Yale A245 Operating Manual Download | Manualshive

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1.

BATTERY CHARGER

Figure 13. On-Board Charger

LED Status Display

The charger has five colored LED's located on the top of
the charger. The LED's are used to indicate the status of
the charger during operation. The order of the LED's may
vary with models, but they are labeled to identify their func-
tion. See

.

Maintenance

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Summary of Contents for A245

Page 1: ...OPERATING MANUAL Motorized Hand Truck MPB045VG A245 PART NO 550068167 3 19 DO NOT REMOVE THIS MANUAL FROM THIS UNIT ...

Page 2: ...ER SERIAL NUMBER COMPOSITION SPECIAL EQUIPMENT OR ATTACHMENTS Yale Material Handling Corporation 2019 All Rights Reserved YALE and VERACITOR are Registered Trademarks of Hyster Yale Group Inc CSS PREMIER and are Trademarks in the United States and certain jurisdictions is a registered copyright Spacer ...

Page 3: ...erator can see hear and has the physical and mental ability to operate the equipment safely Various laws and regulations require the employer to train lift truck operators These laws and regulations include Occupational Safety and Health Act OSHA USA Canada Material Handling Regulations NOTE A comprehensive operator training program is avail able from Yale Company For further details contact your ...

Page 4: ...anual for Industrial Operations from the National Safety Council Guide for Users of Industrial Lift Trucks Yale Part No 550038777 describes lift truck safety good mainte nance practices and training programs and is available from your dealer for Yale Company lift trucks NOTE Yale Company lift trucks are not intended for use on public roads NOTE Throughout this manual the terms right left front and...

Page 5: ...ing 44 Coasting 44 Stopping 44 Load Handling 45 Maintenance 46 HOW TO MOVE A DISABLED LIFT TRUCK 46 HOW TO PUT A LIFT TRUCK ON BLOCKS 47 Maintenance Schedule 48 Checks and Inspection Procedures 53 HYDRAULIC SYSTEM 53 LIFTING MECHANISM 55 CONTROLS 55 WHEELS AND TIRES 57 ELECTRICAL AND BATTERY 57 CHARGING THE BATTERY 58 LED Status Display 60 Specific Gravity Corrections 63 CHECKING THE BATTERY 65 CH...

Page 6: ... Do not ride truck unless it is designated as a rider type truck by manufacturer Do not move truck if anyone is between truck and sta tionary object Keep hands within handle guards and feet clear of truck Do not handle loads taller than load backrest or exten sion unless load is secured so that no part of it can move toward the operator KNOW THE AREA Check dockboard or bridgeplate width capacity a...

Page 7: ...ate truck with forks trailing whenever possible Always face direction of travel WHEN WALKING control truck with one hand using steer handle Walk to the side of the steer handle When truck is operated forks first use two hands on steer handle WHEN RIDING operate from operator s position only DON T GO IF YOU CAN T SEE Always look in direction of travel Keep a clear view AVOID SUDDEN MOVEMENT Start s...

Page 8: ... off power set brakes remove key and dis connect battery Block wheels if truck is parked on an incline TAKE CARE WHEN CHARGING Charge battery only in designated area When charging battery keep vent caps clear Avoid sparks or open flame Provide ventilation Disconnect battery during servicing Warning WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH AUTHORIZED TRAINED OP...

Page 9: ...igure 1 and Figure 2 This lift truck can be stopped by one of three methods of braking 1 Plugging 2 Neutral Braking 3 Returning the control handle or delivery handle to the brake ON position A detailed operating instruction is provided in the Operat ing Procedures section of this manual The operator has a choice of three performance modes that are selectable through the control handle or delivery ...

Page 10: ...ONTROL HANDLE 2 CENTER COVER 3 EMERGENCY POWER DISCONNECT 4 FORK 5 BATTERY COMPARTMENT 6 DRIVE COMPARTMENT COVER 7 OPERATING MANUAL Figure 1 Standard Model View Showing Major Components Model Description 8 ...

Page 11: ...ANUAL 3 CENTER COVER 4 EMERGENCY POWER DISCONNECT 5 DRIVE COMPARTMENT COVER 6 MOVEABLE LOAD BACKREST 7 LOAD RETENTION STRAP 8 BATTERY COMPARTMENT 9 FORK Figure 2 Retail Delivery Model View Showing Major Components Model Description 9 ...

Page 12: ...can handle for the load condition shown on the Nameplate See Fig ure 3 The maximum capacity for the lift truck must be shown on the Nameplate If the lift truck Nameplate already has a capacity for special load handling equipment it will be lis ted Make sure the Nameplate data is complete and fully understood before operating the lift truck The lift truck serial number code is on the Nameplate The ...

Page 13: ...Figure 4 Warning and Safety Labels Model Description 11 ...

Page 14: ...Legend for Figure 4 1 NAMEPLATE 2 DECAL WARNING 3 PATENTS TRADEMARKS LABEL 4 OPERATING MANUAL 5 YALE BLACK DECAL 6 E STOP LABEL 7 WARNING LABEL Model Description 12 ...

Page 15: ...Instruments and Controls Figure 5 Instruments and Controls Model Description 13 ...

Page 16: ...AIL DELIVERY TRUCK 1 CONTROL HANDLE ARM 2 CONTROL HEAD ASSEMBLY 3 EMERGENCY POWER DISCONNECT 4 KEY SWITCH 5 DISPLAY BATTERY INDICATOR HOURMETER 6 DELIVERY HANDLE ARM 7 DELIVERY CONTROL HEAD ASSEMBLY 8 MOVABLE LOAD BACKREST Model Description 14 ...

Page 17: ...dle to engage the brake When the control handle is released from the operating position it will automatically return to the ver tical position and engage the brake Arrows on the butterfly type knobs speed direction control indicate the direction of travel of the lift truck Lift lower traction reverse and the horn are controlled by separate buttons on the control handle Model Description 15 ...

Page 18: ...that vary are Acceleration Deceleration neu tral braking and Top Travel Speed The three user selectable performance modes are factory programmed per the following Mode 1 Soft Acceleration Acceleration Soft Top Speed 90 of full speed Neutral Braking Soft Mode 2 Medium Acceleration Acceleration Medium Top Speed 90 of full speed Neutral Braking Medium level Mode 3 Maximum Acceleration Acceleration ma...

Page 19: ...ts and Controls See Figure 5 Continued Item No Item Function 1 Selectable Performance Modes Continued NOTE See the section Operating Techniques for instructions on changing performance mode setting Model Description 17 ...

Page 20: ...rol Head Assembly The control handle assembly has the following controls a Traction Reverse button b Horn button c Direction and speed control d Slow speed button e Lower button f Lift button NOTE Operation of these controls is described in the following paragraphs Model Description 18 ...

Page 21: ...truck will move away from the operator forks first The button can be pushed intentionally or unintentionally When the button is released the traction motor will be turned OFF The traction motor will not move the lift truck in the direction of the control handle until the control is reset To reset move the speed direction control to the OFF position or move the handle to the BRAKE ON position b Hor...

Page 22: ...direction of travel by rotating the control in the desired direction Maximum rotation of the control causes maximum travel speed To stop or change direction the operator rotates the control in the opposite direction The lift truck will come to a stop If the speed direction control is not returned to OFF when the lift truck stops it will accelerate in the opposite direction Changing direction with ...

Page 23: ...is held the truck will continue in slow speed mode If the turtle button is released the truck will remain in slow speed mode until speed direction control returns to or passes through neutral Speed limiting operation is available in region B from rest to travel by selection and release of the turtle button Upon selection the truck s display will post TURTLE and the audible alarm will sound once Th...

Page 24: ...Table 1 Instruments and Controls See Figure 5 Continued Item No Item Function e Lower Button Press the button to lower the forks Release the button to stop lowering Model Description 22 ...

Page 25: ...ischarge of the battery Your truck may be configured with the optional SMART LIFT For trucks equipped with this feature the option can be activated and deactivated by simultaneous selection of lift and lower buttons on either left or right hand sides To activate the feature select lift and lower simultaneously The vehi cle horn will sound once to indicate feature is active To deactivate the fea tu...

Page 26: ... Switch The key switch is located on the operator s display panel The key switch has two positions O and I No truck functions are enabled when the key is the O OFF position When the key is rotated clockwise to the I ON posi tion power is applied NOTE Always raise the control handle or delivery handle to the full upright position and move the key to the OFF position when leaving the lift truck Mode...

Page 27: ...e and fault indicator is pro vided on this lift truck and includes a diagnostic fault code display The hour meter continually displays total operation hours when the key switch is ON and current is flowing Periodic maintenance recommendations are based on these operating hours At 80 of discharge an LED will flash indicating energy reserve The discharge indicator is programmed for use with a floode...

Page 28: ...lly optimized design of the retail delivery handle allows the operator full command of the truck s functionality with the handle in full upright position With the handle in upright position the truck can be operated in the most compact configuration for maximum maneuverability and visibility Model Description 26 ...

Page 29: ...Item Function 7 Delivery Handle Head Assembly The delivery handle head assembly has the following controls g Traction Reverse button h Horn Button j Direction and Speed control k Lower button m Lift button n Traction switch o Traction Interlock Model Description 27 ...

Page 30: ...truck will move away from the operator forks first The button can be pushed intentionally or unintentionally When the button is released the traction motor will be turned OFF The traction motor will not move the lift truck in the direction of the delivery handle until the control is reset To reset move the speed direction control to the OFF position or move the handle to the BRAKE ON position h Ho...

Page 31: ...in the desired direction Maximum rotation of the control causes maximum travel speed To stop or change direction the operator rotates the control in the opposite direction The lift truck will come to a stop If the speed direction control is not returned to OFF when the lift truck stops it will accelerate in the opposite direction Changing direction with the speed direction control is called pluggi...

Page 32: ...ischarge of the battery Your truck may be configured with the optional SMART LIFT For trucks equipped with this feature the option can be activated and deactivated by simultaneous selection of lift and lower buttons on either left or right hand sides To activate the feature select lift and lower simultaneously The vehi cle horn will sound once to indicate feature is active To deactivate the fea tu...

Page 33: ...Figure 5 Continued Item No Item Function n Traction Switch Unique throttle actuators allow for multiple hand positions when operating the truck Press up to move with forks leading Press down to move with forks trailing Model Description 31 ...

Page 34: ...rlock When the delivery handle is in the up position the traction interlock must be held down in order to use the traction switch on the bottom of the delivery handle When the deliver handle is in the up position release the traction interlock to stop the truck immediately Model Description 32 ...

Page 35: ...a single fork set up The quick latch and pivot arms make it easy to change the position of the backrest when pallet types change Extend the movable load backrest when moving shorter pallets To extend the movable load backrest lift the quick latch in the center of the backrest and pull toward the forks The single seatbelt style ratcheting and locking load retention strap secures the load Model Desc...

Page 36: ... traveling on an incline Keep both hands on the handle and within the han dle guards Always look in the direction of travel NOTE A flexible and comprehensive operator training pro gram is available from and recommended by Yale Com pany For further details contact your dealer for Yale Company lift trucks The following discussion lists safety techniques applicable to lift truck operation 1 Inspect t...

Page 37: ... with the lift truck Keep feet on the rider platform when operating a rider truck 6 For standard truck the proper operator position for walk ing with a motorized hand lift truck is shown in Figure 6 7 For delivery truck there are several operator positions See Figure 7 for two of these positions To operate deliv ery truck in confined areas place delivery handle into verti cal position The operator...

Page 38: ...NOTE ARROWS DENOTE DIRECTION OF TRAVEL Figure 6 Standard Truck Designated Operator Position Operating Procedures 36 ...

Page 39: ...NOTE ARROWS DENOTE DIRECTION OF TRAVEL Figure 7 Delivery Truck Designated Operator Position Operating Procedures 37 ...

Page 40: ...ck must not be driven across an incline Walkie lift trucks are not intended for operation on grades greater than 10 a grade that changes 1 foot in elevation for every 10 feet of horizontal travel 13 Charge the battery only in a designated area and observe the following DO NOT use an open flame to check battery electrolyte level Disconnect battery before performing service or repair When charging b...

Page 41: ... lift truck will remain stable Keep the load against the battery compartment The bat tery compartment acts as a load backrest to help steady the load Handle only stable loads Unstable loads can easily shift and fall DO NOT handle loads taller than the load back rest unless the load is secured so that no part of it can shift toward you NOTE Load backrest extensions are available for this lift truck...

Page 42: ...oad in the available space Enter elevator with load end forward Turn OFF the power set the parking brake and lower the load before operating the elevator Inspection Before Operation WARNING Inspect the lift truck and check the operation of the systems at the start of the day or shift Do the inspec tions and checks before lift truck operation If a repair is required put a tag on the control handle ...

Page 43: ...ake the lift truck wheels skid or oth erwise interfere with the lift truck operation Selectable Performance Modes The user has a choice of three performance modes that are selectable through the control handle or delivery handle The mode selection is made at startup or key ON Per formance parameters that vary are Acceleration and Deceleration The three user selectable performance modes are factory...

Page 44: ... travel Maximum rotation of the control causes maximum travel speed To change direction or to stop the lift truck regardless of lift truck speed rotate the control in the opposite direction The lift truck will come to a stop and then unless the con trol is returned to the OFF position accelerate in the oppo site direction This is called plugging Stop the lift truck as gradually as possible Rapid s...

Page 45: ...allowing the unit to slow to a stop It is applied by returning the speed direction con trol to the OFF position To remain stopped the speed direction control must be in the OFF position 2 Plugging is reversing the speed direction control while traveling causing the unit to stop Return the speed direc tion control to the OFF position to remain stopped If the control is not returned to OFF the truck...

Page 46: ...l initiate plugging Releasing the traction switch allows regen braking Coasting To coast there is a rubber bumper that can flip forward to keep the handle in the down run position The truck can then coast without having to pull the handle down every time With the delivery handle in the down position and the bumper in the forward position release the traction switch or direction and speed control t...

Page 47: ...d Make sure the load is against the battery compartment or load backrest Travel with the forks trailing except in confined areas Always look in the direction of travel Watch clearances avoid racks and other obstructions If you can t see don t go Avoid sudden starts and stops Travel slowly around corners Use special care when traveling on inclines travel slowly and do not angle or turn CAUTION If t...

Page 48: ...ft truck Put the weight of the disabled lift truck at the center of the forks and be careful not to damage the under side of the disabled lift truck Tilt the mast back and travel slowly WARNING Make sure no one except the driver is near the lift trucks during towing Both the tow truck and the disa bled truck can cause a personal injury during towing WARNING To avoid personal injury use extra care ...

Page 49: ... the ground to prevent movement of the lift truck WARNING Do not raise the lift truck by attaching an overhead crane to areas that will be damaged Some of these points are not designed to support the weight of the lift truck The lift truck can be damaged or it can fall caus ing serious injury Attach the chain or sling to a sup port structure of the lift truck frame WARNING Never raise the forks an...

Page 50: ...Figure 9 Putting the Lift Truck on Blocks Maintenance Schedule Maintenance Schedule 48 ...

Page 51: ...Figure 10 Maintenance Points Maintenance Schedule 49 ...

Page 52: ...tions 2 Brake X Check Operation Hold on 10 Grade4 3 Directional Speed Control X Check Operation 4 Gauges Horn and Fuses X Check Operation 5 Hydraulic Oil Full Mark X6 C Maximum 0 75 liter 0 79 qt Minimum 0 6 liter 0 63 qt Standard 0 to 48 C 32 to 120 F 1 Cold Storage Freezer 18 to 48 C 0 to 120 F 2 X Check C Change L Lubricate NOTE Never use steam to clean electrical parts Maintenance Schedule 50 ...

Page 53: ...tion 8 Safety Labels and Operating Manual X Replace if Necessary See Parts Manual 9 Steering Operation X Check Operation 10 Tire Wheels and Casters X Check Condition 11 Contactor Tips X Check Condition Non Servicable 12 Lubrication Fittings L Lubricate Standard8 Cold Storage Freezer3 13 Wheel Bolt Torque X Tighten if Required 120 N m 88 lbf ft X Check C Change L Lubricate NOTE Never use steam to c...

Page 54: ...valent 3 For freezer or cold storage operation MIL G 7711A 4 With rated load 5 Whichever comes first 6 Hydraulic oil changed at initial 350 hour interval 7 Equalization Charge approximately each month but not more than each week 8 Multipurpose Grease with 2 4 Molybdenum Disulfate for normal operations X Check C Change L Lubricate NOTE Never use steam to clean electrical parts Maintenance Schedule ...

Page 55: ...truck on a level surface Lower the forks discon nect the battery and remove the hood Check for any leaks and conditions that are not normal Clean any oil spills WARNING Disconnect the battery before removing the hood WARNING DO NOT operate a lift truck that needs repairs Report the need for repairs immediately If repair if necessary put a DO NOT OPERATE tag on the control handle or delivery handle...

Page 56: ... is 32 to 72 C 90 to 162 F NOTE The location of the breather cap on your lift truck may differ from the illustration but the procedure will be the same See Figure 11 1 BREATHER CAP 2 HYDRAULIC OIL TANK Figure 11 Check and Fill Hydraulic Tank Maintenance 54 ...

Page 57: ...linkage 2 Check for damaged or worn linkage bushings or shafts 3 Check for missing or loose shaft pins 4 Check load wheels and support bearings shafts and shaft pins for wear damage or missing parts Controls Check that all controls operate as described in Table 1 WARNING If any function does not operate or operates incor rectly report the faulty operation immediately DO NOT operate the lift truck ...

Page 58: ...handle or delivery handle direction Push the traction reverse button without changing the position of the speed direction control The lift truck must stop and then accelerate in the opposite direction Once the lift truck changes direction and moves with the control handle or delivery handle trailing release the traction reverse button without releasing the speed direction control The lift truck sh...

Page 59: ...er and load wheels for foreign material cuts and tears Remove all foreign material and smooth any cuts or tears to prevent further damage See Figure 12 1 REMOVE NAILS GLASS AND ALL METAL 2 SMOOTH EDGES Figure 12 Tires Electrical and Battery WARNING Broken electrical connections damaged wires or cables and leakage or corrosion from the battery can Maintenance 57 ...

Page 60: ...ery case top cover and battery areas clean and painted Use a water and soda solution to clean the battery and the battery area 1 pound of baking or commer cial soda ash to 1 gallon of water Keep the top of the bat tery clean dry and free of corrosion NOTE The following electrolyte level and specific gravity checks are not necessary for low maintenance batteries Check that the vent caps are clear C...

Page 61: ...ft truck Make sure the charger voltage is the same as the battery voltage NOTE Some battery chargers have a program to automati cally charge the battery according to battery manufacturer recommendations Use the recommendations of the manu facturer Use only battery chargers approved by the battery manufacturer or dealer NOTE See Charging Lithium Ion Battery section for charging procedures for Lithi...

Page 62: ...harger has five colored LED s located on the top of the charger The LED s are used to indicate the status of the charger during operation The order of the LED s may vary with models but they are labeled to identify their func tion See Figure 14 and Table 3 Maintenance 60 ...

Page 63: ...1 LED 2 LABEL Figure 14 Charger LED s Maintenance 61 ...

Page 64: ...n SDN Red Flashes if abnormal shutdown has occurred Detection Error DET Red Illuminates continuously when battery is not connect to charger or battery voltage is less than 2V Charging CHG Yellow Charge status indicator flashes during charging cycle Charged CHD Green Illuminates continuously when battery is fully charged Maintenance 62 ...

Page 65: ...t 25 C 77 F or the value specified by the manufacturer The cells must be equally charged If necessary give a new battery a slow rate charge for 3 to 6 hours after the normal charge is com plete for an equal charge on all cells NOTE Frequent charging of a battery that has a 2 3 or more charge can decrease battery life Figure 15 Checking Specific Gravity With Hydrometer Maintenance 63 ...

Page 66: ...per use of the hydrometer and proper operation of the charger are important Follow the instructions of the manu facturer See Figure 15 Make specific gravity corrections for the electrolyte temper ature as shown in Table 4 Remove the vent cap from each cell and make sure the plates have electrolyte over them before charging the bat tery Never charge a battery at a rate that will raise the electroly...

Page 67: ...cking the Battery To remove or assemble the battery cover to check the bat teries for maintenance for trucks equipped with battery packs use the handles shown in Figure 16 Figure 16 Handles Maintenance 65 ...

Page 68: ... retainer 2 Use a spreader bar and crane to lift the battery from the lift truck See Figure 17 Before installing the battery make sure the battery is cleaned and painted When a replace ment battery is installed make sure the battery fits the bat tery compartment See Figure 18 and Table 5 for the correct battery specifications Reinstall the battery retainer and capscrew 3 Make sure the weight of th...

Page 69: ...1 CRANE 2 SPREADER BAR 3 INSULATOR STRAPS 4 BATTERY Figure 17 Changing the Battery Maintenance 67 ...

Page 70: ...Figure 18 Battery Compartment Maintenance 68 ...

Page 71: ...attery see sections below and LITHIUM ION BATTERY 2200 YRM 1890 for battery specifications maintenance charging and troubleshooting procedures The lithium ion battery is programmed to conserve power during long period of inactivity For battery serial numbers from 100 2499 the Sleep Mode will initiate after five days in which less than 200mA has been applied For battery serial numbers 2500 and high...

Page 72: ...Refer to Step 2 Knowing When Battery Is Fully Charged WARNING Always connect the positive cable to the positive termi nal and connect the negative cable to the negative ter minal Any other connection will cause injury and damage NEVER connect the battery charger plug to the plug of the lift truck You can damage the traction control cir cuit Make sure the charger voltage is the correct volt age for...

Page 73: ...pere hour rate setting on a battery charger can require a longer charging time but will not damage the battery 3 DO NOT discharge the battery to less than the manufac turer s recommendation If the battery is allowed to dis charge too far it may enter a hibernation mode and require service to recharge or restart 4 Prevent batteries from freezing 5 Keep batteries charged A discharged battery in stor...

Page 74: ...NOTES 72 ...

Page 75: ...Spacer 3 19 2 19 7 18 5 16 1 16 5 14 12 13 ...

Page 76: ...OPERATING MANUAL Motorized Hand Truck MPB045VG A245 PART NO 550068167 3 19 DO NOT REMOVE THIS MANUAL FROM THIS UNIT ...

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