Still ECU-SF-20 Original Instructions Manual
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Still ECU-SF-20 Original Instructions Manual

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Original instructions
ECU-SF-20
0170
45378043402 EN - 10/2011

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Summary of Contents for Still ECU-SF-20

  • Page 1 Original instructions ECU-SF-20 0170 45378043402 EN - 10/2011...

  • Page 3: Table Of Contents

    Table of contents Introduction Forklift data ............General information .
  • Page 4 Table of contents Knowledge of the Truck General Truck View ..........20 Definition of direction of travel .
  • Page 5 Table of contents Load Placement ........... . . 47 Taking up load .
  • Page 6 Table of contents Supply Table ............59 Resolution of Operating Defects .

  • Page 7: Introduction

    Introduction...

  • Page 8: Forklift Data

    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 to things due to the failure to observe the •...

  • Page 9: Delivery Of The Forklift And Documentation

    Introduction Delivery of the forklift and documentation CAUTION NOTE Failure to observe the instructions highlighted with This symbol is used to provide additional this symbol may cause damage to the forklift and, information. in some cases, result in warranty invalidity. ENVIRONMENT NOTE Failure to observe the instructions highlighted with this symbol may cause environmental...

  • Page 10: Ec Declaration Of Conformity In Accordance With Machinery Directive

    Introduction EC declaration of conformity in accordance with Machinery Directive EC declaration of conformity in accordance with Machinery Di- rective Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 11: Technical Service And Spare Parts

    Introduction Technical service and spare parts Technical service and spare parts For scheduled maintenance and any repairs to the technical characteristics of the forklift over the forklift, contact only the authorised service time. network. Only original spare parts provided by the man- The authorised service network has personnel ufacturer may be used for forklift maintenance trained by the manufacturer, original spare...

  • Page 12: Working Conditions

    Introduction Working conditions • transporting and/or lifting people; • colliding with stationary and/or movable structures; • pushing or pulling loads; • inclining the lift unit forwards with the • moving upwards or downwards on a slope forks lifted, except during the lifting and/or with the load facing downwards;...

  • Page 13: Applied Equipment

    Introduction Applied equipment Applied equipment The forklift may be equipped with non-stan- CAUTION dard devices (example: clamp forks, rotating The “crane arm” attachment changes the original forks). intended use of the forklift, which may not move free-swinging suspended loads. For such applica- It is necessary to contact the authorised sales tion, specific approval and the EC Declaration of network for the application of such equipment,...

  • Page 14: Packaging

    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. 45378043402 [EN]...

  • Page 15: Safety

    Safety...

  • Page 16: Safety Regulations

    Safety Safety Regulations Safety Regulations General Precautions regulations integrate those in the manual NOTE "Rules for approved use of industrial vehicles". Some safety regulations to be followed when using the forklift are listed below. These General Safety Rules • Only allow qualified, trained and authorised •...

  • Page 17: Requirements For The Traction-Battery Charging Area

    Safety Safety Regulations 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 ENVIRONMENT NOTE the forklift to be able to better describe any defects and assist maintenance personnel.
  • Page 18 Safety Safety Regulations Oils Battery Acid • Do not allow to come into contact with the • Do not inhale the vapor: it is poisonous. skin. • Use adequate means of individual protec- • Do not inhale oil vapors. tion to prevent contact with the skin. •...

  • Page 19: Location Of Labels

    Safety Location of labels Location of labels OM2160 Read the user and maintenance manual Truck lifting point Battery warning Prohibition against carrying people Cold store version (optional) Danger of moving parts Ignition key 45378043402 [EN]...

  • Page 20: Description Of Labels

    Safety Description of labels Description of labels (1) This label indicates you should consult (5) This symbol, where present, indicates the use and maintenance manual before that the truck is set up for "cold store" use using the truck and prior to carrying out any (optional).

  • Page 21: Safety Devices

    Safety Safety devices Safety devices OM2161 The operator must be aware of the presence • Driver on the step plate sensors (5). of the following safety devices: • Tiller position sensor (6). • Anti-crush safety button (1). NOTE • Emergency stop button (2). •...

  • Page 22: Non-Ionised Radiation

    Safety Non-ionised radiation 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).

  • Page 23: Safety Tests

    Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents STILL GmbH Hamburg The operating company must ensure that the truck is checked at least once a year, or Regelmäßige Prüfung following noteworthy incidents.
  • Page 24 Safety Safety tests 45378043402 [EN]...

  • Page 25: Knowledge Of The Truck

    Knowledge of the Truck...

  • Page 26: General Truck View

    Knowledge of the Truck General Truck View General Truck View OM0388 Tiller head Forks Tiller Removable casing Control panel Side panels (if fitted) Battery compartment cover plate Movable step plate 45378043402 [EN]...

  • Page 27: Definition Of Direction Of Travel

    Knowledge of the Truck Definition of direction of travel Definition of direction of travel OM0389 The direction of travel is defined in the following manner: A = Direction of travel towards forks B = Direction of travel towards the driver 45378043402 [EN]...

  • Page 28: Instrumentation And Controls

    Knowledge of the Truck Instrumentation and Controls Instrumentation and Controls Start/stop key Key 1 has two positions: 0 =No circuit powered (key removal posi- tion); I =Circuit powered. NOTE All of the controls described on the following pages work with the key in position "I" 1958 45378043402 [EN]...

  • Page 29: Tiller Controls

    Knowledge of the Truck Instrumentation and Controls Tiller controls – NOTE All drive and lifting controls can be activated with the tiller in working position. Anti-crush button (1) • By pressing the button (1) while the truck is travelling towards the operator, the truck will stop.

  • Page 30: Tiller Positions

    Knowledge of the Truck Instrumentation and Controls CAUTION The forks can also be lifted and lowered when the truck is moving (with the traction command activated). Tiller positions Position the tiller in accordance with the truck functions In this case the tiller has two positions: •...

  • Page 31: Battery Status Indicator And Hour Meter

    Knowledge of the Truck Instrumentation and Controls Battery status indicator and hour meter The instrument is subdivided into two zones as follows: Zone A • Indicates the actual truck operation time, expressed in hours. • When the counter is working, clock "A1" blinks;...

  • Page 32: List Of Available Options

    Knowledge of the Truck List of available options List of available options OM2164 45378043402 [EN]...

  • Page 33: Operator Side Panels

    Knowledge of the Truck Operator side panels – • Tandem load castors (1). • Pallet guide rollers (5) with single roller(4). • Equipment for cold climates (3). Refer to Chapter 4 for additional information on the use of this version of the truck. •...
  • Page 34 Knowledge of the Truck Operator side panels Position "A" = side panels open Closing the side panels This position is used when the truck is oper- To close the side panels (1) and pass from ated with the driver on the ground and the step position "A"...

  • Page 35: Operator Step Plate

    Knowledge of the Truck Operator step plate Operator step plate The operator step plate (1) has three positions; Traction is constantly blocked in this position. Position "A" = step plate raised Position "C" = step plate in working position with the operator on board This position is used when the truck is oper- ated with the driver on the ground and the side This position is automatic when the operator...

  • Page 36: Internal Accessibility

    Knowledge of the Truck Internal accessibility Internal accessibility DANGER It is prohibited to use the truck with the covers open. In order to use the truck, the covers for access to the inner parts must be closed and secured properly. DANGER Before accessing the inner parts of the truck, carefully follow the instructions given in Chapter...

  • Page 37: Removing The Covers

    Knowledge of the Truck Removing the covers Removing the covers 1 2 3 4 5 6 7 8 9 10 OM2165 DANGER For models with an optional cooling fan (SERVICE KIT), the fans may move even when the key is in the OFF position.

  • Page 38: Truck Identification

    Knowledge of the Truck Truck Identification stem still, using a screwdriver, rotate the button’s head anticlockwise until it is completely unscrewed. • Loosen the screws (3) and remove the cover (4), taking care not to damage the electrical connection wires of the start key (5) and the battery status indicator instrument (6).

  • Page 39: Frame Labelling

    Knowledge of the Truck Truck Identification Frame labelling The truck’s serial number is marked on the chassis frame (1). 1987 Forklift Identification Plate – The identification plate indicates the following data: • A = Type of forklift • B = Serial number •...
  • Page 40 Knowledge of the Truck Truck Identification 45378043402 [EN]...

  • Page 41: Use And Operation

    Use and Operation...

  • Page 42: Truck Transport And Lifting

    Use and Operation Truck Transport and Lifting Truck Transport and Lifting Transporting the truck The forklift is normally transported by road and rail. If the forklift’s dimensions exceed the max. clearance size allowed, it is trans- ported disassembled. The sales network is in charge of the disassembly and reassembly operations.

  • Page 43: Loading And Unloading The Truck

    Use and Operation Truck Transport and Lifting Loading and unloading the truck OM2162 Use a lifting crane to load and unload the compatible with the specifications stated by truck, or use an inclined plane or a movable the manufacturer, which must be suitably platform (with a slope and structural strength positioned and anchored).

  • Page 44: Breaking-In

    Use and Operation Breaking-In DANGER DANGER Use a crane with a suitable lifting capacity for the The slings should have a suitable length so as to weight of the truck, indicated on its data plate. Also not graze the casing or any additional equipment take into account the weight of the battery fitted (if during lifting.

  • Page 45: Wheel Wear Check

    Use and Operation Use of the Truck • Check the battery electrolyte level and den- DANGER sity as indicated in the battery instructions; DO NOT use the truck, but call the manufacturer’s • Check that battery’s wiring is intact; authorised service network, if you notice any mal- functions or if you have any doubts about its correct •...
  • Page 46 Use and Operation Use of the Truck Driving position with the operator on Two types of driving are possible with the operator in different positions: board (Fig. S) • Driving position with the operator on the DANGER ground. • Driving position with the operator standing Risk of falling from the step plate.
  • Page 47 Use and Operation Use of the Truck 1 2 3 4 5 6 7 8 9 10 OM0393-1 Start-up After having performed the daily checks, carry out the following operations to use the truck: – Insert the key (1) and turn it to "I"; the device (2) will light up indicating the number of operating hours and battery status.
  • Page 48 Use and Operation Use of the Truck NOTE During truck operation, releasing the tiller will cause the truck to brake and slow down until it stops. 45378043402 [EN]...

  • Page 49: Reverse Drive

    Use and Operation Use of the Truck Reverse drive Reverse of direction without load on forks Reverse of direction with load on forks • To reverse direction when travelling without • To reverse direction with a load on the fork a load on the fork arms, turn the traction arms, release the traction control throttle control throttle in the opposite direction of...

  • Page 50: Stopping The Truck In An Emergency

    Use and Operation Use of the Truck Stopping the truck in an emergency – In case of emergency, press the emergency stop button (1) (position B); all of the truck’s functions will be blocked. 1999 – To restore operating conditions, eliminate the causes of the emergency, then proceed as follows: –...

  • Page 51: Using The Truck On Inclines, Loading Bridges And Lifts

    Use and Operation Use of the Truck Using the truck on inclines, loading bridges and lifts. Driving on inclines When driving the truck up or down inclines, you must not exceed the values for inclines indicated in the chapter "Technical data". The driver must check that the ground is clean with a good grip.
  • Page 52 Use and Operation Use of the Truck – 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. Using the truck on a lift Using the truck on a lift is only allowed if the lift has sufficient load capacity (check the...

  • Page 53: Forklift Use In Cold-Storage Rooms

    Use and Operation Load Placement Forklift Use in Cold-Storage Rooms. A truck specifically equipped for cold-storage CAUTION rooms must be used when working at temper- If the truck has been working in environments at atures below +5°C. temperatures below -5°C and it is taken outside the cold-storage room, let it stand either for a sufficien- Forklifts equipped for working in cold climates tly long time to allow evaporation of any condensa-...

  • Page 54: Transporting Loads

    Use and Operation Load Placement DANGER Never leave the forklift with the forks raised whether loaded or not. NOTE Further information on the general rules of forklift use and on the lifting and depositing of loads is provided in the "Rules for the Use of Industrial Vehicles Manual"...

  • Page 55: Deposit The Load

    Use and Operation Load Placement Deposit the load. • Approach the load deposit area. • Lower the fork arms until the load is de- posited in the desired area and release the fork arms from the load. • Back up with the forklift. DANGER Never leave the forklift with the forks raised whether loaded or not.

  • Page 56: Forklift Towing

    Use and Operation Forklift Towing Forklift Towing The forklift may not be towed in the case of breakdown. The forklift must be lifted with due caution, as described on the preceding pages. 45378043402 [EN]...

  • Page 57: Battery Recharging

    Use and Operation Battery Recharging Battery Recharging CAUTION • Turn on the external battery charger. • Connect plug the battery charger in to begin The battery is recharged with the forklift off. charging. • After the battery charging operation is DANGER completed, turn off the battery charger.
  • Page 58 Use and Operation Battery Recharging 45378043402 [EN]...

  • Page 59: Maintenance

    Maintenance...

  • Page 60: General Information

    Maintenance General Information General Information To keep your forklift in good condition, carry DANGER out the servicing indicated regularly, within the Scheduled maintenance and repairs must be times indicated and using the consumption done by the service network authorised by the materials provided for that purpose, as speci- manufacturer in order to maintain the machine fied on the following pages.
  • Page 61 Maintenance Scheduled Maintenance Check electromagnetic brake Check wheel tightness Check the condition of battery and truck wiring Check insulation between chassis and any electric motors Check insulation between chassis and electric/electronic com- ponents Greasing: bearings, tie rods and levers Change hydraulic system oil ENVIRONMENT NOTE During maintenance operations, follow the instructions provided in the section "Safety...

  • Page 62: Maintenance As Required

    Maintenance Maintenance as required Maintenance as required Cleaning the Forklift Cleaning depends on the type of use and the Use water-dampened rags to clean the parts workplace. Should the truck come into contact of the body. with highly aggressive elements such as salt CAUTION water, fertilizers, chemical products, cement, etc., it should be cleaned as carefully as...

  • Page 63: Fuse Replacement

    Maintenance Maintenance as required Fuse replacement 2154 • Turn off the truck and perform the prelimi- Fuse values nary maintenance operations. • 1F1 = 150 A traction motor safety fuse • 2F1 = 80 A pump motor safety fuse DANGER For models with an optional cooling fan (SERVICE Service fuses KIT), the fans may move even when the key is in the...

  • Page 64: Decommissioning

    Maintenance Decommissioning Decommissioning General Information The operations to be performed for "Tem- porary decommissioning" and "Permanent decommissioning" are listed in this chapter. Temporary Putting Out of Commission The following operations must be performed • Perform the lubrication operations indicated when the forklift is not going to be used for a in the maintenance chapter.

  • Page 65: Supply Table

    Maintenance Supply Table Supply Table Quantity Element to be International lubricant Lubricants supplied specifications MIL-H-24459-DIN 51524/51525 Hydraulic IDRAULICAR AP31 ISO-VG-32 system TUTELA GI/M ( ) ATF Type A - Suffix A ( ) SAE 75W/85– API GL4– ALLISON C4– ZF TE ML06 4B&C) LEVVEL TUTELA MATRIX SAE 75W/85–...
  • Page 66 Maintenance Resolution of Operating Defects Tiller in rest position Position the tiller in the working position The operator side panels are open when the Close the side panels. truck is operated from the ground. Defect: THE TRUCK IS NOT ABLE TO LIFT THE LOAD. POSSIBLE CAUSES SOLUTIONS Make sure the weight of the load to be lifted...

  • Page 67: Technical Data

    Technical data...

  • Page 68: Overall Dimensions

    Technical data Overall dimensions Overall dimensions OM1355 45378043402 [EN]...

  • Page 69: Technical Data

    Technical data Technical data Step plate up Step plate down Forks 1504 1247 1830 1554 1134 1684 1427 2010 1734 1150 1304 1854 1597 2180 1904 1450 1172 1604 2154 1897 2480 2204 1600 1322 1754 2304 2047 2630 2354 Technical data Characteristics 1.3 Power unit type...
  • Page 70 Technical data Technical data Dimensions 4.4 Lifting (mm) Tiller height in operating 1145 / 1342 position (min / max) (mm) 4.15 Lowered fork arms height (mm) Total length (step plate up / 1854 / 2180 4.19 down) (mm) Length including shoulder of 4.20 704 / 1030 (mm)
  • Page 71 Technical data Technical data Lifting motor, performance 15% ED Battery according to British DIN 43535 B / (British Standard) Standard / DIN 43531/ 35 / 36 A, B, C Battery voltage / rated 24 / 250 (300) V / Ah capacity 6.5 Battery weight (+/- 5%) 220 (245)

  • Page 72: Battery Dimensions And Weights

    Technical data Battery dimensions and weights Battery dimensions and weights General battery characteristics DIN references EN 60254-2 references Com- Com- nent Volt- Dimen- Com- Compo- Weight Termi- ponent pacity sions Standard ponent nent length kg±5% nals diagram ries Ah±5% code type 624 x screw...
  • Page 73 Technical data thus the daily exposure must be calculated using the relative workplace data. 45378043402 [EN]...
  • Page 74 Technical data 45378043402 [EN]...
  • Page 75 Index Battery EC declaration of conformity in accordance with Machinery Disposal ..... . Directive ....Declaration of conformity .
  • Page 78 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 45378043402 EN...

  • Page 79: Annex

    Original instructions ECU-SF-20 0170 Annex 45378043402 EN - 10/2011...

  • Page 81: Diagrams

    Diagrams...

  • Page 82: Hydraulic Diagrams

    Diagrams Hydraulic diagrams Hydraulic diagrams Hydraulic connection diagram 45378043402 [EN]...

  • Page 83: Circuit Diagram

    Diagrams Circuit diagram Circuit diagram Electrical connection diagrams Diagram part 1 45378043402 [EN]...
  • Page 84 Diagrams Circuit diagram 2 A fan Steering Emergency Description Code Position safety fuse power relay stop button CURTIS (OPTIONAL) contact 8 A diode traction 2–7 Traction Thermal control unit Socket-plug motor switch LES steering 14-19 n.o. 50° Insulator Lift motor control unit (OPTIONAL) terminal...
  • Page 85 Diagrams Circuit diagram Diagram part 2 45378043402 [EN]...
  • Page 86 Diagrams Circuit diagram Overcurrent Fork lowering DIN 43650 Description Code Position suppressor solenoid A1 PG9 CURTIS (varistor) valve connector 35–39 / traction 55–61 12-pin 25-pin AMP Hour meter 62-65 control unit MOLEX 40-53 connector + flat battery 27-34 LES steering connector 62-65 8-pin MOLEX...
  • Page 87 Diagrams Circuit diagram Diagram part 3 45378043402 [EN]...
  • Page 88 Diagrams Circuit diagram Steering MTA 8-way 25-pin AMP 65-75 / Description Code Position 68 / 78 power relay fuse holder connector 89-109 CURTIS coil 16-pin Black 4-pin 76-88 / traction 76-88 / 111-116 INTERLOCK MOLEX SAAB 91-94 111-116 control unit relay coil connector connector...
  • Page 89 Diagrams Circuit diagram Diagram part 4 45378043402 [EN]...
  • Page 90 Diagrams Circuit diagram Slow speed 12-pin 2-pin AMP Description Code Position 141-142 buttons MOLEX 125-141 connector Tiller card 117-149 connector 2-pin AMP Lift push 143-144 button 7-pin connector Traction po- 122-124 DUBOX 118-124 2-pin AMP tentiometer Lift push 145-146 connector button connector Operator-...
  • Page 91 Diagrams Circuit diagram Diagram part 5 45378043402 [EN]...
  • Page 92 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 45378043402 EN...

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