Page 1
Original instructions
Electric pallet truck
ECH 12
0139
50018011505 EN - 10/2018
Page 2
Page 3
Preface
Address of manufacturer and contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: info@still.de
Website: http://www.still.de
Made in China
Rules for the operating company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how
industrial trucks
application
• Prerequisites for the safe operation of
industrial trucks
• Information on the use of industrial trucks
• Information
sioning and sto
to select suitable
for a particular area of
on transport, initial commis-
rage of industrial trucks
g
18011505 EN - 10/2018 I
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Page 4
g
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
Preface
II 5
0018011505 EN - 10/2018
Page 5
Table of contents
1 Introduction
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 3
ECdeclarationofconformity ............................................. 4
Information about document
Documentationscope ................................................. 4
Copyrightandpropertyrights ............................................ 5
Explanation of symbols use
Date of edition and latest update of this manual ............................... 7
Listofabbreviations ................................................... 7
Environmental considera
Packaging ......................................................... 10
Disposal of components and batteries ..................................... 10
Technicaldescription ................................................. 1
Use of the truck ..................................................... 11
Intended use of the trucks .............................................. 11
Unauthorised use .................................................... 12
Precautions ........................................................ 12
Descriptionofuse ................................................... 12
Residual risks ...................................................... 13
Residualrisks ...................................................... 13
Specialrisksassociatedwithusingthetruckandattachments ................... 13
Overview of hazards an
Danger to employees . . ............................................... 17
ation ......................................... 4
d ............................................ 6
tions .......................................... 10
dcountermeasures ................................. 14
g
0
2Safety
Safety regulations ................................................... 20
Definition of terms us
Operatingcompany .................................................. 20
Specialist .......................................................... 20
Drivers ........................................................... 21
Basic principles for safe operation ....................................... 22
Insurance cover on company premises .................................... 22
Modifications and
Warning regarding non-original parts ..................................... 22
Damage, faults ..................................................... 23
Medical devices
Vibrations ......................................................... 24
ed for responsible persons ............................. 20
refitting .............................................. 22
..................................................... 23
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Table of contents
g
Safety tests ........................................................ 25
Carrying out regular inspections on the truck ................................ 25
Insulationtesting .................................................... 25
Safety regulations for handling consumables ............................... 27
Permissibleconsumables ............................................. 27
Oils .............................................................. 27
Hydraulicfluid ...................................................... 28
Disposalofconsumables .............................................. 28
Safety devices ...................................................... 28
Damage, faults ..................................................... 28
Battery connection cables ............................................. 29
EMC – Electromagnetic com
patibility ..................................... 30
3Views
Drive directions ..................................................... 32
Overview of main components .......................................... 33
Control handle ...................................................... 34
Installing the operating handle .......................................... 35
Instrument display ................................................... 36
Safety devices and wa
Identification plate ................................................... 41
rning labels ....................................... 40
4 Operation
Handling of the Lithium-Ion battery ....................................... 44
Information on th
Speciallithium-ionsafetyrules .......................................... 45
Whattodointheeventofincorrectuse .................................... 46
Personal prote
What to do in the event of an accidental spillage . . ........................... 47
Transportingalithium-ionbattery ........................................ 49
Scrapping lithi
Labelsonthelithium-ionbatterys ........................................ 51
Lithium-ionbatteries:Long-termstorage .................................. 52
IV 5
econformityoflithium-ionbatteries .......................... 44
ctive measures following an incident .......................... 47
um-ionbatteries .......................................... 50
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Table of contents
Operating instructions ................................................ 53
Checks before use ................................................... 54
Break-in period precautions ............................................ 5
Drive system ....................................................... 55
Drivesystem ....................................................... 55
Lifting, lowering, braking
Safetyreverseandemergencystop ...................................... 59
Usingthetruckonaslope .............................................. 60
Load handling ...................................................... 62
Safety guidelines for handling loads ...................................... 62
Loading ........................................................... 63
Parking the vehicle safe
Battery use ........................................................ 66
Mounting the battery charger ........................................... 66
Batteryprecautions .................................................. 66
Batterycharger ..................................................... 69
Hoisting ........................................................... 73
Truck transport ..................................................... 74
Cleaning the Forklift .................................................. 76
Storing the truck for an extended period ................................... 76
andusingthehorn ................................ 57
ly .............................................. 65
g
5
5 Maintenance
General servicing i
General ........................................................... 78
Servicing and maintenance personnel training and qualification . ................. 78
Inspection and mai
Maintenance - 1000 hours / every 6 months . ................................ 79
Maintenance - 2000 hours / every 12 months ................................ 80
Technical inspection and
Essential maintenance ................................................ 84
Replacing the drive wheel .............................................. 84
Replacing the load wheels
Changing the hydraulic oil ............................................. 86
nformation ........................................... 78
ntenance ............................................ 79
maintenance data ................................ 81
............................................. 85
6 Technical data
Main technical data .................................................. 90
Technical datasheet .................................................. 91
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Page 9
1
Introduction
Page 10
1 Introduction
Your industrial truck
Your industrial truck
General
The truckdescribed in these operating instructions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regulations for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
The truck has been fitted wit
art technology. Following
instructions will allow t
safely. By complying with
these operating instruct
and the approved features
retained.
Get to know the technology, understand it
and use it safely - these operating instructions
provide the necessary information and help to
avoid accidentsand to keep the truck ready for
operation beyond the warranty period.
Therefore:
– Before commissioning t
the operating instruct
instructions.
– Always follow all of the safety information
contained in the operating instructions and
on the truck.
h state-of-the-
these operating
he truck to be handled
the specifications in
ions, the functionality
of the truck will be
he truck, read
ions and follow the
250
018011505 EN - 10/2018
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Introduction 1
Your industrial truck
CE labelling
The manufacturer uses CE labe
cate that the truck complies w
and regulations valid at the t
This is confirmed by the issued
of conformity. The CE labelli
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
llingtoindi-
ith the standards
ime of marketing.
EC declaration
ng is attached to
CE-Symbol
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1 Introduction
Information about documentation
EC declaration of conformity
Declaration
STILL GmbH
Berzeliusstraße 10
22113 Hamburg Germany
We declare that the machine
Industrial truck
Model
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
EC declaration of conformity
The manufacturer declares that the truck complies with the requirements of the EC machinery directive and any other EC directives, if
applicable, that are valid at the time of placing on the market. This is confirmed by the
EC declaration of conformity and by the CE
labelling on the nameplate.
The EC declara
is delivered w
Informat
tion of conformity document
ith the truck. The declaration
ion about documentation
according to these operating instructions
according to these operating instructions
shown explains the conformity with the requirements of the EC machinery directive.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC decla
carefully s
responsibl
also be handed
truckissoldo
tored and made available to the
e authorities if applicable. It must
ration of conformity must be
over to the new owner if the
n.
Documen
• Opera
• Operating instructions for attachment parts
(special equipment)
450
tation scope
ting instructions
• Spare
• VDMA rules for the proper use of industrial
trucks (EU countries only)
These operatinginstructions describe all measures necessary for the safe operation and
018011505 EN - 10/2018
parts list
Page 13
Introduction 1
Information about documentation
proper maintenance of the truck in all possible
variants at the time of printing. Special designs to meet customer requirements are documented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year of
production located on the nameplate in the
field provided:
Production no. ...........
Year of production ..........................................
.........
Please quote these numbers for all technical
enquiries.
Operating instructions a
truck. These instruction
carefully and must be avai
and operator at all times.
................................
re provided with each
smustbestored
lable to the driver
Copyright and property rights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.
If the operating instructions are lost, the operator must immediately request a replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
asparepart.
Personnel responsible for o
maintaining the equipment m
with these operating instru
The operating company (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must ensure that all operators
have received, read and understood these
instructions.
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
perating and
ust be familiar
ctions.
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1 Introduction
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedurethat must followedto avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid materialdamage and/or destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
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Introduction 1
Information about documentation
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 claimsconcerning the information
provided in this manual.
To receive technical assis
contact the service centre
closest manufacturer.
tance, please
authorised by your
List of abbreviations
NOTE
This list of abbreviations applies to all types
of operating instructions. Not all of the abbreviations that are listed here will necessarily
appear in these operating instructions.
Abbreviation
ABE
ArbSchG
BetrSichV
BG
BGG
BGR
DGUV
CE
CEE
DC Direct Current Dire
DFÜ
DIN
EG
Meaning
Display operating unit
Arbeitsschutzgesetz
Betriebssiche
Berufsgenossenschaft
Berufsgenossenschaftlicher Grundsatz
Berufsg
Berufsgenossenschaftliche Vorschrift German accident prevention regulations
Commu
Commission on the Rules for the Approval
of the Electrical Equipment
Datenfernübertragung
Deutsches Institut für Normung German standardisation organisation
European Community
rheitsverordnung
enossenschaftliche Regel
nauté Européenne
Explanation
German implemen
tional health and
German implementation of the EU working
equipment directive
German insurance company for the company and employees
German principles and test specifications
for occupational health and safety
German ru
tional health and safety
occupa
Confirms conformity with product-specific
European directives (CE mark)
International commission on the rules for
the approval of electrical equipment
ct current
ote data transmission
Rem
tation of EU occupa-
safety directives
les and recommendations for
18011505 EN - 10/2018 7
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1 Introduction
Information about documentation
Abbreviation
EN
FEM
F
max
Meaning
European standard
Fédération Européene de la Manutention
maximum Force
Explanation
European Federation of Materials Handling and Storage Equipment
Maximum power
German authority for monitoring/issuing
GAA Gewerbeaufsichtsamt
regulations for worker protection, environmental protection, and consumer protection
GPRS General Packet Radio Service
Transfer of data packets in wireless
networks
ID no. ID number
ISO
International Organization for Standardization
International sta
ndardisation organisation
LAN Local Area Network Local area network
K
pA
LED
L
p
L
pAZ
LSP
MAK
Max. Maxi
Min
PIN
PPE
SE
SIT
StVZO
TRGS
VDE
Uncertainty of measurement of sound
pressure levels
Light Emittin
g Diode
Light emittin
g diode
Sound pressure level at the workplace
Average c
in the dri
Load centre of gravity
Maximum workplace concentration
.
Min
ontinuous sound pressure level
ver's compartment
mum
imum
e of the centre of gravity of the load
Distanc
e front face of the fork backs
from th
Maximum permissible air concentrations
of a substance at the workplace
Highest value of an amount
Lowest value of an amount
Personal Identification Number Personal identification number
Personal protective equipment
Super-Elastic Superelastic tyres (solid rubber tyres)
Snap-In Tyre
Straßenverkehrs-Zulassungs-Ordnung
Technische Regel für Gefahrstoffe
Verband der Elektrotechnik Elektronik
Informationstechnik
Tyres for simplified assembly, without
loose rim parts
German regulations for approval of vehicles on public roads
Ordinance on hazardous materials applicable in the Federal Republic of Germany
German technical/scientific association
850
018011505 EN - 10/2018
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Introduction 1
Information about documentation
Abbreviation
VDI
VDMA
Meaning
Verein Deutscher Ingenieure
Verband Deutscher Maschinen- und
Anlagenbau e.V.
Explanation
German technical/scientific a
German Mechanical Enginee
Association
WLAN Wireless LAN Wireless local area network
.
ssociation
ring Industry
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1 Introduction
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completelyprior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
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:
•disposedof,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when disposing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste management company for disposal purposes.
Technical description
This series of electric pallet trucks is used
for handling pallets and has a maximum load
capacity of 1200 kg.
Design
The latest ergonomic and practical design,
adaptable to all operators and working conditions.
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0018011505 EN - 10/2018
The polyurethane cowling provides superior
stability and shock resistance.
The chassis is made of thick steel plate and is
suitable for the harshest working conditions.
Steering system
Extremely smooth steering makes the vehicle
easier to manoeuvre in tight spaces.
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Introduction 1
Use of the truck
A gas spring enables the tiller to quickly return
to the vertical position after it is released.
Tiller
The composite construction tiller head provides excellent impact resistance.
Ergonomic, suitable for le
operators. The push-butto
lifting and lowering can be
hand without changing grip
ft and right-handed
ns for the horn,
operated using one
.
The walking, lifting and lowering devices,
harnesses and components are IP55 dustand water-resistant.
The anti-crush button integrated into the
tiller head protects the operator if the vehicle
recoils.
Drive
Precise, load-indepen
Jolt-free starting and smooth acceleration to
maximum speed.
dent travel.
Use of the truck
Intended use of the trucks
Simply release or turn the drive direction
switch to brake.
Booster circuit prevents the truck rolling back
when starting on a gradient.
Brake system
The electromagnetic brake
tion function can be used as
and parking brake. Braking
the drive controller: the b
acts on the motor shaft and s
cuts off the power. Automat
tivated when the tiller is i
vertical position (end st
with dust protec-
a safety brake
is controlled by
rake's electromagnet
imultaneously
ic braking is ac-
n the horizontal or
op brake).
Battery
24V/20Ah maintenance-free industrial battery.
The display instrument displays the battery’s
remaining charge.
CAUTION
This machine was
storage on rack
packedonpalle
signed for thi
The dimension
ner must be adap
and must ensu
Thetableofc
ched to this us
you need to che
the work being c
Any specific usa
site manager;
associated wi
place anyneces
s (pallet stackers only) of loads
s purpose.
s and capacity ofthe pallet or contai-
re stability.
haracteristics and performance atta-
er manual gives you the information
an analysis of the potential risks
th this usage will enable him to put in
designed for the transport and
ts or in industrial containers de-
ted to the load being transported
ck that the equipment is suitable for
arried out.
ge must be authorised by the
sary additionalsafety measures.
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1 Introduction
Use of the truck
Unauthorised use
Any dangercaused as a result of unauthorised
use becomes the responsibility of the operator
or driver and not that of the manufacturer.
Use for purposes other than those described
in these operating instructions is prohibited.
Transporting people is proh
ibited.
Precautions
– Do not drive on steep slope
load from slipping off.
– The truck must be switched off when left
unattended.
s, to prevent the
Description of use
– Due to the characteristics of the lithium
battery, use the vehicle at an ambient
temperature of -10° C to +45°C.
– The truck can climb gentle gradients below
4% at full load, or below 10% without a load.
– Only use the truck at a
2000 metres.
ltitudes not exceeding
The forklift truck should not be used in areas
where there is a risk of fire, explosion or
corrosion, or in areas that are particularly
dusty.
Stacking or unstacking is not permissible on
inclined surfaces or ramps.
– When using this truck, pay
the surroundings and do no
distracted.
– Please pay attention to the moving parts of
the truck to prevent your hands from being
crushed.
– Indoor use only.
– Use the truck properly, to avoid being
crushed by the drive wheel.
– Do not use the truck to
– Do not drive on slippery surfaces such as
grease, etc.
attention to
t become
carry passengers.
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Introduction 1
Residual risks
Residual risks
Residual risks
Despite carefuloperation and compliance with
all applicable standards and regulations, the
possibility of other dangers when using the
truck cannot be entirely excluded.
The truck and additional equipment comply
with applicable safety regulations. However,
residual risks cannot be excluded even if the
truck is used correctly and instructions are
carefully followed.
Even beyond the danger area
itself, residual risks re
area around the truck must
caution. They must react i
event of malfunction, inc
They must be informed of the risks associated
with the use of the forklift.
These operating instructions also contain
additional safety instructions.
Residual risks can incl
s of the truck
main. Persons in the
exercise particular
mmediately in the
ident, breakdown etc.
ude:
– Escape of consumables due to leakages or
the rupture of lines, hoses or containers.
– Risk of accident when driving over difficult
ground such as gradients, smooth or
irregular surfaces, or with poor visibility
etc.
– Risk of falling, tripping o
movement of the truck, espe
icy surfaces or in the event
leaks.
– Risk of fire and explosion due to the battery
and electrical voltages.
– Human error.
– Disregarding the safety
– Risk caused by unrepaired damage.
– Risk caused by insufficient maintenance
and testing.
– Risk caused by using un
ables.
r slipping during
cially on wet or
of consumable
regulations.
suitable consum-
Special risks associ
The manufacturer's
soon as:
• The truck is used differently from its normal
use
• The driver is not sure if he can use the truck
correctly and without risk of accident
ated with using the truck and attachments
approval is required as
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1 Introduction
Residual risks
Overview of hazards and countermeasures
NOTE
This table is intended to help evaluate the
hazards in your facility and applies to all drive
types. It does not claim to be complete.
– Observe the national regulations for the
country in which the truck is being used.
Hazard Measure
Truck equipment does
not comply with local
regulations
Lackofskillsand
qualification of driver
Usage by unauthorised
persons
Truck not in a safe
condition
Risk of falli
using working
platforms
Impaired visibility due
to load
Contamination of
respiratory air
ng when
Test
Driver training (sit-on
and stand-on)
Access with key only
for authorised persons
Recurrent testing and
rectification of defects
Compliance wi
national regul
(different nat
Resource planning
Assessment of diesel
exhaust gases
Assessment of LPG
exhaust gases
th
ations
ional laws)
Check note
√ Complete
- Not applicable
O If in doubt, consult
O BGG 925
O
O German Ordinance on
O German Ordina
O German Ordi
O
O German threshold limit
Notes
competent factory
inspectorate or
employers' liability
insurance association
VDI 3313 driver permit
Industrial Safety and
Health (BetrSichV)
nce
on Industria
and Health (B
and employer's
insurance assoc
Industri
Health (B
Techn
for Ha
Sub
554
Ord
afety and Health
S
BetrSichV)
(
values list (MAK-Liste)
and the German
Ordinance on Industrial
Safety and Health
(BetrSichV)
l Safety
etrSichV)
liability
iations
nance on
al Safety and
etrSichV)
ical Regulations
zardous
stances (TRGS)
and the German
inance on Industrial
14 5
0018011505 EN - 10/2018
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Introduction 1
Residual risks
Hazard Measure
Impermissible usage
(improper usage)
When fuelling
a) Diesel Note the German
b) LPG Note German Social
Issuing of operating
instructions
Written notice of
instruction to driver
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Accident Insurance
(DGUV) regulation
D34, the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Check note
√ Complete
- Not applicable
O German Ordinance on
O German Ordinance on
O
O
O
Notes
Industrial Safety and
Health (BetrSichV) and
German Health and
labour protection law
(ArbSchG)
Industrial Safety and
Health (BetrSichV) and
German Health and
labour protection law
(ArbSchG)
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1 Introduction
Residual risks
Hazard Measure
When charging the
traction battery
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
When using battery
chargers
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers' liability
insurance association
regulation 104 and the
operating instructions
When parking LPG
trucks
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers' liability
insurance association
regulation 104 and the
operating instructions
With driverless transport systems
Roadway quality
Clean/clear driveways O German Ordinance on
inadequate
Load carrier
Reattach load to pallet
incorrect/slipped
Drive behaviour
Employee training
unpredictable
Driveways blocked Mark driveways
Keep driveways clear
Driveways intersect
Announce right-of-way
rule
No person detection
Employee training
during depositing and
retrieval
.
Check note
√ Complete
- Not applicable
O Association for
O German Ordinance
O German Ordinance
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
Notes
Electrical, Electronic
and Information
Technologies (VDE)
regulation 0510: In
particular
- Ensure adequate
ventilation
- Insulation value within
the permissible range
on Industrial Safety
and Health (BetrSichV)
and employers' liability
insurance association
regulation 104
on Industrial Safety
and Health (BetrSichV)
and employers' liability
insurance association
regulation 104
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
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Introduction 1
Residual risks
Danger to employees
The operating company must identify and
evaluate the dangers involved in using the
truck. It must also establish which occupational health and safetymeasures are required
to protect employees. Appropriate operating
instructions must be drafted and provided for
the driver accordingly. A person responsible
for health and safety must be appointed.
Construction andequipment ofthe truck correspond to the Machinery Directive 2006/42/EC
and they are therefore identified with the CE
symbol. As a result, these factors are not
included in the hazard assessment; nor are
the attachments, which have their own CE
labelling. The operating company must, however, select the type and equipment of the
truck so as to comply with the local provisions
for deployment.
The results must be published. In the case
of truck deployment involving similar hazard
situations it is permitted to summarise the
results. This overview (see chapter entitled
"Overview of hazards and countermeasures")
is intended to facilitate compliance with the
conditions of these regulations. The overview
indicates the main causes of accidents in
the event of non-compliance. If other major
operational hazards are involved, they must
also be taken into consideration.
The working conditions for the trucks are
largely similar for many sites. The dangers
can therefore be summarised in a single
overview. It is recommended that the information provided by the relevant employers'
liability insurance association be observed in
this respect.
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1 Introduction
Residual risks
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Page 27
2
Safety
Page 28
2 Safety
Safety regulations
Safety regulations
These operating instructions, which come
with the truck, must be communicated to all
those concerned andin particular to personnel
responsible for maintenance and driving.
The employer must make sure that the forklift
operator has properly understood all the safety
information.
Please observe the directives and safety
regulations attached, in particular:
• Information concerning the
handling trucks
• Regulations concerning traffic lanes and
working areas
• Appropriate behaviour, rights and responsibilities of the driver
• Use in particular areas
• Information about the weight and dimensions of pallets or any other container
• Information concerning starting, driving and
braking
• Information concerning
repair
use of materials
maintenance and
• Regular checks and technical inspections
• Recycling of lubricants, oils and batteries
• Residual risks.
Care is recommended both for the user and
the person in charge (employer) with regard to
adhering to all safety rules concerning the use
of material-handling trucks.
When instructing forklift operators, we recommend the following points are emphasized:
• The features of the truck
• The special accessories
• The specific features of the working environment.
Train the user in how to dri
is under proper control.
Then, and only then, proceed to transferring
pallets.
Forklift truck stability is guaranteed when the
unit is used correctly.
ve the truck, until it
Definition of terms use
d for responsible persons
Operating company
The operating company
person or group who opera
whose authority the truck
The operating company must ensure that the
truck is only used for its intended purpose and
in compliance with the safety guidelines set
out in these operating instructions.
is the natural or legal
tes the truck or on
is used.
The operating company
all users read and unde
information in these i
The operating company is responsible for the
scheduling andcorrect performance ofregular
safety checks.
It is recommended that these checks comply
with national performance specifications.
must ensure that
rstand the safety
nstructions.
Specialist
A specialist is deemed to be: • A person whose experience and technical
20 5
0018011505 EN - 10/2018
training hasallowed him to develop relevant
knowledge of industrial trucks
• A person who is al
health and safet
so familiar with national
y regulations and gener-
Page 29
Safety 2
Definition of terms used for respons
ible persons
ally recognised technical directives and
conventions (standards, VDE regulations,
technical regulations of other European
Union member states or countries that are
Drivers
Driver rights, duties and rules of behaviour
The driver must be trained in his rights and
duties.
The driver must be granted
The driver must wear protective equipment
(protection suit, safety footwear, safety
helmet, industrial goggles and gloves) that
is appropriate for the conditions, the job and
the load to be lifted. Solid footwear should be
worn to ensure safe driving and braking.
The driver must be familiar with the operating
instructions and have access to them at all
times.
The driver must:
• have read and understo
manual
• have familiarised himself with safe operation of the truck
• be physically and mentally able to drive the
truck safely
the requiredrights.
od the operating
signatories to the treaty that established the
European Economic Area). This expertise
allows him to assess the condition of industrial trucks in terms of health and safety
DANGER
The use of drugs, alcoholor medications that affect
reactions impair the ability to drive the truck!
Individuals under the influence of the aforementioned substances are not permitted to perform work
of any kind on or with the truck.
Prohibition of use by unauthorised
persons
The driver is respon
working hours. He mu
rised persons to ope
When leaving the truck, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.
sibleforthetruckduring
st not allow unautho-
rate the truck.
18011505 EN - 10/2018 21
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Page 30
2 Safety
Basic principles for safe operatio
n
Basic principles for safe operation
Insurance cover on company premises
The company premises are very often restricted public traffic areas.
NOTE
It is advisable to review the operationalliability
insurance so that insurance covers the truck
with respect to third parties in the event of
damage caused in restricted public traffic
areas.
Modifications and refitting
If your truck is to be used in specific conditions
(e.g. refrigerated warehouse or flameproof
protection), it must be specially equipped and
approved for this purpose, if applicable.
If your truck is used for work that is not specified in the guidelines or in these instructions,
and it must be modified or refitted for this purpose, it is important to remember that any
structural modification could affect truck handling while driving as well as the stability of the
truck, and could lead to accidents. You should
therefore contactthe manufacturer before carrying out any modification. Permission from
the manufacturer is required for any modification that may affect the truck's stability.
Any constructional modification or transformation of your truck is forbidden without prior
written permission from the manufacturer.
Authorisation from the relevant authority may
also be required.
SPECIAL CASE: if the manufacturer of the
truck is no longer in business and its activity is
unlikely to be taken over by a successor
In this specific case, you may plan a modification or alteration to your truck provided that:
• The modification or alteration is designed,
tested and implemented by one or more
engineers who are experts in the field of
industrial trucks and their safety
• A record is kept of the design, the different
tests and the implementation of the modification or alteration
• Appropriate changes are approved and
made to the capacity plate, decals, labels
and operating instructions
• a permanent and clearly visible label is
attached to the truck indicating the nature of
the modification or alteration as well as the
date of the modification or alteration, and
the name and address of the company that
carried out the work.
Warning regarding non-original parts
Original parts, attachments and accessories
are specially designed for this truck. We
draw your attention to the fact that parts,
22 5
0018011505 EN - 10/2018
attachment parts and accessories supplied
by other companies have not been tested or
approved by STILL.
Page 31
Safety 2
Basic principles for safe operatio
CAUTION
The installationor use of such products may have a
negative impacton the design of the truck and thus
impair active or passive driving safety.
We recommend that you obtain approval from the
manufacturer and, if applicable, from the relevant
regulatory authoritiesbefore installing such parts.
The manufacturer accepts no liability for any damage caused by the use of non-original parts and
non-original accessories.
Damage, faults
Any damage or faults observed on the truck or
the accessories must be reported immediately
to the responsible personnel. The truck and
accessories must never be used before they
are correctly reconditioned as they cannot be
guaranteed to be safe for operating or driving.
The safety mechanisms and switches must
never be removed ordisabled. The predefined
setpoint values must not be modified.
Work on the electric
ing a radio, additio
sories) is permitte
installation (e.g. connect-
nal lights or other acces-
d only with the approval of
the manufacturer.
Medical devices
The operation of
pacemakers or he
Check with your d
medical devices
against electro
medical devices, for example
aring aids, can be impaired.
octor or manufacturer if the
are sufficiently protected
magnetic interference.
n
18011505 EN - 10/2018 23
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Page 32
2 Safety
Basic principles for safe operatio
Vibrations
Vibrations to which the hands and arms
are exposed
The following value isvalid for all truck models:
•ā
<2.5m/s
w
NOTE
It is mandatory to specify the hand-arm
vibrations, even where the values do not
indicate any danger, as in this case.
2
n
CAUTION
The value expressed above can be used to compare forklift trucks of the same category. It cannot
be used to determine the operator's daily exposure to vibrations during real operation of the truck;
these vibrations depend on the conditions of use
(floor conditions,method of use etc.) and therefore
daily exposure must be calculated using data from
the place of use.
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0018011505 EN - 10/2018
Page 33
Safety 2
Safety tests
Safety tests
Carrying out regular inspections on the truck
The operating company must ensure that the
truck is checked by a specialist at least once a
year or after particular incidents.
As part of this inspection, the technical condition of the truck must be completely tested
with regard to accident safety. In addition, the
truck must be thoroughly checked for damage
that may have been caused by improper use.
A test log must be created. The results of the
inspection must be retained at least until a further two inspections have been carried out.
The inspection date is in
sive label on the truck.
– Arrange for the authorised service centre to
perform regular testing on the truck.
– Observe the guidelines for tests carried out
on the truck in accordance with FEM 4.004.
The operating company
ensuring that any defe
without delay.
– Notify your authorised service centre.
dicated by an adhe-
is responsible for
cts are remedied
NOTE
In addition, observe the national regulations
for the country of use.
Insulation testing
The insulation of the truck must have sufficient
insulation resistance. For this reason, insulation testing in accordance with DIN EN 1175
and DIN 43539, VDE 0117 and VDE 0510
must be conducted at least once yearly as part
of the FEM testing.
The insulation testing results must be at least
the test values given in the following two
tables.
– For insulation testing, contact the autho-
rised service centre.
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Page 34
2 Safety
Safety tests
The exact procedure for this insulation testing
is described in the workshop manual for this
truck.
NOTE
The truck's electrical system and drive batteries must be checked separately.
Test values for the drive battery
Component
Recommended
test voltage
Measurements
50 VDC 24 volts > 1200 Ω
Battery
100 VDC 48 volts > 2400 Ω
Batt+
Batt-
Battery tray
100 VDC
.
Test values for the entire truck
Nominal voltage Test voltage
24 volts 50 VDC Min. 50 kΩ > 24 kΩ
48 volts 100 VDC Min. 100 kΩ > 48 kΩ
80 volts 100 VDC Min. 200 kΩ > 80 kΩ
.
Test values for new trucks
Nominal voltage
U
Batt
80 volts > 4000 Ω
Minimum values over the
duration of the service life
Test values
26 5
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Page 35
Safety 2
Safety regulations for handling co
nsumables
Safety regulations for handling consumables
Permissible consumables
WARNING
Consumables can be dangero
It isnecessary to follow
handling these substan
the safety regulations when
ces.
Oils
DANGER
Oils are flammable!
– Follow the statutoryregulations
– Do not allow oils to come into
contact withhot motor parts.
– No smoking, fires or flames!
DANGER
Oils are toxic!
– Avoid contact and consumption
– In case of inhalation of steam or fu-
mes, breathefresh air immediately.
– After contact with the eyes, rinse
thoroughly with water (for at least
10 minutes) and then consult an
eye specialist.
– If swallowed, do not induce
vomiting. Seek immediate medical
attention.
us.
Refer to the maintenance data table for
the permissible substances necessary for
operation.
WARNING
There is a risk of slipping on spilled oil, particularly
when combined with water!
– Collect spilled oil immediately using an oil-
binding agent and dispose of it in accordance
with regulations.
ENVIRONMENT NOTE
Oils are water pollutants!
Always store oil in containers that comply with
the applicable regulations.
Avoid spilling oils.
Collect spilt oil immediately using an oil
binding agent and dispose of it in accordance
with regulations.
Dispose of old oils according to the applicable
regulations.
WARNING
Prolonged intensive contact with the
skin can result in loss of skin oils and
cause irritation.
– Avoid contact and consumption.
– Wear protective gloves!
– After any contact, wash the skin
with soapand water and then apply
askincareproduct.
– Immediately change soaked
clothing and shoes.
18011505 EN - 10/2018 27
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Page 36
2 Safety
Safety devices
Hydraulic fluid
WARNING
During operation of the forklift truck,
hydraulic fluids are pressurised and
are hazardous to your health.
– Do not spill these fluids!
– Follow the statutory regulations
– Do not allow the fluids to come into
contact withhot motor parts.
– Do not allow to come into contact
with the skin.
– Avoid inhaling the spray
– Penetration of pressurised fluids
into the skin is particularly danger-
ous if these fluids escape at high
pressure due to leaks inthe hydrau-
lic system. In case of such injury,
seek medicaladvice immediately.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
ENVIRONMENT NOTE
Disposal of consumables
ENVIRONMENT NOTE
Materials that have to be disposed of following
maintenance, repair and cleaning must be
systematically collected and disposed of in
accordance with regulations. Observe the
national regulations for your country. Work
may only be carried out in areas designated
for this purpose. Take care to minimise, as far
as possible, any impact on the environment.
Hydraulic fluid is a water-polluting substance!
Always store hydraulic fluid i
complying with the regulatio
Avoid spilling.
Spilt hydraulic fluid should be removed with
oil-binding agents at once and disposed of
according to the regulations.
Dispose of old hydraulic flu
regulations.
• Any spillage of fluids such as hydraulic oil,
brake fluid or gear lubricant oil must be
immediately soaked up with an oil-binding
agent.
• The regulations for disposal of used oil are
applicable.
• Any spilla
tralised i
ge of battery acid must be neu-
mmediately.
n containers
ns.
id according to
Safety devices
Damage, faults
Any damage or faults observed on the truck or
the accessoriesmust be reported immediately
to the responsible personnel. The truck and
28 5
0018011505 EN - 10/2018
accessories must never be used before they
are correctly reconditioned as they cannot be
guaranteed to be safe for operating or driving.
Page 37
Safety 2
Battery connection cables
The safety mechanisms and switches must
never be removed ordisabled. The predefined
setpoint values must not be modified.
Battery connection cables
CAUTION
Using sockets with NON-ORIGINAL battery connection cables can be dangerous (see purchase
references in the parts catalogue)
Work on the electric installation (e.g. connecting a radio, additional lights or other accessories) is permitted only with the approval of
the manufacturer.
18011505 EN - 10/2018 29
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Page 38
2 Safety
EMC – Electromagnetic compatibili
ty
EMC – Electromagnetic compatibility
Electromagnetic compatibility (EMC) is a key
quality feature of the truck.
EMC involves
• limiting the emission of electromagnetic
interference to a level that ensures the
troublefree operation of other equipment
in the environment.
• ensuring sufficient resista
electromagnetic interfere
guarantee proper operation
usage location under the ele
interference conditions to
.
ncetoexternal
ncesoasto
at the planned
ctromagnetic
be expected there
An EMC test thus firstly measures the electromagnetic interferenceemitted by thetruck and
secondly checks it for sufficient resistance to
electromagnetic interference with reference
to the planned usage location . A number of
electrical measures are taken to ensure the
electromagnetic compatibility of the truck .
CAUTION
The EMC regulations for the truck must be observed.
When replacing truck components the protective
EMC componentsmust be installed and connected
again.
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0018011505 EN - 10/2018
Page 39
3
Views
Page 40
3 Views
Drive directions
Drive directions
The drive directions of the truck are forward
(1) and reverse (2).
32 5
0018011505 EN - 10/2018
Page 41
Views 3
Overview of main components
Overview of main components
1 Tiller
2 Hydraulics cowling
3 Rollers
4 Front protectivepanel
5 Battery
6 Emergency stop switch
7Key
18011505 EN - 10/2018 33
500
Page 42
3 Views
Control handle
Control handle
1 Horn switch
2 Lifting switch
3 Power display
4 Manual lowering handle
5 Emergency reverse switch
6 Drive switch
7 Handle
34 5
0018011505 EN - 10/2018
Page 43
Views 3
Installing the operating handle
Installing the operating handle
1 Square operating tube
2 Mounting base
3 Screw (M6x10)
4 Control harness
– Connect the square tube harness connector
to the control harness.
– Insert wire (6) and ball head wire (8) into
bracket (7) (press the hydraulic pressure
release switch from the right side cover auxiliary hole), release the pressed hydraulic
18011505 EN - 10/2018 35
500
5 Square tube harness
6Wire
7Bracket
8 Ball head wire
Page 44
3 Views
Instrument display
release switch, the ball head wire (8) will
become taut and correctly installed.
– Use 4 screws to install the square control
tube on the mounting base (standard
torque).
Instrument display
Normal display state
36 5
1 Horn in norma
2 Interlock
(flashi
3Tot
4T
backward, fork lifting and fork lowering. The
display changes occasionally from time to
time depending on the operation
0018011505 EN - 10/2018
l working state
switch status, acceleration status
ng)
al operating time
he display description includes forward,
Page 45
Views 3
Instrument display
Charge percentage display
Motor temperature too high
18011505 EN - 10/2018 37
500
Page 46
3 Views
Instrument display
Other battery faults
Battery CAN signal
not connected
38 5
0018011505 EN - 10/2018
Page 47
Views 3
Instrument display
Controller CAN signal not switched on
F.X.X:Error code (
X refers to a number)
18011505 EN - 10/2018 39
500
Page 48
3 Views
Safety devices and warning labels
Safety devices and warning labels
1 “Forbid stampede” label
2 "Anti-pinch" label
3 "Identification plate" label
4 "Filler port" label
40 5
5 "Pallet truck model" label
6 "Instructions" label
7 Slinging label
8ChassisNO.
0018011505 EN - 10/2018
Page 49
Views 3
Identification plate
Identification plate
1 Type
2 Serial number
3 Year of manufacture
4 Unladen mass in kg
5 Max. permissible battery weight in kg (for
electric trucks only)
6 Min. permissible battery weight in kg (for
electric trucks only)
18011505 EN - 10/2018 41
500
7 Own mass (self weight) in kg without battery
8 Manufacturer
9 Refer to technicaldata listedin thisoperating
instructions for more detailed information
10 CE label
11 Rated drive power in kW
12 Battery voltage in V
13 Rated capacity
Page 50
3 Views
Identification plate
42 5
0018011505 EN - 10/2018
Page 51
4
Operation
Page 52
4 Operation
Handling of the Lithium-Ion batter
y
Handling of the Lithium-Ion battery
Information on the conformity of lithium-ion batteries
The manufacturer of the lithium-ion battery
and Kion group provider declares that:
the lithium-ion battery
conforms with the provisio
EU directive 2004/108/EC
ns of the following
in accordance with EN 61000–6–2:2006 and
EN 61000–6–3:2007.
This declaration of conformity with EC directives applies only to battery use that conforms
to the recommendations described in the operating instructions.
44 5
0018011505 EN - 10/2018
Page 53
Operation 4
Handling of the Lithium-Ion batter
Special lithium-ion safety rules
y
DANGER
There is a risk of fire.
Have class D fire extinguish
dioxide, powder or foam fire
zone in which the lithium
ers or inert gas, carbon
extinguishers near the
-ion batteriesare used.
DANGER
Electrical danger
Do not open the battery. Electrical risk.
Only the After-Sales Service Centre technicians
can open the battery.
It is necessary to respect the following guidelines:
– Read the documents provided with the
battery carefully.
– Only persons who have been trained to
work with lithium-ion technology are permitted to work on the batteries (for example
After-Sales Service Centre technicians).
– Do not place lithium-ion batteries on or near
flames or hot heat sources (> 70°C). This
may cause the batteries to overheat or burst
into flames. This typeof usealso impairsthe
performance of the batteries and reduces
their service life.
– Improper use may cause overheating or
serious injury. Respect the following safety
rules:
• Never short circuit the battery terminals
• Do not reverse the battery polarity
• Do not open the battery
• Do not submit the battery to excessive
mechanical constraints
• Do not expose the battery unit
to humidity or
water (> 95%)
• Install the batteries in a Level 2 pollution
zone in accordance with standard EN
60664-1
– Batteries must be installed in a room that
can be easily ventilated in the event of
incorrect use.
– The forklift operator must
carefully to avoid any ri
damaging the lithium-io
drive the truck
sk of piercing or
n batteries.
DANGER
Risk of injury
In the event of an accident (shock, fall, collision),
the batterymay be damaged,pierced or deformed.
Establish a 5-metre safety perimeter around the
battery. Contact the emergency services and tell
them that there is a lithium-ion battery fire. Contact
the after-sales service department.
– Store strapped batteries on pallets. Do
not store them too high to reduce any risk
of falling. Do not store on the ground to
reduce the risk of humidity and impacts. We
recommend that batteries are stored at a
height between 60 and 120 cm.
– If an unusual smell, change of shape or
any other anomaly is observed during
operation, immediately disconnect the
battery (using either the emergency stop or
the charger socket). Contact the after-sales
service department. If necessary, also
contact the emergency services and tell
them that there is a lithium-ion battery fire.
18011505 EN - 10/2018 45
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Page 54
4 Operation
Handling of the Lithium-Ion batter
What to do in the event of incorrect use
Lithium-ion batteries present no chemical
danger in the context of normal use. Batteries
must not be opened or burned for example.
In the event of exposure to the internal components or of their being burned, follow these
instructions.
In the event of contact with eyes
The content of an open batte
irritation.
Dust is likely to cause inflammation of the
eyelids.
– Rinse immediately and thoroughly with
water for at least 15 minutes
– See a doctor as quickly as
In the event of contact w
An open battery can lead to skin irritation and
allergies.
– Remove contaminated clothes
– Rinse the parts of the
oughly for at least 15
– Wash the skin using soap and water
– See a doctor if the irritation persists
In the event of inhalation
An open battery can cau
respiratory tracts an
an allergic reaction.
During disassembly of the battery, a gas may
be released and irritate the throat.
– Carry the person into the open air
– See a doctor as quickly
In the event of ingest
– Rinse the mouth thoroughly with water
– Drink lots of water
ry can cause eye
possible
ith skin
skin affected thor-
minutes
se irritation of the
d mucous membranes or
as possible
ion
y
– Do not make the person vomit
– See a doctor as quickly as possible
In the event of a fire
If a fire breaks out, follow t
For a small fire:
– Use class D fire extinguishers or inert
gas, carbon dioxide, powder or foam fire
extinguishers
– Establish a safety perime
around the battery
– Call the emergency services and tell them
that it is a lithium-ion battery fire
– After extinguishing the fire, do not reuse
the battery. Contact the after-sales service
department.
For a large fire:
– Establish a safety perimeter of five metres
around the battery
– Call the emergency services and tell them
that it is a lithium-ion battery fire
Special fire-fighting procedures (intervention
of firefighters):
• Firefighters must w
breathing apparat
• Use an approved mask to avoid inhalation
of toxic fumes
• Wear protective clothing and equipment
to avoid accidental bodily contact with the
electrolyte solution
• All the types of extingui
above can be used on the ba
• Use a large amount of water to cool the
outside of the batteries if they are exposed
to fire to prevent them rupturing
– After extinguishing the fire, do not reuse
the battery. Contact the after-sales service
department.
hese instructions:
ter of five metres
ear self-contained
us
shing agents given
tteries
46 5
0018011505 EN - 10/2018
Page 55
Operation 4
Handling of the Lithium-Ion batter
y
DANGER
Electrical risk
Do not use water on connected batteries in the
charging room.
Personal protective measures following an incident
WARNING
Handle an open battery only in a well-ventilated
place.
If an element is opened or if it leaks, use a gas mask covering the entire
Respiratory protection
Hand protection
Eye protection
Other
.
face and fitted with ABEK filters or self-contained breathing apparatus
(escape mask-type).
Firefighters must wear self-contained breathing apparatus.
Use polypropylene, polyethylene, rubberor Viton gloves to handle leaking
or broken elements.
Wear safety goggles with side shields or a mask covering the face to
handle leaking or broken elements.
Wear a rubber apron and a protection suit to handle leaking or broken
elements.
DANGER
Risk of explosion: release of gas that may create
an explosive atmosphere
After extinguishing the fire, establish a safety
perimeter of at least five metres around the battery.
DANGER
Risk of release of toxic products
What to do in the event of an accidental spillage
Take the following precautions in the event of
leakage:
Precautions for individuals
– Evacuate staff from the contaminated area
until the vapours have dispersed
d inhaling the gas in the event of
–Avoi
trolyte leakage from an element or a
elec
ry
batte
– Follow the instructions on What to do in the
event of incorrect use if there is contact with
18011505 EN - 10/2018 47
500
the skin or eyes, or if there is inhalation or
ingestion
– Wear goggles and protective gloves
Precautions for the environment
–Avoid
water
– Avoid pollution of the soil and atmosphere
– Use absorbent materials (sand, earth) to
absorb exudation
– Seal ba
pollution of wastewater, surface
and groundwater
ttery leakages
Page 56
4 Operation
Handling of the Lithium-Ion batter
y
– Put the contaminated absorbent product
in a plastic bag and dispose of it as special
waste according to the local regulations in
force
DANGER
Environmental danger
Do not reuse a lithium-ion battery that has leaked.
Call the After-Sales Service Centre.
48 5
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Page 57
Operation 4
Handling of the Lithium-Ion batter
Transporting a lithium-ion battery
Before transporting any lithium-ion battery,
check the current regulations on the transport
of dangerous goods. Comply with these
when preparing the packaging and transport.
Train authorised staff to dispatch lithium-ion
batteries.
NOTE
It is recommended that the original packaging
is kept for any subsequent dispatch.
A lithium-ion battery is a special product.
Special precautions should be taken when:
• Transporting a truck equipped with a
lithium-ion battery
• Transporting only the lithium battery
A class 9 danger label must be affixed to the
packaging for transport.
It is different if the battery is transported on
its own or in a truck. An example of a label
appears in this supplement. Refer to the latest
current regulations before dispatch as the
information might have changed since this
supplement was written.
Special documents must be sent with the
battery. Refer to the applicable standards or
regulations.
y
NOTE
Recharge the lithium-ion battery before transporting it taking account of the transport mode
(plane, boat, road). Excessive discharge on
arrival could damage the performance of the
battery.
18011505 EN - 10/2018 49
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Page 58
4 Operation
Handling of the Lithium-Ion batter
Scrapping lithium-ion batteries
ENVIRONMENT NOTE
Comply with current regulations for scrapping
batteries. Take care to minimise, as far as
possible, any impact on the environment.
Lithium-ion batteries must be sent to the
collection centre to be recycled. Contact the
After-Sales Service Centre to agree how to
send them.
Apply the following main rules for transport:
• Make sure that the battery is discharged
•AffixtheClass 9 transport label on the
battery
y
• Use packaging that complies w
tional regulations
• Use the original packaging, if possible. Use
sturdy packaging capable of bearing the
weight of the batteries. Store it in a dry
place.
• Wedge the battery well in the packaging to
prevent it moving during transport
• Pack batteries individual
Package them to prevent any
circuit between terminals
• Identify the type and number of batteries on
the outside of the packaging
• Do not store near to a heat source
ith interna-
ly in plastic bags.
risk of short-
.
50 5
0018011505 EN - 10/2018
Page 59
Operation 4
Handling of the Lithium-Ion batter
Labels on the lithium-ion batterys
y
1 Battery nameplate
2 No impact
3 No collision
18011505 EN - 10/2018 51
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Page 60
4 Operation
Handling of the Lithium-Ion batter
Lithium-ion batteries: Long-term storage
y
DANGER
Electrical danger
We recommend that batterie
between 60 and 120 cm.
Remain extremely vigila
avoid piercing the batt
Special precautions sh
storing lithium-ion ba
– Store the battery in a dry place at a tem-
perature between 0 and 40° to preserve its
service life. This area must not be hermetically sealed to allow air renewal.
– Indicate the storage area. Access should be
strictly limited to personnel who are aware
of the risks and safety instructions.
– It is strongly advisa
battery fully before
– Batteriescanbestoredforamaximum
period of 12 months if they are fully charged
(100%).
– Check the battery chargelevel regularly. Do
this at least every three months to maintain
the charge level above 30%. Recharge the
battery if necessary.
– Completely rechar
three months to avoid
formance of the batte
– Recharging could take up to 24 hours.
CAUTION
A battery that has reached an excessively low level
cannot be recharged.
Contact your After-Sales Service immediately.
Precautions should be taken if the truck must
not be used for a reasonably long period. The
operations depend on the length of time it is
unused.
s are stored at a height
nt when manoeuvring to
eries.
ould be taken when
tteries.
ble to recharge the
storing it.
ge the battery every
impairing the per-
ry.
Storage of trucks for a period of less than
two months
If the truck is not used for a pe
two months, it is necessary to
operations:
– Clean the truck carefully.
– Check the hydraulic oil level and refill if
necessary.
– Coat any unpainted metal p
layer of oil or grease.
– Grease all hinges and joints.
– Spray contacts with a suitable aerosol
product.
– Place the truck on chock
becoming flat.
– Cover the truck with a cotton cover to protect
it from dust. Avoid using a plastic sheet.
riod of up to
perform certain
arts with a thin
stoavoidthetyres
Long-term truck storage
The following work must be carried out on
the truck to prevent corrosion if it needs to be
stored fora long period of time. If the truck isto
be stored for more than two months, itmust be
positioned in a clean and dry area. The area
must bewell-ventilated with no risk of freezing.
The following operation
– Clean the truck carefully.
– Check the hydraulic oil level and refill if
necessary.
– Coat any unpainted met
layer of oil or grease.
– Grease all hinges and joints.
– Recharge the lithium-ion battery every
3 months. Please observe the above
instructions.
– Spray contacts with an aeros
designed for contacts.
s must be performed:
al parts with a thin
ol product
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Page 61
Operation 4
Operating instructions
– Raise and chock the truck: the wheels must
not touch the ground in order to prevent
irreversible deformation of the tyres.
– Cover the truck with a cotton cover to protect
it from dust.
CAUTION
We recommend that you do not use a plastic sheet
as this encourages condensation to form.
Consult the After-Sales Service for further
measures to take if the truck must be stored
for a longer period of time.
Recommissioning after storage
If the truck has been stored for more than
six months, it must be checked carefully
before being recommissioned. This check
is similar to the workplace accident prevention
inspection. It is therefore necessary to check
Operating instructions
The pallet truck is designed for use in safe
environments: the ambient temperature must
be between -10°C and +45°C and the altitude
must not exceed 2000 metres.
NOTE
The floor surface must be dry, clean and level.
For braking and stability reasons, the maximum permissible gradient over short distances is limited to 10% unladen and 4%
laden.
The pallet truck can only carry pallets up to a
maximum weight of 1200 kg evenly distributed
on the forks. For uses other than those
specified above, contact an authorised dealer.
CAUTION
The pallets used must be in
good condition.
all points and devices that are important for
truck safety.
Carry out the following operations:
– Clean the truck carefully.
– Grease all hinges and joints.
– Check the battery charge status and
recharge the battery if necessary.
– Check that there are no trac
sation water in the hydraul
es of conden-
ic oil. Drain if
necessary.
– Carry out the same maintenance work as
for the first time it was commissioned.
– Commission the truck.
– In particular, check the
following during
start-up:
• traction, control and steering
• brakes (service brake and parking brake).
WARNING
Risk of serious inju
damage.
Always drive in accor
(uneven floor,etc.
dous work areas and
ry and/or major equipment
dance with the floor conditions
), especiallyin the case of hazar-
hazardous loads.
CAUTION
Equipment wear or damage
To avoid scraping the bottom of the lifting system
on the floor, keep the forks raised before starting.
CAUTION
Equipment wear or damage
Thedrivermustturnofftheignitionandremovethe
key before leaving the pallet truck.
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4 Operation
Checks before use
CAUTION
Equipment wear or damage
Safety shoes must be worn to provide effective
protection.
WARNING
Risk of serious injury and/or major equipment
damage.
Place both hands on the tiller and turn off the
power supply before touching moving parts and
any equipment.
WARNING
Risk of serious inju
damage.
To prevent visibil
obstructed durin
not install or affi
screen.
ry and/or major equipment
ity being affected or completely
g operation of the stacker, do
x anything on the mast protection
DANGER
Fatal crushing hazard!
The fork carriage must be at its lowest position
when carrying out any work on the protection
screen (cleaning,replacement, etc.).
CAUTION
Equipment wear or damage
Thedriverisnotpermittedtositonthedash-
board/battery cover.
WARNING
Risk of serious injury and/or major equipment
damage.
Before driving forwards or backwards, carefully
check in the direction of travel to ensure that it is
safe to proceed.
CAUTION
Equipment wear or damage
To ensure the safety of the driver, the pallet truck
must not be used in the vicinity of forklift trucks.
CAUTION
Equipment wear or da
To prevent feet fro
forks, keep a safe d
lowering the fork
mage
m being crushed by the load or
istance from other people when
s.
WARNING
The working area of the industrial truck must be
adequately lit.
If it is insufficiently lit, working spotlights must
be installed. To ensure that the driver can see
properly.
Checks before use
WARNING
ck can only be driven by battery power!
The tru
After the truck hasarrived orbeen transported,
you must perform the following checks before
putting it into use:
• Check whether the equipment is intact and
in good condition.
•Checkwh
good con
54 5
ether the hydraulic system is in
dition.
0018011505 EN - 10/2018
• Check the vertical creep of the truck.
• Check t
he smoothmovement of thewheels.
• Check the function of the emergency brake
by activating the emergency button.
• Check, the tiller arm- switch braking function
k the lifting and lowering functions by
• Chec
ating the buttons.
oper
• Check if all bolts and nuts are tightened
firmly.
Page 63
Operation 4
Break-in period precautions
• Visual check if there are any broken hoses
or broken electric wires.
• If the truck does not yet have a battery
installed, you must install a battery, making
sure not to damage the battery cables.
• Recharge the battery.
Break-in period precauti
During the initial stage o
into use, it should be oper
Within the first 100 hours i
following requirements s
– Excessive discharge of a new batteryduring
initial use must be prevented.It should
generally be charged promptly when at
20%.
– The specified preventivemaintenance must
be done thoroughly.
– Avoid sudden braking, d
sharp turns.
f putting the truck
ated with low loads.
n particular, the
hould also be met:
riving quickly or
ons
Drive system
Drive system
Instructions fo
– Insert the magnetic key into the key hole
and switch on the power supply.
rdriving
If the truck is parked for too long, the wheels
may become slightly flattened where they
touch the ground.The flat areas will automatically return to their former condition after the
truckisdrivenforashorttime.
– Change oil or lubricant pr
to the instructions.
– Limit the load weight to 70-80% of the rated
load.
CAUTION
When the truck is in the running-instage (approx.
100 hoursof operation), the equipment user should
check the fastening of the wheel nuts and bolts and
refasten them if necessary.
omptly according
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4 Operation
Drive system
– Tilt the control handle to the drive position.
– Rotate the drive button to drive the vehicle
forward or backward.
CAUTION
Carry out a routine inspectionon the vehicle before
using it.
NOTE
The drive switc
vehicle’s speed.
h can be used to adjust the
NOTE
Releasing the drive switch causes the vehicle
to brake.
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Page 65
Operation 4
Drive system
Lifting, lowering, braking and using the horn
Lifting
– Press and hold down the lift button on the
control handle (1).The forks will be lifted
to the maximum height until they stop by
themselves.
Manual lowering
– Pull and hold the manual lower switch
(2).The forks will lower to the minimum
height until they stop by themselves.
CAUTION
Before lifting a load, make sure that it has been
properly laid out on the pallet and that its weight
does not exceed therated load capacity of 1200 kg.
CAUTION
Make sure that the forks are completely under the
load before the vehicle moves off.
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4 Operation
Drive system
Mechanical operating brake
The truck is braked when the operating handle
is released.
The mechanical brake engages
is positioned in areas (1) and
Reverse braking
– Braking can be accomplished by changing
the direction of travel.
–Pressthereverse
direction until t
then release the d
switch in the opposite
he truck comes to a stop,
rive switch.
when the tiller
(3).
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Page 67
Operation 4
Drive system
Horn
– Press the warning horn button (1).
NOTE
The horn must be used at junctions or places
with poor visibility.
Safety reverse and emergency stop
Safety reverse
– Press the safety reverse button (1). The
vehicle will begin to travel in the opposite
direction.
CAUTION
If the safety reverse switch resets slowly, this indicates a fault.The cause of the fault must be identified and eliminated.The spring can be replaced if
necessary.
NOTE
The safet
in variou
y reverse button (1) can be pressed
s ways, such as against the belly.
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4 Operation
Drive system
Emergency stop
– Press the emergency switch (2). All power
will be cut off and the vehicle will stop
working.
CAUTION
When the emergency stop button (2) is pressed, it
will lock in position.Rotate the button clockwise half
a turn to release it.Do not pull hard, as itwill reseton
its own.
CAUTION
The condition ofthe floo
distance of the truck a
considered by the ope
Using the truck on a slope
NOTE
Incorrect use of the truck on slopes is not
recommended.It places particular stress on
the traction motor, brakes and battery.
Be particularly careful near slopes:
• Never attempt a slope with a gradient
greater than that specified in the truck's
datasheet.
• Make sure that the ground is dry with a
non-slip surface and that the route is clear.
r surface affectsthe braking
nd should be taken into
rator.
Ascending slopes
Always ascend slopes travelling in the reverse
direction, with the load facing uphill.
Without a load, it is recommend to ascend
slopes forwards.
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Page 69
Operation 4
Drive system
Descending slopes
Travel down slopes must always be forwards,
with the load uphill.
Without a load, it is recommen
slopes forwards.
In all cases, travel at a very low speed and
brake very gradually.
DANGER
Risk to life and/or risk of major equipment damage.
Never park the truck on a slope.Never make a
U-turn or take shortcuts on a slope.On a slope, the
operator must drive very slowly.
WARNING
Risk of serious injur
equipment
Duetolimitedbraki
version:must not be
10% when unladen, o
4% under full load.
driven on a gradi
on a gradient of m
y and/or serious damage to
ng capacity, the large drive
driven on a gradient of over
r on a gradient of more than
Small drive version:must not be
ent of over 8% when unladen, or
ore than2% under full load.
ded to descend
Starting on a sl
ope
If you have to stop and then start on slope,
proceed as follows:
– Stop on the slope by pressing the accel-
erator in the opposite direction until the
machinecomestoastandstill.
– Return the acc
tion, then r
button to appl
elerator to the neutral posi-
elease the accelerator control
y the parking brake.
– To restart, press the accelerator button for
the desired direction.
– The truck will move off.
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4 Operation
Load handling
Load handling
Safety guidelines for handling loads
WARNING
Closely observe the follow
picking up loads.Never t
parts of the truck (e.g. l
picking up loads).
ing instructions before
ouch or stand on moving
ifting devices, equipment for
WARNING
Risk ofcrushing hands and feet when using the lift.
When usingthe lift, keep hands and feet away from
moving parts.
DANGER
It is not permitted to walk under the forks. It is not
permitted to transport or lift people on the forks.
If there are people under or on top of the forks, do
not move the truck. Do not move the forks and do
not drive the truck.
DANGER
Risk of accident when forks
If the forks are changed a
forks to the original fo
capacity changes.
When forks are changed
plate must be affixed.
If a truck is supplied
capacity plate for st
chapter "Technical
are changed:
nd a different type of
rks is fitted, the residual load
, a new residual capacity
without forks, the residual
andard forks is affixed.(See
Datasheet”)
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.
CAUTION
Be especially careful not to collide with adjacent
loads.
The load must be properly positioned to prevent
collisions in narrow aisle spaces.
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Page 71
Operation 4
Load handling
Loading
Loading
CAUTION
Before liftinga load, ensure that its weight does not
exceed the truck’s maximum loadcapacity.
– Refer to the rated load capacity specified on the
truck's identification plate.
– Ensure that the load is stable and uniform to
prevent any partial spillage.
– Check that the width of the load is compatible
with the width of the forks.
DANGER
It is mandatory to wear safety footwear for pedestrian mode driving.
WARNING
Transporting peopleis strictly prohibited.
CAUTION
Take care not to
those which may
being handled
Loads should be
– Lineuploadswi
one and its nei
disturb any adjacent loads, or
be to the side or in front of the load
.
laid out as follows:
th a small space between each
ghbour toavoid any fouling.
CAUTION
Only transportloads that have been positioned and
secured in accordance with regulations.
Take appropriateprotective measures if the load is
at risk of tipping over or falling during transport.
– Approach the load carefully.
– Adjust the height of the forks until they can
be easily inserted into the pallet.
– Insert the forks under the load.
– If the load is shorter than the forks, posi-
tion the forks so that the front of the load
overhangs them by a few centimetres, to
avoid interference with the load immediately ahead.
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Page 72
4 Operation
Load handling
– Raise the load a few centimetres above its
support.
– Back the truck away from the stack or any
neighbouring loads, gently and in a straight
line.
Transporting loads
– Always carry loads in the fo
of travel (A) in order to hav
visibility.
– When carrying a load ona slope, always as-
cend or descend with the load uphill.Never
drive sideways across a slope or perform a
U-turn.
– Reverse travel (B) is to be used solely for
unloading.Since visibility is reduced when
travelling in this direction, drive only at very
slow speed.
Unloading
– Carefully drive t
location.
– Carefully drive the truck to the unloading
area.
– Lower the load until the fork arms are free
from the pallet.
– Back the truck
– Raise the forks to mid-height.
CAUTION
Take care not to disturb any adjacent loads, or
those which may be to the side or infront of the load
being handled.
he truck to the desired
away in a straight line.
rward direction
e the best
64 5
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Page 73
Operation 4
Parking the vehicle safely
Parking the vehicle safely
– Lower the forks to the lowest position.
– Remove the magnetic key.
WARNING
Do not park the truck on slopes. If unavoidable,
secure the truck with chocks.
Never leavethe truck with the load raised.
CAUTION
The forks mus
tbefullylowered.
CAUTION
Always park the truck on a level surface that does
not interfere with traffic.
ION
CAUT
If the vehicle isto be parked for an extended period,
remove the battery and refer to the servicing and
maintenance instructions.
18011505 EN - 10/2018 65
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4 Operation
Battery use
Battery use
Mounting the battery charger
NOTE
The charging stand can be secured to the wall
using expansion screws (1).
Battery precautions
– Avoid the battery becoming corroded by
water or corrosive liquid.
66 5
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Page 75
Operation 4
Battery use
– Keep the battery away from all fire sources,
heat sources and flammable or explosive
materials.
– Do not place the bat
tery on top ofconductive
objects.
WARNING
If this happens, the battery may leak, emit heat
or smoke, which may lead to a serious fire or
explosion.
18011505 EN - 10/2018 67
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Page 76
4 Operation
Battery use
– The charging environment temperature
should be 0°C to 40°C.
WARNING
If the battery fails, please contact an authorised
dealer to have it repaired.
Do not disassemble the battery.
68 5
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Page 77
Operation 4
Battery use
Battery charger
1 Battery
2 Charging stand
3 LED light
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4 Operation
Battery use
Battery charger
– Remove the battery.
– Plug into chargin
(110/220V 50/60H
g stand and charge
Z).
70 5
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Page 79
Operation 4
Battery use
– The LED light (1) comes on.
NOTE
LED light mode
•
Charging:red LED light
•
Fully charged:green LED light
•
Charging fault:flashing yellow LED light
•
Battery fault:steady yellow LED light
WARNING
Before removing the bat
is completely powered o
The figure on the right is a top view diagram
of the charging contact pins (2).Correctly plug
the battery into the charging stand.
NOTE
tery, make sure the vehicle
ff.
If the battery is still not fully charged after five
hours, contact an authorised dealer.
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Page 80
4 Operation
Battery use
Charging complete
– The battery will take approximately 2.5
hours to fully charge at a voltage of
100–240 V AC.
– Insert the batter
holder.
y into the vehicle's battery
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Page 81
Operation 4
Hoisting
– A fully charged battery can last for three
hours of continuous use.
WARNING
Before returning the battery to the vehicle, ensure
that the vehicle is powered off.
CAUTION
Identify the positive and negative terminals according to the charging standcontact pins.
NOTE
Due to the characteristics of lithium batteries,
battery capacityis reduced in low-temperature
environments.
Hoisting
DANGER
Danger to life!
Personnel must not stand below or near the truck
when the pallet truck is being lifted.
WARNING
Risk of serious injury and/or major equipment
damage.
Use lifting hooks and a hoist with adequate lifting
capacity. Protect all components that come into
contact with the lifting device.
Truck weight (with battery):see technical specifications.
– Remove the load before hoisting the pallet
truck.
– Disconnect the power supply.
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4 Operation
Truck transport
– Attach slings in the positions identified by
the hook symbol.
CAUTION
Risk of major equipment damage.
It is strictly forbidden to attach the lifting slings to the
operating handle or to other points not intended for
this purpose.
Truck transport
– Place the truck on a wooden pallet.
NOTE
Only use haulage equipment with sufficient
load capacity.
•
The load weight is greater than the net
weight of the truck (including battery
weight). The load weight does not just
include the net weight of the truck, it also
includes the wooden pallet.
•
The pallet or wooden box should be large
and strong enough to withstand the weight
of the truck.
•
Pay attention to the fork blades when lifting
the truck onto the pallet, to prevent injuries
caused by the fork blades trailing on the
ground.
– Follow the prescribed steps and park the
vehicle correctly.
74 5
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Page 83
Operation 4
Truck transport
– Make sure the forks are aligned with the
pallet, move slowly and stop after inserting
the forks as far into the pallet as possible.
CAUTION
Operate on open, level ground and pay attention
to ground conditions when lifting and lowering the
pallet to prevent the truck from tipping.
When transporting the truck, make sure
it is fully secured and take precautionary
measures against bad weather.
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Page 84
4 Operation
Cleaning the Forklift
Cleaning the Forklift
Cleaning depends on the type of use and the
workplace. Should the truck come into contact
with highly aggressive elements such as salt
water, fertilizers, chemical products, cement,
etc., it should be cleaned as carefully as
possible afterevery work cycle. It is preferable
to use cold compressed air and detergents.
Use water-dampened rags to clean the parts
of the body.
CAUTION
Do not clean the truck with direct jets of water; DO
NOT use solvents and petrols that could damage
parts of the truck.
Storing the truck for an extended period
If the truck is to be decommissioned for a long
period, it must be parked in a frost-free anddry
location.Before decommissioning:
– Clean the truck thoroughly.
– Lower the fork arms to the lowest position
and unload the load.
– Check the brakes
– Check the hydraulic oil level and top up if
required.
– Apply a thin layer of lubricating oil or grease
to all non-painted mechanical components.
– Lubricate the truck in accordance with the
lubrication schedule.
– Remove the battery and recharge it at least
once per month.
– Clean the battery and apply specialised
grease to the terminals.
– Spay all exposed electrical contacts with a
suitable contact spray.
CAUTION
Jack up the truck so th
ground.This preven
the tyres.
at all wheels are clear of the
ts permanent deformation of
– Cover the truck with a cotton cover to protect
against dust.
CAUTION
We do not recommend using a plastic sheet as this
promotes the formation of condensation.
WARNING
Lithium-ion
and ventila
High tempe
life.
batteries must be stored in a cool, dry
ted place.
ratures (above 40°C) reduce the battery
76 5
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Page 85
5
Maintenance
Page 86
5 Maintenance
General servicing information
General servicing information
General
The following instructions contain all the
information required for servicing your truck.
Carry out the various maintenance work in
compliance with the maintenance plan. This
will ensure that your truck is reliable and in
good working order and that the warranty
remains valid.
Maintenance should only be carried out by
authorised technicians, or by authorised dealers in accordance with a signed maintenance
contract.
Modifying or installing a
on the forklift truck is pr
agreement of the manufact
NOTE
dditional equipment
ohibited without the
urer.
If the data plates or affixed labels are incomplete or damaged, they should be replaced
with new ones. For locations and reference
numbers, please see the spare parts catalogue.
CAUTION
If the forklifttruck is used in anextreme environment
(such as excessive heat, excessive cold or areas
with high dust concentrations), the time intervals
given inthe maintenance tables should be reduced
accordingly.
ENVIRONMENT NOTE
Please comply with regulations regarding
the use, handling and disposal of fuel and
lubricating oil.
The forklift must undergo functional testing
and a trial run after each inspection.
Service plan
Maintenance work must be carried outaccording to the maintenance checklist.
The service plan is follow
facilitate work.
Maintenance intervals must be reduced if the
truck is used under harsh conditions (extreme
heat or extreme cold, large quantities of dust).
ed by advice to
Grade and quantity of lubricants and
other consumables
Only lubricants and other consumables
specified in these operating instructions are
authorised for use during maintenance work.
Lubricants and other
for truck maintenanc
nance specifications
Never mix different qualities of grease or oil.
If it is absolutely necessary to change brands,
make sure to flush thoroughly beforehand.
Before changing any filters or working on
the hydraulic system, thoroughly clean the
surface and the areas around the part.
All containers used to
consumables required
e are listed in the mainte-
table.
pour oil must be clean.
Servicing and maintenance personnel training and qualification
Truck maintenance must only be carried out
by qualified and authorised personnel.
The annual inspection for prevention of
accidents at work must be carried out by a
person qualified to do so. The person carrying
out thisinspection must provide their expertise
and opinion without being influenced by
78 5
0018011505 EN - 10/2018
economic factors or company internal issues.
Safety is the only critical deciding factor.
The person responsible for carrying out the
inspection must have sufficient knowledge
andexperiencetobeabletoassessthe
condition of the truck and the efficiency of
the protective installations in accordance
Page 87
Maintenance 5
Inspection and maintenance
with the technical regulations and principles
established for checking industrial trucks.
Inspection and maintenance
Maintenance - 1000 hours / every 6 months
At operating hours
1000 3000 5000 7000 9000
11000 13000 15000 17000 19000
Functions and controls
Check and fasten the controller and contactor.
Check that cables are free from damage and that terminals are firmly attached.
Power and drive system
Check whether battery cables are damaged and replace if necessary.
Check the battery charging connector.
Check battery and battery holder for damage and liquid ingress.
Check the wheel bearings and their mounting.
Check whether weight-bearing bridge is damaged or broken.
Check the gearbox for abnormal sound and leakage.
Check and lubricate the bearings between the drive motor and gearbox.
Check and lubricate the drive chain.
Hydraulics
Check hoses, pipes and interfaces for damage and ensure their tightness and sea-
ling.
Check cylinders for leaks.
Check valves for leaks.
Check the hydraulic oil level.
Brake sy
Check the electromagnetic brake air gap.
Lithiu
Check the battery for damage.
Perform insulation testing of the battery.
Lifting system
stem
m-ion battery
Carried out
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Page 88
5 Maintenance
Inspection and maintenance
At operating hours
1000 3000 5000 7000 9000
11000 13000 15000 17000 19000
Check link mechanism for wear or damage.
Check whether pin shaft is fixed securely.
Check and lubricate moving parts on link mechanism.
Other
Check connections between nuts and bolts.
Check that labels are clear and complete.
Check covers for cracks.
Maintenance - 2000 hours / every 12 months
At operating hours
2000 4000 6000 8000 10000
12000 14000 16000 18000 20000
Note
Perform all 1000-hour maintenance work.
Functions and controls
Check error message record and operating time.
Power and driv
Check bearing positions for noise.
Clean or add gearbox grease.
Check driving speeds.
Hydraulics
Check cylinders for damage and ensure that they are properly secured.
Clean or change hydraulic oil.
Check overflow pressure.
Brake sy
Check that electromagnetic brakes are installed and connected.
Check braking distance of electromagnetic brakes.
Lifting system
e system
stem
Carried out
Carried out
80 5
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Page 89
Maintenance 5
Inspection and maintenance
At operating hours
2000 4000 6000 8000 10000
12000 14000 16000 18000 20000
Carried out
Check lifting and lowering speeds.
Other
Check chassis for cracks or damage.
Technical inspection and maintenance data
Lubricants table
Designation
Antifriction hydraulic oil
Antifriction hydraulic oil
(cold stores)
Multi-purpose lubricating
grease
Moly lithium grease no. 3
.
Model no. Amount added Position used
L-HM46
L-HV32
0.16–0.18 L
Hydraulics
Polylub GA352P As appropriate Sliding surfac
–
100 g
Transmissio
es
n
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5 Maintenance
Inspection and maintenance
Diagram for lubrication and servicing
A Hydraulic oil filler port
B Lubrication surface
C Gear oil filler port
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Maintenance 5
Inspection and maintenance
Lubrication of sliding surfaces
L1 Steel stopper ball
L2 Steering bearing
L3 Drive wheel
*L3 Drive wheel and drive chain
L4 Rollers
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5 Maintenance
Essential maintenance
Essential maintenance
Replacing the drive wheel
Replacing the drive wheel
– Remove the drive cowling (1).
– Remove the plate (2).
– Remove the motor and cable mounting
base and remove the motor cables (3).
– Loosen the six screws using a spanner,
then remove the drive wheel (5) from the
drive assembly (4).
– Refit in reverse order to removal.
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Maintenance 5
Essential maintenance
Replacing the load wheels
– Place a wooden block (1) under the load
wheels to raise them off the floor.
Double load wheels
– Remove the spiral slotted spring pin on the
wheel frame (1).
– Turn the wheel f
tion.
– Tap out the wheel pin spindle from the side.
– Remove the load wheels (2) and bearing
assembly (3).
rame to the vertical direc-
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5 Maintenance
Essential maintenance
Single load wheels
– Use a knockout pin to remove the spiral
slotted spring pin (1).
– Tap out the wheel pin spindle from the side.
– Remove the wheel (2) and bearing assem-
bly (3).
Changing the hydraulic oil
– Remove the hydraulic station protective
covers on both sides.
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Maintenance 5
Essential maintenance
– Remove the two screws on the left.
– Remove the screw on the right.
– Then remove the pu
mp housing and motor.
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5 Maintenance
Essential maintenance
– Remove the plug and drain theold hydraulic
fluid from this hole.
– Add new oil.
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6
Technical data
Page 98
6 Technical data
Main technical data
Main technical data
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Technical data 6
Technical datasheet
Technical datasheet
Description
1.1 Manufacturer Still
1.2 Model
Drive type:Battery, diesel, petrol, LP gas, mains
1.3
power
Operation
1.4
Nominal loading capacity Q (kg)
1.5
1.6 Load centre
1.8
Axle centre to fork face
1.9 Wheelbase
Weight
Service weight
2.1
Axle load with load, drive side/load side (±10%)
2.2
Axle load without load, drive side/load side (±10%)
2.3
Wheels
Tyres:pneumatic, polyurethane, rubber
3.1
3.2 Drive wheel sizes
Load wheel specifications Ø x w (mm)
3.3
Wheels, number d
3.5
Dimensions
Lift height h3 (mm)
4.4
Tiller height, t
4.9
Fork height, lowered
4.15
Overall length l1 (mm)
4.19
Length to fork
4.20
4.21 Total width
4.22 Dimensions of forks
Fork spread (outside of forks) b5 (mm) 560 (685)
4.25
rive side/load side (x=traction)
ravel position (min./max.)
face
c (mm)
x (mm) 950 (880)
y (mm) 1190 (1120)
kg
kg
kg
Ø x w (mm)
h14 (mm)
h13 (mm)
l2 (mm)
b1/b2
(mm)
s/e/l (mm)
ECH 12
Battery
Pedestrian
1200
600
130
420/910
110/20
PU/PU
210x70
80x60
1x+/4
110
800/1190
80
1540
390
560 (685)
53x150x1150
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6 Technical data
Technical datasheet
Dimensions
Ground clearance at centre of wheelbase, with load
4.32
Aisle width with 800 x 1200 mm pa
4.34
Turning radius
4.35
llet along forks
Performance data
Driving speed, full load/no load
5.1
Lifting speed, full load/no load
5.2
Lowering speed, full load/no load
5.3
Maximum climbing abilit
5.8
Acceleration time, with/without load
5.9
Brake type Electromagnetic
5.10
y, with/without load
Drive
Traction motor rating S2 60 min
6.1
Lifting motor rating at S3 15%
6.2
Battery according to DIN 43531/35/36 A, B, C, no
6.3
Battery voltage, nominal capacity K5
6.4
Battery weight (± 10%)
6.5
Energy consumption according to VDI cycle
6.6
m2 (mm)
Ast (mm)
Wa (mm)
27
2062
1390
km/h 4.0/4.5
m/s 0.02/0.025
m/s 0.06/0.03
%4/10
s
n/a
kW 0.65
kW 0.5
Lithium battery
V/Ah 24/20
kg
3.7
kW/h n/a
Other
8.1 Drive control method
Noise level at opera
8.4
.
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dB(A)
DC
<74
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