Original instructions

Electric pallet truck

ECU-14
ECU-16
ECU-18
ECU-20

0164 0165 0166 0167 0176

45588043482 EN - 04/2016
Table of contents
g

1 Introduction
Forklift data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Consult the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Date of edition and latest update of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Delivery of the forklift and documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . 5
Technical service and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Type of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Working conditions .................................................. 7
Modifications to Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applied equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
User obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
Flooring requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
Battery connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 13
Requirements for the traction-battery charging area . . . . . . . . . ............... .. 13
Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . ............... .. 13
Safety Regulations Relative to Operating Materials . . . . . . . . . . ............... .. 13
Electromagnetic radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Non-ionised radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 Table of contents
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Damage, defects and misuse of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3 Knowledge of the Truck

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Truck View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Definition of direction of travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Instrumentation and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 26
Start/stop key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 26
Tiller controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 27
Tiller positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 28
Battery status indicator and hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 29
Numerical keypad (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
On-board battery charger (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Internal accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Truck Identification . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 33
Location of labels . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 33
Description of labels . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 33
Location of Data Plates ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 35
Serial number . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 36
Frame labelling . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 36
Data plate . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 37
Capacity rating plate . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 38
Options and variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
List of available options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Use and Operation

Authorised and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety instructions relating to use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Truck Transport and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 44
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 44
Climatic Conditions for Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . ...... 44
Loading and unloading the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 45
Breaking-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checks and actions prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
List of checks before use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 47

Stopping the truck in an emergency . . . . . . . . . . . . . . . . . . . . . ............... .. 47
Operator position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 48
Starting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 49
Truck operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 49
Truck steering direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 50
Using the forklift with the "tiller always active" function (optional) ............... .. 51
Reverse drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 52
Truck brake systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 53
Parking and stopping the truck . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 53
Forklift Use in Cold-Storage Rooms. . . . . . . . . . . . . . . . . . . . . . ............... .. 55
Load Placement . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 56
Safety guidelines for handling loads . . . . . . . . . . . .......... ............... .. 56
Taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 57
Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 58
Deposit the load. . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 59
Using the truck on inclines, loading bridges and lifts. ......... ............... .. 60
Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 60
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61
Battery Recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61
Recharging the battery, specific for batteries with electrolyte recirculation system . . . .. 62
Recharging the battery using the on-board battery charger (optional) . . . . . . . . . . . . .. 64
Battery electrolyte level indicator LED (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 66
Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69

5 Servicing
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Preliminary maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Synoptic Table of Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Maintenance as required ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 75
Cleaning the Forklift . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 75
Battery rplacement . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 75
Fuse replacement . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 77
Putting out of commission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Forklift Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

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 Table of contents
g

Temporary Putting Out of Commission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Checks and Inspections After a Long Period of Inactivity . . . . . . . . . . . . . . . . . . . . . . . 79
Permanent Putting Out of Commission (Demolition) . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Resolution of Operating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6 Technical data
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Supply Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

IV 45588043482 EN - 04/2016
 1

Introduction
1 Introduction
Forklift data

Forklift data
We recommend that you record the principal
forklift data in the following table so that they
are available if required by the sales network
or authorised service centre.

Type
Serial number
Date of delivery
.

General information
• This manual contains "Original Instructions" to things due to the failure to observe the
provided by the manufacturer. instructions in this manual, in the "Rules for
• The "operator" is defined as the person the use of industrial vehicles" and on the
driving the forklift. labels and adhesive supplied to the forklift.
• The "user" is the physical or legal person • The forklift may not be put to any use other
who has the forklift truck used by the that than indicated in this manual.
operators. • The forklift must be used by appropriately
• For correct use of the forklift and in order trained operators only. For the necessary
to avoid accidents, the operator is obliged operator training, contact the authorised
to read, understand and apply the contents sales network.
of this manual, the "Rules for the use of • Persons working near the forklift must also
industrial vehicles" and the labels and be instructed in the risks associated with
plates applied to the forklift. use of the forklift.
• This manual and the attached "Rules for • In the interests of clear information, some
the use of industrial vehicles" must be kept illustrations in this manual show the forklift
carefully and must always be on the forklift without the safety equipment (guards,
for fast consultation. panels, etc.). The forklift may not be used
• The manufacturer assumes no responsibil- without safety equipment.
ity for any accidents to persons or damage

How to Consult the Manual

There is a table of contents at the beginning Some general information is provided in this
of the manual for ease of use. The manual is manual. Please only consider the information
divided into chapters with specific topics. The relevant for your specific forklift.
name and title of the chapter are given at the
The following symbols have been used to
top of each page The following is found at the
highlight some parts of this manual.
bottom of each page: the type of manual, the
identifying code, the language and the manual DANGER
version.
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.

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Introduction 1
How to Consult the Manual

CAUTION
NOTE
Failure to observe the instructions highlighted with
this symbol may cause damage to the forklift and, This symbol is used to provide additional
in some cases, result in warranty invalidity. information.

ENVIRONMENT NOTE
Failure to observe the instructions highlighted
with this symbol may cause environmental
damage.

45588043482 EN - 04/2016 3
1 Introduction
Date of edition and latest update of this manual

Date of edition and latest

update of this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.

Copyright and trademark

rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.

Delivery of the forklift and documentation

Ensure that the truck has all of the options included, as well as the EC declaration for the
requested and that it has been delivered with battery charger.
the following documentation:
If applied equipment, other equipment or
• Original instructions devices are present, ensure that they conform
• Rules for the compliant use industrial to the order and that the relative use and
vehicles; maintenance manual and of the relative EC
• EC Declaration of Compliance; declaration (if provided by regulations in
• Warranty book. effect) are included.

If the forklift has been delivered with a traction All of the above documentation must be kept
battery and/or battery charger, ensure that for the entire operative life of the forklift. In the
such products conform to the order and that event that the documentation is lost or dam-
the relative user and maintenance manual are aged, contact the authorised sales network for
copies of the original documentation.

4 45588043482 EN - 04/2016
Introduction 1
EC declaration of conformity in accordance with Machinery Directive

EC declaration of conformity in accordance with Machinery Di-

rective

Declaration

STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany

We declare that the

Industrial truck according to these operating instructions

Model according to these operating instructions

conforms to the latest version of the Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL GmbH

45588043482 EN - 04/2016 5
1 Introduction
Technical service and spare parts

Technical service and spare parts

For scheduled maintenance and any repairs to the technical characteristics of the forklift over
the forklift, contact only the authorised service time.
network.
Only original spare parts provided by the man-
The authorised service network has personnel ufacturer may be used for forklift maintenance
trained by the manufacturer, original spare and repairs. The use of non-original spare
parts and the tools necessary to carry out parts invalidates the warranty and renders the
maintenance and repairs. user responsible for any accidents due to the
inappropriateness of the non-original parts.
Servicing by the authorised service network
and the use of original spare parts maintain

Normative References
This forklift complies with: in accordance with the EN 12053 standard
• The most recent version of Machine Direc- and declared according to the EN ISO 4871
tive 2006/42/EC in effect standard
• Electromagnetic Compatibility Directive The vibration tests were carried out in accor-
2014/30/EC and subsequent amendments, dance with standard EN 13059 and declared
relative to forklifts for handling in accor- in accordance with standard EN 12096.
dance with the EN 12895 standard
The limit values for the electromagnetic
The noise tests regarding the sound pressure emissions and immunity relative to the forklift
level at the driver’s seat were carried out are those set out in the EN 12895 standard.

Type of use
"Normal use conditions" of the forklift are The following scenarios are examples of
understood as: incorrect use of the forklift truck:
• lifting and/or transport of loads using forks • Transport on uneven (irregular or non-
with weight and load centre within the compact) surfaces
values provided (see Chapter 6 - Technical • loads that exceed the weight and/or load
Data). centre limits;
• transport and/or lifting on smooth, flat and • transporting non-stable loads;
compact surfaces;
• transporting loads not equally distributed on
• transport and/or lifting of stable loads the forks;
uniformly distributed on the forks;
• transporting swinging loads;
• transport and/or lifting with the load centre
• transporting loads whose load centre is
approximately on the forklift’s median
considerably displaced with respect to the
longitudinal plane.
forklift’s longitudinal median plane;
DANGER • transporting loads of dimensions such as to
block the view of the operator when driving;
The forklift must not be used for other purposes.
• transporting loads piled so high that they
Any other use renders the user solely responsible
for injury/damage to persons and/or objects and could fall onto the operator;
voids the warranty. • travelling with a load over 300 mm off the
ground;

6 45588043482 EN - 04/2016
Introduction 1
Working conditions

• transporting and/or lifting people; • turning and/or moving sideways on slopes

• pushing or pulling loads; (upwards or downwards);
• moving upwards or downwards on a slope • colliding with stationary and/or mobile
with the load facing downwards; structures;
• turning at high speed; DANGER
Improper use of the forklift could cause it and/or at
the load to overturn.

Working conditions
The forklift has been designed and built for cold-storage rooms, presence of strong mag-
internal transport. netic fields etc), appropriate equipment and/or
use precautions are necessary. Contact the
Do not use beyond the limits of the climatic authorised sales network for more informa-
conditions indicated below: tion.
• Maximum ambient temperature: +40°C
• Minimum ambient temperature: +5°C DANGER
• Altitude up to 2000 m The forklift may not be used in environments in
which there is a risk of explosion. It may not be
• Relative humidity between 30% and 95% used to handle explosive loads.
(without condensation).

CAUTION For forklifts that must operate in environments

in which there is a risk of explosion or must
Do not use the forklift in dusty areas. handle explosive loads, appropriate equip-
Using the forklift in environments with high concen- ment is necessary and must be accompanied
trations of salty air or water could interfere with its by a specific EC Declaration of Compliance
proper operation and cause corrosion of metallic
parts. which replaces that of the standard forklift,
and by the relevant User and maintenance
If the forklift must be used in conditions that manual.
exceed the limits indicated or, in any case, Contact the authorised sales network for more
under extreme conditions (extreme weather, information.

Modifications to Forklift
No modifications may be made to the forklift, DANGER
otherwise the EC certificate and the warranty
If the forklift is equipped at the factory or later with
will become invalid, with the exception of: devices that emit non-ionising radiation (such as
• assembly of the options provided by the radio transmitters, RFID players, data terminals,
manufacturer scanners, etc), the compatibility of such devices
must be verified with the presence of operators
• assembly of applied equipment using medical devices (such as heart pacemakers).
for which it is necessary to refer exclusively to
the authorised sales network

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1 Introduction
Applied equipment

Applied equipment
To use equipment that has not been applied, • add a label with the new residual capacity is
please contact the authorised sales network, • provide documentation on the equipment
in order to: (user and maintenance manual and EC
• verify feasibility certificate).
• install the equipment

User obligations
Users must comply with applicable local legis-
lation governing forklift use and maintenance.

Environmental considerations
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.

NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.

ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.

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Introduction 1
Environmental considerations

Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.

ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.

45588043482 EN - 04/2016 9
1 Introduction
Environmental considerations

10 45588043482 EN - 04/2016
 2

Safety
2 Safety
Safety regulations

Safety regulations
General Precautions

NOTE
Some safety regulations to be followed when
using the forklift are listed below. These
regulations integrate those in the manual
"Rules for approved use of industrial vehicles".

General Safety Rules

• Only allow qualified, trained and authorised the safety distances established by the
personnel to use the forklift. competent authorities.
• Do not install equipment on the forklift un- • Never raise the load using just one fork.
less supplied or indicated by the manufac- • Place the load on the fork carriage or in such
turer. a way that the centre of gravity of the load is
• Maintain the forklift in full working efficiency as close as possible to the fork carriage.
in order to keep any type of risk to the • The load must be placed on the forks so
minimum. that the centre of gravity falls on the mid
• Do not use the forklift with hoods and doors point between the forks.
open. • Do not drive with loads decentralised
• The data plates found on the forklift must laterally with respect to the forklift’s median
be kept in good condition and replaced if axis. Lack of compliance with this regulation
damaged. can compromise forklift stability.
• Carefully read and follow all of the safety • Make sure that the surface on which the
indications found on the forklift. load rests is able to support its weight.
• Make sure that the forklift has sufficient • Always use safety clothing that complies
overhead clearance. with the current regulations.
• Do not park the forklift in front of fire-fighting • Do not travel on loose or hilly ground or on
devices or fire escapes or anywhere that it steps.
blocks traffic. • Do not turn or stack on slopes.
• If the forklift shows signs of failure or break- • Do not overload the forklift beyond the
age and there is reason to consider it un- capacity limits indicated on the capacity
safe, stop, park it and notify the mainte- plates.
nance manager.
• Pay attention to the distances from high
voltage overhead cables. Comply with

Flooring requirements
The work floor must be even and free of holes CAUTION
or dips, which can be difficult to get around.
Passing over cracks or damaged parts of the floor
Any steps must be equipped with ramps to with the truck is prohibited. Dirt and any objects in
prevent impacts with the wheels, which affect the work path must be removed immediately.
the entire structure of the truck.

12 45588043482 EN - 04/2016
Safety 2
Safety regulations

Battery connection cables

CAUTION
Using sockets with NON-ORIGINAL battery con-
nection cables can be dangerous (see purchase
references in the parts catalogue)

Requirements for the traction-battery

charging area
When the traction battery is being charged, the
area must be sufficiently ventilated in order to
download or eliminate the gases produced
(EN 50272-3).

Safety Regulations Relative to Forklift Use

• The operator must familiarize himself with
ENVIRONMENT NOTE
the forklift to be able to better describe any
defects and assist maintenance personnel. Report any oil and/or battery fluid leaks: they
The operator, trained and authorized to use are dangerous and highly polluting.
the forklift, must be familiar with the controls
and performances of the forklift. CAUTION
• Any defect (squeaking, leaks, etc.) must be If you notice a burning smell, stop the forklift and
promptly reported because, if neglected, it turn off the engine, then disconnect the battery.
could cause more serious failures/defects.
• Carry out the inspections indicated in the
chapter on "Daily Inspections".

Safety Regulations Relative to Operating Materials

Rules for handling and disposing of Keep the operating materials only in contain-
operating materials ers intended for this purpose and in a location
that satisfies the requirements.
ENVIRONMENT NOTE The operating materials may be flammable, so
Improper use and disposal of operating and avoid contact with hot objects or open flames.
cleaning materials can cause serious damage When topping up the operating materials, only
to the environment. clean containers should be used.
Always use and handle the operating materi- Follow the manufacturer’s safety and disposal
als in a suitable manner and follow the manu- instructions regarding the operating and
facturer’s instructions for the product’s use. cleaning materials.
Do not disperse oils or other operating liquids!
Any spilt liquid must be immediately collected

45588043482 EN - 04/2016 13
2 Safety
Electromagnetic radiation

and neutralised with a binding material (such DANGER

as an oil binder) and then disposed of in
The penetration in the skin of hydraulic oil that has
accordance with current regulations. leaked under pressure from the forklift’s hydraulic
system is dangerous. If this type of lesion should
Always comply with anti-pollution regulations! occur, contact a doctor immediately.
Before carrying out work that involves lubrica-
tion, filter replacement or hydraulic equipment
interventions, the area in question must be DANGER
thoroughly cleaned. Small high pressure jets of oil can penetrate the
skin. Look for any leaks using a piece of cardboard.
The replaced parts must always be disposed
of in accordance with the anti-pollution laws.
Battery Acid
ENVIRONMENT NOTE • Do not inhale the vapor: it is poisonous.
The incorrect or unlawful use of brake fluid is • Use adequate means of individual protec-
harmful to people’s health and the environ- tion to prevent contact with the skin.
ment. • Battery acid is corrosive: if it should come
into contact with your skin, rinse abundantly
Oils with water.
• Explosive gas mixtures can form when
• Do not allow to come into contact with the charging the battery; therefore, the rooms
skin. in which the battery is charged must be in
• Do not inhale oil vapors. compliance with the specific regulations on
• Wear appropriate means of individual the subject (e.g. EN 50272-3 etc.).
protection during forklift maintenance • DO NOT smoke or use open flames and
operations (gloves, goggles, etc.) to lights within a 2 m radius from the charged
prevent the oil from coming into contact battery and in the battery charging area.
with your skin.
NOTE
ENVIRONMENT NOTE
For greater information, consult the specific
The used oils and relative filters contain sub- battery manual that comes with the battery.
stances that are hazardous to the environment
and must be disposed of according to current ENVIRONMENT NOTE
regulations. We advise you to contact the au-
thorised service network. The batteries contain substances that are ha-
zardous to the environment. The replacement
and disposal of the life-expired battery must
be carried out as required by law. We advise
you to contact the authorised service network
that is equipped for eco-friendly disposal in
accordance with current regulations.

Electromagnetic radiation
The limit values for electromagnetic emissions
and for immunity relative to the forklift are
those provided by the EN 12895 standard.

14 45588043482 EN - 04/2016
Safety 2
Non-ionised radiation

Non-ionised radiation
If the forklift is equipped at the factory or
later with devices that emit non-ionising
radiation (such as radio transmitters, RFID
players, data terminals, scanners, etc), the
compatibility of such devices must be verified
with the presence of operators using medical
devices (such as heart pacemakers).

Noise
Sound pressure level in driver’s seat LpAZ < 70 dB (A)
Uncertainty factor KpA=4 dB (A)

The value is determined in a test cycle in CAUTION

accordance with Harmonised European
The value expressed above can be used to com-
Standard EN 12053 and declared according to pare forklift trucks of the same category. This can-
EN ISO 4871 with weighted time percentages not be used to determine the noise level in workpla-
of the Transport, Lifting and Idling modes. ces (daily personal noise exposure). Noise values
that are lower or higher than those indicated above
can occur during actual truck use, for example
following different operating modes, different envi-
ronmental conditions and additional noise sources.

45588043482 EN - 04/2016 15
2 Safety
Vibrations

Vibrations
Value of the vibrations to which the hands- CAUTION
arms are exposed:
The value expressed above can be used to com-
āw< 2.5 m/s2 pare forklift trucks of the same category. It cannot
be used to determine the operator’s daily expo-
The value complies with Harmonised Euro- sure to vibrations during real operation of the truck;
pean Standard EN 13059 (Safety of industrial these vibrations depend on the conditions of use
(floor conditions, method of use etc.) and therefore
trucks — methods for measuring vibration). daily exposure must be calculated using data from
the place of use.

16 45588043482 EN - 04/2016
Safety 2
Safety tests

Safety tests
Regular safety inspection of the truck
Safety inspection based on time and
extraordinary incidents
The operating company must ensure that STILL GmbH Hamburg
the truck is checked at least once a year, or
Regelmäßige Prüfung
following noteworthy incidents. (FEM 4.004)
As part of this inspection, a complete check nach nationalen Vorschriften
of the technical condition of the truck must be basierend auf den EG-Richtlinien:
95/63/EG, 99/92/EG, 2001/45/EG
performed with regard to accident safety.
In addition, the truck must be thoroughly Nächste Prüfung
checked for damage that could potentially
have been caused by improper use. A test
log must be created. The results from the
inspection must be retained until a further two

56344391019
inspections have been carried out.
The inspection date is indicated by an adhe-
sive label on the truck.
– Arrange for the service centre to perform
periodic safety inspections on the truck.
– Observe guidelines for checks carried out Die Prüfplakette ersetzt nicht das Prüfprotokoll

on the truck in accordance with FEM 4.004. Mitglied der:

Fédération
The operator is responsible for ensuring any Européene
de la Manutention
defects are remedied without delay.
0000_003-001_V3

– Contact your service centre.

NOTE
Observe the national regulations for your
country!

45588043482 EN - 04/2016 17
2 Safety
Safety devices

Safety devices
Safety devices

2 5 1

OM1759

The operator must be aware of the presence

of the following safety devices:
• Anti-crush button(1)
• Horn (2)
• Start/stop key(3)
• E(4)lectromagnetic brake
• EMERGENCY battery warning light (5)

18 45588043482 EN - 04/2016
Safety 2
Safety devices

NOTE
These devices most be checked daily, as
described in Chapter 4.

45588043482 EN - 04/2016 19
2 Safety
Safety devices

Damage, defects and misuse of

safety devices
The driver must report any damage or other
defects to the truck or attachment immediately
to the supervisory personnel.
Trucks and attachments that are not functional
or safe may not be used until they have been
properly repaired.
Do not remove or deactivate safety devices
and switches.
Fixed set values may only be changed with the
approval of the manufacturer.
Work on the electrical system (e.g. connecting
a radio, additional headlights etc.) is only
permitted with the manufacturer’s written
approval. All electrical system interventions
must be documented.

20 45588043482 EN - 04/2016
 3

Knowledge of the Truck

3 Knowledge of the Truck
Technical description

Technical description
The trucks described in this manual ECU 14,
ECU 16, ECU 18 and ECU 20 are designed
to move and stack pallets inside shops,
warehouses and factories.

General characteristics
• The traction motor operates the drive wheel
using a reduction gear unit
• Three-phase traction motor
• Starting and accelerating without jerking
• Regenerative braking

Lift
Nominal load:
• 1400 kg (ECU 14)
• 1600 kg (ECU 16)
• 1800 kg (ECU 18)
• 2000 kg (ECU 20)
Pump unit:
• Power 1 kW
Other lifting features:
• Fork lift limit using electric timer that
switches off the pump motor

Guidance
The operator guides the truck from the ground.
A long and ergonomic tiller allows the operator
to guide the truck easily.
The tiller is used to activate the following
controls:
• Steering
• Drive control throttle
• Horn
• Fork lifting and lowering buttons
• Anti-crush safety button
• Truck braking when the tiller reaches the
upper end position and lower end position
For safety reasons, the tiller automatically
returns to the vertical position when released.

22 45588043482 EN - 04/2016
Knowledge of the Truck 3
Technical description

Braking system
Braking:
• When the accelerator is released
• By reversing the direction of movement
• By pressing the anti-crush safety button
• By pulling the emergency shutdown handle
• By pushing the tiller until it reaches the
upper or lower end position
• Electromagnetic parking, applied when the
power supply is cut

45588043482 EN - 04/2016 23
3 Knowledge of the Truck
General Truck View

General Truck View

9
8 8 7

3
4
5 1
6
17 10

13 14
2

15

16
12
11
16 1842

1 On / off key 10 Flat battery indicator

2 Tiller 11 Battery plug-outlet
3 Horn button 12 Drive Wheel
4 Fork arm lifting push button 13 Load castors
5 Fork arm lowering push-button 14 Fork arms
6 Battery cover 15 Motor compartment cover
7 Tiller head 16 Pivot wheels
8 Traction control throttles 17 Hour meter
9 Anti-crush button

24 45588043482 EN - 04/2016
Knowledge of the Truck 3
Definition of direction of travel

Definition of direction of travel

OM1761

The direction of travel is defined in the follow-

ing manner:
A = Direction of travel towards the fork arms
(Backwards travel)
B = Direction of travel towards the driver
(Forwards travel)
The preferred direction of travel is "B"

45588043482 EN - 04/2016 25
3 Knowledge of the Truck
Instrumentation and Controls

Instrumentation and Controls

Start/stop key
Key 1 has two positions: 1
0 =No circuit powered (key removal posi-
tion);
I =Circuit powered.

NOTE
All of the controls described on the following
pages work with the key in position "1"

OM1767

26 45588043482 EN - 04/2016
Knowledge of the Truck 3
Instrumentation and Controls

Tiller controls
Anti-crush button (1)
• Pressing the button (1) while the truck is 1
travelling towards the operator will reverse
the direction of travel and, after six seconds,
B
stop the truck.
2 3
• If the button (1) is released after the direc- A
tion of travel is reversed the truck will stop.
Traction control throttle (2 - 3)
• When the throttle (2 -3) is turned in direction 6
(A), the truck starts moving in the direction
of the fork arms.
• When the throttle (2 -3) is turned in direction 5
(B), the forklift starts moving in the direction
of the operator.
4
• The truck speed increases according to the
angular position of the throttle.
• Releasing the throttle causes braking and
subsequently the stopping of the truck.
Fork lowering button (4)
• Press push-button (4) to lower the fork
arms; when the push-button is released, the A 1
fork arms will stop in the position attained.
Fork raising button (5)
B 2
• Press push-button (5) to raise the fork arms; 3
when the push-button is released, the fork
arms will stop in the position attained.
• The fork lifting pushbutton (5) is active only
when the tiller is angled to the working
position.
Horn button (6) 7
• Press push-button (6) to operate the horn.
This device allows the driver to signal his
presence when necessary.
Slow-speed button (7) (optional)
• The forklift is equipped with the optional
"tiller always active" pushbutton (7).
OM1762
• Keeping the button (7) pressed while
turning the throttle (2 - 3) activates the slow
speed only if the tiller is in vertical position.
• Keeping the button (7) pressed while
pressing the fork lifting button (5) activates

45588043482 EN - 04/2016 27
3 Knowledge of the Truck
Instrumentation and Controls

fork lifting only if the tiller is in vertical

position.
• The button (7) does not work if pressed
when the tiller is inclined.
WARNING
The truck is blocked when the button (7) is pressed
while the tiller is moved from vertical position to
inclined working position and vice versa
In this case, switch off the truck and start it again
using the switch key

NOTE
This function is ideal for manoeuvres in
confined spaces.

Tiller positions
Position the tiller in accordance with the
forklift functions A 2
In this case the tiller has two positions:
• Position (1) = working position.
1
In this position the driver can begin travel
using the throttle.
In this position the driver can begin lifting or
lowering using the appropriate button. 2
• Position (2) = braking position.
In this position the drive is locked and the
parking brake is engaged.
In this position, fork lifting is deactivated;
fork lowering remains activated, by means
of the relative pushbutton OM1763
• Position (2) using the “tiller always active”
function (optional) = slow speed position
This function is activated by pressing the
slow speed button on the tiller and rotating
the traction control throttle or by pressing
the slow speed button and the fork lifting
button.

NOTE
When the tiller is released, it automatically
returns to position (A), the braking position.

28 45588043482 EN - 04/2016
Knowledge of the Truck 3
Instrumentation and Controls

Battery status indicator and hour

meter 3 2
1
4
Battery charging status indicator
• Indicates the battery charge level; it is
subdivided into ten sectors with respective
coloured LEDs.
• When the battery is 100% charged, LED 1
remains lit up.
• As the battery discharges, the LEDs light
up one at a time from right to left, starting
N
from LED 1, which indicates the completely
charged battery status.
12345.6
?

• At 50% charged, LED 2 lights up

• When the battery is 20% charged, LEDs 3
and 4 flash alternately. Lifting is blocked at
this discharge threshold.
5 OM1766
CAUTION
Charge the battery to at least 30% charged; below
this level the truck will not lift.

Hour meter (5)

• Indicates the actual forklift operation time,
expressed in hours.
• When the hour meter is working, the
hourglass flashes; five numbers plus one
decimal digit are displayed. The hours are
counted progressively and start from zero.

45588043482 EN - 04/2016 29
3 Knowledge of the Truck
Numerical keypad (optional)

Numerical keypad (optional)

Use instructions for the person responsi-
ble for operators
The person responsible for operators has
a password(Master Code) that makes it
possible to:
• memorise several personal operator pass-
words (Pin Code) for turning on the forklift.
• cancel one or more personal operator (Pin
Code) passwords
• change the password of the person respon-
sible for operators (Master Code)

D A B Entering a new Master Code:

• Enter the password of the person responsi-
OM1782
ble for operators (Master Code) (for the first
time memorised, the password is the one
set by the factory: 111111) and press the
Use instructions for the operator
key (OK). The green LED (A) turns off and
A numerical keypad is available as an alterna- the yellow LED turns on(D).
tive to the ignition key: • Using the keyboard, enter the control code
• numerical keys (1 -2 -3 -4) ’11’ and press the key (OK). The yellow LED
• confirmation key (OK) (D) will begin to flash.
• cancellation key (C), used to enter the • Enter a new six-number password (Master
machine start-up code Code) and press the key (OK).

When the forklift is turned off, the green LED WARNING

(A) remains lit. The new password (Master Code) will overwrite the
When the forklift is turned on, the green LED previous password.
flashes. We recommend that the person responsible for
operators change the password (Master Code)
The forklift is turned on by entering the four- when the forklift is delivered.
number user password and then pressing the
key (OK): Entering a password (Pin Code) for the
• if the password (Pin Code) entered is operator
correct, the green LED (A) begins to flash. • The four-digit user password for the first
• if the password (Pin Code)entered is start-up is factory-set and is: 1234. We
incorrect, the red LED (B) lights up and recommend that the person responsible
the numerical keypad emits an acoustic for operators change this password and
warning signal, after which the green LED personalise it as follows:
(A) lights up and remains lit. • Enter the password of the person responsi-
ble for operators (Master Code) (for the first
The forklift is turned off by pressing key (C). time memorised, the password is the one
The four-digit user password for the first set by the factory: 111111) and press the
start-up is factory-set and is: 1234 key (OK). The green LED (A) turns off and
the yellow LED turns on(D).

30 45588043482 EN - 04/2016
Knowledge of the Truck 3
On-board battery charger (optional)

• Using the keyboard, enter the control code after which the green LED (A) comes on and
’33’ and press the key (OK). The yellow LED remains lit. Repeat the procedure
(D) will begin to flash.
Cancelling all the operator passwords (Pin
• Enter a new four-digit password for the
Code)
operator (Pin Code) and press the key (OK).
• Enter the password of the person responsi-
• At the end of the procedure, the green LED ble for operators (Master Code) (for the first
(A) comes on and remains lit. time memorised, the password is the one
• In the case of an error in the procedure, the set by the factory: 111111) and press the
red LED (B) comes on and the numerical key (OK). The green LED (A) turns off and
keypad emits an acoustic warning signal, the yellow LED turns on(D).
after which the green LED (A) comes on and
• Using the keyboard, enter the control code
remains lit. Repeat the procedure
’22’ and press the key (OK). The yellow LED
Cancelling an operator password (Pin Code) (D) will begin to flash.
• Enter the password of the person responsi- • Enter the password of the person respon-
ble for operators (Master Code) (for the first sible for the operators (Master Code) and
time memorised, the password is the one press the key (OK).
set by the factory: 111111) and press the • At the end of the procedure, the green LED
key (OK). The green LED (A) turns off and (A) comes on and remains lit.
the yellow LED turns on(D). • In the case of an error in the procedure, the
• Using the keyboard, enter the control code red LED (B) comes on and the numerical
’13’ and press the key (OK). The yellow LED keypad emits an acoustic warning signal,
(D) will begin to flash. after which the green LED (A) comes on and
• Enter the operator’s password to be can- remains lit. Repeat the procedure
celled (Pin Code) and press the key (OK).
WARNING
• At the end of the procedure, the green LED
(A) comes on and remains lit. This procedure cancels all of the operator pass-
words (Pin code) memorised, including the fac-
• In the case of an error in the procedure, the tory-set password (1234).
red LED (B) comes on and the numerical
keypad emits an acoustic warning signal,

On-board battery charger

(optional)
Read the User and maintenance manual.

45588043482 EN - 04/2016 31
3 Knowledge of the Truck
Internal accessibility

Internal accessibility
3
DANGER
It is prohibited to use the truck with the covers open.
In order to use the truck, the covers for access to the
inner parts must be closed and secured properly.

DANGER
Before accessing the inner parts of the truck,
carefully follow the instructions given in Chapter
5, entitled "Maintenance".
2

– To access the battery (1) and respective 1

plug/outlet (2), raise the battery compart- OM1770
ment cover (3).
– To access the inner parts of the forklift
(electronic, electric and mechanical parts),
remove the covers (A), (B), (C).
– Unscrew the 2 screws (2) on the cover (A).
C
– Remove the cover (A)
– Use a screwdriver to remove the hood (B)
– Unscrew the 4 screws (1) on the cover (C) B
– Remove the cover (C)
– For reassembly, proceed in the reverse
order 1
2
A OM1771

32 45588043482 EN - 04/2016
Knowledge of the Truck 3
Truck Identification

Truck Identification
Location of labels

3
6

2
2319

1 Read the user and maintenance manual 4 Prohibition against carrying people
2 Truck lifting point 5 Cold-storage room version (optional)
3 Battery warning 6 Version set up for gel batteries

Description of labels
(1) This label indicates you should consult the
user and maintenance manual before using

45588043482 EN - 04/2016 33
3 Knowledge of the Truck
Truck Identification

the truck or performing any maintenance work

on it.
(2) This label indicates where to attach the
truck’s lifting hook.
(3) This plate indicates that only the on-board
battery should be connected.
(4) This label indicates that it is prohibited to
carry people on the truck.
(5) This symbol, where present, indicates that
the truck is designed for the cold-storage room
version (optional).
(6) This symbol, where present, indicates that
the truck is set up for the gel battery version.
Do not use other types of battery.

34 45588043482 EN - 04/2016
Knowledge of the Truck 3
Truck Identification

Location of Data Plates

max XXXX kg

2320

1 Truck identification plate 2 Capacity rating plate

45588043482 EN - 04/2016 35
3 Knowledge of the Truck
Truck Identification

Serial number

NOTE xx xxxx x xxxxx

Please quote the serial number with all
technical questions.
The serial number contains the following
1
information:
1 Production location 2
2 Type
3
3 Year of production
4 Sequential number
4
7090_921-004

Frame labelling
The truck’s serial number is marked on the
chassis frame (1).
The serial number is not visible when the truck
forks are lowered.
To view the serial number, raise the forks,
as the truck serial number (1) is positioned in
the lower part of the fixed chassis in an area
specifically protected from damage during
use.

1
2337

36 45588043482 EN - 04/2016
Knowledge of the Truck 3
Truck Identification

Data plate

NOTE 1 2 3 4 5 6
Please indicate the serial number for all
technical enquiries.

7 8
9 10 11 12 13
2327

1 Model
2 Rated capacity in kg
3 Manufacturer
4 Serial no.
5 Unladen weight (without battery) in kg
6 Year of manufacture
7 EC conformity symbol
8 QR code
9 Battery voltage V
10 Nominal power rating in kW
11 Minimum battery weight
12 Maximum battery weight
13 Additional weight (ballast) in kg

45588043482 EN - 04/2016 37
3 Knowledge of the Truck
Truck Identification

Capacity rating plate

Only one of the four plates shown in the
illustration is affixed to the forklift. max 1400kg
The plate indicates the maximum load capac-
ity of the truck.
The truck is available in four versions:
max 1600 kg
• With maximum load capacity of 1400 kg.
• With maximum load capacity of 1600 kg.
• With maximum load capacity of 1800 kg. max 1800 kg
• With maximum load capacity of 2000 kg.

NOTE max 2000kg

For more information, see the "Technical Data OM1716
chapter"

38 45588043482 EN - 04/2016
Knowledge of the Truck 3
Options and variants

Options and variants

List of available options

1
4

6
2

6 7

7
8
2321

• On/Off numerical keypad (1). • Double pivoting wheels (7)

• Tandem load castors (2). • Various types of drive wheel tyres (8)
• Control panel (3). • Equipment for cold climates (9). Refer to
• Tiller always active (4). Chapter 4 for additional information on the
use of this version of the truck
• On-board battery charger (5).
• Roll holder (10)
• Various fork measurements (6)

45588043482 EN - 04/2016 39
3 Knowledge of the Truck
Options and variants

CAUTION
Contact the technical service network authorised by
the manufacturer for information on the assembly
of the options.

40 45588043482 EN - 04/2016
 4

Use and Operation

4 Use and Operation
Authorised and safe use

Authorised and safe use

Intended use of the trucks

CAUTION
This machine is intended for the transport of loads
packed on pallets or in industrial containers de-
signed for this purpose, as well as for placing pallets
into and removing pallets from stock.
The dimensions and capacity of the pallets or
containers must be adapted to the load being
transported to ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of the
information you need to check that the equipment
is suitable for the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.

Safety instructions relating to use of

the truck
Behaviour when driving
The operator must obey the same rules within
the plant as on the road. The operator must
drive at a speed appropriate for the driving
conditions. For example, the operator should
drive slowly around corners, when entering
and travelling through narrow passageways,
when driving through swing doors, at blind
spots, or on uneven surfaces. The operator
must always maintain a safe braking distance
from vehicles and persons in front of him and
must always have the truck under control. The
operator must avoid sudden stops, making
fast U-turns and overtaking other vehicles in
potentially dangerous areas or areas with poor
visibility.

WARNING
Driving the truck while sitting down is prohibited.

Please remember the following:

• Drive the truck as described in the "Operator
positions" section.
• The truck must not be used as a stepladder.

42 45588043482 EN - 04/2016
Use and Operation 4
Authorised and safe use

• The truck has not been designed to trans-

port anyone other than the operator and
must not be used for this purpose.
• The operator must always stay within the
truck clearance.
• Stay in the safety area (working area
defined by the manufacturer).

NOTE
Using a telephone or radio in the truck is
permitted, but avoid using these devices when
driving as they may distract you.

People in the danger area

Before starting the truck and while you are
working, ensure that no one is in the danger
area. If people are in danger, warn them
well in advance. Stop working with the truck
immediately if the people do not leave the
danger area despite the warnings.

DANGER
Risk of injury! There is a risk of physical injury inside
the danger area. Danger of death from falling loads!
Do not stand on the forks!
Standing or walking under the forks is strictly
forbidden, even when they are not loaded!

Danger area
The danger area is the area in which people
are in danger from the forklift truck move-
ments, from its work equipment and from its
load lifting devices (e.g. accessories) or from
the load. The danger area also includes ar-
eas in which a load could fall or in which work
equipment could lower or fall.

Traffic route conditions

The surface of traffic routes must be suf-
ficiently level, clean and clear of objects.
Drainage channels, railway crossings and
other similar obstacles must be levelled and, if
necessary, fitted with ramps so that the truck
can cross without jolting.
There must be sufficient distance between
the highest part of the truck or the load and

45588043482 EN - 04/2016 43
4 Use and Operation
Truck Transport and Lifting

the surrounding fixed installations. The

height depends on the lift height and the
dimensions of the load. Refer to the technical
characteristics.

Regulations regarding the traffic routes

and the manoeuvring areas
Only traffic routes authorised by the operator
or his agent may be used. Traffic routes
must be free of obstacles. Loads may only
be unloaded and stored in places designed
for this purpose. The operator or his agent
must ensure that no unauthorised person
approaches the working area.

Hazards
Hazards on the traffic routes must be signalled
by standard road signs or possibly by addi-
tional warning notices.

Truck Transport and Lifting

Transporting the truck
The forklift is normally transported by road
and rail. If the forklift’s dimensions exceed
the max. clearance size allowed, it is trans-
ported disassembled. The sales network is
in charge of the disassembly and reassembly
operations. The forklift must be secured to the
transport means during transport using appro-
OM0747
priate restraint systems. Block the wheels with
wedges to prevent even the slightest move-
ment.

Climatic Conditions for Transport and Storage

The forklift must be protected from atmo-
spheric agents during transport and storage.

44 45588043482 EN - 04/2016
Use and Operation 4
Breaking-In

Loading and unloading the truck

Use a lifting crane to load and unload the truck,
or use an inclined plane or a movable platform
with a slope and structural strength compatible
with the truck’s performance and weight (see
"Technical Data" chapter).

DANGER
Use a crane with a suitable lifting capacity for the
weight of the truck, indicated on its designation
plate. Also take into account the weight of the 1
mounted battery (if applicable), consulting the
relevant designation plate. The lifting operations
must be performed by qualified personnel. DO
NOT stand within the crane’s radius of action or
near the truck. Use NON METALLIC slings. Make
sure that the lifting capacity of the slings is suitable
for the weight of the truck.

To lift the truck:

• Manually raise the battery cover
• Insert the sling hooks (1) in the appropriate 2
points (2). The sling and hook must have an
adequate capacity for the load to be lifted.
• Connect the other end of the slings to the
hook of a crane.
DANGER OM1773

It is prohibited to use any other method for lifting

and transporting the truck.
Do not stand in the hazard area beneath suspended
loads

Breaking-In
This type of forklift does not require special
breaking-in operations.

45588043482 EN - 04/2016 45
4 Use and Operation
Checks and actions prior to commissioning

Checks and actions prior to commissioning

List of checks before use

WARNING • Check that NO stickers are missing or

damaged. Replace damaged or missing
Damage or other faults to the truck or attachments
(special equipment) can result in accidents. stickers in compliance with the marking
position table.
If damage or other faults are noticed on the truck
or attachments (special equipment) during the • Visually check that the forks or other
following checks, do not use the truck until it has load-carrying equipment show NO obvious
been properly repaired. Do not remove or disable damage (e.g. bends, cracks, significant
the safety systems and switches. Do not change
the pre-set values. wear).
• Check that the battery male connector and
female connector are fully intact and in good
CAUTION condition. Check that they are working
Only use the truck if all of the covers are fitted correctly.
correctly and the covers and doors are closed • Check that the start/stop key works cor-
correctly. rectly.
• Check that the horn works correctly.
CAUTION • Check that the buttons and the control
throttles on the tiller are working correctly.
Perform checks on a flat surface. Make sure that
there are no people or objects in the test area in • One at a time, push the buttons and then
front of and/or behind the truck. release them. Check that the buttons return
automatically to their initial positions. The
buttons must not remain activated or stuck.
CAUTION • Turn the drive control throttle and then re-
Drive very slowly during the operational tests. lease it. Check that the throttle automat-
ically returns to the initial position when it
Ensure that the vehicle is in good working is released. The throttle must not remain
condition prior to start-up. These checks activated or locked.
supplement and do not replace the scheduled • Test that the truck brakes and stops when
maintenance operations. the throttle is released during travel.
• Check that there are NO oil leaks in the area • Tilt the tiller, then release it. Check that the
under the truck. tiller automatically returns to the vertical
• Check that there are no objects (wires of position.
various types, nails, screws, pieces of tape • Test that the truck brakes and stops when
etc.) impeding the operation of the wheels the tiller is released during travel.
and rollers. The wheels and the load rollers • Check that the truck brakes and stops when
must roll freely. the tiller is pushed all the way down during
• The wheels must not show any sign of travel.
damage or heavy wear. They must be • Check that the emergency shutdown
correctly mounted. handle is operating correctly. Carry out
• Check that the battery hood is fully and the test when travelling towards the forks.
properly closed. • Check that the anti-crush/operator anti-
• Test that all of the hoods and protective crush protective device is operating cor-
guards are present and check that they are rectly.
correctly mounted. • Check that the brake is operating correctly.

46 45588043482 EN - 04/2016
Use and Operation 4
Use of the truck

• Test that the electromagnetic brake works • Check and test the battery electrolyte level
effectively. and density as indicated in the battery
• Check that the battery harness is in good instructions.
condition. • The operator must be qualified to drive the
truck. The operator must be able to reach
the controls and operate them (especially
the anti-crush protective device). Do not
obstruct access to the controls.

Use of the truck

Stopping the truck in an emergency
In case of emergency, take hold of the battery
plug (1) and, pulling upwards, remove it from
the battery socket. 1
This blocks all of the forklift functions; the
forklift will brake and stop.

OM1774

45588043482 EN - 04/2016 47
4 Use and Operation
Use of the truck

Operator position
The driving position is on the "Ground", and
the operator should drive the truck using the
driving and lifting controls located on the tiller
head.
DANGER
All other positions should be considered incorrect
and dangerous.

– Recommended position for pick-up and

deposit of the load.

OM2278

– Recommended position during travel

(preferred direction of travel).

48 45588043482 EN - 04/2016
Use and Operation 4
Use of the truck

Starting the truck

Carry out all of the daily checks to be per-
formed by the operator.
Pull the emergency shutdown handle.
Put the tiller in the vertical position.
To start the truck, turn the switch key to the
position I. If the truck has a numeric keypad
rather than a key, insert the appropriate PIN
code.
Check the battery charge status on the
indicator and replace or charge the battery
if necessary.

Truck operation
• Grip the tiller head correctly
• Tilt the tiller in the working position (1). B
• Select the desired direction of travel (A) or
(B) use the throttle (3); the forklift speed is 3 A
proportional to the angular position of the
throttle(3).

CAUTION
If there are difficulties starting the truck, do not
persist but look for the cause.
1

OM1776

45588043482 EN - 04/2016 49
4 Use and Operation
Use of the truck

Truck steering direction

A A
C E
G H

D F
B B
OM2314

Use the tiller to steer during travel.

• When the tiller is turned anti-clockwise (G)
while travelling towards (A), the truck steers
towards (C)
• When the tiller is turned anti-clockwise (G)
while travelling towards (B), the truck steers
towards (D)
• When the tiller is turned clockwise (H) while
travelling towards (A), the truck steers
towards (E)
• When the tiller is turned clockwise (H) while
travelling towards (B), the truck steers
towards (F)

50 45588043482 EN - 04/2016
Use and Operation 4
Use of the truck

Using the forklift with the "tiller

always active" function (optional)
The "tiller always active" function can be
enabled when operating the truck in confined
spaces.
5 5
This function allows the forklift to be operated
with the tiller in any position.
To activate the forklift’s slow speed, keep the
key (6) pressed while turning the throttle (5) in
the desired direction.
To activate lifting in any tiller position, keep 6
the key (6) pressed and press the fork lifting
pushbutton.
OM1777
Release the key (6) to disable this function.

45588043482 EN - 04/2016 51
4 Use and Operation
Use of the truck

Reverse drive
Reverse of direction without load on forks Reverse of direction with load on forks
• To reverse direction when travelling without • To reverse direction with a load on the fork
a load on the fork arms, turn the traction arms, release the traction control throttle
control throttle in the opposite direction of and wait for the truck to come to a stop.
travel. The truck will stop with energetic but • Reverse direction using the traction control
gradual braking and will start to move again throttle.
in the opposite direction.
DANGER
Brake by releasing the traction control throttle,
adapting deceleration to the type of load you are
carrying to avoid losing the load itself.

52 45588043482 EN - 04/2016
Use and Operation 4
Use of the truck

Truck brake systems

WARNING CAUTION
The condition of the floor surface considerably Regulate the throttle by adapting truck braking to
affects the braking distance of the truck. the type of load you are carrying in order to avoid
The operator must consider this factor while driving. losing the load.

While driving, the truck can be braked in the Service braking

following three ways:
CAUTION
• Releasing the drive control throttle
• Reversing the drive control throttle (see In hazardous situations, always brake using the
service brake.
also paragraph ⇒ Chapter "Reverse
drive", P. 4-52)
• During travel, push the tiller to the upper
• With the tiller service brake
end position. The truck will decelerate very
Braking by releasing the drive control throttle quickly.
• During travel, release the drive control • During travel, push the tiller to the lower
throttle. The truck will decelerate gently end position. The truck will decelerate very
to a stop. quickly.

Braking by reversing the drive control throttle WARNING

• During travel, turn the drive control throttle To activate the service brakes, always push the
in the opposite direction to the direction of tiller as far as it will go.
movement. The truck will decelerate more
forcefully but will come to a gradual stop. Parking brake
When the truck has stopped, release the
drive control throttle. – When the truck is stationary and the tiller is
in the vertical rest position, the electromag-
CAUTION netic brake functions as the parking brake.
Do not brake by reversing the drive control throttle
when travelling with a load on the forks.

Parking and stopping the truck

• Park in pre-arranged and designated areas
• Lower the fork arms to the ground.
• Release the tiller to activate the parking
brake
• Switch off the truck: turn the key to position
"0" and remove the key from the panel, or
alternatively switch off the truck by means of
the numeric keypad (Digicode) if available

45588043482 EN - 04/2016 53
4 Use and Operation
Use of the truck

DANGER
Park the truck in such a way that it does not ob-
struct passageways and/or render unusable emer-
gency equipment (e.g. fire extinguishers and fire
hydrants).

DANGER
Parking on ramps is strictly prohibited! Park on flat
surfaces only.

54 45588043482 EN - 04/2016
Use and Operation 4
Use of the truck

Forklift Use in Cold-Storage Rooms.

A truck specifically equipped for cold-storage CAUTION
rooms must be used when working at temper-
If the truck has been working in environments at
atures below +5°C. temperatures below -5°C and it is taken outside the
cold-storage room, let it stand either for a sufficien-
Forklifts equipped for working in cold climates tly long time to allow evaporation of any condensa-
and cold-storage rooms may be used at a tion (at least 30 minutes) or a sufficiently short time
minimum temperature of -5°C for continuous to prevent the formation of any condensation (less
service in cold-storage rooms and at -32°C than 10 minutes).
for non-continuous service in cold-storage Avoid the formation of ice on the forklift.
rooms.
CAUTION CAUTION
The forklift must always be turned off and parked NEVER drive the truck into the cold-storage room
outside the cold area/cold-storage room. when condensation has formed on it

45588043482 EN - 04/2016 55
4 Use and Operation
Load Placement

Load Placement
Safety guidelines for handling loads

DANGER
Wear protective footwear. Always keep a suitable
distance between your feet and the truck.
Risk of crushing feet when manoeuvring the truck.

CAUTION
The transport of persons or passengers is strictly
prohibited.

DANGER
Before picking up the load, make sure that its di-
mensions and weight fall within the truck specifi-
cations, as indicated in the "TECHNICAL DATA"
chapter.

DANGER
The loads must be arranged so that they cannot
slip or overturn and fall to the ground. In order to
guarantee load stability, make sure that the load is
balanced and centred on the forks.

CAUTION
Make sure that nobody is standing in the truck’s
area of operation.

NOTE
Further information on the general rules of
truck use and taking up and depositing loads
is provided in the "Safety Regulations for
Industrial Forklift Use" manual attached to
this manual.

56 45588043482 EN - 04/2016
Use and Operation 4
Load Placement

Taking up load
– Approach the load with caution and with as inserted far enough in that the load is resting
much precision as possible. against the fork carriage. The load centre of
gravity must be centred between the forks.
– Lower the fork arms so that they can easily
be inserted into the pallet. DANGER
– Slowly insert the forks at the centre of the Pay attention to the part of the forks protruding from
load to be lifted. the load to be lifted.
Do not strike the wall, the shelving or other loads
CAUTION and/or objects behind the load to be picked up.
Insert the fork without bumping into either the
shelving or the load. – Lift the load a few centimetres from the
ground and read the "Transporting loads"
– Insert the forks as far as possible below section.
the load. If possible, the forks should be

45588043482 EN - 04/2016 57
4 Use and Operation
Load Placement

Transporting loads
As a general rule, loads must be transported
one by one (e.g. pallets). Transporting several
loads at once is only authorised:
• If the safety requirements are met
• On the orders of the supervisor in charge
The operator must ensure that the load is
properly packaged. The operator can only
move loads that have been properly packaged
and are safe and secure.
WARNING
Always drive forwards for optimum visibility.
– Only travel in the direction of the forks when
depositing a load, as visibility in this direction is 0252_003-103

restricted.
If the load height or dimensions are likely to obstruct
the operator’s view, a second person on foot must
assist with manoeuvres in order to warn the driver
of any obstacles. In this case, driving is only autho-
rised at walking speed and with the greatest care.
Stop the truck immediately if you lose contact with
the person accompanying you.

DANGER
Lower or raise the load until there is sufficient
ground clearance.
Do not allow the load, the pallets or the container to
trail along the floor.

DANGER 0252_003-104

When travelling and transporting the load, be aware

of the side clearance of the load, particularly when
cornering.
Avoid hitting shelving and objects in your path.

DANGER
Danger of load tipping over
Avoid sudden starts and stops.
Approach corners slowly and carefully.

58 45588043482 EN - 04/2016
Use and Operation 4
Load Placement

Deposit the load.

• Approach the load deposit area.
• Lower the fork arms until the load is de-
posited in the desired area and release the
fork arms from the load.
• Back up with the forklift.

DANGER
Never leave the forklift with the forks raised whether
loaded or not.

NOTE
Further information on the general rules of
forklift use is provided in the Rules for the Use
of Industrial Vehicles Manual enclosed with
this manual.

45588043482 EN - 04/2016 59
4 Use and Operation
Load Placement

Using the truck on inclines, loading bridges and lifts.

Driving on inclines Using the truck on a lift
When driving the truck up or down inclines, Using the truck on lifts is only allowed if the
you must not exceed the values for inclines lift has sufficient load capacity (check the
indicated in the chapter "Technical data". maximum weight of the truck including the
traction battery) and only with appropriate
The operator must check that the ground is
authorisation.
clear with a good grip.
Slowly drive the truck onto the lift load-first.
WARNING
Secure the truck in the lift so that no part
When driving up or down inclines, the speed of comes into contact with the walls of the lift.
travel must be reduced.
A minimum distance of 100 mm from the walls
of the lift must always be observed.
DANGER WARNING
Risk of tipping!
The truck must be correctly immobilised so that it
When driving up or down inclines, do not turn, cannot move inadvertently.
reverse and/or travel diagonally.

CAUTION
WARNING
Personnel accompanying the truck onto the lift may
When driving on an incline with a load, you must only enter the lift once the truck is secure and must
keep the load facing upwards. exit the lift first after transit.

DANGER Using the truck on loading bridges

Risk of accident DANGER
Keep the truck at a safe distance from the edges of
Risk of accident
ramps, tailboards etc.
Before driving on to a loading bridge, the operator
must check that it has been properly fitted and
CAUTION secured and has sufficient load capacity.
You must drive onto the loading bridge slowly and
In certain cases, it is permitted to drive with the carefully.
forks pointing towards the top of the incline even if
the truck is not loaded. The operator must check that the vehicle to be
loaded or unloaded is sufficiently secure so that it
In these cases, drive with the utmost care and avoid will not move and that it is suitable to support the
turning until all the wheels are on a flat surface. strain of the truck.
The lorry driver and the forklift truck operator must
agree on the time of departure of the lorry.
DANGER
Risk of accident
Do not park on an incline: if, in the event of an
emergency, you have to do so, apply the parking
brake and block the wheels with chocks.

Towing trailers
The forklift is not qualified to tow trailers.

60 45588043482 EN - 04/2016
Use and Operation 4
Battery

Battery
Battery Recharging

CAUTION • Turn on the external battery charger.

The battery is recharged with the forklift off. • Connect plug the battery charger in to begin
charging.
• After the battery charging operation is
DANGER completed, turn off the battery charger.
The battery must be charged in rooms that comply • Unplug the battery charger.
with the specific regulations on the subject. Refer • Replace the battery caps (if removed
to the battery and battery charger manual for the
charging procedures, level checks etc., checking
previously).
the type of battery (gel, lead etc.) and the voltage • Plug the battery in again.
and current delivered. Excessive currents can • Lower the battery compartment cover.
damage batteries and cause dangerous situations.
As far as the safety precautions are concerned,
follow the instructions given in the battery manual NOTE
and those included in "Safety regulations "of this
manual. Refer to the battery charger manual for more
information.
• Access the upper part of the battery as
described in the "Internal accessibility"
paragraph.
• Remove the battery caps (if indicated in the
battery maintenance booklet).

45588043482 EN - 04/2016 61
4 Use and Operation
Battery

Recharging the battery, specific for

batteries with electrolyte recircula- B C A
tion system

CAUTION
The battery is recharged with the forklift off.

DANGER
The battery must be charged in rooms that comply
with the specific regulations on the subject. Refer
to the battery and battery charger manuals to
see the charging procedures, level checks etc,
checking the type of battery (gel, lead etc) and
making sure of the voltage and current delivered.
Excessive currents can damage batteries and
cause dangerous situations. As far as the safety
precautions are concerned, follow the instructions
given in the battery manual and those included in
"Safety regulations "of this manual.

Access the upper part of the battery as de- 2252

scribed in the "Internal accessibility" para-

graph.
Remove the battery caps (if indicated in the
battery maintenance booklet).

CAUTION
The battery socket (A) is not suitable for the plug of
the external battery charger for batteries electrolyte
recirculation.
Do not connect the battery socket (A ) to the battery
charger to begin charging.

Disconnect the plug (C) from the socket (B).

Connect the socket (B) to the battery charger
to begin charging.
Turn on the external battery charger.
After the battery charging operation is com-
pleted, turn off the battery charger.
Unplug the socket (B) from the battery
charger.
Replace the battery caps (if removed previ-
ously).
Plug the battery (C) into the socket (B) again.
Lower the battery compartment cover.

62 45588043482 EN - 04/2016
Use and Operation 4
Battery

NOTE
Refer to the battery charger manual for more
information.

45588043482 EN - 04/2016 63
4 Use and Operation
Battery

Recharging the battery using the

on-board battery charger (optional)

CAUTION
Charge the battery with the truck turned off and the
start key removed.

DANGER
The battery must be charged in rooms that comply
with the specific regulations on the subject. Refer
to the battery manual and the manual of the battery
charger used for charging procedures, level checks
etc. and check the voltage delivered. As far as
the safety precautions are concerned, follow the
instructions given in the battery manual and those
included in "Safety regulations "of this manual.

DANGER
If the truck is fitted with an on-board battery charger,
it is strictly prohibited to connect the battery to an
external battery charger.

DANGER
The electrical system must comply with the current
national regulations.

64 45588043482 EN - 04/2016
Use and Operation 4
Battery

Instructions for recharging - (excluding

1400 kg version) 3
Follow the instructions below:
• Lift the battery cover (1)
• Take the plug (2) of the on-board battery 4 2
charger and connect it to the socket.
• The green LED (3) begins to flash
• When charging is completed, the green
LED (3) remains lit.
• Replace the plug in its housing.
• Close the battery compartment cover.

WARNING
The red LED (4) indicates that the battery has been
left to charge for too long.
Do not leave the battery to charge for longer than
24 hours.

1 1843

Instructions for recharging (specific to

1400-kg version with GEL batteries) A
Follow the instructions below:
• Lift the battery compartment cover (A)
• Take the plug (B) of the on-board battery
charger and connect it to the socket.
• The yellow LED (C) lights up and begins to
flash.
• When charging is completed, the LED (C)
B
becomes green and flashes slowly.
• Replace the plug in its housing.
C
• Close the battery compartment cover.

WARNING
If there is an alarm or a problem, the LED (C) turns
red.
Contact the technical service department authori-
sed by the manufacturer.

2251

45588043482 EN - 04/2016 65
4 Use and Operation
Battery

Instructions for recharging (specific

to 1400-kg version with "FULL LEAD" C
batteries)
Follow the instructions below:
• Lift the battery compartment cover (A)
• Take the plug (B) of the on-board battery
charger and connect it to the socket.
A
• The yellow LED (C) lights up and begins to
flash. B
• When charging is completed, the LED (C)
turns green.
• Replace the plug in its housing.
• Close the battery compartment cover.

WARNING
If there is an alarm or a problem, the LED (C) turns
red.
Contact the technical service department authori-
sed by the manufacturer.
2324

Battery electrolyte level indicator

LED (optional)
1
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the battery plug.
The LED indicates whether it is necessary to 2
top up the distilled water in the battery.
Operation:
• If the LED (1) or (2) is green, there is a
sufficient level of electrolyte in the battery.
The battery must not be topped up with
distilled water.
• If the LED (1) or (2) is red, there is an
insufficient level of electrolyte in the battery.
The battery must be topped up with distilled
water.

2256

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Use and Operation 4
Battery

Battery type
Trucks can be fitted with different types of
battery. Observe the instructions on your
battery type plate, as well as the specifications
defined in the chapter "Technical data".

WARNING
The weight and size of the battery influence the
stability of the truck.
The new battery must weigh the same as the old
one. Do not change its position from the original
one.

CAUTION
Be careful not to damage any wiring when replacing
the battery.

Preparation
Maintenance personnel
The battery may only be changed by spe-
cially trained personnel, in accordance with
the manufacturer’s instructions for the battery,
the battery charger and the truck. The main-
tenance instructions for the battery must be
observed.

Fire prevention measures

WARNING
Do not smoke or use a naked flame
when handling batteries. In the
area designated for parking the
truck to recharge the battery or
battery charger, there should be no
flammable materials or substances
that can cause sparks within a radius
of at least 2 metres. The charging
area must be well ventilated. Keep a
fire extinguisher at hand.

Safe parking
Park the truck securely before carrying out
work on the battery. The truck can only be
operated when the battery cover is closed

45588043482 EN - 04/2016 67
4 Use and Operation
Battery

and the battery outlet is inserted. If the truck

is enabled for side removal of the battery, the
truck can only be operated once the battery
is fixed in place properly using the battery
locking system.

68 45588043482 EN - 04/2016
Use and Operation 4
Battery

Batteries

Standard batteries

Bat-
Voltage tery
Trog Battery type Dimensions (mm) Truck
(V) weight
(kg)
ECU
/ 12 V 12XFC58 280x97x264 12 14 Full
Lead
ECU
/ 12 V -------- 221x138x228 18.2
14 Gel
ECU
73 24 V 2 PzS-B 110 655x147x627 123
16
ECU
73 24 V 2 PzS-B 150 655x147x627 152
16
ECU
73 24 V 2 PzS-B 110 655x147x627 123
18
ECU
73 24 V 2 PzS-B 150 655x147x627 152
18
ECU
112 24 V 2 PzV 200 624x212x627 212
20
2 PzV 220
ECU
112 24 V HAWKER 624x212x627 212
20
Evolution
ECU
112 24 V 2 PzS 230 624x212x627 212
20
ECU
112 24 V 2 PzS 250 624x212x627 212
20
ECU
112 24 V 2 CSM 250 624x212x627 212
20

Optional batteries
Battery
Voltage
Trog Battery type Dimensions (mm) weight Truck
(V)
(kg)
112 24 V 2 PzV 200 624x212x627 212 ECU 16
2 PzV 220
112 24 V HAWKER 624x212x627 212 ECU 16
Evolution
112 24 V 2 PzS 230 624x212x627 212 ECU 16
112 24 V 2 PzS 250 624x212x627 212 ECU 16
112 24 V 2 CSM 250 624x212x627 212 ECU 16
112 24 V 2 PzV 200 624x212x627 212 ECU 18

45588043482 EN - 04/2016 69
4 Use and Operation
Battery

2 PzV 220
112 24 V HAWKER 624x212x627 212 ECU 18
Evolution
112 24 V 2 PzS 230 624x212x627 212 ECU 18
112 24 V 2 PzS 250 624x212x627 212 ECU 18
112 24 V 2 CSM 250 624x212x627 212 ECU 18

CAUTION
Using NON-ORIGINAL batteries can cause safety
risks (see purchase references in the parts catalo-
gue).

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 5

Servicing
5 Servicing
General Information

General Information
To keep your forklift in good condition, carry
NOTE
out the servicing indicated regularly, within the
times indicated and using the consumption Contact the authorised service network for
materials provided for that purpose, as speci- a maintenance contract appropriate to your
fied on the following pages. Please make sure forklift.
that you keep a record of work done; this is the
only way for the guarantee to remain valid. CAUTION
Maintenance intervals are defined for standard use.
Maintenance is divided into: In the following cases, it is necessary to reduce the
• scheduled (to be done by the service interval between the various scheduled mainten-
network authorised by the manufacturer) ance operations: in the event of use in dusty of salty
environments, extremely high or low ambient tem-
• as required (done by the user) peratures, high levels of air humidity, particularly
intense and heavy uses, specific national regulati-
DANGER ons for trucks or individual components.
Scheduled maintenance and repairs must be
done by the service network authorised by the
manufacturer in order to maintain the machine
in perfect condition and compliant with technical
specifications.

Preliminary maintenance operations

Do the following before performing mainte- DANGER
nance operations:
Disconnect the power terminal from the battery be-
• Position the forklift on a flat surface and fore performing any work on the electrical system.
ensure that it cannot move accidentally.
• Lower the forks fully.
• Turn off the truck.

72 45588043482 EN - 04/2016
Servicing 5
Scheduled Maintenance

Scheduled Maintenance
Synoptic Table of Maintenance Operations

Com-
Operations Intervals in hours
pleted
1000 2000 3000
(a) (b) (c) v

Checks and tests before use (see ⇒ Chapter "List of checks

before use", P. 4-46)
Check wheel tightness
Grease the reducer fifth wheel
Check the condition of the piping
Check hydraulic system oil level
Check reducer oil level
Check bushes and levers
Check pivot wheels
Check the condition of battery and truck wiring
Check insulation between chassis and any electric motors
Check insulation between chassis and electronic control
Grease micro tiller (1)
Check air gap, carry out any adjustment or disc replacement
Grease the rods and levers
Change hydraulic system oil

(1)
= to be carried out every 1000 hours or
6 months, whichever comes first.
1000 (a) = To be repeated every 1000 hours.
For example at 1000, 2000, 3000, 4000, 5000.
..
2000 (b) = To be repeated every 2000 hours.
For example at 2000, 4000, 6000, 8000,
10,000. . .
3000 (c) = To be repeated every 3000 hours.
For example at 3000, 6000 and 9000. . .

ENVIRONMENT NOTE
During maintenance operations, follow the
instructions provided in the section "Safety

45588043482 EN - 04/2016 73
5 Servicing
Scheduled Maintenance

regulations relative to operating materials" in

"Chapter 2".

74 45588043482 EN - 04/2016
Servicing 5
Maintenance as required

Maintenance as required
Cleaning the Forklift
Cleaning depends on the type of use and the Use water-dampened rags to clean the parts
workplace. Should the truck come into contact of the body.
with highly aggressive elements such as salt
water, fertilizers, chemical products, cement, CAUTION
etc., it should be cleaned as carefully as Do not clean the truck with direct jets of water; DO
possible after every work cycle. It is preferable NOT use solvents and petrols that could damage
to use cold compressed air and detergents. parts of the truck.

Battery rplacement
Instructions for ECU 14 version
CAUTION
Before replacing the battery, contact the authorised
sales network.

45588043482 EN - 04/2016 75
5 Servicing
Maintenance as required

Instructions for ECU 16–18–20 version

• Turn off the truck and perform the prelimi-
nary maintenance operations.
• Raise the battery compartment hood (1).
• Disconnect the plug (2) from the outlet (3).
• Insert the sling hooks in the two battery
points (4). The entire sling must be suitably
sized for the weight of the battery.
• Lift the battery using a hoist suitably sized
for the weight of the battery.
• Change the battery and refit it by following
the above steps in the reverse order.

CAUTION
To decide which type of battery to use, check the 1
battery characteristics provided in the "TECHNI-
CAL DATA" chapter. 3

DANGER 2
Use a crane with a suitable lifting capacity for
the weight of the battery. Lifting operations must
be performed by qualified personnel. DO NOT
stand within the crane’s radius of action or near
the truck. Do not stand in the danger area beneath
suspended loads. Use NON-METALLIC slings.
Make sure that the lifting capacity of the slings is
suitable for the weight of the battery. The rope
slings must be pulled vertically. To prevent short
circuits, it is recommended that batteries with polar
terminals or unprotected connections be covered
with a rubber mat. 4 OM1778

76 45588043482 EN - 04/2016
Servicing 5
Maintenance as required

Fuse replacement
1 2
• Turn off the truck and perform the prelimi-
nary maintenance operations.

CAUTION
Before carrying out any operations on the electrical
system, turn off the truck power supply by discon-
necting the battery connector.

CAUTION
Before replacing the fuse, eliminate the cause that 4
led to its blowing. The blown fuse must only be
replaced with a fuse of the same amperage. Do not
tamper with the truck’s electrical system.

• Access the fuses as indicated in the "Inter-

nal Accessibility" section.
3 OM1779
Service fuses (1) and (2)
• Remove the cover and replace the blown
fuse, then replace the cover.
Power fuses (3) and (4)
• Loosen the screws, replace the fuses and
retighten the screws.
Fuse values
• (1) Fuse = 5A
• (2) Fuse = 5A
• (3) Lifting motor protection fuse = 80A
• (4) Traction motor protection fuse = 100A

45588043482 EN - 04/2016 77
5 Servicing
Putting out of commission

Putting out of commission

General Information
The operations to be performed for "Tem-
porary decommissioning" and "Permanent
decommissioning" are listed in this chapter.

78 45588043482 EN - 04/2016
Servicing 5
Putting out of commission

Forklift Towing
The forklift may not be towed in the case of
breakdown.
The forklift must be lifted with due caution, as
described on the preceding pages.

Temporary Putting Out of Commission

The following operations must be performed • Perform the lubrication operations indicated
when the forklift is not going to be used for a in the maintenance chapter.
long time: • Remove the battery and put it in a room
• Clean the forklift as indicated in the "Mainte- where there is no danger of freezing.
nance" chapter and put it in a dust-free and Charge the battery at least once a month.
dry room. - • Raise the forklift so that the wheels do not
• Lower the forks. touch the ground; otherwise, the wheels will
become flat at the point of contact with the
• Lightly grease all of the unpainted parts with
floor.
oil or grease.
• Cover the forklift with a NON-plastic sheet.

Checks and Inspections After a Long Period of Inactivity

DANGER • Carry out the fluid level checks.

Perform the following operations before using the • Perform all of the functional maneuvers of
forklift: the forklift and of its safety devices both
loaded and unloaded.
• Clean forklift truck thoroughly. DANGER
• Check the battery charge level and re-
Follow the instructions provided in the maintenance
assemble it in the forklift, making sure to
chapter for the operations indicated previously.
spread Vaseline on the terminals.
• Lubricate all of the parts provided with
lubricating nipples and the chains.

Permanent Putting Out of Commission (Demolition)

The forklift must be demolished in compliance components and rubber components must
with local legislation. Contact the authorised be disposed of in compliance with specific
service network or authorised companies to local legislation for each type of material.
scrap the forklift according to local legislation.
DANGER
ENVIRONMENT NOTE Disassembly of the forklift for scrapping is extre-
mely hazardous.
In particular, batteries, fluids (oils, fuels,
lubricants, etc, electrical and electronic

45588043482 EN - 04/2016 79
5 Servicing
Resolution of Operating Defects

Resolution of Operating
Defects
The operating defects which can occur during
forklift use are indicated in this section, with
relative causes and solutions. If the defects
should persist even after having carried
out all of the checks indicated, contact the
manufacturer’s authorised service network.

Defect: THE TRUCK DOES NOT START

POSSIBLE CAUSES SOLUTIONS
Battery outlet not connected or connected Check the battery outlet and, if necessary,
incorrectly. connect it correctly.
Check the battery charge level and, if neces-
Low battery charge.
sary, charge it.
The key ignition switch is set to position "0"
Turn the switch to "I" (forklift on).
(forklift off).

Defect: THE TRUCK IS TURNED ON, BUT DOES NOT MOVE

POSSIBLE CAUSES SOLUTIONS
Turn the drive control throttle in the desired
The drive control throttle is not turned.
direction of travel.
Incorrect command sequence when switching
Repeat the sequence of commands correctly.
on the truck.
Tiller in rest position Position the tiller in the working position
The slow speed button has not been pressed
Press the slow speed button (optional)
(tiller always active version only)

Defect: THE FORKLIFT IS NOT ABLE TO LIFT THE LOAD

POSSIBLE CAUSES SOLUTIONS
Make sure the weight of the load to be lifted
Load too heavy! does not exceed the forklift’s maximum capac-
ity.
Perform all of the checks indicated for “the
The forklift is not ready for service.
forklift does not start or move".
Check the battery charge level and, if neces-
Low battery charge.
sary, charge it.
Use the correct sequence: tiller in working
Incorrect lifting starting sequence
position, lifting button pressed
.

80 45588043482 EN - 04/2016
 6

Technical data
6 Technical data
Technical data

Technical data

OM1781

Characteristics
ECU ECU
ECU
1.2Model 14 Full 14 ECU 16 ECU 18
20
Lead GEL
Power
1.3 Electric
unit type
Drive
1.4 Tiller
type

82 45588043482 EN - 04/2016
Technical data 6
Technical data

Load
Q
1.5capacity 1.4 1.4 1.6 1.8 2
(t)
/ Load
Centre of c
1.6 (mm) 600
gravity
Load
distance
from load x
1.8wheel (mm) 914
axle with
forks
raised
Distance
between
axles y
1.9 (mm) 1210 1275 1275 1342 1275 1342 1342
with
forks
raised
Weights
Tare
weight
2.1(includ- kg 306 289 401 465 401 465 465
ing bat-
tery)
Load
per axle
596 / 568 / 825 /
when 705 / 732 / 754 /
2.2loaded kg 1124 1121 778 / 1487(3) 1640
(8) (1) 1296(2) 1334(3) 1447(2) (3)
(front /
rear)
Load
per axle
when 242 / 224 / 312 / 358 /
2.3 empty kg 358 / 107(3) 312 / 89(2) 358 / 107(3)
64 (8) 65 (1) 89(2) 107 (3)
(front /
rear)
Wheels, Chassis
3.1Tyres Polyurethane
Front
wheel
3.2 mm ø 230 x 75 / ø 100 x 40
dimen-
sions
Rear
wheel
3.3 mm ø 85 x100
dimen-
sions

45588043482 EN - 04/2016 83
6 Technical data
Technical data

Wheels:
front
/ rear
3.5 1x - 2 / 2
number
(x=drive
wheel)
Front
b10
3.6track 458
(mm)
width
Rear
b11
3.7track 350 / 390 / 510
(mm)
width
Dimensions
h3
4.4Lift 123
(mm)
Tiller
height in
operat- h14
4.9ing posi- 840 / 1240
(mm)
tion (min
/ max)
Lowered
h13
fork arms
4.15 85
(mm)
height
Total I1
4.19
length (mm) 1595 1660 1660 1727 1660 1727 1727
Length
including
I2
4.20
shoulder 445 510 510 577 510 577 577
(mm)
of fork
arms
Total b1
4.21 720
width (mm)
Fork arm
s/e/l
4.22
dimen- 52 / 170 / 1150(4)
(mm)
sions
External
b5
fork arm
4.25 520 / 560 / 680
(mm)
gauge
Clear-
ance m2
4.32
at mid (mm) 36
wheel-
base

84 45588043482 EN - 04/2016
Technical data 6
Technical data

Working
aisle with
pallet
1000 x
Ast3 1707
1200 fork
4.33 1771(5) 1771(5) 1838(5) 1771(5) 1838(5) 1838(5)
(mm) (5)
insertion
1200
(forks l =
1000 mm)
Working
aisle with
pallet
Ast3 1907
800x1200
4.34 1971(5) 1971(5) 2038(5) 1971(5) 2038(5) 2038(5)
(mm) (5)
fork
insertion
800
Radii of
Wa 1420
4.35
curva- 1485(5) 1485(5) 1552(5) 1485(5) 1552(5) 1552(5)
(mm) (5)
ture
Performance
Travel
5.1speed km/h 5/5 6 / 6
(loaded/empty)
Lifting
5.2speed m/s 0.039 / 0.047
(loaded/empty)
Lowering
5.3speed m/s 0.072 / 0.028 0.087 / 0.037 0.044 / 0.044
(loaded/empty)
Sur-
mount-
3.8(6)
able
5.7 % 5.9(6) / 25 (6) (7) 4.7(6) / 25 (6) (7) 4.2(6) / 25 (6) (7) / 25 (6)
gradient (7)
KB 30I
(loaded/empty)
Max.
sur-
mount- 6.6(6)
5.8able % 10(6) / 25 (6) (7) 8 (6)
/ 25 (6) (7)
7.3 (6)
/ 25 (6) (7)
/ 25 (6)
(7)
gradient
with/with-
out load
Service
5.10 Electric
brake
Electric motor

45588043482 EN - 04/2016 85
6 Technical data
Technical data

Traction
motor,
6.1perfor- kW 1
mance
KB 60I
Lifting
motor,
6.2perfor- kW 1
mance
15% ED
Type of
battery
accord-
DIN
ing to DIN 43535
6.3 / / no no DIN 43535 B 43535
DIN B
B
43531/35/36,
A, B, C,
no
Battery
voltage V/ 2x 2 x 12 24/110 24/110
6.4 24/250 24/250 24/250
/ rated Ah 12/58 / 44 24/150 24/150
capacity
Battery
123 123
6.5weight kg 36 36.4 212 212 212
152 152
(+/- 5%)
Other
Control
8.1 Electronic
type
Oper-
ating dB
8.4noise in <70
(A)
driver’s
ear

(1) With battery 12 V / 44 Ah

(2) With 24 V / 150 Ah battery
(3) With 24 V / 250 Ah battery
4) For other lengths, see the table below
(5) The values refer to the tiller always active
position rotated 90°
6) The values in the table are for fork arms with
length l = 1150mm.
(7) Geometric limit
(8) With 12 V/58 Ah batteries

86 45588043482 EN - 04/2016
Technical data 6
Technical data

DIN battery 43535 B

Forks Battery with DIN elements
(standard)
l c x y l1 Wa y l1 Wa
980 500 744 1105 1490 1441 1172 1557 1508
1150 600 914 1275 1660 1611 1342 1727 1678
1200 600 964 1325 1710 1535 1392 1777 1602
1450 750 1214 1575 1960 1911 1642 2027 1978
1600 800 1364 1725 2110 2061 1792 2177 2128
dimensions expressed in millimetres

(d008)

45588043482 EN - 04/2016 87
6 Technical data
Supply Table

Supply Table
Supply table for standard trucks

Element to be supplied Lubricants

Hydraulic system HLF 32

Reduction gear unit Tutela MATRIX
General lubrication Tutela MP02
.

Supply table for cold-storage trucks

Element to be supplied Lubricants

Hydraulic system Tutela GI/M

Reduction gear unit Tutela MATRIX
General lubrication Tutela Jota
.

88 45588043482 EN - 04/2016
Index
g

B I
Battery Intended use of the trucks . . . . . . . . . . . . 42
Disposal . . . . . . . . . . . . . . . . . . . . . . 8
Type . . . . . . . . . . . . . . . . . . . . . . . . . 67
P
before use . . . . . . . . . . . . . . . . . . . . . . . 46 Packaging . . . . . . . . . . . . . . . . . . . . . . . 9
Preparation . . . . . . . . . . . . . . . . . . . . . . 67
C
Checks before use . . . . . . . . . . . . . . . . . 46
S
Copyright and trademark rights . . . . . . . . 4 Safety devices
Misuse . . . . . . . . . . . . . . . . . . . . . . . 20
D Safety guidelines for handling loads . . . . 56
Danger area . . . . . . . . . . . . . . . . . . . . . 43 Safety Inspection . . . . . . . . . . . . . . . . . . 17
Date of edition of this manual ......... 4 Serial number . . . . . . . . . . . . . . . . . . . . 36
Declaration of conformity . . . ......... 5
Disposal
T
Battery . . . . . . . . . . . . . . ......... 8 Technical description . . . . . . . . . . . . . . . 22
Components . . . . . . . . . . ......... 8 Braking system . . . . . . . . . . . . . . . . . 23
Driving Characteristics . . . . . . . . . . . . . . . . . 22
Safety instructions . . . . . . . . . . . . . . . 42 Guidance . . . . . . . . . . . . . . . . . . . . . 22
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E Transporting loads . . . . . . . . . . . . . . . . . 58
EC declaration of conformity in
accordance with Machinery U
Directive . . . . . . . . . . . . . . . . . . . 5 Update of this manual . . . . . . . . . . . . . . . 4

45588043482 EN - 04/2016 89
STILL GmbH

45588043482 EN – 04/2016