Blue Giant BG E-Step User manual

OWNER’S MANUAL
BG E-STEP SEMI ELECTRIC ACCESS VEHICLE
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: DECEMBER 7, 2020 REV. 1.0 (PART # 038-XXXXE)
ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN

WARNING
Do not operate this vehicle unless you have been
authorized and trained to do so, and have read all
warnings and instructions in Operator’s Manual and on
this vehicle. Read, understand and comply with the
information on the vehicle’s nameplate at all times.
Do not operate this vehicle until you have performed
the daily operation’s check list. Verify and inspect tires,
horn, battery, controller, lift and hydraulic systems,
brakes, steering mechanism and guards. Verify that all
emergency controls, personal protection and safety
devices are in place and functioning correctly and
ensure the vehicle is free of fluid leaks and has no
loose or missing parts. Report any problems to the
designated authority and do not use the vehicle until
they are corrected by a qualified mechanic.
This vehicle must not be modified without the manu-
facturer’s consent. Components critical to the vehicles
stability such as batteries shall not be replaced with
lighter weight components.
Operate vehicle only from designated platform operat-
ing position. Use this vehicle indoors on level surfaces
only. Never operate on ramps and slopes or uneven
floors. This vehicle is not for use on mezzanines or
balcony areas. Before operating, inspect the floor area
it will be used on and be certain it will support the
vehicle at full capacity and lift height. Identify and
avoid holes, drop-offs, bumps and obstructions.
Before and during all vehicle operations ensure that
adequate clearance is maintained from overhead
obstructions and energized electrical conductors and
parts.
Before elevating platform be sure access gates are in
position. Keep feet on platform floor at all times while
using vehicle, never climb onto access gates or
platform shelf. Do not use ladders, planks or other
devices to achieve additional height on platform.
When transferring loads to platform or platform shelf,
do not exceed capacity ratings on vehicle nameplate.
Ensure loads are centered and do not contact any
obstructions in the vehicle’s vicinity. Do not stabilize
the platform by contact with adjacent objects such as
racks or shelving. Do not use the platform as a crane.
Take care to prevent electrical cords, hoses or other
equipment from entangling in platform. Ensure area
surrounding the vehicle is free of personnel and
equip-ment before lowering platform.
Maintain a clear view of the ground while travelling and
a safe distance from obstacles in the vehicle or
platform’s path. Ensure personnel in the vicinity are
aware of the vehicle’s movement. Travel at a safe
speed for the conditions the vehicle is operating in.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed. Avoid
hazardous locations.
Enter and exit platform only through open access
gates and with the platform fully lowered and vehicle
stopped. When leaving vehicle unattended, remove
key to prevent unauthorized use.
2

NOTES
3

TABLE OF CONTENTS
Section Page Section Page
1 DESCRIPTION ............................................................1-1
1-1 GENERAL DESCRIPTION ...........................1-1
1-2 DATA PLATE AND WARNING DECAL........1-3
1-3 INSTALLATION / WARRANTY
CHECK LIST.................................................1-3
2 PLANNED MAINTENANCE ........................................2-1
2-1 GENERAL.....................................................2-1
2-2 MONTHLY AND QUARTERLY CHECKS.....2-1
2-3 FREQUENT INSPECTIONS.........................2-1
2-4 ANNUAL INSPECTIONS..............................2-1
2-5 BATTERY CARE ..........................................2-1
2-5.1 General.....................................................2-1
2-5.2 Safety Rules .............................................2-2
2-5.3 Maintenance Personnel............................2-2
2-5.4 Maintenance Personnel............................2-2
2-5.5 Maintenance Personnel............................2-2
2-5.6 Battery Care and Charging.......................2-2
2-5.7 Battery Cleaning .......................................2-2
2-5.8 Maintenance Free Battery ........................2-2
2-6 CHARGING BATTERIES..............................2-2
2-7 REPLACING BATTERIES ............................2-3
2-7.1 Battery disposal ........................................2-3
2-8 LUBRICATION..............................................2-4
3 TROUBLESHOOTING ................................................3-1
3-1 GENERAL.....................................................3-1
4 COMPARTMENT COVER REMOVAL........................4-1
4-1 FRONT COMPARTMENT COVER...............4-1
4-1.1 Cover Removal.........................................4-1
4-1.2 Cover Installation......................................4-1
5 FLOOR LOCK SYSTEM..............................................5-1
5-1 FLOOR LOCK...............................................5-1
5-1.1 Floor Lock Motor Replacement ................5-1
6 LOAD WHEEL, CASTERS ......................................... 6-1
6-1 LOAD WHEEL.............................................. 6-1
6-1.1 Removal................................................... 6-1
6-1.2 Installation................................................ 6-1
6-2 CASTER.......................................................6-1
7 HYDRAULIC SYSTEM SERVICING........................... 7-1
7-1 LINES AND FITTINGS................................. 7-1
7-2 HYDRAULIC PUMP, MOTOR
AND RESERVOIR ASSEMBLY ................... 7-1
7-2.1 Removal................................................... 7-1
7-2.2 Installation................................................ 7-3
7-2.3 Disassembly and Reassembly................. 7-3
7-3 LIFT CYLINDER........................................... 7-3
7-3.1 Removal................................................... 7-3
7-3.2 Repair ...................................................... 7-3
7-3.3 Installation................................................ 7-4
8 ELECTRICAL COMPONENTS ................................... 8-1
8-1 ELECTRICAL CONTROL PANEL................ 8-1
8-1.1 Maintenance ............................................ 8-1
8-1.2 Cleaning...................................................8-1
8-2 HORN REPLACEMENT............................... 8-1
8-3 BATTERY REPLACEMENT......................... 8-2
8-4 BATTERY CHARGER.................................. 8-2
8-4.1 Removal................................................... 8-2
8-4.2 Installation................................................ 8-2
8-5 PLATFORM CABLE REPLACEMENT ......... 8-3
8-5.1 Platform.................................................... 8-3
9 OPTIONAL EQUIPMENT
9-1 N/A ............................................................... 9-1
10 ILLUSTRATED PARTS BREAKDOWN .................... 10-1
4

SECTION 1
DESCRIPTION
1-1. INTRODUCTION.
This publication describes the 24 volt BG E-Step
Semi-Electric Access Vehicle by Blue Giant. Included
are planned maintenance instructions, lubrication
procedures, cor-rective maintenance procedures and
a complete parts list with part location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and the current edition of
A.N.S.I. A92.6. By following these requirements and
the recommendations contained in this manual, you
will receive many years of dependable service from
your BG E-Step Semi-Electric Access Vehicle.
1-2. GENERAL DESCRIPTION.
The self-propelled BG E-Step Semi-Electric Access
Vehicle Electric Access Vehicle lifts and transports up
to 750 pounds capacity including load and operator.
The vehicle enables general maintenance work and
effi-cient selection and moving of materials in any
area or at any level of the warehouse or storeroom.
This vehi-cle is not for use on mezzanines or balcony
areas. The design permits one man to perform all
operations of selecting stock, driving vehicle, and
replacing the stock at the designated place. The
battery-powered vehicle is quiet and allows operation
in closed areas without special provisions for
ventilation.
Figure 1-1 BG E-Step Elevating Work Platform
R8551
ITEM COMPONENT
1 Control panels
2 Storage tray
3Lift mast
4 Cover plate
5 Emergency "Lowering" button
6 Cup holder
7Casters
8 Emergency stop switch
9 Charger socket
10 Battery
11 Frame
12 Load wheels
13 Operator platform
14 Hydraulic pump assembly
15 Gate Pads
16 Access gates
ITEM COMPONENT
5

Figure 1-2
ITEM CONTROL / DISPLAY FUNCTION
1Cup holder Storage
2Battery discharge indicator Display battery power level.
3 Horn Button Activates the horn.
4 Lift Button Lift the operator platform.
5 Lowering Button Lower the operator platform.
6 Key switch
Switches control current on and off. Removing the
key prevents the access vehicle from being
switched on by unauthorized personnel.
7 Emergency stop switch
Disconnects the supply current, deactivates all
electrical functions, causing the access vehicle to
brake automatically.
8Emergency lowering button Lower the operator position manually.
R8552
6

n e
e
e e t
1-3. DATA PLATE AND WARNING DECAL.
Blue
Giant Authorized Dealer for replacement.
1-4. INSTALLATION / WARRANTY CHECK LIST.
Blue Giant
initiate t
.
t t all
e a
a e en
Blue
Giant
at
Figure 1-3 Data Plate
R8553
7
BLUE GIANT EQUIPMENT CORPORATION
www.BlueGiant.com
MODEL
WEIGHT LB/KG
SERIAL
NUMBER
BG E-STEP
2281300008
630/285

Warranty Claim Form
ATTN: WARRANTY MANAGER Email: [e-mail]
Dealer ID # Dealer Name Claim Form Date (MM/DD/YYYY)
Has Unit Been Maintained / Lubricated as Specified in Accordance with Owner’s Manual?
Yes No
Equipment Model # Serial # Customer
Date of Equipment Sale (MM/DD/YY) Hour Meter Reading Customer Address
Equipment Purchase Invoice # Dealer Repair Order # City / State / Province
Submitted By (Print Full Name) Title Zip / Postal Code
Phone: Fax: Email:
Labor Total Hours: Rate: Labor Total: $ Start Date
(MM/DD/YY)
Travel Total Hours: Rate: Labor Total: $ Start Date
(MM/DD/YY)
Description of Fault:
Nature of Fault:
Corrective Procedure (Full Details Required, Incomplete Information will Delay Process)
Blue Giant Part # Part Description QTY. Blue Giant Replacement
Part(s) Invoice Number(s) Price Total
$$
$$
$$
$$
$$
Freight P E The totals calculated on this form are estimates only. Warranty guidelines may apply. Final totals will appear on your
warranty invoice. Please go to www.BlueGiant.com for Warranty Coverage and Warranty Guidelines for your product. $$
GL # WC # RGA#
A confirmation receipt will be faxed back with a warranty claim number attached. If Blue Giant deems that part(s) need to be returned, an RGA numbered form
will be faxed as well. Please include a copy of the RGA form with returning part(s) to Blue Giant Brampton location only.
0.00
0.00
0.00
0.00
0.00
0.00
0
0

SECTION 2
PLANNED MAINTENANCE
2-1. GENERAL.
Planned maintenance consists of periodic visual and
operational checks, inspection, lubrication, and
scheduled maintenance designed to catch an issue in
the early hours or discover malfunctions and defective
parts. The operator performs the checks in the
Operator’s Manual, and refers any required servicing
to a qualified maintenance technician who performs
the planned maintenance and any required servicing.
2-2. MONTHLY AND QUARTERLY CHECKS.
Table 2-1 is a monthly and quarterly inspection and
service chart based on normal usage of equipment
eight hours per day, five days per week. If the vehicle
is used in excess of forty hours per week, the
frequency of inspection and service should be
increased accordingly. These procedures must be
performed by a qualified service technician or your
Blue Giant Service Representative.
2-3. FREQUENT INSPECTIONS.
The owner and user are required by ANSI A92.6 to
ensure frequent inspections of the BG E-Step Semi-
Electric Access Vehicle occur and are performed in
accor-dance with the following points: 1. If purchased
used unless it's determined that the frequent and
annual inspections are current. 2. The BG E-Step
Semi-Electric Access Vehicle has been in service for
three (3 months or 150 hours, whichever comes first.
3. The BG E-Step Semi-Electric Access Vehicle has
been out of service for a period longer than three (3
months. inspection is to be performed by a mechanic
that is qualified and authorized to perform service on
the BG E-Step Semi-Electric Access Vehicle. All
service records must be maintained.
2-4. ANNUAL INSPECTIONS.
The owner and user are required by ANSI A92.6 to
ensure annual inspections of the BG E-Step Semi-
Electric Access Vehicle occur and are performed no
later than 13 months from the date of prior annual
inspection or every 700 hundred hours of use,
whichever occurs first. This annual inspection is to be
performed by a mechanic that is qualified and
authorized to perform
service on the BG E-Step Semi-Electric Access
Vehicle. All service records must be maintained..
2-5. BATTERY CARE.
2-5.1. General
The vehicle may be equipped with maintenance free
Lithium ion battery.
The care and maintenance of the battery is very
important to obtain efficient vehicle operation and
maximum battery life.
CAUTION: Gases produced by a battery can be
explosive. Do not smoke, use an open
flame, create an arc or sparks in the
vicinity of the battery. Ventilate an
enclosed area well when charging.
CAUTION: Batteries contain sulfuric acid which may
cause severe burns. Avoid contact with
eyes, skin or clothing. In case of contact,
flush immediately and thoroughly with
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
bubbling stops, neutralizes the acid for
safe handing and disposal.
Table 2-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check brake for proper operation.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Check wheels for wear and damage.
Quarterly Check lift cylinder for leakage.
9

2-5.2. Safety Rules
• Wear protective clothing, such as rubber apron,
gloves, boots and goggles when performing any
maintenance on batteries. Do not allow electrolyte to
come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush
immediately and thoroughly with clean water.
Obtain medical attention immediately. Should
electrolyte be spilled on skin, rinse promptly with
clean water and wash with soap. A baking soda
solution (one pound to one gallon of water) will
neutralize acid spilled on clothing, floor or any other
surface. Apply solution until bubbing stops and rinse
with clean water.
•Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging, is
highly explosive. This gas remains in cell long after
charging has stopped.
•Do not lay metallic or conductive objects on battery.
Arcing will result.
•Do not touch non-insulated parts of DC output
connector or battery terminals to avoid possible
electrical shock.
•Disconnect all AC and DC power connections before
servicing battery.
•Do not charge a frozen battery.
•Do not use charger if it has been dropped or
otherwise damaged.
2-5.3. Maintenance Personnel
Batteries may only be charged, serviced or replaced
by trained personnel. This manual and the
manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out
the work.
2-5.4. Maintenance Personnel
Batteries may only be charged, serviced or replaced
by trained personnel. This manual and the
manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out
the work.
2-5.5. Maintenance Personnel
Batteries may only be charged, serviced or replaced
by trained personnel. This manual and the
manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out
the work.
2-5.6. Battery Care and Charging
CAUTION: Never smoke or bring open flame near
the battery. Gas formed during
charging is highly explosive and can
cause serious injury.
1. Charge the battery only in areas designated for
that use.
2. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal
contact is essential not only for operation, but also
for proper charging of the battery.
3. Make certain battery used meets weight and size
requirements of vehicle. NEVER operate vehicle
with an undersized battery.
2-5.7. Battery Cleaning
Wipe batteries with a clean rag.
2-5.8. Maintenance Free Battery
This vehicle is equipped with a maintenance free
battery. The battery is completely sealed, will not
require any watering and have a full 80% discharge
available.
Sealed Maintenance Free batteries contain a
pressure release valve and under normal operating
conditions do not require any special ventilation.
CAUTION: Do not try to open this battery or remove
the pressure release valve.
Only under severe overcharging, such as connected
to an improperly sized charger, will any significant
amount of gases be released from the battery. Also,
being a valve regulated battery, it never requires
watering.
2-6. CHARGING BATTERIES
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park vehicle at charging station with platform
lowered and turn the key switch OFF.
2. Apply the emergency disconnect switch.
3. Check the condition of the cord. If there are any
cuts in the cord, any exposed wires, loose plugs
or connectors, DO NOT attempt to charge the
batteries.
4. Connect plug from the vehicle to a power outlet
and charge the battery according to Supplement
374 *.
10

Figure 2-1 Battery Charging
2-7. REPLACING BATTERIES
1. Engage the emergency power disconnect switch
and turn off key switch.
2. Remove the compartment cover as described in
paragraph 4-1.1.
3. Remove the four screws, lock washers and flat
washers that holds the battery brackets in place.
4. Disconnect the battery cables from the batteries.
5. Carefully lift the batteries out of the vehicle.
6. for installation please reverse step 1-5.
Replace only with original OEM batteries or batteries
approved by an authorized Blue Giant dealer.
Contact your authorized Blue Giant dealer for
information on optional batteries and battery
chargers.
WARNING: The weight and dimensions of the
battery have considerable affect on the
operational safety of the vehicle. Battery
equipment may only be replaced with the
agreement of the manufacturer.
2-7.1. Battery disposal:
Dispose in accordance with national environmental
protection regulations or disposal laws. The
manufacturer’s disposal instructions must be followed
R8555
11

Figure 2-2 Lubrication Diagram
2-8. LUBRICATION.
Refer to Table 2-2 for the recommended types of
grease and oil in conjunction with Figure 2-2 identifies
the items requiring lubrication.
Table 2-2 Recommended Lubricants
R8556
Code Description Used for
A L-HM46 Hydraulic oil
B Polylub GA352P Multi-purpose grease
12

SECTION 3
TROUBLESHOOTING
3-1. GENERAL
Use Table 3-1 as a guide to determine possible causes
of trouble. The table is divided into five main categories:
Vehicle and Hydraulic System Will Not Operate: Vehicle
Does Not Operate Forward or Reverse: Trouble With
Braking: Trouble With Lifting Or Lowering, and
Miscellaneous malfunctions.
Table 3-1 Troubleshooting Chart
Table 3-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING OR
LOWERING
• Oil sprays or flows from the top
of the lift cylinder.
Defective packing in lift cylinder Repair lift cylinder.
• Squealing sounds when lifting
Operator’s platform.
Identify oil leak and fill reservoir.
Apply grease.
a. Oil level too low.
b. Dry channels in mast.
c. Defective mast or Platform
rollers
Replace rollers.
• Platform does not lift to full lift
height.
a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to I.D.plate for capacity.
• Weak, slow or uneven action of
hydraulic system.
a. Defective pump or relief valve. Check pressure. Adjust as
necessary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.platefor capacity.
d. Defective lift motor relay. Replace relay on pump motor.
e. Battery charge low. Charge battery.
• Platform does not lift, pump
motor does not run.
Check and recharge if required.
Check and repair as required.
a. Battery is dead or
disconnected.
b. Defective wiring.
c. Defect in electrical system for
operating pump motor.
Check lift switch on platform, as well
as the relay.
• Platform does not lift, motor
runs.
Defect in hydraulic system. Check the oil level in the reservoir and
the oil lines to the lift cylinder, and
repair as required. If normal, check the
hydraulic pump, and relief valve.
Repair, or adjust.
• Platform lifts, but will not go
down.
Defect in hydraulic system Check lowering control switch and
lowering solenoid. Replace as
required.
• Load will not hold Replace valve assembly.
a. Oil bypassing internally in
control valve
b. Worn lift cylinder or packing. Repack cylinder.
• Platform does not lift to top.
Pump motor runs.
a. Oil level too low. Add oil to reservoir.
b. Load larger than capacity. Refer to nameplate on side of mast for
maximum load capacity.
c. Batteries need charging. Charge batteries.
• Platform drifts down under load
when in a raised position.
Leak in hydraulic system, lift
cylinder or lowering valve.
Check for leaking fitting in hydraulic
line and repair as required. Repack lift
cylinder or replace valve assembly.
13

NOTES
14

SECTION 4
COMPARTMENT COVER REMOVAL
4-1. FRONT COMPARTMENT COVER
4-1.1. Cover Removal.
1. Engage the emergency power disconnect switch
and turn off key switch.
2. Remove four screws that holds the cover down .
3. Carefully lift cover up and off the vehicle.
4-1.2. Cover Installation.
1. Carefully position cover on the vehicle.
2. Install four screws.
3. Disengage the emergency power disconnect
switch and turn on key switch.
Figure 4-1 Rear Compartment Cover
ED_0001
15

NOTES
16

SECTION 5
FLOOR LOCK SYSTEM
5-1. FLOOR LOCK.
The floor lock system consists of a motor mounted
horizontally that moves 2 stability pads to touch the
floor when the platform is raised up. The lock is
electrically applied & released. Figure 5-1
5-1.1. Floor Lock Motor Replacement
1. Engage the emergency power disconnect switch
and turn off key switch.
2. Block load wheels.
3. Remove the compartment cover as described in
paragraph 4-1.1.
4. Disconnect electric motor from harness.
5. Remove the mounting screws and motor
assembly.
6. Place the new motor assembly into position and
secure with the mounting screws.
7. Reconnect electric motor to harness.
8. Install the cover as described in paragraph
4-1.2.
9. Remove load wheel blocks and check operation.
10. Disengage the emergency power disconnect
switch and turn on key switch.
Figure 5-1
17

NOTES
18

SECTION 6
LOAD WHEEL, CASTERS
6-1. LOAD WHEEL.
6-1.1. Removal
1. Engage the emergency power disconnect switch
and turn off key switch.
2. Block the drive wheel to prevent the vehicle from
rolling.
3. Jack up the vehicle to raise the load wheels off
the floor. Securely block the vehicle in the raised
position by positioning supports under both fork
tips.
4. Remove the compartment cover as described in
paragraph 4-1.1.
5. Remove the screws and cover inside the unit.
6. Remove the axle.
7. Remove the load wheel.
8. Remove bearings from load wheel.
9. Inspect bearings and replace if necessary.
6-1.2. Installation
1. Pack bearings with grease.
1. Reassemble bearings in load wheel.
2. Position load wheel on the axle and install two
bolts, two lock washers and two flat washers.
3. Install cover and secure with the screws.
4. Remove the blocking from under the vehicle and
lower it to the ground.
5. Disengage the emergency power disconnect
switch and turn on key switch.
6-2. CASTER.
1. Engage the emergency power disconnect switch
and turn off key switch.
2. Jack up the vehicle to gain access to the caster;
then securely block the vehicle to prevent
movement.
3. Remove four screws, four lock washers and four
flat washers.
4. Remove caster.
5. Install new caster in reverse order of removal.
19

Figure 6-1 Frame
ED_0001
20