Ballymore PLD PLUS manual
INSTRUCTION HANDBOOK
PLD PLUS
WARNING
Do not use the electric PLD before reading and
understanding these operating instructions.
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.
2018-6
1. Pull out red E-Stop button
2. Type in code “1234” and press green check
button
3. With Portable Loading Dock in the lowered
position,
4. Roll item on to the platform
1. Use steering controls on control panel to
operate the Portable Loading Dock
2. Position the Portable Loading Dock behind
truck
3. Raise platform above truck tailgate
4. Lower platform on to truck bed
LOADING MERCHANDISE
UNLOADING MERCHANDISE
5. Platform should sit on truck bed, not on tailgate
6. Remove item from platform on to customer
vehicle
7. Raise platform off customer vehicle
8. Move the dock away from customer vehicle
9. Return dock to the assigned area
10. Remember to charge the Portable Loading
Dock regularly
UNLOADING MERCHANDISE
Please view Portable Loading Dock Training Video for more instructions.
WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS
Do not use inside the store. Always bring the product out to the Portable Loading Dock.
LOAD CAPACITY = 1,500 lbs.
Never operate lift equipment recklessly.
Do not use in the parking lot. Have customer bring their vehicle to the loading area.
Always secure the load before moving the Portable Loading Dock.
Always load vehicles on level surfaces.
Never use the Portable Loading Dock to load product on top of the roof of a vehicle.
Do not allow vehicles to back under the Portable Loading Dock
Never turn the Portable Loading Dock with an elevated load. Lower the load prior to turning.
Never push or pull the Portable Loading Dock with an associate on the platform of the equipment.
Do not allow customers to operate the equipment or be on the platform.
Ensure vehicle to be loaded has come to a complete stop, and is in park.
After use, return the Portable Loading Dock to its designated storage area.
Do not put foot or hand under or into the lifting mechanism.
Be aware of your surroundings. No one should be standing in front of or behind when the PLD is in
use.
Do not use PLD on ramps.
Lower the Portable Loading Dock all the way to the ground to prevent unintentional rolling.
The PLD should always be operated on level surfaces. Keep watching the condition of
load. Stop operating the PLD if load becomes unstable. Brake the PLD and activate the
emergency button (3) by pushing when sliding load on or off the PLD. If the PLD has any
malfunctions, follow chapter 6. Practice maintenance work according to regular
inspection. This PLD is not designed to be water resistant. Use the PLD under dry
conditions. Prolonged continuous operation might cause damage of the power pack.
Stop operation if temperature of hydraulic oil is too high.
•
When operating the PLD, the operator must wear safety shoes.
•
The operating lighting must be minimum 50 lumens.
•
Toprevent unintended sudden movements when not operating the PLD (i.e. from
another person, etc.) lower the PLD all the way to the ground and turn off.
•
DURING TRANSPORTATION ON A TRUCK ALWAYS FASTEN THE PLD
SECURELY
•
Lower the platform and park the PLD securely. Dedicated lashing belts at both sides
each of the PLD deck’s handrail and fasten the other side at the transporting truck.
- Decommissioning
•
For storage, remove the load, lower the PLD to the lowest position, grease all in this
handbook mentioned greasing points (regular inspection), eventual protect the PLD
against corrosion and dust. Remove the batteries and jack the PLD safety, so that
there will be no flattening after storage.
•
For final decommissioning, send the PLD to a designated recycling company. Oil,
batteries and electric components must be recycled due to legal regulations.
- DAILY INSPECTION
•
This chapter describes pre-shift checks before putting the PLD into operation.
•
Daily inspection is effective to find the malfunction or fault on this PLD. Check the
PLD on the following points before operation.
Remove load from PLD and lower the deck.
DO NOT USE THE PLD IF ANY MALFUNCTION IS FOUND.
•
Check for scratches, deformation or cracks.
•
Check if there is any oil leakage from the cylinder.
•
Check the vertical creep of the PLD.
•
Check the chain and rollers for damages or corrosion.
•
Check the smooth movement of the wheels.
•Check the function of the emergency brake by activating the emergencybutton.
•
Check, the tiller arm- switch braking function
•
Check the lifting and lowering functions by operating the buttons.
•
Check if the protective screen has no damages and that is correctlyassembled.
•
Check the audio warning signal.
•
Check if all bolts and nuts are tightened firmly.
•
Check the function of number code pad.
•
Check the speed limitation switch.
•
Visual check if there are any broken hoses or
broken electric wires.
-
- OPERATING INSTRUCTIONS
BEFORE OPERATING THIS PLD, PLEASE FOLLOW THE WARNINGS AND
SAFETY INSTRUCTIONS (CHAPTER 3). BEFORE OPERATING THIS PLD, ENSURE THAT
THE LOAD OR OTHER EQUIPMENT DOES NOT CAUSE INSUFFICIENT VISIBILITY!
- Parking
DO NOT PARK THE PLD ON INCLINED SURFACES
The PLD is equipped with an electromagnetic failsafe stopping
and parking brake.
Always fully lower the platform and drive the PLD to a safe area.
Press the E-stop button to turn off PLD.
- TRAVELLING
TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL.
DO NOT TRAVEL ON INCLINES MORE
THAN SPECIFIED.
TRAVELLING IS ONLY
ALLOWED IF THE DECK IS
LOWERED DOWN TO THE
LIFTING POINT (<12in).
After starting the PLD by pulling
out the E-Stop and typing in
code, move the tiller to the
Operating zone (‘F’, fig.11).
Turn the accelerator button to the desired direction forward ‘Fw.’ Or backwards ‘Bw.’(fig.
11).
Control the travelling speed by moving the accelerator button (13) carefully until you
reached the desired speed.
If you move the accelerator button back to the neutral position, the controller
decelerates the PLD until the PLD stops. If the PLD stopped, the parking brake will be
engaged.
Drive the PLD carefully to the destination. Watch the route conditions and adjust the
travelling speed with the accelerator- button.
- Steering
You steer the PLD by moving the tiller to the left or right side.
-Braking
THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITONS AND
THE LOAD CONDITONS OF THE PLD
The braking function can be activated in 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 PLD brakes until itstops.
•
By moving the accelerator button (13) from one driving direction directly to the
opposite direction, the PLD brakes regenerative until it starts travelling into the
opposite direction.
•
The PLD brakes, if the tiller is moved up or down to the braking zones (‘B’). If the
tiller is released, the tiller moves automatically up to the upper baking zone (‘B’).
The PLD brakes until it stops.
•
The safety (belly) button (12) prevents the operator from being crushed. If this button
is activated, the PLD decelerates and/ or starts travelling into the backwards direction
(‘Bw.’) for a short distance and stops. Please consider, that this button also operates,
if the PLD is not travelling and the tiller is in the operatingzone.
- Malfunctions
If there are any malfunctions or the PLD is inoperative, please stop using the PLD and
activate the emergency button (3) by pushing it. If possible, park the PLD in a safe area,
and press the E-Stop button.
Inform the manager and/or call for service.
- Emergency
In emergencies, push the emergency button (3). All electrical functions will be stopped.
Keep safe distance.
- BATTERY CHARGING AND REPLACEMENT
•
Only qualified personnel are allowed to service or charge the batteries. The
instructions of this handbook and from the battery- manufacturer must be observed.
•
These batteries are maintenance free; re- filling is prohibited.
•
Recycling of batteries undergoes national regulations. Please follow all
regulations.
•
When handling batteries, open fire is prohibited, gases could causeexplosion!
•
In the area of battery charging neither burning materials nor burning liquids are
allowed. Smoking is prohibited and the area must be ventilated.
•
Park the PLD securely before starting charging or installing/changing the batteries
•
Before finishing the maintenance work, make sure, that all cables are connected
correctly and that there is no contact with other components of the PLD.
The PLD is equipped with following
sealed liquid acid batteries:
•
2 pc 12V/ 85Ah(C5)
•
Optional: 2 pc 12V/ 106Ah
ONLY USE SEALED LIQUID ACID BATTERIES.
THE WEIGHT OF THE BATTERIES WILL AFFECT THE
PLD’S OPERATING BEHAVIOR.
PLEASE CONSIDER THE MAXIMUM OPERATING
TEMPERATURE OF THE BATTERIES.
Replacement
Park the PLD securely (1) and activate the emergency button (3).
Unbolt the 2 screws on the main cover and remove the cover.
First, unbolt the screws of the negative terminals (indicated with
‘-‘). Then, unbolt the screws of the positive terminals (indicated
with ‘+’) and put the cables aside.
Unbolt the batteries connecting bars and remove them (fig. 13).
Remove the batteries carefully by observing not to hit the upper
electrical instruments board or the upside oil tank. The
installation is in the reverse order of the
First, connect the positive terminals. Otherwise the PLD could
be damaged.
Fig. 12: battery replacement
- Battery Indicator
The discharge status is indicated by ten red LED segments.
Battery discharged Battery full charged
Fig.14: Battery discharge indicator
When the PLD is fully charged, all LED indicators will be lit. As the battery decreases
in charge, successive LEDs light up, only one on at a time.
The 2nd from left LED flashes, indicating “energy reserve” (70% depth of discharge).
The 2 most left LEDs alternately flash, indicating “empty” (80% depth of discharge).
-Charging
•
The attached automatic charger is only available for the optional voltage of 110V.
•
The exactl charge status can only be checked from the discharge indicator. To
control the status, the charging must be interrupted and the PLD must bestarted.
Park the PLD at a dedicated secured area with a dedicated power supply.
Lower the platform and remove the load.
Switch the PLD off and connect the main power
connector (7) to the power supply. The charger starts
charging the battery.
Charging is finished when the charging LED
(fig.14,15) produces permanent green light. The
charger then goes into a floating mode to prevent the
battery against damages. Following table shows the
function of the LED-status:
Table 3: LED-Status
LED- signal
Function
Red
Battery discharged
Orange
Charging
Green
Fully charged
When charging is finished, disconnect the connector from the socket and place it in the designated
pocket.
Fig. 15
- REGULAR MAINTENANCE
•
Only qualified and trained personnel are permitted to do maintenance on thisPLD.
•
Before maintaining, remove the load and lower the platform to the ground level.
•
If you need to lift the PLD, follow chapter 4 d by using designated lashing or jacking
equipment.
•
Please pay attention by maintain the tiller arm. The gas pressure spring is
pre-loaded by compression. Carelessness can cause injury.
•
Use approved and from your dealer released original spare parts.
•
Please consider that oil leakage of hydraulic fluid can cause failures andaccidents.
•
It is allowed to adjust the pressure valve only from trained service technicians.
•
If you need to change the wheels, please follow the instructions above. The castors
must be round and they should have no abnormal abrasion.
Check the items emphasized maintenance checklist.
a. Maintenance checklist
Table 4: Maintenance checklist
Interval (Month)
1
3
6
12
Hydraulic
1
Check the hydraulic cylinder, piston for damage noise and leakage
•
2
Check the hydraulic joints and hose 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 the function of the pressure valve (2200lbs +0/ +10%)
•
Mechanical system
6
Inspect the platform for deformation and cracks
•
7
Check the chassis for deformation and cracks
•
8
Check if all screws and nuts are tight
•
9
Check mast and chain for corrosion, deformation or damages, replace if necessary
•
10
Check the gearbox for noise and leakage
•
11
Check the wheels for deformation and damages, replace if necessary
•
12
Lubricate the steering bearing
•
13
Inspect and lubricate the pivot points
•
14
Lubricate the grease fittings
•
15
Replace the guarding and/or protective screen if it is damaged
•
Electric system
16
Inspect the electric wiring for damage
•
17
Check the electric connections and terminals
•
18
Test the Emergency switch function
•
19
Check the electric drive motor for noise and damages
•
20
Test the display
•
21
Check if correct fuses are used, if necessary replace.
•
22
Test the audio warning signal
•
23
Check the contactors
•
24
Check the frame leakage (insulation test)
•
25
Check function and wear of the accelerator
•
26
Check the electrical system of the drive motor
•
Braking system
27
Check brake performance, if necessary replace the brake disc or adjust the air gap
•
Battery
28
Check the battery voltage
•
29
Clean and grease the terminals and check for corrosion and damage
•
30
Check the battery housing for damages
•
Charger
31
Check the main power cable for damages
•
32
Check the start-up protection during charging
•
Function
33
Test the audio warning signal
•
34
Check the air gap of the electromagnetic brake
•
35
Test the emergency brake
•
36
Test the reverse and regenerative braking
•
37
Test the safety (belly) button function
•
38
Check the steering function
•
39
Check the lifting and lowering function
•
40
Check the tiller arm switch function
•
41
Test the keypad for damages and function
•
42
Test the speed limitation switch (lifting height >~12in)
•
General
43
Check if all decals are legible and complete
•
44
Check if the protective screen and or guarding is not damaged
•
45
Inspect the castor, adjust the height or replace it, if worn out
•
46
Carry out a test run
•
b. Check and refill hydraulic oil
The required hydraulic fluid- type is
•
H-LP 46, DIN 51524
•
Viscosity is 41.4 - 47
•
Depending on the type the amount
is 2,5L to 3,0L
Waste materials like oil, used batteries, or other items must
be properly disposed and recycled according to the
national regulations, and if necessary brought to a
recycling company.
c. Checking electrical fuses
Remove the main cover. The fuses are located according
to fig. 18; the size is according to table 5.
Rate
FU1
10A
FU2
0.5A
FU 01
60A
FU 02
100A
- TROUBLE SHOOTING
If the PLD malfunctions, follow these instructions:
Table 6: Trouble shooting
TROUBLE
CAUSE
REPAIR
Load can’t be lifted
Load weight too high
Lift only the max. capacity,
mentioned on the ID-plate
Battery discharged
Charge the battery
Lifting fuse faulty
Check and eventually replace
the lifting fuse
Hydraulic oil level too low
Check and eventually refill
hydraulic oil
Oil leakage
Repair the hoses and/or the
seals of the cylinder
Oil leakage from
air breathing
Excessive quantity of oil.
Reduce oil quantity.
Load can’t be
lowered
Dirty oil blocks control valve.
Check hydraulic oil and clean
control valve. Replace the oil if
necessary.
The solenoid valve for lowering is
not opened or is damaged.
Check or replace the valve for
lowering.
PLD does not start
Battery is charging
Charge the battery completely
and then remove the main
power plug from the electrical
socket.
Battery not connected
Connect the battery correctly
The fuse is faulty
Check and eventually replace
fuses
Battery discharged
Charge the battery
Combined emergency switch is
activated
De-activate the combined
emergency switch by pulling
the knob.
Tiller in the operating zone
Move the tiller to the
braking zone.
Only travelling in
one direction
The accelerator and the
connections are damaged.
Check the accelerator and the
connections.
The PLD only
travels very slowly
The battery is discharged.
Check the battery status at the
discharge indicator
The electromagnetic brake is
engaged.
Check the electromagnetic
brake
The relating tiller cables are
disconnected or damaged
Check the tiller cables and
connections.
The PLD starts up
suddenly
The controller is damaged.
Replace the controller.
The accelerator not moved back to
its neutral position.
Repair or replace the
accelerator.
Fuses ECL22M
FU1 : 10 A
FU2 : 0,5 A
FU01 : 60 A
FU02 : 100 A
Table of contents
