UniCarriers PLL Series Instruction Handbook Manual Download Page 54

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14 SERVICING AND MAINTENANCE

TS components requiring lubrication

Location

Explanation

Mast section - roller surfaces and slide surfaces

Thrust rollers - all

Lift chains - all

Fork carriage - support rollers

Fork carriage – slide surfaces

Bogie – axle (unloaded)

Battery rollers

Guide ring

Gearbox

Speed and brake controls – slide surfaces and springs
lubricated

Attachment gas spring steering arm

Steering arm housing

Upper/lower guide bearings lubricated

Hydraulic tank

Steering chain

Castor wheel, sliding bearings, wheel bearings

Symbol key lubrication chart

Symbol

Explanation

Symbol

Explanation

Oil filter and air filter,
change

Hydraulic oil, oil filter
and air filter, change

Gearbox oil, check

Gearbox oil, change

Grease

Only cold store
version

Chain spray

Chain spray/oil

Applicable in general for the symbols:

Unfilled symbol, check lubrication.

Filled symbol – Change.

Fuses

General

WARNING!

Fuses should be changed by an authorised service
technician.

WARNING!

Always switch off the current by pulling out the
battery plug when changing fuses.

Instruction Handbook PLL, PLE, PSL, PSD, PS, PSH, PLP, TS — D002652, B, GBR, ForTranslation

Summary of Contents for PLL Series

Page 1: ...LP TS Instruction handbook UniCarriers Europe AB SE 435 82 M lnlycke Sweden Phone 46 0 31 98 40 00 info unicarriers com www unicarriers com P N 159147 Rev A GB l002_handbook_Brandless_spr k_Pedestrian...

Page 2: ...ied fully or in part without written permission The material has undergone careful examination with regard to correctness We reserve the right to make changes Copyright UniCarriers Europe AB 2015 Inst...

Page 3: ...on of machine plates 13 07 DESCRIPTION OF THE TRUCK 14 Powered trucks PLL PLE PSL PSD PS PSH 14 PLL PLE PSL PSD PS PSH driver environment 15 PLP pedestrian truck 16 PLP driver environment 16 TS pedest...

Page 4: ...ling 38 12 GENERAL INFORMATION CONCERNING STACKING 39 Stacking 39 13 MAINTENANCE OF THE TRUCK 40 Daily maintenance before each shift 40 Daily Service after each shift 40 Weekly inspection 41 Preventiv...

Page 5: ...69 In the event of accidents 70 Noise Sound levels 70 Vibrations 70 Climatic conditions 70 Work platforms 70 Overhead guard 70 Protective shoes 70 Lighting 70 Additional units Trailers 70 Safety and w...

Page 6: ...g of replacement parts Refer to the nearest authorised sales agent or service workshop for assistance Genuine Parts The reliability that we promise is contingent upon using our original spare parts On...

Page 7: ...ust also be changed accordingly Only in the event that the manufacturer is no longer in business and there is no successor to the company s stakeholders may the user implement a modification or altera...

Page 8: ...the environmental impact Waste Waste material in conjunction with repairs maintenance cleaning or scrapping must be collected and disposed of in an environment friendly way and in accordance with the...

Page 9: ...rvicing shall be carried out by the operator once he or she has received sufficient training in the truck s construction and care Ongoing routine servicing should be performed by an authorised service...

Page 10: ...r shall have the permission of the supervisor to drive the type of truck in question and be specially trained for the work and the traffic conditions involved The responsibilities of the driver in spe...

Page 11: ...ery voltage 8 Permitted load 9 Distance to centre of gravity 10 Reference number year and nonth of manufacture Figure 2 Load limit plates 1 Actual capacity Q 2 Load centre distance D 3 Lift height for...

Page 12: ...voltage 10 Battery type maximum capacity 11 Actual capacity Q 12 Load centre distance D Figure 4 Load limit plates 1 Actual capacity Q 2 Load centre distance D 3 Lift height for fork lift H 4 Lift hei...

Page 13: ...PLATES 06 13 Location of machine plates Location of machine plates PSD PSL PS PSH TS PLE PLP A Machine plate B Load limit plate Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D002652 B GBR ForTran...

Page 14: ...l load carrier types Usual loads are pallets or roller containers The trucks are intended for use indoors on hard level surfaces PS is an electric truck for walking operators specially adapted for sta...

Page 15: ...E J Lower vertically adjustable straddle leg option PSD PLE Controls PSH A Tiller up drive driving at slow speed with the tiller in its end position option B Lower vertically adjustable straddle leg o...

Page 16: ...ading bays The truck can be equipped with a mast for stacking and the transport of double load carriers or with long forks for the transport of several load carriers Usual loads are pallets or roller...

Page 17: ...re also prevented if there is no operator standing on the platform Automatic reversing if the driver becomes trapped between the tiller arm and an obstacle belly safety switch Automatic stop when a fa...

Page 18: ...ttery plug emergency stop B Battery indicator C Hour meter D Key switch Controls for manual operation of lifting lowering forks A Not used B Not used C Not used D Horn E Speed Controller F Belly safet...

Page 19: ...itch G Lowering of the adjustable height straddle legs option otherwise the same function as button B H Lifting of the adjustable height straddle legs option otherwise the same function as button C I...

Page 20: ...ed up manually A number of safety functions have been built into the truck to avoid accidents A Platform folded down without operator standing on it The truck cannot be driven B Platform folded down a...

Page 21: ...hing strap x x x x x Rubber foot protection x x Stretch film holder x Pen holder x AC 12 V DC converter x Fire extinguisher x Table 1 PLL PLE PS PSL PSD PSH Additional equipment PLP TS Writing desk x...

Page 22: ...nging Battery servicing may only be performed by specially trained personnel The battery may however be charged by other personnel on the condition that a battery connector is used to connect the batt...

Page 23: ...e 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 I...

Page 24: ...ng charging if the acid level is too high 5 Connect the battery plug to the charger s connector 6 Set the charging switch on the battery charger to on 7 Check that the ammeter shows a normal indicatio...

Page 25: ...ng and changing the battery PL PS PS 1 Pull out the battery plug 2 Open the battery cover WARNING There is a risk of crushing injury Do not insert a hand between the battery cover and the chassis 3 At...

Page 26: ...changing the battery PLP 1 NOTE A battery carriage must be used when changing battery Pull out the battery plug 2 Release the battery lock 3 Roll out the battery on the battery carriage WARNING Observ...

Page 27: ...nscrew and remove the safety stop 4 Perform a battery inspection in accordance with Maintenance of the truck page 40 5 Roll the battery in 6 Refit the battery locks 7 Refit the battery plug 8 Check th...

Page 28: ...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 A Date Day month year B Time Hours minutes C...

Page 29: ...e 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...

Page 30: ...elease throttle The driver is asked to position the speed lever in neutral Release controls The driver is asked to set all hydraulic levers to their neutral positions Release tiller The driver is inst...

Page 31: ...technician Settings Here it is possible to set the language to be shown in the display ATC supports Swedish English German and French It is also possible to install one additional language using spec...

Page 32: ...r 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 Instruction Handbook PLL PLE PSL PSD PS PSH PLP...

Page 33: ...n the truck is started you will see a message on the display asking you to reposition the lever to neutral position Then the truck may be operated This means that sudden movements are avoided when sta...

Page 34: ...g operations Select crawl speed by pressing the button F Button F to go directly to normal speed 7 Switch off the truck in accordance with Switching off the truck page 34 Switching off the truck 1 To...

Page 35: ...is only used for shorter stops during the work shift At the end of the work shift or when the truck is going to be left unattended it should always be turned off 1 To enter standby mode Keep the butt...

Page 36: ...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 3 The truck b...

Page 37: ...ull out the battery plug 6 In order to avoid crushing injuries during driving there is a belly switch at the end of the tiller arm When the belly switch is pressed in the truck will move in the direct...

Page 38: ...refer to the fork lift truck load limit plate Note the effect of the centre of gravity on the lifting capacity Picking up a load Always pick up a load so that it comes to rest as close to the mast as...

Page 39: ...ack 3 When the load is in a suitable position lower it onto the stack 4 Lower the forks so that they release the load pallet and check that no one is behind the truck before reversing away from the st...

Page 40: ...cessive wear on the wheels 7 Check that there are no error messages or warnings on the truck computer display 8 Check that the securing arrangements for the finger protection are intact and that there...

Page 41: ...he fork truck raise all the way up to maximum lift height without the pump sucking air 3 Check that the wheels have not separated tread hub and tread cord 4 The outside of the truck must be cleaned Va...

Page 42: ...led out before working on the truck Ensure that the drive wheel is off the ground before trouble shooting Secure the truck with blocks To prevent injuries caused by crushing the battery plug should al...

Page 43: ...he operation of the truck and its component parts The gearbox oil and hydraulic oil filter must be changed and a functional test carried out in accordance with the following list Check for external da...

Page 44: ...oints X Obligatory O Not obligatory Chassis Descriptions PLP PS PSH TS Signs Decals X X Covers and panels X X X Overhead guard X Rail wheel X X O Battery stop Lock Rollers X X X Rubber mat X X Chassis...

Page 45: ...aulic system Descriptions PLP PS PSH TS Hydraulic oil level X X X Hoses X X X Hydraulic system Descriptions PLP PS PSH TS Couplings X X X Pump motor X X X Hydraulic pump X X X On off valve proportiona...

Page 46: ...X Parking brake X X X Brake disc X X X Service points PLL PLE PSD PSL Planned service inspections are implemented in accordance with the following points X Obligatory X Not obligatory Chassis Descrip...

Page 47: ...PSD PSL Sliding bearing X X X Tiller foot X X X Steering Bearing X X X Hydraulic system Descriptions PLL PLE PSD PSL Hydraulic oil level X X X Hoses X X X Couplings X X X Pump motor X X X Hydraulic pu...

Page 48: ...stem Descriptions PLL PLE PSD PSL Brake function X X X Parking brake X X X Brake disc X X X Consumable materials Only supplies oils grease lubricants etc that have been approved by our genuine spare p...

Page 49: ...slide surfaces A2 Thrust rollers B Lift chains C Straddle legs D Fork carriage E Bogie wheel F Battery rollers G Castor wheel sliding bearing grease nipple H Speed and brake controls slide surfaces an...

Page 50: ...D MAINTENANCE 50 Lubrication chart PS PSH Figure 7 PS 1 500 hr service 2 Annual service Figure 8 PSH 1 500 hr service 2 Annual service Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D002652 B GBR...

Page 51: ...surfaces and springs B Lift chains I Steering arm gas spring C Straddle legs J Steering arm housing D Fork carriage K Hydraulic tank E Bogie wheel L Guide ring F Battery rollers M Gearbox Lubrication...

Page 52: ...t link bearings 12 grease nipples D Hydraulic oil E Castor wheel sliding bearings 2 grease nipples F Gearbox oil G Platform 2 grease nipples Lubrication chart PLP CD 1 500 hr service 2 Annual service...

Page 53: ...ie wheel D Gates bearing surfaces E Fork carriage F Spring mounted drive unit link bearings 12 grease nipples G Lift chains H Hydraulic oil I Castor wheel sliding bearings 2 grease nipples J Gearbox o...

Page 54: ...M Hydraulic tank N Steering chain O Castor wheel sliding bearings wheel bearings Symbol key lubrication chart Symbol Explanation Symbol Explanation Oil filter and air filter change Hydraulic oil oil...

Page 55: ...ignations Heavy current A Use F4 5 For additional equipment Max 120 W F5 25 Servo steering TS fuses Model Heavy current A Use TS 1 1 kW TS 2 kW 3 Manoeuvring TS 1 1 kW TS 2 kW 7 5 Manoeuvring TS 1 1 k...

Page 56: ...urn the key switch to position I or enter the appropriate Operator ID and password Truck condition Possible cause Procedure The truck cannot be driven The truck is not ready for use Carry out all the...

Page 57: ...y stop button 2 Take out the plastic plug from the plastic cover over the battery 3 Insert a round rod or similar into the emergency stop button Turn the emergency stop button until the hole in the sh...

Page 58: ...mbly and support the fork in a vice 4 Undo the bolt and drive out the wheel axle Now the wheel can be taken out of the fork 5 Install in the reverse order Torque The bolts must be tightened to a torqu...

Page 59: ...e the retaining pin should also be replaced 5 Install in the reverse order Torque The bolts must be tightened to a torque of 47 Nm Dismantling and assembling the drive wheel Pull out the battery plug...

Page 60: ...under a raised lift whether this is loaded or unloaded WARNING Take great care in the machinery compartment beware of hot surfaces etc Getting in and out Be careful when getting in and out Use the ha...

Page 61: ...ft is started Floor load Carefully check notices or other instructions concerning the maximum floor load or maximum wheel pressure to ensure that these are not exceeded For the truck s total weight se...

Page 62: ...y 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 t...

Page 63: ...guard Figure 12 Load guard 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 ra...

Page 64: ...ng For information on the truck s total weight see the truck s machine plate Direction of travel when driving on slopes Outrigger trucks These trucks are always driven unloaded with the forks facing a...

Page 65: ...rking conditions are of a temporary nature take suitable measures such as using a larger truck or reducing the load appropriately Work in hazardous environments A truck operating in an area where ther...

Page 66: ...g the truck General The truck may only be lifted using lifting eyes directly intended for lifting The image shows where the permitted lift points are located on the truck The lift points are marked wi...

Page 67: ...LATIONS 15 67 When lifting a PLP truck The illustration below shows where the jack should be placed When lifting truck types PS PSH Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D002652 B GBR For...

Page 68: ...truck including the forks for signs of damage Check that the safety and warning signs are in place and are legible See Safety and warning signs page 71 Temporarily taking the truck out of service Sto...

Page 69: ...act the supervisor immediately In consultation with an authorised service organisation the supervisor must make sure that the move can take place in a controlled manner so that there is no risk of acc...

Page 70: ...hort term temperature 25 C Work platforms When temporarily lifting persons with a truck without driver lifting national regulations and recommendations for working with work platforms must be complied...

Page 71: ...ing risk between moving parts Do not stand under the forks Do not stand on the forks Passengers are only allowed at the designated positions on the truck platform Read and comply with the Instruction...

Page 72: ...72 Only one person is allowed on the truck Locations of safety and warning signs on PLE PSL PSD PS PSH A Only applies to PL PS without mast Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D002652...

Page 73: ...ocations of safety and warning signs on PLL Europe A Only applies to PLL with battery on rollers USA A Only applies to PLL with battery on rollers Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D0...

Page 74: ...15 SAFETY REGULATIONS 74 Locations of safety and warning signs on PLP Locations of safety and warning signs on TS Instruction Handbook PLL PLE PSL PSD PS PSH PLP TS D002652 B GBR ForTranslation...

Page 75: ...0 R2 1385 1575 1385 1575 1385 1575 H6 L 1495 1685 1495 1685 1495 1685 B 660 660 660 L1 1000 1190 1000 1190 1000 1190 V width over forks std max min 520 680 520 680 520 680 V width between fork shanks...

Page 76: ...dimensions PLE Figure 15 Positions for dimensions PSD PSL Measurements PLE PSD 125 160 PSL D 600 600 600 H4 730 H3 880 Table 11 Truck type and dimensions in mm Instruction Handbook PLL PLE PSL PSD PS...

Page 77: ...n 534 540 540 V width between fork shanks 170 170 L4 570 673 673 B1 184 60 185 65 185 65 H1 88 92 B2 166 175 L2 990 990 950 L3 1412 1510 1510 Dimensions PS PSH Measurements PSH 200 SDTFV PSH 200 BDTFV...

Page 78: ...5400 3600 5400 1670 4200 1670 4200 1670 4200 2900 4200 H3 1740 2340 1740 2340 1375 2640 1375 2640 1375 2640 1990 2640 Mea sure men ts PSH 160 SDTFV BDTFV BT ST STFV BTFV H1 90 60 60 90 90 60 L 1980 20...

Page 79: ...Figure 17 PLP CD Measurements PLP 200 PLP 250 PLP 200 CD H5 2095 H4 205 205 1675 H3 1410 H1 85 85 90 R2 770 L2 835 L2 1900 Table 12 Truck type and dimensions in mm Instruction Handbook PLL PLE PSL PS...

Page 80: ...375 1000 2375 1150 V width over forks std max min 680 460 680 480 560 V width between fork shanks V 350 V 350 190 L4 750 825 934 B1 175x55 175x55 185x65 H1 85 85 90 L2 785 1765 785 1465 958 L3 551 L2...

Page 81: ...375 2640 1375 2640 H2 170 203 203 170 203 203 H1 90 90 90 90 90 90 L L1 L4 L1 L4 L1 L4 L1 L4 L1 L4 L1 L4 L1 1200 1000 11 50 1000 11 50 1200 1000 11 50 1000 11 50 L2 750 650 800 650 800 750 650 800 650...

Page 82: ...1300 PSH 200SDTFV 1550 1250 PSH 160BT 1350 1050 PSH 160ST 1300 1000 Truck Service weight with without battery kg PSH 160STFV 1300 1000 PSH 160BTFV 1350 1050 Weight PLP Truck Service weight with witho...

Page 83: ...without battery kg TSL 120 TV 1070 800 TSL 140T 1120 850 TSL 140TFV 1230 960 TSL 140DTFV 1230 960 TSL 150T 1120 850 TSL 150TFV 1230 960 TSL 150DTFV 1230 960 Instruction Handbook PLL PLE PSL PSD PS PS...

Page 84: ...a Spare Parts Manual via your local distributor for a fee Delivery time is estimated at around three weeks Complete the order form below and send it to your local distributor TRUCK TYPE P N QUANT ITY...

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