Global Industrial Powered Pallet Truck

FOR OPERATION SAFETY

Please read and understand instructions carefully prior to assembling, installing, operating, or performing maintenance on the product. Be sure to observe all safety information. Failure to comply with instructions could result in personal injury and/or property damage. Retain instructions for future reference.

WARNING: Do not operate this truck unless you have been authorized and trained to do so, and have read all warnings and instructions in the operator manual and on this truck.

WARNING: 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. Do not carry passengers. Keep feet clear of truck and wear foot protection.

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.

Always look in the direction of travel. Keep a clear view, and when load interferes with visibility, travel with load trailing.

Take special care when operating on ramps - travel slowly, and do not travel in an angle or make turns. Travel with forks facing downhill.

Do not overload truck. Check nameplate for capacity 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, make sure the load is centered, forks are completely under load, and load is as far back as possible against load backrest.

When leaving the truck, neutralize travel control, fully lower the forks and set brake. When leaving truck unattended, also shut off power.

PROPOSITION 65 WARNING: In accordance with California Health & Safety Code Sections 25249.5 et. seq., this warning is to let you know that this product can expose you to chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. For more information visit: www.p65warnings.ca.gov

FOREWORD

As a lift truck operator, you are responsible for a machine that is useful, powerful, and can be hazardous if not operated as described. Your Global Industrial 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. Focusing on the task at hand 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 service manual for the specific truck model, and are to be performed only by a qualified technician. For further information on obtaining a complete parts and service manual, see page 23 of this manual.

The operator who knows his truck will learn to spot problems as they develop. This is accomplished by performing the Daily Checks and reporting any problems to the designated authority.

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.

Symbol: ⚠️

A Warning indicates a hazard which could result in injury or death if proper precautions 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.

Symbol: ?

GENERAL DESCRIPTION

Global Industrial 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 PLATE AND WARNING DECAL

Name plate and warning decal locations may vary between models, but they are always near the steering arm within sight of the operator.

If the name plate or warning decal are lost or damaged they should be replaced immediately. Have your supervisor or the designated authority contact Global Industrial Authorized Dealer for replacement.

The name plate shows the model number, serial number, and truck type. Battery type, with voltage and minimum weight, is shown along with 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.

Typical Name Plate and Warning Decal Locations:

• ITEM 1: Lifting Label
• ITEM 2: Charging Light Indicator
• ITEM 3: Global Logo
• ITEM 4: Warning Label
• ITEM 5: Key Label
• ITEM 6: Name Plate
• ITEM 7: Name Plate - UL Battery Info.
• ITEM 8: Forward - Reverse Label
• ITEM 9: No "Riding” Label

Truck Overview

• ITEM 1: Control Handle
• ITEM 2: Control Arm
• ITEM 3: Lift Cylinder
• ITEM 4: Drive Assembly
• ITEM 5: Emergency Stop Switch
• ITEM 6: Frame
• ITEM 7: Forks
• ITEM 8: Load Wheels

BATTERY HAZARD WARNING: This truck is equipped with a battery. Read and heed the following warning plus any other warnings located near or on the battery.

DANGER: EXPLOSIVE/POISON/CAUSTIC. NO SPARKS, FLAMES, SMOKING. BATTERY ACID can cause blindness and severe burns. SHIELD EYES, AVOID SKIN CONTACT. IF SPLASHED flush immediately 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. Check name plate for load weight capacity 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 centered between the forks. The maximum 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 wheelbase 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.

Load Center Diagram Description: The diagram shows a pallet truck with labels indicating 'FORK LENGTH' and '1/2 FORK LENGTH' to illustrate the concept of load center.

Name Plate Description: The name plate includes fields for MODEL NO., SERIAL NO., MAX CAP LB/KG, LOAD CTR IN/MM, LIFT HGT IN/MM, ALT CAP LB/KG, LOAD CTR IN/MM, LIFT HGT IN/MM, TRUCK WT LESS BATTERY LB/KG, BATTERY MIN WT LB/KG, TRUCK WT WITH BATTERY LB/KG, BATTERY MAX WT LB/KG, TRUCK TYPE, CERTIFIED BATTERY TYPE, VOLTAGE. It also states 'COMPLIES WITH THE APPLICABLE REQUIREMENTS OF ANSI/ITSDF B56.1 STANDARDS' and provides Global Industrial contact information.

BEFORE OPERATION

The table on page 10 covers important inspection points on trucks which should be checked prior to operation. Depending on use, some trucks may require additional checks. The illustration on page 10 shows a sample format for an Operator Check-List, which can be modified as necessary to fit your operation.

WARNING: Periodic maintenance of this truck by a QUALIFIED SERVICE TECHNICIAN is required.

WARNING: A QUALIFIED SERVICE TECHNICIAN should check the truck.

WARNING: If the truck is found to be unsafe and in need of repair, or contributes to an unsafe condition, report it immediately to the designated authority. Do not operate it until it has been restored to a safe operating condition. Do not make any unauthorized repairs or adjustments. All service must be performed by a qualified service technician.

Sample of Operator Check List

Date: __________ Operator: __________

Truck No.: __________ Model No.: __________

Dept.: __________ Shift: __________

Hour Meter Reading - Drive: __________ Hoist: __________

Operator Checks

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 all models have a "belly-button” reversing switch which reverses the direction of the truck upon contact with the operator.

Display Unit

• The LED display (1) shows the residual battery capacity, when it's lower than 20% it must be charged.
• When the display (2) shows “NO BMS" the communication with the battery is disconnected and when it shows "BMS EER” the battery temperature or voltage is unbalanced.
• When display (3) is solid On the interlock switch is open. when flashing the interlock switch is closed and the running time will start.
• The display (4) will normally show the total running time however if there is a fault code on the truck it will be displayed here.

The display unit has a range between 0 to 99999 hours and it will log hours when traveling or lifting.

The battery discharge indicator has a memory function. It will display the state of charge (SOC) stored in memory, until a full charge cycle has been completed, and the battery SOC reset threshold is exceeded.

Low Voltage Protection

When the battery power is low the Low Voltage Protection will prevent the forks from being raised and you must charge battery.

Control Handle - Top Description:

Diagram shows the top of the control handle with labels for Horn Button, Emergency Rev. Switch, Travel Switch, Lift Button, and Lowering Button.

Control Handle - Back Description:

Image shows the back of the control handle with two red "Turtle" buttons. Instructions state that holding down one of these buttons while activating the accelerator allows the truck to move in the desired direction with the steer handle in the upright position, aiding maneuverability in tight spaces.

OPERATION

Driving Instructions

1. Turn the key to turn the truck on or off.

2. Tilt the steering arm to the travel position.

3. Turn the travel switch to move forward or reverse.

Forward and Reverse Travel and Speed Control

All directional and speed controls are located on the control handle. Forward and reverse are controlled by rotating the speed control lever. The lever is spring loaded to return to neutral when released. Further rotation in either direction will progress the truck from slow to maximum 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 connects 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

Stop the truck as gradually as possible. Unnecessary rapid stopping could be hazardous. Load could become unstable.

To stop the truck's movement (forward or reverse), raise the control handle to the up position or push the control handle all the way down. In both positions, the brake will apply. To release the brake, just move the control handle to the operating position.

NOTE: The steering arm gas spring automatically raises the steering arm to the upright position when the steering arm is released.

CAUTION: If the control handle does not raise immediately to the vertical position when released, the truck should be placed "OUT OF SERVICE" until it can be inspected by a qualified service technician.

Parking

When parking the truck, do not obstruct traffic lanes or aisles.

1. Park the truck in its designated parking area.
2. Raise the steering arm until vertical to apply parking brake.
3. Fully lower forks.
4. Remove the key from the keyhole.
5. On the 989069 push the red disconnect plunger to remove all power from the truck circuits.

Steering Arm Braking Positions Description: Diagrams illustrate the steering arm in different positions indicating brake application.

Load Handling

Handle only loads arranged for stability and always use caution. Raise and lower the load smoothly to prevent the load from falling.

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 truck slowly into position so that the forks are within pallet or skid, and the load is centered over the forks and as far back as possible.
3. Push the button to raise the forks and lift the load.
4. Lead the truck by the control handle 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 standing off to side of truck.
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 follow the turn path of the drive wheel. Instead they tend to cut the corner.
8. Line up the truck with the unloading 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 by pushing the lowering button 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.

Battery Charging

WARNING: Before removing the battery make sure that the truck is completely powered down.

WARNING: Before installing the battery make sure that the truck key is not on.

Using internal charger

Proceed as follows:

1. Park truck at charging station with forks lowered and turn the key switch off.
2. Check the condition of the AC cord. If there are any cuts in the cable, any exposed wires, loose plugs or connectors, DO NOT attempt to charge the batteries. Contact appropriate personnel for repairs to be made.
3. Pull the charger cord (1) out of the top cover and connect to the appropriate power supply.

Internal Battery Charging Description: Diagram shows the charger cord (1) and power supply connection (2).

Charger LED Status Indicator

Operating Instructions from Warning Decal

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

Description: Image of a person operating the pallet truck with a warning symbol indicating "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."

Description: Image of a person inspecting the pallet truck with a warning symbol indicating "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 questions, notify your supervisor or proper authority."

Walkie Pallet Trucks: Operate truck only from walking position.

Description: Image of a person operating a walkie pallet truck with a prohibition symbol over a person riding on it, indicating "Walkie Pallet Trucks: Operate truck only from walking position."

Wear foot protection and keep feet clear of truck.

Description: Image of a person operating the pallet truck, with a prohibition symbol over their feet being near the truck, indicating "Wear foot protection and keep feet clear of truck."

Do not carry passengers.

Description: Image of two people on the pallet truck with a prohibition symbol, indicating "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 obstructed.

Description: Image of a person falling off the pallet truck due to an obstructed view at an aisle intersection, with a prohibition symbol, illustrating the danger of not observing traffic regulations.

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.

Description: Image of a person operating the pallet truck on a slippery surface with a prohibition symbol, illustrating the risk of overturn.

Always look in direction of travel.

Keep a clear view, and when load interferes with visibility, travel with load or lifting mechanism trailing (except when climbing ramps).

Description: Image of a person operating the pallet truck with a load that obstructs their view, showing them trailing the load.

Use special care when operating on ramps; travel slowly, and do not angle or turn.

Travel with lifting mechanism downhill.

Description: Image of a person operating the pallet truck on a ramp with a prohibition symbol, illustrating the danger of angling or turning on a ramp.

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.

Description: Image of a person operating the pallet truck with an unsecured, high load that is about to fall, with a prohibition symbol.

Before lifting, be sure load is centered, forks are completely under load, and load is as far back as possible against load backrest.

Description: Image of a person operating the pallet truck with an improperly positioned load, with a prohibition symbol.

Keep hands out of lifting mechanism.

Description: Image of hands being near the lifting mechanism of the pallet truck with a prohibition symbol.

When leaving truck neutralize travel control.

Fully lower lifting mechanism and set brake. When leaving truck unattended also shut off power.

Description: Image of a person walking away from the pallet truck after properly parking it.

NOTICE - OBTAINING A PARTS AND SERVICE MANUAL

A complete parts and service manual covering this truck is available from Global Industrial.