EZ40 Truck - Big Lift, LLC Support Site for Big Joe …

1 Big Lift LLCMANUAL NO. BL- ez40 -0515 - , PALLET LIFT Patents Nos. D739,112; D770,719; D770,720; 9,586,605 OperationMaintenanceRepair Parts ListNOTE: For the most current parts information and service updates, please refer to the Big JoeSupport site at not operate this Truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator s Manual and on not operate this Truck until you have checked itscondition. Give special attention to wheels, horn, bat-tery, controller, lift system, brakes, steering mecha-nism, guards and safety Truck only from designated operating not carry passengers. Keep feet clear of Truck andwear foot applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is , stop, travel, steer and brake smoothly.

2 Slowdown for turns and on uneven or slippery surfaces thatcould cause Truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with special care when operating on ramps travelslowly, and do not angle or turn. Travel with not handle loads which are higher than the chassisunless load is secured so that no part of it could fallbackward. Before lifting, be sure load is centered,forks are completely under the chassis leaving Truck , neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off OF CONTENTSBL- ez40 -0515 - 01-28-2019iSectionPageSectionPage1 LIST OF LIST OF TABLES ..1-II1 DESCRIPTION .. DESCRIPTION.. OPERATION.

3 CONTROL AND STOPPING PROCEDURES.. SWITCH.. ARM GAS SPRING.. AND LOWER .. RAILS.. AND PLANNED MAINTENANCE .. AND QUARTERLY BATTERY CARE.. CARE AND CHARGING .. FREE BATTERIES .. BATTERIES .. TROUBLESHOOTING .. TROUBLESHOOTING .. Truck AND STEERING ARM, CONTROL HEADAND COMPARTMENT .. HEAD .. HEAD HEAD ASSEMBLY REMOVAL.. ASSEMBLY INSTALLATION.. POT. REPLACEMENT.. SWITCH SWITCH REPLACEMENT.. AND LOWER SWITCH COVERS .. SPRING REPLACEMENT.. ARM REMOVAL.. ARM INSTALLATION.. 5-76 BRAKE SERVICING .. GAP ADJUSTMENT.. DISTANCE ADJUSTMENT.. ASSEMBLY 6-27 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .. WHEEL INSTALLATION .. WHEEL.. 7-38 ELEVATION SYSTEM SERVICING .. LINKAGE .. 8-29 HYDRAULIC SYSTEM AND AND ELECTRICAL ASSEMBLY REMOVAL .. PUMP, MOTOR, AND RESERVOIR AND 9-410 ELECTRICAL COMPONENTS.

4 CONTROL MAINTENANCE .. CONTROLLER REMOVAL.. CONTROLLER INSTALLATION.. CHARGER CHARGER EMERGENCY DISCONNECT REMOVAL. EMERGENCY DISCONNECT CONTACTOR CONTACTOR FUSE REMOVAL.. FUSE COOLING FAN COOLING FAN BUZZER REMOVAL.. 10-4 TABLE OF CONTENTS - ContinuediiBL- ez40 -0515 - BUZZER INSTALLATION.. KEY SWITCH REMOVAL.. KEY SWITCH INSTALLATION.. BATTERY INDICATOR REMOVAL.. BATTERY INDICATOR INSTALLATION.. LIFT LIMIT SWITCH REMOVAL.. LIFT LIMIT SWITCH INSTALLATION.. MOTOR.. MOTOR.. SWITCH .. 10-711 OPTIONAL EQUIPMENT .. 11-112 ILLUSTRATED PARTS BREAKDOWN .. 12-1BL- ez40 -0515 - 01-28-20191-1 SECTION 1 DESCRIPTION1-1. publication describes the 24 volt ez40 lift truckdistributed by Big Lift LLC. Included are operatinginstructions, planned maintenance instructions, lubri-cation procedures, corrective maintenance proceduresand a complete parts list with part location shall comply with all requirements indicated inapplicable OSHA standards and current edition Part II.

5 By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your ez40 lift Truck . 1-2. GENERAL self-propelled ez40 Truck , Figure 1-2, lifts andtransports payloads up to 4000 pounds on rigid forward and reverse motion is controlled by eitherof two controller levers mounted on the control and turning is controlled by the steering and Lower is controlled by pushbuttons on the con-trol head. The battery powered lift Truck is quiet andreliable. The reversible AC motor propels the lift Truck in for-ward or reverse direction throughout the availablespeed range. The ez40 lift Truck can be driven withforks raised or lowered. The lift Truck must be pro-tected from the model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center.

6 Figure 1-2 shows the locations ofthe Truck s main components and 1-1 Name PlateFigure 1-2 . ez40 Lift TruckR6209 COMPLIES WITH THE APPLICABLE REQUIRE-COMPLIESWITH THE APPLICABLEREQUIRE-MENTS OF ANSI AND OSHA STANDARDSMENTSOF ANDOSHA STANDARDSBIG LIFT LLCBIGLIFT LLCWISCONSIN DELLS, WISCONSIN 53965 WISCONSINDELLS,WISCONSIN53965 AUSTRALIAN PATENT NO. 537,987 AUSTRALIANPATENT , PATENT NO. 4,444, ,444,284 TRUCKTYPEMODEL CAP LB/MAXCAP LB/LOAD CTR IN/LOADCTRIN/LIFT HGT IN/LOAD CTR IN/LOADCTRIN/LIFT HGT IN/ALT CAP LB/BATTERY MIN WT LB/BATTERY MINWT LB/ Truck WT LESS BATTERY LB/TRUCKWT LESSBATTERY LB/BATTERY MAX WT LB/BATTERY MAXWT LB/ Truck WT WITH BATTERY LB/TRUCKWT WITHBATTERY LB/KGMMMMMMMMKGKGKGKGKGEZ40-91-2BL- ez40 - 0515 - 01-28-20191-3. SAFETY ez40 is designed and engineered to provide max-imum safety for operator and payload. Some of thesafety features incorporated into the design are: Dead-man brake to apply the brake and cut off drivepower when the steering arm is released.

7 Belly-button switch to reverse Truck should the oper-ator accidentally pin himself against a wall orobstruction when backing up in slow speed. All control functions automatically return to OFF when released. Emergency Disconnect within operator's reach. Readily accessible horn button. Handle to provide a firm hand hold for operator. Flow control valve regulates maximum loweringspeed within prescribed limits. Relief valve maintains hydraulic pressure within pre-scribed limits. High visibility color scheme of Truck provides visualalert of Truck s presence. Battery Indicator. Guard rails adjustable for various pallets. Adjustable load - 01-28-20192-1 SECTION 2 OPERATION2-1. section gives detailed operating instructions forthe ez40 lift Truck . The instructions are divided into thevarious phases of operations, such as operating Lift, driving, and stopping.

8 Routine precautions areincluded for safe OPERATING :Improper operation of the lift Truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the ez40 following safety precautions must be adhered toat all times. Do not operate this Truck unless you have beentrained and authorized to do so and have read allwarnings and instructions in this manual and on thetruck. All warnings and instructions must be read andunderstood before using the equipment. Equipment must be inspected by a qualified personon a regular basis. Do not operate this Truck until you have checked itscondition. Give special attention to Wheels, Horn,Batteries, Controller, Lift System, Brakes, SteeringMechanism, Guards and Safety Devices Operate Truck only from designated operating posi-tion.

9 Do not carry passengers. Keep feet clear oftruck and wear foot protection. Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed. Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfacesthat could cause Truck to slide or overturn. Use spe-cial care when traveling without load as the risk ofoverturn may be greater. Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel withload or lifting mechanism trailing. Do not overload Truck . Check nameplate for loadweight and load center information. Before lifting, be sure load is centered, forks arecompletely under load, and load is as far back aspossible against the chassis. Do not handle loads which are higher than the chas-sis unless load is secured so that no part of it couldfall backward.

10 When leaving Truck , neutralize travel control. Fullylower lifting mechanism and set brake. When leavingtruck unattended, turn off key switch and disconnectswitch, and remove key. The lift Truck must be protected from the BEFORE OPERATIONT able 2-1 covers important inspection points on theEZ40 lift Truck which should be checked prior to opera-tion. Depending on use, some trucks may requireadditional 2-1 shows a sample format for an OperatorChecklist, which can be modified as necessary to fityour :Periodic maintenance of this Truck by aQUALIFIED TECHNICIAN is :A QUALIFIED SERVICE TECHNICIAN should check the Truck monthly forproper lubrication, proper fluid levels,brake operation, motor maintenance andother areas specified in the SECTION :If the Truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority.