OPERATOR’S MANUAL

PDSSTRADDLE

LIFT TRUCK

Big Lift LLCwww.bigjoeforklifts.com

Manual No. BL-PDS-OP-011104/01/2011

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 substitutefor common sense. Focusing on thetask at hand, 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..................................................................................................4

BEFORE OPERATION..........................................................................................5

INSTRUMENTS AND CONTROLS .......................................................................7

OPERATION..........................................................................................................8Forward and Reverse Travel and Speed Control .................................8Steering....................................................................................................8Stopping...................................................................................................9Parking ...................................................................................................10Battery Charging ...................................................................................10Load Handling .......................................................................................10Moving a Disabled Truck......................................................................11

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

1

SAFETY SYMBOLSWARNING and CAUTIONS 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 speedcontrol are all located on the controlhandle. All trucks feature an auto-

matic high speed cut-off circuit whichlocks out high speed when the forksare elevated.

Trucks in this series may vary in loadcapacity, battery arrangement, instru-mentation and lift/lower controls,depending on model and options.

NAME PLATE AND WARNING DECALWarning decal locations may varybetween models, but they are alwaysnear the steering arm within sight ofthe operator. The name plate ismounted on the right side of the truckframe. See illustration on next page

If the name plate or warning deal 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,in the Operating Precautions sectionof this manual.

2

Name Plate and Warning Decal Locations - Typical

This truck is equipped with a battery. Read and heed the warning decal locatednear the battery. An example is shown here:

WARNING:

R6728

3

LOAD CAPACITY

The further the load center is from thebackrest, the lower the load capacity.The load center must also be nohigher than that specified above thelifting surface (Top side of forks). Forexample, a load capacity of 3,000pounds with a load center of 24inches means that the truck can beused to lift 3,000 pounds only when

the load’s center of gravity is no morethan 24 inches from the face of theforks or 24 inches above the top sideof the forks. Note that a truck under-going speed changes is less stablethan a standing truck. If you are notsure that the truck can lift a certainload, consult your supervisor or thedesignated authority.

Load Center

R3814

4

BEFORE OPERATION

The table on page 6 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,which can be modified as necessaryto fit your operation.

Periodic maintenance of thistruck by a QUALIFIED TECH-NICIAN is required.

A QUALIFIED SERVICETECHNICIAN should check thetruck monthly for proper lubri-

cation, proper fluid levels,brake maintenance, motormaintenance and other areasspecified in the parts and ser-vice manual maintenance sec-tion.

If the truck is found to beunsafe and in need of repair, orcontributes to an unsafe condi-tion, report it immediately to thedesignated authority. Do notoperate it until it has beenrestored to a safe operatingcondition. Do not make anyunauthorized repairs or adjust-ments. All service must be per-formed by a qualifiedmaintenance technician.

Sample of Operator Check List

WARNING:

WARNING:

WARNING:

R6235

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Operator Checks

ITEM PROCEDURETransmission 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.

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.

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.

6

INSTRUMENTS AND CONTROLS

The steering arm and control handleprovide controls for steering, forwardand reverse speed control, braking,horn, and raising and lowering theforks. Control handles on all modelshave a “belly-button” reversing switchwhich reverses the direction of thetruck upon contact with the operator.

Detailed operating instructions are inthe Operation section of this manual.

A battery disconnect is mounted nearthe steering arm. Pulling the discon-nect removes all power from truck cir-cuits in the event of an emergency.

Control Handle

R6694

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OPERATION

Forward and Reverse Travel andSpeed 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

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Stopping

Stop the truck as gradually as possi-ble. Unnecessary rapid stopping couldbe hazardous. Load could becomeunstable.

To stop the tucks movement (forwardor reverse), raise the control handle tothe up position or push the controlhandle all the way down. In both posi-tions, the electric brake will deactivateand the brake will apply. To releasethe brake, just move the control han-dle to the operating position.

NOTE: The steering arm gas springautomatically raises thesteering arm to the uprightposition 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.

Steering Arm Braking Positions

R6650

9

Parking

When parking the truck, do notobstruct traffic 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.

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

5. Pull out battery disconnect.

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. 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.

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 be traveled with operatoruphill of truck when empty, oroperator downhill of truck withload on forks.

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

WARNING:

WARNING:

10

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. Be

sure 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 notdisturb 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 disabledtruck; notify your supervisor or properauthority.

11

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.

R6710

R6711

Do not operate this truck until you havechecked its condition. Give special atten-tion to wheels, horn, lights, battery, con-troller, lift systems (including forks orattachments, chains, cables and limitswitches), brakes, steering mechanism, guards and safety devices. If you have any questions, notify your supervisor or proper authority.

12

Operate truck only from walking position.

R6712

Never place any part of the bodyinto the mast structure.

R6713

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R6714

Do not carry passengers.

Keep feet clear of truck.

R6715

14

R6716

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. Usespecial care when traveling withoutload as the risk of overturn may begreater.

15

Travel with lifting mechanism as low aspossible. Always look in direction oftravel. Keep a clear view, and when loadinterferes with visibility, travel with loador lifting mechanism trailing.

R6718

R6719

Use special care when operating onramps; travel slowly and do not angle orturn. Travel unloaded with lifting mecha-nism downhill and travel loaded with loaduphill.

16

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

R6720

When using forks, space forks as farapart as load will permit. Before lifting,be sure load is centered, forks are com-pletely under load, and load is as farback as possible against load backrest.

R6721

17

R6722

Do not handle unstable or looselystacked loads. Use special care whenhandling long, high or wide loads toavoid losing the load, striking bystandersor tipping the truck.

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

R6723

18

R6724

Elevate forks or other lifting mech-anism only to pick up or stack aload. Lift and lower with mast inthe vertical position. Watch out forobstructions, especially overhead.

R6725

Do not lift personnel on forks or workplatform with this truck. It is not designedfor this function and someone could get seriously injured if they fell off. Use the correct equipment for this task.

19

Do not allow anyone tostand or pass under a loador lifting mechanism.

R6726

When leaving truck neutralize travelcontrol. Fully lower lifting mechanismand set brake. When leaving truckunattended also shut off power.

R6727

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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