OPERATOR’S MANUAL

POWER DRIVE
MANUAL LIFT
PALLET TRUCK
U.S. Patents Nos. 9,475,513; D754,415; D767,847 and D765,939

Big Lift LLC Manual Part No. 901637

www.bigjoeforklifts.com 08/16/2018
 FOREWORD

As a lift truck operator, you are reference guide to operation. Detailed

responsible for a machine that is use- maintenance procedures are found in
ful, powerful, and can be hazardous if the parts and service manual for the
not operated as described. Your Big specific truck model, and are to be
Lift LLC truck may weigh more than performed only by a qualified techni-
some cars, depending on the model. cian. For further information on
Observing and practicing the safety obtaining a complete parts and ser-
warnings in this manual cannot be vice manual, see page 17 of this man-
overemphasized. Just knowing the ual.
warnings, however, is no substitute for
The operator who knows his truck will
common sense. Focusing on the task
learn to spot problems as they
at hand will, in almost all cases, pre-
develop. This is accomplished by per-
vent accidents. Think of the truck as
forming the Daily Checks and report-
your own. In this way you will learn its
ing any problems to the designated
capabilities and limitations.
authority.
This manual is intended to remain
with the truck at all times as a handy
TABLE OF CONTENTS

SAFETY SYMBOLS ..............................................................................................2

GENERAL DESCRIPTION ....................................................................................2
NAME PLATE AND WARNING DECAL ...............................................................2
LOAD CAPACITY..................................................................................................4
BEFORE OPERATION ..........................................................................................5
INSTRUMENTS AND CONTROLS .......................................................................7
OPERATION ..........................................................................................................9
Forward & Reverse Travel ......................................................................9
Steering ....................................................................................................9
Lift and Lower. .........................................................................................9
Parking .....................................................................................................9
Battery Charging ...................................................................................10
Load Handling .......................................................................................10
Moving a Disabled Truck ......................................................................10
NOTICE - OBTAINING A PARTS AND SERVICE MANUAL..............................17

1
 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
Big Lift LLC Pallet trucks lift and trans- Trucks in this series may vary in load
port loads on rigid forks. capacity, battery arrangement, and
Controls for steering, braking, for- instrumentation, depending on model
ward and reverse travel, horn, lift, and options.
lower and speed control are all
located on the control handle.
NAME PLATE AND WARNING DECAL
Name plate and warning decal loca- The name plate shows the model
tions may vary between models, but number, serial number, and truck
they are always near the steering arm type. Battery type, with voltage and
within sight of the operator. minimum weight, is shown along with
information on the load capacity and
If the name plate or warning decal is
load center.
lost or damaged they should be
replaced immediately. Have your The warning decal contains warnings
supervisor or the designated author- which also appear, with illustrations, in
ity contact Big Lift LLC Authorized the Operation section of this manual.
Dealer for replacement.

2
 R7166

Name Plate Location - Typical

WARNING:
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:

3
 LOAD CAPACITY

Do not overload truck. Check name the load center exceeds 1/2 the length
plate for load weight capacity and load of the forks or is not centered between
center information. the forks. The fork length and wheel-
The load capacity depends on the base must be adequate for the skid or
load center. The load maximum bin to be handled.
capacity listed on the capacity plate Note that a truck undergoing speed
assumes a uniform load whose center changes is less stable than a standing
is at 1/2 the length of the fork and cen- truck. If you are not sure that the truck
tered between the forks. The maxi- can lift a certain load, consult your
mum load capacity is reduced when supervisor or the designated authority.

R7167

Load Center

4
 BEFORE OPERATION

The table on page 6 covers important monthly for proper lubrication,

inspection points on trucks which proper fluid levels, brake main-
should be checked prior to operation. tenance, motor maintenance
Depending on use, some trucks may and other areas specified in the
require additional checks. parts and service manual main-
The illustration below shows a sample tenance section.
format for an Operator Checklist, which
can be modified as necessary to fit your
operation.
WARNING:
If the truck is found to be unsafe
and in need of repair, or contrib-
WARNING: utes to an unsafe condition,
Periodic maintenance of this report it immediately to the des-
truck by a QUALIFIED SERVICE ignated authority. Do not operate
TECHNICIAN is required. it until it has been restored to a
safe operating condition. Do not
make any unauthorized repairs
or adjustments. All service must
WARNING: be performed by a qualified ser-
vice technician.
A QUALIFIED SERVICE TECH-
NICIAN should check the truck

Electric Truck
Big Joe Manufacturing Company Daily Operator Check-Off List

Date Operator

Truck No. Model No.

Dept. Shift
Hour Meter
Reading Drive Hoist

Check O.K. ( ) Need Maintenance

Tires
Load Wheels
Horn
Lift Lower Control
Attachment Operation
Forward & Reverse Controls
Steering
Electrical Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.

R6235

Sample of Operator Check List

5
 Operator Checks

ITEM PROCEDURE
Transmission and hydraulic Check for signs of fluid leakage.
systems
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 the 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.
Manual lift controls Check operation of manual lift and lower to
their maximum positions.
Brakes Check that brakes actuate when steering arm
is raised to upright position and when the bat-
tery disconnect is pulled out.
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.

6
 INSTRUMENTS AND CONTROLS

The steering arm and control handle Detailed operating instructions are in
provide controls for steering, forward the Operation section of this manual.
and reverse speed control, braking,
A battery disconnect is mounted near
and raising and lowering the forks.
the steering arm. Pulling the discon-
Control handles on all models have a
nect removes all power from truck cir-
“belly-button” reversing switch which
cuits in the event of an emergency.
reverses the direction of the truck
upon contact with the operator.

R7160

Control Handle

1 Power Button
2 Optional Key Switch
3 Belly Button Switch
4 Reverse Button
5 Forward Button
6 Battery Indicator
7 Horn Button

7
POWER BUTTON charge decreases, additional LEDs
The power button (1) is used to switch will light.
control current on and off. • When the second to the last LED
flashes, the battery is 70% dis-
OPTIONAL KEY SWITCH charged.
The optional key switch (2) has two • When the last two LEDs flash alter-
positions, ON and OFF. Removing the nately, the battery is 80% dis-
key prevents use by unautorized per- charged and needs to be
sonal recharged.
The battery indicator has a memory
BELLY-BUTTON BUTTON
function, it can remember the battery
The belly-button button (3) minimizes power after the power is shut down.
the possibility of the driver being The next time the power is turned on,
pinned by the steering arm. If the it will show the last level of discharge.
switch presses against the operator
while the lift truck is being driven
toward the operator, the switch
changes the direction of the lift truck.

FORWARD AND REVERSE BUT-

TONS
The forward button (5) and the
reverse button (4) provide fingertip
control for driving the truck.

BATTERY INDICATOR
When the key switch is turned on the Figure 1-1 Battery Indicator
battery charge indicator (6) displays
the battery status. The colors of the
LED represent the following condi- HORN BUTTON
tions:
The horn button (7) located on the
• The first LED lights when the battery front of the control head activates the
is properly charged. As the battery horn.

8
 OPERATION

FORWARD & REVERSE TRAVEL eratively until it starts to move in the

The forward and reverse controls are opposite direction.
located on the control handle.
LIFT AND LOWER.
Lower the control handle to a comfort-
able position to disengage the brake Lift
and to energize the electric circuits. Push down on control lever (2) and
Press the forward button (5) move for- move control handle (1) up and down
ward (with load in front). until the desired lifting height is
achieved. Reset lever (2) to the neu-
To change direction or to stop the tral position.
truck, press the reverse button (4).
The truck will come to a stop and Lower
then, unless the button is released, Pull up on control lever (2) until the
accelerate in the opposite direction. desired lower height is achieved.
Reset lever (2) to the neutral position.
STEERING
Moving the control handle right or left
will turn the truck right or left. When
maneuvering around corners, make
square turns and be sure there is
adequate clearance.

STOPPING
Emergency Stop
Pull out the battery disconnect. All Figure 1-2 Lift Controls
electrical functions are cut out and the
brake is applied. PARKING
Automatic Braking When parking the truck, do not
When the control handle is released, it obstruct traffic lanes or aisles.
will automatically return to the vertical 1. Park the truck in its designated
position and the brake will apply. parking area.
Regenerative Braking 2. Raise the control handle until ver-
When the travel button (4 or 5) is tical to apply the parking brake.
released, the truck automatically 3. Fully lower forks.
brakes regeneratively. Once the truck
4. Turn power switch or optional
slows down the brake then fully
keyswitch to off position. Remove
applies.
key for added security.
Inversion Braking 5. Pull out battery disconnect.
Press the opposite direction travel
button (4 or 5). The truck brake regen-

9
BATTERY CHARGING tered over the forks and as far
Refer to DOC 245 for battery safety back as possible.
and maintenance. 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
NOTE: Battery charging instructions obstructions.
are contained in the service 6. Do not make sudden starts and
manual. stops. Operate truck smoothly
Load Handling and gradually.
7. Travel slowly and squarely
around corners. Remember that
the trailing load wheels do not fol-
WARNING: low the turn path of the drive
wheel. Instead they tend to cut
Handle only loads arranged for
the corner.
stability and always use cau-
tion. Raise and lower the load 8. Line up the truck with the unload-
smoothly to prevent the load ing area.
from falling. 9. Stop the truck and check the load
alignment with surrounding
objects.

WARNING: 10. Be careful not to damage or

move adjacent loads and objects.
Always be sure the load and
load center are within the 11. Lower the forks until the load is
capacity of the truck. If in doubt resting on its own.
check the nameplate. 12. Move the truck back until the
1. Approach the load slowly. forks are clear of the pallet.

2. Move the truck slowly into posi- Moving a Disabled Truck

tion so that the forks are within Do not attempt to move a disabled
pallet or skid, and the load is cen- truck; notify your supervisor or proper
authority.

10
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.

R7168

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 ques-
tions, notify your supervisor or
proper authority.

R7169

11
 Operate truck only from walking
position.

R7170

Wear foot protection and

keep feet clear of truck.

R7171

12
 Do not carry passengers.

R7172

Observe applicable traffic regulations. Yield right-of-

way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.

R7173

13
 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.
R7174

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.

R7175

14
Use special care when operating on ramps; travel slowly, and do not angle
or turn. Travel with lifting mechanism downhill.

R7176

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.

R7177

15
 Keep hands out of lifting mechanism.

R7178

When leaving truck neutralize travel con-

trol. Fully lower lifting mechanism and
set brake. When leaving truck unat-
tended also shut off power.

R7179

16
 NOTICE - OBTAINING A PARTS AND SERVICE MANUAL

A complete parts and service manual covering this truck is available from Big Lift
LLC. Visit www.bigjoesupport.com to download a .pdf manual.

17
Big Lift LLC