RAVAS Ergo Truck Move And Weigh Your Goods Ergonomically User Manual

ERGO TRUCK User Manual
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2020.7 15 st EDITION

Ergo Truck Move And Weigh Your Goods Ergonomically

Foreword
The present operation manual are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely.
Our trucks are subject to ongoing development. No guarantee of particular features of the truck should therefore be assumed from the present operation manual.
Safety notices and text markups
Safety instructions and important explanations are indicated by the following graphics:
Please strictly adhere to these safety instructions to avoid personal injury or major damage to equipment.
Please pay attention to the important safety instructions.
Pay attention to Instructions.

Application

The truck described in these operation manual is designed for transporting loads. It must be used, operated and maintained according to the information presented in this operation manual. Any other uses exceed the design scope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. permissible load to be picked up is indicated on the nameplate or load curve label shown on the truck. The truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
Duties of the user: A “user” within the meaning of these operation manual is defined as any natural or legal person who either uses the truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the truck, is charged with the observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design scope and that all danger to the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood this operation manual.
If this operation manual is not observed, the warranty becomes void. The same applies if improper works are carried out on the device by the customers and/or third parties without permission of our customer service.
Adding attachments: Adding or fitting any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
Modification: If you want to use the truck for purposes that are not mentioned in the user manual, please contact dealers accredited by EP. Any modification to your truck, in particular fitting of equipment or conversion to the truck, is prohibited without the permission of the manufacturer.
Intended use
The truck is designed for transporting and stacking the loads indicated in the load capacity diagram. Especially:

• In accordance with the safety rules of your industry association
• Other local regulations

In all cases, the people in charge, particularly operators and service personnel, must comply with the specific approved rules for the use of industrial trucks.
The user, and not the manufacturer EP, is liable for any hazards caused by any application not authorised by the truck manufacturer.
Please contact your authorised dealer if you want to use the truck for an application that is not specified in this manual.
The truck must not be altered, especially by making modifications or installing attachments, without the manufacturer’s approval.
Improper use
The operating company or driver, and not the manufacturer, is liable if the truck is used in a manner that is not permitted.One of the main causes of accidents is the driver ignoring or being unaware of the basic safe operating practices of the truck.
The following basic safe operating practices must be observed to ensure the safety of operators and others.Never operate the truck in environments with s potentially explosive atmosphere.

• Never carry passengers.
• Do not overload the truck. (by exceeding the rated load indicated on the load designation plate)
• Overloading can affect braking distances, truck stability and the strength of the lift mast.
• Do not pick up an off-centre load.
• Do not stack loads or turn when driving on a ramp.
• Do not operate the truck on loose or greasy surfaces.
• Do not drive on uneven or obstructed surfaces. Never park the truck in a place that may obstruct fire extinguishers, fire escapes or aisles.
• Do not dismount from the truck while it is moving.
• Do not leave the truck unattended when the load is raised.
• Never leave the vehicle unattended on a ramp. When driving, do not place any part of your body outside the confines of the truck, lean on the edge of the truck or attempt to jump onto another truck or object.
• Do not use the forks or any other part of the truck to push, pull or support items, unless the design permits this.

Truck Description

1.1 Application
The truck is intended for transporting goods on a level floor. It can pick up pallets that are open to the ground or trolleys.
Permissible application temperature range of truck -10°C to 40°C. Lithium-ion battery operation application 0°C to 40°C.
NOTE
The truck may only be operated in cold stores temporarily. If the truck remains too long in a cold store,we recommend coid store equipment for the truck.
Only use the truck at altitudes not exceeding 2000 meters.
The walking, lifting and lowering devices, harnesses and components are IP55 dust and water- resistant.
Trucks can only be operated in adequately illuminated working areas to avoid injuries. In case of insufficient light, an additional lighting equipment is needed to ensure that the driver can see properly.
If you must travel on an incline, the gradients should be below A% at full load, or below B% without a load.(For the value of A and B, refer to the Gradability in Performance Data Sheet) There should be no risks of fire, explosion or corrosion in the working area, or too much dust.
Forks can only be operated in adequately illuminated working areas to avoid injuries or injuries.
In case of insufficient light, an additional equipment is needed to run the fork lift truck.
1.2 Truck assemblies

1.2.1 Control handle

to its maximum height and stop on its own.
3| Lowering lever| Pull the lowering lever and hold. The forks will be lowered to its minimum height and stop on its own.
4| Emergency reverse
switch| By pressing this switch, the vehicle starts to travel in the opposite direction.
5| Drive switch| Select the required driving direction and speed.
6| Creep speed switch| Keep the handle in the vertical state, and press creep speed switch and drive switch at the same time, then the vehicle will move at a low speed.

1.2.2 Key switch
Connect and interrupt the control current.

• When pulling out the key switch, the control current of the truck will be interrupted;
• When inserting the key switch, the control current of the truck will be connected.

Pulling out the key switch of a truck before leaving can prevent the truck from starting accidentally.

1.2.3 Charging indicator

The LED (1) remain green light lit under normal, flashing show the failure state of truck.

(See section H Controller Error Message)  The LED display (2) show battery residual capacity.

The color of the LED (2) represent the following conditions:

If the controller detects a battery failure, flashes of LED（2）represent battery failure information until the failure is remedied.
Details of failure information are shown as below:

• Under-voltage of single cell battery: The green light repeats in a cycle of flashing once in 1 second, pausing for 2 seconds and then flashing twice, pausing for 3 seconds.
• Over-voltage of single cell battery: The green light repeats in a cycle of flashing once in 1 second, pausing for 2 seconds and then flashing three times, pausing for 3 seconds.
• Short circuit protection: The green light repeats in a cycle of flashing once in 1 second, pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
• Over-current protection: The green light repeats in a cycle of flashing once in 1 second, pausing for 2 seconds and then flashing five times, pausing for 3 seconds.
• Battery temperature is too high: The green light repeats in a cycle of flashing twice in 1 second, pausing for 2 seconds and then flashing three times, pausing for 3 seconds.
• Battery temperature is too low: The green light repeats in a cycle of flashing twice in 1 second, pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
• Contactor-related failures: The green light repeats in a cycle of flashing three times in 1 second, pausing for 2 seconds and then flashing four times, pausing for 3 seconds.
• The yellow light flashes rapidly in 1 second when other failures happen.

When powered off, if the green light of power indicator is always on, it means that the battery is in a balanced state, which is a normal phenomenon.
1.2.4 Emergency reverse switch
To protect the operator from becoming pinned against an obstacle by the control handle, an emergency reverse switch is provided at the end of the control handle. If this switch is pressed during operation, the truck will move off in reverse. The mechanical brake will then engage to stop the truck. The travel control must then be returned to neutral before the truck can again be operated.
1.3 Standard version specifications
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
1.3.1 Performance data for standard trucks

Distinguishing mark

1.1| Manufacturer| | | | | EP
1.2| Model designation| | | | | EPL1531
1.3| Drive unit| | | | | Battery
1.4| Operator type| | | | | Pedestrian
1.5| rated capacity| Q| lb.| kg| | 1500
1.6| Load center distance| c| in.| mm| | 600
1.8| Load distance| x| in.| mm| | 950(880)
1.9| Wheelbase| y| in.| mm| | 1190/1120
Weight
2.1| Service weight (include battery)| | lb.| kg| | 120
2.2| Axle loading, laden driving side/ loading side| | lb.| kg| | 480/1140
2.3| Axle loading, unladen driving side/loading side| | lb.| kg| | 90/30
Types,Chassis
3.1| “Tyre type driving wheels/loading wheels”| | | | | PU/PU
3.2| Tyre size, driving wheels(diameterxwidth)| | in.| mm| | 0210×70
---|---|---|---|---|---|---
3.3| Tyre size, loading wheels(diameterxwidth)| | in.| mm| | 080×60 (074×88)
3.5| Wheels, number driving, caster/loading (x=drive wheels)| | in.| mm| | lx, 4(1x, 2)
3.6| Track width, front,driving side| b10| in.| mm| |
3.6| Track width,rear,loading side| b11| in.| mm| | 410 (535)
Dimensions
4.4| Lift height| h3| in.| mm| | 115
4.9| Height drawbar in driving position min./max.| h14| in.| mm| | 750/1190
4.15| Lowered height| h13| in.| mm| | 80
4.19| Overall length| 11| in.| mm| | 1540
4.20| Length to face of forks| 12| in.| mm| | 400
4.21| Overall width| b1/ b2| in.| mm| | 685
4.22| Fork dimensions| s/ e/ I| in.| mm| | 50x150x1150
4.25| Distance between fork- arms| b5| in.| mm| | 560(685)
4.32| Ground clearance, center of wheelbase| m2| in.| mm| | 30
4.34.1| Aisle width for pallets 1000 x 1200 crossways| Ast| in.| mm| | 2145
4.34.2| Aisle width for pallets 800 x 1200 lengthways| Ast| in.| mm| | 2050
4.35| Turning radius| Wa| in.| mm| | 1330
Performance data
5.1| Travel speed, laden/ unladen| km/ h| mph| km/h| | 4.5/5
5.2| Lifting speed, laden/ unladen| | fpm| m/ s| | 0.017/0.020
5.3| Lowering speed, laden/ unladen| | fpm| m/ s| 0.09/0.06
---|---|---|---|---|---
5.8| Max. gradeability, laden/ unladen| | ok| | 6116
5.10| Service brake type| | | | Electromagnetic
Electric-engine
6.1| Drive motor rating S2 60 min| | hp| kW| 0.75
6.2| Lift motor rating at S3 15%| | hp| kW| 0.7
6.3| The maximum allowed size battery| | in.| mm| 200x100x300
6.4| Battery voltage/nominal capacity K5| | V/ Ah| | 24V/20
6.5| Battery weight| | lb.| kg| 7
Addition data
8.1| Type of drive control| | | | DC
10.5| Steering type| | | | mechanical
10.7| Sound pressure level at the driver’s ear| | dB (A)| | <74

1.3.2 Dimensions

Safety

1.1 Before operation
Before using the truck, inspect the work area. It should be neat, well lit, adequately ventilated, and free from hazardous material. Aisles and roadways should be unobstructed and well ma- rked. Operators must know the classification for the truck and use the truck only in permissible areas. Ensure that there are no loose objects on the truck or in the operator compartment, especially on the floor plate where they could interfere with pedal operation (if equipped) or foot room. Fire extinguishers and other emergency equipment should be visible and easy to reach.
Wear safety equipment when required. Don’t smoke in “No Smoking” areas, or while charging batteries or refueling combustion engine trucks. Never operate the truck with greasy hands.
This will make the controls slippery and result in loss of truck control. Any questions or concerns about safety should be brought to the attention of a supervisor. If an accident should occur, it must be reported immediately.
WARNING
Unauthorized modifications to the truck can result in injury or death.
Do not remove, disable or modify any safeguards or other safety devices. These include any alarms, lights, mirrors, overhead guards, and load backrest extensions. If present, an overhead guard is intended to provide protection to the operator from falling objects, but cannot protect from every possible impact.
1.2 Operating position
The truck may be operated in either direction while walking. When operating in reverse(forks leading), always keep both hands on the control handle. When operating forwards(forks trail- ing) keep one hand on the controls and, if possible, walk ahead and to the side of the truck.
During operation, always grasp the handle at the travel control. Keep fingers within the protec ted area of the handle at all times. Operators must not ride the truck unless it is designed for riding.
WARNING
Injury to hands can occur if the handle is grasped incorrectly. Keep hands and fingers within the protected area of the handle. Injury can occur if the truck contacts any part of the body.
Remain clear of the truck frame at all times.
1.3 Travel
The truck is designed for operation on smooth, dry surfaces such as warehouse and factory floors, loading docks or paved areas. Under all travel conditions operate the truck at a speed that will permit it to be brought to a stop in a safe manner. Avoid running over loose objects on the roadway surface.
WARNING
Loss of control!
Do not travel at excessive speeds; keep your truck under control at all times.
Always watch for pedestrians. When travelling in reverse (load end leading) be careful of drive end swing. The drive end of the truck will swing out if a turn is made while travelling in reverse. Always use caution when turning into an aisle. The load wheels can cut the corner sooner than expected.
Unstable loads are hazardous. Ensure all loads are secure and evenly positioned across both forks. Never lift a load with only one fork. Never carry anything on any part of the truck except the forks unless a specific area has been provided by the manufacturer.During travel, always watch for over head obstructions such as lights, wiring, pipes, sprinkler systems, doorways, etc. Never overtake another truck at an intersection, blind spot or other dangerous location. Use the horn at intersections and any location where visibility is limited.
Inclines, Ramps, Docks, Elevators If you must travel on an incline, do so with caution. Do not operate truck on a wet incline.
Keep the forks upgrade to maintain control when travelling up or down an incline with a loaded truck.Keep the forks downgrade when travelling up or down an incline with an empty truck.
DANGER
Tip-over will occur if you turn while travelling on a ramp or travel at an angle other than straight up or straight down a ramp.
Never turn on an incline or ramp either loaded or unloaded. Travel straight up or straight down.
Be aware that when descending an incline your stopping distance will be greater than when on a level surface. Reduce your speed, and ensure that there is adequate clear space at the bottom of the ramp to stop and turn.
To avoid hazards associated with a dock, you should personally check that the trailer brakes have been applied, wheel chocks are in place, and that any trailer-to-dock locking systems are being utilized. The impact of moving in and out of a trailer may cause the trailer to creep or move. Confirm that the driver will not move the trailer until you are done.
Do not drive the truck onto an elevator without specific authorization. Verify that the capacity of the elevator exceeds the weight of the truck and the weight of the load. Approach elevators slowly and ensure that the elevator car is level with the floor before entering. Enter elevators squarely with the load end leading. Ensure that no part of the truck or load contacts any part of the elevator other than the floor. Once on the elevator, neutralize the truck controls, shut off the power, and set the brakes. Any other personnel should leave the elevator before the truck is allowed to enter or leave.
Be especially cautious when driving the truck on ramps or bridge plates. Be sure to maintain a safe distance from each edge. Before driving the truck over a ramp or bridge plate, verify that its position is secured to prevent movement. Never exceed the rated capacity of a ramp or bridge plate.
1.4 Battery safety
WARNING
Batteries contain dissolved sulfuric acid, which is poisonous and caustic. Batteries also can produce explosive gases.
Remain aware of the following information.

• Wear protective equipment (protective apron and gloves) and protective glasses when working with battery acid. If clothing, skin or eyes come into contact with battery acid, immediately flush the affected areas with water. If acid contacts the eyes, seek medical attention at once. Clean spilled battery acid immediately with large amounts of water.
• Remove any metal rings, bracelets, bands, or other jewelry before working with or near batteries or electrical components.
• Never expose batteries to open flame or sparks.
• Areas in which batteries are stored or charged must be well ventilated to prevent concentration of explosive gases.
• If a battery is charged while installed in the truck, the battery cover must remain completely open during the entire charging period.
• Shorting of battery terminals can cause burns, electrical shock, or explosion. Do not allow metal parts to contact the top surface of the battery. Make sure all terminal caps are in place and in good condition.
• Batteries may only be charged, serviced, or changed by properly trained personnel.
  Always follow all instructions provided by the manufacturers of the battery, charger, and the truck.

1.5 EMC-Electromagnetic compatibility
Electromagnetic compatibility (EMC) is a key quality feature of the truck.
EMC involves

• Limiting the emission of electromagnetic interference to a level that ensures the troublefree operation of other equipment in the environment.
• Ensuring sufficient resistance to external electromagnetic interference so as to guarantee proper operation at the planned usage location under the electromagnetic interference conditions to be expected there An EMC test thus firstly measures the electro-magnetic interference emitted by the truck and secondly checks it for sufficient resistance to electromagnetic interference with reference to the planned usage location . A number of electrical measures are taken to ensure the electromagnetic compatibility of the truck .

CAUTION
The EMC regulations for the truck must be observed.
When replacing truck components the protective EMC components must be installed and connected again.

Transport and Commissioning

1.1 Using the truck for the first time
The truck must only be operated on battery current!
To prepare the truck for operation after delivery or transportation, the following operations must be performed:

• Check the equipment for completeness.

• If necessary, install the battery. Make sure that the battery cable is not damaged.

• Charge the battery.

• Put the truck into operation in the stipulated manner.
  When the truck is parked, the surface of the tyres may flatten. The flattening will disappear after the truck has been operated for a short time.

• Check for fluid leakage.

• Check forks and chassis.

• Check battery connector.

• Check decal condition.

• Check control handle pivot.

• Check operating controls.

1.2 Break-in period precautions
Fasten wheel screws again at 50 hours of operation.
Within the first 100 hours in particular, the following requirements should also be met:

• Excessive discharge of a new battery during initial use must be prevented.It should generally be charged promptly when at 20%.
• The specified preventive maintenance must be done thoroughly.
• Avoid sudden braking, driving quickly or sharp turns.
• Change oil or lubricant promptly according to the instructions.
• Limit the load weight to 70-80% of the rated load.

Operation

1.1 Safety regulations for the operation of pallet trucks
Driving permission: The fork lift truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operation manual. All necessary rights must be granted to him. If the fork lift truck can be used in the pedestrian- controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorized use: The driver is responsible for the fork lift truck during working time. He must forbid unauthorized persons to drive or operate the fork lift truck. The transport or lifting of persons is forbidden.
Repairs: Without specific training and express authorization, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling / lowering truck attachments.
Unauthorized persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operation manual must always be heeded.
1.2 Operate and run the truck
1.2.1 Turning the truck on and off
Switching the truck on

• Insert the key (3) into the key hole and switch on the power supply;
• Make sure the emergency stop button (2) is not pressed;
• Tilt the control handle to the drive positio M;
• Rotate the drive switch (1) to drive the truck forward or backward.

The truck is equipped with a static-return-to-neutral function. If the control handle is held in its working range (M) when the truck is turned on, the travel function will not operate. The control handle must then be returned to either end position and then  oved back into its working range to enable travel.
Switching the truck off
To turn the truck off, remove the key from its slot.
Press the emergency stop switch.
1.2.2 Driving, steering, braking
Driving
Operators must be familiar with all safety procedures that apply to truck operation before driving.
Read and understand all safety information in Section C before operating the truck.
Tilt the control shaft into the driving range (M) and set the controller to the desired direction (V or R). Steering
Steering the truck is done using the control handle. Manually moving it to the left or right will swivel the drive wheel. The truck then turns in forward or reverse according to the handle direction.
Emergency stop
Push the emergency stop switch. All of the electrical functions are switched off.
Braking
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck can be braked in three ways:

• by using the generator brake (controller)

• by counter-current braking (controller)

• by using the service brake (control shaft)
  Braking using the generator brake:

• Release the drive switch.
  Counter-current braking:

• While driving, switch the controller to the opposite direction.

• The truck is decelerated by counter-current braking until it starts moving in the opposite direction. In case of emergency, the service brake must be used to brake the truck.
  Braking using the service brake:

• Tilt the control shaft upwards or downwards into one of the braking ranges (B).

WARNING
If the control handle moves slowly or not at all to the upper brake zone, the truck must be taken out of service until the cause of this fault is be rectified.
Replace the gas pressure spring if necessary.
WARNING
In hazardous situations set the control handle to the brake position or set the travel switch to the opposite direction.
WARNING
If the travel switch moves slowly or not at all to 0, the truck must be taken out of service until the cause of this fault is be rectified.
WARNING
When driving on a hill or uneven roads, please lift fork to stop the bottom of fork and the ground being rubbed.
1.2.3 Loading
CAUTION
Before lifting a load, ensure that its weight does not exceed the truck’s maximum load capacity.
Refer to the rated load capacity specified on the truck’s nameplate.
Ensure that the load is stable and uniform to prevent any partial spillage.
Check that the width of the load is compatible with the width of the forks. Take care not to disturb any adjacent loads, or those which may be to the side or in front of the load being handled. Loads should be laid out as follows:
Line up loads with a small space between each one and its neighbour to avoid any fouling.
CAUTION
Only transport loads that have been positioned and secured in accordance with regulations.
Take appropriate protective measures if the load is at risk of tipping over or falling during transport.
Approach the load carefully.
Adjust the height of the forks until they can be easily inserted into the pallet. Insert the forks under the load. If the load is shorter than the forks, position the forks so that the front of the load overhangs them by a few centimeters, to avoid interference with the load immediately ahead. Raise the load a few centimeters above its support. Back the truck away from the stack or any neighbouring loads, gently and in a straight line. Transporting loads Always carry loads in the forward direction of travel (R) in order to have the best visibility.
When carrying a load on a slope, always ascend or descend with the load uphill. Never drive sideways across a slope or perform a U-turn. Reverse travel (V) is to be used solely for unloading. Since visibility is reduced when travelling in this direction, drive only at very slow speed. Unloading
Carefully drive the truck to the desiredlocation. Carefully drive the truck to the unloading area.
Lower the load until the fork arms are free from the pallet. Back the truck away in a straight line. Raise the forks to mid-height.
CAUTION
Take care not to disturb any adjacent loads, or those which may be to the side or in front of the load being handled. 1.3 Raising and lowering the forks
Lifting
Press “Lift” button(2) until the height you need.
Lowering
Set fork to the lowest position by pulling lowering lever (1) upward. WARNING
Before lifting a load unit the driver must make sure that it has been correctly stowed and does not exceed the truck’s capacity.
Make sure long loads are stable supported by the forks.
1.4 Parking the truck securely

• Lowering the forks.
• Press emergency stop switch.
• Remove the key.
• It is forbidden to park on the slope for a long time.

1.5 Using the truck on a slope
NOTE
Incorrect use of the truck on slopes places stress on the traction motor, brakes and battery. Be particularly careful near slopes:

• Never attempt a slope with a gradient greater than that specified in the truck’s data sheet.
• Make sure that the ground is dry with non-slip surface and that the route is clear.

Ascending slopes
Always ascend slopes travelling in the reverse direction, with the load facing uphill.
Without a load, it is recommend to ascend slopes forwards.
Descending slopes
Travel down slopes must always be forwards, with the load uphill.
Without a load, it is recommended to descend slopes forwards.
In all cases, travel at a very low speed and brake very gradually. DANGER
Risk to life and/or risk of major equipment damage. Never park the truck on a slope. Never make a U-turn or take shortcuts on a slope. On a slope, the operator must drive very slowly.
1.5.1 Starting on a slope
If you have to stop and then start on slope, proceed as follows:

• Stop on the slope by pressing the accelerator in the opposite direction until the machine comes to a standstill.

• Return the accelerator to the neutral position, then release the accelerator control button to apply the parking brake.
  To restart, press the accelerator button for the desired direction.

• The truck will move.

1.6 Hoisting the truck
This section explains the attachment of lifting equipment to the truck for the purpose of hoisting. Many methods of rigging to a crane or hoist are possible. Explanation of such methods as well as operation of lifting equipment is outside the scope of this manual. Both the attachment of lifting equipment to the truck and the hoisting operation itself must be performed by personnel experienced in hoisting.
WARNING
Lifting equipment of insufficient capacity can fail and cause severe injury or death.
Ensure that all lifting slings, hardware, or other equipment has sufficient capacity to carry the weight of the truck. Refer to the truck data plate for truck weight. If a battery is installed, its weight must be added to the truck weight listed on the data plate. Switch the truck off and press the emergency stop button. Attach lifting equipment to the holes in each side of the chassis. Attach lifting equipment to the fork tips to keep the truck approximately horizontal as it is lifted.

Battery Maintenance & Charging

1.1 Safety regulations for handling acid batteries
The truck must be parked and rendered safe before any operations on batteries are under taken.Operational application temperature
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
DANGER

• Battery has high voltage and energy.
• Do not short circuit.
• Do not place any metal objects on the battery.
• Do not put tools on the battery.

1.2 Battery type & dimension
All the batteries are maintenance free.
Battery type & dimension as follow:

Tuck type| Voltage/ Rated capacity(V/AH)| Dimension (mm)| Charger(A)| Charging time(h)
---|---|---|---|---
Internal
EPL1531| 24/20| 2001 00*300| 10A| 2

1.3 Charging the battery
Safety regulations for charging the battery

• Before charging, check all cables and plug connections for visible signs of damage.
• Before start and finish charging make sure power is turn OFF.
• It is essential to follow the safety regulations of the battery and charging station manufacturers.

The charging environment temperature should be 5°C to 40°C.
NOTE
The truck can be operated at -20°C for a short period after it work above 5°C for a while.
WARNING

1. Battery life will be shortened if the battery is used for a long time at low temperature or stored.
2. No charging below 0°C.
3. Only temporary cold store application permissible as the permissible battery operating temperature is between 0°C and 40°C

NOTE
A fully charged battery will provide approximately 2 hours of continuous use. Capacity will be reduced when used in low-temperature environments.
1.4 Battery removal and installation
Park the truck securely(See Parking the truck securely ) and turn off the power before removal and installation of the battery.
Battery removal and installation steps:

• Turn the battery block;
• Just hold the handle and pull the battery out；
• Install in reverse order.

WARNING
Well place cables to avoid be damaged when you remove and install battery.
Installation is in the reverse order, pay attention on battery install position and cable connection. Make sure to protect the cables to avoid damage when you install the battery.
1.5 Daily maintenance

• When it is displayed in the display instrument that the electric quantity is insufficient, please charge timely without any excessive discharging. Please refer to 2.2.3 display instrument for details.
• Maintain clean the surface of the battery.

1.6 Storage
If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room.
If the battery is not used for an extended period, it must receive a supplementary charge every two months to prevent permanent damage to the battery.

• We recommend that batteries are stored at a heightbetween 60 and 120 cm.
• Store the battery in a dry place at a temperaturebetween 0 and 40° to preserve its service life. This area must not be hermetically sealed to allow air renewal.
• In case of long-term storage of the storage battery, the supplementary charging should be conducted for the battery once every two months, and charging quantity should be proper but not full, namely maintaining the discharging depth at about 80%.

1.7 Transportation
Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train authorised staff to dispatch lithium-ion batteries. NOTE
It is recommended that the original packaging is kept for any subsequent dispatch.
A lithium-ion battery is a special product.
Special precautions should be taken when:

• Transporting a truck equipped with a lithium-ion battery.
• Transporting only the lithium battery A class 9 danger label must be affixed to the packaging for transport.

It is different if the battery is transported on its own or in a truck. An example of a label appears in this supplement.
Refer to the latest current regulations before dispatch as the information might have changed since this supplement was written.
Special documents must be sent with the battery. Refer to the applicable standards or regulations.
NOTE
Recharge the lithium-ion battery before transporting it taking account of the transport mode (plane, boat, road).
Excessive discharge on arrival could damage the performance of the battery.

Pallet Truck Maintenance

1.1 Operational safety and environmental protection

• The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the service checklists.

• Only use original spare parts that have been certified by our quality assurance.
  Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
  Upon completion of inspection and servicing, carry out the activities listed in the

• “Recommissioning ”section.

1.2 Maintenance safety regulations
Servicing and maintenance personnel:
Only qualified personnel authorized by the owner are permitted to perform maintenance or repair work. All items listed in the Scheduled Maintenance Charts must be performed by qualified truck technicians only. They must have knowledge and experience sufficient to assess the condition of a truck truck and the effectiveness of the protective equipment according to established principles for testing truck trucks. Any evaluation of safety must be unaffected by operational and economic conditions and must be conducted solely from a safety standpoint Daily inspection procedures and simple maintenance checks, e.g. checking the hydraulic oil level or checking the fluid level in the battery, may be performed by operators. This does not require training as described above.
Lifting and jacking up:
When a fork truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations:
No inflammable liquids must be used when cleaning the fork truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short circuits) have to be taken. For battery operated trucks, the battery plug must be removed. Only weak pressure, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
Work on the electric system:
Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated trucks, the truck must also be powered down by removing the battery plug.
Settings
When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck specific settings

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