ECOVOLVE ED800 User manual

ED800/1000/1500 OWNER’S MANUAL
Battery Hi-Tip Dumpers

1 Introduction
Introductionoverview ......................................................................
2 Safety
Safety guidelines ...........................................................................
3 Overview
Vehicleidenticationplate..................................................................
Operatorsplatformandsafetyrails .........................................................
Controls.....................................................................................
4 Operation
Driving ....................................................................................
Switchingthedumperonando ...........................................................
Operatorsplatformandsafetyrails .........................................................
Forwardtravel ..............................................................................
Reversetravel...............................................................................
Operatingspeed ...........................................................................
Steeringsystem ............................................................................
Brakingsystem .............................................................................
Lights ........................................................................................
Horn .......................................................................................
Operatingthehightipfunction .............................................................
Load ........................................................................................
Emergencystopbutton ....................................................................
Parking .....................................................................................
Batterydischarge ..........................................................................
Charging .................................................................................
Chargingthedumper ......................................................................
ChargingtheQUIQ1000 ....................................................................
ChargingtheIC1200 .......................................................................
CONTENTS
Transportation ..........................................................................
Transportingtheelectricdumper ...........................................................
Cleaning and washing .................................................................
Daily checklist ...........................................................................
5 Servicing
50 Working Hour inspection ..........................................................
Inspectionchecklist ........................................................................
Chassis and frame .........................................................................
Wheels .....................................................................................
Steering and dashboard ...................................................................
Lubrication .................................................................................
Hydraulic system ...........................................................................
Rear drive unit ..............................................................................
Braking system .............................................................................
Electric Charging ..........................................................................
150 Working hour service ............................................................
Servicechecklist ...........................................................................
Reardriveunitoilchange ..................................................................
500 Working hour service ...........................................................
Servicechecklist ...........................................................................
Chassis and frame .........................................................................
Wheels ....................................................................................
Steering and dashboard ...................................................................
Lubrication .................................................................................
Hydraulic system ..........................................................................
Rear drive unit ..............................................................................
Braking system ............................................................................
Battery care ................................................................................
2000 Working hour service ..........................................................
Servicechecklist ...................................................... ....................
Reardriveunitoilchange .............................................. ...................
CONTENTS

6 Technical Data
Technical data sheet EU .................................................................
Technical data sheet US .................................................................
ED800 Parts list
Exploded front view parts list ............................................................
Exploded rear view parts list .............................................................
Steering .................................................................................
Platform and safety rail ..................................................................
Tiller head ...............................................................................
Hydraulic system ........................................................................
Electrical system .........................................................................
Rear drive unit ...........................................................................
ED1000 Parts list
Exploded front view parts list ............................................................
Exploded rear view parts list .............................................................
Steering .................................................................................
Platform and safety rail ..................................................................
Tiller head ...............................................................................
Hydraulic system ........................................................................
Electrical system .........................................................................
Rear drive unit ...........................................................................
ED1500 Parts list .....................................................................
Exploded front view parts list ............................................................
Exploded rear view parts list .............................................................
Steering .................................................................................
Platform and safety rail ..................................................................
Tiller head ...............................................................................
Hydraulic system ........................................................................
Electrical system .........................................................................
Rear drive unit ...........................................................................
CONTENTS
7 Troubleshooting
Troubleshooting charts ............................................................

1. INTRODUCTION
Your electric high tip dumper oers premium economic
eciency, safety and driving
comfort. It is primarily
down to you to maintain these characteristics over
time and take
advantage of the resulting benets.
During manufacture:
• All safety requirements of the relevant EC directives were observed.
• All conformity assessment procedures stipulated in the applicable directives were
carried out.
This is attested by the CE mark shown on the
Identication plate.
The operating instructions contain everything
you need to know commissioning, driving
and
maintenance. Observe the operating instructions
for the electric dumper in question.
Carry out the specied work regularly, at the due
times and using the consumables
envisaged for
this purpose in accordance with the inspection
and maintenance overview.
Servicing work not described here will require
specialist knowledge, measuring devices
and
specialist tools. Contact the service
partner for more information.
Servicing should only be carried out by qualied
personnel approved by the manufacturer
(specialists).
This material is proprietary to Ecovolve, and is
not to be reproduced, used, or disclosed
except
in accordance with written authorisation from
Ecovolve.
Each new user must read the Operator’s Hand Book before operating any Ecovolve
truck for the rst time.
This manual diers from the Operator’s Hand Book which provides comprehensive
instructions of how to operate any dumper manufactured by Ecovolve. The Operator’s
Hand
Book must be kept in the trucks manual holder at all times. A copy of this manual
is
included within this document or can be downloaded at www.ecopvolve.ie.
All maintenance personnel should read and understand the instructions in this service
manual before performing maintenance and/or operational checks on the machine.
All safety notices, warnings and cautions must be understood and followed when
accomplishing repairs on the electric dumper.r
Your high tip electric dumper
1
INTRODUCTION

Warranty and liability
To maximize your warranty, after each periodic
inspection, proof must be submitted to Ecovolve
by way of electronic submission on our website.
This is the only way to prove an eective service
has been completed by a competent and
qualied person as per instructions in this service
manual.
Werrenty submission forms can be downloaded from our website. If you have any questions
regarding your warranty please contact your local distributor. A copy of each periodic inspection
form can also be found at the end of this manual. Please keep and save a detailed record of the
maintenance process. All maintenance procedures must be recorded, otherwise you will limit or
lose your warranty.
Users, especially the truck operators and maintenance personnel, must strictly adhere
to
regional and international safety regulations
including “Guidelines on correct and safe use of
materials handling equipment”. (Overseas
edition). User shall be responsible for any loss
caused
by improper use. Ecovolve Ltd will not be responsible for such loss. If you want to use an
Ecovolve product for purposes that are not mentioned in the user manual, please contact
dealers accredited by Ecovolve Ltd.
Any modication of your machine, in particular
tting of
equipment or conversion of the truck,
is prohibited without the permission of the
manufacturer.
Maintenance
Do not make repairs yourself. Servicing should ony be carried out by competent personnel.
Service technicians are trained professionals and must be competent to carry out the periodic
maintenance required to keep the Ecovolve range operating at peak performance and also to
maximize your warranty.
Inspections and periodic service is vital to the safe operation of the truck. Adhere to a strict
inspection, lubrication and maintenance schedule. Only use original approved spare
replacement parts when carrying out repair work.
Keep the maintenance and service area clean, free from obstacles and anything which may
cause personal injury. Never wear loose objects or jewellery when servicing the truck. Never
attempt to weld or attach ttings to the dumper. This should only be completed by suitable
personnel from Ecovolve. Never attempt to alter the the dumper in any way, especially to drill
any holes on any locations on the machine.
Any modication should only be completed by suitable personnel after consultation and
authorisation from the design team. To comply with warranty conditions, please ensure that
work carried out is recorded in the registration documents. Record and submit all necessary
proof of scheduled service to Ecovolve. Use dedicated work supplies according to checking
and maintenance overviews.
1. INTRODUCTION
This manuals contains, among other things, information on the intended operation of the
dumper and
instructions of how to operate, maintain,
and inspect the truck safely. The
troubleshooting
section of this manual has additional instruction
for safely diagnosing
malfunctions of the electric dumper
to maintain service and performance levels.
Information about this service manual including
the specications, illustrations, weight
information
and technical data are not binding and
correspond to the design at the time of
creation.
Ecovolve reserve the right to make changes without prior notice in the area of
design, conguration, appearance and technology on
account of the ongoing further
development of the products.
Always strictly observe the safety instructions in
this service manual, the operator’s manual and
the legal and trade association regulations at the
usage location.
Despite the utmost care, we cannot rule out deviations from drawings or dimensions,
computing errors, printing errors or incompleteness in this operator’s manual. Therefore, we
make no guarantee for the
correctness and completeness of our statements
in this Owners
Manual.
We guarantee the faultless functionality of our
products within the context of normal operating
conditions.
However, no manual can address every possible
risk. The end-user ultimately must apply sound
judgment whenever using this product. It is up
to you, the operator, to take good care when
working thedumper and use it to its full potential. During the manufacturing process (if axed
with CE mark): Ecovolve adhered to all CE safety requirements. We carried out all
compliance
tests required by law. This is proven
by the CE stamp shown on the identication
plates. The
manual provides you with important information on activating, driving, operating and maintaining
an Ecovolve product.
It is essential you regularly complete the maintenance checklists and make sure it is done on
time. Use the correct tools, products
etc. specied in order to maintain valid warranty service for
your electric dumper.
Please keep and save a complete, detailed record
of the maintenance process. All maintenance
procedures must be recorded; otherwise you
will limit or void your warranty. Users, especially
dumper
operators and maintenance personnel,
must strictly adhere to regional and
international
safety regulations such as “Guidelines on correct
and safe use of material handling
equipment”.
User shall be responsible for any loss caused by improper use. Ecovolve Ltd will not be
responsible for such loss. If you want to use
an Ecovolve product for purposes that are not
mentioned in the user manual, please contact a distributor accredited by Ecovolve Ltd. Any
modication of your dumper, in particular tting of
equipment or conversion of the dumper, is
prohibited
without the permission of the manufacturer.
Owners manual
1. INTRODUCTION

2
SAFETY
1. INTRODUCTION
Replacement parts
The Ecovolve range has been designed to be extremely low maintenance. Therefore
ordering spare parts is much less frequent than of traditional trucks. For questions about the
Truck and orders for spare parts, please contact your local Ecovolve distributor.
If the need to order spare parts arises, please provide the following information in addition to
the part numbers:
�Model number
�Serial number/Year of manufacturing
�Delivery date
Intended use
All Ecovolve electric dumpers have been built according to applicable standards and
regulations. Operationby inexperienced persons or in an unintended manner can result in
hazards that can lead to personal risk and subsequent harm to the operator and persons in
the operating area of the electric dumper. Improper use can damage the machine as well
as property in the vicinity of operation. The electric dumper is designed to work in conned
spaces such as narrow corridors and basements. It sits on a unique shaped chassis which
allows it to turn on its own axis. It is therefore far more maneuverable than a conventional
dump truck.
The Ecovolve Range are intended to transport
and empty materials within the specied
load capacity in normal operating conditions. It is the operators responsibility to use sound
judgment to assess whether a ground material
is compatible with use of the Truck. If in
doubt
contact your nearest distributor. Unintended use
can endanger the lives of operating
personnel
or other persons and cause injuries or extensive damage to the truck.
The rules for the normal and proper use of industrial trucks must be followed under all
circumstances by the responsible persons, in
particular by the operators and service personnel.
Failure to read and understand the entire manual before using or servicing the product
constitutes misuse. Always follow the warnings contained within this guide and on the
Truck to avoid incidents and accidents from occurring.

Operating Instructions
All operators must read and understand the
operating instructions before operating the truck.
A
copy of the Operators Manual should be kept in
the manual holder on the Truck at all times. A
copy
of this manual can be found in this document – Section 2. Before carrying out any work,
the operator should nd a remote site to become
familiar with the controls and machine
response.
The truck shall be in serviceable condition before
attempting to use it as described in
the operating
instructions. If the truck is determined not to be in
serviceable condition, notify the
site or machine
supervisor to have it repaired before use.
Damage and Defects
�Damages and other defects to the truck must be reported to the Supervisor immediately.
Trucks which are not safe to operate may not be used until they have been properly
repaired.
�Safety installations and switches may not be removed or rendered unusable.
�Specied settings may only be changed with the approval of the manufacturer.
Danger Area
�People must not stand in the danger area of an industrial truck. Danger areas are those areas
in which persons are in danger as a result of the movements of machines, their operating
equipment, their load carrying devices (e.g. their attachments) or the loaded goods. This also
includes the area which can be reached by falling goods or lowering or falling operating
equipment and devices.
Driving Conditions
�Use lights in dark and dim areas. Always ensure that there are no pedestrians in the trucks
rear swing area before turning.
�Under all travel conditions, operate the truck at a speed that will permit it to be brought to a
stop in a safe manner.
�It is essential to keep your truck under control at all times.
Load
�Do not exceed the capacity of the dumper. The capacity appears on the trucks identication
plate and the safety labels on skip.
�Do not overll the skip to impair the operators vision.
�Always make certain that the load is secured and arranged evenly in the skip.
�Do not allow people to ride on the dumper. Do not raise the skip over people. Never lift or
lower the load when the truck is in motion.
Unstable loads are a hazard to you and to your fellow workers.
2. SAFETY
Safety guidelines
Ecovolve strives to identify foreseeable hazards associated with the use of it’s products.
However,
no manual can address every possible risk. The possibility of other dangers when
using the truck
cannot be entirely excluded. The end-user ultimately must apply sound
judgment whenever using
the electric truck. Improper or careless use might result in serious
personal injuries or death. Below is
an overview of steps, warnings and advice that can be taken
to prevent and minimize the risk of injury.
This list is not exhaustive and awareness to each local
environment and situation must be exercised by the operator.
Failure to read and understand the entire manual before using or servicing the product
constitutes
misuse. Always follow the warnings contained within this guide and on the Truck to
avoid incidents
and accidents from occurring.
Safety Features
Ecovolve has introduced many safety features to
make the Ecovolve range safe and user
friendly. An overview of these are as follows:
�Three operating speeds: Creeper for when the skip is raised (under 1 km), Walking (under
4km), and Full (7km). The Truck automatically selects Creeper mode when the hi tip function
is activated, . It will automatically select the Walking mode when the step
is in the raised position. The operator can manually select the slower speed at any time if
necessary.
�The Truck has two pull-up safety rails for extra stability for the operator. These must be
used when the operator is using the operators platform.
�The Truck is tted with standard features such as a beacon light, motion buzzer and LED
lamps allowing for high visibility at all times.
�The operator Must use both hands on the tiller head when operating the Truck.
�The Truck is tted with both dynamic and static brakes. When the Truck is in reverse, if the
operator collides with an object, Their body will engage the large red EMR Reverse
protection switch which will stop the truck and move the truck forward. The Truck must only
be maneuvered in reverse and not driven for any prolonged distances.
�The Truck has an emergency stop button which can be easily accessed at any time during
operation by pushing down on the button.
�If the Truck is switched on and unattended for a period of longer than nine minutes, as a
safety precaution the machine will automatically switch all power o.
The operator must always be aware of their surroundings and maintain vigilance for their
safety and the safety of others.
2. SAFETY
Safety guidelines
Safety guidelines

OPERATORS PERSONAL PROTECTIVE EQUIPMENT (PPE)
HARD HAT REQUIRED When the instruction for a hard hat is stated, a hard hat
must always be worn when operating the machine to avoid personal injury.
PROTECTIVE EYEWEAR REQUIRED When the instruction for protective eyewear
is stated, protective eyewear must always be worn when operating the machine
to avoid personal injury.
SAFETY SHOES REQUIRED When the instruction for safety shoes is stated,
safety shoes must always be worn when operating the machine to avoid
personal injury.
APPROPRIATE CLOTHING REQUIRED When the instruction for safety clothing is
stated, safety clothing must always be worn when operating the machine to
avoid personal injury.
HAND PROTECTION REQUIRED When the instruction for hand protection is
required to avoid personal injury.
2. SAFETY
Safety guidelines
Driving Routes and Tip Over
Stability is guaranteed if the electric dumper is
used correctly according to specied targets.
�Driving routes shall be free of objects.
�Gradients used by the truck cannot exceed a max of 10°.
�Drivable uphill/downhill gradient cannot exceed a max of 15°.
Common reasons for a lack of stability are:
�Cornering at excessive speeds.
�Moving with the load raised.
�Moving with a load that is protruding to the side.
�Turning and driving diagonally across gradients.
�Driving on gradients with the load on the downhill side.
�Ramp edges or steps.
Tip over can occur with a combination of speed
and sharpness of turn. This condition of
instability
is even more likely with an unloaded skip.
�Lateral tip over can occur loaded or unloaded by turning on a ramp.
�Longitudinal tip over can occur with a combination of overloading and load elevated.
2. SAFETY
Safety guidelines
Modication
Do not modify the truck!
Modifications automatically void the limited warranty and might make the truck unsafe to
use. Check with the manufacturer or regional
distributor for use of approved attachments.
Chassis Safety
�Inspect the product as described in the maintenance schedule. Do not use the truck unless
it is in normal conditions.
�Do not use the product until it is fully restored to normal condition.
�Only use manufacturer-approved replacement parts.
�Do not remove or obscure any label. All labels must be readable and undamaged.
Inform all persons in the area that you are going to use the truck and instruct them to take
the necessary precautions about the truck during operation.
�Clear all debris from your driving path.

I
J
K
L
M
N
E
F
G
H
D
B
C
A
I J K L M NHG
FC D EA
DANGER! The operator must read and fully understand the owners manual
including all warning signs and labels before use.
SAFETY SYMBOL EXPLANATION
DANGER! Operator must wear the correct Personal Protective Equipment (PPE) to
ensure safe use.
DANGER! Crush hazard. Can cause serious injury or death. Keep clear.
DANGER! Do not drive on incline with the skip raised. High risk of tip over causing
injury.
DANGER! Do not enter the turning circle of the machine at all times.
DANGER! Do not raise the skip while moving. Risk of tipping over causing injury or
death.
WARNING! Indicate change of direction on turning.
DANGER! Crush hazard. Can cause serious injury or death. Avoid moving
mechanisms.
DANGER! Crush hazard. Can cause serious injury or death. Keep out of the danger
zone while loading.
DANGER! Do not exceed the max load rating.
DANGER! Do not empty skip on decline. High risk of tipping over causing injury or
death.
DANGER! Risk of overturning. Max permissible gradient is 10 degrees.
DANGER! Driveable uphill max permissible gradient is 15 degrees.
DANGER! Indicate change of direction on turning.
B
2. SAFETY
Safety guidelines
SAFETY SYMBOL EXPLANATION
CAUTION! Indicates a hazardous situation which, if not avoided, could result in
moderate injury.
ELECTRICAL WARNING! Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CRUSH PARTS WARNING! Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
WHEEL CRUSH WARNING! Indicates a hazardous situation which, if not avoided,
could result in serious injury.
NO NAKED FLAME! Indicates if naked ames are used in situations where naked
ames are prohibited, a serious accident can occur.
NO SMOKING! Indicates if smoking occurs where a restriction is in place, a
serious accident can occur.
ADVISORY TEXT WARNING! Indicates that the following text advice must be
adhered to.
REVERSE HAZARD WARNING! Indicates a hazard is present to the operator and
pedestrians while reversing. Extra attention is required.
2. SAFETY
Safety guidelines

Identication plate
3. OVERVIEW
Identication plate
NOTE
The CE mark conrms
compliance with the EC
machinery directives and with
all regulations applicable to
the Ecovolve hi tip electric
dumper.
Identication pate
1 Nameplate
2 Manufacturer
3 Model number
4 Serial no/year of manufacture
5 Unladen weight
6 Laden weight
7 CE mark
Identication plate
2
1
3
4
5
6
7
OVERVIEW
3