OPERATOR’S MANUAL

STRADDLELIFT TRUCK

Big Lift LLCwww.bigjoeforklifts.com

Manual Part No. 90163508/16/2018

FOREWORD

As a lift truck operator, you are respon-sible for a machine that is useful, pow-erful, and can be hazardous if notoperated as described. Your Big LiftLLC truck may weigh more than somecars, depending on the model. Observ-ing and practicing the safety warnings inthis manual cannot be overempha-sized. Just knowing the warnings, how-ever, is no substitute for commonsense. Focusing on the task at hand, inalmost all cases, prevent accidents.Think of the truck as your own. In thisway you will learn its capabilities andlimitations.

This manual is intended to remain withthe truck at all times as a handy refer-ence guide to operation. Detailed main-tenance procedures are found in theparts and service manual for the spe-cific truck model, and are to be per-formed only by a qualified technician.For further information on obtaining acomplete parts and service manual, seepage 26 of this manual.

The operator who knows his truck willlearn to spot problems as they develop.This is accomplished by performing theDaily Checks and reporting any prob-lems 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 - PDS 20/25/30/40, S22/25/S30..................11

INSTRUMENTS AND CONTROLS - PDI, PDM, PDH ........................................12

OPERATION ........................................................................................................13Forward and Reverse Travel and Speed Control ...............................13Steering..................................................................................................13Stopping.................................................................................................14Parking ...................................................................................................15Battery Charging ...................................................................................15Load Handling .......................................................................................15Moving a Disabled Truck ......................................................................16

NOTICE - OBTAINING A PARTS AND SERVICE MANUAL..............................26

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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

The Big Lift LLC Straddle trucks utilizethe straddle leg configuration, whichnormally straddles the load.

Control for steering, braking, forwardand reverse travel, horn and speed con-trol are all located on the control handle.All trucks feature an automatic highspeed cut-off circuit which locks outhigh speed when the forks are elevated.

Trucks in this series may vary in loadcapacity, battery arrangement, instru-mentation and lift/ lower controls,depending on model and options. Theforks may be rigid or adjustable. Onemodel has a reach and tilt mechanismwhich extends the forks toward the load,then retracts and tilts back the forks fortransporting the load.

NAME PLATE AND WARNING DECAL

Warning decal locations may varybetween models, but normally they arenear the steering arm within sight of theoperator. The name plate is mounted onthe truck frame or mast. See illustrationon next pages

If the name plate or warning decal arelost or damaged they should bereplaced immediately. Have yoursupervisor or the designated authority

contact Big Lift LLC Authorized Dealerfor replacement.

The name plate shows the model num-ber, serial number, and truck type. Bat-tery type, with voltage and minimumweight, is shown along with informationon the load capacity and load center.

The warning decal contains warningswhich also appear, with illustrations, inthe Operation section of this manual.

5

PDS 20/25 Name Plate and Warning Decal Locations - Typical

PDS 30/40 Name Plate and Warning Decal Locations - Typical

R6728

R7030

6

S22, S25 & S30 Name Plate and Warning Decal Locations - Typical

PDI, PDM & PDH Name Plate & Warning Decal Locations -Typical

R7031 R8308

R3965

7

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:

LOAD CAPACITY

The further the load center is from thebackrest, the lower the load capacity.The load center must also be no higherthan that specified above the lifting sur-face (Top side of forks). For example, aload capacity of 3,000 pounds with aload center of 24 inches means that thetruck can be used to lift 3,000 poundsonly when the load’s center of gravity is

no more than 24 inches from the face ofthe forks or 24 inches above the top sideof the forks. Note that a truck undergo-ing speed changes is less stable than astanding truck. If you are not sure thatthe truck can lift a certain load, consultyour supervisor or the designatedauthority.

WARNING:

R6115

R3814

8

Load Center

BEFORE OPERATION

The table on page 10 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 technicianshould check the truck monthlyfor proper lubrication, proper fluidlevels, brake maintenance,

motor maintenance and otherareas specified in the parts andservice manual maintenancesection.

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 qualified ser-vice technician.

Sample of Operator Check List

WARNING:

WARNING:

WARNING:

R6235

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Operator Checks

ITEM PROCEDURE

Transmission and hydraulic systems

Check for signs of fluid leakage.

Forks Check for cracks and damage and that they are properly secured.

Chains, cables and hoses Check that they are in place, properly secured and not damaged.

Guards and load backrest Check that safety guards are in place, prop-erly 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 and casters 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. PDI,PDM,PDH (w. Dynamic Brakes):Check that dynamic brake (if so equipped - not available on newer trucks) actuates when dynamic brake pushbutton on control handle is pressed.

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. On the S22 & S25 check that the emergency power disconnect is functioning properly.

High speed limit switch Allow for enough space to operate truck in high speed. Elevate forks approximately two feet, then test drive truck to check if high speed is cut out.

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INSTRUMENTS AND CONTROLS - PDS 20/25/30/40, S22/25/S30

The steering arm and control handleprovide controls for steering, forwardand reverse speed control, braking,horn, and raising and lowering the forks.Control handles on all models have a“belly button” reversing switch whichreverses the direction of the truck uponcontact with the operator.

Detailed operating instructions are inthe Operation section of this manual.

A battery disconnect is mounted nearthe steering arm. Pulling the gray dis-connect on PDS trucks or pushing thered disconnect plunger on S22 & S25trucks removes all power from truck cir-cuits in the event of an emergency.

Control Handles

R8254 - PDS20-25, PDS30-40 (w.o. Side Shift), S22-25-30

R8255 - PDS30/40 (w. Side Shift) - Used up to Sn. S2315284R8256 - PDS30/40 (w. Side Shift) - Used from Sn. S2315285

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INSTRUMENTS AND CONTROLS - PDI, PDM, PDH

The steering arm and control handleprovide controls for steering, forwardand reverse speed control, braking, andhorn. Control handles on some modelshave pushbuttons for raising and low-ering the forks, and for an additional"dynamic brake" independent from themechanical brake.Control handles onall models have a "belly button" revers-ing switch which reverses the directionof the truck upon contact with the oper-ator.

Detailed operating instructions are inthe Operation section of this manual.

A battery disconnect is mounted nearthe steering arm. Pulling the disconnectremoves all power from truck circuits inthe event of an emergency.

Control Handle - PDI, PDM, PDH

All models come standard with a lift/lower control lever mounted near thesteering arm. Some models have addi-tional control levers for operating areach and tilt functions which move theforks out or in, and tilt the fork tips up ordown.

Lift/Lower Control Level

Optional Features

The optional remote lift/lower control (ifequipped) allows the operator to raiseand lower the forks while standing awayfrom the control handle.

Optional Remote Lift/Lower Control

Other options are the battery capacityindicator, hourmeter and keyswitchwhich mount on the panel near the con-trol handle. The battery capacity indi-cator monitors the battery dischargerate to indicate the remaining batterycapacity. The hour meter records theaccumulated hours that electricalenergy is being drawn from the batteryto run the pump and drive motors. Thekeyswitch provides added security tothe truck, preventing unauthorized per-sonnel from operating the machine.

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OPERATION

Forward and Reverse Travel and Speed Control

Control Handles

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. Furtherrotation in either direction will progressthe truck from slow to maximum travelspeed.

To change directions or to stop the truck,rotate the speed control lever in theopposite direction. The truck will come

to a stop and then, unless the controlsare returned to the center neutral posi-tion, accelerate in the opposite direc-tion.

Steering

Moving the control handle (which con-nects to the steering arm) right or left willturn the truck right or left. When maneu-vering around corners, make squareturns and be sure there is adequate clearance.

R8257

13

Stopping

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

You can use plugging to stop the truck,this electrical braking function consistsof rotating the speed control lever in theopposite direction of travel and thenreleasing it when the truck stops. Plug-ging is a convenient way to stop thetruck during normal operation. If thecontrol is not released, the truck willaccelerate in the opposite direction.

You can also stop the tucks movement(forward or reverse) by raising the con-trol handle to the up position or push thecontrol handle all the way down. Ineither positions, the travel controls willdeactivate and the brake will apply. Torelease the brake, just move the controlhandle to the operating position.

NOTE: The steering arm gas springautomatically raises thesteering arm to the upright

position when the steeringarm is released.

CAUTION: If the control handle doesnot raise immediately tothe vertical position whenreleased, the truck shouldbe placed “OUT OF SER-VICE” until it can beinspected by a qualifiedrepair technician.

PDI,PDM,PDH (w. Dynamic Brakes):

The Dynamic Brake (if so equipped - notavailable on newer trucks) serves as asecondary braking system completely inde-pendent from the mechanical brake. Press-ing the dynamic brake pushbutton applies aconstant DC voltage across the drive motor

field coils to stop the motor.

The dynamic brake pushbuttonshould not be held in place longerthan one or two seconds. Exces-sive use may blow the 40 Ampfuse, which will render dynamicbrake inoperative.

Steering Arm Braking Positions

WARNING:

R6650 R3629

14

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 verti-cal to apply the parking brake.

3. Fully lower forks and make surethe lift carriage is all the waydown.

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

5. Pull the gray battery disconnector push red disconnect plungeron S22 & S25 trucks.

Battery Charging

Refer to DOC 245 for battery safety andmaintenance.

NOTE: Battery charging instructionsare contained in the servicemanual.

Load Handling

Handle only loads arranged forstability and always use caution.Ra ise and lower the loadsmoothly to prevent the load fromfalling.

Always be sure the load and loadcenter are within the capacity ofthe truck. If in doubt check thenameplate.

1. Approach the load slowly.

2. Stop the truck when the forks arejust in front of the load.

3. Adjust the forks to the maximumpractical width to support the loadto be lifted.If the truck has rigidforks, position the truck so theforks will give maximum supportto the load.

4. Raise or lower the forks until theyare properly aligned with the pal-let openings.

5. Move the truck slowly into posi-tion so that the forks are centeredabout the load.

6. Make sure the load is against thebackrest and then raise the forksuntil the pallet clears the rack.

7. Move the truck away from therack until the load clears the rackand then lower the forks.

8. Always operate the truck with theforks in the DOWN position andslightly raised when operating ona grade.

9. Lead the truck by the control han-dle with the load trailing exceptwhen in confined areas. Rampsshould always be traveled withoperator uphill of truck

.

10. Always look in the direction oftravel. Move slowly and checkclearances when approachingobstructions.

WARNING:

WARNING:

15

11. Do not make sudden starts andstops. Operate truck smoothlyand gradually.

12. 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.

13. Line up the truck with the unload-ing area.

14. Stop the truck and raise or lowerthe forks until the pallet is in posi-tion with the unloading area.

15. Check the load alignment withsurrounding objects.

16. Be careful not to damage ormove adjacent loads and objects.

17. Slowly move into position.

18. Lower the forks until the load issecurely settled on its own. Besure there is no downward forceon the forks on the rack or floor.

19. Carefully move the truck awayfrom the load watching to makesure the load doesn’t move orshift. If the load does move,return the truck to the load andreset.

NOTE: Make sure when working in arack area, that you do not

disturb another load whileplacing yours in the rack.This may cause a danger-ous situation for other opera-tors or pedestrians working inthis area later.

20. If forks are elevated, lower totravel position.

Moving a Disabled Truck

Do not attempt to move a disabled truck;notify your supervisor or proper author-ity.

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

16

Do not operate this truck unless you havebeen trained and authorized to do so, andhave read and understand all warningsand instructions contained in this opera-tor’s manual.

R6710

R6711

Do not operate this truck until you havechecked its condition. Give special attentionto wheels, horn, lights, battery, controller, liftsystems (including forks or attachments,chains, cables and limit switches), brakes,steering mechanism, guards and safety devices. If you have any questions, notify your supervisor or proper authority.

17

Operate truck only from walking position.

R3946

Never place any part of the bodyinto the mast structure.

R6713

18

R3948

Do not carry passengers.

Keep feet clear of truckand always wear foot pro-tection

R6715

19

R3950

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

R6717

Start, stop, travel, steer and brakesmoothly. Slow down for turns and onuneven or slippery surfaces that couldcause truck to slide or overturn. Use spe-cial care when traveling without load asthe risk of overturn may be greater.

20

Travel with lifting mechanism as low aspossible. Always look in direction of travel.Keep a clear view, and when load inter-feres with visibility, travel with load or liftingmechanism trailing.

R6718

R3953

Use special care when operating onramps; travel slowly and do not angle orturn. Always travel with lifting mechanismdownhill and driver uphill.

21

Do not overload truck. Checkcapacity plate for load weight andload center information.

R6720

When using forks, spaceforks as far apart as load willpermit. Before lifting, be sureload is centered, forks arecompletely under load, andload is as far back as possibleagainst load backrest.

R3955

22

R6722

Do not handle unstable or loosely stackedloads. Use special care when handlinglong, high or wide loads to avoid losing theload, striking bystanders or tipping thetruck.

Do not handle loads which are higher thanthe load backrest or load backrest exten-sion unless load is secured so that no partof it could fall backward.

R63957

23

R6724

Elevate forks or other lifting mech-anism only to pick up or stack a load.Watch out for obstructions, espe-cially overhead.

R3970

Do not lift personnel on forks or workplatform with this truck. It is notdesigned for this function andsomeone could get seriouslyinjured if they fell off. Use the correctequipment for this task.

24

Do not allow anyone to standor pass under a load or liftingmechanism.

R6726

When leaving truck neutralizetravel control. Fully lower liftingmechanism and set brake.When leaving truck unat-tended also shut off power.

R3960

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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.

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Big Lift LLC