Page 1
Original instructions
Pallet stacker
EXV 14 / 16 / 20
EXV14i/16i/20i
EXV-SF 14 / 16 / 20
EXV-SF 14i / 16i / 20i
EXP 14 / 16 / 20
0301 0303 0305 0323 0324
0325 0326 0327 0328 0329
0330 0331 0332 0333 0334
45758043402 EN - 02/2015
Page 2
Page 3
Table of contents
1 Introduction
Forklift data ......................................................... 2
General information ................................................... 2
How to Consult the Manual .............................................. 2
Date of edition and latest update of this manual ............................... 4
Copyright and trademark ri
Delivery of the forklift and documentation ................................... 4
EC declaration of conformity in accordance with Machinery Directive ............... 5
Technical service and spar
Normative References ................................................. 6
Type of use ......................................................... 6
Working conditions ................................................... 7
Modifications to Forklift ................................................. 7
Applied equipment .................................................... 8
User obligations ...................................................... 8
Environmental considerations ........................................... 8
Disposal of components and batteries ...................................... 8
Packaging .......................................................... 9
ghts ........................................... 4
e parts ......................................... 6
g
2Safety
Safety guidelines .................................................... 12
GeneralPrecautions ................................................. 12
General Safety Rul
Flooringrequirements ................................................ 12
Batteryconnectioncables ............................................. 13
Requirements for t
SafetyRegulationsRelativetoForkliftUse ................................. 13
SafetyRegulationsRelativetoOperatingMaterials ........................... 14
Residual risks ...................................................... 15
Residual dangers, residual risks ......................................... 15
Electromagnetic radiation .............................................. 17
Non-ionised rad
Noise ............................................................. 17
Vibrations ......................................................... 18
Safety tests ........................................................ 19
Regular safety inspection of the truck ..................................... 19
es ................................................. 12
hetraction-batterychargingarea .......................... 13
iation ................................................. 17
758043402 [EN] I
45
Page 4
Table of contents
g
Safety devices ...................................................... 20
Locationofsafetydevices ............................................. 20
Damage, defects and misuse of s
afetydevices .............................. 22
3Overview
Technical description ................................................. 24
Overview .......................................................... 26
Instruments and controls
Start/stopkey ....................................................... 27
Display ........................................................... 28
Emergency shutdown handl
Tillercontrols ....................................................... 35
Tiller ............................................................. 38
Tillerpositions ...................................................... 38
Combitiller(ifpresent) ................................................ 40
OptiSpeed tiller (only present on EXV and EXVi versions) ...................... 42
Types of lifting masts ................................................. 4
Side protection ...................................................... 45
Description ........................................................ 45
Platform .......................................................... 47
Description ........................................................ 47
Definition of directions ................................................ 49
Markings .......................................................... 50
Locationoflabels .................................................... 50
Serialnumber ...................................................... 52
Dataplate ......................................................... 52
Capacityplate ...................................................... 53
Chassisframelabelling ............................................... 54
Options and varian
Listofoptionsandvariants ............................................. 55
Straddle automatic lowering (optional) .................................... 56
Accessories moun
Digicodeoption ..................................................... 58
BatteryelectrolytelevelindicatorLED(optional) ............................. 60
.............................................. 27
e ........................................... 34
ts ................................................. 55
tingbarwithdatasocket ................................. 57
3
4Use
Authorised and
Intended use of the trucks .............................................. 62
II
safe use ............................................... 62
45758043402 [EN]
Page 5
Table of contents
Safetyinstructionsrelatingtouseofthetruck ............................... 62
Truck transport and lifting .............................................. 64
Transportingthetruck ................................................ 64
Transport .......................................................... 65
ClimaticConditionsforTransportandStorage ............................... 65
Loading and unloading the tr
Breaking-In ........................................................ 66
Checks and actions prior to commissioning ................................. 67
Listofchecksbeforeuse .............................................. 67
Operator position .................................................... 69
Operator’spositionforversionwithoutplatform .............................. 69
Operator position for ver
Use of the truck ..................................................... 72
Stoppingthetruckinemergencies ....................................... 72
Startingthetruck .................................................... 72
Truckoperation ..................................................... 73
Trucksteeringdirection ............................................... 74
Usingthetruckwiththe"
Reversedrive ...................................................... 76
Truckbrakesystems ................................................. 76
Parking and stopping t
ForkliftUseinCold-StorageRooms. ...................................... 78
Movement of the load ................................................. 79
Safety guidelines for
Checkstobecarriedoutbeforeliftingaload ................................ 82
Adjustingtheforkdistance(ifpresent) ..................................... 83
Automatic speed redu
Pickinguptheload ................................................... 84
Transportingloads ................................................... 88
Deposit the load. .................................................... 89
Usingthetruckoninclines,loadingbridgesandlifts. .......................... 90
Towingtrailers ...................................................... 90
Charging the batte
Internalaccessibility .................................................. 91
BatteryRecharging .................................................. 93
Charging curve sel
Recharging the battery using the on-board battery charger (optional) . . . ........... 94
Batterytype ........................................................ 95
Preparation ........................................................ 95
ry .................................................. 91
ector(onlywithon-boardbatterycharger) .................... 93
uck ......................................... 66
sionwithplatform .................................. 70
Tiller always active — Creep Speed" function (optional) . . . . . 75
hetruck .......................................... 77
handling loads ...................................... 79
ction with forks raised above the safety sensors ............. 84
g
758043402 [EN] III
45
Page 6
Table of contents
g
5 Maintenance
General Information .................................................. 98
Preliminary maintenance oper
Scheduled maintenance .............................................. 99
SummaryTableofMaintenanceOperations ................................ 99
Maintenance as required ..............................................10
Cleaning the Forklift ..................................................101
Cleaning the lift chains ................................................101
Fuses ........................................................... . 102
Batteryreplacementwithremovalfromthetop ..............................102
Batteryreplacementwithsideremoval ....................................105
Puttingoutofcommissio
General Information ..................................................108
ForkliftTowing ......................................................109
Temporary Putting Out of
Checks and Inspections After a Long Period of Inactivity .......................109
Permanent Putting Out of Commission (Demolition) ..........................109
ations ...................................... 98
n ..............................................108
Commission ....................................109
6 Technical data
EXV and EXVi overall d
EXV-SF and EXVi-SF overall dimensions ..................................113
Datasheet .........................................................114
EXP overall dimensio
Datasheet .........................................................128
Batteries ..........................................................131
Supply table ........................................................133
imensions .......................................112
ns ...............................................127
1
IV
45758043402 [EN]
Page 7
1
Introduction
Page 8
1 Introduction
Forklift data
Forklift data
We recommend that you record the principal
forklift data in the following table so that they
are available if required by the sales network
or authorised service centre.
Type
Serial number
Date of delivery
.
General information
• This manual contains "Original Instructions"
provided by the manufacturer.
• The "operator" is defin
driving the forklift.
• The "user" is the physical or legal person
who has the forklift truck used by the
operators.
• For correct use of the forklift and in order
to avoid accidents, the operator is obliged
to read, understand and apply the contents
of this manual, the "Rules for the use of
industrial vehicles" and the labels and
plates applied to the forklift.
• This manual and the a
the use of industria
carefully and must a
for fast consultati
• The manufacturer assumes no responsibility for any accidents to persons or damage
ed as the person
ttached "Rules for
l vehicles" must be kept
lways be on the forklift
on.
to things due to the failure to observe the
instructions in this manual, in the "Rules for
the use of industrial vehicles" and on the
labels and adhesive supplied to the forklift.
• The forklift may not be
that than indicated in
• The forklift must be used by appropriately
trained operators only. For the necessary
operator training, contact the authorised
sales network.
• Persons working near the forklift must also
be instructed in the risks associated with
use of the forklift.
•Intheinterestsofc
illustrations in th
without the safety e
panels, etc.). The f
without safety equi
put to any use other
this manual.
lear information, some
is manual show the forklift
quipment (guards,
orklift may not be used
pment.
How to Consult the Manual
There is a table of contents at the beginning
of the manual for ease of use. The manual is
divided into chapters with specific topics. The
name and title of the chapter are given at the
top of each page The following is found at the
bottom of each page: the type of manual, the
identifying code, the language and the manual
version.
24
Some general information is provided in this
manual. Please only consider the information
relevant for your specific forklift.
The following symbols have been used to
highlight some parts of this manual.
DANGER
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.
5758043402 [EN]
Page 9
Introduction 1
HowtoConsulttheManual
CAUTION
Failure to observe the instructions highlighted with
this symbol may cause damage to the forklift and,
in some cases, result in warranty invalidity.
ENVIRONMENT NOTE
Failure to observe the instructions highlighted
with this symbol may cause environmental
damage.
NOTE
This symbol is used to provide a
information.
dditional
758043402 [EN] 3
45
Page 10
1 Introduction
Date of edition and latest update of
this manual
Date of edition and latest update of this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assis
contact the service centre
closest manufacturer.
tance, please
authorised by your
Copyright and tradema
rk
rights
These instructions m
translated or made ac
ties—including as ex
express written app
Delivery of the fo
Ensure that the tr
requested and tha
the following doc
• Original instructions
• Rules for the compliant use industrial
vehicles;
• EC Declaration o
• Warranty book.
If the forklift has been delivered with a traction
battery and/or battery charger, ensure that
such products conform to the order and that
the relative user and maintenance manual are
ust not be reproduced,
cessible to third par-
cerpts—except with the
roval of the manufacturer.
rklift and documentation
uck has all of the options
t it has been delivered with
umentation:
f Compliance;
included, as well
battery charger.
If applied equipment, other equipment or
devices are present, ensure that they conform
to the order and that the relative use and
maintenance manual and of the relative EC
declaration (if provided by regulations in
effect) are included.
All of the above documentation must be kept
for the entire operative life of the forklift. In the
event that the documentation is lost or damaged, contact the authorised sales network for
copies of the original documentation.
as the EC declaration for the
44
5758043402 [EN]
Page 11
Introduction 1
EC declaration of conformity in acc
ordance with Machinery Directive
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
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
mbH
STILL G
.
according to these operating instructions
according to these operating instructions
758043402 [EN] 5
45
Page 12
1 Introduction
Technical service and spare parts
Technical service and spare parts
For scheduled maintenance and any repairs to
the forklift, contact only the authorised service
network.
The authorised service network has personnel
trained by the manufacturer, original spare
parts and the tools necessary to carry out
maintenance and repairs.
Servicing by the authorised
and the use of original spare
service network
parts maintain
the technical characteristics of the forklift over
time.
Only original spare parts provided by the manufacturer may be used for forklift maintenance
and repairs. The use of non-original spare
parts invalidates the warranty and renders the
user responsible for any accidents due to the
inappropriateness of the non-original parts.
Normative References
This forklift complies
• The most recent version of Machine Directive 2006/42/EC in effect
• Electromagnetic Compatibility Directive
2004/108/EC and subsequent amendments, relative to forklifts for handling in
accordance with the EN 12895 standard
The noise tests regard
level at the driver’s s
with:
ing the sound pressure
eat were carried out
in accordance with the E
and declared according
standard
The vibration tests were carried out in accordance with standard EN 13059 and declared
in accordance with standard EN 12096.
The limit values for the electromagnetic
emissions and immunity relative to the forklift
are those set out in the EN 12895 standard.
N 12053 standard
to the EN ISO 4871
Type of use
"Normal use conditions" of the forklift are
understood as:
• lifting and/or tra
with weight and loa
values provided (s
Data).
• transport and/or lifting on smooth, flat and
compact surfaces;
• transport and/or lifting of stable loads
uniformly distributed on the forks;
• transport and/or
approximately on
longitudinal pla
DANGER
The forklift must not be used for other purposes.
Any other use renders the user solely responsible
for injury/damage to persons and/or objects and
voids the warranty.
64
nsport of loads using forks
dcentrewithinthe
ee Chapter 6 - Technical
lifting with the load centre
the forklift’s median
ne.
The following scenarios are examples of
incorrect use of the forklift truck:
• Transport on uneve
compact) surfaces
• loads that exceed the weight and/or load
centre limits;
• transporting non-stable loads;
• transporting load
the forks;
• transporting swinging loads;
• transporting loads whose load centre is
considerably displaced with respect to the
forklift’s longitudinal median plane;
• transporting loa
block the view of t
• transporting loads piled so high that they
could fall onto the operator;
• travelling with a load over 300 mm off the
ground;
5758043402 [EN]
n (irregular or non-
s not equally distributed on
ds of dimensions such as to
he operator when driving;
Page 13
Introduction 1
Working conditions
• transporting and/or lifting people;
• pushing or pulling loads;
• moving upwards or downwards on
with the load facing downwards
a slope
;
• turning at high speed;
Working conditions
The forklift has been designed and built for
internal transport.
Do not use beyond the limits of the climatic
conditions indicated below:
• Maximum ambient temperature: +40°C
• Minimum ambient temperature: +5°C
• Altitude up to 2000 m
• Relative humidity between 30% and 95%
(without condensation).
CAUTION
Do not use the forklift in dusty areas.
Using the forklift in environments with high concentrations of salty air or water could interfere with its
proper operation and cause corrosion of metallic
parts.
If the forklift must be used in conditions that
exceed the limits indicated or, in any case,
under extreme conditions (extreme weather,
• turning and/or moving sideways on slopes
(upwards or downwards);
• colliding with stationary and/or mobile
structures;
DANGER
Improper use of the forklift could cause it and/or at
the load to overturn.
cold-storage rooms, presence of strong magnetic fields etc), appropriate equipment and/or
use precautions are necessary. Contact the
authorised sales network for more information.
DANGER
The forklift may not be used in environments in
which there is a risk of explosion. It may not be
used to handle explosive loads.
For forklifts that must operate in environments
in which there is a risk of explosion or must
handle explosive loads, appropriate equipment is necessary and must be accompanied
by a specific EC Declaration of Compliance
which replaces that of the standard forklift,
and by the relevant User and maintenance
manual.
Contact the authorised sales network for more
information.
Modifications to Forklift
No modifications may be made to the forklift,
otherwise the EC certificate and the warranty
will become invalid, with the exception of:
• assembly of the options provided by the
manufacturer
• assembly of applied equipment
for which it is necessary to refer exclusively to
the authorised sales network
758043402 [EN] 7
45
DANGER
If the forklift is equipped at the factory or later with
devices that emit non-ionising radiation (such as
radio transmitters, RFID players, data terminals,
scanners, etc), the compatibility of such devices
must be verified with the presence of operators
using medical devices (such as heart pacemakers).
Page 14
1 Introduction
Applied equipment
Applied equipment
To use equipment that has not been applied,
please contact the authorised sales network,
in order to:
• verify feasibility
• install the equipment
• add a label with the new residual capacity is
• provide documentation on the equipment
(user and maintenance manual and EC
certificate).
User obligations
Users must comply with app
lation governing forklif
licable local legis-
t use and maintenance.
Environmental consi
Disposal of compone
derations
nts and
batteries
The truckis compose
components or batt
and disposed of, th
•disposedof,
• treated or
• recycled in accord
national regulati
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.
d of different materials. If
eries need to be replaced
ey must be:
ance with regional and
ons.
84
5758043402 [EN]
Page 15
Introduction 1
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material mu
properly after delivery o
st be disposed of
f the truck.
758043402 [EN] 9
45
Page 16
1 Introduction
Environmental considerations
10
45758043402 [EN]
Page 17
2
Safety
Page 18
2 Safety
Safety guidelines
Safety guidelines
General Precautions
NOTE
Some safety regulations to be followed when
using the forklift are listed below. These
General Safety Rules
• Only allow qualified, trained and authorized
personnel to use the forklift.
• Do not install equipment
less supplied or indica
turer.
• Maintain the forklift in full working efficiency
in order to limit any type of risk to the
minimum.
• Do not use the truck with bonnets or doors
open or with guards removed.
• The data plates found o
be kept in good condit
damaged.
• Carefully read and follow all of the safety
indications found on the forklift.
• Make sure that the forklift has sufficient
overhead clearance.
• Do not park the forkli
devices or fire escap
blocks traffic.
• If the forklift shows signs of failure or
breakage and there is reason to consider
it unsafe, stop, park it, and notify the
maintenance manager.
• Maintain appropriate distances from high
voltage overhead cables. Comply with
the safety distances established by the
competent authorities.
• Never raise the loa
on the forklift un-
ted by the manufac-
n the forklift must
ion and replaced if
ft in front of fire-fighting
es or anywhere that it
d using just one fork.
regulations integrate those
"Rules for approved use of ind
• Place the load on the fork carriage orin such
a way that the centre of gravity of the load is
as close as possible to the fork carriage.
• The load must be placed o
so that the centre of gra
on the mid point between
• Do not drive with loads off-centre laterally
with respect to the forklift’s median axis.
Lack of compliance with this regulation can
compromise forklift stability.
• Make sure that the surface on which the
load rests is able to support its weight.
• Always use safety clo
current regulations
tective equipment th
• Do not travel on loose or hilly ground or on
steps.
• Do not drive with loads raised more than
300 mm from ground level.
• Do not turn or stack o
• Reduce speed on slopes.
• Do not overload the forklift beyond the
capacity limits indicated on the capacity
plates.
• Individuals under t
alcohol are not per
• The operator may not use an MP3 player
or any electrical device that may distract
their attention from the surrounding work
environment.
in the manual
ustrial vehicles".
ntheforkarms
vity falls lengthwise
the fork arms.
thing compliant with
and any personal pro-
at may be applicable.
nslopes.
he influence of drugs and
mittedtousethetruck.
Flooring requirements
The forklifts do not have a shock absorbing
system; therefore, the work floor must be even
and without holes, which can be difficult to
12
get around. Any stairs must be equipped with
accompanying ramps to prevent impacts with
45758043402 [EN]
Page 19
Safety 2
Safety guidelines
the wheels, which affect the entire structure of
the forklift.
CAUTION
DO NOT pass over cracks or damaged parts of the
floor with the forklift. Dirt and any objects inthe work
path must be removed immediately.
Battery connection cables
CAUTION
Using sockets with NON-ORIGINAL battery connection cables can be dangerous (see purchase
references in the parts catalogue)
Requirements forthe traction-battery charging area
When the traction battery is being charged, the
area must be sufficiently ventilated in order to
download or eliminate the gases produced
(EN 50272-3).
Safety Regulations Relative to Forklift Use
• The operator must familiarize himself with
the forklift to be able to better describe any
defects and assist maintenance personnel.
The operator, trained and authorized to use
the forklift, must be familiar with the controls
and performances of the forklift.
• Any defect (squeaking, leaks, etc.) must be
promptly reported because, if neglected, it
could cause more serious failures/defects.
• Carry out the inspections indicated in the
chapter on "Daily Inspections".
758043402 [EN] 13
45
ENVIRONMENT NOTE
Report any oil and/or battery fluid leaks: they
are dangerous and highly polluting.
CAUTION
If you notice a burning smell, stop the forklift and
turn off the engine, then disconnect the battery.
Page 20
2 Safety
Safety guidelines
Safety Regulations Relative to Operating Materials
Rules for handling and disposing of
operating materials
ENVIRONMENT NOTE
Improper use and disposal of operating and
cleaning materials can cause serious damage
to the environment.
Always use and handle the operating materials in a suitable manner and follow the manufacturer’s instructions for the product’s use.
Keep the operating materials only in containers intended for this purpose and in a location
that satisfies the requirements.
The operating materials may be flammable, so
avoid contact with hot objects or open flames.
When topping up the operating materials, only
clean containers should be used.
Follow the manufacturer’s safety and disposal
instructions regarding the operating and
cleaning materials.
Do not disperse oils or other operating liquids!
Any spilt liquid must be immediately collected
and neutralised with a binding material (such
as an oil binder) and then disposed of in
accordance with current regulations.
Always comply with anti-pollution regulations!
Before carrying out work that involves lubrication, filter replacement or hydraulic equipment
interventions, the area in question must be
thoroughly cleaned.
The replaced parts must always be disposed
of in accordance with the anti-pollution laws.
ENVIRONMENT NOTE
The incorrect or unlawful use of brake fluid is
harmful to people’s health and the environment.
Oils
• Do not allow to come into contact with the
skin.
• Do not inhale oil vapors.
• Wear appropriate means of individual
protection during forklift maintenance
operations (gloves, goggles, etc.) to
prevent the oil from coming into contact
with your skin.
ENVIRONMENT NOTE
The used oils and relati
stances that are hazard
andmustbedisposedofa
regulations. We advise
thorised service netwo
DANGER
The penetration in the skin of hydraulic oil that has
leaked under pressure from the forklift’s hydraulic
system is dangerous. If this type of lesion should
occur, contact a doctor immediately.
DANGER
Small high pressure jets of oil can penetrate the
skin. Look for any leaks using a piece of cardboard.
ve filters contain subous to the environment
ccording to current
youtocontacttheau-
rk.
Battery Acid
• Do not inhale the vapor: it is poisonous.
• Use adequate means of individual protection to prevent contact with the skin.
• Battery acid is corrosive: if it should come
into contact with your skin, rinse abundantly
with water.
• Explosive gas mixtures can form when
charging the battery; therefore, the rooms
in which the battery is charged must be in
compliance with the specific regulations on
the subject (e.g. EN 50272-3 etc.).
• DO NOT smoke or use open flames and
lights within a 2 m radius from the charged
battery and in the battery charging area.
14
45758043402 [EN]
Page 21
Safety 2
Residual risks
NOTE
For greater information, cons
battery manual that comes with
ENVIRONMENT NOTE
ult the specific
the battery.
The batteries contain substances that are hazardous to the environment. The replacement
Residual risks
Residual dangers, residual risks
Despite careful use and compliance with
standards and regulations, the possibility
of other risks occurring when using the truck
cannot be entirely excluded.
The truck and all othe
comply with current s
Nevertheless, even w
for its proper purpo
are followed, some r
excluded.
Even outside the defined danger areas of
the truck, residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck must
be instructed regarding the risks that arise through
use of the truck.
In addition, we draw your attention to the Safety
Guidelines in these operating instructions.
r system components
afety requirements.
hen the truck is used
se and all instructions
esidual risks cannot be
and disposal of the life-expired battery must
be carried out as required by law. We advise
you to contact the authorised service network
that is equipped for eco-friendly disposal in
accordance with current regulations.
Risks can include:
• Escape of consumables due to leakages,
rupture of lines and containers etc.
• Risk of accidents when driving on ramps or
in conditions of poor visibility, etc.
• Falling, tripping etc. when moving the truck,
especially in wet or icy conditions or when
consumables are leaking.
758043402 [EN] 15
45
Page 22
2 Safety
Residual risks
• Fire and explosion risks due to batteriesand
electrical voltages.
• Human error resulting from failure to
observe the safety guidelines.
• Unrepaired damage or defectiv
components.
• Insufficient maintenance and testing
• Use of incorrect consumables
• Maintenance intervals exce
The manufacturer shall not be held responsible for accidents involving the truck caused by
the failure of the operating company to comply
with these regulations either intentionally or
due to negligence.
Stability
The stability of the truck has been tested
in accordance with up-to-date technical
regulations and is guaranteed if the truck is
used correctly and in line with the intended
purpose. These standards only take into
account the static and dynamic tipping forces
that can arise during use in accordance
with the operating standards and intended
purpose. In extreme cases there is a risk of
exceeding the moment of tilt due to improper
use or incorrect operation, which will affect
stability.
Risks can include:
• loss of stability due t
loads etc.;
• turns at excessive speeds;
• moving with the load raised;
• moving with a load that
side (e.g. side shift)
• turning and driving diagonally across
slopes;
• driving on slopes with the load pointing
downhill;
• oversized loads;
• swinging loads;
• steps or ramp edges.
o unstable or sliding
;
e and worn
eded
is projecting to the
16
45758043402 [EN]
Page 23
Safety 2
Electromagnetic radiation
Electromagnetic radiation
The limitvalues for electromagnetic emissions
and for immunity relative to the forklift are
those provided by the EN 12895 standard.
Non-ionised radiation
If the forklift is equipped at the factory or
later with devices that emit non-ionising
radiation (such as radio transmitters, RFID
players, data terminals, scanners, etc), the
compatibility of such devices must be verified
with the presence of operators using medical
devices (such as heart pacemakers).
Noise
Sound pressure level in driver’s seat L
Uncertainty factor KpA=4 dB (A)
The value is determined in a test cycle in
accordance with Harmonised European
Standard EN 12053 and declared according to
EN ISO 4871 with weighted time percentages
of the Transport, Lifting and Idling modes.
CAUTION
The value expressed above can be used to compare forklift trucks of the same category. This cannot be used to determine the noise level in workplaces (daily personal noise exposure). Noise values
that are lower or higher than thoseindicated above
can occur during actual truck use, for example
following different operating modes, different environmental conditions and additional noise sources.
<70dB(A)
pAZ
758043402 [EN] 17
45
Page 24
2 Safety
Vibrations
Vibrations
Value of the vibrations to which the handsarms are exposed:
ā
<2.5m/s
w
The value complies with Harmo
pean Standard EN 13059 (Safe
trucks — methods for measuri
2
nised Euro-
ty of industrial
ng vibration).
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.
18
45758043402 [EN]
Page 25
Safety 2
Safety tests
Safety tests
Regular safety inspection of the truck
Safetyinspectionbasedontimeand
extraordinary incidents
The operating company must ensure that
the truck is checked at least once a year, or
following noteworthy incidents.
As part of this inspection
of the technical conditio
performed with regard to a
In addition, the truck mus
checked for damage that co
have been caused by impro
log must be created. The r
inspection must be retai
inspections have been ca
, a complete check
n of the truck must be
ccident safety.
t be thoroughly
uld potentially
per use. A test
esults from the
ned until a further two
rried out.
The inspection date is indicated by an adhesive label on the truck.
– Arrange for the service centre to perform
periodic safety inspections on the truck.
– Observe guidelines fo
on the truck in accorda
r checks carried out
nce with FEM 4.004.
The operator is responsible for ensuring any
defects are remedied without delay.
– Contact your service centre.
STILL GmbH Hamburg
Regelmäßige Prüfung
(FEM 4.004)
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
95/63/EG, 99/92/EG, 2001/45/EG
Nächste Prüfung
Die Prüfplakette ersetzt nicht das Prüfprotokoll
Mitglied der:
Fédération
Européene
de la Manutention
0000_003-001_V3
56344391019
NOTE
Observe the national regulations for your
country!
758043402 [EN] 19
45
Page 26
2 Safety
Safety devices
Safety devices
Location of safety devices
Main safety devices on the truck
14
13
3
11
10
7
10-11-12
3
1
9
8
1Emer
2Til
20
gency shutdown handle.
ler position sensor. The truck will not
e if the tiller is not in the correct usage
mov
sition.
po
4
2
6
5
3 Oper
45758043402 [EN]
ator anti-crush safety button. Protects
operator from potential crushing by
the
king the truck.
bra
OM2308
Page 27
Safety 2
Safety devices
4 Operator side protection. Prevents the
operator from fallingfrom the platformduring
ride-on driving (if present).
5 Protective covers fastened with screws.
Do not use the truck without the protective
covers.
6 Operator on the platform presence sensor
(if present). Only ride-on driving is allowed
with the platform lowered.
7 Anti-shearing protective guard. Available in
a metal grille version or a transparent plastic
material version.
8 "500-mm" sensor. Automatic speed reduc-
tion with forks raised approximately 500 mm
above the ground.
9 "1500-mm" sensor. Automatic speed
reduction with forks raised approximately
1500 mm above the ground.
10 Automatic truck braking when the tiller is
released by the operator
11 Horn. Used to indicate the presence of the
truck during travel.
12 Combi tiller clasp closure sensor. If the
clasp is not closed properly, the truck will not
move.
13 Fork stop latches. Used to adjust the
distance between the forks. Do not use
the truck with the latches open (EXP only).
14 Screw that acts as a mechanical stop. The
screw prevents the unintentional extraction
of the forks. Do not unscrew or remove the
stop. Do not use the truck if the mechanical
stop is missing (EXP only).
758043402 [EN] 21
45
Page 28
2 Safety
Safety devices
Damage, defects and misuse of safety devices
The driver must report any damage or other
defects to the truck or attachment immediately
to the supervisory personnel.
Trucks and attachments that are not functional
or safe may not be used until they have been
properly repaired.
Do not remove or deactivate
and switches.
Fixed set values may only be changed with the
approval of the manufacturer.
Work on the electrical system (e.g. connecting
a radio, additional headlights etc.) is only
permitted with the manufacturer’s written
approval. All electrical system interventions
must be documented.
safety devices
22
45758043402 [EN]
Page 29
3
Overview
Page 30
3 Overview
Technical description
Technical description
General characteristics
The trucks described in this manual EXV 14,
EXV 16, EXV 20, EXV 14i, EXV 16i and EXV
20i, EXV 14-SF, EXV 16-SF, EXV 20-SF, EXV
14i-SF, EXV 16i-SF, EXV 20i-SF, EXP 14,
EXP 16, EXP 20 are designed to move and
stack pallets inside shops, warehouses and
factories.
Versions
• For the basic version (EXV a
the operator always guides
pedestrian mode (operated
ground)" as there is no pla
• The version"SF" is provided with a platform
for driving on board the truck. The operator
can use the truck both in pedestrian mode
(driving "on the ground") and in the mode
of "driving on board" by getting up on to the
appropriate operator’s platform.
• The version"i" is prepared for lifting and
lowering the spokes. It is available for both
the basic version of the truck and for the
version ."SF".
nd EXP)
the truck in
"from the
tform.
Lift
Nominal load:
• 1400 kg (EXV 14, EXV 14
EXV 14i-SF, EXP 14)
• 1600 kg (EXV 16, EXV 16i, EXV 16-SF,
EXV 16i-SF, EXP 16)
• 2000 kg (EXV 20, EXV 20i, EXV 20-SF,
EXV 20i-SF, EXP 20)
Pump unit
• Power rating 3.2 kW
i, EXV 14-SF,
Different types of lift mast:
• Telescopic "post": two-section telescopic
post without free lifting and two side cylinders
• "NiHo" post: two-section te
withfreelifting,lateralc
cylinders plus a central cyl
• Triplex "post" : three-section telescopic
post with free lifting, lateral chains and two
lateral cylinders plus a central cylinder
lescopic post
hains and two lateral
inder
Driving
The 185-W electric steering motor operates
the drive wheel using a reduction gear unit.
2.3 kW drive motor
On EXV, EXVi and EXP versions the operator
guides the truck from the ground. A long
ergonomic helm together with electric steering
allows the operator to drive the truck without
effort.
In versions EXV-SF the operator can drive the
truck on land or on board. A strong ergonomic
helm together with electric steering allows the
operator to drive the truck without effort.
The tiller is used to activate the following
controls:
• Steering
• Drive control throttle
•Horn
• Fork lifting and lowe
• Anti-crush safety button
• Truck braking when the tiller reaches the
upper end position and lower end position
(service brake)
• Buttons for raising
(only for versions"
For safety reasons, the helm automatically
returns to its initial position when released.
ring buttons
and lowering spokes
i")
Braking system
Regenerative braking
24
45758043402 [EN]
Page 31
Overview 3
Technical description
Braking:
• when the accelerator is released,
• Select the direction of travel
• controlled by the anti-crush safety button
• electromagnetic safety device, controlled
by the emergency stop handle
• electromagnetic safety dev
by the release of the tiller.
• safety electromagnetic, controlled when
the tiller arm reaches the lower end position
(service brake)
• Electromagnetic parking device, applied
when there is a power cut.
ice, controlled
On-board equipment
The on-board equipment includes:
• a glove compartment for storing adhesive
tape, gloves,pens etc.,
• A switch for emergency shutdow
on the chassis
• A multifunction display.
• A4 paper spring holder
n located
758043402 [EN] 25
45
Page 32
3 Overview
Overview
Overview
14
123
456
879
0*#
19
1
2
15
16
13
12
11
1On/of
2Lift
3Helm
4Eme
5He
6Wi
7B
8 Pivoting wheel
9 Operator’s Platform
10 Drive wheel
11 Display
fkey
ing post
head
rgency stop handle
lm
th operator side protective guards
onnet
10
17
3
4
18
5
6
6
7
8
9
12 Strad
13 Load
14 Batt
15 For
16 Ba
17 An
8
1
19 Digicode- Numeric Keypad
20 Helm
dles
rollers
ery plug/socket
ks
ttery compartment hood
ti-shearing guard
iagnostic test socket Service technical
D
assistance
20
OM2284
26
45758043402 [EN]
Page 33
Overview 3
Instruments and controls
Instruments and controls
Start/stop key
The key has two positions:
0 = Stop. No voltage to the circuit (Key
removal position)
I = Start. Circuit powered
758043402 [EN] 27
45
Page 34
3 Overview
Instruments and controls
Display
NOTE
The messages shown in the following illustrations are indicative and may vary depending
on the language chosen by the operator via
the display.
Buttons and indicator lights
– By pressing the button (A
the required performanc
Every time that you press
select a different perfo
three possible options
as follows:
• (1) Blue-Q symbol: maximum battery
consumption optimisation
• (2) Hare symbol: maximum truck performance
• (3) Tortoise symbol: au
and limited performan
Other indicator ligh
• (4) The light comes on depending on
whether the operator is present
The indicator light flashes when the truck
does not detect the presence ofthe operator
through the tiller or the platform. The tiller
is not tilted to the working position or the
operator is not correctly positioned on the
platform.
The indicator light
to detect the presen
through the tiller o
indicator light rem
ten seconds, after w
The indicator light is off after the truck has
detected the presence of the operator
through the tiller or the platform for more
than approximately ten seconds.
• (5) The indicator light comes on when the
battery is low
• (6) The indicator l
truck component o
ts:
), you can select
eforthetruck.
the button, you
rmance from the
. The three types are
tomatically reduced
ce
is lit when the truck starts
ce of the operator
r the platform. The
ains lit for approximately
hich it goes out.
ightcomesonwhena
verheats
7 6
11:05
93
5242.8
STATUS
58
05.12.2014
%
hrs
A B C D
4
1
2
3
OM2306
28
45758043402 [EN]
Page 35
Overview 3
Instruments and controls
• (7) The indicator light comes on for scheduling truck routine maintenance
• (8) The indicator light comes on when there
is a problem inside the truck (CAN etc.)
– By pressing the button (B), you
backwards between the entries
screen or backwards between
and the other.
– By pressing the button (C), you move
forwards between the items for each screen
or forwards between one screen and the
other.
– By pressing the button (D), you confirm your
selection of the item of the selected screen.
move
for each
one screen
Status
– The following are displa
screen:
• Clock and date
• Battery charge level
• Hours of work
yedontheStatus
11:05
93
05.12.2014
%
5242.8
STATUS
758043402 [EN] 29
45
hrs
OM2296
Page 36
3 Overview
Instruments and controls
Setting
– The following can be set on the Setting
screen:
• Language
• Unit of measurement
•Date
•Time
• Brightness
• Contrast
• Date format
Error
– Truck blocking errors or warnings for the
operator are displayed on the Error screen.
– The message warns that the scheduled
maintenance is due today. The message
is set by the technical service department
authorised by the manufacturer according
to the agreements with the customer.
Language
Units
/
Dateformat
1
Date
Time
SETTING
Visita di manutenzione
prevista oggi
1/1
OM2307
– The message informs you of when the next
maintenance work is due. The message
is set by the technical service department
authorised by the manufacturer according
to the agreements with the customer.
30
ERROR
OM2292
Prossima manutenzione :
100 hrs
1/1
ERROR
OM2293
45758043402 [EN]
Page 37
Overview 3
Instruments and controls
– The message warns that the maximum
height set for the forks has been reached
(optional function called" lifting block
h3=..."). The word "OK" appears on the
display in the red rectangle (E).
– To delete the message and be able to lift
the forks and the load higher, keep the
first button on the right on the keypad (D)
pressed for around three seconds.
Avvertimento
Altezza superata
Ok
– The rectangle (E) on the display turns
yellow and the word "OK" disappears. The
warning triangle that warns the operator to
pay special attention when moving loads
appears in its place.
– The message
sons, the op
to be able to
warns that, for safety rea-
erator must lower the straddles
lift the forks higher.
ED
OM2295
Avvertimento
Altezza superata
F
1/1
ERROR
OM2294
OM2305
758043402 [EN] 31
45
Page 38
3 Overview
Instruments and controls
– The message may appear on the display
when lifting approximately 1500 mm from
the ground (only for trucks for the version
with platform and side protection). To
remove the message from the display,
lower the load or close the operator side
protection (for more information, also see
⇒ Chapter "Location of labels", P. 3-50):
CAUTION
The operator must assess whether to close the side
protection before lifting the forks higher.
– The message indicates that the battery
charge level is low. Charge the battery.
1/1
ERROR
OM2298
Livello di carica
della batteria basso
1/1
ERROR
– If you continue to use the truck without
recharging the battery, the display shows
the message to the side. The battery is
low and lift does not work. Immediately
recharge the battery.
32
OM2303
Batteria scarica 0%
Sollevamento limitato!
1/1
ERROR
OM2304
45758043402 [EN]
Page 39
Overview 3
Instruments and controls
– When the battery is charging, the display
shows that battery charging is in progress.
Carica in corso
11.8 hrs
OM2302
– The message highligh
the truck. Switch the
If the message does no
the technical servic
by the manufacturer.
– The message highlights that the electronic
system has overheated. Shut down the
truck and wait for it to cool down. If the
message reappears, contact the technical
service department authorised by the
manufacturer.
ts a problem inside
truck off and on again.
t disappear, contact
e department authorised
CAN
LAC - Problema di
comunicazione
1/1
ERROR
OM2301
LAC - Temperatura
(elevata) anormale
1/1
ERROR
OM2299
758043402 [EN] 33
45
Page 40
3 Overview
Instruments and controls
– The message highlights that the motor has
overheated. Shut down the truck and wait
for it to cool down. If the message reappears, contact the technical service department authorised by the manufacturer.
CAUTION
If the Error screen displays messages other than
those mentioned above, please contact the sales
network authorised by the manufacturer.
Emergency shutdown handle
– Pushing the emergency shutdown handle
will lock all of the functions on the truck.
Temperatura motore
troppo alta (anormala)
1/1
ERROR
OM2300
34
45758043402 [EN]
Page 41
Overview 3
Instruments and controls
Tiller controls
1 — Tiller head handle
2 and 3 — Traction control throttle
4 — Fork lowering button
5 — Fork lifting button
6 — Horn button
7 — Anti-crush button
8 — Slow speed button (optional — Creep
Speed)
9 — Straddle lifting button (optional)
10 — Straddle lowering button (optional)
7
2
1
4
6
3
5
1
NOTE
The following controls are active with the tiller
in the "working position".
Tiller head handle (1)
• Areas designed for holding the tiller head
during use.
Traction control throttle (2 – 3)
• When the throttle (2 or 3
direction (A), the tru
direction of the forks
• When the throttle (2 or 3) is turned in
direction (B), the truck starts moving in the
direction of the operator.
• The truck speed increases or decreases
according to the angular position of the
throttle.
• Releasing the thrott
subsequently the sto
Fork lowering butto
• Press the button (4) to lower the forks.
• Fork movement can be stopped at any time
by releasing the button (4). The forks will
stop in the position attained.
• The fork lowering b
when the tiller is a
position.
) is turned in
ck starts moving in the
.
le causes braking and
pping of the truck.
n(4)
utton (4) is active only
ngled to the working
9
10
7
A
3
B
2
1
1
8
OM2279
NOTE
The speed of the forks is proportional to how
•
hard the button (4) is pressed
•
When the forks are fully lowered, a reduction in the fork lowering speed is automa-
758043402 [EN] 35
45
Page 42
3 Overview
Instruments and controls
tically triggered just before the end of the
stroke (soft landing)
Fork lifting button (5)
• Press the button (5) to lift the forks and
reach the maximum height.
• Fork movement can be stopped at
by releasing the button (5).
stop in the position attaine
• The fork lifting button (5) is active only when
the tiller is angled to the working position.
NOTE
The speed of the forks is pr
hard the button (5) is pre
Horn button (6)
• Press the button (6) to operate the horn.
This device allows the driver to signal his
presence when necessary.
Anti-crush button (7)
• Press the button (7) while the truck is travelling towards the operator to automatically
reverse the direction of travel When reversing, the truck travel speed is reduced for a
few seconds
The button (7) is a safe
useful in narrow areas
from being crushed bet
tiller head.
The direction of travel of the truck will be
reversed if the button (7) comes into contact
with the body of the operator. When the
operator moves away and releases the button
(7), the truck stops.
oportional to how
ssed
ty device. Particularly
, it prevents the operator
ween a wall and the
any time
The forks will
d.
NOTE
In "SF" trucks wit
button (7) is usua
36
h a platform, the anti-crush
lly disabled.
45758043402 [EN]
Page 43
Overview 3
Instruments and controls
Slow-speed button (8) (optional — Creep
Speed)
• The button (8)is fitted with the optional "tiller
always active" option (Creep Speed).
• Keeping the button (8) pressed
turning the throttle (2 – 3) act
speed, regardless of the til
• Keeping the button (8) pressed at the same
time as the fork lifting button (5) activates
fork lifting, regardless of the tiller position
NOTE
This function is ideal for
confined spaces.
manoeuvres in
while
ivates the slow
ler position.
Initial lift (9 and 10) (
available for EXP versi
The straddle lift function increases the ground
clearance, meaning that the truck can be used
on uneven ground or slopes.
WARNING
Risk of crushing feet.
Be careful not to put your feet under the straddles
while using the initial lift function.
Straddle lifting button (9)
• Press the button (9) to lift the straddles;
when the button is released, the straddles
will stop in the position attained.
• The straddle lifting button (9) is active only
when the tiller is angled to the working
position.
Straddle lowering button (10)
• Press the button (10) to lower the straddles;
when the button is released, the straddles
will stop in the position attained.
• The straddle lowering button (10) is active
only when the tiller is angled to the working
position.
optional) (not
on)
758043402 [EN] 37
45
Page 44
3 Overview
Tiller
Tiller
Tiller positions
Position the tiller in accordance with the
truck functions
With the truck stopped, the two following tiller
positions are available:
• Position (1) = working position.
In this position, the oper
using the throttle.
In thisposition, the operator can begin lifting
or lowering the forks using the appropriate
throttle.
In this position, the operator can raise
or lower the straddles; for versions with
straddle initial lift only.
• Position (2) = braking po
In this position, the drive is locked and the
parking brake is engaged.
ator can begin travel
sition.
A
2
1
2
OM2277
2
NOTE
In this position, lif
•
forks and straddles,
ting and lowering of the
if fitted, is blocked.
1
A
NOTE
When the tiller is released, it automatically
returns to position (A), the braking position.
38
2
OM2285
45758043402 [EN]
Page 45
Overview 3
Tiller
“Timone sempre attivo” version (optional
— Creep Speed)
• Position (2) using the "tiller always active"
function (optional) = slow speed position
This function is activated by p
slow speed button on the tiller
rotating the traction contr
by pressing the slow speed bu
fork lifting button. The tru
speed.
ol throttle (4) or
ck travels at limited
ressing the
(3) and
tton and the
4
4
3
OM2283
758043402 [EN] 39
45
Page 46
3 Overview
Tiller
Combi tiller (if present)
Instructions for opening the combi tiller
CAUTION
Perform the operation, preferably before starting
the truck and only when the truck is stationary.
Carrying out the operation when the truck is moving
is prohibited.
NOTE
The preferred means of use with the combi
tiller open is in pedestrian mode (operated
"from the ground").
– Open the clasp to release the tiller.
– Use the handle to pull the tiller to open it.
40
45758043402 [EN]
Page 47
Overview 3
Tiller
– The tiller is open.
Instructions for closing the combi tiller
CAUTION
Perform the operation, preferably before starting
the truck and only when the truck is stationary.
Carrying out the operation when the truck is moving
is prohibited.
NOTE
The preferred means of use with the combi
tiller closed is in ride on mode (operated from
the platform).
– Use the handle to push the tiller to fold it.
– The clasp closes automatically to lock the
tiller.
CAUTION
Check that the tiller is locked correctly.
758043402 [EN] 41
45
Page 48
3 Overview
Tiller
OptiSpeed tiller (only present on EXV and EXVi versions)
The different work zones of the tiller depending
on the tilt are explained below:
• In zone (1), the brake is applied and the
truck cannot be moved.
• In zone (2), the maximum aut
varies according to the til
reference (5) represents t
speed inside zone (2).
• In zone (3), the truck can reachits maximum
speed. The traction speed is proportional to
the angular position of the throttle.
In zone (4), the brake is applied and the truck
cannot be moved.
WARNING
During use, tilt the tiller and gradually change the
speed of the throttle in accordance with the above.
horised speed
t of the tiller. The
he curve of the
5
1
2
3
4
OM2282
42
45758043402 [EN]
Page 49
Overview 3
Types of lifting masts
Types of lifting masts
Your truck may be fitted with one of the
following masts:
• Simplex
• Telescopic
•NiHo
• Triplex
Simplex
When the "lift" button is pr
carriage is raised to thehe
cylinder via a chain.
Telescopic
When the "lift" button is pressed, the internal
mast is raised by the lateral cylinders and
drives the fork carriage (h3) via the chains (the
lifting speed of the fork carriage is twice that of
the internal mast).
CAUTION
In locations with a low ceiling, be aware that the
load height may be greater than the mast height.
essed, the fork
ight h3 by the central
h
3
0252_003-097
h
3
h
2
NiHo
When the "lift" button is pressed, the fork
carriage is raised to the top of the internal
mast (h2’) by the central cylinder, then the
lateral cylinders raise the internal mast up to
the maximum height (h3).
NOTE
During lifting, the internal mast is never higher
than the fork carriage.
CAUTION
ns with a low ceiling, be aware that the
In locatio
load heigh
t may be greater than the mast height.
758043402 [EN] 43
45
0252_003-098
h
3
h
2'
0252_003-099-V2
Page 50
3 Overview
Types of lifting masts
Triplex
The function is identical to that of the NiHo
mast, but has a greater lift height with the
same mast height.
CAUTION
In locations with a low ceiling, be aware that the
load height may be greater than the mast height.
h
3
h
2'
0252_003-100-V2
44
45758043402 [EN]
Page 51
Overview 3
Side protection
Side protection
Description
The side protection has been designed to
protect the operator when the truck is used in
ride on mode.
There are two positions:
–Position"A" = side protect
Position used when the oper
the truck in pedestrian mod
the "ground") with the plat
The truck also works with the side protection closed (Position "A") and also with the
operator on board the truck. In this case the
maximum travel speed of the truck will be automatically limited for safety reasons.
–Position"B" = side protection open. Position
used with the operator on board the truck,
standing on the platform.
ion closed.
ator is using
e (operated from
form closed.
Opening and closing the side protection
– To open, pull the two operator side protec-
tive guards outwards.
– Toclose,pusht
protective gua
Adjusting the
– To adjust the height of the side protective
guards according to the height of the
operator, open the side protective guards,
then manually pull the side protective
guards upwards (three positions). To close
the side protective guards, push them down
until they reach the original, lowest position.
he two operator side
rds inwards.
height of the side protection
758043402 [EN] 45
45
Page 52
3 Overview
Side protection
CAUTION
Always lower the side protection bars before re-closing them.
Otherwise the side protective guards will not close
and this may damage the hoods.
DANGER
Do not sit on the side protection bars.
DANGER
Do not climb on the side protection bars.
46
45758043402 [EN]
Page 53
Overview 3
Platform
Platform
Description
The platform can take up three positions A, B,
C:
Position "A" = platform closed. This position
is used when the truck is in pedestrian mode
(operated from the "ground") with the side
protection closed.
Position "B
position:i
locked.
Position "C" = platform in the operating
position in ride on mode: This position is used
with the operator on board.
In this position, the traction and truck speed
depend on the position of the side protection:
• Side protection open: The truck can reach
its maximum speed.
•Sideprote
limited el
" = platform in the intermediate
n this position, the truck traction is
ction closed: The truck speed is
ectronically.
NOTE
758043402 [EN] 47
45
Page 54
3 Overview
Platform
If the platform is closed "A" and the side
protection is open, the traction is locked.
Moving the platform
To lift or lower the platform, move the platform
floor by hand.
CAUTION
Danger of crushing hands.
When closing the platform,do not leave your hands
between the platform and the hood.
Adjusting the platform
For improved absorption of vibrations, the
platform must be adjusted according to the
weight of the operator.
Adjust the pressure of the damping system
based on the weight of the operator using the
valve (1).
Safety
DANGER
Risk of ejection from the platform.
Position yourself correctly on the platform between
the two side protection bars: standing up, facingthe
forks, with both feet inside the platform.
Turn corners at low speed.
Firmly grip the handle on the tiller head with your
hands.
DANGER
It is strictly prohibited to disable protective and
safety devices.
48
45758043402 [EN]
Page 55
Overview 3
Definition of directions
Definition of directions
Definition of directions for EXV, EXVi,
EXP Directionsalso validfor EXV-SF and
EXVi-SF versions with platform closed
and pedestrian mode operation
Direction of movement defined by the regulations:
• Reverse travel (1)
• Left (2)
• Forward travel (3) (Preferred direction of
travel)
• Right (4)
Definition of directions for EXV-SF,
EXVi-SF version with platform lowered
and ride-on mode operation
Direction of movement defined by the regulations:
• Forward travel (1) (Preferred direction of
travel)
• Left (4)
• Reverse travel (3)
• Right (2)
Conclusion
To make it easy for the reader to interpret, the
direction of travel will always be defined in the
following manner:
• (1) Direction of travel towards the forks
• (3) Direction of travel towards the operator
758043402 [EN] 49
45
Page 56
3 Overview
Markings
Markings
Location of labels
2
!
B
A
>
A
B
<
A
B
A
B
3
4
5
1
6
7
16
8
16
GEL
Pb+Sb
9
10
15
!
11
14
1 "Truck capacity diagram" label
2 "Operator side protection" usage label (for
the version with operator platform only)
3 "Hook" symbol
4 "Danger of crushing hands" label
5 "Operating and maintenance manual" label
6 "Lifting danger" label (on initial lift chassis
version only)
7 "Operating and maintenance manual" label
8 Version set up for gel batteries
50
13
9 "On-board battery charger" label
10 Annual checks label (Germany only)
11 "Operator platform capacity diagram" label
12 "Maximum permissible pressure" label
13 "Cold store" label(on cold store version only)
14 "Danger of crushing feet" label (on initial lift
15 Warning label
16 "Danger of crushing hands" label
45758043402 [EN]
12
chassis version only)
OM2291
Page 57
Overview 3
Markings
Description of labels
(1) This label indicates the permissible load on
the forks depending on load centre of gravity
and lift height.
(2) This symbol, where present
correct use of operator side pa
forks are at a height greater
above the ground (depends on
uration). If the height of th
is greater than the height of
side panels must be closed (s
side of the label). If the hei
the forks is less than the hei
rack, the side panels can be o
right-hand side of the labe
(3) This label indicates where to attach the
truck’s lifting hook.
(4) This symbol appears on the lift mast and
indicates danger of cutting due to the mast’s
moving parts.
(5) This label indicates
the use and maintenance m
using the truck and prior
maintenance work.
(6) This label is only present on the version
with initial lift (i). The label indicates that it is
prohibited to lift a load more than 1500 mm
from the ground while the straddles are raised.
To lift a load more than 1500 mm from the
ground, the straddles must be on the ground.
(7) This label indicates that you should consult
the specific use and maintenance manual for
the on-board battery charger.
(8) This symbol, where
the truck is set up for t
Do not use other types
he gel battery version.
, indicates the
nels when the
than 1500 mm
truck config-
e load on the forks
theloadrack,the
ee the left-hand
ght of the load on
ght of the load
pened (see the
l).
you should consult
anual before
to carrying out any
present, indicates that
of battery.
(9) This label is only present on the version
with the on-board battery charger. The label
highlights the possibility of choosing the
charging curve.
(10) This label is only present on trucks sold in
Germany. The label indicates the date of the
truck’s periodic safety inspection.
(11) This label is only prese
with operator platform and s
The label indicates the sett
operator platform dependin
of the operator. 1.5 bar betw
70 kg, 2 bar between 70 kg and 9
between 90 kg and 110 kg, 3 bar
110 kg and 130 kg.
(12) This label is only present on the version
with operator platform and side protection.
The label indicates the maximum setting
pressure for the operator platform. Caution:
Increasing the pressure of the control system
to greater than 8 bar is prohibited.
(13) This symbol, where present, indicates
that the truck is set up for the "cold-storage"
version (optional).
(14) This label is only pr
with initial lift (i). Th
of crushing feet under th
(15) This symbol appears on the lift mast and
indicates danger of cutting due to the mast’s
moving parts, that carrying people on the truck
is prohibited and that standing or passing
under the raised forks is prohibited.
(16) This symbol appears on the battery hood
and indicates the danger of crushing and/or
cutting hands while opening and/or closing
the battery hood on the entire perimeter of the
hood. Take care when operating.
e label indicates the danger
nt on the version
ide protection.
ing pressure of the
g on the weight
een 50 kg and
0 kg, 2.5 bar
between
esent on the version
e straddles.
758043402 [EN] 51
45
Page 58
3 Overview
Markings
Serial number
NOTE
Please quote the serial number with all
technical questions.
The serial number contains the following
information:
1 Production location
2 Type
3 Year of production
4 Sequential number
Data plate
NOTE
Please indicate the serial no. for all technical
enquiries.
xx xxxx x xxxxx
1
2
3
4
7090_921-004
1 Model
2 Manufa
3Serial
4 Year o
5Unla
6Max
7Min
8Ad
9N
0
1
11 Rated capacity in kg
12 EC conformity symbol
52
45758043402 [EN]
cturer
no.
f manufacture
den weight (without battery) in kg
imum battery weight
imum battery weight
ditional weight (ballast) in kg
ominal power rating in kW
attery voltage V
B
Page 59
Overview 3
Markings
Capacity plate
– The identification plate indicates the follow-
ing data:
• (1) CDG = distance "C" from the centre of
gravity of the load on the forks to the fork
carriage (in mm)
• (2) h = lift heightof the for
(in mm)
• (3) Maximum permissible loads "Q" (in kg)
WARNING
The illustrations are only examples.
Only the values stated on your truck’s plate should
be taken into consideration.
(*) Lifting height (HS) refers to h3 (fork lifting)
+ S (fork height).
–
DANGER
The values indicated on the capacity plate refer to
compact and homogeneous loads and must not
be exceeded - otherwise the stability of the truck
and the load-bearing capacity of the structures
may be compromised. The distances C of the load
centre of gravity and the lifting height of the forks
HS determine the maximum load capacity.
ks from the ground
C
S
C
HS
h3
DANGER
Risk of accident when forks are changed:
If the forks are changed and a different type of
forks to the original forks is fitted, the residual load
capacity changes.
When forks are changed, a new residual capacity
plate must be affixed.
If a truck is supplied without forks, the residual
capacity plate for standard forks is affixed (see
chapter 6 "Technical Data").
758043402 [EN] 53
45
1990
Page 60
3 Overview
Markings
Chassis frame labelling
A
The truck’s serial number is marked (A) on the
chassis frame.
54
OM2312
45758043402 [EN]
Page 61
Overview 3
Options and variants
Options and variants
List of options and variants
List:
• Various types of tyre for the drive wheel
• Various types of load rollers
• Tiller always active (Creep Speed)
• Various types of battery
• Various lift masts and lift
• Various fork gauges and fork lengths
• Various types of load rack
• Version with moving stradd
• Load handler (Load Management)
• Access authorisation via: key or, alternatively, numeric keypad (Digicode)
• Fleet Manager
• Anti-shearing protective guard plate in
transparent polycarbonate, positioned on
the mast.
• Cold storage version (Cold store)
• Accessories mounting b
• Accessories mounting bar with clipboard
• Accessories mounting bar with storage tray
• Accessories mounting
and clipboard
• Accessories mounting bar with data socket
• Pivoting wheel lubrication nipples
• Load roller lubricat
• Various types of cables and plugs
• Various types of cables andadditional plugs
• Built-in rectifier
• Battery electrolyte level indicator LED
• Centralised battery top-up with distilled
water
• Extraction of the ba
• Straddle automatic lowering, when forks
are raised approximately 1500 mm above
the ground.
CAUTION
After buying the truck, contact the technical service
network authorised by the manufacturer for information on assembly of the optionals.
heights
les "i"(Initial lift)
ar
bar with storage tray
ion nipples
ttery
758043402 [EN] 55
45
Page 62
3 Overview
Options and variants
NOTE
The above list is only a summary
optionals are NOT available on
For more information, please r
list and contact the authorise
.Some
all models.
efer to the price
d sales network.
Straddle automatic loweri
ng (op-
tional)
This option is available f
with straddle initial lif
For the standard version, when the straddles
are raisedoff the ground, if the operator tries to
raise the forks above approximately 1500 mm
from the ground, a message will appear on the
display to warn that the operator must lower
the straddles to be able to raise the forks any
further (see ⇒ Chapter"Display", P.3-28). The
forks are locked at 1500 mm from the ground
until the operator lowers the straddles.
If the truck is equipped with the "Straddle automatic lowering" option, the truck automatically
lowers the straddles (if raised off the ground)
when the forks are raised above 1500 mm.
NOTE
On the version with platform, the automatic
function is intentionally blocked for safety
reasons when the operator guides the truck
from the ground in pedestrian mode. In this
case, the truck behaves in the same way as
the standard version. With ride-on driving, the
automatic function operates normally.
or all trucks equipped
t.
56
45758043402 [EN]
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Overview 3
Options and variants
Accessories mounting bar with data socket
The optional data socket (6 and 7) is fitted on
the relevant accessories mounting bar (3).
The pre-wired data socket (6) connected to
the truck has the following features:
• Voltage 24 V
• Current 5 A
WARNING
Ifyouarenotusingthedatasocket(6),protectit
from the weather, dust etc. using the cap (5).
Do not leave the data socket (6) uncovered.
In addition to the optional "accessories mounting bar with data socket" the customer is also
provided with a plug (4).
If necessary, wire the plug (4) to be connected
to the customer’s data terminal as follows:
• Connect the positive to terminal (1)
• Connect the negative to terminal (2)
DANGER
Always respect the connections mentioned above
(1 and 2)
Reversing the polarity is dangerous and strictly
prohibited.
7
3
3
5
6
2
1
4
WARNING
The instructions provided are for information only.
Installation must be carried out precisely and in
accordance with technical regulations. Only the
manufacturer’s own approved sales network is authorised to assemble and install accessories. The
manufacturer will NOT be liable for any personal
injury or damage caused by unauthorised third parties. Contact the manufacturer’s authorised service
network.
CAUTION
Fix the data terminal used to the relevant support
(7) precisely and in accordance with technical
regulations.
Do not allow the data terminal used to fall from the
support (7).
758043402 [EN] 57
45
2326
1 Positive
2 Negative
3 Accessories mounting bar
4 Plugtobewired
5Plug
6 Data socket
7 Data terminal support
Page 64
3 Overview
Options and variants
Digicode option
1 SWITCH ON (operating mode)
2 SWITCH OFF and awaiting code
3 Programming mode active
4 Faulty key or incorrect code
5 Delay of automatic switch-off
Operation
ON
OFF
PROGRAMMING MODE — to be carried out with the truck switched off (2)
Operation
THE ADMINISTRATOR CODE
IS IMPORTANT
FOR ALL DIGI-
CODE SET-
TINGS
New operator
code
Allocating
operator codes
Deleting operator
codes
Modifying
administrator
codes
OPERATING MOD
Key
* 1 2 3 4 5 #
(by default)
#
(3 seconds)
Key in
* 0 0 0 0 0 0 0
0 #
(by default)
* 0 * 4 5 6 7 8 #
* 2 * 5 4 3 2 1 #
* 2 * #
* * 9 * 1 2 3 4
5 6 7 8 #
E
LED
red off co
green (1)(P
red flashin
off (4)(PIN
ntinuous
IN correct)
g
green
incorrect)
red off green
flashing (2)
LED status
continuous red
continuous green (3)
red off green flashing
(2) (code accepted)
red off green flashing
(2) (code accepted)
ed off
green flashing
r
) (deletion accepted)
(2
red off green flashing
(2) (code accepted)
Warning
1 2 3 4 5
default
PIN code
Turn off the truck
Warning
Once the diodes have
been switched off,
the electronic key
automatically reverts
to "operating mode"
le of a new
Examp
tor code: 45678
opera
*2*: operator reference
10 options from 0 to 9
*: operator reference
*2
etween 0 and 9)
(b
58
45758043402 [EN]
Page 65
Overview 3
Options and variants
PROGRAMMING MODE — to be carried out with the truck switched off (2)
Restoring
the initial
administrator
code
To reactivate the default
administrator code
(00000000), please
contact your agent or
nearest dealer.
The power supply
Activating the
automatic
switch-off
* * 2 * 1 #
red flashing green
flashing (5) (5 s before
switch-off)
switches off
automatically after
10 min. (600 s by
default) if the truck is
not being used.
Example: automatically
Setting the delay
of the automatic
switch-off
* * 3 * 6 0 #
red off green flashing
(2)(value accepted)
switches off after 1 min.
(60 s) if not used.
Minimum setting = 10 s
/ maximum = 3000 s
Deactivating
the automatic
switch-off
* * 2 * 0 #
red off green flashing
(2)(command accepted)
Stand-by
NOTE
The stand-by function is only available with
the Digicode option.
To prolong battery life, the truck can be put
into energy-saving mode when it is not in use.
After a certain period of downtime, the truck
switches off.
This time period can be configured between 0
and 10 minutes. This function is disabled by
default.
Timeout can be adjusted. Contact the Technical Service Department authorised by the
manufacturer.
758043402 [EN] 59
45
Page 66
3 Overview
Options and variants
Battery electrolyte level indicator LED (optional)
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the battery plug.
The LED indicates whether it is necessary to
top up the distilled water in the battery.
Operation:
• If the LED (1) or (2) is green
sufficient level of electro
The battery must not be topp
distilled water.
• If the LED (1) or (2) is red, there is an
insufficient level of electrolyte in the battery.
The battery must be topped up with distilled
water.
, there is a
lyte in the battery.
ed up with
1
2
2256
60
45758043402 [EN]
Page 67
4
Use
Page 68
4 Use
Authorised and safe use
Authorised and safe use
Intended use of the trucks
CAUTION
This machine is intended for the transport of loads
packed on pallets or in industrial containers designed for thispurpose, as well as forplacing pallets
into and removing pallets from stock.
The dimensions and capacity of the pallets or
containers must be adapted to the load being
transported to ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of the
information you need to check that the equipment
is suitable for the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
Safety instructions relating to use of the truck
Behaviour when driving
The operator must obey the same rules within
the plant as on the road. The operator must
drive at a speed appropriate for the driving
conditions. For example, the operator should
drive slowly around corners, when entering
and travelling through narrow passageways,
when driving through swing doors, at blind
spots, or on uneven surfaces. The operator
must always maintain a safe braking distance
from vehicles and persons in front of him and
must always have the truck under control. The
operator must avoid sudden stops, making
fast U-turns and overtaking other vehicles in
potentially dangerous areas or areas with poor
visibility.
WARNING
Driving the truck while sitting down is prohibited.
Please remember the following:
• Drive thetruck asdescribed inthe "Operator
positions" section.
• The truck must not be used as a stepladder.
62
45758043402 [EN]
Page 69
Use 4
Authorised and safe use
• The truck has not been designed to transport anyone other than the operator and
must not be used for this purpose.
• The operator must always stay within the
truck clearance.
• Stay in the safety area (workin
defined by the manufacturer)
garea
.
NOTE
Using a telephone or radio in the truck is
permitted, but avoid using these devices when
driving as they may distract you.
People in the danger area
Before starting the tru
working, ensure that no
area. If people are in da
well in advance. Stop wo
immediately if the peop
danger area despite the
DANGER
Risk of injury! There is arisk of physicalinjury inside
the danger area. Danger of death from falling loads!
Do not stand on the forks!
Standing or walking under the forks is strictly
forbidden, even when they are not loaded!
ck and while you are
one is in the danger
nger, warn them
rking with the truck
le do not leave the
warnings.
Danger area
The danger area is the area in which people
are in danger from the forklift truck movements, from its work equipment and from its
load lifting devices (e.g. accessories) or from
the load. The danger area also includes areas in which a load could fall or in which work
equipment could lower or fall.
Traffic route conditions
The surface of traffic routes must be sufficiently level, clean and clear of objects.
Drainage channels, railway crossings and
other similar obstacles must be levelled and, if
necessary, fitted with ramps so that the truck
can cross without jolting.
There must be sufficient distance between
the highest part of the truck or the load and
758043402 [EN] 63
45
Page 70
4 Use
Truck transport and lifting
the surrounding fixed installations. The
height depends on the lift height and the
dimensions of the load. Refer to the technical
characteristics.
Regulations regarding the traffic routes
and the manoeuvring areas
Only traffic routes authorised by the operator
or his agent may be used. Traffic routes
must be free of obstacles. Loads may only
be unloaded and stored in places designed
for this purpose. The operator or his agent
must ensure that no unauthorised person
approaches the working area.
Hazards
Hazards on the traffic rou
by standard road signs or
tional warning notices.
tes must be signalled
possibly by addi-
Truck transport and l
Transporting the tr
The forklift is norm
and rail. If the fork
the max. clearance s
ported disassembl
in charge of the dis
operations. The fo
transport means du
priate restraints
wedges to prevent e
ment.
64
uck
ally transported by road
lift’s dimensions exceed
ize allowed, it is trans-
ed. The sales network is
assembly and reassembly
rklift must be secured to the
ring transport using appro-
ystems. Block the wheelswith
ven the slightest move-
ifting
OM0747
45758043402 [EN]
Page 71
Use 4
Truck transport and lifting
Transport
– Disconnect the battery connector.
2
Chocking the truck
– Secure the truck against rol
with chocks (1).
Lashing down the truck
– Attach the lashing ropes (2) to the mast.
ling and sliding
Climatic Conditions for Transport and Storage
The forklift must be protected from atmospheric agents during transport and storage.
1
1
0252_003-010
758043402 [EN] 65
45
Page 72
4 Use
Breaking-In
Loading and unloading the truck
To load and unload the truck, use a loading
bridge or a lift (with a slope and structural
strength compatible with the performance
and weight of the truck as stated by the
manufacturer, and that is suitably positioned
and anchored). See the relevant section.
Alternatively, a crane or a bridge crane may
be used.
The truck must be suitably protected from the
effects of the weather during transport and
storage.
Liftingwithacraneorabridgecrane
CAUTION
Always switch off the ignition and disconnect the
battery.
Never tie down or sling the truck by the tilleror other
points not designed for this.
– Insert the rope sling in the appropriate
eyelet on the column. The hook and the
rope sling must have a capacity suitable
for the weight of the truck. The position is
indicated by a hook symbol
DANGER
Use a crane with a suitable lifting capacity for the
weight of the truck, indicated on its data plate. Also
take into account the weight of the battery fitted (if
applicable), referring to the relevant identification
plate. Lifting operations must be performed by
qualified personnel. DO NOT stand within the
crane’s radius of action or near the truck. Do not
stand in the danger areabeneath suspended loads.
Use NON METALLIC slings. Make sure that the
lifting capacity of the slings is suitable for the weight
of the truck.
DANGER
The rope slings should have a suitable length so
as to not graze the casings or any additional equipment during lifting. Use a lifting beam if necessary.
The rope slings must be pulled vertically.
Breaking-In
This type of forklift does not require special
breaking-in operations.
66
45758043402 [EN]
Page 73
Use 4
Checks and actions prior to commiss
ioning
Checks and actions prior to commissioning
List of checks before use
WARNING
Damage or other faults on the truck or attachments
(special equipment) can result in accidents.
If damage or other faults are noticed on the truck
or attachments (special equipment) during the
following checks, do not use the truck until it has
been properly repaired. Do not remove or disable
the safety systems and switches. Do not change
the pre-set values.
CAUTION
Only use the truck if all of the covers are fitted
correctly and the covers and doors are closed
correctly.
CAUTION
Perform checks on a flat surface. Make sure that
there are no people or objects in the test area in
front of and/or behind the truck.
CAUTION
Drive very slowly during the operational tests.
CAUTION
Perform the braking checks in pedestrian mode
(operated from the "ground").
Ensure that the vehicle is in good working
condition prior to start-up. These checks
supplement and do not replace the scheduled
maintenance operations.
• Check that there are NO oil leaks in the area
under the truck.
• Visually check the uncovered sections of
hydraulic hoses and pipes to ensure that
they are in good condition and to detect any
oil leaks.
• Check that there are no objects (wires of
various types, nails, screws, pieces of tape
etc.) impeding the operation of the wheels
and rollers. The wheels and the load rollers
must roll freely.
• The wheels must not show any sign of
damage or heavy wear. They must be
correctly mounted.
• The roller tracks of the col
coated in a visible film of gr
umn must be
ease.
• The chains must be undamaged and must
be evenly and adequately tensioned.
• Check that the battery cover is fully and
properly closed.
• Test that all of the hoods a
guards are present and ch
nd protective
eck that they are
correctly mounted.
• The mast protective screen must be intact
and correctly mounted.
• There must be no objects on the truck that
may limit visibility.
• Check that NO stickers ar
damaged. Replace dama
stickers in complianc
e missing or
ged or missing
e with the marking
position table.
• Visually check that the forks or other
load-carrying equipment show NO obvious
damage (e.g. bends, cracks, significant
wear).
• Check that the battery male connector and
female connector are fully intact and in good
condition. Check that they are working
correctly.
• Check that the start/
stop key works cor-
rectly.
• Check the indications on the display.
• Check that the horn works correctly.
• Check that the butto
throttles on the til
ns and the control
ler are working correctly.
• One at a time, push the buttons and then
release them. Check that the buttons return
automatically to their initial positions. The
buttons should not remain activated or
stuck.
• Turn the drive control throttle and then release it. Check that the throttle automatically returns to the initial position when it
758043402 [EN] 67
45
Page 74
4 Use
Checks and actions prior to commiss
ioning
is released. The throttle must not remain
activated or locked.
• Test that the truck brakes and stops when
the throttle is released while driving.
• Tilt the tiller, then release i
tiller automatically returns
position.
• Test that the truck brakes and stops when
the tiller is released while driving.
• Check that the truck brakes and stops when
the tiller is pushed all the way down while
driving.
• Check that the emergency shu
handle is operating correct
the test when travelling to
• Check that the anti-crush/operator anticrush protective device is operating correctly.
• Check that the brake is operating correctly.
• Test that the electromagn
effectively.
• Check that the battery harness is in good
condition.
• Check and test the battery electrolyte level
and density as indicated in the battery
instructions.
• The operator must be qual
truck. The operator must
the controls and operate
the anti-crush protect
obstruct access to the c
• Check that the side protection panels are in
good condition and are operating correctly
(EXV-SF only).
• Visually check that the operator platform
is in good condition and that it is operating
correctly (EXV-SF only):
- Climb onto the opera
on the truck.
t. Check that the
to the vertical
tdown
ly. Carry out
wards the forks.
etic brake works
ified to drive the
be able to reach
them (especially
ive device). Do not
ontrols.
tor platform and turn
- Test that the truck goes into forwards/reverse travel using the control throttle.
- Climb down from the step plate and
visually check that the operator platform
automatically moves to a rest position, tilted
slightly upwards.
- Stand to the side of the truc
sure that the area in front of
truck is clear.
- Using a boom, tilt the tiller without turning
and slightly rotate the control throttle
towards the forks. Repeat the sequence,
turning the throttle in the opposite direction.
In both cases, test that the truck remains at
a standstill. The truck must NOT move.
- Push the platform upwards. Push the
operator platform slightly to check that
it automatically moves into a vertical,
fully closed position. Caution: danger of
crushing hands!
- With the platform in a vert
the side panels open, check
does NOT function!
• Check that the fork stop latches are in
good condition, operating and positioned
correctly (EXP only).
• Check that the fork stoplatches are properly
and completely closed (EXP only).
• Check that the forks are l
move accidentally (EXP
• Check for the presence and the correct
positioning of the mechanical stop that
prevents the unintentional extraction of
forks (EXP only).
k and make
and behind the
ical position and
that the truck
ocked and cannot
only).
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Operator position
Operator position
Operator’s position for version
without platform
The driving position is in pedestrian version
(driving on "the ground"). The operator should
drive the truck using the driving and lifting
controls located on the helm head.
DANGER
All other positions should be considered incorrect
and dangerous.
– Recommended position for pick-up and
deposit of the load.
– Recommended position when in gear
(preferential gear)
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4 Use
Operator position
Operator position for version with platform
There are two driving positions:
• Pedestrian mode driving position — "operated from the ground"
• Ride on mode driving positi
on
Pedestrian mode driving po
"operated from the ground
The operator should drive the truck using the
driving and lifting controls located on the tiller
head.
In this configuration:
• The operator side protection panels are
closed completely
• The platform is closed c
• With standard tiller or combi tiller closed,
the maximum speed of travel is limited for
safety reasons.
• With combi tiller open, the maximum
authorised speed is slightly higher, as the
operator moves the truck from a greater
safety distance.
CAUTION
The truck may onlybe operatedin pedestrianmode
ifthesideprotectionandthesidepanelsarefully
closed.
Otherwise the truck will not start.
CAUTION
Risk of feet being crushed.
Ensure that your feet are placed far enough away
from the truck chassis.
sition —
"
ompletely
CAUTION
Sitting on the truck is strictly prohibited.
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Use 4
Operator position
Ride on mode driving position
The operator should drive the truck using the
driving and lifting controls located on the tiller
head.
In this configuration:
• The platform must be fully op
• With the side protection closed, the maximum speed of travel is limited for safety
reasons.
• With the side protection open,the maximum
authorised speed is slightly higher, as
the operator is driving in a safer situation,
restrained by the side protection.
CAUTION
Thetruckmaybeoperatedinrideonmodewiththe
side protectioneither open or closed.
CAUTION
In ride on mode, opening the combi tiller is prohibited.
If the clasp to close the tiller is not shut properly, the
truck will not start.
en
DANGER
Risk of falling from the platform.
Position yourself correctly on the platform between
the two operator side protection panels.
Turn corners at low speed.
While driving, firmly grip the handle on the tiller
head with your hands.
DANGER
Do not sit down and do not climb on the side protection panels
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4 Use
Use of the truck
Use of the truck
Stopping the truck in emergencies
In an emergency, the power supply to all
functions on the truck can be shut down.
– Press the emergency shutdown handle.
This blocks all of the truck functions, so the
truck will brake and stop.
– Before restoring operatin
eliminate the causes of the
– Release the tiller to the rest position.
– To restart the truck, pull the emergency
shutdown handle by lifting it.
CAUTION
This protective device must be used only in emergencies; the repeated use of this device may cause
problems with the electronic equipment or breakdowns.
g conditions,
emergency.
Starting the truck
Carry out all of the daily checks to be performed by the operator.
Pull the emergency shutdown handle.
Put the tiller in the vertical position.
To start the truck, turn the switch key to the
position I. If the truck has a numeric keypad
rather than a key, insert the appropriate PIN
code.
Check the battery charge status on the
indicator and replace or charge the battery
if necessary.
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Use 4
Use of the truck
Truck operation
Pedestrian drive mode version (operated
from the "ground")
• Grip the tiller head correctly
• Tilt the tiller to the working
• Select the desired direction of movement
using the throttle; the truck speed is proportional to the angular position of the throttle
• The truck brakes electrically when the drive
control throttle is released.
CAUTION
If there are difficulties starting the truck, do not
persist but look for the cause.
position
• Manually open the operator protective
guards
• Mount the platform
• Tilt the tiller to the working
• Select the desired direction of movement
using the throttle; the truck speed is proportional to the angular position of the throttle
• Thetruckbrakeselectricallywhenthedrive
control throttle is released.
CAUTION
If there are difficulties starting the truck, do not
persist but look for the cause.
position
Ride-on drive mode version (only for
version with platform)
• Grip the tiller head correctly
• Manually open the platform
CAUTION
Keep both feet inside the platform
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4 Use
Use of the truck
Truck steering direction
AA
CE
G
D
BB
Use the tiller to steer during travel.
• When the tiller is turned anti-clockwise (G)
while travelling towards (A), the truck steers
towards (C)
• When the tiller is turned anti-clockwise (G)
while travelling towards (B), the truck steers
towards (D)
H
F
OM2313
• When the tiller is turned clockwise (H) while
travelling towards (A), the truck steers
towards (E)
• When the tiller is turned clockwise (H) while
travelling towards (B), the truck steers
towards (F)
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Use of the truck
Using the truck with the "Tiller always active — Creep Speed" function (optional)
The "tiller always active" function can be
enabled when operating the truck in confined
spaces.
This function allows the tr
with the tiller in any posit
dard version, by following
low the truck functions (tr
ering of forks) are also act
the vertical position.
To enable truck lifting w
vertical position:
• Press and hold the button (3)
• Then press the fork lifting button
• Release the button (3) to
function.
To enable travel with th
position:
• Press and hold the button (3)
• Then turn the throttle (4) in the desired
direction
• Creep speed of the truc
enabled During creep s
in the vertical positi
pressed, if the operat
the working position
positions", P. 3-38), t
the truck is increase
6km/h
• Release the button (3) to disable this
function.
uck to be operated
ion. Unlike the stan-
the instructions be-
avel and lifting/low-
ive with the tiller in
ith the tiller in the
disable this
e tiller in the vertical
k (1.5 km/h) is
peed with the tiller
on and the button (3)
or tilts the tiller into
(see ⇒ Chapter "Tiller
he speed of travel of
d up to a maximum of
4
4
3
OM2283
NOTE
If the activation sequence is accidentally
reversed, i.e. with the tiller in the vertical
position, the throttle (4) is turned first and then
the button (3) is pressed:
• The truck will move in creep speed as
expected in the direction of the forks
•Travelinthedirec
enabled.
tion of the operator is not
758043402 [EN] 75
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4 Use
Use of the truck
Reverse drive
Reverse ofdirection without load on forks
• To reverse direction when travelling without
a load on the fork arms, turn the traction
control throttle in the opposite direction of
travel. The truck will stop with energetic but
gradual braking and will start to move again
in the opposite direction.
Truck brake systems
Reverse of direction with load on forks
• To reverse direction with a load on the fork
arms, release the traction control throttle
and wait for the truck to come to a stop.
• Reverse direction using the
throttle.
DANGER
Brake by releasing the traction control throttle,
adapting deceleration to the type of load you are
carrying to avoid losing the load itself.
traction control
WARNING
The condition of the floor surface considerably
affects the braking distance of the truck.
The operator mustconsider this factor while driving.
Whiledriving,brakingcanbeperformedinthe
following three ways:
• Releasing the drive control throttle
• Reversing the drive control throttle (see
also paragraph ⇒ Chapter "Reverse
drive", P. 4-76)
• With the tiller service brake
Braking by releasing the drive control throttle
• During travel, release the drive control
throttle. The truck will decelerate gently
to a stop.
Braking by reversing the drive control throttle
• During travel, turn the drive control throttle
in the opposite direction to the direction of
movement. The truck will decelerate more
forcefully but will come to a gradual stop.
When the truck has stopped, release the
drive control throttle.
CAUTION
Do not brake by reversing the drive control throttle
when travellingwith aloadontheforks.
CAUTION
Regulate the throttle by adapting truck braking to
thetypeofloadyouarecarryinginordertoavoid
losing the load.
Service braking
CAUTION
In hazardous situations, always brake using the
service brake.
• During travel, push the tiller to the upper
end position. The truck will decelerate very
quickly.
• During travel, push the tiller to the lower
end position. The truck will decelerate very
quickly.
WARNING
To activate the service brakes, always push the
tiller as far as it will go.
Remember that when you push the tiller down,
there will be mechanical resistance just before
the lower stop due to the presence of the shock
absorber buffer.
Parking brake
– When the truck is stationary and the tiller is
in the vertical rest position, the electromagnetic brake functions as the parking brake.
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Use 4
Use of the truck
Parking and stopping the truck
• Parking in pre-arranged and designated
areas.
• Lower the forks to the ground.
• Release the tiller to activate
brake.
• For the version with platform, close the
platform and the operator’s protective
devices.
• Switch off the truck: by turning the key
to position " 0" and remove the key from
the panel or alternatively, if there is one,
switch off the truck by means of the numeric
keypad (Digicode ),
DANGER
Park the truck in such a way as not to obstruct passageways and/or render unusable the emergency
equipment (e.g. , fire extinguishers and fire hydrants).
the parking
758043402 [EN] 77
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4 Use
Use of the truck
Forklift Use in Cold-Storage Rooms.
A truck specifically equipped for cold-storage
rooms must be used when working at temperatures below +5°C.
Forklifts equipped for working in cold climates
and cold-storage rooms may be used at a
minimum temperature of -5°C for continuous
service in cold-storage rooms and at -32°C
for non-continuous service in cold-storage
rooms.
CAUTION
The forklift must always be turned off and parked
outside the cold area/cold-storage room.
CAUTION
If the truck has been working in environments at
temperatures below -5°C and it is taken outside the
cold-storage room, let it stand either for a sufficiently long time to allow evaporation of any condensation (at least 30 minutes) or a sufficiently short time
to prevent the formation of any condensation (less
than 10 minutes).
Avoid the formation of ice on the forklift.
CAUTION
NEVER drive the truck into the cold-storage room
when condensationhas formed on it
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Movement of the load
Movement of the load
Safety guidelines for handling loads
WARNING
Closely observe the following instructions before
picking up loads. Never touch or stand on moving
parts of the truck (e.g. lifting devices, equipment or
devices for picking up loads).
WARNING
Risk of crushing hands and feet when using the lift.
When using the lift, keep hands and feet away from
moving parts.
DANGER
It is not permitted to go under the forks. It is not
permitted to transport or lift people on the forks.
If there are people under or on top of the forks, do
not move the truck. Do not move the forks and do
not drive the truck.
DANGER
Risk of accident when forks are changed:
If the forks are changed and a different type of
forks to the original forks is fitted, the residual load
capacity changes.
When forks are changed, a new residual capacity
plate must be affixed.
If a truck is supplied without forks, the residual
capacity plate for standard forks is affixed (see
chapter 6 "Technical Data").
DANGER
Wear protective footwear. Always keep a suitable
distance between your feet and the truck.
Risk of crushing feet when manoeuvring the truck.
CAUTION
The transport of persons or passengers is strictly
prohibited.
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4 Use
Movement of the load
CAUTION
Driving or turning with the forks raised above approximately 300 mm from the ground is prohibited.
It is only allowed at reduced speed when depositing
a load and/or picking up a load from shelving.
CAUTION
Insert forks in pallets from the correct side, as
shown in the illustration (only permitted for EXP
models).
CAUTION
It is not permitted totransport loads on the straddles
(1).
Loads may only be transported on the forks (2).
DANGER
Before picking up the load, make sure that its dimensions and weight fall within the truck specifications, as indicated in the "TECHNICAL DATA"
chapter.
DANGER
The loads must be arranged so that they cannot
slip or overturn and fall to the ground. In order to
guarantee load stability, make sure that the load is
balanced and centred on the forks.
1044_800-003
DANGER
Standing or walking under the raised load is strictly
prohibited. Make sure that nobody stands under
the raised load and in the truck’s area of operation.
DANGER
Never leave the truck with the forks raised whether
loaded or not.
WARNING
When lifting the load pay attention to the dimensions of the column and the load.
Do not strike the ceiling, the shelving, loads or other
objects in the vicinity during collection operations.
80
2
1
0252_003-111
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Movement of the load
NOTE
Further information on the gen
truck use and taking up and depo
is provided in the "Safety Regu
Industrial Forklift Use" manu
eral rules of
siting loads
lations for
al attached to
this manual.
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4 Use
Movement of the load
Checks to be carried out before lifting a load
WARNING
Never exceed the capacity of the truck. This capacity is based on the centre of gravity and the lift
height of the load.
Comply strictly with the load diagram! It is not
permitted to increase the capacity by adding extra
weight to the truck. Never exceed the maximum
loads shown! Otherwise, the stability of the truck
can no longer be guaranteed.
Transporting people in order to increase the capacity of the truck is prohibited.
.
Example
Weight of load to be
lifted:
1200 kg (3)
Distance between
theloadcentreof
600 mm (1)
gravity/fork carriage:
Permissible lift
height:
2600 mm (2)
WARNING
The illustrationsare only examples.
Only the values stated on your truck’s plate should
be taken into consideration.
WARNING
If small items are being transported or if the load
exceeds the height of the fork carriage, a load
protective guard must be installed to prevent the
items from falling on the operator.
(1) CDG = distance "C" f
gravity of the loa
carriage (in mm)
(2) h = lift height o
mm)
(3) Maximum permi
d on the forks to the fork
f the forks from the ground (in
ssible loads "Q" (in kg)
rom the centre of
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Use 4
Movement of the load
Adjusting the fork distance (if present)
– Raise the locking lever (1), or raise and
rotate the knob (2) by 180° depending on
the type of lock, (1) or (2), installed on the
forks.
– Move the fork arms (3) in relation to the
dimensions of the load to be lifted.
– Ensure that the two forks ar
equal distance from the axl
truck.
– Lock the forks in position again by moving
the lever (1) or knob (2) in the opposite
direction and ensuring that the forks are
locked in one of the notches on the fork
carriage rail.
e kept at an
ecentreofthe
1
3
2
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4 Use
Movement of the load
Automatic speed reduction with forks raised above the safety sensors
As indicated in the safety devices chapter,
(see ⇒ Chapter "Location of safety devices", P. 2-20), the truck is equipped with:
• 500-mm sensor Automatic speed reduction
with forks raised approximately 500 mm
above the ground.
• 1500-mm sensor Automatic s
duction with forks raised a
1500 mm above the ground.
NOTE
Automatic reduction of the truck’s driving
speed remains active if the forks are lowered below the sensor height (500 mm and
1500 mm) during travel (drive throttle turned).
In this case, to elimina
speed reduction, fully
after lowering the fork
height (500 mm and 1500
point, if the throttle
will continue without
speed reduction.
te automatic driving
release the drive throttle
s below the sensor
is turned again the truck
the previous automatic
peed re-
pproximately
mm). At this
Picking up the load
Load pick up from the
– Approach the load with caution and with as
much precision as possible.
– Lower the forks and the straddles so that
they can easily be inserted into the pallet.
– Slowly insert the f
load to be lifted.
CAUTION
Insert the fork without bumping into either the
shelving or the load.
– Insert the forks as far as possible below
the load. If possible, the forks should be
inserted far enough in that the load is resting
against the fork carriage. The load centre of
gravity must be centred between the forks.
84
ground
orks at the centre of the
45758043402 [EN]
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Movement of the load
DANGER
Pay attention to the part of the forks protruding from
the load to be lifted.
Do not strike the wall, the shelving or other loads
and/or objects behind the load to be picked up.
– Lift the load a few centimetres from the
ground and read the "Transporting loads"
section.
Load pick up from shelving.
– Approach the shelving at moderate speed.
Use the drive control throttles to gradually
slow down and stop the truck perpendicular
to the shelving with the tiller in the braking
position.
– Check that there is sufficient space between
the forks and the shelving.
– Raise the forks until you reach the correct
fork insertion height.
– Move the truck slowly forwards to insert the
forks into the load.
CAUTION
Insert the fork without bumping into either the
shelving or the load.
758043402 [EN] 85
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4 Use
Movement of the load
– Insert the forks as far as possible below
the load. If possible, the forks should be
inserted far enough in that the load is resting
against the fork carriage. The load centre of
gravity must be centred between the forks.
DANGER
Pay attention to the part of the forks protruding from
the load to be lifted.
Do not strike the wall, the shelving or other loads
and/or objects behind the load to be picked up.
– Raise the load a few centimetres until it is
resting fully on the forks. If the load is stable
and secure on the forks, proceed with the
following steps. In the event of uncertainty
and/or a load that is not properly secure or
stable, lower the forks and place the load
back on the shelving.
– Put the tiller in the driving position. Look
behind to check that the way is clear. Turn
the throttle in the direction of travel towards
the operator and drive very slowly and
carefully in a straight line away from the
shelves. Brake gradually.
– Check that there is sufficient space between
the forks and the shelving.
86
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Use 4
Movement of the load
– Lower the load to the transport position,
approximately 300 mm from the ground,
and read the "Transporting loads" section.
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4 Use
Movement of the load
Transporting loads
As a general rule, loads must be transported
one by one (e.g. pallets). Transporting several
loads at once is only authorised:
• If the safety requirements ar
• On the orders of the supervisor in charge
The operator must ensure that the load is
properly packaged. The operator can only
move loads that have been properly packaged
and are safe and secure.
WARNING
Always drive forwards for optimum visibility.
– Only travel in the direction of the forks when
depositing a load, as visibility in this direction is
restricted.
If the load height or dimensions are likelyto obstruct
theoperator’sview,asecondpersononfootmust
assist with manoeuvres in order to warn the driver
of any obstacles. In this case, driving is only authorised at walking speed and with the greatest care.
Stop the truck immediately if you lose contact with
the person accompanying you.
DANGER
Lower or raise the load until there is sufficient
ground clearance (approximately 300 mm).
Never transport loads with forks raised to greater
heights as the truck and the load being carried may
become unstable.
Do not allow the load, the pallets or the container to
trail along the floor.
emet
0252_003-103
DANGER
When travelling andtransporting the load,be aware
of the side clearance of the load, particularly when
cornering.
Avoid hitting shelving and objects in your path.
DANGER
Danger of load tipping over
Avoid sudden starts and stops.
Approach corners slowly and carefully.
88
0252_003-104
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Use 4
Movement of the load
Deposit the load.
• Approach the load deposit area.
• Lower the fork arms until the load is deposited in the desired area and release the
fork arms from the load.
• Back up with the forklift.
DANGER
Never leave the forklift withthe forks raised whether
loaded or not.
NOTE
Further information on the general rules of
forklift use is provided in the Rules for the Use
of Industrial Vehicles Manual enclosed with
this manual.
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4 Use
Movement of the load
Using the truck on inclines, loading bridges and lifts.
Drivingoninclines
When driving the truck up or down inclines,
you must not exceed the values for inclines
indicated in the chapter "Technical data".
The operator must check tha
clear with a good grip.
WARNING
Drive at a reduced speed on descending slopes.
DANGER
Risk of tipping!
When driving up inclines, do not turn, reverse
and/or travel diagonally.
t the ground is
Usingthetruckonalift
Using the truck on lifts is only allowed if the
lift has sufficient load capacity (check the
maximum weight of the truck including the
traction battery) and only with appropriate
authorisation.
Slowly drive the truck onto
Secure the truck in the lift so that no part
comes into contact with the walls of the lift.
A minimum distance of 100 mm from the walls
of the lift must always be observed.
WARNING
The truck must be correctly immobilised so that it
cannot move inadvertently.
the lift load-first.
Using the truck on an incline
WARNING
Whendrivingonaninclinewithaload,youmust
keep the load facing upwards.
DANGER
Risk of accident
Keep the truck at a safe distance from the edges of
ramps, tailboards etc.
CAUTION
In certain cases, it is permitted to drive with the
forks pointing towards the top of the incline even if
the truck is not loaded.
In these cases, drive with the utmostcare and avoid
turning until all the wheels are on a flat surface.
DANGER
Risk of accident
Do not park on an incline: if, in the event of an
emergency, you have to do so, apply the parking
brake and block the wheels with chocks.
Towing trailers
The forklift is not qualified to tow trailers.
CAUTION
Personnel accompanying the truck onto the lift may
only enter the lift once the truck is secure and must
exit the lift first after transit.
Using the truck on loading bridges
DANGER
Risk of accident
Beforedrivingontoaloadingbridge,theoperator
must check that it has been properly fitted and
secured and has sufficient load capacity.
You must drive onto the loading bridge slowly and
carefully.
The operator must check that the vehicle to be
loaded or unloaded is sufficiently secure so that it
will not move and that it is suitable to support the
strain of the truck.
The lorry driver and the forklift truck operator must
agree on the time of departure of the lorry.
90
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Charging the battery
Charging the battery
Internal accessibility
Opening the battery cover
– To access the battery and respective
plug/outlet, raise the battery compartment
cover using the appropriate handle.
– If you need to recharge the battery, discon-
nect the battery plug and socket by means
of the appropriate handle.
Closing the battery cover
– Close the battery cover.
WARNING
Danger of crushing.
Be sure not to leave anything between the battery
cover and the edge of the chassis when closing the
cover.
DANGER
It is absolutely forbidden to use the truck with the
covers open.
In order to use thetruck, the covers for access to the
inner parts must be closed and secured properly.
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4 Use
Charging the battery
DANGER
Before accessing the inner parts of the truck,
carefully follow the instructions given in Chapter
5, entitled "Maintenance".
Access to the inner parts of the truck by personnel
not authorisedby the manufacturer is forbidden.
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Use 4
Charging the battery
Battery Recharging
CAUTION
Thebatteryisrechargedwiththeforkliftoff.
DANGER
The battery must be charged in rooms that comply
with the specific regulations on the subject. Refer
to the battery and battery charger manual for the
charging procedures, level checks etc., checking
the type of battery (gel, lead etc.) and the voltage
and current delivered. Excessive currents can
damage batteries and cause dangerous situations.
As far as the safety precautions are concerned,
follow the instructions given in the battery manual
and those included in "Safety regulations "of this
manual.
• Access the upper part of the battery as
described in the "Internal accessibility"
paragraph.
• Remove the battery caps (if indicated in the
battery maintenance booklet).
Charging curve selector (only with on-board battery charger)
The curve is selected using the selector
located on the front face of the charger. The
curve selector is protected by a cap.
CAUTION
Risk of premature damage to the battery!
It is essential to select the correct type of battery on
the selector.
• Turn on the external battery charger.
• Connect plug the battery char
ger in to begin
charging.
• After the battery charging operation is
completed, turn off the battery charger.
• Unplug the battery charger.
• Replace the battery caps (i
f removed
previously).
• Plug the battery in again.
• Lower the battery compartment cover.
NOTE
Refer to the battery charger manual for more
information.
The four thin lines indicate neutral positions.
The charger does not flow and the two LEDs
flash simultaneously to indicate that no curve
has been selected.
The four thick lines indicate the four charging
curves:
• open lead-acid battery with a capacity
below 210 Ah,
• open lead-acid battery with a capacity
greater than 210 Ah,
758043402 [EN] 93
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4 Use
Charging the battery
• gel battery with a capacity below 210 Ah,
• gel battery with a capacity greater than 210
Ah.
CAUTION
The charger is supplied in the NEUTRAL position.
Recharging the battery using the on-board battery charger (optional)
CAUTION
Charge the battery with the engine switched off and
the start key removed.
DANGER
The battery must be charged in rooms that comply
with applicable regulations. Refer to the battery
and battery charger manual for the charging procedures, level checks etc., checking the type of
battery (gel, lead etc.) and the voltage and current
delivered. Excessive currents can damage batteries and cause dangerous situations. As regards
safety precautions, follow the instructionsgiven in
the battery manual and those included in the "Safety Guidelines "of this manual.
DANGER
If the truckis fitted with an on-boardbattery charger,
it is strictly prohibited to connect the battery to an
external battery charger.
CAUTION
Make sure that the mains supply voltage complies
with the battery charger’s operating voltage.
DANGER
The electrical system must comply with the current
national regulations.
94
45758043402 [EN]
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