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TABLE OF CONTENTS Display of battery status 12 GENERAL INFORMATION CONCERNING ................STACKING ......................Error messages ....................Stacking ........................Change language .................... Warnings 13 MAINTENANCE OF THE TRUCK ..................................Menus Daily maintenance (before each shift) ................................... Navigation in menus Daily Service (after each shift) ..................
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TABLE OF CONTENTS Lifting the forks Additional units/Trailers ....................................Normal operating conditions Safety and warning signs ............................. Exceptional operating conditions ............16 DIMENSIONS ....................... Work in hazardous environments ............Dimensions PL*/PS* ..................Parking ........................Dimensions PS, PSH ................... When lifting the truck ..................
Declaration of conformity UniCarriers Europe AB, SE-435 82 Mölnlycke, Sweden, Thank you for choosing us as your truck supplier. guarantees under its own liability that the product delivered...
TRUCK MODIFICATION 02 Truck modification • approves and makes appropriate changes to the capacity plate(s), decals, tags and Instruction Handbook NOTE! • affixes a permanent and readily visible label to the truck Unauthorized truck modification is not permitted. stating the manner in which the truck has been modified or altered, together with the date of the modification or No modifications or changes to powered industrial trucks that alteration, and the name and address of the organization...
03 ENVIRONMENTAL CONSIDERATIONS We respect the environment The majority of our products consist of steel, and can be completely recycled. Environmental impact All products have an impact on the environment throughout their entire life cycle. The consumption of energy when in use is one of the most important factors that influences the environment.
THE SUPERVISOR 04 Foreman’s responsibility Conditions of use The truck may be driven under the following conditions: It is the responsibility of the supervisor, on behalf of the company management, to ensure that the truck is driven • indoors and used correctly. •...
05 TRUCK DRIVER Authorization to drive a truck • Australia: Users shall follow the requirements of AS 2359.2. The employer must ensure that the employee has the required • North America: Users shall follow the requirements of the training and knows what must be observed in order to avoid applicable part of ANSI/ITSDF B56.
MACHINE PLATES 06 Explanation of machine plates European machine plates The Machine plate contains important information. Read it carefully! The permitted load shall not be exceeded. The stated load limit assumes that the load is evenly distributed on the forks. Figure 2. Load limit plates Actual capacity, Q ...
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06 MACHINE PLATES USA machine plates The machine plate contains important information. Read it carefully! Permitted loads may not be exceeded. The stated load limit assumes that the load is evenly distributed over the forks. Figure 4. Load limit plates Actual capacity, Q Load limit for fork lift with load Load centre distance, D ...
07 DESCRIPTION OF THE TRUCK Powered trucks PLL, PLE, PSL, PSD, PS, equipped with straddle lift for the transport of double load carriers. Usual loads are pallets or roller containers. PL* is an electric truck for walking operators, specially adapted for low level transportation, picking and handling at loading bays.
DESCRIPTION OF THE TRUCK 07 PLL, PLE, PSL, PSD, PS, PSH driver Controls PSH environment Functions Controls PLL, PLE, PSL, PSD, PS “Tiller up drive” driving at Keyboard (the keys may be slow speed with the tiller in its hidden by a cover) end position (option) ...
07 DESCRIPTION OF THE TRUCK PLP driver environment • Automatic reversing if the driver becomes trapped between the tiller arm and an obstacle (belly safety switch). Functions • Automatic stop when a fault occurs in the electrical system. Controls PLP pedestrian truck “Tiller up drive”...
DESCRIPTION OF THE TRUCK 07 • Automatic reversing if the driver becomes trapped between the tiller arm and an obstacle (belly safety switch). • Automatic stop when a fault occurs in the electrical system. TS pedestrian truck Emergency stop Safety functions The truck is equipped with a number of safety functions to minimise the risk of accidents.
07 DESCRIPTION OF THE TRUCK Controls for manual operation of lifting/lowering forks transportation, and order picking. Certain trucks are equipped with straddle lift for the transport of double load carriers, ordinary pallets or handling at loading bays. TS driver environment Functions Common controls Not used ...
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DESCRIPTION OF THE TRUCK 07 Controls for proportional operation of lifting/lowering forks (option) Lower forks Lift forks Not used Belly safety switch Lower Lowering of the adjustable Lift height straddle legs (option), Horn otherwise the same function Speed Controller as button B Lifting of the adjustable height straddle legs (option), otherwise the same function...
07 DESCRIPTION OF THE TRUCK • Driving is prevented if the platform is down and there is no operator standing on it. • Automatic reversing if the driver becomes trapped between the tiller arm and an obstacle (belly safety switch). • Lift stop at 1.8 m forks height and folded up gates.
DESCRIPTION OF THE TRUCK 07 Options Additional equipment Additional equipment Pen holder The truck may be equipped with additional equipment. Among AC/12 V DC other things, there are the following possibilities: converter Fire extinguisher Table 1. PLL, PLE, PS, PSL, PSD, PSH Additional equipment PLE PS PSL Writing desk...
08 BATTERY Specifications Specifications TS Specifications PLL, PSD, PSL, PLE, PS, PSH Table 5. Battery as standard Truck model Battery voltage Capacity Weight Table 3. Battery as standard and capacity (kWh) min/max (kg) (V/Ah) Truck model Battery voltage Capacity Weight and capacity (kWh) min/max (kg) 24/240...
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BATTERY 08 WARNING! Always use safety glasses. Acid can cause serious corrosive injuries. WARNING! Explosive gas is generated during charging! Smoking or a naked flame can cause an explosion! WARNING! Remove all rings, bracelets, necklaces and similar items before handling batteries.
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08 BATTERY Check that the battery electrolyte level is not above or below the cell plates. The battery can be damaged if the cell plates become dry during charging. There is a risk that the acid will spill over during charging if the acid level is too high. Connect the battery plug to the charger's connector.
BATTERY 08 Maintaining and changing the battery Plug the connector into a mains power outlet. Charging will start. Maintaining and changing the battery PL*/PS*, PS NOTE! Pull out the battery plug. For safety reasons the truck cannot be driven while the mains power connector is connected Open the battery cover.
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08 BATTERY Maintaining and changing the battery PLP Connect the battery plug. Check the battery voltage on the battery indicator. NOTE! A battery carriage must be used when changing Maintaining and changing the battery PSH battery. NOTE! Pull out the battery plug. A battery carriage must be used when changing battery.
BATTERY 08 changing the battery on a truck with vertically adjustable WARNING! straddle legs, raise the straddle legs to their highest Avoid short circuits, which can cause explosion or position in order to remove the battery stop. fire. CAUTION! There is a risk of pinching while rolling the battery out or in.
09 TRUCK COMPUTER (ATC) Introduction e.g.: date, time, battery status, as well as any error codes and warnings. The Operator ID and PIN code are supplied along with the delivery of the truck. The code should be changed after delivery. Symbols and characters on the display Date: Day-month-year. ...
TRUCK COMPUTER (ATC) 09 Display of battery status Error messages Error codes All error messages are shown on the bottom row of the display. An error message is presented in the form of a code, consisting of the letter E and a code number, e.g. 008. When an error code is shown, the truck will go into a failsafe mode, which may mean that the truck's functions will stop.
09 TRUCK COMPUTER (ATC) disappear even though the driver has followed the instructions SELECT LANGUAGE: on the display, contact and authorised service technician. English You will now enter the logon mode automatically with the new language setting. Operator ID: Warnings There are a number of different warnings used to catch the driver’s attention in the case of, for example, an operational error.
TRUCK COMPUTER (ATC) 09 Menus ATC has a number of functions available in a menu system. There are five basic menus with multiple submenus. The button is used to navigate between menus. Certain basic menus require a password to be able to access them. •...
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09 TRUCK COMPUTER (ATC) • To enter into a menu: Press the button. • To exit a selected menu: Press . The horn button serves as an "Esc button". Press the button when "Exit" is shown in the display.
DRIVING INSTRUCTIONS 10 Driving instructions PLL, PLE, PSL, PSD, NOTE! PS, PSH, PLP If a lever is activated when the truck is started, you will see a message on the display asking Starting the truck you to reposition the lever to neutral position. Connect the battery plug and check that the emergency Then the truck may be operated.
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10 DRIVING INSTRUCTIONS • Brake by moving the speed control back to its neutral shutting down... position and moving the tiller arm up or down to its end position. Operator ID: NOTE! The brakes function whether the lever is released or not. NOTE! Always turn off the truck in accordance with the above instructions before the battery plug is...
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DRIVING INSTRUCTIONS 10 Crawler mode normal operation, turn the handle anticlockwise back to normal position (B). It is possible to manually activate crawl speed during operations. Button alternates between the two speed selections. (Button to go directly to normal speed.) Various safety systems in the truck may automatically reduce the speed in certain situations.
10 DRIVING INSTRUCTIONS Turn the key. Driving instructions Start the truck in accordance with Starting the truck page Release the parking brake by moving the tiller arm downwards (but not to the bottom position). NOTE! For trucks with fixed/protected platforms, the driver must stand on the platform to be able to use any of the hydraulic functions.
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DRIVING INSTRUCTIONS 10 NOTE! NOTE! The further the speed controller is moved the Emergency stop shall not be used to turn off the greater the braking capacity. truck. • Brake by moving the lever on the operating handle back to its neutral position and moving the operating handle up or down to its end position.
11 GENERAL LOADING AND UNLOADING INFORMATION Responsibility for the load CAUTION! Do not drive with the load lifted, except during The driver of the truck is responsible for the load that is being 2-pallet handling. carried during transport. There must not be any risk of the load tipping or sliding off during transport.
GENERAL INFORMATION CONCERNING STACKING 12 Stacking Approach the stack with the load in the lowered position. Lift the load sufficiently high that it clears the stack or shelf and then drive towards the stack. When the load is in a suitable position, lower it onto the stack.
13 MAINTENANCE OF THE TRUCK Daily maintenance (before each shift) Check that the securing arrangements for the finger protection are intact and that there is a good view through Responsibility: Fork lift truck driver the protection. CAUTION! WARNING! Naked flames or smoking are prohibited when There is the danger of personal injury if the working on or near to the battery.
MAINTENANCE OF THE TRUCK 13 Battery changing fluids. Damage to the truck caused by fluids in electrical components is not covered by the manufacturer's warranty. Check the battery voltage on the battery indicator. Charge the battery as necessary. The battery is charged in Preventive maintenance accordance with the recommendation from the battery manufacturer.
14 SERVICING AND MAINTENANCE Service technician • To prevent injuries caused by crushing the battery plug should always be removed when working on and around NOTE! the mast and hydraulic unit. Servicing and maintenance must be carried out by a • When dismantling parts of the hydraulic system the system specially appointed and trained technician with a must not be pressurised, e.g.
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SERVICING AND MAINTENANCE 14 • The hydraulic oil filter and air filter for the hydraulic oil tank filter must be changed and a functional test carried out in must be changed after every 500 hours of operation. For accordance with the following list. TS, this should happen every 1,000 hours of operation.
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14 SERVICING AND MAINTENANCE servicing includes operations such as test driving, functional Chassis tests, and the changing of filters and oils, etc. Descriptions PS/PSH NOTE! Lubrication In the case of demanding and/or dusty environments Link system with humid or corrosive air, it is advisable to perform maintenance more often.
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SERVICING AND MAINTENANCE 14 Mast system Hydraulic system Descriptions PS/PSH Descriptions PS/PSH Lift chains Couplings Forks, fork carriage Pump motor Bearings/Rollers Hydraulic pump Lubrication On/off valve proportional valve Mast profile Friction force system Pull rods Lift cylinders Steering Descriptions PS/PSH Descriptions PS/PSH Cylinders Servo motor...
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14 SERVICING AND MAINTENANCE Service points PLL, PLE, PSD, PSL Electrical system Planned service inspections are implemented in accordance Descriptions PS/PSH with the following points: Fuses X Obligatory Battery plug X Not obligatory Cooling fan Chassis Truck computer Descriptions PSD/PSL Belly switch button Signs/Decals Emergency stop Covers and panels...
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SERVICING AND MAINTENANCE 14 Drive unit Hydraulic system Descriptions PSD/PSL Descriptions PSD/PSL Gearbox Hydraulic oil level Traction motor Hoses Drive wheel Couplings Drive shaft Pump motor Gearbox oil level Hydraulic pump On/off valve proportional Mast system valve Descriptions PSD/PSL Lift cylinders Lift chains Descriptions PSD/PSL...
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14 SERVICING AND MAINTENANCE Lubrication chart PL*/PS* Electrical system Descriptions PSD/PSL Fuses Battery plug Truck computer Belly switch button Emergency stop Hour meter Battery indicator Key switch Brake-System Descriptions PSD/PSL Brake function Parking brake Brake disc Consumable materials Only supplies (oils, grease, lubricants etc.) that have been approved by our genuine spare parts department may be used for servicing and maintenance of the truck.
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SERVICING AND MAINTENANCE 14 PL*/PS* components requiring lubrication Location Explanation Mast profile roller surfaces and slide surfaces Thrust rollers Lift chains Straddle legs Fork carriage Bogie wheel Battery rollers Castor wheel - sliding bearing, grease nipple Speed and brake controls - slide surfaces and springs Steering arm - gas spring Steering arm housing Hydraulic tank...
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14 SERVICING AND MAINTENANCE Lubrication chart PS/PSH Figure 8. PSH Figure 7. PS 500 hr service Annual service 500 hr service Annual service ...
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SERVICING AND MAINTENANCE 14 PS/PSH components requiring lubrication Lubrication chart PLP Location Explanation Location Explanation Mast profile roller Castor wheel - sliding surfaces and slide bearing, grease nipple surfaces Thrust rollers Speed and brake controls - slide surfaces and springs Lift chains Steering arm - gas spring Straddle legs...
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14 SERVICING AND MAINTENANCE Lubrication chart PLP CD Location Explanation Spring-mounted drive unit – link bearings, 12 grease nipples Hydraulic oil Castor wheel - sliding bearings, 2 grease nipples Gearbox oil Platform, 2 grease nipples 500 hr service Annual service ...
SERVICING AND MAINTENANCE 14 PL*/PS* fuses Designations Heavy current (A) For additional Table 6. PL*/PS* fuses equipment. Max. 120 Designations Heavy current (A) Traction motor Servo steering Pump motor TS fuses Manoeuvring Table 9. TS fuses PS, PSH fuses Model Heavy current (A) Table 7.
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14 SERVICING AND MAINTENANCE Basic trouble shooting Truck condition Possible cause Procedure If the truck does not work after action has been taken in The truck cannot be The truck is not ready Carry out all the accordance with the following table, contact an authorised driven for use actions under the...
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SERVICING AND MAINTENANCE 14 Dismantling and assembling the panels Insert a round rod or similar into the emergency stop button. Turn the emergency stop button until the hole in General the shaft is found. Then remove the emergency stop button shank by turning it counterclockwise. WARNING! The removal and refitting of panels and covers Remove the securing bolts.
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14 SERVICING AND MAINTENANCE WARNING! Torque For optimum performance and so as not to invalidate The bolts must be tightened to a torque of 47 the warranty, use only our genuine replacement parts! Otherwise, we are unable to guarantee stability and brake function. Dismantling and assembling the castor wheel, PLP Lift the load wheel off the ground and secure the truck with WARNING!
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SERVICING AND MAINTENANCE 14 Dismantling and assembling the drive wheel Torque Pull out the battery plug. The bolts must be tightened to a torque of 47 Loosen the drive wheel nuts, without removing them. Lift the load wheel off the ground and secure the truck with Dismantling and assembling the castor wheel, TS blocks.
15 SAFETY REGULATIONS The authority and obligations of the truck WARNING! driver It is not permitted to climb on to the truck. The driver has the authority and the responsibility to refuse to drive the truck in the following cases: Driving the truck •...
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SAFETY REGULATIONS 15 Clearance height NOTE! Bear in mind that the truck cannot be used where the clearance Accessories on the truck may restrict the view. height of an opening is less than the height of the drivers cab, the load or the mast. WARNING! There is a danger to life if the truck is driven with The truck in an industrial lift...
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15 SAFETY REGULATIONS Transports Speed Adjust the speed according to the floor conditions, the line of sight and operational safety. Avoid rapid acceleration, sudden braking and cornering at speed; there is a risk for overturning or that the load will fall off. Driving space Ensure that you have sufficient space for the truck - both the driver and the load - in narrow aisles.
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SAFETY REGULATIONS 15 Load guard WARNING! Figure 12. Load guard Place your feet correctly on the platform to avoid injury. The truck may be equipped with load protection if it is to handle small objects that are at risk of falling down and injuring the operator or the truck while the load is raised.
15 SAFETY REGULATIONS Risk zones Awareness! Do not drive near the edges of loading bays, gangways, etc. Always be aware of personnel in the neighbourhood when where there is a risk of the truck going over an edge. Be careful operating the truck. when operating close to colour marked risk zones.
SAFETY REGULATIONS 15 Exceptional operating conditions PS, PSH: Open the battery cover and thread the strap under it so that the cover is not damaged by the pressure. When the operating conditions differ from the normal conditions above, the following steps must be taken: Lifting the forks •...
15 SAFETY REGULATIONS the truck page 34. If the truck is equipped with a key switch, WARNING! the key must be taken out when leaving the truck, so that If the truck is lifted incorrectly, parts may be unauthorised persons cannot use it. Fire insurance terms damaged by being subjected to excessive force.
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SAFETY REGULATIONS 15 When lifting a PLP truck When lifting truck types PS/PSH The illustration below shows where the jack should be placed.
15 SAFETY REGULATIONS When lifting TS trucks The following actions are to be taken in order to make the truck ready for use. • Charge the battery. • Perform an inspection in accordance with Daily maintenance (before each shift) page 40. •...
SAFETY REGULATIONS 15 Lubricate the truck in accordance with the lubrication chart. In consultation with an authorised service organisation, the supervisor must make sure that the move can take place in a Disconnect the battery plug. controlled manner, so that there is no risk of accident. The truck is moved using another truck of sufficient capacity to a suitable Actions during storage place where the repair can take place.
15 SAFETY REGULATIONS In the event of accidents Work platforms Report all accidents or incidents immediately to the supervisor. When temporarily lifting persons with a truck without driver If possible, leave the truck where it is. If possible, take action to lifting, national regulations and recommendations for working lessen the damage or harm, especially if there are people hurt.
SAFETY REGULATIONS 15 Safety and warning signs Explanation of symbols General NOTE! There are a number of warning signs on the truck. Always replace signs that are damaged or missing. Crushing risk between moving parts Do not stand on the forks Do not stand under the forks Read and comply...
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15 SAFETY REGULATIONS Locations of safety and warning signs on PLE, PSL, PSD, PS, PSH Only one person is allowed on the truck Only applies to PL*/PS* without mast. ...
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SAFETY REGULATIONS 15 Locations of safety and warning signs on PLL Europe Only applies to PLL with battery on rollers Only applies to PLL with battery on rollers. ...
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15 SAFETY REGULATIONS Locations of safety and warning signs on PLP Locations of safety and warning signs on TS...
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16 DIMENSIONS Figure 15. Positions for dimensions PSD/PSL Table 11. Truck type and dimensions in mm Figure 14. Positions for dimensions PLE Measurements PLE PSD 125/160...
18 ORDERING HANDBOOKS AND MANUALS Ordering a Spare Parts Manual We do not automatically send out spare parts catalogues with ...................... delivery of your truck. It is possible to order a Spare Parts Manual via your local distributor, for a fee. Delivery time is estimated at around three weeks.