Class 3 walkies are battery-powered alternatives to hand trucks and manual pallet jacks. These
motorized hand trucks are found in virtually every manufacturing and distribution operation performing loading,
unloading, order picking, stacking, staging, and internal transportation duties . They account for 24% of all industrial
vehicles sold.
The motorized vehicles allow the operator to deliver or store the load much faster than using
manual equipment. At the same time, operator fatigue is reduced and the possibility of injury associated with manually
moving heavy materials is virtually eliminated.
On the down side, the vehicles typically have lower travel and lift speeds, which may limit their
productivity in demanding operations or those covering greater distances. Capacity is limited to about 8000 lb
(4000 lb for higher lifts); however, specially designed and constructed versions can go much higher. Gradeability
is also a concern for some equipment.
There are a wide range of designs and functions available. Most types are low lift, but equipment
reaching 16 ft or so are available. Most vehicles are walkies, but numerous rider versions are on the market.
General features
Motorized hand trucks are operated by an end control handle mounted at the end of a tiller steer
arm. The steer handle (or head) regulates lift and lower functions, speed, direction, steering, braking, and several
safety features. Some rider versions have a center control handle located on the riding platform between the battery
and forks.
Nearly all Class 3 vehicles use transistor-type controls. These devices provide smooth acceleration,
infinite travel speeds, easy maneuverability, and high energy efficiency.
Drive tires are constructed from polyurethane or rubber, with the latter offering better traction.
Load wheels under the forks (and load) are small diameter and usually made from hard polyurethane,
which provides better wear than rubber.
Walkies operate with 12 or 24-V batteries, with the latter used on riders and more demanding
applications. The advent of the maintenance-free or sealed-cell battery has been a major boost to truck performance.
The batteries easily serve an 8-hr shift.
Matching the technology of the vehicle with operator capabilities and needs maximizes safety
and performance. Consequently, ergonomic and safety features are an important part of every vehicle.
The trucks include contoured handles that make it easier for the operator to steer and control
the trucks over longer periods of time. The control handle is designed for minimal wrist exertion. Riders have
safety bars and padding. The vehicles have a low profile to improve visibility, and shorter head length to increase
maneuverability. Improved braking systems and autoreverse features protect the operator.
Ultimately, however, an educated, attentive, and conscientious operator is the best safety feature
the vehicle can have.
A variety of options can be added to the basic truck package. Possibilities include battery discharge
indicators, built-in battery chargers, battery roller conveyors, side shifters, cold storage or corrosion protection,
hour meters, audible alarms, lift interrupts, and stability casters. Various fork widths and lengths are available.
Stacker trucks can employ a variety of handling attachments.
Types
Generally speaking, Class 3 equipment is divided into low-lift and high-lift stacker versions.
Low-lift models handle floor level pallets or skids. High-lift equipment has stacking capability and is offered
in straddle, reach, and counterbalanced versions.
Low lift
Low-lift walkies often called pallet trucks, are the dominant player in the Class 3 category
with nearly half of the unit sales. Forks are inserted between the top and bottom boards of pallets to raise the
load a few inches off the ground for transport. These products are not used for stacking.
Walkie trucks lift the pallet 6 in. off the floor to allow free travel over dock boards, ramps,
and obstacles. Transistorized controller allows infinitely variable drive speeds.
The truck features a speed control device (thumb or twist handle) to match the pace of a walking
worker. They are capable of moving about 4 mph when empty, and about half that loaded. Maximum capacity is 8000
lb.
Low-lift riders generate about 30% of the market and use the same lifting mechanism and perform
the same handling tasks as the walkie. Obviously, this type is used when longer travel distances or quicker handling
is required.
Walkie/rider pallet trucks travel about 8 mph when empty, which is two or three times faster
than walking but slower than a traditional lift truck.
The operator stands on a rear platform, or in a compartment between the batteries and forks.
Most riders can also be operated in a walkie mode.
Tow tractors
(tuggers) are available in walkie or rider versions and pull up to three carts of picked material
in train fashion. A coupler engages the towing arm of the cart to move the train.
Tuggers are an effective approach for moving high volumes of material along varied paths in the
plant. They are capable of moving a 12,000-lb rolling load about 5 mph.
High lift
High-lift walkies take 2000­4000 lb up to about 16 ft using a multistage mast. This walkie
is the best choice when the frequency of use does not justify the higher expense associated with a Class 1 electric
rider lift truck or Class 2 narrow aisle vehicle.
Straddle stackers are used in narrow aisle applications. Outriggers straddle the load, which
reduces the length of the truck and eliminates the need to counterbalance the load weight. Some stackers do not
have outriggers.
Reach trucks require a slightly larger aisle than straddle types, but offer greater flexibility
in load sizes handled. A scissor mechanism (pantograph) extends the forks beyond the outriggers to access and load,
eliminate the straddles, and place material one pallet deep.
Straddle stackers are typically used in narrow-aisle storeroom and warehouse areas to handle
uniform load sizes up to 4000 lb.
Reach trucks offer the maneuverability and economy of a walkie with the stacking capability
of a counterbalance rider or narrow aisle vehicle.
Counterbalanced trucks are similar to Class 1 riders in that they use the frame design and counterweighting
to offset the force of the load held in front of the mast. These vehicles stack two high, and service all types
of storage racks except double deep, which require a double-deep reach truck.
Counterbalanced walkie stackers are available in 12 and 24-V versions, lift at 30 fpm, and lower
at 49 fpm with a 4000-lb load.
Selection considerations
