POWERED PALLET TRUCKMODEL 988993

Global Industrialglobalindustrial.com

Manual Part No. 988993M

08/16/2018

PROPOSITION 65

WARNING

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

FOREWORD

As a lift truck operator, you areresponsible for a machine that is use-ful, powerful, and can be hazardous ifnot operated as described. YourGlobal Industrial truck may weighmore than some cars, depending onthe model. Observing and practicingthe safety warnings in this manualcannot be overemphasized. Justknowing the warnings, however, is nosubstitute for common sense. Focus-ing on the task at hand will, in almostall cases, prevent accidents. Think ofthe truck as your own. In this way youwill learn its capabilities and limita-tions.

This manual is intended to remainwith the truck at all times as a handyreference 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 23 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 ..............................................................................................4

GENERAL DESCRIPTION....................................................................................4

NAME PLATE AND WARNING DECAL ...............................................................4

LOAD CAPACITY..................................................................................................7

BEFORE OPERATION ..........................................................................................8

INSTRUMENTS AND CONTROLS .....................................................................10

OPERATION ........................................................................................................11Forward and Reverse Travel and Speed Control ...............................11Steering..................................................................................................11Stopping.................................................................................................12Parking ...................................................................................................12Battery Charging ...................................................................................13Load Handling .......................................................................................13Moving a Disabled Truck ......................................................................13BATTERY SAFETY AND MAINTENANCE ............................................21

NOTICE - OBTAINING A PARTS AND SERVICE MANUAL..............................23

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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

Global Industrial Pallet trucks lift andtransport loads on rigid forks.

Control for steering, braking, forwardand reverse travel, horn, lift, lower andspeed control are all located on thecontrol handle.

Trucks in this series may vary in loadcapacity, battery arrangement, andinstrumentation, depending on modeland options.

NAME PLATE AND WARNING DECAL

Name plate and warning decal loca-tions may vary between models, butthey are always near the steering armwithin sight of the operator.

If the name plate or warning decal arelost or damaged they should bereplaced immediately. Have yoursupervisor or the designated author-ity contact Global Industrial Autho-rized Dealer 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, inthe Operating Precautions section ofthis manual.

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988993 Name Plate and Warning Decal Locations

Pos. Description

1 Do not ride on truck

2 Lifting Point

3 Direction Decal on Control Handle

4 Emergency Switch Decal

5 Name Plate

6 Key Switch On / Off Decal

R8501-A

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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:

WARNING:

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LOAD CAPACITY

Do not overload truck. Check nameplate for load weight capacity and loadcenter information.

The load capacity depends on theload center. The load maximumcapacity listed on the capacity plateassumes a uniform load whose centeris 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 lengthof the forks or is not centered betweenthe forks. The fork length and wheel-base must be adequate for the skid orbin to be handled.

Note that a truck undergoing speedchanges is less stable than a standingtruck. If you are not sure that the truckcan lift a certain load, consult yoursupervisor or the designated authority.

Load Center

R8502

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BEFORE OPERATION

The table on page 9 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 TECH-NICIAN should check the truck

monthly for proper lubrication,proper fluid levels, brake main-tenance, motor maintenanceand other areas specified in theparts and service manual main-tenance section.

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 qualifiedmaintenance technician.

Sample of Operator Check List

WARNING:

WARNING:

WARNING:

R6235GL

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Operator Checks

ITEM PROCEDURE

Transmission and hydraulic systems

Check for signs of fluid leakage.

Forks Check for cracks and damage.

Guards and load backrest Check that safety guards are properly 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 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.

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INSTRUMENTS AND CONTROLS

The steering arm and control handleprovide controls for steering, forwardand reverse speed control, braking,raising and lowering the forks, and

horn. Control handles on all modelshave a “belly-button” reversing switchwhich reverses the direction of thetruck upon contact with the operator.

Control Handle

Pos. Description

11 Battery Discharge Indicator - BDI

12 Key Switch

13 Lowering Button

14 Lifting Button

15 Directional / Speed Control

16 Horn Button

17 Reversing Switch - Belly Button Switch

R8503

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OPERATION

Forward and Reverse Travel and Speed Control

Control Handle

All directional and speed controls arelocated on the control handle.

Forward and reverse are controlled byrotating the speed control lever in thedesired direction. The lever is springloaded to return to neutral whenreleased. Further rotation in eitherdirection will progress the truck fromslow to maximum 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.

R8504

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Stopping

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

To stop the truck’s movement (forwardor reverse), raise the control handle tothe up position or push the control han-dle all the way down. In both positions,the brake will apply. To release thebrake, just move the control handle tothe operating position.

NOTE: The steering arm gas springautomatically raises the steer-ing arm to the upright positionwhen the steering arm isreleased.

CAUTION: If the control handle doesnot raise immediately to

the vertical position whenreleased, the truck shouldbe placed “OUT OF SER-VICE” un t i l i t can beinspected by a qualifiedservice technician.

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 verticalto apply the parking brake.

3. Fully lower forks.

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

5. Push the red disconnect plunger.

Steering Arm Braking Positions

R8505

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Battery Charging

Refer to page 21 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. Move the truck slowly into posi-tion so that the forks are withinpallet or skid, and the load is cen-tered over the forks and as farback as possible.

3. Raise the forks to lift load.

4. 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 standing off to sideof truck.

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

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

7. 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.

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

9. Stop the truck and check the loadalignment with surrounding objects.

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

11. Lower the forks until the load isresting on its own.

12. Move the truck back until theforks are clear of the pallet.

Moving a Disabled Truck

Do not attempt to move a disabledtruck; notify your supervisor or properauthority.

WARNING:

WARNING:

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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 and on this truck.

R8848

R8489

Do not operate this truck untilyou have checked its condition.Give special attention towheels, horn, battery, controller,lift systems, brakes, steeringmechanism, guards and safetydevices. If you have any ques-tions, notify your supervisor orproper authority.

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R8490-A

Walkie Pallet Trucks: Operatetruck only from walking position.

R8491-A

Wear foot protection andkeep feet clear of truck.

15

R8492

Do not carry passengers.

R8493

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

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R849

Start, stop, travel, steer and brake smoothly. Slow down for turns and onuneven or slippery surfaces that could cause truck to slide or overturn. Usespecial care when traveling without load as the risk of overturn may begreater.

R8495

Always look in direction of travel. Keep aclear view, and when load interferes withvisibility, travel with load or lifting mecha-nism trailing (except when climbingramps.

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R8496-A

Use special care when operating on ramps; travel slowly, and do not angleor turn. Travel with lifting mechanism downhill.

R8497

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

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R8498

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

Keep hands out of lifting mechanism.

R8499

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When leaving truck neutralize travel con-trol. Fully lower lifting mechanism andset brake. When leaving truck unat-tended also shut off power.

R8500

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ALL MODELSSUPPLEMENT

BATTERY SAFETY AND MAINTENANCE

CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

WARNING

Gases produced by a battery can be explosive. Do not smoke, use an open flame, create an arc or sparks in the vicin-ity of the battery. Ventilate area well when servicing and when charging. Batteries contain sulfuric acid which may cause severe burns. Avoid contact with eyes, skin, or clothing.In case of contact, flush immediately and thoroughly with large amounts of clean water. Remove contaminated clothing. Obtain medical attention. In case of spills, dilute spill cautiously with five to six vol-umes of water and gradually neutralize with lime, soda ash or baking soda. For waste disposal consult Federal, State and Local Regulations.

BATTERY TYPE

The batteries in your lift truck are consid-ered a maintenance free type. Mainte-nance free batteries do not have removable vent caps and should never be opened in any way or the battery will be permanently damaged or destroyed.

SAFETY RULES

Wear protective clothing, such as, rubberapron, gloves, boots and goggles whenperforming any maintenance on batteries.Do not allow electrolyte to come in contactwith eyes, skin, clothing, or floor. If electro-lyte comes in contact with eyes, or skinflush thoroughly with large amounts ofclean water, remove contaminated cloth-ing and obtain medical help immediately.

• Keep vent plugs firmly in place at alltimes.

• Do not bring any type of flame, spark,etc., near the battery. Gas formed whilethe battery is charging, is highly explo-sive. This gas remains in the cells longafter charging has stopped.

• Do not lay metallic or conductive objectson battery. Arcing may result.

• Do not allow dirt, cleaning solution, orother foreign material to enter cells.Impurities in electrolyte has a neutraliz-ing effect reducing available charge.

• Observe any battery safety decal orother safety decals that are on your lifttruck

BATTERY CARE

The care and maintenance of your batteryis very important to obtain maximum effi-ciency from the battery charge and obtainmaximum battery life.

CAUTION

Only qualified and experienced personnelshould perform maintenance and repair onbatteries.

Cleaning (Follow Safety Rules at all Always keep vent plugs in place when cleaning battery. When the batteries are discharged and charged correctly, they should remain clean and dry. All that is necessary is to brush or blow off any dust or dirt which may accumulate on the bat-tery. However, if electrolyte is spilled or overflows from the cell, dilute spill cau-tiously with five to six volumes of water and gradually neutralize with lime, soda ash or baking soda. To do this, remove battery from truck and clean with the solu-tion of soda and water, brushing the soda

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solution to get the solution beneath the connectors and removing grime from the covers. Then rinse the battery with cool water from a low pressure supply to remove the soda and loosened dirt. If bat-teries stay wet consistently, they may be either overcharged or overfilled. This con-dition should be investigated by a qualified and experienced maintenance personnel and corrected.

WARNING

Never smoke or bring flames near the bat-tery. Gas formed during charging is highlyexplosive and can cause serious injury.

Charging requirements will vary depend-ing on use of truck. Monitor the batteriesdischarge state with the discharge indica-tor gage on the truck. Avoid using or stor-ing the truck at full discharge, whichshortens battery life. However repeatedpartial charging will also reduce batterylife. Using the truck until 80% dischargedand then fully charging the batteries to100% charged will help ensure maximumoutput for the life of the batteries.

Follow safety rules when placing a batteryon charge. Proceed as follows:

1. Park truck at a charging station withforks lowered and key switch off.Make sure area is well ventilated andnot near any open flame or anythingthat could cause a spark.

2. Check the condition of the AC cord. Ifthere are any cuts in the cable, anyexposed wires, loose plugs or con-nectors, DO NOT attempt to chargethe batteries. Contact a supervisor orappropriate personnel for repairs tobe made.

3. Connect AC cord to AC powersource. The charger will cycle auto-matically (charges the batteries,depending on amount of chargeneeded). Fully charged batteries willread accordingly on the truck's bat-tery discharge indicator gage.

4. Once fully charged disconnect ACplug, wind up or stow (as needed) theAC plug and coiled cable to preventany damage.

BATTERY REMOVAL(Follow Safety Rules at all times)

CAUTION

Only qualified and experienced personnelshould perform maintenance and repair onbatteries.

WARNING

Extreme care must be used when remov-ing a battery from a lift truck. Contactbetween battery terminals and metal com-ponents of the truck or removal equipmentcan cause a short circuit resulting in a bat-tery explosion.

WARNING

Make certain the same type of batteriesare installed in the truck. Also make cer-tain the batteries are of similar weight tothe original batteries to ensure compara-ble performance. See nameplate for mini-mum and maximum battery weights.

CAUTION

Batteries are very heavy, use cautionwhen lifting.

1. Use a non-conductive battery sling toremove battery.

WARNING

Use of non-insulated hooks or chains maycause a spark or explosion, if those hooksor chains come in contact with the batteryterminals or posts.

1. When lifting the battery out, do notallow any metallic object to come incontact with battery cells or posts.

2. When disconnecting battery cables,Use extreme caution to prevent toolsfrom shorting against terminals andfrom positive and negative cablesfrom coming in contact with eachother.

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NOTICE - OBTAINING A PARTS AND SERVICE MANUAL

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

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