Still ECV 10 C, ECV 10i C, ECV 10 Original Instructions Manual

Original instructions

Electric Pallet Stacker

ECV 10 C
ECV 10i C
ECV 10

0342 0343 0344

50028011505 EN - 03/2018

Preface

Address of manufacturer and contact details

STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.still.de

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 to select suitable
industrial trucks for a particular area of
application

• Prerequisites for
industrial trucks

• Information on the use of industrialtrucks

• Information on transport, initial commis­sioning and storage of industrial trucks

thesafeoperationof

g

Internet address and QR code

The information c
by pasting the add
in a web browser or

an be accessed at any time

ress https://m.still.de/vdma

by scanning the QR code.

28011505 EN - 03/2018 I

500

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

Drivedirections ...................................................... 9

Illustrations ......................................................... 9

Environmental considerations .......................................... 10

Packaging ......................................................... 10

Disposal of components and batteries ..................................... 10

Series ............................................................ 10

Technical description ................................................. 1

Use of the truck ..................................................... 12

Intended use of the trucks .............................................. 12

Unauthorised use .................................................... 13

Placeofuse ........................................................ 13

Residual risks ...................................................... 14

Residualrisks ...................................................... 14

Specialrisksassociatedwithusingthetruckandattachments ................... 14

Overviewofhazardsandcountermeasures ................................. 16

Danger to employees . . ............................................... 19

ation ......................................... 4

d ............................................ 6

g

1

2Safety

Definition of terms used for responsible persons ............................. 22

Operatingcompany .................................................. 22

Specialist .......................................................... 22

Drivers ........................................................... 22

Basic principles for safe operation ....................................... 24

Insurance cover on comp

Modificationsandrefitting .............................................. 24

Warning regarding non-original parts ..................................... 24

Damage, faults ..................................................... 25

Medicaldevices ..................................................... 25

anypremises .................................... 24

28011505 EN - 03/2018 III

500

Table of contents

g

Vibrations ......................................................... 26

Safety tests ........................................................ 27

Carrying out regular inspecti

Insulationtesting .................................................... 27

Safety regulations for handling consumables ............................... 29

Permissibleconsumables ............................................. 29

Oils .............................................................. 29

Hydraulicfluid ...................................................... 30

Batteryacid ........................................................ 30

Disposalofconsumables .............................................. 31

Safety devices ...................................................... 31

Damage, faults ..................................................... 31

Battery connection cables ............................................. 31

EMC – Electromagnetic compatibility ..................................... 32

onsonthetruck ................................ 27

3Views

Drive directions ..................................................... 34

Main Components ................................................... 35

Dataplate and safety labels ............................................ 37

Load label ......................................................... 38

Identification plate ................................................... 38

4 Operation

Intended use of the trucks .............................................. 42

First use .......................................................... 42

Daily checks before use ............................................... 43

Checking the working environment ....................................... 43

General informati

Charging and discharging batteries ...................................... 44

Drive operations .................................................... 46

Description ........................................................ 46

Starting ........................................................... 47

Forwardtravel/reversetravel ........................................... 49

Brake ............................................................ 49

Safetyreverser ..................................................... 51

Steering ........................................................... 51

IV 5

on on batteries ......................................... 44

0028011505 EN - 03/2018

Table of contents

Horn operation ...................................................... 52

Usingthetruckonaslope .............................................. 52

Hydraulic operations ................................................. 54

Useofthemast ..................................................... 54

Workingwithloads ................................................... 55

Emergency lowering . . ............................................... 58

Before leaving the equipment ........................................... 60

Putting the equipment back into operation .................................. 61

Slinging ........................................................... 61

Transporting the truck ................................................ 62

5 Maintenance

General maintenance information ........................................ 64

General ........................................................... 64

Servicing and maintenance personnel training and qualification . ................. 64

Battery maintenance staff .............................................. 65

Maintenance operation

Technical inspection and maintenance data ................................ 65

Maintenance - 1000 hours / every 12 months ................................ 65

Maintenance - 2000 ho

Maintenance work ................................................... 67

Changing the battery . . ............................................... 67

Lubricationpoint .................................................... 70

Checkthehydraulicoillevel ............................................ 71

Topping up the gear oil . ............................................... 72

Checkingthefuses ................................................... 73

Tyre operation ...................................................... 74

Drive Wheel ........................................................ 74

Load Wheels - Removal and I

Caster-RemovalandInstallation ........................................ 76

Malfunction analysis ................................................. 78

s that do not require special training ..................... 65

urs / every 2 years .................................. 67

nstallation ................................... 75

g

6 Technical data

ECV 10 Technical Datas

ECV 10i C / ECV 10 C Technical Datasheet ................................. 83

heet ........................................... 80

28011505 EN - 03/2018 V

500

1

Introduction

1 Introduction

Your industrial truck

Your industrial truck

General

The truck described 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 accidents and 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

028011505 EN - 03/2018

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

28011505 EN - 03/2018 3

500

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 operating instructions describe all mea­sures necessary for the safe operation and

028011505 EN - 03/2018

parts list

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. 22) 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.

28011505 EN - 03/2018 5

500

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 procedure that must followed to avoid
injury.

CAUTION

Compulsory procedure that must be followed to
avoid material damage and/or destruction.

NOTE

For technical requirements that require
special attention.

ENVIRONMENT NOTE

To prevent environmental damage.

650

028011505 EN - 03/2018

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 claims concerning 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

28011505 EN - 03/2018 7

500

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

028011505 EN - 03/2018

Introduction 1

Information about documentation

Abbrevi­ation

VDI

VDMA

WLAN Wireless LAN Wireless local area network

.

Meaning

Verein Deutscher Ingenieure
Verband Deutscher Maschinen- und

Anlagenbau e.V.

Explanation

German technical/scientific a
German Mechanical Enginee

Association

Drive directions

The drive directions of the vehicle are forward
(1), reverse (4), left (2) and right (3).

ssociation

ring Industry

Illustrati

At many po
(mostly s
ons or ope
illustrate
sentations

ons

ints in this documentation the

equential) operation of certain functi-

rating procedures is explained. To

these operations, schematic repre-

of an truck are used.

NOTE

These schematic representations do not
represent the design state of the documented
truck. They only serve to illustrate operating
procedures.

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500

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.

Series

The electric Pallet Stacker is suitable for
stacking operations in narrow aisles and
confined spaces.

This series of electric pallet stacker includes
the following models:

10 5

0028011505 EN - 03/2018

• 0342_ECV 10 C: simplex narrow electric
pallettruckwithratedloadof1000kg.

• 0343_ECV 10i C: simplex narrow electric
pallet truck with initial lift and rated load of
1000 kg.

• 0344_ECV 10 duplex narrow electric pallet
truck with rated load of 1000 kg.

Introduction 1

Technical description

Technical description

This product has a compact chassis, 4-point
ground contact, balancedtiller and a micropro­cessor electronic control system.The machine
is lightweight, highly efficient and easy to han­dle.

Design

The latest ergonomic and practical design,
adaptable to all operators and working condi­tions.

The polyurethane cowling p
stability and shock resist
variety of storage spaces

The frame is made of thick steel plate and is
suitable for the harshest working conditions.

rovides superior

ance, and has a

.

The anti-crush button integrated into the
tiller head protects the operator if the vehicle
recoils.

Driving

The MOSFET electronic control unit ensures
comfortable use and lower costs.

Precise control of driving

Jolt-free starting and smooth acceleration to
maximum speed.

Simply release or turn the drive direction
switch to brake.

Booster circuit prevent
when starting on a gradie

speed.

s the truck rolling back

nt.

Steering system

Extremely smooth steering makes the vehicle
easier to manoeuvre in tight spaces.

A gas spring enables th
to the vertical positi

e tiller to quickly return

on after it is released.

Tiller

The composite construction tiller head pro­vides excellent impact resistance.

The ergonomic control layout is suitable for
left-handed and right-handed operators.

The horn, lifting and
operated using one ha
grip.

The walking, lifting and lowering devices,
harnesses and components are IP65 dust­and water-resistant.

lowering devices can be

nd without changing

Hydraulics

Gear pump driven by fully enclosed air-cooled
motor.

Safety valve and lowering brake protect the
hydraulic system.

Brake system

The electromagnetic b
tion function can be us
and parking brake.Br
drive controller, the
acts on the motor shaft
is activated when the t
or vertical position (

rake with dust protec­ed as a safety brake

aking is controlled by the

brake's electromagnet

and automatic braking

iller is in the horizontal

end stop brake).

Battery

2 x 12 V/85 Ah batteries. The display instru­ment indicates the battery’s remaining charge.

28011505 EN - 03/2018 11

500

1 Introduction

Use of the truck

Use of the truck

Intended use of the trucks

CAUTION

This machine was designed f
storage on racks (pallet
packedonpalletsorinin
signed for this purpose

The dimensions and cap
ner must be adapted to t
and must ensure stabi

The table of characte
ched to this user man
you need to check tha
the work being car

Any specific usag
site manager; an
associated wit
place any neces

ried out.

e must be authorised by the

analysis of the potential risks

h this usage will enable him to put in

sary additional safety measures.

or the transport and

stackers only) of loads

dustrial containers de-

.

acity of the pallet or contai­he load being transported

lity.

ristics and performance atta-

ual gives you the information

t the equipment is suitable for

12 5

0028011505 EN - 03/2018

Introduction 1

Use of the truck

Unauthorised use

Any danger caused 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.

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.

Place of use

The truck only can be used i

The sites on which the truck is used must com­ply with the applicable regulations (condition
of the ground, lighting etc.).

The ground must have sufficient load capacity
(concrete, asphalt).

The truck is suitable fo
tures ranging from 5°C t
mum operation altitude

n indoors.

r indoor use (tempera-

o +40°C). The maxi-

is up to 2000 m.

The operator (see chapter
of terms used for responsi
ensure that appropriate
available in the vicinit
operation.

Depending on the application, additional fire
protection must be provided on the industrial
truck. If in doubt, please contact the relevant
authorities.

entitled "Definition

ble persons") must

fireprotectionis

y of the truck during

28011505 EN - 03/2018 13

500

1 Introduction

Residual risks

Residual risks

Residual risks

Despite careful operation 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

softhetruck

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

14 5

ated with using the truck and attachments

approval is required as

0028011505 EN - 03/2018

Introduction 1

Residual risks

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500

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

16 5

0028011505 EN - 03/2018

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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500

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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0028011505 EN - 03/2018

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 safety measures 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 and equipment of the 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.

28011505 EN - 03/2018 19

500

1 Introduction

Residual risks

20 5

0028011505 EN - 03/2018

2

Safety

2 Safety

Definition of terms used for respons

ible persons

Definition of terms used for responsible persons

Operating company

The operating company is the natural or legal
person or group who operates the truck or on
whose authority the truck is used.

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.

Specialist

A specialist is deemed t

• A person whose experience and technical
training has allowed him to develop relevant
knowledge of industrial trucks

• A person who is also familiar with national
health and safety regulations and gener­ally recognised technical directives and

obe:

The operating company must ensure that
all users read and understand the safety
information in these instructions.

The operating company is responsible for the
scheduling and correct performance of regular
safety checks.

It is recommended that thes
with national performance

conventions (standard
technical regulations
Union member states or c
signatories to the trea
European Economic Area
allows him to assess the
trial trucks in terms o

e checks comply

specifications.

s, VDE regulations,

of other European

ountries that are

ty that established the

). This expertise

condition of indus-

f health and safety

Drivers

This truck may only be driven by suitable per­sons who are at least 18 years of age, have
been trained in driving, have demonstrated
their skills in driving and handling loads to
the operating company or an authorised rep­resentative, and have been specifically in­structed to drive the truck. Specific knowledge
of the truck to be operated is also required.

The training requirements
Health and Safety at Work Ac
plant safety regulations
been satisfied if the drive
accordance with BGG (Gene
Liability Insurance Asso
Observe the national regu
country.

Driver rights, duties an
haviour

The driver must be trained in his rights and
duties.

22 5

under §3 of the

t and §9 of the

are deemed to have

r has been trained in

ral Employers'

ciation Act) 925.

lations for your

d rules of be-

0028011505 EN - 03/2018

Safety 2

Definition of terms used for respons

The driver must be granted the required rights.

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 w
instructions and have acces
times.

The driver must:

• have read and understood the operating
manual

• have familiarised himself with safe opera­tion of the truck

• be physically and mentall
truck safely

DANGER

The use of drugs, alcohol or 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.

ith the operating

stothematall

y able to drive the

ible persons

Prohibition of use by unauthorised
persons

The driver is responsible for the truck during
working hours. He must not allow unautho­rised persons to operate the truck.

When leaving the truck, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.

28011505 EN - 03/2018 23

500

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 operational liability
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 contact the 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,

24 5

0028011505 EN - 03/2018

attachment parts and accessories supplied
by other companies have not been tested or
approved by STILL.

Safety 2

Basic principles for safe operatio

CAUTION

The installation or use of such products may have a
negative impact on 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 authorities before 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 removedor disabled. 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

28011505 EN - 03/2018 25

500

2 Safety

Basic principles for safe operatio

Vibrations

Vibrations to which the hands and arms
are exposed

The following value is valid 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.

26 5

0028011505 EN - 03/2018

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.

28011505 EN - 03/2018 27

500

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

28 5

0028011505 EN - 03/2018

Safety 2

Safety regulations for handling co

nsumables

Safety regulations for handling consumables

Permissible consumables

WARNING

Consumables can be dangero
It is necessary to follow

handling these substan

the safety regulations when

ces.

Oils

DANGER

Oils are flammable!
– Follow the statutory regulations
– Do not allow oils to come into

contact with hot motor parts.

– Nosmoking, fires or flames!

DANGER

Oils are toxic!
– Avoid contact and consumption
– Incase of inhalation of steam or fu-

mes, breathe fresh air immediately.

– Aftercontact 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.
– Wearprotective gloves!
– After any contact, wash the skin

with soap and water and then apply
askincareproduct.

– Immediately change soaked

clothing and shoes.

28011505 EN - 03/2018 29

500

2 Safety

Safety regulations for handling co

Hydraulic fluid

nsumables

WARNING

During operation of the forklift truck,
hydraulic fluids are pressurised and
are hazardous to your health.

– Donot spill these fluids!
– Follow the statutory regulations
– Donot allow the fluids to come into

contact with hot motor parts.

– Donot allow to come into contact

with the skin.
– Avoidinhaling the spray
– Penetration of pressurised fluids

into the skin is particularly danger-

ous if these fluids escape at high

pressure due to leaks in the hydrau-

lic system. In case of such injury,

seek medical advice immediately.
– To avoid injury, use appropriate

personal protective equipment

(e.g. protective gloves, industrial

goggles, skin protection and skin

care products).

ENVIRONMENT NOTE

Battery acid

WARNING

Battery acid
sulphuric

– Avoidcon
–Incase

advic

contains dissolved

acid. This is toxic.

tact and consumption.

of injury, seek medical

e immediately.

Hydraulic fluid is a water-polluting substance!

Always store hydraulic fluid i
complying with the regulatio

n containers

ns.

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

id according to

regulations.

WARNING

Battery acid
sulphuric

–Whenwork

always w
and ey

–Dono

th
eye
im
water.

– In case of injury, seek medical

advice immediately.

– Immediately rinse away spilt

battery acid with plenty of water.

– Follow the statutory regulations

contains dissolved

acid. This is corrosive.

ingwithbatteryacid,

ear protective clothing

e protection.

t allow any acid to get onto

eclothingorskinorintothe

s; if this does happen, rinse

mediately with plenty of clean

30 5

ENVI

0028011505 EN - 03/2018

RONMENT NOTE

Safety 2

Safety devices

– Dispose of used battery acid in line with the

applicable regulations.

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.

• Any spillage of fluids such as
brake fluid or gear lubrica
immediately soaked up wit
agent.

• The regulations for disposal of used oil are
applicable.

• Any spillage of battery acid must be neu­tralised immediately.

hydraulic oil,

nt oil must be

hanoil-binding

Safety devices

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 or disabled. The predefined
setpoint values must not be modified.

Work on the electric installation (e.g. connect­ing a radio, additional lights or other acces­sories) is permitted only with the approval of
the manufacturer.

Battery connection cables

CAUTION

Using sockets
nection cab
referenc

with NON-ORIGINAL battery con-

les can be dangerous (see purchase

es in the parts catalogue)

500

28011505 EN - 03/2018 31

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 interference emitted by the truck 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 components must be installed and connected
again.

32 5

0028011505 EN - 03/2018

3

Views

3 Views

Drive directions

Drive directions

The drive directions of the vehicle are forward
(1), reverse (4), left (2) and right (3).

34 5

0028011505 EN - 03/2018

Views 3

Main Components

Main Components

Truck Assemblies

1 Tiller
2 Key switch
3 LED Lamp
4 Mast cover
5 Lift Cylinder
6 Battery discharge indicator
7 Battery charge connector
8 Emergency brake switch
9 Lift mechanism

10 Battery
11 Chassis
12 Balance wheel
13 Cover (nether)
14 Driving wheel
15 Cover(upper)
16 Tank
17 Hydraulic Pump

28011505 EN - 03/2018 35

500

3 Views

Main Components

Tiller

18 “Lower” button
19 “Lift” button
20 Travel switch
21 Warning signal button
22 Collision safety switch

36 5

0028011505 EN - 03/2018

Views 3

Dataplate and safety labels

Dataplate and safety labels

1 Truck identification plate
2 Prohibition label
3 Mast safety label
4 Warning label（For initial lift version only）
5 Indicator label
6 Truck slinging label

28011505 EN - 03/2018 37

500

7 Driving safety label （Adjust position for

initial lift version only）
8 Company logo
9 LOGO sticker
10 Load curve
11 Vehicle body number
12 Warning label（For initial lift version only）

3 Views

Load label

Load label

This label shows the relationship between the
position of the load centre and the maximum
load.

Before loading, check that the load and load
centre distance are within the range permitted
by the bearing capacity icons.

Identification plate

1 Type 2 Serial number

38 5

0028011505 EN - 03/2018

Views 3

Identification plate

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)

7 Own mass (self weight) in kg without battery

8 Manufacturer
9 Refer to technical data listed in this operating

instructions for more detailed information
10 CE label
11 Rated drive power in kW
12 Battery voltage in V
13 Rated capacity

28011505 EN - 03/2018 39

500

3 Views

Identification plate

40 5

0028011505 EN - 03/2018

4

Operation

4 Operation

Intended use of the trucks

Intended use of the trucks

CAUTION

This machine was designed fo
storage on racks (pallet st
packed on pallets or in indu
signed for this purpose.

The dimensions and capa
ner must be adapted to th
and must ensure stabil

The table of characte
ched to this user manu
you need to check tha
the work being carri

Any specific usage m
site manager; an a
associated with
place any necess

ed out.

nalysis of the potential risks

this usage will enable him to put in

ary additional safety measures.

r the transport and

ackers only) of loads

strial containers de-

city of the pallet or contai-

e load being transported

ity.

ristics and performance atta-

al gives you the information

t the equipment is suitable for

ust be authorised by the

First use

Carried out





Check forwar

Check lifti

Check meter status.

Check brak

Check the

Check horn.

Check sa

Check b

Check s

Check

Check

d and reverse driving control functions.

ng and lowering control functions.

e system function.

emergency off switch.

fety reverser function.

attery status.

teering function.

for oil leakage.

whether wheels are tightened.

42 5

0028011505 EN - 03/2018

Operation 4

Daily checks before use

Daily checks before use

Carried out





Check operation switch, display equipment and component functions.

Check alarm system function.

Check the function of the interlock switch.

Check emergency power off function of emergency stop switch.

Check the function of the steering system.

Check travel switch setting function.

Check the battery charging connector.
Check that the battery cable connections are tight and grease the battery poles if

necessary.
Check the drive wheels and rollers for wear and damage.

Check the hydraulic functions.

Check brake function of electromagnetic brakes.

Check whether optional functions are operating normally.

Checking the working environment

Remember to check the working environment
carefully before use.

There must no
consumables un

The work area must be kept clear.There must
not be any obstacles or people on the driving
route.

The driver must be vigilant about anything that
could hinder safe operation:

• There mus
of the veh

• There must not be any people under the
forks after they have been lifted

t be any trace of leakage of

der the equipment.

t not be any people in the vicinity

icle

28011505 EN - 03/2018 43

500

• The driver must not use a media player or
any other electronic device that may affect
their peripheral awareness

• There must be
floor

The driver must be particularly careful when
transporting goods.The size of the goods
may affect vehicle handling and obstruct
visibility.The driver must slow down when
braking or turning, because the truck may tip
over.

The driver must slow down when passing
obstacles, to prevent the truck from losing
balance and driver hand-arm vibration.

no trace of grease on the

4 Operation

General information on batteries

General information on batteries

You can choose different types of batteries.
These must strictly comply with manufacturer
instructions.

Please comply with the details and properties
indicated on the battery type label.

NOTE

Battery maintenance or charging can only

•

be performed by qualified personnel in
accordance with these instructions and the
battery manufacturer’s instructions.

•

Refilling batteries with an electrolyte solu­tion is prohibited if they are a type that does
not require maintenance.

•

Batteries are recycled in accordance with
national regulations; please comply with the
relevant regulations.

•

Open flames are prohibited when handling
batteries, as the gas may cause an explo­sion.

•

Non-flammable materials or liquids may
be stored in locations where batteries
are charged.Smoking is prohibited in
these locations, which must also be kept
ventilated.

•

Please stop the vehicle before starting to
charge or install/replace batteries.

•

Before completing maintena
please ensure that all cable
correctly and do not interfe
parts of the vehicle.

•

Fire-fighting equipment must be prepared.

NOTE

The truck must be parked in a suitable and
safe place when batteries are being handled.

CAUTION

Metal or conductive objects must not be placed on
top of the battery in order to prevent the battery from
short circuiting.

nce work,

s are connected

re with other

Charging and discha

rging

batteries

NOTE

Charging precautions

•

The vehicle must be parked in a well­ventilated room.

•

There must be no metal parts on the surface
of the battery.

•

Before starting to charge, check all cable
connections and plug connectors for
obvious damage.

•

The related safety regulations of the battery
and charging device manufacturer must be
strictly observed.

44 5

0028011505 EN - 03/2018

Operation 4

Charging and discharging batterie

Introduction to battery indicators (with
hour meter)

The battery meter displays the remaining
charge and number of hours.

After turning on the device with the key switch,
the remaining charge and total run time will be
displayed.

The remaining charge indicator will change
colour based on charge changes.

Indicator colour

Green

Orange

Red flashing

NOTE

Remaining charge
(reference value)

70 — 100%

30 — 60%

0 — 20%

1 Remaining charge indicator
2 Hour meter (displays total run time)

When 70% of the battery has been dischar­ged, the indicator will start flashing red and
give a "Battery Low" warning.

NOTE

When 80% of the battery has been dischar­ged, the last two indicator lights will flash red
and give a "Battery Depleted" warning.The
battery must be charged.

s

NOTE

This vehicle has a l
function.When the
fork is still abl
that the battery
the controller wil
protection funct

ow-voltage protection

vehicle slows down but the

e to lift, the vehicle will indicate

voltage is insufficient and

l activate the low-voltage

ion.The battery now needs to

be charged.

The hour meter (2)displays the total run time.
Its display range is from 0.0 to 9999.0 hours
and it records the total time spent on driving
and lifting operations.This is displayed in the
background.

Charging procedure

– Control precautions Check for compliance

with charging requirements.

28011505 EN - 03/2018 45

500

4 Operation

Drive operations

– Park the truck as specified.

– Unplug the mains plug(1), the

suitable power supply.

CAUTION

There is a risk of damage to the equipment.
The charging voltage range is 100-240V. Please do

not exceed this voltage range.

Charging indicator(2)

Charging indicator(2)

Red light remains lit

Green light remains lit

Yellow light remains lit

Flashing yel

low light

Flashing red light

Indicator lights fail to light up Charging equipment fault

.

nplugitintoa

Description

Charger is charging

Battery charging is complete

Battery fault

Charging equipment fault

No output current from charging
equipment

Malfunction analysis

Normal status

Normal status
Battery voltage is less than13V

or greater than 32.5V
Output overcurrent;

output overvoltage;
charging equipment tempera­ture is too high.

Charging eq
remove batt

The inpu
disco
equipme

uipment damaged;

ery.

t power cable is

nnected or the charging

nt is damaged.

Drive operations

Description

This device is designed for non-hazardous
indoor environments.Its working temperature
should be within the specified range.

These models comply with the EN 12895 stan­dard on electromagnetic compatibility.Correct
operation can no longer be guaranteed in ar-

46 5

0028011505 EN - 03/2018

eas where the electromagnetic fields could
exceed the thresholds specified by the stan­dard.

The trucks must be used on dry, clean, flat
ground.

Operation 4

Drive operations

Low-lift stackers without initial lift can go over
ramps and gentle slopes.Low-lift stackers with
initial lift can go over larger obstacles.

Loads must be homogenous, with a maximum
recommended height of 2 m.

CAUTION

Always adapt your driving to the ground conditions
(uneven surfaces, etc.), particularly hazardous
working areas and the load.

CAUTION

– Toprevent the bottom of the lifting system from

scraping the ground, always raise the forks
halfway up before setting off.

– Remember to turn off the power supply before

leaving the equipment.

– Foreffective protection, wearing safety footwear

is compulsory.

– Whentravelling,themastmustbetiltedback-

ward and the load must be in the lowered posi­tion.

Starting

– Pull the emergency off switch (2) to the

raised position.

CAUTION

Driving safety instructions
– Thedriver must drive slowly around corners and

when entering narrow passageways.

– Thedriver must always maintain a safe braking

distance from vehicles or persons in front of him.

– Thedriver must avoid braking suddenly, making

U-turns too quickly and overtaking in areas with
poor visibility.

CAUTION

The working area of the truck must be adequately
lit.

If the working area is not sufficiently illuminated,
working spotlights must be installed to ensure that
the driver can see properly.

28011505 EN - 03/2018 47

500

4 Operation

Drive operations

– Turn the key switch (1) to the ON position;

the battery indicator light will come on.

– Put the tiller in the drive position(M) and

use the drive switch to control direction and
speed.

NOTE

Fisforwards.

•

•

R is reverse.

•

Bisbrake.

•

M is drive.

NOTE

When the tiller is in the brake position(M),
the electromagnetic brake is locked and the
vehicle cannot be driven.

48 5

0028011505 EN - 03/2018

Operation 4

Drive operations

Forward travel/reverse travel

Forward travel

– Use your thumb to press the drive switch,

gently and gradually increasing the force in
the (F) direction.

The vehicle will accelerat
according to the pressure a
switch.

e and move forwards

pplied to the drive

Reverse drive

– Use your thumb to press the drive switch,

gently and gradually increasing the force in
the (R) direction.

The vehicle will accelerate and move back­wards according to the pressure applied to the
drive switch.

Brake

NOTE

The braking performance of the equipment
depends very much on the condition of
the floor surface.This should be taken into
consideration when driving.

NOTE

The driver must drive carefully and cau­tiously.When there is no danger, the driver
must use moderate braking to avoid the load
moving or the trailer becoming detached.

Braking can be done in the following ways:

• Emergency stop brake

• Automatic braking

• Regenerative braking

• Reverse braking

Emergency stop brake

– Press the emergency off sw

equipment power supply wi

itch (2); the

ll be cut off.

28011505 EN - 03/2018 49

500

4 Operation

Drive operations

Automatic braking

– Releasing the tiller (1) will initiate forced

braking.

Slackening the tiller (1) will
to the braking area (B). Altern
the tiller to the brake area (B)
also initiate forced brakin

CAUTION

If the tiller moves slowly into the brake position,
identify the cause and rectify the fault.

If necessary, replace the gas spring!

Regenerative braking

– Release the drive switch. The drive switch

will automatically return to the initial position
and the vehicle will begin to enter the regen­erative braking state. When it decelerates
to <1 km/h, the electromagnetic brake will
bringthemotortoastop.

CAUTION

Open the drive switch; if the drive switch cannot
quickly return to the initial position or resets very
slowly, identify the cause and rectify the fault.

causeittomove

atively, lowering

at the bottom will

g.

Reverse braking

– Switching the drive switch to the opposite

direction while travelling brakes the vehicle
by reverse current until it starts moving in
the opposite direction.

50 5

0028011505 EN - 03/2018

Operation 4

Drive operations

Safety reverser

To protect the driver from any
trapped between an obstacle a
chine, the end of the tiller is
reverser.

Once the safety reverser is triggered(1), the
equipment will stop immediately, then slowly
move back in the direction of the fork.

risk of being

nd the ma-

fitted with a safety

Steering

– Turn the tiller (1) left or right according to the

desired direction.

28011505 EN - 03/2018 51

500

4 Operation

Drive operations

Horn operation

The horn must be used on routes with poor
visibility and at junctions.

– Pressthehornbutton(1)locatedonthe

tiller arm.

Using the truck on

NOTE

Incorrect use of the truck on slopes is not
recommended.It places particular stress on
the traction motor, brakes and battery.

Ramps must always be approached with great
caution:

• Never attempt a slope with a gradient
greater than that specified in the truck's
datasheet

• Make sure that the ground is clean and has
a non-slip surface, and that the route is clear

a slope

52 5

0028011505 EN - 03/2018

Operation 4

Drive operations

Ascending slopes

Travel up slopes must always be in reverse,
with the load uphill.

Without a load, we recommend t

hat you

ascend slopes forwards.

Descending slopes

Travel down slopes must always be forwards,
with the load uphill.

Without a load, it is recommended that slopes
are descended forwards.

In all cases, you must travel at a very low
speed and brake very gradually.

DANGER

Risk to life and/or risk of serious damage to equip­ment.

Never park the truck on a slope.Never make a
U-turn or take shortcuts on a slope.The driver must
drive very slowly on slopes.

CAUTION

Risk of serious injury and/or serious damage to
equipment.

Driving on a slope that exceeds the specified gra­dient is prohibited due to limited braking capacity.

Starting on a slope

– Activate the direction control button in the

required direction.

– Put the tiller in drive.

– Release the control button in order to brake.

28011505 EN - 03/2018 53

500

4 Operation

Hydraulic operations

Hydraulic operations

Use of the mast

CAUTION

Only the specified lifting device can be used. The
driver must receive guidance related to the opera­tional aspects of the lifting device.

CAUTION

Never put your hands nea

CAUTION

The mast protective screen must always be in
place, correctly fixed and clean to provide good
visibility.

DANGER

Loads that are not p
accordance with
risk.

– Instruct all pe

any person is lo
equipment imm

– Onlytranspor

and secured
opt appropri
at risk of tip

– Donot use d

load.

–Nevers
– Personn

compo

–Thiseq
–Tryt

goo

rsonnel to vacate the hazard area.If

in accordance with regulations.Ad-

ate protective measures if the load is

ping over or falling during transport.

amaged handling tools to handle a

tay under raised load components.

el are prohibited from entering load

nents.

uipment must not be used to lift people.

o move the forks until they are under the

ds.

r the lifting mechanism.

ositioned and secured in

the regulations pose an accident

cated in the hazard area, stop the
ediately.

t loads that have been positioned

CAUTION

Before picking up the goods, the driver must ensure
that the goods have been coded correctly and
stacked up well.

The weight must not exceed the rated load of this
equipment.

Do not place long loads sideways across the forks.

54 5

0028011505 EN - 03/2018

Operation 4

Hydraulic operations

Mast lifting and lowering

– Press the lift button(2) until the goods reach

the required height, then release the button.

– Press the lower button(18) until the goods

are lowered to the required height, then
release the button.

CAUTION

To avoid shortening the service life of the cylinder,
try to avoid raising the forks to maximum height
when lifting.

Working with loads

– Before picking up a load

Ensure that its weight does not exceed the
equipment's lift capacity.

– Refer to the nominal capacity specified on

the equipment's capacity rating plate.

– Also make sure that the load is stable,

well-balanced and centred between the
forks to avoid dropping any part of the load.

– Check that the width of the load is compati-

ble with the width of the forks.

CAUTION

Safety foot

wear must be worn.

CAUTION

Transporting people is strictly prohibited.

DANGER

ntial to slow down when approaching a

It is esse

on wet floors.

corner or

28011505 EN - 03/2018 55

500

4 Operation

Hydraulic operations

CAUTION

Do not touch nearby loads or loads positioned at
the side or in front of the load being handled.

Arrange the loads with a small space between
them to prevent them coming into contact with one
another.

Picking up a load from the ground

– Approach goods careful

vehicle.

– Lower the forks so that they can easily be

inserted into the pallet.

– Insert the forks below the pallet.

– If the goods are short

the goods a few centim
the forks so as not to s
front.

– Lift the goods a few centimetres.

Carrying a load

DANGER

Personnel must not stand under or near the truck
when the load is in the raised position.

ly when driving the

er than the forks, move

etres from the end of

cratch the goods in

DANGER

Never transpo
position as t

rtaloadwiththeforksintheraised

he equipment may become unstable.

– Always drive forwards for optimum visibility.

– When carrying a load on a slope, always

climb and descend with the load up­hill.Never travel diagonally across the slope
or make a U-turn.

– Reverse gear mu

ing a load.Sinc
restricted, you s

st only be used for deposit-

e visibility in this direction is

hould only travel at very low

speed.

– Never drive with an unstable load.

– If visibility is p

oor, let someone guide you.

– Be careful of low passageways, low door-

ways, scaffolding, pipes etc.

56 5

0028011505 EN - 03/2018

Operation 4

Hydraulic operations

– To facilitate movement over obstacles,

increase the ground clearance.

– Check that the width of the load is compati-

ble with the width of the aisle.

Setting a load down on the ground

– Carefully move the load int

area.

– Lower the load until the fork arms are free.

– Move the forks straight back.

– Lift the forks a few centime

CAUTION

Be careful not to touch nearby loads or thosebehind
the equipment.

CAUTION

Do not touch nearby loads or loads positioned
behind the equipment.

CAUTION

Before you remove the load, ensure that there are
no people in the vicinity.

o the deposit

tres again.

Stacking a load

– Carefully drive the machine to the required

location.

– Raise the forks clearly above the level

where the load is to be placed.

– Drive the truck forward into the racking.

– Lower the load until the fork arms are free.

– Move the forks straight back.

– Lower the forks again until they are a few

centimetres away from the ground.

DANGER

Personnel must not stand under or near the truck
when the load is in the raised position.

28011505 EN - 03/2018 57

500

4 Operation

Hydraulic operations

Picking up a load at height

– Carefully drive the machine to the required

location.

– Raise the forks to the height o

– Carefully move the forks forward under the

pallet.

– Lift the forks until the pallet moves away

from the racking.

– Reverse the truck to free th

– Lower the goods again until they are a few

centimetres away from the ground.

CAUTION

If the equipment has an initial lift control, separate
the goods from the racking. To maintain maximum
stability, never use the initial lift control, to avoid
overloading the equipment.

Emergency lowering

The solenoid valve is equipped with an emer­gency lowering screw for manual emergency
lowering.This operation can be executed if the
hydraulic system develops a fault.The sole­noid valve with the emergency lowering screw
is located on the valve body of the hydraulic
pump.

CAUTION

Do not stand in t
arms are being lo

Always keep yo
lowering, so
at any time.

he vicinity of the forks when the fork

wered.

ur hands on the screw during

you can stop the lowering operation

f the pallet.

e pallet.

58 5

0028011505 EN - 03/2018

Operation 4

Hydraulic operations

– Unscrew the two large flat-head screws(1)

and pull out the cover(2).

The emergency lowering screw is located on
the solenoid valve(2).

28011505 EN - 03/2018 59

500

4 Operation

Before leaving the equipment

Before leaving the equipment

CAUTION

Always stop the machine on level ground away from
traffic routes.

– Lower the fork arms to the lowest position.

– Turn off the key switch (1).

– Press the emergency off switch (2).

– If the machine is to be taken out of service

for an extended period, disconnect the
battery connections.

NOTE

If the truck is to be decommissioned for more
than two months, it must be parked in a dry,
frost-free location.

NOTE

On decommissioning, the truck must be
jacked up so that all the wheels are clear of
the ground.This is the only way of ensuring
that the wheels and wheel bearings are not
damaged.

NOTE

Precautions p

•

Thoroughly clea

•

Check the brakes.

•

Check the hydraulic oil level.Top up if

rior to decommissioning

n the truck.

required.

•

Apply a thin la
unpainted mec

•

Lubricate the truck in accordance with the

yer of oil or grease to all

hanical components.

lubrication schedule.

•

Disconnect the battery plugs, clean the
battery and apply specialised grease to the
terminals.

•

Spay all exposed el
suitable contact s

60 5

ectrical contacts with a

pray.

0028011505 EN - 03/2018

Operation 4

Putting the equipment back into ope

NOTE

ration

The battery must be charged every month
to avoid depletion of the battery through
self-discharge, as the sulfation would destroy
the battery.

Putting the equipment back into operation

– Thoroughly clean the truck.

– Lubricate the equipment according to the

lubrication and servicing requirements.

– Clean the battery, apply special grease to

the electrode studs, and install and fix the
terminals on the battery.

– Charge the battery.

– Check whether the hydraulic oil contains

condensation water.Change the hydraulic
oil according to requirements.

– Put the equipment back into use.

If there are difficulties with operating electrical
system switches, you should apply contact
spray to the exposed contact surfaces and
remove the oxide layers on the surfaces of the
operating component contacts by performing
repeated switch operations.After putting
the equipment into operation, the driver
should immediately perform repeated brake
performance tests.

Slinging

28011505 EN - 03/2018 61

500

4 Operation

Transporting the truck

CAUTION

Only use slings (1) and a hoist of sufficient ca­pacity.Protect all parts in contact with the lifting
device.Correctly install the hook according to the
lifting label shown in the figure.

Machine weight (with battery):See Technical Da­tasheet.

DANGER

Personnel must not stand under or next to the truck
when it is being lifted.

Do not sling the truck by the tiller.

Transporting the truck

CAUTION

When transporting the truck, check that it is properly
supported on wooden blocks and correctly tied with
rope.

Single-column mast tie points and
position

– Lower the fork arms to the lowest position.

– Use wooden cho

and rear of the

cks (1) to secure the front

vehicle.

Standard mast ti

– Lower the fork arms to the lowest position.

– Use wooden chocks (1) to secure the front

and rear of the vehicle.

– Pass the tensioner t

and outer masts and se
to the upper fixing poi
as indicated by posit
Tighten by pulling in
arrow.

62 5

e points and position

hrough the inner

cure the masts

nts of the vehicle,

ion (2) in the figure.

the direction of the

0028011505 EN - 03/2018

5

Maintenance

5 Maintenance

General maintenance information

General maintenance 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 forklift truck is used in an extreme environment
(such as excessive heat, excessive cold or areas
with high dust concentrations), the time intervals
given in the 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 out accord­ing 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 this inspection must providetheir expertise
and opinion without being influenced by

64 5

0028011505 EN - 03/2018

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

Maintenance 5

Maintenance - 1000 hours / every 12 m

with the technical regulations and principles
established for checking industrial trucks.

onths

Battery maintenance staff

Batteries must only be recharged, maintained
and changed by specially trained personnel.

Personnel must follow the manufacturer’s
instructions of the battery, the battery charger
and the truck.

It is essential to follow the battery maintenance
instructions and the battery charger operating
instructions.

Maintenance operations that do not require special training

Simple maintenance operations such as
checking the hydraulic fluid level or checking
the battery electrolyte level can be carried out
by persons with no special training.

A specific qualification

is not necessary.

Complicated maintenance operations such
as replacing the battery, replacing the wheels
and so on should be carried out by the autho­rised service centre.

Refer to the maintenanc
manual for further info

e section of this

rmation.

Technical inspecti

Assembly

Main hydraulic cir

Brake system Electromagneti

Fuses

.

on and maintenance data

Item/oil

cuit

Hydraulic oil

Pressure max. 150 bar

FU01 150 A

FU02 10 A

c brake air gap

Capacity/standard value

3.8L to 4.8L

0.2mmto0.4mm

Maintenance - 1000 hours / every 12 months

At operating hours

1000 3000 5000 7000 9000

11000 13000

Functions and controls

Check fault information record and run time.

Check that cables are free from damage and that terminals are firmly attached.

28011505 EN - 03/2018 65

500

Carried out





5 Maintenance

Maintenance - 1000 hours / every 12 m

At operating hours

1000 3000 5000 7000 9000

11000 13000

Check and fasten the controller and contactor.

Power and drive system

Check driving speeds.

Check and lubricate the bearings between the drive motor and gearbox.

Check the wheel bearings and their mounting.

Check whether battery cables are damaged and replace if necessary.

Clean or add gearbox grease.

Check the gearbox for abnormal sound and leakage.

Check drive axle for damage or breakage.

Check bearing positions for noise.

Brake system

Check that electromagnetic brakes are installed and connected.

Check braking distance of electromagnetic brakes.

Check the electromagnetic brake air gap.

Hydraulic syst

Check cylinders for damage and leakage and ensure that they are properly secured.

Check that the oil tank is fixed and check it for leaks.

Check the hydraulic oil level.
Check hoses, pipes and interfaces for damage and ensure their tightness andsea-

ling.
Check overflow pressure.

Lifting sy

Check whet

Check lif

Clean an

Check an

Check w

Check and lubricate chains.

Check

Chec

em

stem

her mast is damaged.

ting and lowering speeds.

d lubricate the rolling surface on the lift mast.

d lubricate the rollers on the mast and fork carriage.

hether the hose connections are intact and whether there is oil leakage.

that the lift mast is properly secured.

k the lifting chain and chain guide piece for wear. Adjust and apply grease.

onths

Carried out





66 5

0028011505 EN - 03/2018

Maintenance 5

Maintenance - 2000 hours / every 2 ye

At operating hours

1000 3000 5000 7000 9000

11000 13000

Check the load backrest for damage and ensure that it is properly secured.

Check fork arms for wear and damage.

Visually inspect the roll

Other

Check chassis for cracks or damage.

Check cover for cracks.

Check connections between nuts and bolts.

Check that all support components are intact.

Check that labels are clear and complete.

Check caster for wear and tear.

ers, wear strips and stoppers.

ars

Carried out





Maintenance - 2000 hours / every 2 years

system

urs

Carried out





At operating ho

2000 4000 6000 8000 10000

12000 14000

Note

Perform all 1000-hour maintenance work.

Hydraulic

Change the hydraulic oil.

Replace oil tank air filter and filter.

Maintenance work

Changing the battery

NOTE

Always park the vehicle according to regula­tions and turn off the power before removing
and installing batteries.

28011505 EN - 03/2018 67

500

5 Maintenance

Maintenance work

Removing batteries

– Unscrew the 2 screws (1) and re

cover(2).

– Unscrew the 2 screws(3) and remove the

battery cover(4).

move the

68 5

0028011505 EN - 03/2018

Maintenance 5

Maintenance work

– Remove the three battery cables shown in

the image(5).

– Remove the battery(6).

NOTE

Pay attention to
avoid short cir

the operation of the battery to

cuits.

Installing th

– Install the batteries in reverse order, paying

attention to the location where the batteries
are installed and whether the wiring is
correct.

e battery

NOTE

Route the battery cable so that it is not trapped
when the battery is inserted.

28011505 EN - 03/2018 69

500

5 Maintenance

Maintenance work

Lubrication point

70 5

0028011505 EN - 03/2018

Maintenance 5

Maintenance work

Lubricant

Location

code

Oil name

Antifriction hydraulic

oil

A

Antifriction hydraulic

oil (cold stores)

Multi-purpose grease

B

Moly lithium grease

C

no. 3

Table for lubrication of sliding surfaces

Code Position used

L1 Caster

L2 Rollers

L3 Channel and rollers

L4 Chains

L5

L6 Drive wheel

.

Model no. Amount added

L-HM46

Lift height 1600 mm: 3.8 L

Lift height 2000 mm:3.8L
Lift height 2300 mm:4.0L
Lift height 2500 mm:4.2L

L-HV32

Lift height 2700 mm:4.2L
Lift height 3000 mm:4.5L
Lift height 3300 mm:4.8L
Lift height 3600 mm:4.8L

Polylub

GA352P

-

As appropriate

100 g

Steering bearing

Comment

Hydraulic

system

Sliding

surfaces

Transmis-

sion

Check the hydraulic oil level

NOTE

If there are popping noises coming from the
tubing when lifting, this indicates that the
hydraulic oil is insufficient and should be
promptly replenished.

CAUTION

Do not add hydraulic oil that contains impurities.

– Fully lower the mast.

– Press the emergency off switch.

– Remove the f

ront hood.

28011505 EN - 03/2018 71

500

5 Maintenance

Maintenance work

– Unscrew the oil cap(1).This oil cap has a

dipstick.

– Useacleanclothtodrythedipstick.

– Reinstall the oil cap, then remove it again

and check whether the traces of oil on the
dipstick are between the maximum and
minimum marks.

NOTE

You can lift again after you have finished
adding the oil. You must continue checking
the hydraulic oil level if there is still a banging
noise.

– Reinstall the disassembled parts in reverse

order.

NOTE

Only use hydraulic oil that meets the specifi­cations.Refer to "Lubricants".

Topping up t

CAUTION

Do not add gear oil that contains impurities.

72 5

he gear oil

0028011505 EN - 03/2018

Maintenance 5

Maintenance work

– Pour gear oil into the grease fitting (1)cor-

rectly to replenish it according to specifica­tions.

NOTE

Top up every 1,000 operating hours or an­nually, whichever occurs first.

Checking the fuses

– Fully lower the mast.

– Press the emergency off switch.

– Remove the front hood.

– Check that all fuses are in working order.

If necessary, replace them with fuses that
match the parameters specified in the table
below.

Checking fuses for the

following functions or

No.

components

1 Traction/lift motor fuse 150A

Control system fuses

2

.

Value

10A

28011505 EN - 03/2018 73

500

5 Maintenance

Tyre operation

Tyre operation

Drive Wheel

Removal

– Remove the drive assembly.

– Dismantle the motor cable m

base(1), and remove the mot

– Loosen the eight screws(3) with a wrench,

and remove the gearbox cover(4) and gear
set(5);

– Unscrew the five screws(6) and knock out

the assembly from the gearbox(7);

– Knock out the drive motor(13), and remove

the oil seal(8);

– Loosen the six screws(9) with a wrench,

and dismantle the large ring gear(10),
bearing(11) and drive wheel(12) by order.

Installation

– Install according to the reverse order of

removal.

CAUTION

Tyre wear can affect the stability of the truck, adjust
the caster with minor wear on a regular basis, or
replace the caster with heavy wear.

Quality of tyres directly affects the stability and
driving performance of the device. If you need to
replace the factory-fitted tyres, please use original
spare parts provided by the equipment manufactu­rer to reach the original design performance of the
truck.

ounting

or cables(2);

Faults and Causes

Drive wheel

1

74 5

Fault

Cause

slipping or
jumping

Wear

0028011505 EN - 03/2018

Maintenance 5

Tyre operation

Drive wheel

2

Fault

Cause

.

cracking or
degumming

Improper use

Load Wheels - Removal and Installation

Removal

– Lift the vehicle carefully with lifting equip-

ment through the lifting holes at back;

CAUTION

Make sure the lifting equipment is solid and secure,
and the load capacity should be greater than the
total weight of the vehicle.

– Place a wooden wedge under the chassis

near load wheel, make the load wheel off
the ground;

CAUTION

When replacing w
tilt.

heels, be sure that the truck won't

– Remove the coiled elastic cylindrical pin(2)

within the wheel bridge(1) with an ejector
pin of 4mm in diameter;

–Turnthewhe

knock out th
and remove t

el bridge to vertical direction,

e wheel pin shaft(3) from side,

he load wheel and bearing

assembly;

– Remove the bearing(5) of load wheel(4)

with hammer and jacking equipment.

Installation and Commissioning

– Install according to the reverse order of

removal;

–Runthetru

functio
noise, p

ck to see if the load wheel is

ning properly. If there is blocking or

lease install again.

28011505 EN - 03/2018 75

500

5 Maintenance

Tyre operation

CAUTION

When installing, please apply appropriate amount
of grease on the axle fi rst.

CAUTION

Quality of tyres directly affects the stability and
driving performance of the device. If you need to
replace the factory-fitted tyres, please use original
spare parts provided by the equipment manufactu­rer to reach the original design performance of the
truck.

Caster - Removal and Installation

Removal

– Remove the cover;

– Lift the vehicle carefully with lifting equip-

ment through the lifting holes at front and
back;

WARNING

Make sure the lifting equipment is solid and secure,
and the load capacity should be greater than the
total weight of the vehicle. Lifting height of not
more than 300mm, to prevent the hazards to the
maintenance personnel working under the vehicle
for caster removal and installation.

76 5

0028011505 EN - 03/2018

Maintenance 5

Tyre operation

– Unscrew four screws(1), then remove the

caster(3) and adjustment shim(2).

Installation

– Install according to the reve

removal.

rse order of

Adjustment

– Park the truck with replacement completed

on level ground to see if the casters and
drive wheel can both be in contact with the
ground;

– When the truck is running, check if the three

wheels are functioning properly.

CAUTION

After long time of use, the drive wheel will wear and
tear to certain level, at this time, adjust the height
of caster(3) through increasing or decreasing the
number of adjustment shims(2) to make the two
casters and drive wheel to be in close contact with
the ground.

CAUTION

Tyre wear can affect the stability of the truck, adjust
the caster with minor wear on a regular basis,
or replace the caster with heavy wear. Quality
of tyres directly affects the stability and driving
performance of the device. If you need to replace
the factory-fitted tyres, please use original spare
parts provided by the equipment manufacturer to
reach the original design performance of the truck.

28011505 EN - 03/2018 77

500

5 Maintenance

Malfunction analysis

Upon maintenance or replacement for parts of
the caster, please refer to Figure 116702_04-

006.

Malfunction analysis

Symptoms

Unable to dr

Unable to lift

NOTE

ive

Possible reason
The key switch lock is in the

OFF position

Battery power is too low

Blown fuse Check the fuse device

Equipment is in charge mode

The hydraulic oil level is too low

The load

is overweight

Please contact an authorised dealer if you
have performed all of the steps listed in the
table above but are still unable to eliminate the
fault.Further fault identification and elimination
operations must be performed by after-sales
service personnel who have undergone
special training.

78 5

0028011505 EN - 03/2018

Solution
Put the key swit

position
Check the bat

status and cha
according to req

Stop charge mode

Check the hydraulic oil level

tention to the rated load

Pay at

r to the model identification

(refe

)

plate

ch in the ON

tery charge

rge the battery

uirements

6

Technical data

6 Technical data

ECV 10 Technical Datasheet

ECV 10 Technical Datasheet

80 5

0028011505 EN - 03/2018

Technical data 6

ECV 10 Technical Datasheet

Characteristics ECV 10

1.1

Manufacturer Still

1.2 Model no.

Drive: electric, diesel, petrol, LPG, mains electric

1.3

Operation

1.4

Nominal loading capacity Q (kg)

1.5

Load centre of gravity distance c (mm)

1.6

Front overhang, distance from the vertical surface of

1.8
the forks to the centre of the front axle

1.9 Wheelbase

Weight

Service weight (with battery)

2.1

Axel load when fully loaded, drive side, load side

2.2

Axel load when unloaded, drive side, load side

2.3

Wheels

Tyres, drive side/load side:C=solid rubber,

3.1
P=polyurethane

Tyre size, drive side

3.2

Tyre size, load side

3.3

Number of wheels, fr

3.5

ont/rear (X = drive)

x (mm)

y (mm)

kg

kg

kg

(mm)

(mm)

ECV 10

Electric

Pedestrian

1000

600

795

1240

ECV 10

598

596 / 1002

446 / 152

ECV 10

PU/PU

Ø210 X 70

Ø80 X 60

1x + 1/4

Dimensions

Lowered mast height

4.2

Free lift height h2 (mm)

4.3

Lift height h3 (mm)

4.4

Maximum mast height when in operation

4.5

Tiller height when driving (minimum/maximum)

4.9

Lowered fork height

4.15

Overall length l1 (mm)

4.19

Head length (w

4.20

ithout forks)

28011505 EN - 03/2018 81

500

h1 (mm)

h4 (mm)

h14 (
mm)
h13 (
mm)

l2 (mm)

ECV 10

2097

150

2927

3487

800 / 1250

88

1740

590

6 Technical data

ECV 10 Technical Datasheet

Dimensions

Body width

4.21

4.22 Dimensions of forks

Width of the fork carriage b3 (mm)

4.24

4.25

Width across forks

Ground clearance, centre of wheelbase, min./max.

4.32

Aisle width, 800 x 1200 pallet, lengthwise

4.34

Turning radius

4.35

b1/b2
(mm)

s/e/l

(mm)

b5 (mm)

m2 (
mm)

Ast

(mm)

Wa

(mm)

ECV 10

800

55 / 160 / 1150

600

560

30

2219

1450

Performance ECV 10

Travel speed, with/without load

5.1

Lifting speed, with/without load

5.2

Lowering speed, with/without load

5.3

Climbing ability, with/without load

5.8

Brake type Electromagnetic brake

5.10

km/h 4.5 / 4.8

m/s 0.12 / 0.22

m/s 0.2 / 0.13

%5/15

Drive ECV 10

Drive motor (60 minutes)

6.1

Lift motor 10% power

6.2

Battery to DIN 43 531/35/36 A, B, C, no

6.3

Battery voltage/capacity (5-hour discharge)

6.4

Battery weight kg

6.5

kW 0.65

kW 2.2

-

V/Ah 2 x 12 / 125

2x33

Other ECV 10

8.1

Control method DC

8.4 Noise level at driver's ear

.

82 5

0028011505 EN - 03/2018

dB(A)

74

Technical data 6

ECV 10i C / ECV 10 C Technical Datashe

ECV 10i C / ECV 10 C Technical Datasheet

et

Characteristics ECV 10 C ECV 10i C

1.1

Manufacturer Still Still

1.2 Model no. ECV 10C ECV 10 iC

28011505 EN - 03/2018 83

500

6 Technical data

ECV 10i C / ECV 10 C Technical Datashe

Characteristics ECV 10 C ECV 10i C

Drive: electric, diesel, petrol, LPG, mains

1.3
electric

Operation

1.4

Nominal loading capacity

1.5

Load centre of gravity distance

1.6
Front overhang, distance from the vertical

1.8

surface of the forks to the centre of the
front axle

1.9 Wheelbase

et

Q

(kg)

c

(mm)

x

(mm)

y

(mm)

Electric Electric

Pedestrian Pedestrian

1000 1000

600 600

805 805

1126 1260

Weight

Service weight (with battery)

2.1
Axel load when fully loaded, drive side,

2.2
load side

Axel load when unloaded, drive side, load

2.3
side

Wheels

Tyres, drive side/load side:C=solid

3.1
rubber, P=polyurethane

Tyre size, drive side

3.2

Tyre size, load side

3.3

Number of wheels, fr

3.5

Dimensions

Lowered mast height

4.2

Free lift height

4.3

Lift height

4.4

Tiller height when driving (mini-

4.9
mum/maximum)

4.1
Lowered fork height

5

4.1
Overall length

9

4.2
Head length (without forks)

0

4.2
Body width

1

ont/rear (X = drive)

kg

kg

kg

(mm)

(mm)

h1 (

mm)

h2 (

mm)

h3 (

mm)

h14 (

mm)

h13 (

mm)

l1 (

mm)

l2 (

mm)

b1/b2

(mm)

ECV 10 C ECV 10i C

462 520

530 / 950 580 / 1140

350 /120 350 / 170

ECV 10 C ECV 10i C

PU/PU PU/PU

Ø210 X 70 Ø210 X 70

Ø80 X 60 Ø80 X 60

1x + 1/4 1x + 1/4

ECV 10 C ECV 10i C

1940 1940

1505 1480

1517 1513

800 / 1250 800 / 1250

88 88

1615 1750

465 600

800 796

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0028011505 EN - 03/2018

Technical data 6

ECV 10i C / ECV 10 C Technical Datashe

et

Dimensions

4.2
Dimensions of forks

2

4.2
Width of the fork carriage

4

4.2
Width across forks

5

4.32Ground clearance, centre of wheelbase,
min./max.

4.3
Aisle width, 800 x 1200pallet, lengthwise

4

4.3
Turning radius

5

s/e/l

(mm)

b3

(mm)

b5 (
mm)
m2 (
mm)

Ast

(mm)

Wa

(mm)

ECV 10 C ECV 10i C

60 / 170 / 1150 60 / 190 / 1150

680 680

550 560

28 26

2100 2260

1337 1500

Performance ECV 10 C ECV 10i C

Travel speed, with/without load

5.1

Lifting speed, with/without load

5.2

Lowering speed, with/without load

5.3

Climbing ability, with/without load

5.8

5.1
Brake type

0

Drive

Drive motor (60 minutes)

6.1

Lift motor 10% power

6.2

Battery to DIN 43 531/35/36 A, B, C, no

6.3

Battery voltage/capacity (5-hour

6.4

discharge)
Battery weight kg

6.5

km/h 4 / 4.5 4 / 4.5

m/s 0.10 / 0.17 0.10 / 0.14

m/s 0.2 / 0.13 0.2 / 0.13

% 5/15 5/15

Electromagne

brake

tic

Electromagne

brake

ECV 10 C ECV 10i C

kW 0.65 0.65

kW 2.2 2.2

--

V/Ah 2 x 12 / 85 2 x 12 / 85

2 x 25 2 x 25

tic

Other ECV 10 C ECV 10i C

8.1 Control method DC DC

8.4 Noise lev

.

el at driver's ear

500

dB(A)

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74 74

6 Technical data

ECV 10i C / ECV 10 C Technical Datashe

et

86 5

0028011505 EN - 03/2018

Index

g

A

Address of manufacturer . . . .......... I

Attachments

Specialrisks ................... 14

B

Battery

Disposal ...................... 10

Batteryacid ...................... 30

Battery maintenance staff . . . ......... 65

Before leaving the equipme

Brake .......................... 49

nt ......... 60

C

Caster - Removal and Ins

CElabelling ....................... 3

Changingthebattery ............... 67

Charging and dischargi

Checkthehydraulicoillevel .......... 71

Consumables .................... 29

Battery acid safety i

Disposal ...................... 31

OilSafetyInformation ............ 29

Safety information f

hydraulicfluid................ 30

Contactdetails ..................... I

Copyright and property rights .......... 5

tallation ...... 76

ngbatteries..... 44

nstructions ..... 30

or handling

D

Dailychecksbeforeuse ............. 43

Damage,faults ................ 25,31

Dangertoemployees ............... 19

Dataplateandsafetylabels........... 37

Date of edition of this manual .......... 7

Disposal

Battery ....................... 10

Components ................... 10

Documentation scope

Drivedirections ................. 9,34

Drive Wheel ...................... 74

Driver rights, duti

behaviour .................. 22

............... 4

es and rules of

Drivers.......................... 22

E

EC declaration of conformity
EMC – Electromagnetic compatibility . . . 32

Emergencylowering ............... 58

........... 4

F

Firstuse ........................ 42

Forwardtravel/reversetravel ......... 49

Fusechecking .................... 73

G

Gearoilchecking .................. 72

General ....................... 2,64

H

Hazards and countermeasures . . ...... 16

Hornoperation.................... 52

Hydraulicfluid .................... 30

I

Identification pla

Illustrations ....................... 9

Insulationtesting .................. 27

Drive battery test valu

Testvaluesforthetruck........... 28

Insurance cover on company premises . . 24

te ................. 38

es .......... 28

L

List of abbreviations ................. 7

Load label . . ..................... 38

Load Wheels - Removal

Lubrication point .................. 70

and Installation . 75

M

Main Components ................. 35

Maintenance operations that do not

require special training . . . ...... 65

Medicaldevices ................... 25

Modifications and refi

tting ............ 24

28011505 EN - 03/2018 87

500

Index

g

O

Oils ............................ 29

Operating company ................ 22

P

Packaging ....................... 10

Placeofuse ...................... 13

Prohibition of use by unaut

persons .................... 23

Putting the equipment back into

operation ................... 61

horised

R

Regular inspections ................ 27

S

Safetyinspection .................. 27

Servicing and mainten

training and qualifica

Signals .......................... 6

Slinging ......................... 61

Specialrisks ..................... 14

ance personnel

tion ........ 64

Specialist........................ 22

Starting ......................... 47

Steering......................... 51

T

Technical datasheet ............. 80,83

Technicaldescription ............... 11

Technical inspection and maintenance

data ....................... 65

Transportingthetruck .............. 62

U

Unauthorised use . . ................ 13

Update of this manual ................ 7

Useofthemast ................... 54

Useonaslope .................... 52

W

Warning regarding non

Workingenvironmentcheck .......... 43

Workingwithloads ................. 55

-original parts . . . 24

88 5

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