Page 1
Original instructions
Pallet stacker
EXV 10 Basic
EXV 10 / 10i
EXV 12 / 12i
EXV 14C / 14iC
45728043430 EN - 05/2017
Page 2
Page 3
Preface
Address of manufacturer and contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: info@still.de
Website: http://www.still.de
g
28043430 EN - 05/2017 I
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Page 4
Page 5
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 ............... 6
Technical service and spar
Normative References ................................................. 7
Type of use ......................................................... 7
Working conditions ................................................... 8
Modifications to Forklift ................................................. 8
Applied equipment .................................................... 9
User obligations ...................................................... 9
Environmental considerations ........................................... 9
Disposal of components and batteries ...................................... 9
Packaging ......................................................... 10
ghts ........................................... 4
e parts ......................................... 7
g
2Safety
Safety Guidelines .................................................... 12
GeneralPrecautions ................................................. 12
General Safety Rul
Flooringrequirements ................................................ 12
Batteryconnectioncables ............................................. 13
Requirements for the
SafetyRegulationsRelativetoForkliftUse ................................. 13
SafetyRegulationsRelativetoOperatingMaterials ........................... 14
Residual risks ...................................................... 15
Residual dangers, residual risks ......................................... 15
Electromagnetic radiation .............................................. 17
Non-ionised radiation ................................................. 1
Noise ............................................................. 17
Vibrations ......................................................... 18
Safety tests ........................................................ 19
Regular safety inspection of the truck ..................................... 19
es ................................................. 12
traction-batterychargingarea .......................... 13
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7
Page 6
Table of contents
g
Safety devices ...................................................... 20
Locationofsafetydevices ............................................. 20
Damage, defects and misuse of s
afetydevices .............................. 21
3Overview
Technical description ................................................. 24
Overviews ......................................................... 26
Instruments and controls
Tillercontrols ....................................................... 27
Display ........................................................... 30
Controls for switching on
Emergency stop handle ............................................... 33
Tillerpositions ...................................................... 34
Tiller controls ....................................................... 36
OptiSpeed tiller (if present) ............................................. 39
Types of lifting masts ................................................. 40
Definition of direction
Markings .......................................................... 43
Locationoflabels .................................................... 43
Serialnumber ...................................................... 44
Dataplate ......................................................... 45
Capacityplate ...................................................... 46
Chassis frame labellin
Options and variants ................................................. 47
List of optional fittings ................................................. 47
Digicodeoption ..................................................... 48
BatteryelectrolytelevelindicatorLED(optional) ............................. 50
.............................................. 27
andswitchingoff ................................. 32
s ................................................ 42
g ............................................... 47
4 Application
Authorised and safe use ............................................... 52
Intended use of the tr
Safetyinstructionsrelatingtouseofthetruck ............................... 52
Truck transport and lifting .............................................. 54
Transporting the tr
Transport .......................................................... 55
Climatic Conditions for Transport and Storage ............................... 55
Loading and unloadin
IV 4
ucks .............................................. 52
uck ................................................ 54
gthetruck ......................................... 56
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Table of contents
Breaking-In ........................................................ 57
Checks and actions prior to use ......................................... 58
List of checks prior to start-u
Checkingtheanti-crushsafetydevice ..................................... 60
Checkingthebrake .................................................. 61
Checking the emergency stop
Checkingthehorn ................................................... 62
Operator position .................................................... 63
Operator's position for ve
Driving ............................................................ 65
Drivingsafetyinstructions .............................................. 65
Visibilitywhendriving ................................................. 6
Beforedriving ...................................................... 66
Startingthetruck .................................................... 67
Check the information on
Behaviour in emergencies ............................................. 69
Selectingthedrivingmode ............................................. 69
Driving ............................................................ 70
Using the truck with the "Tiller always active — Creep Speed" function (optional) ..... 71
Reversedrive ...................................................... 73
Truckbrakesystems ................................................. 74
Parking and stopping the truck .......................................... 75
ForkliftUseinCold-StorageRooms. ...................................... 76
Lifting ............................................................ 76
Liftcontrolelements .................................................. 76
Moving the load ..................................................... 79
Safety guidelines fo
Checkstobecarriedoutbeforeliftingaload ................................ 81
Pickinguptheload ................................................... 81
Transportingloads ................................................... 85
Settingdownloadsonshelving .......................................... 86
Depositing a load on the ground ......................................... 86
Using the truck on incli
Towingtrailers ...................................................... 87
Fault displays ...................................................... 88
Error codes ........................................................ 88
Charging the battery .................................................. 88
Opening/closingthebatterycompartment .................................. 88
BatteryRecharging .................................................. 90
Chargingcurveselector(onlywithon-boardbatterycharger) .................... 90
p ........................................... 58
.......................................... 61
rsionwithoutplatform .............................. 63
thecombinedindicator ............................. 68
r handling loads ...................................... 79
nes,loadingbridgesandlifts. .......................... 87
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Table of contents
g
Recharging the battery using the on-board battery charger (optional) . . . ........... 91
Batterytype ........................................................ 91
Preparation ........................................................ 92
Using the truck with extension leads ...................................... 93
5 Maintenance
General Information .................................................. 96
Preliminary maintenance
Regular Service ..................................................... 97
Cleaning the Forklift .................................................. 97
Lubricating and cleaning
Maintenance plans ................................................... 98
Maintenanceplans ................................................... 98
Fuses ........................................................... . 100
Replacing the battery from above for trucks with 1000 kg and 1200 kg capacity .......101
Replacing the battery from above for trucks with 1400 kg capacity ................103
Battery replacement fo
Decommissioning ...................................................106
General Information ..................................................106
ForkliftTowing ......................................................107
TemporaryPuttingOutofCommission ....................................107
Checks and Inspections After a Long Period of Inactivity .......................107
Permanent Putting Ou
operations ...................................... 96
theliftingchains .................................. 97
rversionwithsideremoval ............................104
tofCommission(Demolition) ..........................107
6 Technical data
Overall dimensions ..................................................110
Datasheet (VDI) EXV 10 Basic and EXV 10 .................................111
Datasheet (VDI) EX
Datasheet (VDI) EXV 14C and EXV 14iC ..................................121
Supply table ........................................................129
VI 4
V 12 and EXV 12 i .....................................115
5728043430 EN - 05/2017
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1
Introduction
Page 10
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 at
the use of industri
carefully and must a
for fast consultati
• The manufacturer assumes no responsibility for any accidents to persons or damage
ed as the person
tached "Rules for
al 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.
• In the interests of cl
illustrations in th
without the safety e
panels, etc.). The f
without safety equi
put to any use other
this manual.
ear 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.
245
728043430 EN - 05/2017
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.
Page 11
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 additional
information.
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Page 12
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
ust not be reproduced,
cessible to third par-
cerpts—except with the
roval of the manufacturer.
rklift and
documentation
Ensure that the f
requested and th
the following d
• Instruction and maintenance manual;
• Rules for the compliant use industrial
vehicles;
• EC Declaration
• Spare parts catalogue CD.
If the forklift has been delivered with a traction
battery and/or an external battery charger,
ensure that such products conform to the
order and that the relevant instructions for
operation and maintenance are included, as
well as the EC declaration for the external
battery charger.
If applied equipmen
devices are present,
to the order and that t
maintenance manual a
orklift has all of the options
at it has been delivered with
ocumentation:
of Compliance;
t, other equipment or
ensure that they conform
he relative use and
nd of the relative EC
445
728043430 EN - 05/2017
Page 13
Introduction 1
Delivery of the forklift and docume
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.
ntation
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Page 14
1 Introduction
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
.
645
according to these operating instructions
according to these operating instructions
728043430 EN - 05/2017
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Introduction 1
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
2014/30/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 trans
with weight and load c
values provided (see
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 li
approximately on th
longitudinal plane.
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.
port of loads using forks
entre within the
Chapter 6 - Technical
fting with the load centre
e forklift's median
28043430 EN - 05/2017 7
457
The following scenarios are examples of
incorrect use of the forklift truck:
• Transport on une
compact) surfac
• loads that exceed the weight and/or load
centre limits;
• transporting non-stable loads;
• transporting loads not e
the forks;
• transporting swinging loads;
• transporting loads whose load centre is
considerably displaced with respect to the
forklift's longitudinal median plane;
• transporting loads of dime
block the view of the operat
• transporting loads piled so high that they
could fall onto the operator;
• travelling with a load over 300 mm off the
ground;
ven (irregular or non-
es
qually distributed on
nsions such as to
or when driving;
Page 16
1 Introduction
Working conditions
• transporting and/or lifting people;
• pushing or pulling loads;
• moving upwards or downwards on
with the load facing downwards
• turning at high speed;
aslope
;
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 auth
information.
orised sales network for more
Modifications to F
No modificatio
otherwise the
will become in
• assembly of the options provided by the
manufacturer
• assembly of applied equipment
for which it is
the authorised
845
ns may be made to the forklift,
EC certificate and the warranty
valid, with the exception of:
necessary to refer exclusively to
sales network
orklift
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).
728043430 EN - 05/2017
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Introduction 1
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 truck is compose
components or batt
and disposed of, th
• disposed of,
• treated or
• recycled in accord
national regulatio
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
ns.
28043430 EN - 05/2017 9
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Page 18
1 Introduction
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
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Page 19
2
Safety
Page 20
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 on the forklift unless supplied or indicated by the manufacturer.
• 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 on the forklift must
be kept in good condition and replaced if
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 forklift in front of fire-fighting
devices or fire escapes or anywhere that it
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 load using just one fork.
regulations integrate those
"Rules for approved use of ind
• Place the load on the fork carriage or in such
a way that the centre of gravity of the load is
as close as possible to the fork carriage.
• The load must be placed on the fork arms
so that the centre of gravity falls lengthwise
on the mid point between the fork arms.
• 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 clothing compliant with
current regulations and any personal protective equipment that may be applicable.
• 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 on slopes.
• Reduce speed on slopes.
• Do not overload the forklift beyond the
capacity limits indicated on the capacity
plates.
• Individuals under the influence of drugs and
alcohol are not permitted to use the truck.
• 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".
Flooring requirements
The work floor must be even and free of holes
or dips, which can be difficult to get around.
Any steps must be equipped with ramps to
12 4
5728043430 EN - 05/2017
prevent impacts with the wheels, which affect
the entire structure of the truck.
Page 21
Safety 2
Safety Guidelines
CAUTION
Passing over cracks or damaged parts of the floor
with the truck is prohibited. Dirt and any objects in
the work path must be removed immediately.
Battery connection cabl
CAUTION
Using sockets with NON-ORIGINAL battery connection cables can be dangerous (see purchase
references in the parts catalogue)
es
Requirements for the traction-battery charging area
When the traction battery is being charged, the
area must be sufficiently ventilated in order to
download or eliminate the gases produced
(EN 50272-3).
Safety Regulations Relative to Forklift Use
• The operator must familiarize himself with
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".
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.
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Page 22
2 Safety
Safety Guidelines
Safety Regulations Relative to Operating Materials
Rules for handling and disposing of
operating materials
ENVIRONMENT NOTE
Improper use and disposal
cleaning materials can ca
of operating and
use 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 material
avoid contact with hot o
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 o
Any spilt liquid must
and neutralised wit
as an oil binder) and
accordance with curre
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 a
of in accordance with the
ENVIRONMENT NOTE
s may be flammable, so
bjects or open flames.
r other operating liquids!
be immediately collected
h a binding material (such
then disposed of in
nt regulations.
lways be disposed
anti-pollution laws.
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 relative filters contain substances that are hazardous to the environment
and must be disposed of according to current
regulations. We advise you to contact the authorised service network.
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.
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.
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5728043430 EN - 05/2017
Page 23
Safety 2
Residual risks
NOTE
For greater information, consult the specific
battery manual that comes with the battery.
ENVIRONMENT NOTE
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.
Thetruckandalloth
comply with current
Nevertheless, even
for its proper purp
are followed, some
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.
er system components
safety requirements.
when the truck is used
ose and all instructions
residual 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.
• Fire and explosion risks due to batteries and
electrical voltages.
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Page 24
2 Safety
Residual risks
• Human error resulting from failure to
observe the safety guidelines.
• Unrepaired damage or defective and worn
components.
• Insufficient maintenance and t
• Use of incorrect consumables
• Maintenance intervals exceeded
The manufacturer shall not b
ble for accidents involving
the failure of the operating
with these regulations eith
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 to unstable or sliding
loads etc.;
• turns at excessive speed
• moving with the load raised;
• moving with a load that is projecting to the
side (e.g. side shift);
• turning and driving diag
slopes;
• driving on slopes with the load pointing
downhill;
• oversized loads;
• swinging loads;
• steps or ramp edges.
esting
e held responsithe truck caused by
company to comply
er intentionally or
s;
onally across
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5728043430 EN - 05/2017
Page 25
Safety 2
Electromagnetic radiation
Electromagnetic radiation
The limit values 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 those indicated above
can occur during actual truck use, for example
following different operating modes, different environmental conditions and additional noise sources.
<70dB(A)
pAZ
28043430 EN - 05/2017 17
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Page 26
2 Safety
Vibrations
Vibrations
Vibrations to which the hands and arms
are exposed
The following value is valid for all truck models:
•ā
<2.5m/s
w
NOTE
2
It is mandatory to specify the hand-arm
vibrations, even where the values do not
indicate any danger, as in this case.
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 4
5728043430 EN - 05/2017
Page 27
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!
28043430 EN - 05/2017 19
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Page 28
2 Safety
Safety devices
Safety devices
Location of safety devices
Main safety devices on the truck
The operator must be aware of the following
safety devices:
1 Guard grille
2 Anti-crush safety feature
3 Braking by releasing the drive control throttle
4 Emergency stop button
5 OptiSpeed tiller
6 Protective guard
NOTE
These devices must be checked daily, as
described in Chapter 4.
20 4
5728043430 EN - 05/2017
7Horn
8 Electromagnetic brake
9 Truck braking when the tiller arm reaches
the upper end position and lower end
position.
10 Automatic speed reduction with forks raised
approximately 500 mm above the ground.
(only available on 1400 kg version)
Page 29
Safety 2
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
28043430 EN - 05/2017 21
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Page 30
2 Safety
Safety devices
22 4
5728043430 EN - 05/2017
Page 31
3
Overview
Page 32
3 Overview
Technical description
Technical description
EXV10 Basic, EXV10, EXV12 and EXV12 i,
EXV14C and EXV14iC trucks are designed
to handle and stack pallets with a maximum
weight of 1000 kg (EXV10 Basic and EXV10),
1200 kg (EXV12 and EXV12 i) and 1400 kg
(EXV14C and EXV14iC) inside shops, warehouses and factories.
General characteristics
• The steering mo
using a reduction
• Asynchronous steering motor, 1.2 kW
• Starting and accelerating without jerking
• Regenerative brak
• 6 km/h speed even fully laden
tor operates the drive wheel
unit.
ing
Raising
Nominal load:
• EXV10 Basic and EXV10
• EXV12 and EXV12 i: 1200 kg
• EXV14C and EXV14iC: 1400 kg
24 4
: 1000 kg
5728043430 EN - 05/2017
Pump unit:
• EXV10 Basic: p
• EXV10: power 1.5 kW
• EXV12 - EXV12 i - EXV14C - EXV14iC:
power 3.2 kW
Different
• "Simplex" mast (E): non-telescopic with
• "Telescoping" mast (TE): two-stage tele-
• "NiHo" mast: tw
• "Triplex" mast (TR): three-stage telescop-
types of lift mast:
central cylinder
scoping mast without free lift and two lateral
cylinders
withfreelift,
cylinders plus
ing mast with free lift, lateral chains and two
lateral cylinders plus a central cylinder
ower 2.2 kW
o-stage telescoping mast
lateral chains and two lateral
a central cylinder
Driving
A long, robust and ergonomic tiller arm allows
the operator to drive the truck easily.
Page 33
Overview 3
Technical description
The tiller is used to carry out the following
controls:
•Steering
• Drive control throttles
•Horn
• Fork lifting and lowering buttons
• Anti-crush safety button
• Truck braking when the tiller arm reaches
the upper end position and lower end
position.
For safety reasons, when the tiller arm is
released a gas spring automatically returns
it to the initial position.
Braking system
Braking:
• counter-current, upon accelerator release,
• counter-current by switching the drive
direction,
• counter-current, controlled by the anti-crush
safety button
• Electromagnetic safety, controlled by the
emergency stop handle
• safety electromagnetic, cont
release of the tiller.
• safety electromagnetic, controlled when the
tiller arm reaches the lower end position
• Electromagnetic parking, applied when
power supply is cut off.
rolled by the
On-board equipment
The on-board equipment inc
• an office compartment for storing rolls of
film and adhesive, gloves, pens etc.
• a removable clipboard for attaching lists
and documents in A4 format
• Emergency stop button lo
chassis
• an hour meter/discharge indicator.
ludes:
catedonthe
28043430 EN - 05/2017 25
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Page 34
3 Overview
Overviews
Overviews
18
17
19
20
16
15
1
2
3
4
5
6
7
8
9
14
0252_003-066
1Mast
2 Lift chains
3 Protective screen
4 Tiller
5 Emergency isolator button
6 Fuse carrier
7 Battery connector
8 Built-in battery charger (if present)
9 Pump motor
10 Hydraulic oil reservoir
26 4
13
12
11 Stabiliser wheel
12 Traction wheel
13 Gearbox
14 Traction motor
15 Brake
16 Forks
17 Load wheels
18 Electronic panel
19 Battery
20 Lift cylinder
5728043430 EN - 05/2017
10
11
Page 35
Overview 3
Instruments and controls
Instruments and controls
Tiller controls
1 — Tiller head handle
2and3— Drive control throttle
4 — Fork lowering button
5 — Fork lifting button
6 — Horn button
7 — Anti-crush button
8 — Creep speed button (optional — Creep
Speed)
9 — Straddle lifting button (optional)
10 — Straddle lowering button (optional)
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
Drive control throttle (2 – 3)
• When the throttle (2 or 3) is turned in
direction (A), the truck starts moving in the
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 throttle causes the truck to
brake and then come to a standstill
Fork lowering button (4)
• Press the button (4) to lower the fork arms
• Fork movement can be stopped at any time
by releasing the button (4) The forks will
stop in the position reached
• The fork lowering button (4) is active only
when the tiller is angled to the working
position
7
2
6
3
5
1
1
4
9
10
7
A
3
B
2
1
1
8
OM2279
28043430 EN - 05/2017 27
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Page 36
3 Overview
Instruments and controls
NOTE
The speed of the forks is proportional to how
•
hard the button (4) is pressed, except for the
"BASIC" version
•
When the forks are fully lowered, a reduction in the fork lowering speed is automatically 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 any time
by releasing the button (5) The forks will
stop in the position reached
• The fork lifting button (5) is active only when
the tiller is angled to the working position
NOTE
The speed of the forks is
hard the button (5) is pr
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 travels at creep speed for a
few seconds
The button (7) is a sa
useful in narrow are
from being crushed b
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.
proportional to how
essed
fety device. Particularly
as, it prevents the operator
etween a wall and the
28 4
5728043430 EN - 05/2017
Page 37
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
while
ivates creep
ler position
• 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 manoeuvres in
confined spaces.
Initial lift (9 and 10) (optional)
The straddle lifting 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
while using the init
.
your feet under the straddles
ial lift function.
Straddle lifting bu
tton (9)
• Press the button (9) to lift the straddles;
when the button is released, the straddles
will stop in the position reached
• 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) t
when the button is releas
will stop in the position
o lower the straddles;
ed, the straddles
reached
• The straddle lowering button (10) is active
only when the tiller is angled to the working
position
28043430 EN - 05/2017 29
457
Page 38
3 Overview
Instruments and controls
Display
• (1) Battery charge level indicator The indicator operates after the battery connector
has been connected. Monitoring the discharge process protects the battery against
deep discharge. When the battery is fully
charged, the 10 status bars are lit. As the
battery capacity decreases, the display
moves to the left. If the battery is 80% discharged, two status bars are lit. The lifting
function is shut off. The battery must be
recharged
• (2) Maintenance service alarm (red)
Flashing: less than 50 hours' truck opera-
tion until the next service.
Constant: service date overdue.
• (3) Red indicator light
Indicator light illuminated: indicates an error
or alarm
30 4
5728043430 EN - 05/2017
• (4) Green indicator light
Switched off: truck switched off
Switched on: truck switched on
• (5) Malfunction code
The combined indicator may display an er-
ror code. When an error code is displayed,
please call our service department. Make a
note of these error codes before switching
off the truck.
• (6) Brake malfunction or wear (air gap)
Do not operate the truck
Page 39
Overview 3
Instruments and controls
• (7) Hour meter. Indicates the number of
operating hours of the machine
The hour meter displays hours and tenths
of an hour. The dot next to the tenths of an
hour flashes.
When the power supply is discon
the hours are stored in the me
nected,
mory.
• (8) STOP alarm (red)
Various types of problem. Do not operate
the truck
• (9) Temperature alarm (red)
Cool down the truck. If the problem persists,
contact the technical service centre.
•(
) Tortoise. LED and pictogram illuminated as soon as "tortoise" mode is selected.
28043430 EN - 05/2017 31
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Page 40
3 Overview
Instruments and controls
Controls for switching on and switching off
Switchingonandswitchingoffareperformed
using:
• the key switch (standard version)
• or the numeric keypad "Digi
version)
Standard version with key
On the standard version, t
positions:
• “0” position: Truck switched off.
• (2)"Tortoise" position: truck switched on
and truck speed limited.
• (3)"Hare" position: tru
standard (NOT limited) t
– To select the truck drive mode from the two
available modes ("Tortoise" or "Hare"), turn
the switch key to the desired position.
– To switch off the truck, turn the key to the “0”
position.
code" (optional
he key has three
ck switched on and
ruck speed.
Version with "Digicode" (optional)
– On the optional version with Digicode: start
the truck by following the procedure described in the relevant paragraph (Digicode
option).
Then, turn the selector to the desired position
depending on the desired drive mode:
• (2)"Tortoise" position: truck switched on
and truck speed limited.
• (3)"Hare" position: truck switched on and
standard (NOT limited) truck speed.
32 4
5728043430 EN - 05/2017
3
2
2343
Page 41
Overview 3
Instruments and controls
Emergency stop handle
– Pressing the emergency stop handle (1) will
lock all the functions on the truck.
– To restore the operating cond
inate the causes of the emerge
release the tiller in the res
lock the emergency stop hand
DANGER
This button must be used only in emergencies; the
repeated use of this device may cause problems
with the electronic equipment or breakdowns.
itions, elim-
ncy, then
t position and un-
le by lifting it.
1
0252_003-047
28043430 EN - 05/2017 33
457
Page 42
3 Overview
Instruments and controls
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 opera
using the throttle.
In this position, the operator can begin lifting
or lowering the forks using the appropriate
button.
In this position, the operator can raise
or lower the straddles; for versions with
straddle initial lift only.
• Position (2) = braking pos
In this position the drive is locked and the
parking brake is engaged.
NOTE
•
In this position, lifting and lowering of the
forks and straddles, if fitted, is blocked.
NOTE
When the tiller is released, it automatically
returns to position (A), the braking position.
tor can begin travel
ition.
A
2
1
2
OM2277
34 4
5728043430 EN - 05/2017
Page 43
Overview 3
Instruments and controls
“Timone sempre attivo” version (optional
— Creep Speed)
• Position (2) using the "tiller always active"
function (optional) = creep speed position
This function is activated by pressing the
creep speed button on the tiller (3) and
rotating the drive control throttle (4) or by
pressing the creep speed button and the
fork lifting button. The truck travels at limited
speed.
4
4
3
OM2283
28043430 EN - 05/2017 35
457
Page 44
3 Overview
Tiller controls
Tiller controls
1 — Tiller head handle
2 and 3 — Drive control throttle
4 — Fork lowering button
5 — Fork lifting button
6 — Horn button
7 — Anti-crush button
8 — Creep speed button (optional — Creep
Speed)
9 — Straddle lifting button (optional)
10 — Straddle lowering button (optional)
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
Drive control throttle (2 – 3)
• When the throttle (2 or 3) is turned in
direction (A), the truck starts moving in the
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 throttle causes the truck to
brake and then come to a standstill
Fork lowering button (4)
• Press the button (4) to lower the fork arms
• Fork movement can be stopped at any time
by releasing the button (4) The forks will
stop in the position reached
• The fork lowering button (4) is active only
when the tiller is angled to the working
position
7
2
6
3
5
1
1
4
9
10
7
A
3
B
2
1
1
8
OM2279
36 4
5728043430 EN - 05/2017
Page 45
Overview 3
Tiller controls
NOTE
The speed of the forks is proportional to how
•
hard the button (4) is pressed, except for the
"BASIC" version
•
When the forks are fully lowered, a reduction in the fork lowering speed is automatically 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 any time
by releasing the button (5) The forks will
stop in the position reached
• The fork lifting button (5) is active only when
the tiller is angled to the working position
NOTE
The speed of the forks is
hard the button (5) is pr
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 travels at creep speed for a
few seconds
The button (7) is a sa
useful in narrow are
from being crushed b
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.
proportional to how
essed
fety device. Particularly
as, it prevents the operator
etween a wall and the
28043430 EN - 05/2017 37
457
Page 46
3 Overview
Tiller 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 manoeuvres in
confined spaces.
Initial lift (9 and 10) (optional)
The straddle lifting 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
while using the init
.
your feet under the straddles
ial lift function.
while
ivates creep
ler position
Straddle lifting bu
tton (9)
• Press the button (9) to lift the straddles;
when the button is released, the straddles
will stop in the position reached
• 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) t
when the button is releas
will stop in the position
o lower the straddles;
ed, the straddles
reached
• The straddle lowering button (10) is active
only when the tiller is angled to the working
position
38 4
5728043430 EN - 05/2017
Page 47
Overview 3
OptiSpeed tiller (if present)
OptiSpeed tiller (if present)
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 reach its 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
28043430 EN - 05/2017 39
457
Page 48
3 Overview
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 the he
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 l
load height may be gr
ow ceiling, be aware that the
essed, the fork
ight h3 by the central
eater than the mast height.
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
In locations with a low ceiling, be aware that the
load height may be greater than the mast height.
40 4
5728043430 EN - 05/2017
0252_003-098
h
3
h
2'
0252_003-099-V2
Page 49
Overview 3
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
28043430 EN - 05/2017 41
457
Page 50
3 Overview
Definition of directions
Definition of directions
Direction of movement defined by the regulations:
• Forward travel (1) (preferred direction of
travel)
• Right (2)
• Reverse travel (3)
• Left (4)
1
4
2
3
0252_003-008
42 4
5728043430 EN - 05/2017
Page 51
Overview 3
Markings
Markings
Location of labels
1
8
10
1
3
4
5
6
11
2
GEL
Pb+Sb
13
9
!
12
7
2342
1 "Truck capacity diagram" label
2 "Danger of crushing hands" label
3 "Hook" symbol
4 "Danger of crushing hands" label
5 "Operating and maintenance manual" label
6 "Lifting danger" label (only on version with
straddle initial lift function "i")
7 "Operating and maintenance manual" label
28043430 EN - 05/2017 43
457
8 Version set up for gel batteries
9 "On-board battery charger" label
10 Annual testing label (Germany only)
11 Warning label
12 "Danger of crushing feet" label (only on
version with straddle initial lift function "i")
13 "Cold store" label (on cold store version only)
Page 52
3 Overview
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 appears on the b
and indicates the danger of cru
cutting hands while opening
battery hood around the enti
the hood. Take care when oper
(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 t
the operating and mainten
using the truck and before
maintenance work.
(6) This label is present only 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.
hat you should consult
attery hood
shing and/or
and/or closing the
re perimeter of
ating.
ance manual before
carrying out any
Serial number
(7) This label indicates that you should consult
the specific operating and maintenance
manual for the on-board battery charger.
(8) This symbol, where present, indicates that
the truck is set up for the gel battery version.
Do not use other types of battery.
(9) This label is present onl
with the on-board battery ch
highlights the possibility
charging curve.
(10) This label is present only on trucks sold in
Germany. The label indicates the date of the
truck's periodic safety inspection.
(11) 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.
(12) This label is present
with initial lift (i). The
of crushing feet under th
(13) This symbol, where present, indicates
that the truck is set up as the "cold-storage"
version (optional).
yontheversion
arger. The label
of choosing the
only on the version
label indicates the danger
e straddles.
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
44 4
xx xxxx x xxxxx
1
2
3
4
7090_921-004
5728043430 EN - 05/2017
Page 53
Overview 3
Markings
Data plate
NOTE
Please indicate the serial number for all
technical enquiries.
1 4 63 52
*
7
9 10
1 Model
2 Rated capacity in kg
3 Manufacturer
4 Serial no.
5 Unladen weight (without battery) in kg
6 Year of manufacture
7 EC conformity symbol
8QRcode
9 Battery voltage V
10 Nominal power rating in kW
11 Minimum battery weight
12 Maximum battery weight
13 Additional weight (ballast) in kg
8
13
1211
2327
28043430 EN - 05/2017 45
457
Page 54
3 Overview
Markings
Capacity plate
– The identification plate indi
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 height of the forks from the ground
(in mm)
• (3) = maximum permissible l
kg)
WARNING
The illustrations are only examples.
Only the values stated on your truck's plate should
be taken into consideration.
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.
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").
cates the follow-
oads "Q" (in
46 4
5728043430 EN - 05/2017
Page 55
Overview 3
Options and variants
Chassis frame labelling
A
B
The truck's serial number is marked on the
chassis frame .
The serial number is located in the following
places:
• A for standard versions of the truck
• B for models with initial lift capability
Options and variants
List of optional fittings
List:
• Forks of various gauges
• Load backrest, height 1000 mm
• Various types of tyre for the drive wheel
• Guard plate in transparent polycarbonate
• Access authorisation via Digicodesystem
• Lift height indicator
28043430 EN - 05/2017 47
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2274
Page 56
3 Overview
Options and variants
• Footwell protection for activities in confined
spaces
• Cold storage room version
• Set of cables
• Fleetmanager
• Built-in rectifier
• LED battery electrolyte lev
• Lift lock at predefined heights, unlockable
via appropriate confirmation button (only for
1400 kg version).
• Truck speed limited automatically with load
at h3>1500 mm (only for 1400 kg version)
• Battery removal roller unit
version)
CAUTION
Contact the technical service network authorised by
the manufacturer for information on the assembly
of the options.
NOTE
Contact the authorised sales network for more
information.
el indicator
(only for 1400 kg
Digicode option
1 SWITCH ON (operating mode)
2 SWITCH OFF and awaiting code
3 Programming mode active
Operation
48 4
Key
4 Faulty key or incorrect code
5 Delay of automatic switch-off
OPERATING MODE
LED
5728043430 EN - 05/2017
Warning
Page 57
Overview 3
Options and variants
ON
OFF
PROGRAMMING MODE — to be ca
Operation
THE ADMINISTRATOR CODE
IS IMPORTANT
FOR ALL DIGI-
CODE SETTINGS
New operator
code
Allocating
operator codes
Deleting operator
codes
Modifying
administrator
codes
Restoring
the initial
administrator
code
Activating the
automatic
switch-off
Setting the delay
of the automatic
switch-off
Deactivating
the automatic
switch-off
* 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 #
* * 2 * 1 #
* * 3 * 6 0 #
* * 2 * 0 #
red off continuous
green (1)(PIN correct)
red flashing green off
1 2 3 4 5
PIN code
(4)(PIN incorrect)
red off green
flashing (2)
Turn off the truck
rried out with the truck switched off (2)
LED status
Warning
Once the diodes have
continuous red
continuous green (3)
been switched off,
the electronic key
automatically reverts
to "operating mode"
red off green flashing
(2) (code accepted)
red off green flashing
(2) (code accepted)
red off green flashing
(2) (deletion accepted)
Example of a new
operator code: 45678
*2*: operator reference
10 options from 0 to 9
*2*: operator reference
(between 0 and 9)
red off green flashing
(2) (code accepted)
To reactivate the default
administrator code
(00000000), please
contact your agent or
nearest dealer.
The power supply
red flashing green
flashing (5) (5 s before
switch-off)
switches off automati-
cally after 10 min. (600 s
by default) if the truck
is not being used.
Example: automatically
red off green flashing
(2)(value accepted)
switches off after 1 min.
(60 s) if not used.
Minimum setting = 10 s
/ maximum = 3000 s
red off green flashing
(2)(command accepted)
default
Stand-by
NOTE
The stand-by function is only available with
the Digicode option.
28043430 EN - 05/2017 49
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3 Overview
Options and variants
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 configur
and 10 minutes. This function i
default.
Timeout can be adjusted. Contact the Technical Service Department authorised by the
manufacturer.
ed between 0
s disabled by
Battery electrolyte level indicator LED (optional)
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the bat
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, there is a
sufficient level of electrolyte in the battery.
The battery must not be topped up with
distilled water.
• If the LED (1) or (2) is
insufficient level of
The battery must be top
water.
tery plug.
red, there is an
electrolyte in the battery.
ped up with distilled
1
2
2256
50 4
5728043430 EN - 05/2017
Page 59
4
Application
Page 60
4 Application
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 this purpose, as well as for placing pallets
into and removing pallets from stock.
The dimensions and capacity of the pallets or
containers must be adapted to the load being
transported to ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of the
information you need to check that the equipment
is suitable for the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
Safety instructions relating to use of the truck
Behaviour when driving
The operator must obey the same rules within
the plant as on the road. The operator must
drive at a speed appropriate for the driving
conditions. For example, the operator should
drive slowly around corners, when entering
and travelling through narrow passageways,
when driving through swing doors, at blind
spots, or on uneven surfaces. The operator
must always maintain a safe braking distance
from vehicles and persons in front of him and
must always have the truck under control. The
operator must avoid sudden stops, making
fast U-turns and overtaking other vehicles in
potentially dangerous areas or areas with poor
visibility.
WARNING
Driving the truc
k while sitting down is prohibited.
Please remember the following:
• Drive the truck as described in the "Operator
positions" section.
•Thetruckmu
52 4
st not be used as a stepladder.
5728043430 EN - 05/2017
Page 61
Application 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)
NOTE
Using a telephone or radio in the truck is
permitted, but avoid using these devices when
driving as they may distract you.
garea
.
People in the danger area
Before starting the truck and while you are
working, ensure that no one is in the danger
area. If people are in danger, warn them
well in advance. Stop working with the truck
immediately if the people do not leave the
danger area despite the warnings.
DANGER
Risk of injury! There is a risk of physical injury inside
the danger area. Danger of death from falling loads!
Do not stand on the forks!
Standing or walking under the forks is strictly
forbidden, even when they are not loaded!
Danger area
The danger area is th
are in danger from th
ments, from its work
load lifting device
the load. The danger
eas in which a load co
equipment could
Traffic route con
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.
e area in which people
e forklift truck move-
equipment and from its
s (e.g. accessories) or from
area also includes aruld fall or in which work
lower or fall.
ditions
28043430 EN - 05/2017 53
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Page 62
4 Application
Truck transport and lifting
There must be sufficient distance between
the highest part of the truck or the load and
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 t
The forklift is nor
and rail. If the fo
the max. clearance s
ported disassembled.
in charge of the disass
operations. The forkl
transport means dur
priate restraint sys
wedges to prevent even t
ment.
54 4
ruck
mally transported by road
rklift's dimensions exceed
ize allowed, it is trans-
ift must be secured to the
ing transport using appro-
tems. Block the wheels with
ifting
The sales network is
embly and reassembly
he slightest move-
OM0747
5728043430 EN - 05/2017
Page 63
Application 4
Truck transport and lifting
Transport
– Disconnect the battery connector.
2
Chocking the truck
– Secure the truck against rolling and sliding
with chocks (1).
Lashing down the truck
– Attach the lashing ropes (
2) to the mast.
Climatic Conditions for Transport and Storage
The forklift must be protected from atmospheric agents during transport and storage.
1
1
0252_003-010
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4 Application
Truck transport and lifting
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 tiller or other
points not designed for this.
– Thread the rope sling through the special
eyelet on the mast (designed for lifting the
truck with its battery). The lifting capacity
of the hook and the rope sling must be
sufficient to bear the weight of the truck
(with its battery). The position is indicated
by a hook symbol
DANGER
Use a crane with a
weight of the tr
plate. Also t
battery fitt
tion plate. Lifting operations must be
identifica
ed by qualified personnel. DO NOT stand
perform
the crane's radius of action or near the truck.
within
and in the danger area below suspended
Do not st
se NON-METALLIC slings. Use safety
loads. U
Make sure that the lifting capacity of the
hooks.
gs is suitable for the weight of the truck with its
slin
ry.
batte
suitable lifting capacity for the
uck, which is indicated on its data
ake into account the weight of the
ed (if applicable), referring to the relevant
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.
56 4
5728043430 EN - 05/2017
Page 65
Application 4
Breaking-In
Breaking-In
This type of forklift does not require special
breaking-in operations.
28043430 EN - 05/2017 57
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4 Application
Checks and actions prior to use
Checks and actions prior to use
List of checks prior to start-up
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 inspections, 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 zone in
front of and/or behind the truck.
CAUTION
Drive very slowly during the operational tests.
Ensure that th
condition prio
supplement a
maintenanc
• Check the area under the forklift truck for
leaking consumables.
• Check the condition of the forks(5) and other
load-carrying equipment to ensure they
show no noticeable damage (e.g. bends,
cracks, significant wear).
• Check that
hydraulic
condition
• The guard mesh or plastic screen (2) must
be intact and properly secured.
• Do not restrict the field of vision. Ensure the
visible areas specified by the manufacturer
are observed.
e truck is in good working
r to start-up. These checks
nd do not replace the scheduled
e operations
the uncovered sections of
pipes and hoses are in good
and check them for leaks.
11
6
5
2
3
4
0252_003-068
58 4
5728043430 EN - 05/2017
Page 67
Application 4
Checks and actions prior to use
• Attachment parts (special equipment) must
be properly secured and function according
to their operating instructions.
• Damaged or missing decals must be
replaced in compliance with the marking
position table.
• The roller guide rails must b
visible layer of grease.
• Check that the wheels (traction, load) are in
good condition. The wheels must not show
any sign of damage or heavy wear. They
must be correctly attached.
• Check that there are no objects, twine, etc.
blocking the operation of the wheels and
rollers (4).
• Make sure the horn works cor
• The battery cover (6) must be securely
closed.
• Make sure the cover is (3) present and
properly secured.
• Check that the chains (1) a
and evenly and adequatel
• Visually check that the various parts of the
truck are in good condition and correctly
positioned;
• Make sure that the anti-crush safety pushbutton works correctly;
• Check that the buttons and t
tiller are working correct
• Make sure that the buttons and throttle
automatically return to their correct position
after release
• Check that the battery plug/outlet are
correctly positioned and intact;
• Make sure that the start/stop
correctly
• Check that the truck brakes and stops when
the throttle is released;
• Check that the truck brakes and stops when
the tiller is released;
• Make sure that the electromagne
works effectively;
• Check the automatic return of the tiller to
the vertical position with relative emergency
braking;
• Check the battery electrolyte level and density as indicated in the battery instructions;
ecoatedina
rectly.
re undamaged
y tensioned.
hrottle/s on the
ly;
key works
tic brake
28043430 EN - 05/2017 59
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Page 68
4 Application
Checks and actions prior to use
• Check that the battery wiring is intact;
• Check that the battery lock system is
operating correctly (only for trucks designed
for side removal of the battery). Check that
the battery is locked in place.
• Check the correct operation of
matic speed reduction syste
raised approximately 500 mm
ground. (only available on 1
DANGER
If you notice any malfunctions or if you have any
doubts about the correct operation of the truck,
DO NOT use the truck, but call the manufacturer's
authorised service network.
Checking the anti-crush safety device
Anti-crush safety function
The truck moves in reverse when the anticrush button (2) is pressed.
If the truck is being operated in narrow areas
such as a lift, for example, the operator may
hit the wall if care is not taken. The operator
would be injured by the tiller if this occurred
andthetruckwasnotfittedwithananti-crush
device.
The truck automatically shifts into reverse
when the anti-crush device on the tiller head
comes into contact with the driver's body.
When the operator moves away from the
anti-crush device, the vehicle stops, even if
forward travel is selected again.
Normal operation may be resumed after
releasing the throttles.
the auto-
m with forks
above the
400 kg version)
3
2
1
0203_003-010
Checking the anti-crush safety device
WARNING
Ensure that the test
objects, both in fron
– Operate the throttle (1) or (3) for forward
travel.
60 4
area is free of people and
t of and behind the truck.
5728043430 EN - 05/2017
Page 69
Application 4
Checks and actions prior to use
The truck moves forward.
– Activate the anti-crush safety device (2).
WARNING
The truck stops and shifts into fast reverse.
– Release the anti-crush safety device.
The truck stops.
Checking the brake
CAUTION
Perform this check on a
flat surface.
– While driving, tilt the tiller in areas (C) and
(A) to test brake response.
In these two areas, the truck is stopped and
the drive unit is no longer powered. Releasing
the tiller in driving area (B) sends the tiller into
the area (C) and cuts traction.
Checking the emergency stop
– Drive slowly forwards.
– Press emergency stop button (1).
The truck stops.
– Pull the emergency stop button (1).
The truck is functional.
NOTE
Ensure the stabilising wheels are correctly adjusted. This influences braking effectiveness.
A
0252_003-029
C
5˚
B
1
28043430 EN - 05/2017 61
457
0252_003-047
Page 70
4 Application
Checks and actions prior to use
Checking the horn
– Operate the horn switch (1).
The horn sounds.
1
0203_003-012
62 4
5728043430 EN - 05/2017
Page 71
Application 4
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.
DANGER
Sitting on the truck is
DANGER
Risk of feet being crushed.
Ensure that your feet are sufficiently far away from
the truck chassis.
– Recommended position for pick-up and
deposit of the load.
strictly prohibited.
28043430 EN - 05/2017 63
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OM2278
Page 72
4 Application
Operator position
– Recommended position when in gear
(preferential gear)
64 4
5728043430 EN - 05/2017
Page 73
Application 4
Driving
Driving
Driving safety instructions
Behaviour when driving
The operator must obey the same driving 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 along narrow aisles,
when driving through swing doors, at blind
spots or on uneven surfaces. The operator
must always maintain a safe braking distance
from other vehicles and persons in front of
him and must always have full control of the
truck. The operator must avoid sudden stops,
fast U-turns and overtaking other vehicles in
potentially dangerous areas or areas with poor
visibility.
Driving the truck while s
During operation in pedestrian mode:
• Never sit on the truck to drive it.
• The truck must not be use
• The truck was not designed to transport
people and must not be used for this
purpose.
• The operator must always stay within the
truck clearance.
• Stay in the safety
defined by the manu
Use of a telephone or radio in the truck is
permitted, but avoid using these devices when
driving as they may distract you.
eated is prohibited.
d as a stepladder.
area (working area
facturer).
Visibility when driving
The driver must look in the direction of travel
and have a clear view of the route travelled
on. He must always ensure that the way
is clear, particularly when reversing. When
transporting goods that obstruct visibility, the
truck must be driven with the load trailing.
If this is not possible, a guide must walk
ahead of the truck. In this case, the truck may
only be driven at walking pace and with the
utmost caution. The truck must be stopped
28043430 EN - 05/2017 65
457
Page 74
4 Application
Driving
immediately when eye contact with the guide
is lost.
Before driving
People in the hazard area
Before starting the truck and while you are
working, ensure that no-one is in the hazard
area. If anyone is in the hazard area, warn
them well in advance. Stop manoeuvring
the truck immediately if people remain in the
hazard area despite the warnings.
WARNING
Risk of injury! There is
physical injury inside
Do not stand on the fork
DANGER
Danger of death from falling loads!
Climbing on or walking under the forks
is strictly prohibited, even when they
are not loaded.
ariskof
the hazard area.
s!
Hazard area
The hazard area is the area in which people
are in danger from the movement of the forklift
truck, its work equipment and its lifting devices
(e.g. accessories) or load. The hazard 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 fallen 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.
Maintain suffici
est part of the fo
rounding fixed in
pends on the lift
the load. Refer t
tics.
66 4
ent distance between the high-
rklift truck or load and sur-
stallations. The height de-
height and the dimensions of
o the technical characteris-
5728043430 EN - 05/2017
Page 75
Application 4
Driving
Rules regarding the traffic routes and the
manoeuvring areas
Only drive in approved areas. Traffic routes
must be free of obstacles. Loads may only be
unloaded and stored in places designed for
this purpose. The operator or his representative must ensure that no unauthorised person
accesses the working area.
Hazards
Hazards on traffic routes mu
means of road signs or possi
warning notices.
st be signalled by
bly by additional
Starting the truck
Carry out all of the dail
formed by the operator.
Pull the emergency shutdown handle.
Put the tiller in the vertical position.
To start the truck, tu
truck has a numeric ke
insert the appropria
Check the battery charge status on the
indicator and replace or charge the battery
if necessary.
y checks to be per-
rntheignitionkey. Ifthe
ypad rather than a key,
te PIN code.
28043430 EN - 05/2017 67
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Page 76
4 Application
Driving
Check the information on the combined indicator
The instrument can display several of the
truck's functions:
Discharge indicator
The discharge indicator (3) operates after
the battery connector has been connected.
Monitoring the discharge process protects the
battery against significant discharge.
When the battery is fully c
bars are lighted. As batte
display moves to the left
If the battery is 80% discharged, two status
bars are lit. The lifting function is switched off.
The battery must be recharged.
harged, the 10 status
ry capacity falls, the
.
1
0.0 h
2
3
Hourmeter
The hour meter (4) indicates the number of
operating hours of the machine.
The display is activat
machine is switched on
light (2) comes on.
ed as soon as the
. The green indicator
4
0252_003-049-V2
68 4
5728043430 EN - 05/2017
Page 77
Application 4
Driving
Behaviour in emergencies
In an emergency, all functions on the truck can
be shut down.
– Press the emergency stop button (1). The
1
truck will come to a stop.
– To restart the truck, relea
stop button by pulling on it
se the emergency
.
CAUTION
This safety device must only be used in an emergency.
0252_003-047
Selecting the driving mode
NOTE
The truck has two driving modes.
– Turn the switch key (1) to the desired
position.
"Tortoise" position: gentle acceleration and
deceleration; max. speed: 4 km/h
"Hare" position: strong acceleration and
deceleration; max. speed: 6 km/h
1
28043430 EN - 05/2017 69
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0252_003-051
Page 78
4 Application
Driving
Driving
– TurnthekeytotheTortoise position
(gentle acceleration and deceleration) or
the
Hare position (strong acceleration and
deceleration) as desired.
– Hold one of the tiller handles (1) on the side.
– Lower the tiller.
NOTE
The truck is only in the drive position in the (B)
zone. In the lower (A) or upper (C) zone, the
mechanical brake is applied and the traction
motor is switched off.
NOTE
For details on driving a truck equipped with the
"OptiSpeed" option, see
= "Fahren_Option" not found!
NOTE
Link error: Target with XID
One of the travel throttles (2) or (3) on the tiller
arm can be operated with the right or left hand.
Always operate the travel throttle slowly, as
the truck responds instantly. Abrupt starting
or braking or reversing the direction of travel
should be avoided at all costs.
Forward travel
– Press with your thumb on the lower part of
the throttle.
– The speed increases with the movement of
the throttle; speed is limited to 4 or 6 km/h
depending on the position of the key.
– When the control throttle is released, the
truck brakes electrically.
A
0252_003-029
C
5˚
B
70 4
5728043430 EN - 05/2017
Page 79
Application 4
Driving
Reverse travel
– Press with your thumb on the upper part of
the throttle.
– The speed increases with the mo
the throttle; speed is limited
depending on the position of th
– When the control throttle is released, the
truck brakes electrically.
vement of
to 4 or 6 km/h
ekey.
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 truck to travel and the
forks to be lifted with the tiller in any position.
Unlike the standard version, by following the
instructions below, the truck functions (travel
and lifting/lowering of forks) are also active
with the tiller in the vertical position.
To enable truck lifting with the tiller in the
vertical position:
• Press and hold the b
• Then press the fork lifting button
• Release the button (3) to disable this
function.
To enable travel with the tiller in the vertical
position:
• Press and hold the butt
• Then turn the throttle (4) in the desired
direction
• The truck activates creep speed. During
travel at creep speed with the tiller in the
vertical position and the button (3) pressed,
if the operator tilts the tiller to the working position (see ⇒ Chapter "Tiller positions", P. 3-34), creep speed is disabled and
the speed of travel of the truck increases in
line with the angle of the throttle (4).
• Release the button (3) to di
function.
utton (3)
on (3)
sable this
4
4
3
OM2283
NOTE
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4 Application
Driving
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
• Travel in the direction of th
enabled.
e operator is not
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Application 4
Driving
Reverse drive
Reverse of direction 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.
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
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4 Application
Driving
Truck brake systems
WARNING
The condition of the floor sur
affects the braking distan
The operator must consider
While driving, braking c
face considerably
ce of the truck.
this factor while driving.
an be performed in the
following ways:
• Releasing the drive control throttle (service
brake)
• Reversing the drive control throttle (also
see the paragraph ⇒ Chapter "Reverse
drive", P. 4-73)
• Using the tiller
Braking by releasing t
throttle (service bra
he traction control
ke)
• During travel, release the traction control
throttle. The truck will decelerate sharply to
astop
CAUTION
In dangerous situations, always brake using the
service brake.
Braking by reversing the traction control
throttle
• Duringtravel,turnthetractioncontrol
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 traction control throttle
CAUTION
Do not brake by reversing the
throttle when travelling w
traction control
ith aloadontheforks.
CAUTION
Regulate the throttle by adapting truck braking to
thetypeofloadyouarecarryinginordertoavoid
losing the load.
Braking using the tiller
Braking using the tiller can be performed in the
following ways:
• During travel, push the tiller to the upper
end position. The truck will decelerate very
sharply to a stop
• During travel, push the tiller to the lower
end position. The truck will decelerate very
sharply to a stop
• During travel, release the tiller. The tiller
will automatically return to the upper end
position. The truck will decelerate very
sharply to a stop
WARNING
The condition
affects the b
The operato
Parking bra
• When the traction control throttle is released, the truck stops using the electromagnetic brake when its speed approaches
0 km/h or when the tiller returns to the vertical position
of the floor surface considerably
raking distance of the truck.
r must consider this factor while driving.
ke
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Application 4
Driving
Parking and stopping the truck
WARNING
Do not park the truck on a slope.
Never leave the truck with the forks raised.
– Park in pre-arranged and designated areas.
– Lower the forks to the ground.
– Turn off the truck using the start/stop key. If
the Digicode option is fitted, turn off the truck
by pressing the
– Press the emergency stop button.
DANGER
Park the truck in such a
struct passageways a
gency equipment (e.g
hydrants).
#
button for two seconds.
way that it does not obnd/or render unusable emer. fire extinguishers and fire
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4 Application
Lifting
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 condensation has formed on it
Lifting
Lift control elements
1 Tiller head handle
Straddle lifting button (optional)
2
Fork lowering button
3
Fork lifting button
4
5
Horn button
6 Drive control throttle
7
Anti-crush button
8 Drive control throttle
Straddle lowering button (optional)
9
WARNING
njury!
Risk of i
fety instructions must be strictly adhered to.
The sa
strictly forbidden to touch or stand on moving
It is
ts (e.g. lifting device, pushing devices, work
par
nstallations, load lifting devices).
i
rk lifting
Fo
– Press the button (4).
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Application 4
Lifting
Theforkswillbelifteduptothemaximum
height.
Fork movement can be stopped at any time by
releasing the push-button.
Fork arms lowering
– Press the button (3).
The fork descends to the lowest position. Fork
movement can be stopped at any time by
releasing the push-button.
NOTE
The truck fork speed is proportional to how
hard the raising and lowering button is pressed.
Initial lift
The base lifting function increases ground
clearance by allowing the truck to operate on
uneven surfaces or slopes.
WARNING
Risk of crushing fee
Keep your feet clea
t.
r of the straddles.
– To lift the straddles, press the button (2).
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2
0203_003-025
Page 86
4 Application
Lifting
– To lower the straddles, press the button (1).
0248_003-033
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Application 4
Moving the load
Moving the load
Safety guidelines for handling loads
WARNING
Closely observe the foll
picking up loads. Never
parts of the truck (e.g.
devices for picking up
owing instructions before
touch or stand on moving
lifting devices, equipment or
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
prohibited.
or passengers is strictly
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.
–
1044_800-003
CAUTION
Pallet condition
Insert the forks into the pallets from the correct
side, i.e. the open side, as shown in the illustration
(insertion from all sides permitted only with the EXP
model).
Ensure that the pallet is in good condition before
commencing any operation.
–
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4 Application
Moving the load
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.
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.
2
1
0252_003-111
CAUTION
It is not permitted to transport loads on the straddles
(1).
Loads may only be transported on the forks (2).
Carrying loads on the straddles is only permitted for
the EXV-D range of trucks, which are designed to
perform the double pallet stacker function.
Target with XID = "Doppio_stoccatore" not found!
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.
Link error:
CAUTION
Do not touch nearby loads or loads beside or in front
of the load being handled
Arrange loads with a small space between them to
prevent them coming into contact with one another.
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.
CAUTION
Risk of loss of stability.
When removing the load from the shelf, do not use
the initial lift control (if the truck has one) in order to
maintain maximum stability and avoid any risk of
tipping the truck. This operation is prohibited both
when picking up and when depositing the load on
the shelf.
NOTE
Further information on the general rules of
truck use and taking up and depositing loads
is provided in the "Safety Regulations for
Industrial Forklift Use" manual attached to
this manual.
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Application 4
Moving the load
Checks to be carried out befor
e lifting
aload
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
cannolongerbeguaranteed.
Transporting people in order to increase the capacity of the truck is prohibited.
.
Example
Weight of load to
lifted:
Distance between
the load centre of
gravity/fork carriage:
Permissible lift height: 2600 mm (2)
WARNING
The illustr
Only the v
be taken in
ations are only examples.
alues stated on your truck's plate should
be
to consideration.
1200 kg (3)
600 mm (1)
(1) CDG = distance "C" from the centre of
gravity of the load on the forks to the fork
carriage (in mm)
(2) h = lift height of the forks from the ground (in
mm)
(3) Maximum permissible loads "Q" (in kg)
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.
Picking up the load
Load pick up from the ground
– 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 forks at the centre of the
load to be lifted.
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4 Application
Moving the load
CAUTION
Insert the fork without bumping into either the
shelving or the load.
– Insert the forks as far as pos
the load. If possible, the fo
inserted far enough in that
against the fork carriage.
gravity must be centred bet
sible below
rks should be
the load is resting
The load centre of
ween 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.
– 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.
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Application 4
Moving the load
– Raise the forks until you reach the correct
fork insertion height.
– Move the truck slowly forward
forks into the load.
CAUTION
Insert the fork without bumping into either the
shelving or the load.
s to insert the
– Insert the forks as
the load. If possib
inserted far enoug
against the fork ca
gravity must be cen
far as possible below
le, the forks should be
h in that the load is resting
rriage. The load centre of
tred 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.
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4 Application
Moving the load
– 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.
– Lower the load to the transport position,
approximately 300 mm from the ground,
and read the "Transporting loads" section.
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Application 4
Moving 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 are met
• On the orders of the supervis
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 likely to obstruct
the operator's view, a second person on foot must
assist with manoeuvres in order to warn the driver
of any obstacles. In this case, driving is only authorised at walking speed and with the greatest care.
Stop the truck immediately if you lose contact with
thepersonaccompanyingyou.
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.
or in charge
0252_003-103
DANGER
When travelling and transporting the load, be aware
of the side clearance of the load, particularly when
cornering.
Avoid hitting shelving and objects in your path.
DANGER
of load tipping over
Danger
udden starts and stops.
Avoid s
ach corners slowly and carefully.
Appro
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4 Application
Moving the load
Setting down loads on shelving
DANGER
Pay attention to the part of t
the load to be set down.
Do not strike the wall, the s
and/or objects behind th
DANGER
Driving or turning with the fork carriage in the raised
position is prohibited.
This is only allowed at very slow speed when setting
down a load and/or picking one 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.
he forks protruding from
helving or other loads
eloadtobepickedup.
Depositing a load on the ground
• Approach the load deposit area.
• Lower the fork arms unti
posited in the desired a
fork arms from the load
• Back up with the forklift.
DANGER
Never leave the forklift with the forks raised whether
loaded or not.
l the load is derea and release the
.
– Raise the forks until you reach the correct
fork insertion height.
– Move the truck slowly forward
the load.
– Lower the load until it is resting properly on
the racking.
– After setting down the load, lower the forks
without touching either the shelving or the
load.
– Put the tiller in the drivin
behind to check that the w
the throttle in the direc
the operator and drive ve
carefully in a straight l
shelves. Brake graduall
– Check that there is sufficient space between
the forks and the shelving.
– Lower the forks to the ground.
s to set down
g position. Look
ay is clear. Turn
tion of travel towards
ry slowly and
ine away from the
y.
NOTE
Further informat
forklift use is pr
of Industrial Vehic
ion on the general rules of
ovided in the Rules for the Use
les Manual enclosed with
this manual.
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Application 4
Moving 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
When driving up or down inclines, the speed of
travel must be reduced.
DANGER
Risk of tipping!
When driving up or down 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
Securethetruckintheliftsothatnopart
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.
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 utmost care 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 accompanyi
only enter the lift onc
exit the lift first af
ng the truck onto the lift may
e the truck is secure and must
ter transit.
Using the truck on loading bridges
DANGER
Risk of accident
Before driving on to a loading bridge, the operator
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.
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4 Application
Fault displays
Fault displays
Error codes
The combined indicator may display an error
code. When an error code is displayed, please
call our service department.
NOTE
Four error codes may be displayed. For
example:
• E1: 239
• E2: 212
• E3: 426
• E4: 320
Make a note of these error codes before
switching off the truck. These error codes
are stored, but are not necessarily displayed
on the combined indicator.
0.0 h
0252_003-065-V2
Charging the battery
Opening/closing the battery compartment
Open
– Park the truck.
– Lift the cover (1).
2
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Application 4
Charging the battery
– Disconnect the battery plug (2).
Closing
WARNING
Risk of crushing.
Be sure not to leave anything between the battery
cover and the edge of the chassis when closing the
cover.
– Connect the battery plug .
– Close the battery cover.
2
0252_003-088-V2
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4 Application
Charging the battery
Battery Recharging
CAUTION
The battery is recharged wit
h the forklift off.
DANGER
The battery must be charged in rooms that comply
with the specific regulations on the subject. Refer
to the battery and battery charger 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, open
the battery hood and hold the hood open.
• 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.
• Close the battery hood.
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-aci
d battery with a capacity
below 210 Ah,
• open lead-acid battery with a capacity
greater than 210 Ah,
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Application 4
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 instructions given in
the battery manual and those included in the "Safety Guidelines "of this manual.
DANGER
If the truck is fitted with an on-board battery charger,
it is strictly prohibited to connect the battery to an
external battery charger.
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.
attery type
B
rucks can be fitted with different types of
T
attery. Observe the instructions on your
b
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4 Application
Charging the battery
battery type plate, as well as the specifications
defined in the chapter "Technical data".
WARNING
The weight and size of the battery influence the
stability of the truck.
The new battery must weigh the same as the old
one. Do not change its position from the original
one.
CAUTION
Be careful not to damage any wiring when replacing
the battery.
Preparation
Maintenance perso
The battery may only be changed by specially trained personnel, in accordance with
the manufacturer's instructions for the battery,
the battery charger and the truck. The maintenance instructions for the battery must be
observed.
nnel
Fire prevention measures
WARNING
Do not smoke or use a naked flame
when handling batteries. In the
area designated for parking the
truck to recharge the battery or
battery charger, there should be no
flammable materials or substances
that can cause sparks within a radius
of at least 2 metres. The charging
area must be well ventilated. Keep a
fire extinguisher at hand.
Safe parking
Park the truck securely before carrying out
work on the battery. The truck can only be
operated when the battery cover is closed
and the battery outlet is inserted. If the truck
is enabled for side removal of the battery, the
truck can only be operated once the battery
is fixed in place properly using the battery
locking system.
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