WALKIE POWERED PALLET TRUCK
Contents
1. Stop the truck as gradually as possi de energizes the controls ble Unnecessary rapid stopping could 3 Steering arm in vertical posi be hazardous Load could become tion Raising the steering arm to unstable near vertical position applies brake pad pressure to the brake EE EO PD Wave TO SIOP disc Further vertical positioning the truck increases the braking force and 1 Plugging This electrical braking de energizes the controls This function consists of rotating the position services as a parking speed control lever in the oppo brake As a safety precaution the site direction of travel and then steering arm is spring loaded to releasing it when the truck stops return to the vertical position in Plugging is a convenient way to the event the driver releases the stop the truck during normal control handle during operation operation If the control is not This is Known as deadman brak released the truck will accelerate ing in the opposite direction l 2 Steering arm in horizontal Parang position Lowering the steering When parking the truck do not arm to the horizontal position obstruct traffic lanes or aisles applies brake pad pressure to the 1 Park the truck in its designated brake disc Lowering the steering l ik parking area arm below the horizontal position CONTROLS ARE ENERGIZED MECHANICAL BRAKE STARTS TO ENGAGE CONTROLS ARE DE ENERGIZED MECHANICAL BRAKE IS ENGAGED CONTROLS ARE ENERGIZED MECHAN2. or comnecior damage High speed limit switch Allow for enough space to operate truck in high speed Disengage third speed using the high speed cut out switch then test drive truck to check if high speed is cut out INSTRUMENTS AND CONTROLS The steering arm and control handle provide controls for steering forward and reverse speed control braking raising and lowering the forks and horn Control handles on some mod els have the high speed cut out switch Control handles on all models have a belly button reversing switch which reverses the direction of the truck upon contact with the operator REVERSE SPE CONTROL LEVER ALL MODELS STEER LEFT LIFT ALL MODELS HORN ALL MODELS BELLY BUTTON REVERSING SWITCH ALL MODELS LOWER ALL MODELS Detailed operating instructions are in the Operation section of this manual A battery disconnect is mounted near the steering arm Pulling the discon nect removes all power from truck cir cuits in the event of an emergency HIGH SPEED CUT OUT FORWARD SPEED CONTROL LEVER ALL MODELS _ Control Handle Walkie Rider Pallet Trucks have a grab handle which also contains lift lower and horn controls Optional Features The optional battery capacity indica tor hour meter and keyswitch mount on the panel near the control handle The battery capacity indicator moni tors the battery discharge rate to indi cate the remaining bat
3. 30 BIGJOE WALKIE POWERED PALLET TRUCK 5 00 WARNING DO NOT OPERATE THIS TRUCK UNLESS YOU HAVE BEEN TRAINED AND AUTHORIZED TO DO SO AND HAVE READ ALL WARNINGS AND INSTRUCTIONS IN OPERATORS MANUAL AND ON THIS TRUCK DO NOT OPERATE THIS TRUCK UNTIL YOU HAVE CHECKED ITS CONDITION GIVE SPECIAL ATTENTION TO TIRES HORN BATTERY CONTROLLER LIFT SYSTEM BRAKES STEERING MECHANISM GUARDS AND SAFETY DEVICES OPERATE TRUCK ONLY FROM DESIGNATED OPERATING POSITION WEAR FOOT PROTEC TION DO NOT CARRY PASSENGERS OBSERVE APPLICABLE TRAFFIC REGULATIONS YIELD RIGHT OF WAY TO PEDESTRIANS SLOW DOWN AND SOUND HORN AT CROSS AISLES AND WHEREVER VISION IS OB STRUCTED 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 ALWAYS LOOK IN DIRECTION OF TRAVEL KEEP ACLEAR VIEW AND WHEN LOAD INTERFERES WITH VISIBILITY TRAVEL WITH LOAD OR LIFTING MECHANISM TRAIL ING USE SPECIAL CARE WHEN OPERATING ON RAMPS TRAVEL SLOWLY AND DO NOT ANGLE OR TURN TRAVEL WITH LIFTING MECHANISM DOWNHILL DO NOT OVERLOAD TRUCK CHECK CAPACITY PLATE FOR LOAD WEIGHT AND LOAD CENTER INFORMATION DO NOT HANDLE LOADS WHICH ARE HIGHER THAN THE LOAD BACKREST OR LOAD BACKREST EXTENSION UNLESS LOAD IS SECURED SO THAT NO PART OF IT COULD FALL BACKWARD BEFORE LIFTING BE SUR
4. E LOAD IS CENTERED FORKS ARE COMPLETELY UNDER LOAD AND LOAD IS AS FAR BACK AS POSSIBLE AGAINST LOAD BACKREST WHEN LEAVING TRUCK NEUTRALIZE TRAVEL CONTROL FULLY LOWER LIFTING MECHA NISM AND SET BRAKE WHEN LEAVING TRUCK UNATTENDED ALSO SHUT OFF POWER FOREWORD As a lift truck operator you are responsible for a machine that is use ful powerful and can be hazardous if not operated as described Your Big Joe truck may weigh more than some cars depending on the model Observing and practicing the safety warnings in this manual cannot be overemphasized Just knowing the warnings however is no substitute for common sense Using your common sense will in almost all cases prevent accidents Think of the truck as your own In this way you will learn its capabilities and limitations This manual is intended to remain with the truck at all times as a handy reference guide to operation Detailed maintenance procedures are found in the parts and service manual for the specific truck model and are to be performed only by a qualified techni cian For further information on obtaining a complete parts and ser vice manual see page 21 of this man ual The operator who knows his truck will learn to spot problems as they develop This is accomplished by per forming the Daily Checks and report ing any problems to the designated authority TABLE OF CONTENTS MFT TE Le 2 GENERAL BESCRIFTION neigen 2 NAME PLATE AND WAR
5. G If the truck is found to be unsafe and in need of repair or con tributes to an unsafe condition report it immediately to the des ignated authority Do not oper ate it until it has been restored to a safe operating condition Do not make any unauthorized repairs or adjustments All ser vice must be performed by a qualified maintenance techni cian Electric Truck Daily Operator Check Off List Hydraulic Leaks Cylinders Valves Hoses Etc Sample of Operator Check List Operator Checks ITEM PROCEDURE Transmission and hydraulic Check for signs of fluid leakage systems Check for cracks and damage and not damaged are in good condition and legible 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 and tilt to ees mann pollen oO 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 ME on when released and brake apples Battery disconnect Check that battery can be disconnected and remera Check
6. ICAL BRAKE IS DISENGAGED CONTROLS ARE ENERGIZED MECHANICAL BRAKE STARTS TO ENGAGE CONTROLS ARE DE ENERGIZED SIDE VIEW MECHANICAL BRAKE IS ENGAGED Steering Arm Braking Positions 10 2 Raise the steering arm until verti cal to apply the parking brake 3 Fully lower forks 4 Turn keyswitch if so equipped to off position Remove key for added security 5 Pull out battery disconnect Battery Charging Refer to DOC 245 for battery safety and maintenance 7 AD JAN ICE TET BR A BATTERY win Ly z m EXPLOSIVE POISON CAUSTIC NO SPARKS FLAMES SMOKING BATTERY ACID can cause blindness and severe b 7 A 7 SHIELD EYES AVOID SKIN CONTACT IF SPLASHED flush immediatly with water get medical help fast Do not s e batter nn charge ttery from orem Don or dis charger while charger On Dan a er ee nn ko nel uld perfor nee repai ho ae tion while servicing or removing battery gt mi Refer to Battery Safety Sheet S A NOTE Battery charging instructions are contained in the service manual Load Handling AN WARNING Handle only loads arranged for stability and always use cau tion Raise and lower the load smoothly to prevent the load from falling A N WARNING Always be sure the load and load center are within the capacity of the truck If in doubt check the nameplate 1 Approach the load slowly 2 Move the truc
7. NING DECAL nernnnernnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennn 2 Ke re Ne EE EN DEFORE DPERATION sitter einen 5 OIEA FAR a tada 8 INSTRUMENTS AND CONTROLS u 7 FEO al Pe AA 8 ear a aia NN 9 Forward and Reverse Travel and Speed Control 2 2022002200 9 ii ios 9 ge A RE 10 A A 10 Ben Gar ascii iii 11 LOMO FAROS erario 11 Moving a Disabled Truck eiii een 11 NOTICE OBTAINING A PARTS AND SERVICE MANUAL ennnnnrnnnnnnnnnvnnnnnener 21 SAFETY SYMBOLS WARNING and CAUTIONS 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 Joe Pallet trucks lift and transport loads on rigid forks Control for steering braking forward and reverse travel horn lift lower and speed control are all located on the control handle Trucks in this series may vary in load Capacity battery arrangement and instrumentation depending on model and options NAME
8. PLATE AND WARNING DECAL Name plate and warning decal loca tions may vary between models but they are always near the steering arm within sight of the operator If the name plate or warning deal are lost or damaged they should be replaced immediately Have your supervisor or the designated authority contact Big Joe Authorized Dealer for replacement The name plate shows the model number serial number truck type battery type voltage and minimum weight It also contains information on the load capacity and load center The warning decal contains warnings which also appear with illustrations in the Operating Precautions section of this manual WARNING DECAL NAME Name Plate and Warning Decal Locations Typical AN WARNING This truck is equipped with a battery Read and heed the warning decal located near the battery An example is shown here BATTERY HAZARD AD JAN NGE GER EXPLOSIVE POISON CAUSTIC NO SPARKS FLAMES SMOKING BATTERY ACID can cause blindness and severe burns SHIELD EYES AVOID SKIN CONTACT IF SPLASHED flush immediatly with water get medical help fast Do not service battery while on charge Do not connect or disconnect battery from charger while charger is on Only qualified and experienced personnel should perform maintenance and repair on batteries Use caution while servicing or removing battery Refer to Battery Safety Sheet LOAD CAPACITY Do not overload truck Ch
9. ained in this operator s manual and on this truck Do not operate this truck until you have checked its condition Give special attention to tires horn battery controller lift sys tems brakes steering mecha nism guards and safety devices If you have any ques tions notify your Supervisor or proper authority 12 0 a 2 Q O Y 6 S 2 j jad A Q x truck only from walking position Trucks Pallet Walkie Rider Keep feet within limits of truck 3 1 OD E f O O O Sa oa f O O q pun keep feet clear of truck Do not carry passengers 4 1 Observe applicable traffic regulations Yield right of way to pedestrians Slow down and sound horn at cross aisles and wherever vision is obstructed 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 R4077 15 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 Use special care when operating on ramps travel slowy and do not angle or turn Travel unloaded with lifting mechanism downhill and travel loaded with load uphill 16 Do not handle loads which a
10. eck capacity plate for load weight and load center information The load capacity depends on the load center The load maximum capacity listed on the capacity plate assumes a uniform load whose center is 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 length of the forks or is not centered between the forks The fork length and wheel base must be adequate for the skid or bin to be handled Note that a truck undergoing speed changes is less stable than a standing truck If you are not sure that the truck can lift a certain load consult your supervisor or the designated authority R5060 a Length of Forks 1 2 Length y je A or JU Load Center BEFORE OPERATION The table on page 6 covers important inspection points on trucks which should be checked prior to operation Depending on use some trucks may require additional checks The illustration below shows a sample format for a Operator Checklist which can be modified as necessary to fit your operation A N WARNING Periodic maintenance of this truck by a QUALIFIED TECH NICIAN is required A N WARNING A QUALIFIED SERVICE TECHNICIAN should check the truck monthly for proper lubrica tion proper fluid levels brake maintenance motor mainte nance and other areas speci fied in the parts and service manual maintenance section AN WARNIN
11. k slowly into posi tion so that the forks are centered about the load 3 Make sure the load is against the backrest and then raise the forks until the pallet clears the rack 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 obstructions 6 Do not make sudden starts and stops Operate truck smoothly and gradually 7 Travel slowly and squarely around corners Remember that the trailing load wheels do not fol low the turn path of the drive wheel Instead they tend to cut the corner 8 Line up the truck with the unload ing area 9 Stop the truck and check the load alignment with surrounding objects 10 Be careful not to damage or move adjacent loads and objects 11 Lower the forks until the load is resting on its own 12 Move the truck back until the forks are clear of the pallet Moving a Disabled Truck Do not attempt to move a disabled truck notify your supervisor or proper authority 11 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 warn ings and instructions cont
12. re higher than load backrest or load backrest extension unless load is secured so that no part of it could fall backward Before lifting be sure load is centered forks are completely under load and load is as far back as possible against load backrest 17 Keep hands out of lifting mechanism When leaving truck neutralize travel con trol Fully lower lifting mechanism and set brake When leaving truck unat tended also shut off power 18 NOTES 19 NOTES 20 NOTICE OBTAINING A PARTS AND SERVICE MANUAL A complete parts and service manual covering this truck is available from Big Joe Manufacturing Company To order obtain the serial number of your truck and con tact your Big Joe Authorized Dealer 21 23 24 25
13. tery capacity The hour meter records the accumu lated hours that electrical energy is being drawn from the battery to run the pump and drive motors The key switch provides added security to the truck preventing unauthorized per sonnel from operating the machine Grab Handle OPERATION Forward and Reverse Travel and Speed Control REVERSE SPEED CONTROL LEVER ALL MODELS STEER LEFT LIFT ALL MODELS HORN ALL MODELS BELLY BUTTON REVERSING SWITCH ALL MODELS LOWER ALL MODELS R4070 HIGH SPEED CUT OUT pe RIGHT S CONTROL LEVER ALL MODELS Control Handle All directional and speed controls are located on the control handle Forward and reverse are controlled by rotating the speed control lever as shown The lever is spring loaded to return to neutral when released Fur ther rotation in either direction will progress the truck from slow to maxi mum travel speed To change directions or to stop the truck rotate the speed control lever in the opposite direction The truck will come to a stop and then unless the controls are returned to the center neutral position accelerate in the opposite direction Steering Moving the control handle which con nects to the steering arm 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 increases the braking force and
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