User Manuals: Blue Giant EPJ-40 Electric Pallet Jack

User Manuals: Blue Giant EPJ-40 Electric Pallet Jack

Manuals and User Guides for Blue Giant EPJ-40 Electric Pallet Jack. We have 1 Blue Giant EPJ-40 Electric Pallet Jack manual available for free PDF download: Owner's Manual

Blue Giant EPJ-40 Owner's Manual

Blue Giant EPJ-40 Owner's Manual (124 pages)

ELECTRIC PALLET TRUCK

Brand: Blue Giant | Category: Trucks | Size: 5 MB

Table of Contents

Table of Contents
3
Figure 1-1 Name Plate
7
Figure 1-2. D40 Lift Truck
7
General Description
7
Introduction
7
Belly-Button Switch
8
Safety Features
8
D40 Lift Truck
9
Operation2-1
9
- General
  9
- Operating Precautions
  9
- Before Operation
  9
Name Plate
10
- Figure 2-1Sample of Operator Check List
  11
- Belly-Button Switch
  12
- Driving and Stopping Procedures
  12
- Figure 2-2Forward/Reverse Control
  12
- Figure 2-3Pushbutton Switches
  12
- Figure 2-4Brake Actuation
  12
- General Control Operation
  12
- Backrest
  13
- Figure 2-5Belly-Button Switch
  13
- Guide Rails
  13
- Lift and Lower Controls
  13
- Loading and Unloading
  13
- Parking
  13
- Steering Arm Gas Spring
  13
Planned Maintenance3-1
15
- General
  15
- Monthly and Quarterly Checks
  15
- Battery Care
  15
- Safety Rules
  16
- Battery Care and Charging
  16
- Battery Cleaning
  16
- Maintenance Free Batteries
  16
- Charging Batteries
  17
- Figure 3-1Charging Battery
  17
- Batteries Replacement
  18
Controller Board Removal
18
Cover Removal
18
- Figure 3-2Cover Removal
  18
  - Figure 3-3Controller Board Removal
    18
  - Figure 3-4Lubrication Diagram
    20
  - General
    21
  - Controller Troubleshooting
    24
  - Fault Detection
    24
  - Figure 4-1Zapi Controller
    24
  - Testing Truck Operation
    24
  - Zapi Handset
    24
  - Figure 4-2Zapi Handset
    25
  - Settings and Adjustments
    25
  - Figure 4-3Zapi Handset
    29
  - Figure 4-4Throttle Regulation
    30
  - Figure 4-5Zapi Handset
    31
- Lubrication
  19
Lubrication Diagram
20
Figure 4-6Zapi Controller Connections
33
Zapi Controller
33
Steering Arm, Control Head and Compartment
37
- Control Head
  37
- Control Head Removal
  37
- Figure 5-1Steering Arm
  37
- Figure 5-2Control Head
  38
- Control Head Installation
  39
- 5-1.3. Cap Assembly Removal
  39
- 5-1.4. Cap Assembly Installation
  39
- 5-1.5. Speed Potentiometer Replacement
  39
- Figure 5-3Emergency Reverse Switch as
  40
- Figure 5-4Cap Assembly
  41
- Compartment Covers
  42
- Removal
  42
- Installation
  42
- Figure 5-5Compartment Cover
  42
- Steering Arm
  43
- Return Spring Replacement
  43
  - Steering Arm Removal
    43
- Steering Arm Installation
  43
Brake Servicing6-1
45
- Brakes
  45
- Air Gap Adjustment
  45
- Figure 6-1Brake Assembly
  45
- Stopping Distance Adjustment
  46
- Brake Assembly Replacement
  46
Transmission, Drive Wheel, Load Wheel7-1
47
- Load Wheel
  48
- Removal
  48
- Repair
  48
- Load Wheel Installation
  48
- Figure 7-1Wheel Assembly
  48
- Drive Wheel
  49
- Transmission
  49
- Figure 7-2Transmission Motor, Brake
  50
Elevation System Servicing8-1
51
- General
  51
- Lift Linkage
  51
- Removal
  51
- Figure 8-1Frame
  51
- Repair
  52
- Installation
  52
- Figure 8-2Lift Linkage Assembly
  52
Hydraulic System Servicing9-1
53
- Lines and Fittings
  53
- Figure 9-1Hydraulic System
  53
- Hydraulic and Electrical Assembly
  54
- Removal
  54
- Installation
  54
- Hydraulic Pump, Motor, and Reser
  54
Voir Assy9-2
54
- Disassembly and Reassembly
  54
- Figure 9-2Pump & Motor Assy
  55
- Installation
  56
  - Lift Cylinder
    56
Electrical Components10-1
59
- Electrical Control Panel
  59
- 10-1.1.Maintenance
  59
- 10-1.2.Cleaning
  59
- 10-1.3.Controller Removal
  59
- 10-1.4.Controller Installation
  59
- 10-1.5.Charger Removal
  59
- 10-1.6.Charger Installation
  59
- 10-1.7.Emergency Disconnect Removal
  60
- 10-1.8.Emergency Disconnect Installation
  60
- 10-1.9.Contactor Removal
  60
- 10-1.10.Contactor Installation
  60
- 10-1.11.Fuse Removal
  60
- 10-1.12.Fuse Installation
  60
- Figure 10-1Electrical Components
  61
- 10-1.13.Cooling Fan Removal
  62
- 10-1.14.Cooling Fan Installation
  62
- 10-1.15.Buzzer Removal
  62
- 10-1.16.Buzzer Installation
  62
- 10-1.17.Key Switch Removal
  62
- 10-1.18.Key Switch Installation
  62
- 10-1.19.Battery Indicator Removal
  62
- 10-1.20.Battery Indicator Installation
  62
- Figure 10-2Electrical Components
  63
- 10-1.21.Lift Limit Switch Removal
  64
- 10-1.22.Lift Limit Switch Installation
  64
- Figure 10-3Electric System
  64
- Deadman Switch
  65
- 10-4.1.Replacement
  65
Optional Equipment11-1
67
Illustrated Parts Breakdown12-1
69
Figure 12-1Steering Arm
70
Steering Arm
71
Figure 12-2Control Head
72
Cap Assembly
73
Control Head
75
Figure 12-3Cap Assembly
76
Figure 12-4 Emergency Reverse Switch Assembly
78
Emergency Reverse Switch Assembly
79
Figure 12-5Transmission Motor, Brake Mounting
80
Brake Assembly
81
Transmission Motor, Brake Mounting
81
Figure 12-6Transmission Transmission Used up to Serial # E2219364
82
Figure 12-7Transmission Used from Serial # E2219365
88
Figure 12-8Compartment Covers
90
Compartment Cover
91
Figure 12-9Load Backrest
92
Load Backrest
93
Figure 12-10Frame
94
Frame
95
Figure 12-11Lift Link Assembly
96
Load Wheel
97
Figure 12-12Load Wheel
98
Figure 12-13Caster
100
Caster
101
Figure 12-14Hydraulic System
102
Hydraulic System
103
Figure 12-15Pump & Motor Assy
104
Figure 12-16Lift Cylinder
106
Lift Cylinder
107
Figure 12-17Electrical System
108
Electrical System
109
Figure 12-18Motor Assembly
110
Motor Assembly
111
Figure 12-19Electrical Components
112
Figure 12-20Electrical Components (Sheet 2)
116
Electrical Components (Sheet 2)
117
Figure 12-21Wiring Harness
118
Wiring Harness
119
Figure 12-22Wiring Cables
120
Wiring Cables
121

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