PDF DOWNLOAD: Yale Forklift MP20XUX (A7R1) Operating Manual

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PART NO. 550215646

MP20XUX (A7R1)

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 2019. 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 2019

550215646 - 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.

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

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.

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

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.

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.

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

TRUCK SCRAPPING

BATTERY DISPOSAL

The truck is composed of metal and plastic components, which can be recycled. The materials used for the truck components are listed below:

NOTE: Do not dispose of exhausted lead-acid batteries with normal solid waste. They are composed of noxious material. They must be collected, disposed of and/or recycled as prescribed by legislation in force in individual countries.

CHASSIS • Frame: Steel • Wheels: Polyurethane, rubber • Finishing: Plastic ELECTRICAL SYSTEM

RECYCLE

DISPOSAL OF LUBRICANT OILS NOTE: Used oil must be specially collected. It must not be disposed of into normal drainage system pipes.

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

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

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

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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

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

• USE AND MAINTENANCE MANUAL NOTE: The following Declaration of Conformity is a Facsimile. The Declaration of Conformity is not present on trucks shipped to China and Ukraine.

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.

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

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

Masate Day of week, MM/DD/YYYY

Name and Job title

Technical file controlled by:

Plant Manager - Masate

Name and Job Title Hyster-Yale Italia SpA Via Confalonieri 2 - 20060 Masate (Mi) Italy

Compliance with this directive is established by meeting the technical requirements of standard EN12895:YYYY.

- Electromagnetic Compatibility Directive 2014/30/UE

Other applicable Directives:

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 EN ISO 3691-1:YYYY including the standards mentioned therein.

Year of construction:

Serial number:

Type:

Model:

declare under our sole responsibility that the industrial truck:

we

DECLARATION OF CONFORMITY

INTRODUCTION

5

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 ............................................

HARNESSING THE TRUCK IN PREPARATION FOR HOISTING ................................................................

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 ................................................

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1 1 3 4 4 7 8 8 10 11 13 14 14 14 16 17 18

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

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

OPTIONS ...................................................................

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

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

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

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

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

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

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

MAINTENANCE / BATTERY .......................................

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

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

LUBRICANTS .............................................................

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

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

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

REPLACING THE BATTERY .....................................

19 25 27 28 36 37 41 46 49 58 61 61 63 67 68 69 71 73

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.

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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.

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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.

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.

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.

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.

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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 lift truck, refer to the identification data plate.

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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 HARNESSING THE TRUCK IN PREPARATION FOR HOISTING UNLOADING THE TRUCK: EQUIPMENT AND TOOLS

Forklift truck Bridge crane Lifting band

PHASE 1: Pick up the pallet using the lift truck, raise it and carry it to a safe place, provided with a bridge crane, away from the transit areas of other vehicles and pedestrians.

Lift Belt

PROCEDURE

CAUTION Before starting work, ensure that you are wearing suitable protective clothing.

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RISKS / TRANSPORTING THE TRUCK PHASE 2: • Remove the packaging.

• Fix the band or the pendants directly to the bridge crane (A).

• Fit the band or the hooks of the pendants in the dedicated slots (B), prearranged for lifting the lift truck.

CAUTION Ensure that the bridge crane is positioned perpendicularly above the truck to be lifted.

• Slowly raise and carefully position the truck on the ground.

To load and unload the truck, in the absence of the pallet, refer directly to phase 2, or use a lifting platform with a suitable load capacity if there is the possibility to set the truck into operation.

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RISKS / TRANSPORTING THE TRUCK MAKING THE TRUCK READY AFTER TRANSPORTATION Following transportation, the lift truck must be prepared for use in order to ensure its correct operation.

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

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

• Connect the truck plug with the battery socket.

• Set the truck into operation.

• Check the battery charge level (Indicator).

• Make a general inspection of the controls and instrumentation.

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.

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DESCRIPTION / OPERATING INSTRUCTIONS

DESCRIPTION / OPERATING INSTRUCTIONS CONSTRUCTIONS STANDARDS

DESCRIPTION OF THE MODEL

The truck described in this manual is constructed in accordance with the standards indicated in the EC Declaration of Conformity.

The machines in this series are electric forklift trucks with man on board or on the ground and horizontal load handling.

See the "EC Declaration of Conformity".

The normal configuration of the truck has it being driven with the operator on the machine and occasionally, when necessary, it can be driven by the operator on the ground.

The truck has mechanisms such that the configuration can vary to adapt to the different styles of driving.

The parts comprising the cab that normally contains the operator are movable.

NOTE: Travelling speed is lower when it is driven by the operator on the ground or when it is driven with the operator on the machine and the side barriere are closed.

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DESCRIPTION / OPERATING INSTRUCTIONS 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.

• 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.

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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.

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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).

DESCRIPTION / OPERATING INSTRUCTIONS IDENTIFICATION DATA 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.

IDENTIFICATION DATA PLATE

FOR TRUCKS SHIPPED TO UKRAINE

The fields listed below are not completed for these models.

• Maximum force of traction (N) • Towing force (N) • Application time (h)

FACSIMILE IN ENGLISH

FOR TRUCKS SHIPPED TO RUSSIA

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DESCRIPTION / OPERATING INSTRUCTIONS WARNING AND INFORMATION PLATES AND ADHESIVE DECALS Warranty (Facsimile in English).

Crushing hazard.

Indicates the sling points for hoisting the truck.

Indicates the point of recharge (Configuration with on-board charger).

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Indicates that the lift truck is suitable to work in cold rooms (Optional).

CAUTION The warning and information decals must never be removed, painted over or made undecipherable.

Should a decal be undecipherable it must be replaced.

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.

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DESCRIPTION / OPERATING INSTRUCTIONS OVERALL DISPLACEMENT DIAGRAMS

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DESCRIPTION / OPERATING INSTRUCTIONS

21

DESCRIPTION / OPERATING INSTRUCTIONS SPECIFICATION SHEET

Distinguishing mark

PLATFORM PALLET TRUCK

Model Driving model Driving model (Manual, Walking, Stand driving, Seat driving, Order picking) Rated load Load centre distance Front overhang

Q (Kg) c (mm) x (mm)

MP20XUX Motor-driven Stand driving 2000 600 865

1.9

Tread

y (mm)

1261

Weight

Technical features

1.2 1.3 1.4 1.5 1.6 1.8

2.1 2.2 2.3

Service weight (with battery) Axle loading, laden front/rear Axle loading, unladen front/rear

kg kg kg

710 1300 / 1410 600 / 110

Tyres, chassis

VDI 2198

3.1 3.2 3.3 3.4 3.5 3.6 3.7

Wheels (rubber, high elesticity, pneumatic tyre, polyurethane wheel) Tyre size, front Tyre size, rear Additional wheels (dimensions) Wheels, number front/rear (x = driven wheels) Tread, front Tread, rear

ø (mm x mm) ø (mm x mm) ø (mm x mm)

Polyurethane 250 x 70 82 x 126 127 x 57 1x + 2 / 2

b 10 (mm) b 11 (mm)

490 370 / 505

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Performance data

Dimensions

DESCRIPTION / OPERATING INSTRUCTIONS 4.4 4.9 4.15 4.19 4.20 4.21 4.22 4.25 4.32 4.33 4.34 4.35

Lift Height drawbar in driving position min./max.

Height, lowered Overall length Length to face of forks Overall width Fork dimensions Distance between fork-arms Ground clearance, centre of wheelbase Aisle width for pallets 1000mm x 1200mm crossways Aisle width for pallets 800mm x 1200mm lengthwise Turning radius

5.1 5.2 5.3 5.7 5.8

Travel speed, laden/unladen (pedestrian) Lift speed, laden/unladen Lowering speed, laden/unladen Gradeability, laden/unladen Max. gradeability, laden/unladen

5.10

Service brake

h3 (mm) h14 (mm) h13 (mm) l1 (mm) l2 (mm) b1 (mm) s / e / l (mm) b5 (mm) m2 (mm) A st (mm) A st (mm) W a (mm)

120 1070 / 1450 82 1760 610 775 54 / 180 / 1150 550 / 685 28 1960 2010 1600

km/h m/s m/s % %

6.7 / 7.1 0.039 / 0.056 0.064 / 0.050 6 / 12 8 / 20 Electromagnetic

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Addition data Electric - engine

DESCRIPTION / OPERATING INSTRUCTIONS

24

6.1 6.2 6.4 6.5

Drive motor, S2 60 minute rating Lift motor, S3 15% rating Battery voltage/nominal capacity K5 Battery weight Battery dimension

8.4

Sound pressure level at the driver’s seat

kW kW (V)/(Ah) kg

1.2 (1.5) 0.8 (1.2) 24 / 210 170

l / w / h (mm)

750 / 170 / 534

dB (A)

< 70

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. OPERATOR SIDE GUARDS 2. STEERING TILLER AND CONTROLS 3. BATTERY COMPARTMENT COVER 4. FRAME WITH FORKS 5. LEAD-IN ROLLERS 6. LOAD WHEELS 7. CHASSIS 8. CASTER WHEELS 9. OPERATOR PLATFORM 10. MOTOR COVER

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DESCRIPTION / OPERATING INSTRUCTIONS 11. COMMAND AND CONTROL PANEL 12. ELECTRICAL SYSTEM 13. DRIVE UNIT 14. HYDRAULIC SYSTEM

26

DESCRIPTION / OPERATING INSTRUCTIONS OPTIONS 1.

2.

3.

CHARGING SOCKET ON-BOARD CHARGER KEY PAD

27

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.

ACCESS TO THE CAB (POS. 1-9) To get into the cab, fully lower the platform and open the side guards completely. Before leaving the machine, make sure you have closed the side guards and raised the platform completely.

It is also possible to drive the machine with the side guards closed.

NOTE: The "cab" is defined as the area used by the operator on the machine between the two open side guards and the lowered platform.

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NOTE: The platform has a device which causes the truck to decelerate and then brake if the driver gets down from the platform while the truck is travelling.

DESCRIPTION / OPERATING INSTRUCTIONS STEERING TILLER AND CONTROLS (POS. 2)

SERVICE BRAKING:

The steering tiller in position “1” enables the truck to be driven.

• Move the steering tiller to position “2” to brake.

• It causes a deceleration due to braking of the electric braking of the drive motor with subsequent engagement of the electromagnetic brake.

Operate the driving tiller to steer.

PARKING BRAKE: • The parking brake (electromagnetic brake) is automatically engaged by releasing the drive throttles that return on their neutral position or by releasing the steering tiller that returns to the vertical position "2".

CAUTION As always it must be gripped in the right gripping positions in order to reduce the possibility of involuntary finger crushing.

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DESCRIPTION / OPERATING INSTRUCTIONS FORKS LOWERING / LIFTING BUTTON (POS. A) Press this button to lower / lift the forks.

HORN BUTTON (POS. B) Press this button to operate the horn.

BELLY SWITCH - REVERSING BUTTON (POS. C) 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 side. If bumped, the truck reverses immediately.

A. B. C. D. E.

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FORK LOWERING / LIFT BUTTON HORN BUTTON BELLY SWITCH (REVERSING BUTTON) DRIVE COMMAND THROTTLES SNAIL ( ) BUTTON

DRIVE COMMAND THROTTLES (POS. D) The operation of the throttles permits travelling both in the operator side direction and in the fork side direction.

DESCRIPTION / OPERATING INSTRUCTIONS PEDESTRIAN MODEL:

ON-BOARD MODEL:

Turning the throttles clockwise, the truck moves in the fork direction.

Turning the throttles clockwise, the truck moves in the fork direction.

Turning the throttles counter-clockwise, the truck moves in the operator direction.

Turning the throttles counter-clockwise, the truck moves in the operator direction.

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DESCRIPTION / OPERATING INSTRUCTIONS The truck speed increases proportionally according to the angle of rotation of the throttles.

Reversing the travel causes a progressive deceleration of the truck to a stop due to the traction engine electrical braking (reverse braking).

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).

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SNAIL (

) BUTTON (POS. E)

By pressing this button and operating the transfer control throttles, the truck moves forwards or backwards at reduced speed.

DESCRIPTION / OPERATING INSTRUCTIONS COMMAND AND CONTROL PANEL (POS. 11)

IGNITION KEY SWITCH (POS. A) The ignition switch has two positions: • Position “0” (off): the entire electrical circuit is isolated • Position “1” (on): the entire electrical circuit is powered up Do not operate any truck functions until the truck has completed its start-up cycle.

A. IGNITION KEY SWITCH B. BDI DISPLAY C. EMERGENCY STOP BUTTON

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DESCRIPTION / OPERATING INSTRUCTIONS BDI DISPLAY (POS. B)

EMERGENCY STOP BUTTON (POS. C)

This instrument is a combination of battery capacity indicator and LCD hour meter, with the battery indicator of ten segments of colourful LED display (5 green segments, 3 yellow segments and 2 red LED).When battery discharges by 70% capacity, one red flicker lamp shows “energy storage” alarm.

When the battery discharges by 80%, two red flicker lamps show “energy exhaust”.

By pressing it, the battery supply is disconnected and all the electric controls are disabled (Button down: electrical system disconnected).

After the external power supply is cut off, the internal battery can generally keep storage memory of 10 years.

The life service time for monitoring of this instrument is 99999.9 hours recorded on LCD displays. Hour meter resets automatically and continue to time and display. Only if it is connected to battery, LCD hour meter will start working.

This instrument possesses high reliability under extremely bad environment.

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

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

DESCRIPTION / OPERATING INSTRUCTIONS TRUCK PLUG / BATTERY SOCKET

plug is fixed to the truck and is connected to the truck electrical system; the socket is connected to the battery and is extractable.

The battery socket must be disconnected from the truck and connected to the battery charger for recharging operations.

To remove the socket use the handle.

NOTE: If necessary, by taking out the socket, the truck would be completely disconnected from the mains.

Use this procedure in the event of a short-circuit or malfunctioning of the operating controls.

The truck plug and battery socket is the connection point between the truck electric installation and the battery. The

By disconnecting the battery supply, all the operating controls are disabled.

35

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 platform conditions and functionality.

• Check the side guards conditions and functionality.

• 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.

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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 conditions of the castor wheel support bearings.

• Check the correct operation of the tiller.

• Check the correct operation of the horn button.

• Check the correct operation of the BELLY switch.

• Check the correct operation of the button.

• 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.

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.

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

37

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.

38

DESCRIPTION / OPERATING INSTRUCTIONS LONGITUDINAL STABILITY AREA

Example of the variation of longitudinal stability:

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

39

DESCRIPTION / OPERATING INSTRUCTIONS WARNING

TRANSVERSE STABILITY AREA

• 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.

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

40

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.

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 licence 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.

41

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 40°C

Altitude:

up to 2000 metres

Relative humidity:

30 to 95 % (without condensation)

Lighting minimum required:

40 lux.

If the truck works for long periods of time at altitudes above 1000 m 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.

A model specifically manufactured to work in cold rooms (-30°) exists.

42

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.

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.

Contact the service network for advice concerning the flooring, or the most suitable type of truck for a particular type of flooring.

43

DESCRIPTION / OPERATING INSTRUCTIONS ROUTE

PERSONS

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.

• Never carry passengers on the truck.

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

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

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.

DRIVING

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.

TOWING OR PUSHING The truck must not be used to push or tow loads or persons.

44

• 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.

DESCRIPTION / OPERATING INSTRUCTIONS STOPS • Before parking, lower the load completely.

• if you leave the truck, switch it off.

• 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.

REMOVAL IN THE EVENT OF LIFT TRUCK BREAKDOWN

In the absence of electrical power supply, the steering wheel is not operational and the electromagnetic brake is engaged, therefore to move this type of lift truck when it is broken-down it is necessary to lift it.

Make sure that the means used for lifting has adequate capacity and that the slinging equipment is of suitable capacity and in good condition.

To know the weight of the out-of-service lift truck, refer to the summary identification data plate.

If present, the load must be removed from the broken-down lift truck before proceeding with the lifting operations.

Secure the hooks of the pendants / the band, in the dedicated slots prearranged for lifting the lift truck (for the procedure refer to the "Transporting the truck" chapter).

Raise the broken-down truck just enough to move it out of the work area.

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

45

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.

46

DESCRIPTION / OPERATING INSTRUCTIONS 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.

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 HANDLING

WARNING Only work with loads that do not exceed the load capacity indicated on the plate.

This information concerns the maximum weight that may be lifted to the respective height and centre of gravity.

Other factors, such as unstable or uneven ground, loads with high centres of gravity, should also be taken into consideration as they reduce stability; to ensure safe working conditions, the real loadbearing capacity should always be taken as less than the maximum permissible capacity.

47

DESCRIPTION / OPERATING INSTRUCTIONS 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.

CENTRED LOAD

48

NON-CENTRED LOAD

DESCRIPTION / OPERATING INSTRUCTIONS DRIVING RULES NOTE: Carefully read the GENERAL CONDITIONS, RISKS and the GENERAL STABILITY PRINCIPLES chapters and the instructions described below, before driving the truck.

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

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. FORWARD (PEDESTRIAN MODEL) B. FORWARD (ON-BOARD MODEL) C. BACKWARD (PEDESTRIAN MODEL) D. BACKWARD (ON-BOARD MODEL)

49

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.

50

Keep the "FORWARD" driving position for the picking up/ putting down operations (With the operator on the machine).

DESCRIPTION / OPERATING INSTRUCTIONS DRIVING POSITION Do not lean out of the truck drive when driving.

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.

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.

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.

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.

51

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.

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.

PRUDENCE

1.

RUN OUT

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

52

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.

DESCRIPTION / OPERATING INSTRUCTIONS RISES AND DESCENTS Proceed slowly on ramps or slopes. The rises and descents must be travelled, either laden and unladen, with the forks pointing upstream. When laden just enough to allow the movement of the pallet/load without dragging it on the ground.

When unladen lift the forks just enough to allow not dragging them on the ground.

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

A. B.

LIFTING LOWERING

53

DESCRIPTION / OPERATING INSTRUCTIONS 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.

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. 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.

54

DESCRIPTION / OPERATING INSTRUCTIONS 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.

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 ad 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.

1.

RUN OUT

55

DESCRIPTION / OPERATING INSTRUCTIONS 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.

56

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.

DESCRIPTION / OPERATING INSTRUCTIONS PARKING THE TRUCK 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.

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

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.

57

DESCRIPTION / OPERATING INSTRUCTIONS STORAGE AND RESTARTING OPERATIONS

SHORT TERM STORAGE 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. 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.

58

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

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

• Perform a thorough general cleaning operation.

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

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

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

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

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

DESCRIPTION / OPERATING INSTRUCTIONS • Check that the filler caps are on tight.

• 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, 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.

RESTARTING THE TRUCK AFTER A SHORT PERIOD OF INACTIVITY When restarting the truck, the following procedure is recommended: • Remove the blocks and rest the truck on the ground.

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

• Check the battery charge and the electrolyte level.

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

• Grease all the parts that require greasing.

• Check all the truck functions and especially the braking system.

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

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

59

DESCRIPTION / OPERATING INSTRUCTIONS STORING THE TRUCK FOR A LONG PERIOD OF INACTIVITY

RESTARTING THE TRUCK AFTER A LONG PERIOD OF INACTIVITY

Storage periods exceeding 6 months.

When restarting the truck, the following procedure is recommended:

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

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

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• Carry out all suggested operations for restarting after a short period of inactivity (see the "RESTARTING THE TRUCK AFTER A SHORT PERIOD OF INACTIVITY" paragraph).

• Refit the battery; connect the cable clamps to the battery terminals, clean 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.

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.

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.

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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.

62

OUT OF ORDER DO NOT USE

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 paragraph “Removal in the event of forklift truck breakdown” in the “Operating instructions” chapter.

SCHEDULED MAINTENANCE TABLES ■

= 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.

●

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

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.

63

MAINTENANCE / BATTERY

BRAKING SYSTEM

OPERATION DESCRIPTION PULL OPERATION TILLER TO MAKE IT SWITCH BETWEEN AREAS A AND B; THE BRAKE MAKES A NOISE WIPE OUT DIRT AND OIL ON STEERING GEAR BRAKE CLEARANCE SHALL BE KEPT BETWEEN 0,2 TO 0,8MM

STEERING SYSTEM

TRUCK FRAME

OVERALL CONDITION, ABNORMAL CONDITION

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HORN SOUND, ABNORMAL OR NOT TRUCK FRAME, FASTENERS, FUNCTIONS, CRAKINGS, LUBRICATING CONDITION, FASTENERS LOOSE OR NOT CONNECTING ROD AND WHEEL CARRIAGE, FUNCTIONS, CRACKINGS, CROOKING, DISTORTION, LUBRICATING CONDITION FORKWHEEL AND FORKWHEEL BEARING, WEARING CONDITION, REPLACE ACCORDING TO THE CONDITION PULL OPERATION TILLER TO MAKE IT SWITCH BETWEEN AREAS ‘A’ AND ‘B’; BRAKE HAS SOUNDS OF ABSORPTION OPERATION TILLER, DEGREE OF TIGHTNESS AND FLEXIBILITY OF STEERING

After 50 hr (weekly)

■ ■ ■

MAINTENANCE INTERVALS After 200 hr After 600 hr (monthly) (three months)

● ● ● ■

●

After 1200 hr (half a year)

●

■ X

■ ■

MAINTENANCE / BATTERY OPERATION DESCRIPTION

After 50 hr (weekly)

KEY SWITCH, FUNCTION CONTACTOR, PERFORMANCE AND FUNCTION MICROSWITCH, FUNCTION CONTROLLER, FUNCTION WEARING CONDITION OF DRIVING MOTOR WEARING CONDITION OF LIFTING MOTOR, CARBON BRUSH AND COMMUTATOR WEARING CONDITION OF STEERING MOTOR, CARBON BRUSH AND COMMUTATOR FUSE, COMPLETE OR NOT WIRING HARNESS AND TERMINAL, LOOSE OR DAMAGED POLISH UNEVEN CONTACTS WITH ABRASIVE PAPER REPLACE WHEN FAIL TO FUNCTION WELL WEARING CONDITION OF MOTOR CARBON BRUSH AND COMMUTATOR ELECTROLYTE CAPACITY, CHECK LIQUID LEVEL, DISTILLED WATER ELECTOLYTE DENSITY. TESTED VALUE AFTER CHARGING SHOULD BE 1.28G/ML CLEAN STORAGE BATTERY, FASTEN CAP, AND RINSE WITH TAP WATER CHECK CONTACTOR; POLISH THE ROUGH SIDE OF CONTACTS WITH ABRASIVE PAPER

After 1200 hr (half a year)

■ ■ ■ ● ● ● ● ● ● ●

PLUG, FUNCTION, DAMAGE

ELECTRICAL SYSTEM

MAINTENANCE INTERVALS After 200 hr After 600 hr (monthly) (three months)

●

●

X

X

● ■ ■ ● ●

■ ■

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MAINTENANCE / BATTERY OPERATION DESCRIPTION

After 50 hr (weekly)

REDUCTION GEARBOX

HYDRAULIC SYSTEM

OIL PIPES LEAK OR NOT HYDRAULIC OIL, PROPER AMOUNT LIFTING OIL CYLINDER, LEAK OR NOT FILTER CLEANSING REPLACE HYDRAULIC OIL, CHECK IF LIFTING OIL CYLINDER HAS LEAKAGE; REPLACE SEALINGS WHEN NECESSARY

REPLACE GEAR OIL

Full inspections on truck can prevent it from faults and shorter service life.

Hours listed in the maintenance procedures is based on the condition that the truck works 8 hours a day and 200 hours a month.

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MAINTENANCE INTERVALS After 200 hr After 600 hr (monthly) (three months)

■ ■ ■ ■

After 1200 hr (half a year)

● X

X

For safe operation, please maintain the truck according to the procedures.

MAINTENANCE / BATTERY LUBRICANTS APPLICATION OIL for lubrication of the HYDRAULIC CIRCUIT OIL for lubrication of the REDUCTION UNIT Gear lubricant Pin lubricant Insulation of BATTERY TERMINALS

STANDARD MODEL SHELL TELLUS S3 V 46 Double curve gear oil 85W-90(GL-5) Lubricant grease Lubricant grease

COLD STORE MODEL SHELL TELLUS S3 V 32 Double curve gear oil 85W-90(GL-5) Lubricant grease Lubricant grease

Pure Vaseline

Pure Vaseline

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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.

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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.

The following instructions are general, since the user is free to use different batteries and battery chargers from those initially supplied by YALE.

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

The container is acid resistant and 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 acid present in the solution can cause serious injury.

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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.

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WARNING It is recommended to use batteries compatible with the lift 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.

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: lead-acid (with flat plates or tubes) 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 The recharge method depends on the type of battery.

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

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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.

• Switch off the truck.

• Check that the voltage and the polarity are correct so as to avoid causing serious damage to the battery and the battery charger.

• Disconnect the battery socket from the truck plug and connect it to the battery charger plug.

• Disconnect the battery socket from the battery charger and connect it to the truck plug when the charging is completed.

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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.

MAINTENANCE / BATTERY REPLACING THE BATTERY • • • •

Switch off the truck.

Open the battery compartment cover (A).

Remove the side door (B).

Disconnect the battery from the truck electrical system via the handle.

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

• Remove the battery catchs (C).

NOTE: The battery can be unlocked only when the battery socket and truck plug are disconnected.

• Remove the flat battery carefully from the truck battery compartment and put it on the battery trolley.

CAUTION Pay attention to the hands when placing the battery in its compartment in order to avoid injury. During this step, be careful not to pinch the battery cable between the battery and the truck chassis.

NOTE: Make sure the battery is properly locked and that it does not protrude beyond the truck profile, to prevent it from coming out from the battery compartment when the truck is travelling.

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NOTES

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DO NOT REMOVE THIS MANUAL FROM THIS UNIT

PART NO. 550215646

MP20XUX (A7R1)

OPERATING MANUAL