BALLYMORE INSTRUCTION HANDBOOK Electric Pallet Truck BALLYPAL33N/BALLYPAL45N WARNING Do not use the pallet truck beforereading and understanding these operatinginstructions. NOTE: • • Please check the designation of your present type at the last page of this document as well as on the ID-plate. Keep for future reference.
FOREWORD Before operating the truck, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric pallet trucks. When operating and servicing the truck, make sure, that it applies to your type. Keep this handbook for future reference. If this or the warning/ caution labels are damaged or got lost, please contact your local dealer for replacement.
TABLE OF CONTENTS 1. 2. CORRECT APPLICATION ................................................................................................................ 4 DESCRIPTION OF THE PALLET TRUCK ........................................................................................ 5 a. Overview of the main components ................................................................................................ 5 b. Main technical data .....................................................................
b. Description warning labels (only US- market) .............................................................................. 34 c. Technical data for US market ......................................................... Error! Bookmark not defined. 13. DECLARATION OF CONFORMITY (valid, if sold within the EU) ....................................................
1. CORRECT APPLICATION It is only allowed to use this electric pallet truck according to this instruction handbook. The trucks described in this handbook are self propelled electric power pallet trucks. The trucks are designed to lift, lower and transport palletized loads. A wrong usage can cause human injuries or can damage equipment.
2. DESCRIPTION OF THE PALLET TRUCK a. Overview of the main components Fig. 1: Overview main components 1. 2. 3. 4. 5. 6. 7. Safety (belly) button Tiller Pin-code panel (BALLYPAL45N with card) Discharge indicator and charging indicating LED Emergency button Hydraulic unit cover Chassis 5 8. 9. 10. 11. 12. 13.
b. Main technical data Fig. 2: Technical data Table 1: Main technical data for standard version Distinguishing mark Type sheet for industrial truck acc. to VDI 2198 1.2 Manufacturer`s designation type 1.3 Drive 1.4 Operator type 1.
1.6 1.8 1.9 Tyres, chassis Weight 2.1 2.2 2.3 Dimensions x (in) 37.3 y (in) 46.6 46.8 lbs 271 278 328 337 laden lbs 1373 / 2198 1380 / 2198 1369/3368 1378/3368 unladen lbs 211 / 60 218 / 60 254/75 262/75 3.2 Tire size,front Æ x w (in) Æ 8.27×2.76 3.3 Æ x w (in) Æ 3.15×3.66(Æ 3.15×2.76) Æ x w (in) -/Æ 3.15×1.18 3.6 Tire size,rear Additional wheels(dimensions) Wheels,number front/rear(x=driven wheels) Tread, front 3.7 Tread, rear b11 (in) 4.4 Lift h3 (in) 4.
c. Description of the safety devices and warning labels (Europe and other, excepting USA) For the USA –market, the description of the safety and warning labels is mentioned in chapter 12. A B C D E F N P Fig.
Follow also the instructions given on the decals. Replace the decals if they are damaged or missing. d. Identification plate 1 2 3 4 5 6 Designation, type Serial number Rated capacity in lbs/kg Supply voltage in V Own mass (self weight) in lbs/kg without battery 7 8 9 10 11 Name and address of manufacturer) Battery weight minimum/ maximum Nominal power in kW Load center distance Manufacturing date Option 1 2 3 11 4 10 5 9 8 7 6 Fig.
Keep watching the condition of load. Stop operating the truck if load becomes unstable. Brake the truck and activate the emergency button (5) by pushing when sliding load on or off the truck. If the truck has any malfunctions, follow chapter 10. Practice maintenance work according to regular inspection. This truck is not designed to be water resistant. Use the truck under dry condition. Prolonged continuous operation might cause damage of the power pack.
according to the Fig. 5. Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck securely. Fasten the truck according to Fig. 6 by fixing dedicated lashing belts to each side of the trucks crane hook holes and fasten the other side at the transporting truck. Fig. 5: Lifting with a crane Fig. 6: fixing points c.
• • • • • • • • Check the vertical creep of the truck. Check the smooth movement of the wheels. Check the function of the emergency brake by activating the emergency button. Check, the tiller arm- switch braking function Check the lifting and lowering functions by operating the buttons. Check if all bolts and nuts are tightened firmly. Visual check if there are any broken electric wires. If supplied with a backrest extension, check it for damages and correct assembling. 6.
THE MAXIMUM CAPACITY OF BALLYPAL45N IS 4500lbs/2000 kg. Travel with the lowered forks fully underneath the pallet and press the lifting button (Fig. 7, 15) until you reached the desired lifting height. c. Lowering Press the lowering button (22) carefully. Lower the load until the forks are clear of the pallet, then drive the truck carefully out of the load unit. Fig. 8: Load facing uphill d. Travelling TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL.
f. Braking PLEASE CHECK THE BRAKING DISTANCE WITH TRUCK BEFORE OPERATION THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITIONS AND THE LOAD CONDITIONS OF THE TRUCK The braking function can be activated on several ways: • By moving the accelerator button (13) back to the initial ‘0’ position or by releasing the button, the regenerative braking is activated. The truckbrakes until it stops.
Ambient temperature：-40℉to 190℉ (-40℃ to +90℃) IP grade：IP65 c. Main functions For BALLYPAL33N,it can be operated only when correct password is typed. For BALLYPAL45N, it can be operated only when correct password is typed or valid ID card is used. There are two passwords of pin-code panel, one is the default user password 1234, and you can use it immediately.
IT IS ONLY ALLOWED TO USE LITHIUM BATTERIES. PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE BATTERIES. a. Replacement Park the truck securely and press emergency switch (5). Hold the battery grip with one finger pull out the lock, and then take out the battery vertically. The installation is in the reverse order. Fig. 10: Battery replacement b. Battery indicator Battery discharged Battery charged Fig.
It is normally off, when it appears (fixed) it shows the request of programmed maintenance or the alarm state. In this case the relative code will be displayed. The information supplied by the MDI-CAN can be extremely useful. Failures can be quickly identified by the operator or service technician thereby finding the fastest solution to the problem. Hourglass Symbol: It blinks when the hour meter is working. c.
DZL2420SS02 24V5A 100Vac -240Vac～2.0A MAX 29.4V 5.0A DZL300SS02 24V8A 180Vac -240Vac～3.0A MAX 29.4V 8.0A SSLC300V29 24V8A（EU） 180Vac -240Vac～3.0A MAX 29.4V 8.0A SSLC300V29 24V8A（US） 108Vac -132Vac～5.0A MAX 29.4V 8.0A QQE288-10CH109 24V12A 100Vac -240Vac～6.0A MAX 29.4V 12.0A Input 180Vac -240Vac ～2.0A MAX Output 100Vac -132Vac ～5.0A MAX 54.6V 9.0A 180Vac -240Vac ～2.0A MAX 54.6V 9.
1 Hydraulic 1 Check the hydraulic cylinder(s), piston for damage noise and leakage 2 Check the hydraulic joints for damage and leakage 3 Inspect the hydraulic oil level, refill if necessary 4 Refill the hydraulic oil ( 12 month or 1500 working hours ) 5 Check and adjust function of the pressure valve (3300lbs(BALLYPAL33N)+0/ +10% or 4500lbs(BALLYPAL45N)+0/+10%) Mechanical system 6 Inspect the forks for deformation and cracks 7 Check the chassis for deformation and cracks 8 Check if all screws are fixed 9 Ch
37 Check the steering function 38 Check the lifting and lowering function 39 Check the tiller arm switch function General 40 Check if all decals are legible and complete 41 Inspect the castors, adjust the height or replace these if worn out.
b. Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. 1. 2. 3. 4. 5. 6. 7. Load roller bearing Cylinder Axle Bearing Gear box Side roller bearing Connection point Fig. 13: Lubricating points c.
d. Checking electrical fuses Remove the main cover. The fuses are located according to Fig. 14; the size is according to table 7. Fig. 15 Location of fuses for BALLYPAL33N Fig. 14: Location of fuses for BALLYPAL45N Table 7: Size of the fuses FU 1 FU 01 Rate 10A 70A 10. TROUBLE SHOOTING • If the truck has malfunctions follow the instructions, mentioned in chapter 6.
Emergency switch is Turn the emergency clockwise activated Tiller in the operating Move the tiller firstly to the braking zone. If the truck haszone malfunctions and can’t be operated out of the working zone, jack the truck up and go with a load handler under the truck and safe the truck securely. Then move truck out of the aisle.
11. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram BALLYPAL33N without speed reduction on curves Fig.
Table 9: Description of electrical diagram Code Item Code Item GB Battery B CAN tiller Et Controller SA Proximity switch Mp Pump motor Mt Traction motor KMp Pump contactor YB Electromagnetic brake SM Emergency button FU1 10A fuse YV Electromagnetic valve FU01 70A fuse SU Micro switch 25
BALLYPAL33N with speed reduction on curves Fig.
Table 10: Description of electrical diagram Code Item Code Item GB Battery B CAN tiller Et Controller SA Proximity switch Mp Pump motor Mt Traction motor KMp Pump contactor YB Electromagnetic brake SM Emergency button FU1 10A fuse YV Electromagnetic valve SE Proximity switch SU Micro switch FU01 70A fuse 27
BALLYPAL45N without speed reduction on curves Fig.
Table 11: Description of electrical diagram Code Item Code Item GB Battery B CAN tiller Et Controller SA Proximity switch Mp Pump motor Mt Traction motor KMp Pump contactor YB Electromagnetic brake SM Emergency button FU1 10A fuse YV Electromagnetic valve FU01 70A fuse SU Micro switch HA Buzzer 29
BALLYPAL45N with speed reduction on curves Fig.
Table 12: Description of electrical diagram Code Item Code Item GB Battery B CAN tiller Et Controller SA Proximity switch Mp Pump motor Mt Traction motor KMp Pump contactor YB Electromagnetic brake SM Emergency button FU1 10A fuse YV Electromagnetic valve FU01 70A fuse SU Micro switch HA Buzzer SE Proximity switch 31
b. Hydraulic circuit Lifting cylinder Lowering valve Throttle valve Pressure control valve Hydraulic power unit Oil tank Fig.
12. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET The content in this chapter is specialized for the US-American market. a. Foreword/ Compliance Operating this truck requires knowledge which can be acquired from this instruction handbook. This handbook must be kept available throughout the entire period of use of the industrial truck.
b. Description warning labels (only US- market) Fig.
Sign read and follow this instruction (D) Sign warning electrical devices (K) Sign oil filling point (E) Sign no collision(N) Sign warning stay clear stop truck (J) Sign emergency switch(P) 35
CE-DD-002 13. DECLARATION OF CONFORMITY (valid, if sold within the EU) [GB] CE Declaration of Conformity The signatory hereby declares that the specified machine conforms to the EU Directive 2006/42/EC (Machine Directive) and 2014/30/EU (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatory is individually authorized to compile the technical documents.
nacionālajai likumdošanai. Parakstu īpašnieki ir atsevišķi pilnvaroti sastādīt tehniskās dokumentācijas. [N] EU-KONFORMITETSERKLÆRING Undertegnede bekrefter hermed at de enkelte betegnede maskin med kraftdrift tilsvarer de europeiske retningslinjene 2006/42/EC (maskinretningslinje) og 2014/30/EU (elektromagnetisk fordraglighet - EMV) inklusiv disses endringer og den tilsvarende rettsforordning til omsetning av nasjonal rett. Hver undertegnede er fullmektig til å sette sammen de tekniske dokumentene.
