OPERATOR’S MANUAL

POWEREDPALLET TRUCK

U.S. Patent Nos. D739,112; D770,719; D770,720;

8,540,213; 8,833,736; 9,079,754; D692,202;

D692,203; D692,204 and D767,236

Big Lift LLCwww.bigjoeforklifts.com

Manual Part No. 901634

08/02/2018

FOREWORD

As a lift truck operator, you areresponsible for a machine that is use-ful, powerful, and can be hazardous ifnot operated as described. Your BigLift LLC truck may weigh more thansome cars, depending on the model.Observing and practicing the safetywarnings in this manual cannot beoveremphasized. Just knowing thewarnings, however, is no substitute forcommon sense. Focusing on the taskat hand will, in almost all cases, pre-vent accidents. Think of the truck asyour own. In this way you will learn itscapabilities and limitations.

This manual is intended to remainwith 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..................................................................................................6

BEFORE OPERATION ..........................................................................................7

INSTRUMENTS AND CONTROLS .......................................................................9

OPERATION ........................................................................................................11Forward and Reverse Travel and Speed Control ...............................11Steering..................................................................................................11Stopping.................................................................................................12Parking ...................................................................................................12Battery Charging ...................................................................................13Load Handling .......................................................................................13Moving a Disabled Truck ......................................................................13

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

1

SAFETY SYMBOLS

WARNING and CAUTION 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

Big Lift LLC Pallet trucks lift and trans-port loads on rigid forks.

Control for steering, braking, forwardand reverse travel, horn, lift, lower andspeed control are all located on thecontrol 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, butthey are always near the steering armwithin sight of the operator.

If the name plate or warning decal arelost or damaged they should bereplaced immediately. Have yoursupervisor or the designated author-ity contact Big Lift LLC AuthorizedDealer for replacement.

The name plate shows the modelnumber, serial number, and trucktype. Battery type, with voltage andminimum weight, is shown along withinformation on the load capacity andload center.

The warning decal contains warningswhich also appear, with illustrations, inthe Operating Precautions section ofthis manual.

2

E30 / EZ30 Name Plate and Warning Decal Locations - Typical

D40 / EZ40 Name Plate and Warning Decal Locations - Typical

R6837

3

WPT Name Plate and Warning Decal Locations - Typical

WRT Name Plate and Warning Decal Locations - Typical

R6692

R6838

4

This truck is equipped with a battery. Read and heed the following warning plusany other warnings located near or on the battery. An example is shown here:

WARNING:

5

LOAD CAPACITY

Do not overload truck. Check nameplate for load weight capacity and loadcenter information.

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

R6693

6

BEFORE OPERATION

The table on page 8 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 an Operator Checklist, whichcan be modified as necessary to fit youroperation.

Periodic maintenance of thistruck by a QUALIFIED SERVICETECHNICIAN is required.

A QUALIFIED SERVICE TECH-NICIAN should check the truck

monthly for proper lubrication,proper fluid levels, brake main-tenance, motor maintenanceand other areas specified in theparts and service manual main-tenance section.

If the truck is found to be unsafeand in need of repair, or contrib-utes to an unsafe condition,report it immediately to the des-ignated authority. Do not operateit until it has been restored to asafe operating condition. Do notmake any unauthorized repairsor adjustments. All service mustbe performed by a qualifiedmaintenance technician.

Sample of Operator Check List

WARNING:

WARNING:

WARNING:

R6235

Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Load Wheels

Horn

Lift Lower Control

Need MaintenanceO.K. ( )

Shift

Hour MeterReading 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 handleprovide controls for steering, forwardand reverse speed control, braking,raising and lowering the forks, and

horn. Control handles on all modelshave a “belly-button” reversing switchwhich reverses the direction of thetruck upon contact with the operator.

Control Handle

R6694

9

Walkie/Rider Pallet Trucks have a grabbar which also contains lift, lower andhorn controls.Detai led operatinginstructions are in the Operation sectionof this manual.

On the WPT & WRT trucks a battery dis-connect is mounted near the steeringarm. Pulling the disconnect removes allpower from truck circuits in the event ofan emergency.

On the E30/EZ30 and D40/EZ40 push-ing the red disconnect plunger removesall power from the truck circuits in theevent of an emergency.

Grab Bar

R6803

10

OPERATION

Forward and Reverse Travel and Speed 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.

R6694

11

Stopping

Stop the truck as gradually as possible.Unnecessary rapid stopping could behazardous. Load could become unsta-ble.

To stop the truck’s movement (forwardor reverse), raise the control handle tothe up position or push the control han-dle all the way down. In both positions,the brake will apply. To release thebrake, just move the control handle tothe operating position.

NOTE: The steering arm gas springautomatically raises the steer-ing arm to the upright positionwhen the steering arm isreleased.

CAUTION: If the control handle doesnot raise immediately tothe vertical position when

released, the truck shouldbe placed “OUT OF SER-VICE” un t i l i t can beinspected by a qualifiedservice technician.

Parking

When parking the truck, do not obstructtraffic lanes or aisles.

1. Park the truck in its designatedparking area.

2. Raise the steering arm until verticalto apply the parking brake.

3. Fully lower forks.

4. Turn keyswitch to off position.Remove key for added security.

5. On the WPT & WRT pull out batterydisconnect or push the red discon-nect plunger on the E30/EZ30 andD40/EZ40.

Steering Arm Braking Positions

R6620

12

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 withinpallet or skid, and the load is cen-tered over the forks and as farback as possible.

3. Raise the forks to lift load.

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 standing off to sideof truck.

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 surrounding objects.

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:

13

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

Do not operate this truck unless youhave been trained and authorized to doso, and have read and understand allwarnings and instructions contained inthis operator’s manual and on this truck.

R6695

R6696

Do not operate this truck untilyou have checked its condition.Give special attention towheels, horn, battery, controller,lift systems, brakes, steeringmechanism, guards and safetydevices. If you have any ques-tions, notify your supervisor orproper authority.

14

R6697

Walkie Pallet Trucks: Operatetruck only from walking position.

R6839

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

15

R6699

Wear foot protection andkeep feet clear of truck.

R6701

Do not carry pas-sengers.

16

R6702

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

R6703

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.

17

R6704

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.

R6705

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

18

R6706

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

R6705

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

19

R6708

Keep hands out of lifting mechanism.

R6709

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

20

NOTICE - OBTAINING A PARTS AND SERVICE MANUAL

A complete parts and service manual covering this truck is available from Big LiftLLC. To order, obtain the serial number of your truck and contact your Big JoeAuthorized Dealer.

21

Big Lift LLC