps.
R6705
Use special care when operating on ramps; travel slowly, and do not angle
or turn. Travel with lifting mechanism downhill.

18
R6706
Do not handle loads which are higher
than load backrest or load backrest
extension unless load is secured so that
no part of it could fall backward.
R6707
Before lifting, be sure load is centered,
forks are completely under load, and
load is as far back as possible against
load backrest.