Blue Giant LPJ-44 User manual

OPERATOR’S MANUAL
LPJ-44 SELF-PROPELLED
PALLET LIFT TRUCK
ISSUE DATE: SEPTEMBER 24, 2020 REV.1.0 (PART # 038-1146EO)
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.
ACTUAL PRODUCT MAY NOT APPEAR EXACTLY AS SHOWN

LPJ-44 SELF-PROPELLED PALLET LIFT TRUCK—OPERATOR’S MANUAL
2ISSUE DATE: SEPTEMBER 24, 2020 REV.1.0 (PART # 038-1146EO)
Do not operate this truck unless you have:
Been authorized and
trained to do so.
Have read all warnings and instructions in operator manual
and on this truck.
Do not operate this truck until you have :
Checked its condition. Give special attention to tires, horn,
battery, controller, lift
system, brakes, steering mechanism,
guards and safety devices.
Operate truck only from designated operating position. Do not
carry passengers. Keep feet clear of truck and wear foot protection.
Observe applicable traffic regulations. Yield right of way to
pedestrians. Slow down and sound horn at cross aisles and
wherever vision is obstructed.
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.
Always look in the direction of travel. Keep a clear view, and when
load interferes with visibility, travel with load trailing.
Take special care when operating on ramps - travel slowly, and
do not travel in an angle or make turns. Travel with forks facing
downhill.
Do not overload truck. Check nameplate for capacity and load
center information.
Do not handle loads which are higher than the load backrest or
load backrest extension unless load is secured so that no part of
it could fall backward. Before lifting, make sure the load is
centered, forks are completely under load, and load is as far
back as possible against load backrest.
When leaving WKH truck, neutralize travel control, fully lower the
foUks
and set brake. When leaving truck unattended, also
shut off power.

LPJ-44 SELF-PROPELLED PALLET LIFT TRUCK—OPERATOR’S MANUAL
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LPJ-44 SELF-PROPELLED PALLET LIFT TRUCK—OPERATOR’S MANUAL
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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. Focusing on the
task at hand will, in almost all cases,
pre-vent 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 service manual for the specific
truck model, and are to be performed
only by a qualified technician. For fur-
ther information on obtaining a com-
plete parts and service manual, see
page 21 of this manual.
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 ..............................................................................................5
GENERAL DESCRIPTION....................................................................................5
NAME PLATE AND WARNING DECAL ...............................................................5
LOAD CAPACITY..................................................................................................8
BEFORE OPERATION ..........................................................................................9
INSTRUMENTS AND CONTROLS .....................................................................12
Display Unit ...........................................................................................12
Low Voltage Protection.........................................................................12
OPERATION ........................................................................................................13
Driving Instructions ..............................................................................13
Steering..................................................................................................14
Stopping.................................................................................................14
Parking ...................................................................................................14
Load Handling .......................................................................................14
Moving a Disabled Truck ......................................................................15
Battery Charging ...................................................................................15
NOTICE - OBTAINING A PARTS AND SERVICE MANUAL..............................23

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SAFETY SYMBOLS
WARNING and CAUTION 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
Blue Giant 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 Blue Giant 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.

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2
1
4
5
6
78
Top
Right
Front
LPJ-44 Name Plate and Warning Decal
Locations - Typical
ITEM COMPONENT ITEM COMPONENT
1Forward and Reverse Decal 5 Li-Ion Decal
2 Lift Point Decal 6 Caution Decal
3 Name Plate 7 Pinch Hazard Decal
4 Warning Decal 8 “Do not stand” Decal

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Truck Overview
This truck is equipped with a battery. Read and heed the following warning plus
any other warnings located near or on the battery. An example is shown here:
ITEM COMPONENT ITEM COMPONENT
1 Control Handle 7 Load Wheels
2 Battery 8 Pump and Motor Assembly
3 Steering Arm 9 Forks
4 Lift Cylinder 10 Top Cover
5 Drive Wheel 11 Charger Cable
6 Emergency Stop Switch
WARNING:

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LOAD CAPACITY
Do not overload truck. Check name
plate for load weight capacity 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 authority.
Name Plate
Load Center
COMPLIES WITH THE APPLICABLE
REQUIREMENTS OF ANSI B56.1
STANDARDS & CAN ICES-Lor 2/NMB-2
em ipsum
BLUE GIANT EQUIPMENT
Lorem ipsum
CORPORATION
www.BlueGiant.com
R6693

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BEFORE OPERATION
The table on page 11 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 SERVICE
TECHNICIAN is required.
A QUALIFIED SERVICE TECH-
NICIAN should check the truck
monthly for proper lubrication,
proper fluid levels, brake main-
tenance, motor maintenance
and other areas specified in the
parts and service manual main-
tenance section.
If the truck is found to be unsafe
and in need of repair, or contrib-
utes to an unsafe condition,
report it immediately to the des-
ignated authority. Do not operate
it until it has been restored to a
safe operating condition. Do not
make any unauthorized repairs
or adjustments. All service must
be performed by a qualified ser-
vice technician.
WARNING:
WARNING:
WARNING:

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Sample of Operator Check List

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Operator Checks
ITEM PROCEDURE
Transmission and hydraulic
systems
Check for signs of fluid leakage and/or abnor-
mal noise.
Forks and Frame 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.
Tiller switch/Parking brake Check that steering arm raises to upright posi-
tion when released and brake applies.
Brakes Check that brakes actuate when steering arm
is raised to upright position, and when lowered
to horizontal position.
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 flat spots, 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. Check the oil levels.
Electrical Check that there is no damage to the cables
on the truck and that the horn and lift buttons
work.
Battery disconnect Check that battery can be disconnected and
reconnected. Check for connector damage.

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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 - Top
On the LPJ-44 pushing the red
discon-nect plunger removes all
power from the truck circuits in the
event of an emergency.
Control Handle - Back
Display Unit
Display Unit
• The LED display (1) shows the
residual battery capacity, when it’s
lower than 20% it must be charged.
• When the display (2) shows “NO
BMS” the communication with the
battery is disconnected and when it
shows
“BMS EER” the battery temperature
or voltage is unbalanced.
• When display (3) is solid On the
interlock switch is open. when flash-
ing the interlock switch is closed
and the running time will start.
• The display (4) will normally show
the total running time whoever if
there is a fault code on the truck it
will be displayed here.
The display unit has a range between
0 to 99999 hours and it will log hours
when traveling or lifting.
The battery discharge indicator has a
memory function. It will display the
state of charge (SOC) stored in
mem-ory, until a full charge cycle has
been completed, and the battery SOC
reset threshold is exceeded
Low Voltage Protection
When the battery power is low the
Low Voltage Protection will prevent
the forks from being raised and you
must charge battery.

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OPERATION
Driving Instructions
Forward and Reverse Travel and Speed Control
Control Handle
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.
R8625
R8624

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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 ade-
quate clearance.
Stopping
Stop the truck as gradually as possi-
ble. Unnecessary rapid stopping could
be hazardous. Load could become
unstable.
To stop the truck’s 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 brake 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 steer-
ing 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
service 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
vertical to apply parking brake.
3. Fully lower forks.
4. Remove the key from the keyhole.
5. On the LPJ-44 push the red
discon-nect plunger to remove all
power from the truck circuits.
Steering Arm Braking Positions
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 position
so that the forks are within pallet or
skid, and the load is centered over
the forks and as far back as pos-
sible.
3. Push the button to raise the forks
and lift the load.
WARNING:
R8608

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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 oper-
ator downhill of truck with load on
forks standing off to side of truck.
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 trail-
ing load wheels do not follow the
turn path of the drive wheel.
Instead they tend to cut the corner.
8. Line up the truck with the unloading
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 by pulling the low-
ering lever 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.
Battery Charging
Using internal charger
Proceed as follows:
1. Park truck at charging station
with forks lowered and turn the
key switch off.
2. Check the condition of the AC
cord. If there are any cuts in the
cable, any exposed wires, loose
plugs or connectors, DO NOT
attempt to charge the batteries.
Contact appropriate personnel for
repairs to be made.
3. Pull the charger cord (1) out of
the top cover (Figure 3-1) and
connect to the appropriate power
supply.
Internal Battery Charging
Using External Charger
Proceed as follows:
1. Park truck at charging station
with forks lowered and turn the
key switch off.
2. Unlock the battery lock and with
the battery handle slowly pull the
battery straight up.
WARNING: Before remov-
ing the battery make sure
that the truck is com-
pletely powered down.
WARNING: Before install-
ing the battery make sure
that the truck key is not
on.

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3. Make sure the charger is plugged
in and then insert the battery to
the charger cradle.
The LEDs should light up.
External Battery Charging
Charger LED Status Indicator
NOTE: The figure above shows the
view of how to plug the
charger in to the charger base,
make sure you plug in the bat-
tery accordingly.
NOTE: When plugging in the battery
on the truck make sure that
the contact pins on the battery
match those on the truck.
NOTE: With a lithium battery it is pos-
sible to have some attenuation
when used in a low tempera-
ture environment. The operat-
ing temperature for the
lithium battery is between
14°F - 113°F.

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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.
R8627
R8628
Do not operate this truck until you
have checked its condition. Give
special attention to wheels, horn,
battery, controller, lift systems,
brakes, steering mechanism,
guards and safety devices. If you
have any questions, notify your
supervisor or proper authority.

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R8629
Walkie Pallet Trucks: Operate
truck only from walking position.
R8630
Wear foot protection and
keep feet clear of truck.

LPJ-44 SELF-PROPELLED PALLET LIFT TRUCK—OPERATOR’S MANUAL
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R8631
Do not carry passengers.
R8643
Observe applicable traffic regulations. Yield right-of-way to pedestrians.
Slow down and sound horn at cross aisles and wherever vision is
obstructed.

LPJ-44 SELF-PROPELLED PALLET LIFT TRUCK—OPERATOR’S MANUAL
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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.
R8635
R8636
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.