TECHNICAL MANUAL
WALKIE RIDER
TRUCK
MODEL WRT-40 AND
WRT-60 SERIES LIFT TRUCKS

PREPARATION FOR USE

Remove cardboard banded to forks. Check truck for scratches and dents. Inspect for oil leaks and loose wiring connections.
Before the truck is moved, the battery must be checked, recharged if necessary, and connected. If the truck was ordered without a battery, a freshly charged battery of adequate size and proper weight must be installed. Refer to para. 3-5, Battery Care, in Section III for battery checking instructions. Connect battery quick-disconnect plug to receptacle located near battery on the frame of the truck.

Refer to section II for operating instructions to test the following controls:

Steering Arm Return Spring
FORWARD Speed Control
REVERSE Speed Control
Belly-Button Guard
Grab Handle Controls
Lift Controls
Lower Controls
Dynamic Brake Controls
High-Speed Switch

If you do not obtain the proper results, or improper operation occurs, refer to “Troubleshooting” and “Repair” in Section III. The adjustment and repair procedures are supplemented with illustrations and part lists. All parts identification illustartions have been integrated with the text rather than separated into a separate section.

______________________________________________________________

NOTE: This Manual has been updated to reflect the latest changes for the WRT-40 and WRT-60. Revisions have been footnoted on the pages where the revisions have been made.

Figure 1-1. Walkie Rider Truck (WRT-40 and WRT-60)

SECTION I
DESCRIPTION

1-1. INTRODUCTION. (Figure 1-1)
This manual describes the Walkie Rider Truck (Models WRT-40 and WRT-60) manufactured by Big Joe Manufacturing Company, Linkcolnwood, Illinois 60646. The WRT truck (figure 1-1) is described in detail, with instructions for operation, lubrication, adjustment, and repair.

By following the recommendations contained in this manual, you will receive many years of dependable service from your truck.

1-2. DESCRIPTION.

1-3. General.

The WRT truck efficiently lifts and moves heavy pallet-mounted loads. By using the simple steering arm and pushbutton/rocker switches located in the control head as well as the pushbuttons on the grab handle, the operator moves, stops the truck and operates the lift/lower mechanism in both the walking and riding modes of operation.

The battery-powered truck operates quietly and without exhaust fumes, allowing operation in closed areas without special provisions for ventilation. This manual covers trucks having 12-volt or 24-volt electrical systems.  

1-4. Capabilities.

The lifting of the truck is 4000 pounds for the WRT-40 and 6000 pounds for the WRT-60. The main difference in the construction of these models is in the electrical panel, the WRT-60 using larger electrical contactors. Both models are actuated by either a 12-volt battery-powered hydraulic system or a 24-volt system. The lift height of the forks is 9 inches.
1-5. Safety Features.

This Truck is designed and engineered to provide maximum safety for operator and payload. Some of the safety for operator and payload. Some Some of the safety features incorporated into the design are:

•Steering arm automatically applies brake and cuts-off drive power when released.
•Belly-button reverses the motion of the truck switch should the operator accidentally pin himself against a wall or obstruction when backing up in the walking mode of operation.
•Skid-resistant operators platform.
•Externally accessible quick disconnect battery plug.
•Separately fused control circuits and power circuits.
•Horn.
•High Speed Pushbutton switch on 24-volt systems to control high speed when in the walking mode. 
•All control functions are operable with either hand and are accessible without removing hands from the steering arm when walking and the steering arm and the grab handle when riding.

SECTION II
OPERATION

2-1. GENERAL.

This section gives detailed operating instructions for the Walkie Rider Truck. The instructions are divided into the various phases of operations, such as operating lift, traveling, and stopping. Precautions are included to highlight safe operation.

2-2. OPERATING PRECAUTIONS.

Improper operation may result in operator injury, or damage to the truck and/or load. Observe the following precautions when operating the truck.

1.Do not exceed the rated capacity. Overloading may result in damage to the hydraulic, electrical and structural components.
2. Do not pick up loads on the tips of the forks.
3. Pick up loads on both forks. Do ot pick up loads on only one fork.
4. Use care when moving a load. Driving the truck too quickly around a turn may upset the balance of the load.
5. Apply the mechanical brake gently except in case of emergency.
6. Observe all operating precautions indicated on the trucks WARNING DECAL.

2-3. OPERATION.

The Walkie Rider Truck is operated from a walking position or a riding position. In the walking mode of operation, all controls needed by the operator to safely and efficiently maneuver truck and load have been designed into the control head at the end of the steering arm. In the riding mode of operation, the steering arm is used to start and stop the truck and to steer the truck, and the grab handle controls are used to brake, use the horn, control high speed, and lift or lower the backrest/fork assembly.

2-4. Steering Arm Controls. (Figure 2-1)

The switch boxes, which are located on both sides of the control head, have parallel controls to allow operation from either side. Each box has a dynamic brake, horn, and lift and lower pushbutton switches. The control head contains the forward/reverse speed control, the belly-button guard, and the high speed switch on 24 volt systems. Figure 2-1, steering Arm Controls, illustrates the controls , and Table 2-1 lists their functions.

Figure 2-1. Steering Arm Controls   

Table 2-1. Steering Arm Controls

2.5. Grab Handle Controls. (Figure 2-2)

The switches are located on the grab handle are used to control truck functions in the riding mode of operation. The switch box contains the dynamic brake, horn, high speed, lift and lower pushbuttons. Figure 2-2, lists their functions.

 
Figure 2-2. Grab Handle Controls 

Table 2-2. Grab Handle Controls

2-6. Starting and Driving

The speed control (see figure 2-1) located on the control head provides fingertip control for driving the truck. As the upper portion of the speed control is pressed, it actuates microswitches for first speed and forward direction. Pressing the speed control farther actuates a switch for second speed and further pressure actuates a switch for third speed. On trucks with 24 volt electrical systems, the third speed is controlled by a High Speed pushbutton switch. These trucks will not switch into third speed unless the pushbutton switch is held in the depressed position. Release of the High Speed pushbutton will cause the truck to switch back to second speed regardless of the position of the speed control. The lower portion of the speed control governs speeds in the same manner on 24 volt systems and three reverse speeds on 12 volt systems.

The grab handle controls (see figure 2-2) provide fingertip control for driving the truck in the rider mode of operation. The starting of the truck in forward or reverse, as well as the steering of the truck, is done with the speed control and the control head similar to the walking mode, High speed selection, dynamic braking, use of the horn and lifting or lowering of the backrest/fork assembly is controlled using the grab handle controls.
1. When carrying no load, lower the forks fully for maximum stability when traveling.
2. In the walking mode, grasp the grips of the steering arm so that the speed control can be comfortably operated by either thumb.
3. In the riding mode, keep both feet on the operator's platform and do not carry passengers. Place one hand on the steering arm grip and the other on the grab handle.
4. Lower the steering arm to disengage the mechanical brake and energize the electrical circuits.
5. To move forward, slowly press the upper (FORWARD) portion of the speed control (see figure 2-1).
6. To stop, release the speed control and allow the spring-loaded steering arm to return to the upright position, or gently press the steering arm down to a horizontal position. Either action applies the mechanical brake and de-energizes the electrical controls.
7. To travel in reverse, lower steering arm and slowly press lower (REVERSE) portion of speed control. Press this control farther to increase speed in reverse.

NOTE: In the walking mode, the belly-button guard activates a switch which will reverse the motion of the truck should the operator accidentally pin himself against a wall or obstruction when backing up.

2-7. Braking and Stopping.
After release of the speed control, the truck will coast to a halt. For stopping on demand, each truck has two separate braking systems: the primary mechanical disc-type service brake and dynamic brake.
a. Machanical Brake. (Figure 2-3)
When the steering arm is moved to the vertical or horizontal position, the mechanical brake is applied (see figure 2-3). All traction power is shut off in these positions. By leaving the steering arm in the upright position, the mechanical brake acts as a parking brake. When released, the handle is raised to the upright position by spring action so that dead-man braking occurs.
b. Dynamic Brake.
CAUTION: The dynamic brake pushbutton should not be held in place any longer than necessary to bring the truck to a stop. Keeping it depressed may blow the 40-Amp fuse.

Figure 2-3. Mechanical Brake Application

The dynamic brake is secondary braking system, completely independent from the mechanical brake, operating only when the steering arm is away from the upright or horizontal positions. Pressing the BRAKE pushbutton on either the left side or right side switch box or the BRAKE pushbutton on the grab handle applies a dc voltage across the drive motor field coils stopping the motor. The dynamic brake will bring the truck to a smooth jar-free stop, except on inclines.

2-8. Operating Lift and Lower.
The lift and lower pushbuttons regulate the lifting and lowering of the forks.
CAUTION: TO avoid excessive heating and aeration of hydraulic oil, always release the lift pushbuttton.
2. To lower the forks, depress the lower pushbutton and hold it until the forks are lowered.

2-9. Loading. (typical)
1. Lower forks ALL  THE WAY DOWN.

2. Lower steering arm and drive truck to the location where the load is to be picked up.
3. Move the truck into position so the forks are aligned with pallet openings and the load is centered over the forks.
4. Move the truck forward and enter the pallet fully. Lift the forks to raise the pallet.

2-10. Unloading.
CAUTION: Avoid spilling the load. Move slowly and use extra care when turning.
1. Drive truck carefully to area where the load is to be placed.
2. Move truck to align the load with its new position.
3. When load is in position, lower the forks to the lowest position, allowing pallet to rest on the floor.
4. Slowly move truck backward, making sure that the forks do not catch on the pallet.
5. Proceed to move to next load.

2-11. Parking
1. When fnished moving loads, drive truck to its maintenance or storage area.
2. To park the truck, allow steering arm to return to its upright position which de-energizes the electrical circuits and engages the mechanical brake, Refer to Section III, Maintenance and Maintenance Parts, for mechanical brake adjustment details if the mechanical brake allows the truck to move.
3. Lower forks to their fully lowered position.
4. Charge battery as necessary. Refer to battery care instructions.

SECTION III
MAINTENANCE AND MAINTENANCE PARTS

3-1. GENERAL
This section information and procedures for preventive and corrective maintenance of the WRT Lift Truck. Planned maintenance includes periodic inspection, service and lubrication. Corrective maintenance includes troubleshooting, adjustment, and repair.

This section also contains parts lists adn illustrations identifying maintenance parts. The callouts on each illustration corrspond to the index numbers in the applicable parts list. Each parts list provides the Big Joe Manufacturing Company part number, the part description and the quantity of the part required in the assembly.

Whe identifying each part to be ordered, visually compare the part in the illustration with the actual part needed. To assure proper identification of each part being ordered, include your truck model number, your truck serial number (check nameplate), the part number, description, and quantity of the part(s) needed.

3-2. PART NUMBER IDENTIFICATION
To determine the part number of a replacement part, identify the assembly in which the part is used and locate the illustration of the applicable assembly. Find the index number of the part on the illustration and refer to that index number in the parts list. If the part number is NP, order the next higher assembly. If the part number is VAR, order by part name with truck model number, capacity, and serial number.

If the part is listed with more than one part number, select the proper  part number by comparing the description in the parts list with the specifications of your truck. Refer to the data plate to determine application to your truck.

3-3. PLANNED MAINTENANCE.

3-4. Inspection and Service.
The design of the lift truck provides a long and useful life with a minimum of maintenance. It is important to follow the operating instructions carefully and not to exceed the rated capacity of the truck. Follow the maintenance and lubrication procedures presented in this chapter to keep the equipment in top operating condition.

Table 3-1 is an inspection and service chart based on normal usage of the truck during an eight hour shift, five days per week. If the truck is used in excess of forty hours per week, the frequency of inspection and service should be increased accordingly.

Table 3-1. Inspection and Service Chart

3-5. Battery Care.
The life of the battery can be extended by giving it good care at the proper time. Perform a daily check of the battery whether or not equipment is in daily use. Check water level, and recharge to maximum capacity immediately after use rather than waiting until the next day. Perform the following procedures at end of each day.
1.Open battery cover and remove vent caps.
2. Check specific gravity of each cell. If the average specific gravity is less than 1.250, recharge the battery.

NOTE: Battery specific readings should agree within ± 0.025 from cell to cell. If the variation is greater, the battery may have to be repaired or replaced. 

3. Add enough distilled or or filtered water to cover battery plates, but do not let electrolyte level rise higher than base of battery filler neck.
4. Charge battery, if necessary, according to the instructions packed with battery charger.
5. When battery is properly charged, return truck to operating readiness.

3-6. Lubrication. (Figure 3-1)
Refer to table 3-2 for the recommended types of grease and oil. Table 3-3 in conjunction with figure 3-1 identifies the items requiring lubrication.

Figure 3-1. Lubrication Points

Table 3-2. Recommended Lubricants (See Table 3-3)

Table 3-3. Lubrication

3-7. TROUBLESHOOTING. 
Table 3-4 serves as a guide to determine possible causes of trouble. The table is divided into five main categories: Truck dead; trouble with braking; trouble with lifting or lowering; and miscellaneous troubles. Refer to electrical wiring diagram (figure 3-2) as a supplement to the troubleshooting chart or when tracing an electrical circuit.

Table 3-4. Troubleshooting Chart

Table 3-4. Troubleshooting Chart (Cont.)

Table 3-4. Troubleshooting Chart (Cont.)

Figure 3-2. Wiring Diagram 12 Volt Trucks (Sheet 1 of 2)

Figure 3-2. Wiring Diagram 24 Volt Trucks (Sheet 2 of 2)

3-8. ADJUSTMENT AND REPAIR.
The following procedures cover adjustments, part or assembly replacement, and repair of assemblies. The replacement procedures include reassembly where procedures are not obvious from the disassembly procedures. The procedures are independent of each other unless specifically referenced.

3-9. Steering Arm. (Figure 3-3)
a. Steering Arm Return Spring Adjustment.
The tension on the steering arm return spring should allow the arm to return gently to its upright position. Excessive tension will cause the arm to snap up and may cause damage to the electrical cable, brake linkage, or the spring itself. If the steering arm does not return fully, check for binding in the brake linkage or wiring harness before making any adjustments. If they do not bind, refer to figure 3-3 and proceed as follows to adjust the steering arm return spring tension

1.Lower the control head assembly until it is 29.25 inches from the floor as measured from the center of the rubber handle on the control head.
2. Butt the stop-adjustment (22) against the control handle (3) and lock into place with 3/8 inch bolts (25).

NOTE: The steering arm return torque is adjustable by means of rotating the handle shaft (15). The handle shaft end is ½-inch square and is accessible on the left side of the steering arm.

3. Fit a torque wrench with a ½-inch socket over the exposed left end of the handle shaft (15). 
4. Place the control handle (3) in vertical position, and torque handle shaft from 52 to 54 foot/pounds.

CAUTION: Excessive torque on the handle shaft (15) will cause overstress on the this amount torque, the assembly should be checked for interference.

b. Steering Arm Return Spring Replacement 

When replacing the return spring, begin with the steering arm in the upright position.
1. Disconnect battery.
2. Remove serice cover (2, figure 3-11) by removing three flathead screws (3).

CAUTION: The steering arm has a tendency to fall downward when the tension on the return spring released.

 
Figure 3-3. Steering Arm

3. Hold steering arm in upright position, making sure the arm cannot fall.
4. Remove screw (10, figure 3-3) and handle ratchet cover (11).
5. Fit a 1/2 -inch wrench (socket-type preferred) on the exposed left end of the handle shaft (15).

WARNING: The steering arm return spring will rapidly rotate the handle shaft and any attached tools approximately 180° if the ratchet lever suddenly is released. Make sure the movement is kept under control.

6. Actuate the lever protruding from the handle ratchet (12) and allow the handle shaft to rotate slowly counterclockwise until spring tension has been released.

NOTE: At this time, the steering arm should be swung down and supported. Bumper stops (7) may be removed to allow more room to perform the following steps.

7. Remove bumper stops (7) and disconnect wire harness.
8. Lift out the handle ratchet (12).
9. Extract screw (16), washers (14) and locknut (13) that attaches the end of the spring (19) to the handle shaft (15).

CAUTION: The steering arm may fall from the truck when the handle shaft ie removed. Make sure support for the steering arm is adequate and secure before proceeding.

10. Drive the handle shaft out of the steering arm through the side hole, amd remove sleeve (18).
11. Remove two cotter pins (21) from spring pin (20) and remove spring pin from the transmission.
12. Remove the steering arm return spring (19).
13. Reinstall the handle shaft and sleeve while placing a new steering arm return spring in the position formerly occupied by the old spring.
14. Rotate the handle shaft (15) until the small hole lines up with the hooked end of the steering arm return spring (19).
15. Reinstall the screw (16), washers (14) and locknut (13) in the stering arm return spring hooked end and into the handle shaft hole.
16. Reinstall spring pin (20) and cotter pins (21), and hook end of spring on pin.
17. Reinstall the handle ratchet (12) removed in step 8.
18. Reinstall bumper stops (7) if removed.
19. Position the handle ratchet lever to allow clockwise movement (viewed from steering arm left side), and adjsut the steering arm return spring tension as described in paragraph 3-9a.  

c. Handle Stop Adjustment.
To avoid unnecessary strains on the brake linkage, the adjustment stop (22, figure 3-3) should halt steering arm downward movement. The adjustment stop can be moved back and forth, and set to absorb the shock of steering arm over-travel.
1. Remove service cover (refer to 2, figure 3-10).
2. Refer to paragraph 3-9a and perform steps 1 and 2.
3. Reinstall the service cover.

3-10. Grab Handle Replacement. (Figure 3-4)

The handle may be replaced if accidentally damaged using the following precedence.
1. Disconnect battery.
2. Remove the switch box cover (6) by removing four screws (5).
3. Unscrew the five locknuts (8) and remove the five pushbuttons, the bezels (7) and spacer (11).
4. Remove two screws (18), nuts (17), and bar (19), and slide the grab handle assembly over the wiring harness.

NOTE: Replace grab handle assembly by performing steps 1 through 4 in reverse.

Figure 3-4. Grab Handle Assembly

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