PDF DOWNLOAD: Yale A3D4 (MPS30UX, MPS15UX, MPC15) Forklift Operating Manual

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DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 550241431

MPC15, MPS15UX (A3D4)

OPERATING MANUAL

Spacer LIFT TRUCK MODEL

SERIAL NUMBER

TRACTION MOTOR

SERIAL NUMBER

HYDRAULIC PUMP MOTOR

SERIAL NUMBER

STEERING GEAR MOTOR

SERIAL NUMBER

LIFT HEIGHT

GROUP NUMBER

DRIVE TIRE SIZE

COMPOSITION

SPECIAL EQUIPMENT OR ATTACHMENTS

© yale Company 2021. All Rights Reserved.

YALE and VERACITOR are Registered Trademarks of Hyster-Yale Group, Inc. PREMIER, and tions.

is a registered copyright.

are Trademarks in the United States and certain jurisdic-

INTRODUCTION

INTRODUCTION GENERAL CONDITIONS This Operating and maintenance manual contains original instruction.

A self-propelled industrial truck is understood to be any vehicle equipped with wheels (except for those running on rails) designed to transport, tow, push, lift, stack or set on shelving any type of load and operated by an operator who moves on foot together with the truck or on the machine, on a seat or on a specific platform.

The person in charge, acting on behalf of the company that owns the truck, must observe the general safety conditions detailed below in order to comply with safety standards.

Compliance with the instructions provided in this manual is mandatory for the safe use of this truck. Failure to comply with the operating conditions constitutes “incorrect use” by the operator and as such relieves YALE of all responsibility with regard to compliance with all essential safety requirements.

©YALE EUROPE 2021

550241431 - ENGLISH-UK

The operator and the maintenance technician must be thoroughly acquainted with the contents of this “Operating and maintenance manual”.

All operators must read the manual carefully and, if doubts arise before operating the truck, should contact the YALE service network for further explanations.

THE TRUCK MAINTENANCE MANUAL MUST ALWAYS BE AVAILABLE TO THE OPERATOR FOR CONSULTATION. The employer, through the personnel in charge at his company, must ensure that these regulations are observed.

The operator must not allow the truck to be used by unskilled personnel and must remove the starting key when leaving the truck unattended in order to prevent it being used by others. Keys must be given only to qualified personnel.

1

INTRODUCTION The person in charge, acting on behalf of the company, must:

In these cases the manufacturer will be released from all liability in relation to the general safety regulations.

• Ensure that the operators are in a good psychological and physical condition; • Ensure that the operators know how to use the truck and are aware of the contents of this operating and maintenance manual.

The repairer or maintenance technician (other than YALE) will assume all liability in relation to the safety regulations for the entire machine and the technical file, held by the manufacturer (YALE), will no longer be considered to be representative of the machine as a whole.

The operator and the maintenance technician must carry out the routine maintenance operations indicated in this manual in the dedicated chapter.

The operator and maintenance technician must ask the person in charge at the company to contact the YALE technical service centre regarding the supplementary maintenance operations indicated in this manual. The operator must not use the truck if any kind of operating fault is detected.

Any repairs or major maintenance carried out by the user or in an unauthorised workshop during the guarantee period will automatically make the warranty void.

IT IS FORBIDDEN TO CARRY OUT REPAIRS OR MAJOR MAINTENANCE OPERATIONS. Any repairs or major maintenance carried out by the user or in an unauthorised workshop may result in failures that could cause personal injury or damage to property.

2

The use of special equipment that has not been made and installed by YALE may modify the conditions under which the machine may be used. It is mandatory to submit the installation of equipment directly to YALE, for any acceptance. Failure to meet this requirement will relieve YALE of all liability, as already specified in the case of major maintenance.

The special equipment installed directly by YALE will be provided with the necessary documentation for compliance with safety standards. The instructions for use and maintenance of the truck with special equipment will be attached to this document.

INTRODUCTION INFORMATION ABOUT DISPOSAL

DISPOSAL OF LUBRICANT OILS

BATTERY DISPOSAL

NOTE: Used oil must be specially collected.

NOTE: Do not dispose of exhausted batteries with normal solid waste.

It must not be disposed of into normal drainage system pipes.

They are composed of noxious material.

Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

They must be collected, disposed of and/or recycled as prescribed by legislation in force in individual countries.

RECYCLE RECYCLE

3

INTRODUCTION TRUCK SCRAPPING

ELECTRICAL SYSTEM

The truck is composed of metal and plastic components, which can be recycled.

• Connections: Copper cores and PVC insulation • Motors: Steel, copper and aluminium • Electronic controller and electronic board: Aluminium, copper, ceramic and plastic

The materials used for the truck components are listed below: CHASSIS • Frame: Steel • Wheels: Polyurethane, rubber • Finishing: Plastic HYDRAULIC SYSTEM • • • • •

4

Reservoir: Plastic Pump unit: Steel and aluminium Flexible pipes: Rubber, steel and plastic Cylinders: Steel and cast iron, rubber (seals) Valves: Steel and aluminium

NOTE: This controller has both mechanical parts and high-density electronic parts (Printed circuit boards and integrated circuits).

If not properly handled during waste processing, this material may become a relevant source of pollution.

The disposal and recycling of this controller has to follow the local laws in force in individual countries.

INTRODUCTION DOCUMENTS

Manufacturer

The truck is supplied complete with accompanying documents in order to ensure its identification and to provide correct instructions for operation and maintenance.

On receiving the truck, be sure to check that the purchase documents are correct and that the following documents are present: • CE DECLARATION OF CONFORMITY / UKCA DECLARATION OF CONFORMITY (1)

YALE EUROPE Centennial House Frimley Business Park Frimley, Surrey GU16 7SG United Kingdom

• USE AND MAINTENANCE MANUAL If any of these documents are missing, it is essential to inform the dealer from whom the truck was purchased. Use of the truck is prohibited if any of the accompanying documents are missing.

(1)

The following Declarations of Conformity are a Facsimile.

The Declarations of Conformity are not present on trucks shipped to China and Ukraine.

The Declarations of Conformity will change based on the truck destination country.

SERVICE NETWORK ADDRESSES To comply with general warranty conditions, all service and repair operations must be carried out by qualified technicians that are part of the YALE authorized service centre network.

To find your nearest YALE authorized service centre, see the website at: www.yale.com 5

6 YALE EUROPE CENTENNIAL HOUSE FRIMLEY BUSINESS PARK FRIMLEY, SURRY GU16 7SG UNITED KINGDOM

PLANT MANAGER - MASATE

NAME AND JOB TITLE HYSTER-YALE ITALIA SPA VIA CONFALONIERI 2 - 20060 MASATE (MI) ITALY

Note that some products have options for equipment that are subject to Radio Equipment Directive 2014/53/EU. Where applicable, product/option meets the requirements outlined in this Directive.

PLACE Day of week, MM/DD/YYYY

NAME AND JOB TITLE

TECHNICAL FILE CONTROLLED BY:

OTHER APPLICABLE DIRECTIVES: 2014/30/EU - EMC EMISSIONS.

IS IN CONFORMITY WITH THE MACHINERY DIRECTIVE 2006/42/EC. COMPLIANCE WITH THIS DIRECTIVE IS ESTABLISHED BY MEETING THE TECHNICAL REQUIREMENTS OF THE RELEVANT STANDARDS, INCLUDING EN ISO 3691-1:YYYY.

YEAR OF CONSTRUCTION

SERIAL NUMBER(S)

TYPE

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE CATEGORY:

WE

EC DECLARATION OF CONFORMITY

INTRODUCTION

YALE EUROPE CENTENNIAL HOUSE FRIMLEY BUSINESS PARK FRIMLEY, SURRY GU16 7SG UNITED KINGDOM

PLACE Day of week, MM/DD/YYYY

NAME AND JOB TITLE

TECHNICAL FILE CONTROLLED BY:

OTHER APPLICABLE DIRECTIVES: EMC REGULATIONS 2016

PLANT MANAGER - MASATE

NAME AND JOB TITLE HYSTER-YALE UK Limited 88 Charlestown Road, Portadown Co Armagh, BT63 5PP Northern Ireland

IS IN CONFORMITY WITH THE SUPPLY OF MACHINERY (SAFETY) REGULATIONS 2008.

COMPLIANCE WITH THESE REGULATIONS IS ESTABLISHED BY MEETING THE TECHNICAL REQUIREMENTS OF THE RELEVANT STANDARDS, INCLUDING BS EN ISO 3691-1:YYYY

YEAR OF CONSTRUCTION

SERIAL NUMBER(S)

TYPE

DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE MACHINE CATEGORY:

WE

UK DECLARATION OF CONFORMITY

INTRODUCTION

7

Contents

Contents INTRODUCTION ..........................................................

GENERAL CONDITIONS ...........................................

INFORMATION ABOUT DISPOSAL ..........................

DOCUMENTS ............................................................

SERVICE NETWORK ADDRESSES .........................

Warning .......................................................................

Risks / transporting the truck ....................................

RISKS AS A RESULT OF INCORRECT USE ............

GENERAL GUIDELINES ............................................

MAKING THE TRUCK READY AFTER TRANSPORTATION ................................................

Description / Operating instructions ........................

CONSTRUCTIONS STANDARDS .............................

DESCRIPTION OF THE MODEL ...............................

CHANGES TO THE TRUCK ......................................

IDENTIFICATION DATA ............................................

WARNING AND INFORMATION PLATES AND ADHESIVE DECALS ................................................

TECHNICAL DATA .....................................................

COMPONENTS AND POSITIONING .........................

INSTRUCTIONS FOR USING THE CONTROLS AND INSTRUMENTS .......................................................

8

1 1 3 5 5 9 10 10 12 13 15 15 15 16 17 18 19 25 26

SMART FUNCTIONS .................................................

PRELIMINARY CHECKS ...........................................

GENERAL STABILITY PRINCIPLES .........................

OPERATING TECHNIQUES ......................................

CONSIDERATIONS CONCERNING LOADS ............

DRIVING RULES ........................................................

STORAGE AND RESTARTING OPERATIONS .........

Maintenance / Battery ................................................

MAINTENANCE GENERAL PRINCIPLES .................

SCHEDULED MAINTENANCE TABLES ...................

CLEANING .................................................................

MAINTENANCE PROCEDURES ...............................

FIRST TIME SETUP ...................................................

REPAIR PROCEDURES ............................................

TROUBLESHOOTING ...............................................

BATTERY INTRODUCTION ......................................

LITHIUM-ION BATTERY WARNINGS .......................

LITHIUM-ION BATTERY SPECIFICATIONS .............

RECHARGING THE BATTERY .................................

30 33 34 38 43 45 54 56 56 58 61 62 66 68 78 82 84 86 89

Warning

WARNING SAFETY WARNINGS AND MARKINGS

NOTE: It is given before warnings and explanations.

The safety regulations and important explanations are marked by the following symbols:

These symbols are used to draw attention to the presence of a risk: failure to comply with safety regulations and all relative instructions may be hazardous for people and property.

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This signal word is to be limited to the most extreme situations.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor injury and/or damage to the equipment.

A general risk is defined as the possibility of major hazard situations ensuing, such as: • Overturning • Falling load • Explosion • Crushing • Electrocution The operators, maintenance engineers and anyone working near the truck are exposed to these risks.

9

Risks / transporting the truck

Risks / transporting the truck RISKS AS A RESULT OF INCORRECT USE In order to operate in safe conditions, the following instructions must be followed and dangerous situations must be handled with caution.

DEFINITION OF OPERATOR The operator is defined to be any person who is trained and responsible for moving the truck and handling the load.

The operator can be transported on the truck or drive the truck from the ground or remotely (by cable, radio, etc.)

The truck may only be driven by trained and authorised personnel.

RESTRICTIONS ON USE BY UNAUTHORISED PERSONNEL The operator must prevent the truck from being used by unauthorised personnel by removing the key from the control panel when leaving the truck unattended.

When remaining in the vicinity of the truck with the key inserted, the driver must make sure that no unauthorised persons gain access to the controls.

KNOWING THE TRUCK The operator must be fully acquainted with the truck he is using, carefully study the operating instructions and work only with loads that do not exceed the load capacity indicated on the nameplate.

KNOWING THE LOAD The operator must be fully aware of the nature and the stacking condition of the load that is being transported.

The operator has the right to refuse to transport loads he considers to be hazardous to the transit environment or loads that are incorrectly stacked.

10

Risks / transporting the truck KNOWING THE ENVIRONMENT

KNOWING THE MAINTENANCE SCHEDULE

The operator must be fully aware of the presence, within the transit area, of pollutants that are dangerous to humans or that may cause explosions out of incompatibility with the truck, or that may trigger a reaction with the load carried.

The operator and the maintenance engineer must know the maintenance schedule and how to perform routine maintenance meticulously.

The presence of holes, bumps or obstacles along the route may pose a risk for the operator or for the truck. Handling and transit areas must be suitably paved, flat and cleared of any obstacles.

The operator has the right to refuse to transit through areas or along routes that may be dangerous to persons or the truck. The operator has the right to refuse to transport loads that he considers to be dangerous to the transit areas.

If routine maintenance operations are assigned to operators from outside companies, they must ensure that the schedule is followed strictly and that work is performed scrupulously.

Extraordinary maintenance must always be carried out by authorised YALE service centres.

CLOTHING The truck operator must use clothing that reduces risks to a minimum. It is recommended to wear safety footwear, gloves, and close-fitting jackets and trousers.

It is recommended not to wear watches or metal jewellery so as to avoid short-circuiting near to the battery.

Use suitable safety equipment in aggressive environments.

Carefully read the operating instructions.

11

Risks / transporting the truck GENERAL GUIDELINES For the transportation of industrial trucks by road or rail, be sure to verify acceptable dimensions for freight, bearing in mind both maximum profile dimensions and permissible weight.

If the dimensions of the truck are higher than this limit, the truck must be disassembled by removing the parts that exceed the permissible dimensions.

For this operation please contact YALE technical support.

To transport the truck without a proper container it is necessary to fasten the truck firmly to the transport vehicle.

In case of exposure to weather the truck must be protected against atmospheric agents.

To load and unload the truck from the carrier use appropriate hoisting systems with suitable load capacities and in good condition. To know the weight of the truck, refer to the identification data plate.

12

Use the tools and equipment listed in the procedure given in below. Do not improvise any kind of manoeuvre that is not officially approved by authorised and specialised personnel.

While parking the truck, the operator must not leave it in conditions that could cause damage to people or things.

Risks / transporting the truck NOTE: Avoid scratching the forks or covers of the pallet truck when loading, especially when inserting the forks into the shipping pallet. Do not drop the truck when loading.

• Ensure that any packaging including the shipping pallet or crate are of sufficient strength to bear the weight of the pallet truck and large enough to accomodate the pallet truck.

• Ensure that the forks of the pallet truck are fully inserted into the shipping pallet.

• Once the truck is inserted into the shipping pallet, park the truck as described in the Parking section of this manual.

MAKING THE TRUCK READY AFTER TRANSPORTATION

• Ensure the capacity of the transporting equipment is of sufficient capacity to hold the combined weight of the pallet truck and any packaging.

Following transportation, the truck must be prepared for use in order to ensure its correct operation.

• If the pallet truck is not to be shipped on a pallet, only lift the truck using the lifting points marked on the truck on the left and right sides of the chassis.

If the truck has been dismantled for transport requirements, request technical assistance from YALE to reassemble it.

Use the storage battery to drive the truck.

13

Risks / transporting the truck NOTE: It is normal for wheels to show some deflection or distortion in shape after the truck is parked for an extended period. The wheels will restore to their original shape after the truck is driven for a time.

WARNING Now proceed to make the checks listed below: • Inspect the truck to make certain there is no damage and there are no parts missing.

• Install the battery, making sure not to damage any electrical wires.

• Charge the battery.

• Check the battery charge level (Indicator).

• Test the lift and lower system.

• Make a general inspection of the controls and instrumentation.

14

Any damage or incorrect operation of the truck must be reported immediately to the YALE service centre.

Never start the truck if it is damaged or defective.

Trucks may only operate when they are in good condition.

NOTE: If the truck needs to be repaired, place a clearly visible sign saying “OUT OF ORDER - DO NOT USE” on the truck and remove the key from the control panel.

Description / Operating instructions

Description / Operating instructions CONSTRUCTIONS STANDARDS The truck described in this manual is constructed in accordance with the standards indicated in the EC Declaration of Conformity.

• An approved safety platform is attached to the forks.

The supplier of the platform is responsible that all applicable regulations are met. He has to deliver all necessary instructions for a safe operation.

See the "EC Declaration of Conformity".

DESCRIPTION OF THE MODEL The MPC15 / MPS15UX [A3D4] machines in this series are electric pallet trucks operated by a user walking alongside the pallet truck.

WARNING This lift truck is designed and intended for handling materials. A lift truck is not designed to lift people.

If a lift truck is used to elevate a worker it must be ensured that: • It is allowed by the national regulations of the country in which the truck is used.

15

Description / Operating instructions CHANGES TO THE TRUCK DANGER No modifications may be made to the truck without prior authorization.

No changes which could alter load bearing, stability and safety of the truck must be carried out without YALE written approval.

This refers to changes in brakes, steering system and visibility. It is also forbidden to install removable equipment.

When the manufacturer approves a change, the capacity rating plate, the adhesive decals, the labels and the use and maintenance manual must be updated accordingly.

The user can modify a motorized industrial truck, only if the manufacturer of the truck has closed down and there are no successors.

The user must: • Make sure that any change or alteration is designed, tested and carried out by an engineer specialized in industrial trucks and their safety; • Keep a permanent record of drawings, tests and equipment relevant to the changes or alterations which have been carried out; • Approve and make appropriate changes to the capacity plate, decals, labels and the use and maintenance manual; • Put a permanent and visible decal on the truck detailing the way in which the truck has been modified, the date on which this change introduced, the name and address of the company which carried out the modification.

The CE Declaration of Conformity issued with the vehicle will be invalidated by any substantial modifications.

The party carrying out the modifications becomes the manufacturer, and is required to issue a new CE Declaration of Conformity.

This also applies to any modifications made to the accessories (i.e any replaceable parts).

16

Description / Operating instructions IDENTIFICATION DATA

IDENTIFICATION DATA PLATE

NOTE: The plates and decals positioned on the truck have a warning and information function; it is forbidden to remove them, paint over them or to render them illegible.

If a plate or decal is found to be illegible it should be replaced by means of an SUPPLEMENTARY MAINTENANCE operation.

A

For trucks shipped to India

B

For trucks shipped to Asia-Pacific region

C

For trucks shipped to Europe

Facsimile in English

17

Description / Operating instructions WARNING AND INFORMATION PLATES AND ADHESIVE DECALS CAUTION The warning and information decals must never be removed, painted over or made undecipherable.

Should a decal be undecipherable it must be replaced.

WARNING Stay away from all moving parts. Moving parts may cut or crush hands, feet, arms or legs.

18

CAUTION Do not soak the battery in water. Do not recharge battery at less than 0°C (32°F). To reduce the risk of damage when installing or changing battery, insert the battery gently and do not allow battery to drop into battery compartment from more than 15 cm (5.9 in).

Description / Operating instructions TECHNICAL DATA The dimensions diagram and the specification sheet contain the truck data.

Knowledge of weight, dimensions, movement areas, are essential for enabling the operator to avoid the general risks for misuse.

NOTE: ALL VALUES ARE NOMINAL AND SUBJECT TO TOLERANCES. FOR MORE INFORMATION, PLEASE CONTACT YOUR SUPPLIER. YALE PRODUCTS ARE SUBJECT TO CHANGE WITHOUT NOTICE. THE TRUCKS ILLUSTRATED MAY FEATURE OPTIONAL EQUIPMENT. THE VALUES MAY VARY DEPENDING ON THE DIFFERENT CONFIGURATIONS.

19

Description / Operating instructions OVERALL DISPLACEMENT DIAGRAMS MPC15 / MPS15UX

20

Description / Operating instructions

21

Description / Operating instructions SPECIFICATION SHEET

Technical features

The following data is according to standard GB/ T27542-2011. The manufacturer reserves the right to update this data.

Reference and unit of measurement

Model

MPC15 / MPS15UX

Drive

Electric

Operator type

Pedestrian

Load capacity / rated load

Q [kg(lb)]

1500 (3307)

Load centre

C [mm(in)]

600 (23.6)

Height, fork lowered

h13 [mm(in)]

82±2 (3.2±.08)

Wheelbase

Y [mm(in)]

1197 / 1267 (47 / 50)

Wheel

PU

Wheel size, front

mm (in)

ø140x55 (ø5.5x2.2)

Wheel size, rear

mm (in)

Single wheel: ø80x93 (ø3.1x3.7)

mm (in)

Double wheel: ø80x70 (ø3.1x2.8)

Wheel, number front/rear (x=driven wheels) Lift

22

1x+2/4 h3 [mm (in)]

115 (4.5)

Description / Operating instructions Technical features

Reference and unit of measurement

Height of tiller in drive position, minimum / maximum

h14 [mm (in)]

820 / 1150 (32.3 / 45.3)

Overall length

l1 [mm (in)]

1552 / 1622 (61 / 64)

Fork length

l2 [mm (in)]

1150 / 1220 (45 / 48)

Width over forks

b1 [mm (in)]

550 / 685 (22 / 27)

Fork dimensions

s/e/l [mm (in)]

58 / 160 / 1150 or 1200 (45 / 48)

Overall fork width

b5 [mm (in)]

550 / 685 (22 / 27)

Ground clearance, center of wheelbase h1 [mm (in)]

22 / 137 or 24/139 (0.87 / 5.39 or 0.94 / 5.47)

Aisle width for pallets 1000x1200 mm (39.3x47.2 in) crossways

mm (in)

1718 (68)

Aisle width for pallets 800x1200 mm (31.5x47.2 in) lengthways

mm (in)

1687 (66)

Turning radius

Wa [mm (in)]

1353 / 1426 (53.3 / 56.1)

Travel speed, with / without load

Km/h (mph)

4.0 / 5.0 (2.5 / 3.1)

Lift speed, with / without load

mm/s (ft/s)

18/23 (0.06/0.08)

Lower speed, with / without load

mm/s (ft/s)

54/46 (0.18/0.15)

Max. gradeability, with/without load

%

6%/20% 23

Description / Operating instructions Technical features

Reference and unit of measurement

Drive motor

kW

DC brushless 0.75 kW

Lift motor

kW

DC 0.5 kW

Battery voltage / nominal capacity

V/Ah

48V / 10Ah (48V / 15 Ah)

Traveling brake

Regenerative

Brake

Electromagnetic

Sound level at the driver's ear according dB(A) to EN 12053

<70 dB

Service weight including battery

114.5 / 119.5 / 121 (252.4 / 265.5 / 266.8)

24

Kg (lb)

Description / Operating instructions COMPONENTS AND POSITIONING The figures below indicate the terminology used to describe the main components of this truck and their location.

1.

2.

3.

4.

5.

6.

HANDLE ASSEMBLY DRIVE MOTOR ASSEMBLY POWER SWITCH (EMERGENCY POWER OFF) LITHIUM-ION BATTERY CHASSIS COVER

25

Description / Operating instructions INSTRUCTIONS FOR USING THE CONTROLS AND INSTRUMENTS The following diagrams and instructions show the type of control or instrument, their position and the way to use them.

STEERING TILLER The steering tiller in position “M” enables the truck to be driven. If travel, lift, or lower is commanded with the steering tiller in position "B", the truck will not respond and the display will read SRO ERR. Push the throttle in the direction of desired travel to move the truck. The more the throttle is pressed, the faster the truck will move.

Operate the driving tiller to steer.

REGENERATIVE BRAKING • Release the throttle.

• It causes a deceleration due to braking of the electric braking of the drive motor.

26

Description / Operating instructions WARNING When the throttle is released, it should return to neutral position immediately. If it does not, have the truck repaired immediately to reduce the risk of personal injury or property damage.

If the truck moves with the handle in the "B" position, have the truck repaired immediately to reduce the risk of personal injury or property damage.

PLUG BRAKING

HARD BRAKING

To brake quickly with more control, use controlled braking or "plugging".

To brake the truck more quickly, do one of these things:

• Release the throttle.

• Release the steering tiller.

• Move the steering tiller to position “B”.

• Pull the steering tiller down to the lowest position.

• Move the throttle in the direction opposite the current direction of travel.

It causes a deceleration due to braking of the electric braking of the drive motor.

WARNING

• When the truck just begins to move in the opposite direction, release the throttle.

NOTE: Use hard braking or plugging when an unexpected situation arises and it is necessary to stop quickly.

When the steering tiller is in the "B" position, the truck should stop moving until the throttle is pressed again.

27

Description / Operating instructions HORN BUTTON (POS. 1) Press this button to operate the horn.

THROTTLE (POS. 2) The operation of the throttles permits traveling both in the operator side direction and in the fork side direction.

Turning the throttles toward the operator, the truck moves in the operator direction.

Turning the throttles toward the forks, the truck moves in the fork direction.

1.

2.

3.

4.

5.

6.

28

HORN BUTTON THROTTLE BATTERY DISCHARGE INDICATOR (BDI), HOURMETER, FAULT CODE DISPLAY LOWER BUTTON LIFT BUTTON BELLY SWITCH - REVERSING BUTTON

The truck speed increases proportionally according to the angle of rotation of the throttles.

Reversing the throttle causes a progressive deceleration of the truck to a stop due to the traction engine electrical braking (reverse braking or 'plugging').

On releasing the butterfly controls, they return to their neutral position, causing a progressive deceleration, due to the traction engine electrical braking, with subsequent engaging of the electromechanical brake (release braking).

Description / Operating instructions BATTERY DISCHARGE INDICATOR (BDI) AND ERROR CODE INDICATOR (POS. 3)

To reset, pull the button and move the tiller to the vertical position (Button up: electrical system connected).

The display screen will show remaining charge left in the battery and also will list any active fault codes.

By pressing it, it also acts as an emergency brake (the electromagnetic brake engages).

LOWER BUTTON (POS. 4) Press this button to lower the forks.

LIFT BUTTON (POS. 5) Press this button to lift the forks.

BELLY SWITCH - REVERSING BUTTON (POS. 6) It is a device located at the tiller end to reverse the direction of travel when it is hit. It works during the truck travel on the operator direction. If bumped, the truck reverses and stops immediately. To reset the truck functions it is necessary to turn the truck off and then on again.

POWER SWITCH (EMERGENCY STOP BUTTON) (POS. 7) By pressing it, the battery supply is disconnected and all the electric controls are disabled (Button down: electrical system disconnected).

29

Description / Operating instructions SMART FUNCTIONS UP-RIGHT DRIVE Up-right drive allows the truck to be driven with the tiller in the fully vertical position. Use up-right drive to maneuver the truck in tight quarters.

To activate up-right drive on non-CE-certified trucks, turn the truck off, put the tiller into the fully vertical position, then press and hold the belly switch - reversing button and push the throttle toward the forks and hold. When the truck is powered on, it will start in up-right drive mode.

To activate up-right drive on CE-certified trucks, use the handheld intelligent control. See SMART FUNCTIONS. When up-right drive mode is active, the top speed is 2.5km/h (1.5 mph).

30

TURTLE SPEED Turtle speed allows the truck to move at a reduced speed.

Normal top speed for the pallet truck is 5km/h (3.1 mph).

When turtle speed is active, the top speed is 2.5km/h (1.5 mph).

To activate or deactivate turtle speed, hold the horn button, then press (but do not hold) the throttle toward the forks two times.

Description / Operating instructions The optional intelligent control allows operation of some features of the truck using the handheld remote control.

The remote control uses radio-frequency (RF) technology, and is powered by an L828 (12V/27A) non-rechargeable alkaline battery. Each remote control is tied to the specific truck.

To use the intelligent control, it must be within 2 m (6.5 ft).

Press the function buttons on the control to use the features in this table.

HANDHELD INTELLIGENT CONTROL (OPTION)

If the LED on the remote control is dim or off, or if the buttons do not work, replace the battery in the remote control.

If the buttons still do not work, the remote control may be damaged and should be replaced.

31

Description / Operating instructions ICON

FUNCTION DESCRIPTION Lock or Unlock Up-right Drive

To lock the truck, press the Lock button once. The truck will beep once to indicate it is locked.

To unlock the truck, turn truck power ON and press the Lock button twice. The truck will beep twice and the display will show the Unlock icon to indicate the truck is ready for operation.

Press the Up-right Drive button to activate Up-right Drive mode. On non-CE-certified trucks, the truck will beep continuously and travel at a reduced speed with the handle in the upright position.

CE-certified trucks will not beep.

Press the Up-right Drive button again to deactivate Up-right Drive mode. The truck will beep once and will now travel at normal speeds with the handle in the travel position.

Travel Speed

Press the Travel Speed button to cycle through speed presets.

• • • • •

One press - Level 1 - 0.5 km/h (0.3 mph) Two presses - Level 2 - 1.5 km/h (0.9 mph) Three presses - Level 3 - 2.5 km/h (1.5 mph) Four presses - Level 4 - 3.5 km/h (2.2 mph) Five presses - Level 5 - Full speed

The display indicates the selected speed. Travel Speed is limited until this setting is changed.

Horn

Press and hold the Horn button to make the truck beep continuously.

Release the Horn button to stop the truck from beeping.

32

Description / Operating instructions PRELIMINARY CHECKS WARNING Before daily use of the lift truck check the condition of the following parts as described in the "Maintenance" chapter.

PRELIMINARY CHECKS WITH THE TRUCK TURNED OFF • Check for oil leaks from the drive unit and the hydraulic system.

• Check the conditions and wear of the wheels.

• Check the fork conditions.

• Check the linkage conditions.

• Check the integrity of the battery socket and plug.

• Check for liquid leakage from the battery.

• Check the conditions of the warning and information plates and decals.

PRELIMINARY CHECKS WITH THE TRUCK TURNED ON • Check the correct operation of the brakes using the different braking methods.

• Check the correct operation of the valves.

• Check the correct operation of the tiller.

• Check the correct operation of the horn button.

• Check the correct operation of the emergency reverse button (belly switch).

• Check the correct operation of the Turtle Speed feature.

• Check the battery charge level.

WARNING Any damage or incorrect operation of the truck must be reported immediately to the YALE service centre.

Never start the truck if it is damaged or defective.

Trucks may only operate when they are in good condition.

NOTE: If the truck needs to be repaired, place a clearly visible sign saying “OUT OF ORDER - DO NOT USE” on the truck and remove the key from the control panel.

33

Description / Operating instructions GENERAL STABILITY PRINCIPLES KNOWING THE TRUCK Fork lift trucks are designed for loading and transporting materials. In their standard version, these vehicles have a fork lift mechanism, which is used to pick up the load.

The lift mechanism raises the load to facilitate transportation and storage operations.

In order to understand the operation of the truck, it is essential to have some familiarity with a few basic concepts regarding the forces and dynamics of trucks with and without a load.

1.

2.

3.

4.

5.

6.

34

TRUCK CENTRE OF GRAVITY COMMON CENTRE OF GRAVITY LOAD CENTRE OF GRAVITY LOAD DRIVE WHEEL AXLE LOAD WHEELS AXLE

Description / Operating instructions LOAD CENTRE OF GRAVITY The "load centre" (or "centre of gravity of the load") is the point where the object is balanced in all directions.

In practical terms, the centre of gravity of a uniform object is the centre of the body (e.g.: the centre of gravity of a cubic and uniform load of wood is at the centre of the cube).

For loads made up of non-uniform objects, the centre of gravity is located in an area between the full (heavy) zones and the empty zones.

When empty, the centre of gravity of the truck is normally situated in the area between the mast and the battery.

When the truck is loaded, the truck and the load together have a new common centre of gravity.

The lift truck remains stable when the centre of gravity of the load and of the truck are both positioned between the drive wheel axle and the load wheel axle. The area between these two axles is defined as the "area of stability".

COMMON CENTRE OF GRAVITY The "common centre of gravity" is defined to be the centre of gravity for the truck configuration with the load on board.

The truck must remain stable in both a longitudinal and transversal direction.

35

Description / Operating instructions LONGITUDINAL STABILITY AREA

"The longitudinal area of stability" is defined as the zone between the drive axle and the load wheel axle.

Example of the variation of longitudinal stability:

WARNING • The maximum gradient of the truck is given in the specification sheet. Never exceed the stated limits.

• Never drive the truck transversely at the slopes.

• In case of rises and descents drive the truck with the forks facing the top of the rise, either with or without load, and with lowered lifting system at a minimum height, which enables the translation.

36

Description / Operating instructions TRANSVERSE STABILITY AREA

"The transverse area of stability" is defined as the zone between the front and rear track widths.

GENERAL DIAGRAMS OF THE CENTER OF GRAVITY IN RELATION TO THE POSITION OF THE LOAD

NOTE: Truck stability is reduced, during the phases of putting down and picking up, with the load in a high position. it should be remembered that excessive stacking (e.g. 2 or more stacked containers) raises the common centre of gravity, which has the effect of reducing the stability of the truck.

37

Description / Operating instructions OPERATING TECHNIQUES

DANGER

NOTE: When using the truck there are some operations that, in spite of all the safety precautions, may cause it to overturn unless performed with care.

If the truck should tip over try and keep body parts as far as possible from the point of impact with the ground.

The main causes of tipping over are:

NOTE: Carefully read the GENERAL CONDITIONS, RISKS and the GENERAL STABILITY PRINCIPLES chapters and the instructions described below.

• • • • • • • •

Turning too fast.

Driving and turning on a slope.

Driving with raised loads.

Driving with a side-positioned load.

Driving on a slope with a load facing downwards.

Loads out of size.

Driving with swinging loads.

When transporting liquids, the centre of gravity inside one of the containers loaded may change; this can cause the truck to tip up as a result of the force of inertia, for example when switching on, braking or on bends.

• Ramps or steps.

• Loading operations on a lorry, for example if the lorry engine is switched on while the forks are still raised above the loading area, if the ramp is not in the right position or if a truck wheel is beyond the edge/limit.

• Driving over rough ground.

38

BASIC PRINCIPLE Because of the specific skills required, it is advisable that each individual operator follow a special training course, even if he has already obtained a license entitling him to drive lift trucks in general.

The following pages contain a list of some of the basic regulations and manoeuvres that should be employed when using the truck.

Description / Operating instructions USE IS RESTRICTED TO AUTHORISED AND TRAINED PERSONNEL This means that only operators who have followed a specific training course, aimed at providing total comprehension of the truck functions, should be allowed to operate the truck.

The instructor should therefore be an expert truck user and should work alongside beginners for a period of time, until they are judged to be sufficiently proficient.

A thorough basic training in driving techniques and load handling is absolutely essential to enable the operator to handle dangerous and unexpected situations effectively.

WORK ENVIRONMENT The truck may only be used in suitable areas and normal environmental conditions. Do not operate the industrial truck outdoor in the event of adverse weather conditions or in hazardous areas.

Acceptable environmental conditions: Temperature:

5°C to 45°C (41°F to 113°F)

Altitude:

up to 2000 metres (6562 ft)

This truck is not for use on cold rooms or applications that experience drastic changes in humidity. Contact your dealer for any special modifications required for operating in these environments.

If the truck works for long periods of time at altitudes above 1000 m (3281 ft) it is necessary to take into account that the engine cooling will be less efficient than the working conditions at sea level.

NOTE: In environments with critical conditions of temperature, humidity or aggressive agents (salinity, dust, etc.), contact your dealer.

39

Description / Operating instructions WARNING DO NOT ALLOW THE TRUCK TO ENTER AREAS WHERE FLAMMABLE GASES, VAPOURS OR POWDERS ARE GENERATED. THE TRUCK IS NOT EQUIPPED WITH ANTI-EXPLOSION PROTECTION. Take the utmost care when transporting dangerous materials: flammable liquids, acids, etc. must be transported in appropriate closed containers.

Where possible, avoid routes with holes, bumps and obstacles; if this proves to be impossible, calculate whether each individual obstacle can be negotiated and always drive the truck with extreme caution. Take steps to ensure that all holes, bumps and obstacles are removed wherever possible.

WARNING INCORRECT USE ON UNSUITABLE FLOORING MAY CAUSE DANGEROUS SITUATIONS AND REDUCE THE WORKING LIFE OF THE TRUCK. Contact the service network for advice concerning the flooring, or the most suitable type of truck for a particular type of flooring.

40

IMPROPER LIFTING This truck has been designed and constructed for the handling of materials.

WARNING The truck is not suited to lifting or carrying persons on the forks.

LIFTS Never enter lifts without first having obtained permission from the person in charge.

NOTE: Check the load bearing capacity of the lift (it must be able to sustain the weight of the truck + operator + load if present).

• Approach the lift slowly.

• Only activate the lift after the truck is correctly centred and perfectly level, so that the lift is well balanced.

• Make sure that the forks or other parts of the truck do not protrude beyond the lift perimeter.

Description / Operating instructions ROUTE NOTE: Never enter railway wagons or trailers without first checking that their wheels are braked or locked with chocks. Check the grip and condition of the flooring. Check the width, the load capacity and the reliability of loading platforms.

Study the route.

Check that the manoeuvring clearance zone is free.

Pay attention to obstacles and the surrounding space, especially the headroom.

Points of hazard along corridors or pathways must be made safe and appropriately signposted, with road signs and any additional signs that may be required.

• Never start the truck if there is someone positioned between the truck and a fixed structure.

DRIVING • Pay attention and do not exceed the established speed limits.

• Pay attention to and observe road signs.

• Do not overtake and use the horn in narrow lanes, on a bend, at crossings and in all cases of poor visibility.

• Do not travel alongside other trucks.

• Observe the rules of priority.

• Slow down at crossroads, pedestrian crossings, on ramps and gangways and on wet or slippery surfaces.

WARNING Do not use the truck on routes outdoors when there is a risk of storms with lightning strikes. The truck does not have a grounding system.

PERSONS • Never carry passengers on the truck.

• Prevent persons from standing under the fork lift mechanism or within its range of action.

41

Description / Operating instructions STOPS • Before parking, lower the load completely.

• if you leave the truck, switch it off and press down the emergency power off button.

• If the truck is to remain out of sight of the operator, he must remove the key in order to prevent unauthorised personnel from using the truck.

• Do not park on slopes; if unavoidable, place chocks under the wheels. During halts, even for brief periods, do not stop the truck on a gradient unless absolutely unavoidable.

42

REMOVAL IN THE EVENT OF LIFT TRUCK BREAKDOWN

CAUTION The operations mentioned above must be carried out wearing protective gloves, protective boots and suitable clothing.

Description / Operating instructions CONSIDERATIONS CONCERNING LOADS

PICKING UP THE LOAD FROM THE GROUND

Avoid loading materials that may fall. You should bear in mind that the truck, even when it is equipped with a load backrest, offers a reasonable degree of protection for the operator against objects falling, but it cannot protect against all possible risks.

• Position the truck in line with the load to be lifted.

• Move slowly when moving the forks into position under the load and make sure that the load is correctly centred on the forks.

• After fitting the forks in the pallet, slightly lift the load just enough to move it.

Only move stable loads with weights that can be supported by the truck (see the summary identification data plate on the truck). Pick up the load so that its weight is well distributed and balanced on the forks.

Even if a load no greater than that indicated on the load capacity data plate affixed on the truck weighs entirely on the tip of a fork, this could constitute a tipping hazard. The load must not excessively overreach the tip of the forks.

PUTTING DOWN THE LOAD ON THE GROUND • Put the load on the ground.

• Lower the forks.

• Move slowly to remove the forks from the pallet.

NOTE: During all the operations of picking up/putting down the load, use the machine at the lowest speed allowed by the operation. Always make sure that the space in the aisle is sufficient, during operations of picking up/putting down goods, to prevent the operator from coming into contact with other persons working in the same aisle.

43

Description / Operating instructions WARNING The lift unit is lowered by gravity.

If the lowering command does not actually lower the lift unit (laden or unladen), take immediate action, placing adequate guarding to ensure that no one stands below or near the raised load, transferring the load if possible using other vehicles and calling the YALE service centre for assistance.

LOAD STABILITY

WARNING • Only work with stable loads.

• Never load unstable elements.

• Do not handle a load, composed of a number of separate parts, when any one of them is precariously balanced and in danger of falling.

• It is not permitted to carry swinging loads.

POSITIONING THE LOAD Make sure that the weight of the load is equally distributed and balanced on the forks, so that the load will not overturn when negotiating a bend.

WARNING A load that is placed in an unbalanced position on the forks will increase the risk of overturning.

44

Description / Operating instructions chapters and the instructions described below, before driving the truck.

CENTRED LOAD

VISIBILITY In order to define the concept of visibility, it is necessary to indicate the terminology used for the direction of movement (see the pictures).

This truck can be driven with the operator either on the machine or occasionally on the ground.

Generally, the truck forward movement direction provides the operator with the best visibility.

A. B.

FORWARD BACKWARD

NON-CENTRED LOAD

DRIVING RULES NOTE: Carefully read the GENERAL CONDITIONS, RISKS and the GENERAL STABILITY PRINCIPLES 45

Description / Operating instructions WARNING If the truck has to travel in conditions of poor visibility, it is recommended that the operator be assisted by specialised and authorised personnel.

A. SIDE SHIFT B. PICK UP / PUT DOWN Keep the "BACKWARD" driving position for the load picking up/putting down operations (With the operator on the ground).

Keep the "FORWARD" driving position for the truck or load movement.

46

Description / Operating instructions CHANGING DIRECTION The direction of the truck is changed by turning the steering tiller (or, if present, the steering wheel).

WARNING Drive slowly when negotiating bends. When the truck is cornering it tends to increase in speed, due to inertia and the centrifugal force.

The truck can overturn even when moving at low speed, depending on where the centre of gravity of the load is located. If a dangerous bend is approached at a relatively high speed, the truck could overturn. The truck is less stable when the forks are raised, even without a load.

Loads not centred on the forks and uneven road surfaces increase the risk of overturning. These trucks are designed to operate in relatively narrow spaces; when negotiating a bend, the operator must take into account the movements the truck will make when changing direction.

The geometry of the truck is such that it can pivot on a point mid way between the wheels, which means that if a tight 90° bend is to be negotiated, the entire length of the truck (including the dimension attributable to the load) will be needed to make the turn. The space required by the truck to turn is called the manoeuvring clearance.

Most operators fully understand the need to be careful when handling a load, but some do not realise that the truck can overturn even when there is no load being carried. It is in fact easier to overturn a truck when it is travelling unloaded and with raised forks.

47

Description / Operating instructions WARNING While driving in fork direction side take great care with the manoeuvring clearance. Always make sure that the space required to negotiate the bend is free of obstacles. Serious accidents can occur if insufficient manoeuvring clearance is allowed when negotiating a bend.

DANGER To eliminate the risk of overturning, never turn on a gradient.

SPEED The speed at which the truck is driven must take into account the presence of people in the truck working area, visibility, floor conditions and the load.

Pay special attention when driving on wet and slippery surfaces. In any case, the truck must travel at a speed which allows its immediate stop in safety conditions.

PEDESTRIANS Use the horn to warn others of your presence and of the potential danger that this may cause to exposed persons such as pedestrian and persons on the truck’s route.

Slow down near crossroads, on ramps and at blind bends in order to reduce the risk of hitting people.

1.

48

RUN OUT

Description / Operating instructions PRUDENCE

ASCENTS AND DESCENTS

Always drive the truck with extreme caution in order to avoid skidding, jumping, etc.

Avoid creating dangerous situations by engaging in competitions, acrobatics or misusing the truck in any other way.

Proceed slowly on ramps or slopes. The ascents and descents must be travelled, either laden or unladen, with the forks pointing upstream. When laden or unladen, lift the forks just enough to allow the movement of the pallet without dragging it on the ground.

WARNING Always bear in mind the maximum gradient that the truck can travel (see the dedicated "SPECIFICATION SHEET" paragraph).

49

Description / Operating instructions ASCENT

DESCENT OVERTAKING Never overtake other trucks near junctions, blind corners or other dangerous points.

OBSTACLES ON THE GROUND Avoid holes, bumps, puddles, and any scattered objects that may cause skidding or overturning. Always choose the easiest route for the truck.

50

Description / Operating instructions MANOEUVRING SPACE Pay attention to the manoeuvring space, with special regard to the forks and to the manoeuvring clearance.

The operator should remember that the forks may protrude beyond the load, which means they may collide against or lift other material accidentally.

NARROW PASSAGES Narrow passages must be appropriately signposted.

Before entering a narrow passage, the driver must check that there are no persons or other trucks in the passage.

KERBS AND VERGES

DANGER Always observe safety distances from the edge of hazardous routes, e.g. platforms, verges, ramps, etc.

Always pay attention to the clearance while driving in the fork direction side.

Remember that if you steer so as to move away from the end of a loading platform, while driving in the fork direction side, the truck will move towards the end of the platform.

In this case, or if there are insufficient measures to protect people or prevent collisions with other trucks, it is forbidden for the driver to enter the passage.

1.

RUN OUT 51

Description / Operating instructions CONNECTION RAMPS Before proceeding along connection ramps, the operator must make sure that the ramp has been correctly mounted and secured and that it is of an appropriate capacity. On connecting ramps, proceed only at reduced speed and with great caution.

The operator must make sure that the vehicle on which the loading and unloading operations take place does not move and that it can support the weight of the truck, the load and the operator.

BRAKING DISTANCE In all driving situations the truck must be driven at a speed that will allow it to stop safely in all situations, even in the event of unexpected obstacles.

Remember that braking distances increase when the truck is loaded and on smooth or wet floors.

52

TRANSFER ON ROAD-GOING TRAILERS AND RAILWAY WAGONS Before beginning work inside a trailer or a railway wagon, the operator must be trained to work in these particular conditions and must observe the following instructions: • Never use the truck to open or close the doors of the wagons; • Check that the trailer brakes have been applied and that blocks have been positioned on both rear wheel units (unless a specific locking mechanism is installed); • Fixed supports may be required to sustain the front and rear parts of the trailer, in order to prevent movement when loading and unloading material; • Make sure that the railway wagon brakes have been applied and that the wheels are correctly locked for loading and unloading operations, in order to prevent movement caused by the truck entering and leaving the wagon; • Check the solidity of the manoeuvring surface and that the deck board is capable of supporting the weight of the truck, the load and the operator.

Description / Operating instructions DRIVING IN CONTAINERS The operator must make sure that the container on which the loading and unloading operations take place does not move and that it can support the weight of the truck, the load and the operator.

STOPPING THE TRUCK The truck should always be stopped as gradually as possible. Sharp braking and skidding can cause the load to fall.

PARKING THE TRUCK

If the truck is parked on a slope, place chocks under the wheels on the downhill side so that the truck is unable to move.

CAUTION Never park the truck in a position where it may obstruct access to emergency exits, stairs or fire-fighting equipment.

Never park the truck in a cold room, even if it is a vehicle model specifically manufactured to work in cold rooms.

NOTE: THE OPERATOR MUST NEVER LEAVE THE LIFT TRUCK IN A CONDITION SUCH THAT IT COULD CAUSE DAMAGE OR INJURY. In order to park the truck, proceed as follows: • • • • •

Stop the truck.

Lower the forks completely.

Switch off the truck.

Remove the key from the dashboard.

Press the emergency power off button.

With the truck stationary, the parking brake located on the drive wheel will be applied automatically.

53

Description / Operating instructions STORAGE AND RESTARTING OPERATIONS

7. Protect the battery terminals with an anti-corrosion product (pure Vaseline).

STORING FOR A SHORT PERIOD OF INACTIVITY

8.

Short term storage is intended as storage for a period from 1 to 6 months.

The procedure detailed below is suitable for environmental conditions with temperatures above 0°C.

9. Check that the filler caps are on tight.

In order to allow for different local conditions this procedure must be adjusted. Unforeseen variations in climatic conditions during the period of inactivity should also be taken into account.

In order to store the truck for a short period of time, proceed as follows: 1. Position the truck in a dry and dust-free place.

2.

Switch off the truck using the key and make sure that all the instruments are turned off.

3. Perform a thorough general cleaning operation.

4.

Keep the lifting system completely lowered; grease the guideways and lubricate only the exposed part of the cylinder rods.

5.

Check that the battery is charged and that the electrolyte level is correct. If not, recharge the battery and top up with distilled water.

6.

Disconnect the cables from the battery. Protect the terminal clamps with insulating tape.

54

10.

Important: recharge the battery every month and top up with distilled water if necessary.

Position blocks under the chassis in order to keep it raised from the ground.

This will prevent the weight of the truck from deforming the wheels and rollers over time. Take care when raising the truck to position the blocks and make sure that it is in a stable position.

Protect the truck with a sheet or other protective material. In humid conditions, 11. a cover is not sufficient to protect the truck from rusting; if the environment is humid or saline, it is preferable to store in a closed environment.

STORING FOR A LONG PERIOD OF INACTIVITY Storage periods exceeding 6 months.

In order to store the truck for a long period of time, proceed as follows: 1.

Carry out all suggested operations for a short storage period (as described in the "SHORT TERM STORAGE" paragraph).

Remove the battery from the truck and place it in a position which is raised from the ground and has been approved for this purpose. Make sure that local 2. legislation is complied with. Long storage periods can damage batteries. If possible, it is advisable to use the batteries removed trucks in storage in other trucks performing normal duties. Batteries deteriorate when not used.

3. Treat the chassis and the external surfaces with a protective spray.

Description / Operating instructions RESTARTING AFTER A SHORT PERIOD OF INACTIVITY When restarting the truck, the following procedure is recommended: 1. Remove the blocks and rest the truck on the ground.

2.

Reconnect the cable clamps to the battery terminals, clean them and smear the terminals with Vaseline.

3. Check the battery charge and the electrolyte level.

4. Check the level and condition of the hydraulic system oil.

5. Grease all the parts that require greasing.

Check all the truck functions and especially the braking system.

6. Perform a few trial braking operations without a load and check that the braking action is continuous.

RESTARTING AFTER A LONG PERIOD OF INACTIVITY When restarting the truck, the following procedure is recommended: Carry out all suggested operations for restarting after a short period of inactiv1. ity (see the "RESTARTING THE TRUCK AFTER A SHORT PERIOD OF INACTIVITY" paragraph).

Refit the battery; connect the cable clamps to the battery terminals, clean 2. them and smear the terminals with Vaseline. Check the battery charge and the electrolyte level.

NOTE: If there are any malfunctions, switch off the truck and contact the YALE service centre.

NOTE: If there are any malfunctions, switch off the truck and contact the YALE service centre.

55

Maintenance / Battery

Maintenance / Battery MAINTENANCE GENERAL PRINCIPLES This section includes the Maintenance schedule and detailed instructions for inspection and maintenance operations.

The maintenance schedule indicates the recommended time intervals between routine inspection, maintenance and replacement operations. These intervals are those envisaged for normal work cycles.

By normal work cycle one intends eight hour shifts on a daily basis in relatively clean environments and on suitable floor surfaces.

56

Particular environmental conditions (e.g. dusty environments or cold stores) may call for a reduction in the intervals indicated in the maintenance schedule.

Failing to follow the recommend maintenance schedules will reduce the operating efficiency and working life of the truck.

The operator or maintenance staff must carry out periodic inspections, formulating his opinions or evaluations only on the basis of safety criteria, without being influenced by business or economic factors.

He must have sufficient knowledge and experience to be able to verify the condition of the truck.

YALE dealers can provide specialised personnel and suitable equipment for the performance of these maintenance operations.

It is advisable to ask the YALE service network annually to carry out a check to ensure that the truck meets safety standards.

Maintenance / Battery NOTE: THE REPLACEMENT OF PARTS MUST BE ENTRUSTED ONLY TO SPECIALIST SERVICE TECHNICIANS APPROVED BY THE TRUCK MANUFACTURER. TO CARRY OUT ALL REPLACEMENTS, PLEASE CONTACT THE YALE SERVICE CENTRE.

WARNING • Do not use a truck if it requires repairs.

• Any damage or incorrect operation of the truck must be reported immediately to the Yale service centre.

• If the truck needs to be repaired, place a clearly visible sign saying “OUT OF ORDER - DO NOT USE” on the truck and remove the key from the control panel.

• Trucks may only operate when they are in good condition.

• Never carry out repairs or fine tuning operations on the truck without the required authorisation and the necessary technical training. Incorrectly executed repairs or fine tuning operations may lead to dangerous working conditions.

OUT OF ORDER DO NOT USE

57

Maintenance / Battery CAUTION If checks, maintenance or cleaning operations are carried out immediately after the truck is stopped, some components of the motor or of the hydraulic system could be hot.

It is recommended to wear safety footwear, gloves, and suitable clothing.

NOTE: If traffic is obstructed because of a truck breakdown, move the truck as indicated in dedicated paragraph, “Removal in the event of truck breakdown”.

58

SCHEDULED MAINTENANCE TABLES ■

= Checks and maintenance to be performed by the operator or the person assigned to truck maintenance.

TO CARRY OUT THESE CHECKS AND MAINTENANCE OPERATIONS, PLEASE REFER TO THE INSTRUCTIONS GIVEN IN THE “MAINTENANCE PROCEDURES” PARAGRAPH.

●

= Checks and maintenance operations that should only be performed by a technician authorised by the truck manufacturer.

TO CARRY OUT THESE CHECKS AND MAINTENANCE OPERATIONS, PLEASE CONTACT THE YALE SERVICE CENTRE.

X

= Replacement of parts that should only be performed by a skilled technician authorised by the truck manufacturer.

TO CARRY OUT THESE REPLACEMENTS, PLEASE CONTACT THE YALE SERVICE CENTRE.

Maintenance / Battery

CHASSIS

OPERATION DESCRIPTION CHECK THE SCREWS AND BOLTS VISUALLY CHECK THE MAIN WELDS GENERAL CLEANING

BRAKING SYSTEM

CHECK SERVICE BRAKING ACTION CHECK REVERSE BRAKING ACTION CHECK EMERGENCY BRAKING ACTION CHECK RELEASE BRAKING ACTION

LINKAGE, FORKS WHEELS & HYDRAULIC LEVERS TYRES SYSTEM

ELECTROMAGNETIC PARKING CHECK CHECK FOR OIL LEAKS

Every 8 hours 1 day

■

CHECK CONDITION OF LOAD WHEEL BEARINGS (1)

■ ■ ■

CHECK CONDITONS OF FORKS

■

CHECK CONDITIONS OF THE LINKAGE

■

CHECK CONDITION AND WEAR OF LOAD WHEELS (1)

Every 3000 hours 3 years

■ ■ ■ ■ ■ ■ ■ ■ ■

CHECK HYDRAULIC OIL LEVEL CHECK CONDITION AND WEAR OF DRIVE WHEEL (1)

MAINTENANCE INTERVALS Every Every 1000 hours 2000 hours 1 year 2 years

59

Maintenance / Battery

GEARBOX PLATES, BATTERY ELECTRONIC CONTROLS, TILLER DECALS SYSTEM INSTRUMENTATION

OPERATION DESCRIPTION

(1)

60

Every 8 hours 1 day

BELLY SWITCH OPERATION CHECK (REVERSING BUTTON)

■ ■ ■

HORN BUTTON OPERATION CHECK

■

BATTERY PLUG/SOCKET INTEGRITY CHECK

■

CHECK BATTERY CHARGE LEVEL

■

CHECK CONDITIONS OF VISIBLE WARNING AND INFORMATION PLATES AND DECALS (1)

■

GENERAL CLEANING OF VISIBLE WARNING AND INFORMATION PLATES AND DECALS

■

STEERING TILLER OPERATION CHECK CHECK TIGHTENING OF TILLER HEAD SCREWS

LUBRICATE GEARBOX

Replace if necessary.

MAINTENANCE INTERVALS Every Every 1000 hours 2000 hours 1 year 2 years

■

Every 3000 hours 3 years

Maintenance / Battery CLEANING CLEANING OF CASING, PLASTIC COVERS, PLATES, DECALS AND PAINTED PARTS Use only dry air, cloths moistened with water, or cleaning products.

CAUTION Do not use jets of water or steam, a solvent or explosive, oxidizing, flammable, toxic, corrosive and harmful/irritant product which can damage the truck, plates, decals or that can be dangerous for the operator.

CLEANING OF ENGINES, BRAKING SYSTEM AND ELECTRIC PANEL Use only dry air at low pressure and a clean dry brush.

CAUTION Do not use wet rags, water jets, vapour, solvents or flammable products that may damage the truck or that may be dangerous for the operator.

CLEANING OF HYDRAULIC SYSTEM, REDUCTION GEAR AND BEARING SLIDING GUIDES Use degreasing products.

CAUTION Do not use water jets, vapours, solvents or flammable products that may damage the truck or that can be dangerous for the operator.

BATTERY CLEANING Follow the directions on the instruction manual of the battery.

61

Maintenance / Battery MAINTENANCE PROCEDURES CAUTION Before carrying out all the maintenance operations described in this chapter ensure that the truck is on a flat surface, with no load (1) and that the battery is disconnected (1).

(1)

Except for the checks that require the use of the load or which require that the machine is in operation.

BRAKING SYSTEM Carry out the checks listed below with the forks raised just enough to allow the transfer on a section of flat and dry road, free from obstacles and sufficiently long to allow the truck to stop in case of brakes failure.

WARNING Never allow people to stand around anywhere near the truck when testing the braking action.

Never carry out tests where damage could be caused by a lengthy braking action.

62

CHECK SERVICE BRAKING ACTION Move the steering tiller into position “B”.

CHECK EMERGENCY BRAKING ACTION Drive the truck forward and press the emergency button.

CHECK REVERSE BRAKING ACTION Drive the truck forward and reverse the travel using the transfer control throttles.

CHECK RELEASE BRAKING ACTION Drive the truck forward and release the control throttles in rest position.

NOTE: In the event of irregular operation, contact the YALE service centre.

Maintenance / Battery HYDRAULIC SYSTEM

WARNING During the following tests, never allow anyone to climb onto the forks, never insert any part of the body between the lifting mechanisms.

CHECK FOR OIL LEAKS Check if there are evident oil leaks in the hydraulic system.

NOTE: In the event of oil leakage or irregular operation of the valves, contact the YALE service centre.

NOTE: Should replacement be necessary, contact the YALE service centre.

FORKS CHECK CONDITIONS OF FORKS Check the integrity and wear of the forks.

Check that there is no visible damage such as cracked, deformed or very worn forks.

NOTE: In the event of trouble, contact the YALE service centre.

WHEELS & TYRES CHECK THE CONDITION AND WEAR OF DRIVE WHEEL, LOAD WHEELS It is important that there are no strands or any other material wrapped between the rim and the drive unit hub, between the load wheels and the support (levers/frame) and that there are no objects stuck in, flattening or big cuts in the tread.

The consumption of the load wheels must take place evenly for both of them.

63

Maintenance / Battery LINKAGE, LEVERS

CONTROLS AND INSTRUMENTATION

LINKAGE, LEVERS CONDITIONS CHECK

BELLY SWITCH OPERATION CHECK

Check that the linkage and levers for visible damage such as cracks or bends.

When lifting the load arms, with load arms completely lowered, check that the tips lift at the same time.

Check the integrity and correct operation: the truck must stop and reverse the travel (see the dedicated "BELLY SWITCH - REVERSING BUTTON" paragraph).

NOTE: In the event of trouble, contact the YALE service centre.

STEERING TILLER CHECK STEERING TILLER CONDITIONS AND OPERATION Check that the steering tiller turns freely and does not present an excessive clearance.

NOTE: In the event of irregular operation, contact the YALE service centre.

64

HORN BUTTON OPERATION CHECK Check the integrity and correct operation: horn operation.

CHECK TURTLE MODE OPERATION Check the integrity and correct operation: the truck travels at low speed.

NOTE: In the event of irregular operation, contact the YALE service centre.

Maintenance / Battery ELECTRICAL SYSTEM

PLATES AND DECALS

BATTERY PLUG/SOCKET INTEGRITY CHECK

CHECK CONDITIONS AND CLEANING OF VISIBLE WARNING AND INFORMATION PLATES AND DECALS

Check the integrity of the battery socket and plug.

The plug must be securely attached to the truck and the handle for quick removal must be securely attached to the socket.

NOTE: Should replacement be necessary, contact the YALE service centre.

NOTE: In the event of irregular operation, contact the YALE service centre.

BATTERY CHECK BATTERY CHARGE LEVEL Check the battery charge level through the battery discharge indicator (see dedicated "DISPLAY" paragraph).

65

Maintenance / Battery FIRST TIME SETUP

1.

Disconnect the battery.

INSTALL THE TILLER HANDLE

2.

Remove handle shaft (item 2) from handle socket.

If the truck was shipped without the tiller handle installed, attach the handle to the truck.

3.

Put the chassis connector through the wire supporting plate (item 5) and lock hole.

4.

Install the handle assembly (item 1) to handle socket.

Be careful to avoid damaging the wire harness.

5.

Install handle shaft through the handle assembly and handle socket.

6.

Install spring pin (item 3) to left side of handle shaft.

7.

Press down on the handle assembly and remove spring holder (item 4).

8.

Connect and lock the wire harness from handle assembly to chassis connector.

9.

Fix the wire harness to wire holder (item 6).

10. Reconnect the battery.

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Maintenance / Battery FIRST TIME USE CHECKS • Check that all accessories are complete and in good condition.

• Check that the hydraulic system operates correctly and has no leaks.

• Check the battery state of charge and charge if necessary.

NOTE: During storage or shipping, the drive wheel may be slightly flattened. After a short time driving the truck, the wheel shape will be restored.

• Install the battery if it is not already installed.

• Check that all truck functions work correctly, including travel, lifting and lowering, braking, and horn.

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Maintenance / Battery REPAIR PROCEDURES

Service mode for non-CE-certified trucks

BRAKE RELEASE MODE (SERVICE MODE)

WARNING The brake release mode is for service use only. To reduce the risk of personal injury, do not use brake release mode in normal operation.

This pallet truck is fitted with an electromagnetic brake.

When the truck has no power, the brake is closed and the truck will not move. If the truck has no power but must be moved to a service location, enter brake release mode so that the truck can be pulled manually.

1.

Make sure the power is off and the power button is down.

2.

Press and hold the Horn button, then lift the power button to provide power to the truck.

The display will read NO BRAKE and the truck will beep to indicate the brake release mode is active.

3.

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Manually pull the truck to the service location.

Maintenance / Battery REPLACE THE DRIVE WHEEL

1.

2.

Support the truck on blocks so that the drive wheel (item 9) is off the ground.

3.

Remove 3 bolts (item 8) from controller cover (item 7), then remove the controller cover .

4.

Remove 4 bolts (item 4) from the nut cover (item 3), the remove the nut cover.

5.

Remove nut (item 2).

6.

Gently tap the wheel shaft (item 10) and pull it out of the drive wheel.

7.

Remove the drive wheel.

8.

To install the drive wheel, perform these steps in reverse order.

9.

Reconnect the battery.

Disconnect the battery.

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Maintenance / Battery REPLACE THE LOAD WHEELS

1.

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Turn off the truck, remove the battery, and turn over the truck. Be careful to avoid damaging the tiller handle.

2.

Remove snap ring (item 1) with snap ring pliers, the remove the shaft (item 2).

3.

Tap out the spring pin (item 3), then tap out the wheel fork shaft (item 4).

4.

Remove the load wheel assembly (item 5 for tandem wheel, item 13 for single wheel).

5.

Tap out the spring pin (item 6 or 9), then remove the wheel shaft (item 7 or 10) and remove the load wheel.

6.

Replace the load wheel (item 8 for tandem wheel, item 12 for single wheel). For single wheels, install nylon gasket (item 11).

7.

Reinstall wheel shaft and spring pin.

8.

Reinstall the load wheel assembly into the frame, then repeat steps 1 through 3 in reverse order to complete installation.

Maintenance / Battery REPLACE THE HYDRAULIC CYLINDER

1.

Disconnect the battery.

2.

Lower the forks completely, raise up the truck, and put a 200 mm (8 in) block underneath the ends of the fork closest to the main frame.

3.

Remove screw (item 4) and remove wire clamp (item 5), then remove 4 screws (item 7) with a hex wrench.

4.

Remove the oil pipe (item 6), remove the piston rod shaft end (item 1) and shaft gland (item 3).

5.

Press down the piston rod, allow the cylinder to separate from the frame, and remove the cylinder assembly from the truck.

6.

Remove the oil pipe join (item 8) and install on the new cylinder assembly.

7.

Place the new cylinder on the cylinder holder and install locking screw (item 7).

8.

Reinstall the piston shaft, pull up on the piston rod, and connect the shaft gland to the frame.

9.

Connect and tighten the oil pipe, then reinstall the wire clamp.

10. Take the truck off of the 200 mm (8 in) block, then remove the battery.

11. Open the screw on the tank, then fill the tank with LHV32 hydraulic oil, close the screw on the tank, then install and connect the battery.

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Maintenance / Battery CAUTION To avoid damage to the seal ring and oil leaks, always bleed the air from the cylinder after replacement.

12. Loosen screw (item 11), then use a truck to lift a pallet with a load of at least 500 kg (1102 lb). Lift and lower

72

the pallet 2 or 3 times to bleed air from the cylinder, then tighten the screw.

13. Reconnect the battery.

Maintenance / Battery REPLACE SEAL KITS

1.

Disconnect the battery.

2.

Use a hook head wrench to unscrew the upper part of the cylinder (item 1), and remove the upper part from the rest of the cylinder (item 2).

3.

Remove guide ring (item 3) and guide sleeve (item 4).

4.

Pull out piston (item 5).

5.

Remove dust ring (item 6), seal ring (item 7), and step seal (item 8). Replace all with new parts.

6.

Reinstall piston into the top of the upper cylinder.

Install in the direction of the arrow in the image, and be careful not to damage the seals.

7.

Reinstall guide sleeve and guide ring. Reinstall upper cylinder into the rest of the cylinder.

8.

Reconnect the battery.

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Maintenance / Battery REPLACE THE HANDHELD INTELLIGENT CONTROL

3.

If the handheld intelligent control must be replaced for any reason, the current handheld intelligent control must be unpaired from the truck, and the new handheld intelligent control must paired.

Press and hold the white button (item 2) on the circuit board until the red LED (item 1) turns of.

The current handheld intelligent control is now unpaired from the truck and will not operate the truck anymore.

Pair a new handheld intelligent control 1.

Ensure that the original handheld intelligent control is unpaired from the truck.

2.

Press the white button on the display circuit board (item 2) one time.

The LED (item 1) will blink red once.

3.

Unpair the handheld intelligent control 1.

Turn on the truck.

2.

Remove the cover to allow access to the display circuit board.

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Quickly press any key on the handheld intelligent control.

The LED (item 1) will flash red 4 times to indicate that the new handheld intelligent control is paired to the truck.

Maintenance / Battery

Figure 1. WIRING DIAGRAM 75

Maintenance / Battery

Figure 2. HYDRAULIC DIAGRAM

76

Maintenance / Battery Table 1. HYDRAULIC SCHEMATIC COMPONENTS Item

Description

Item

Description

1

Tank

5

One-way valve

2

Oil filter

6

Solenoid valve

3

DC motor

7

Overflow valve

4

Gear pump

8

Built-in balancing valve

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Maintenance / Battery TROUBLESHOOTING OBSERVED SYMPTOM TROUBLESHOOTING Observed failure

Possible cause

No power

Loose terminal or bad switch connection Check battery and wire harness termicauses interrupted current nals, tighten screw connections, and keep switch contacts clear

Lift speed not uniform

Air in the hydraulic cylinder

Bleed air from cylinder as described in cylinder replacement procedure

No lift

Hydraulic oil is low

Fill with hydraulic oil L-HV32

Low battery

Recharge battery

Oil leaking

Inspect and repair hydraulic system, replace seal kit, or tighten oil pile connection screws

Overload

Reduce the load weight

Lift limit switch failure

Repair the limit switch

Hydraulic assembly is loose

Tighten the retaining screw

Hydraulic motor or gear pump failure

Inspect hydraulic motor and gear pump

Abnormal noise during lifting

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Solution

Maintenance / Battery FAULT CODE TROUBLESHOOTING

When the controller detects a failure, a fault code is displayed on the display in the format ERR+nn, where nn is the fault code number from this table.

Fault code

Description

Possible cause

Solution

SRO

Operation sequence wrong

Lift, lower, or travel comman- Turn truck power off and then ded before handle is in the on, and be sure to pull the operation position handle into operating position before commanding lift, lower, or travel

11

Parameters incorrectly set

Parameters setting is incorrect

12

Overcurrent

Motor short or controller fault Replace motor or controller or Hall signal interference

14

M+ current zero bit detection error

Controller failure

Replace controller

15

— current zero bit detection error

Controller failure

Replace controller

16

Emergency reverse button has signal when turning on power

Emergency reverse button stuck or LCD monitor fault

Check or replace the belly switch

Adjust the parameters or replace the controller

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Maintenance / Battery Fault code

Description

Possible cause

Solution

18

Motor Hall fault

Motor Hall fault, connector fault or controller fault

Check the motor wiring, replace motor, or replace controller

19

Temperature sensor fault

Temperature sensor failure or Check the motor wiring or open in sensor wiring replace the motor

21

Potentiometer fault

Potentiometer failure or fault in potentiometer wiring

Check the potentiometer wiring or replace the potentiometer

22

Overheat current limit

Controller overheated and within the current limit working state (derate)

Wait 15-25 minutes for the controller to cool before operating

23

Overheat protection

Controller overheated and shut down

Wait 15-25 minutes for the controller to cool before operating

25

Motor overheat limit

Motor temperature too high, output limited (derate)

Wait 15-25 minutes for the controller to cool before operating

26

Motor stalling

Motor stall protection active

Replace the motor

27

Brake fault

Brake failure, or open on brake wiring

Check and repair the brake wiring or replace the brake

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Maintenance / Battery Fault code

Description

Possible cause

Solution

29

Motor open

Open on motor cable or motor fault

Check and repair the motor cabling or replace the brake

31

Battery voltage low current limit

Low battery voltage and within the current limit working state (derate)

Charge or replace the battery

32

Low battery voltage protection

Low battery voltage and shut Charge or replace the battery down

33

Over high battery voltage

Battery voltage too high

Wait 15-35 minutes for voltage to level before operating

35

Contactor error

Controller fault

Replace controller

38

Communication error

Display wiring fault or display Check and repair display wirfault ing, replace tiller handle harness, replace the display, or replace the controller

39

Version error

Controller version is incorrect Replace controller

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Maintenance / Battery BATTERY INTRODUCTION NOTE: THE BATTERY ON BOARD THE TRUCK IS THE ONLY POWER SOURCE THAT MAY BE USED. NO OTHER POWER SOURCE CONNECTED BY CABLES TO THE TRUCK MAY BE USED.

WARNING Failure to follow the instructions in this chapter and the information of the battery and charger instruction manuals, can cause serious damage to persons or property in relation to the danger level of the batteries.

The aim of this chapter is to provide the operator with the instructions needed to perform the battery checking and recharging operations in safe conditions.

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It is recommended to use the battery that is included with the truck. If it requires replacement, replace it with the same type. The manufacturer shall not be liable for accidents caused by a failure to operate in accordance with this specification.

WARNING It is recommended to wear safety footwear, gloves, safety glasses and suitable clothing when working with the batteries.

The container must be kept in a vertical position (or as close to vertical as possible): it must never be turned upside down in order to avoid electrolyte spillage.

The electrolyte present in the solution can cause serious injury.

Maintenance / Battery CHOICE OF BATTERY The battery used in this truck is a "TRACTION BATTERY".

The truck is normally supplied by the manufacturer complete with traction battery.

If it is not, the purchaser must follow the indications given in the specification sheet included in this operation and maintenance manual.

The choice of battery must fall within the range of the specifications indicated in the specification sheet depending on the more or less demanding duties the truck will be required to perform.

WARNING It is recommended to use batteries compatible with the truck, for dimensions, weight and capacity.

• Do not use batteries that are too small for the compartment where they are housed (even if the capacity is the same).

• Do not make alterations to the battery compartments in order to house batteries that are too large.

• Do not use batteries of lower weight (even if the capacity is the same); this can dangerously affect the stability of the truck.

• The weight of the battery must fall within the range between the battery min. and max. weight stated on the summary table of the machine identification data plate.

• Do not use batteries with different capacities from those specified on the specification sheet.

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Maintenance / Battery LITHIUM-ION BATTERY WARNINGS WARNING Please read carefully and follow these terms and conditions for installing and using the battery. Improper installation or use may cause excessive heat and other hazardous conditions. Failure to follow these instructions may pose risks to life and property.

• Do not immerse the battery in water. Keep it in a cool and dry environment when not in use.

• Do not put turn the battery upside down.

• Do not transport or store batteries with metal objects such as hairpins, coins, or tools.

• Do not strike, drop, throw, crush, or step on the battery.

• Please read the battery warning labels.

• Direct welding on batteries is prohibited.

• Do not subject the battery to fire or heat.

• Do not pierce the battery with nails or other sharp objects.

• Do not use metal to connect the battery anode and cathode directly to short-circuit the battery.

• Do not disassemble the battery or change the battery structure.

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Maintenance / Battery WARNING

WARNING

If the battery leaks and electrolyte comes into contact with skin or clothing, rinse immediately with clean water.

The battery has been inspected prior to shipment. If you find deformation, heating, or peculiar smells upon receiving the battery, please contact the manufacturer.

If the battery leaks and electrolyte comes into contact with skin or clothing, rinse immediately with clean water.

The battery should be stored at room temperature and charged to about 30-50% of capacity. When storing for a long time, it is recommended to charge the battery every 3 months to prevent over-discharge.

If the battery emits a peculiar smell or heat, becomes discolored or deformed, or shows any other abnormality during use, storage, or charging, immediately remove the battery from the device or charger to a safe place and stop using.

Keep batteries out of reach of children. Cover waste batteries with insulating paper to reduce risk of fire or explosion.

Do not use unqualified equipment when charging and discharging, and follow the instructions.

Do not mix batteries of different manufacturers or different types and models. Do not mix old and new batteries.

85

Maintenance / Battery LITHIUM-ION BATTERY SPECIFICATIONS Model

48V/10Ah; 48V/15Ah

Capacity

10Ah/15Ah

Voltage

48V

Battery life

800-1000 cycles

86

Maintenance / Battery Work environment Work envi- Room temronment perature temperature

Cold storage

Use condition

<0°C

0°C

45°C

55°C

75°C

(<32°F)

(32°F)

(113°F)

(131°F)

(167°F)

Prohibited

Use allowed

Discharge capacity

Normal discharge

Battery life impact

No impact

Use condition

High

Prohibited

Cold storage use is prohibited

Discharge capacity Battery life impact Battery tem- N/A perature

Use condition

Prohibited

Use allowed

Discharge capacity

Normal discharge

Battery life impact

No impact

Prohibited

Capacity loss

87

Maintenance / Battery Work environment Charging N/A environment temperature Battery parameter setting

88

Use condition

0°C

45°C

55°C

75°C

High

(<32°F)

(32°F)

(113°F)

(131°F)

(167°F)

Prohibited

Charging allowed

Charging prohibited

39.2V

43.5V

44.5V

54.6V

Black screen

0%

4%

100%

Vehicle stops

Traction speed derate, charge symbol blinking

Normal

Battery life impact

ApproxiVoltage mately 20°C Power dis(Approximately 68°F)

<0°C

play

Vehicle con- No output dition

Maintenance / Battery RECHARGING THE BATTERY

BATTERY CHARGER

BATTERY CHARGE STATUS

The battery charger should be chosen according to the technical characteristics of the battery:

The battery provided by the manufacturer is already correctly charged and filled with electrolyte to the right level.

The level of charge of the battery is shown by the battery charge indicator located on the truck display.

RECHARGING ENVIRONMENT

WARNING The battery should be recharged in a special well ventilated room separated from the working environment because the batteries generate flammable gases that may cause explosions if they come into contact with flames or sparks.

In the case of forced ventilation, flues also used for the extraction of combustion products may not be used.

• • • • •

Number of elements in the battery Nominal capacity.

Type: lithium-ion Available power supply: voltage, frequency Time available to perform charging

NOTE: Call a technician from the manufacturer if you have any doubts regarding compatibility with the battery.

RECHARGING METHODS NOTE: Follow the instructions on the instruction manual of the battery and recharging methods.

CAUTION To avoid damage to the battery, never charge the battery in an environment with a temperature of 0°C (32°F) or less.

The charging area should be a dry location.

89

Maintenance / Battery RECHARGING PROCEDURE

WARNING Follow the instructions on the instruction manual of the battery and battery charger for the recharging procedure.

It is good practice to allow a battery to cool down after taking it out of service and before starting to recharge.

The element caps are provided with vents. Before recharging the battery, make sure the holes are not obstructed.

• Take the truck to a recharge area.

• Turn off the truck, then press down the emergency power off (item 1).

• Disconnect the battery connector (item 2).

90

Maintenance / Battery • Connect the charger to the battery connector and begin the charging cycle according to the battery and charger manufacturers' instructions.

NOTE: The battery socket and truck plug must only be separated when the truck is switched off. The battery socket and charger plug must only be connected and separated when the charger is switched off.

CHARGING TIME With a 48V/10Ah battery and a 2A external charger, it takes 5 hours to achieve full charge.

With a 48V/15Ah battery and a 5A external charger, it takes 3 hours to achieve full charge.

When the truck or a battery is in storage for an extended period, charge the battery to 30-50% state of charge every three months.

91

NOTES

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DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 550241431

MPC15, MPS15UX (A3D4)

OPERATING MANUAL