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4

Use and Operation

Truck Transport and Lifting

Truck Transport and Lifting

OM0747

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-

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.

36

45378043402 [EN]

Summary of Contents for ECU-SF-20

Page 1: ...Original instructions ECU SF 20 0170 45378043402 EN 10 2011 ...

Page 2: ......

Page 3: ... obligations 7 Environmental considerations 7 Disposal of units and batteries during repair work 7 Packaging 8 2 Safety Safety Regulations 10 General Precautions 10 General Safety Rules 10 Flooring requirements 10 Requirements for the traction battery charging area 11 Safety Regulations Relative to Forklift Use 11 Safety Regulations Relative to Operating Materials 11 Location of labels 13 Descript...

Page 4: ...lates 32 Frame labelling 33 Forklift Identification Plate 33 4 Use and Operation Truck Transport and Lifting 36 Transporting the truck 36 Climatic Conditions for Transport and Storage 36 Loading and unloading the truck 37 Breaking In 38 Checks and Inspections 38 Daily checks before use 38 Wheel Wear Check 39 Use of the Truck 39 Operator position 39 41 Reverse drive 43 Truck braking stopping 43 Stop...

Page 5: ...formation 54 Operations Preliminary to Maintenance 54 Scheduled Maintenance 54 Synoptic Table of Maintenance Operations 54 Maintenance as required 56 Cleaning the Forklift 56 Changing the battery 56 Fuse replacement 57 Decommissioning 58 General Information 58 Temporary Putting Out of Commission 58 Checks and Inspections After a Long Period of Inactivity 58 Permanent Putting Out of Commission Demo...

Page 6: ...fects 59 6 Technical data Overall dimensions 62 Technical data 63 Battery dimensions and weights 66 Noise 66 Vibrations 66 Annex 7 Diagrams Hydraulic diagrams 76 Hydraulic connection diagram 76 Circuit diagram 77 Electrical connection diagrams 77 IV 45378043402 EN ...

Page 7: ...1 Introduction ...

Page 8: ... industrial vehicles and on the labels and adhesive supplied to the forklift The forklift may not be put to any use other that than indicated in this manual The forklift must be used by appropriately trained operators only For the necessary operator training contact the authorised sales network Persons working near the forklift must also be instructed in the risks associated with use of the forkli...

Page 9: ...pliant use industrial vehicles EC Declaration of Compliance Spare parts catalogue CD If the forklift has been delivered with a traction battery and or battery charger ensure that such products conform to the order and that the relative user and maintenance manual are included as well as the EC declaration for the battery charger If applied equipment other equipment or devices are present ensure th...

Page 10: ... 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 4 45378043402 EN ...

Page 11: ...dard EN 13059 and declared in accordance with standard EN 12096 The limit values for the electromagnetic emissions and immunity relative to the forklift are those set out in the EN 12895 standard Type of use Normal use conditions of the forklift under stood as lifting and or transport of loads using forks with weight and centre of gravity within the values provided see Chapter 6 Technical Data tra...

Page 12: ...s extreme weather cold storage rooms presence of strong mag netic fields etc appropriate equipment and or use precautions are necessary Contact the authorised sales network for more informa tion DANGER The forklift may not be used in environments in which there is a risk of explosion It may not be used to handle explosive loads For forklifts that must operate in environments in which there is a ris...

Page 13: ...tion of Compliance is required for the forklift equipped in this manner In this regard it is necessary to con tact your authorized dealer User obligations Users must comply with applicable local legis lation governing forklift use and maintenance Environmental considerations Disposal of units and batteries during repair work It may be necessary to exchange units as part of maintenance work Exchang...

Page 14: ...ivery 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 8 45378043402 EN ...

Page 15: ...2 Safety ...

Page 16: ...d cables Comply with the safety distances established by the competent authorities Never raise the load using just one fork Place the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork carriage The load must be placed on the forks so that the centre of gravity falls on the mid point between the forks Do not drive with loads decentr...

Page 17: ...use and disposal of operating and cleaning materials can cause serious damage to the environment Always use and handle the operating materi als in a suitable manner and follow the manu facturer s instructions for the product s use Keep the operating materials only in contain ers intended for this purpose and in a location that satisfies the requirements The operating materials may be flammable so av...

Page 18: ...eaks using a piece of cardboard Battery Acid Do not inhale the vapor it is poisonous Use adequate means of individual protec tion to prevent contact with the skin Battery acid is corrosive if it should come into contact with your skin rinse abundantly with water Explosive gas mixtures can form when charging the battery therefore the rooms in which the battery is charged must be in compliance with ...

Page 19: ...n of labels 1 3 4 5 2 6 7 OM2160 1 Read the user and maintenance manual 2 Truck lifting point 3 Battery warning 4 Prohibition against carrying people 5 Cold store version optional 6 Danger of moving parts 7 Ignition key 45378043402 EN 13 ...

Page 20: ...uck 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 set up for cold store use optional 6 The symbol appears on the motor compart ment and indicates danger due to unprotected moving parts 7 This label indicates the positions of th...

Page 21: ... Protective casing fastened with screws 3 Operator safety side panels if fitted 4 Driver on the step plate sensors 5 Tiller position sensor 6 NOTE These devices must be checked daily as described in Chapter 4 Electromagnetic radiation The limit values for electromagnetic emissions and for immunity relative to the forklift are those provided by the EN 12895 standard 45378043402 EN 15 ...

Page 22: ...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 16 45378043402 EN ...

Page 23: ...complete check of the technical condition of the truck must be performed with regard to accident safety In addition the truck must be thoroughly 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 inspections have been carried out The inspection date is indicated by an adhe sive l...

Page 24: ...2 Safety Safety tests 18 45378043402 EN ...

Page 25: ...3 Knowledge of the Truck ...

Page 26: ...k General Truck View General Truck View 1 2 4 5 8 6 OM0388 3 7 1 Tiller head 2 Tiller 3 Control panel 4 Battery compartment cover plate 5 Forks 6 Removable casing 7 Side panels if fitted 8 Movable step plate 20 45378043402 EN ...

Page 27: ...efinition of direction of travel Definition of direction of travel B A OM0389 The direction of travel is defined in the following manner A Direction of travel towards forks B Direction of travel towards the driver 45378043402 EN 21 ...

Page 28: ...trols Instrumentation and Controls 1 1958 Start stop key Key 1 has two positions 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 I 22 45378043402 EN ...

Page 29: ...irection of the operator 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 3 Press button 3 to lower the forks when the button is released the forks will stop in the position attained Fork lifting button 4 Press button 4 to lift the forks when the button is released the f...

Page 30: ...on 1 working position In this position the driver can begin travel using the throttle In this position the driver can begin lifting or lowering the forks using the appropriate buttons Position 2 braking position In this position the drive is locked and the parking brake is engaged NOTE In this position lifting the forks is blocked NOTE When the tiller is released it automatically returns to positi...

Page 31: ...level it is subdivided into ten sectors with respective coloured LEDs When the battery is 100 charged LED 10 remains lit up As the battery discharges the LEDS light up one at a time from right to left starting from LED 10 which indicates that the battery is completely charged When 70 of the battery s power has been used up LED 2 blinks indicating that the battery is going flat and must be charged B...

Page 32: ...3 Knowledge of the Truck List of available options List of available options OM2164 2 1 3 26 45378043402 EN ...

Page 33: ...heel Cables for 2nd shift battery CAUTION Contact the technical service network authorised by the manufacturer for information on the assembly of the options NOTE Contact the authorised sales network for more information Operator side panels OM0170 1 1 A C 2 The side panels 1 are designed to keep driver securely on board and have two posi tions Position C side panels closed This position is used w...

Page 34: ...tically locked by the lock cylinder in order to prevent them from accidentally closing Closing the side panels To close the side panels 1 and pass from position A to position C proceed as follows Press the lock pin 2 until it reaches the stopper and at the same time gently push one of the side panels 1 turning it to position C NOTE Traction of the truck is enabled when side panels C are closed and...

Page 35: ...onstantly blocked in this position Position C step plate in working position with the operator on board This position is automatic when the operator steps onto the step plate 1 Truck traction is constantly enabled in this position and the speed of the truck varies in relation to the position of the side panels With the side panels closed the truck can reach its maximum speed With the side panels o...

Page 36: ...er 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 Battery compartment To access the battery 1 and respective plug outlet 2 raise the battery compart ment cover 3 30 45378043402 EN ...

Page 37: ... KIT the fans may move even when the key is in the OFF position Risk of cutting DANGER Protective covers must only be disassembled by specially trained personnel Turn off the truck and perform the prelimi nary maintenance operations Remove the head of the emergency stop button 1 by inserting a screwdriver in the hole 2 then while keeping the button s 45378043402 EN 31 ...

Page 38: ...rgency stop button 1 functions correctly Truck Identification Location of Data Plates OM2163 Tensione batteria Battery voltage Tension batterie batteriespannung kW V kg kg kg kg kg Portata nominale Rated capacity Capacit nominale Nenn Tragf higkeit Potenza trazione Rated drive power Puissance motr nom Nenn Anfriebsleist Massa a vuoto Unladen mass Masse vide Leergewicht Vedere istruzioni d uso see O...

Page 39: ...wicht Vedere istruzioni d uso see Operating instructions voir Mode d emploi siehe Betriebsanleitung kW V kg kg kg kg kg max min Tipo Type Mod le Tip Matricola Serial no No de s rie Serien Nr Anno year ann e Baujahr B D E F H G I A C The identification plate indicates the following data A Type of forklift B Serial number C Year of manufacture D Empty mass without traction battery E Min Max mass trac...

Page 40: ...3 Knowledge of the Truck Truck Identification 34 45378043402 EN ...

Page 41: ...4 Use and Operation ...

Page 42: ...t 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 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...

Page 43: ...truck 2 1 OM2162 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 specifications stated by the manufacturer which must be suitably positioned and anchored 45378043402 EN 37 ...

Page 44: ...l breaking in operations Checks and Inspections Daily checks before use The following checks must be performed on a daily basis in order to keep your truck in good condition and to operate safely These checks supplement and do not replace the scheduled maintenance operations Visually check that the various parts of the truck are in good condition and correctly positioned Check that the fork arms a...

Page 45: ...re in good condition DANGER DO NOT use the truck but call the manufacturer s authorised service network if you notice any mal functions or if you have any doubts about its correct operation OM1290 Wheel Wear Check The forklift s wheels and rollers should be replaced when there are signs of wear NOTE Contact the service network authorised by the manufacturer for replacement of the wheels and roller...

Page 46: ...or on the ground is disabled when the side panels 1 are closed in position C Driving position with the operator on board Fig S DANGER Risk of falling from the step plate Correctly position yourself on the step plate be tween the two side protection bars Travel round corners at low speed The operator should drive the truck standing on the step plate using the driving and lifting controls located on...

Page 47: ...2 will light up indicating the number of operating hours and battery status Check that the emergency stop button 3 is not pressed Drive Tilt the tiller 4 to the working position Turn the throttle 5 to the desired direction to start moving the truck and the speed will increase according to the angular position of the throttle CAUTION If there are difficulties starting the truck do not persist but lo...

Page 48: ...4 Use and Operation Use of the Truck NOTE During truck operation releasing the tiller will cause the truck to brake and slow down until it stops 42 45378043402 EN ...

Page 49: ...he fork arms release the traction control throttle and wait for the truck to come to a stop Reverse direction using the traction control throttle DANGER Brake by adapting deceleration to the type of load you are carrying so that you don t lose the load itself Truck braking stopping The truck can be braked by Releasing the tiller Reversing the direction of travel using the traction control throttle...

Page 50: ...e tiller to the rest position A Unblock the emergency stop button 1 position C by lifting it CAUTION This button must only be used in emergencies re peated use of this device may cause the electronic equipment to malfunction Leaving truck Follow the operations listed below in the order given when leaving the forklift Lower the fork arms to the ground Release the tiller to activate the parking brak...

Page 51: ...ot turn or travel diagonally Using the truck on an incline When driving on an incline without a load the forks must face the bottom of the incline WARNING When driving on an incline with a load you must keep the load pointing towards the top of the incline DANGER Risk of accident Keep the truck at a safe distance from the edges of ramps tailboards etc CAUTION In certain cases it is permitted to dr...

Page 52: ...es into contact with the walls of the lift WARNING The truck must be secured in place in such a way that it cannot be accidentally started CAUTION Personnel accompanying the truck onto the lift may only enter the lift once the truck is secure and must exit the lift first after transit Using the truck on loading bridges DANGER Risk of accident Before driving onto a loading bridge the driver must che...

Page 53: ...y long time to allow evaporation of any condensa tion at least 30 minutes or a sufficiently short time to prevent the formation of any condensation less than 10 minutes Avoid the formation of ice on the forklift CAUTION NEVER drive the truck into the cold storage room when condensation has formed on it Using the truck with extension leads DANGER The truck may only be used with extension leads fitted...

Page 54: ... a slope always climb and descend with the load uphill Never travel diagonally across the slope or make a U turn Reverse gear must only be used for deposit ing a load Since visibility in this direction is restricted you should only travel at very low speed To move past obstacles more easily increase the ground clearance by raising the fork arms Transporting pallets or other contain ers As a genera...

Page 55: ... 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 Towing trailers The forklift is not qualified to tow trailers 45378043402 EN 49 ...

Page 56: ...Use and Operation Forklift Towing 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 50 45378043402 EN ...

Page 57: ...recautions 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 described in the Internal accessibility paragraph Remove the battery caps if indicated in the battery maintenance booklet Turn on the external battery charger Connect plug the battery charger in to begin charging After the batt...

Page 58: ...4 Use and Operation Battery Recharging 52 45378043402 EN ...

Page 59: ...5 Maintenance ...

Page 60: ...work for a maintenance contract appropriate to your forklift CAUTION When the forklift is used in dusty environments at below zero temperatures and for especially heavy uses it is necessary to reduce the interval between the various scheduled maintenance operations Operations Preliminary to Maintenance Do the following before performing mainte nance operations Place the truck on a flat surface and ...

Page 61: ... between chassis and any electric motors Check insulation between chassis and electric electronic com ponents Greasing bearings tie rods and levers Change hydraulic system oil ENVIRONMENT NOTE During maintenance operations follow the instructions provided in the section Safety regulations relative to operating materials in Chapter 2 45378043402 EN 55 ...

Page 62: ...er DO NOT use solvents and petrols that could damage parts of the truck 1 5 5 4 3 2 OM1391 Changing the battery Turn off the truck and perform the prelimi nary maintenance operations Raise the battery compartment cover 1 Disconnect the plug 3 from the outlet 2 Remove the battery holddowns 4 Attach hooks to the battery at the two points 5 using a sling which is suitably sized for the weight of the ...

Page 63: ... tamper with the truck s electrical system Raise the battery cover as indicated in the relative section Fuse values Power Fuses Unscrew the nut change the fuse and tighten the nut again Fuse values 1F1 150 A traction motor safety fuse 2F1 80 A pump motor safety fuse Service fuses Remove the cover and replace the blown fuse then replace the cover Fuse values V2 8 A step plate sensor protection diod...

Page 64: ...ng Period of Inactivity DANGER Perform the following operations before using the forklift Clean forklift truck thoroughly Check the battery charge level and re assemble it in the forklift making sure to spread Vaseline on the terminals Lubricate all of the parts provided with lubricating nipples and the chains Carry out the fluid level checks Perform all of the functional maneuvers of the forklift ...

Page 65: ... 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 OR MOVE POSSIBLE CAUSES SOLUTIONS Battery socket not connected or connected incorrectly Check the battery socket and if necessary connect it correctly The emergency stop button is pressed Release the emergency stop button and...

Page 66: ...O LIFT THE LOAD POSSIBLE CAUSES SOLUTIONS Load too heavy Make sure the weight of the load to be lifted does not exceed the truck s maximum capacity The truck is not ready for service Perform all of the checks indicated for The truck does not start or move The hydraulic oil level is too low Restore the level as indicated in the Mainte nance chapter Low battery charge Check the battery charge level ...

Page 67: ...6 Technical data ...

Page 68: ...6 Technical data Overall dimensions Overall dimensions OM1355 62 45378043402 EN ...

Page 69: ...iller pedestrian standing 1 5 Load capacity Load Q t 2 1 6 Centre of gravity c mm 600 1 1 8 Load distance from load wheel axle with forks raised x mm 872 1 9 Wheelbase y mm 1304 Weights 2 1 Tare weight without battery kg 352 1 2 2 Load per axle when loaded front rear kg 1676 978 2 3 Load per axle when empty front rear kg 79 575 Wheels Chassis 3 1 Tyre Polyurethane 3 2 Front wheel dimensions mm 85 ...

Page 70: ...ad m2 mm 33 4 33 Working aisle with pallet 1000 x 1200 fork insertion 1200 step plate up down Ast3 mm 1925 3 4 2604 3 5 4 34 Working aisle with pallet 800 x 1200 fork insertion 800 step plate up down Ast3 mm 2125 4 2622 5 4 35 Turning radius step plate up down Wa mm 1597 1904 Performance 5 1 Drive speed loaded empty km h 6 6 7 5 6 5 2 Lifting speed loaded empty m s 0 034 0 045 5 3 Lowering speed l...

Page 71: ...ic 8 4 Operating noise in driver s ear dB A 70 NOTE 1 The values in the table unless indicated otherwise are for fork with length l 1150 mm 2 For different lengths refer to the table in the section Overall dimensions 3 With forks l 980 mm 4 Calculated using the formula for pede strian pallet trucks 5 Calculated using the formula for ride on trucks or forklifts with tiller 6 With compulsory side gu...

Page 72: ...dicated above can occur during actual forklift use for example following different operating modes different environmental conditions additional noise sources Vibrations Vibrations to which hands and arms are exposed aw 2 5 m s2 Vibrations to which the body is exposed aw z 1 1 m s2 with an uncertainty factor k 0 3m s2 The value for the body has been calculated and declared in conformity with the H...

Page 73: ...Technical data 6 thus the daily exposure must be calculated using the relative workplace data 45378043402 EN 67 ...

Page 74: ...6 Technical data 68 45378043402 EN ...

Page 75: ... g B Battery Disposal 7 D Declaration of conformity 4 Disposal Battery 7 Units 7 E EC declaration of conformity in accordance with Machinery Directive 4 P Packaging 8 S Safety Inspection 17 45378043402 EN 69 ...

Page 76: ......

Page 77: ......

Page 78: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 45378043402 EN ...

Page 79: ...Original instructions ECU SF 20 0170 45378043402 EN 10 2011 Annex ...

Page 80: ......

Page 81: ...7 Diagrams ...

Page 82: ...7 Diagrams Hydraulic diagrams Hydraulic diagrams Hydraulic connection diagram 76 45378043402 EN ...

Page 83: ...Diagrams 7 Circuit diagram Circuit diagram Electrical connection diagrams Diagram part 1 45378043402 EN 77 ...

Page 84: ... safety fuse OPTIONAL 22 9F4 Thermal switch n c 25 OPTIONAL 22 G1 Battery 1 1K1 Traction contactor 3 2K1 Lifting contactor 13 3K1 Steering power relay contact 15 1M1 Traction motor 9 2M1 Lift motor 13 3M1 Steering motor 16 17 9M1 Fan motor OPTIONAL 21 9R1 Resistor OPTIONAL 22 S1 Key 24 S2 Emergency stop button auxiliary micro contact 24 7S1 Emergency stop button 3 V1 8 A diode 24 X1 Socket plug 1 ...

Page 85: ...Diagrams 7 Circuit diagram Diagram part 2 45378043402 EN 79 ...

Page 86: ...ur meter flat battery lifting block 27 34 1S2 Intermediate position side panel microswitch 47 1S3 Load detector pressure switch 200 kg 38 2Y2 Fork lowering solenoid valve 44 XA 12 pin MOLEX connector 40 53 XO 12 pin MOLEX connector 41 52 X4 10 pin SAAB connector 41 52 1X1 16 pin MOLEX connector 35 39 55 61 1X7 2 pin MOLEX connector 47 66 2X2 4 pin MOLEX connector 33 34 2X3 DIN 43650 A1 PG9 connecto...

Page 87: ...Diagrams 7 Circuit diagram Diagram part 3 45378043402 EN 81 ...

Page 88: ...112 115 3R2 Steering po tentiometer 92 95 3R3 Drive wheel potentiome ter 97 101 V2 8 A diode 78 Y1 Electromag netic brake 79 X3 MTA 8 way fuse holder 68 78 1X1 16 pin MOLEX connector 76 88 111 116 1X2 3 pin ITT CANNON MINI SURE SEAL connector 73 74 1X3 3 pin ITT CANNON MINI SURE SEAL connector 77 78 1x4 2 pin MOLEX connector 79 1X5 2 pin MOLEX connector 79 81 1X6 4 pin MOLEX connector 83 84 3X2 25...

Page 89: ...Diagrams 7 Circuit diagram Diagram part 4 45378043402 EN 83 ...

Page 90: ...136 2S1 Lift push button 139 2S2 Lift push button 141 2S3 Lowering button 143 2S4 Lowering button 145 4S1 Horn button 147 7S2 Tiller safety button 126 130 XA 12 pin MOLEX connector 125 141 XB 7 pin DUBOX connector 118 124 XD Connections 126 130 XE 2 pin AMP connector 132 134 XF 2 pin AMP connector 136 137 XG 2 pin AMP connector 139 140 XH 2 pin AMP connector 141 142 XI 2 pin AMP connector 143 144 ...

Page 91: ...Diagrams 7 Circuit diagram Diagram part 5 45378043402 EN 85 ...

Page 92: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 45378043402 EN ...

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