TABLE OF CONTENTS 01 INTRODUCTION 07 DESCRIPTION OF THE TRUCK ................................Instruction Handbook UFW Tergo four-way truck ................................Conversion table for forklift truck models Driver environment ..........................Stability Support System, S3-1 ............. 02 TRUCK MODIFICATION ................. Stability Support System, S3-2 .............
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TABLE OF CONTENTS Keyboard 12 STACKING ............................................. Battery indicator General ..........................................Error messages Trucks with reach capability ..................................Warnings Trucks with mast tilt ........................................Functions ....................... 13 MAINTENANCE OF THE TRUCK ............Change language .................... Daily maintenance (before each shift) ..........
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TABLE OF CONTENTS Speed (UFW) Lighting ............................................Transportation security Additional units/Trailers ................................Moving the forks (UFW) Safety and warning signs ............................... Normal operating conditions ..............16 DIMENSIONS ....................... Exceptional operating conditions ............Dimensions ......................Work in hazardous environments ............
Sales and customer service via: therefore reserve the right to make alterations without prior notice. STILL GmbH, Berzeliusstrasse 4, 22113 Hamburg, Germany. Thank you for choosing UniCarriers Manufacturing Sweden Conversion table for forklift truck models AB as your truck supplier.
Only in the event that STILL is no longer in business and there is no successor in the interest to the business, may the user perform a modification or alteration to a powered industrial truck.
03 ENVIRONMENTAL CONSIDERATIONS We respect the environment The majority of our products consist of steel, and can be completely recycled. Environmental impact All products have an impact on the environment throughout their entire life cycle. The consumption of energy when in use is one of the most important factors that influences the environment.
Climatic conditions page 78 • good visibility, adequate lighting and approved routes. • use in still air. If draughts or wind are present, load handling and transportation must be adapted to suit the prevailing conditions.
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04 THE SUPERVISOR WARNING! A truck operating in an area where there is a risk of fire, explosion, or in any other high risk area, must be specially equipped for the purpose. Trucks are not normally equipped for these situations.
TRUCK DRIVER 05 Authorization to drive a truck • Australia: Users shall follow the requirements of AS 2359.2. The employer must ensure that the employee has the required • North America: Users shall follow the requirements of the training and knows what must be observed in order to avoid applicable part of ANSI/ITSDF B56.
06 MACHINE PLATES Explanation of machine plates Location of machine plates The Machine plate contains important information. Read it The machine plate is located behind the driving seat. The load carefully! The permitted load shall not be exceeded. limit plate is located on the overhead guard pillar, in front of the driver.
DESCRIPTION OF THE TRUCK 07 UFW Tergo four-way truck Driver environment Functions Controls UFW Tergo (U** Tergo) is an electric four-way truck, specially adapted for handling long and bulky loads and different types of Figure 3. Foot control load carriers. Driving in four directions is possible due to load wheel rotation.
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07 DESCRIPTION OF THE TRUCK Table 1. Switches G. Camera 1/2 (option) Floor lift/lower Options Work lighting (option) Camera on/off (option) Rear view camera system for sideways driving (option) UFW four-way trucks can be equipped with a rear view camera system which gives the driver a better reverse view during sideways driving.
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DESCRIPTION OF THE TRUCK 07 Hydraulic functions Table 2. Control functions To use any of the hydraulic functions, the driver must be sitting Four-way trucks in the driver's seat, so that the seat switch (safety function) is activated. Control Functionality Movements Ergologic joystick Forks lower/raise...
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07 DESCRIPTION OF THE TRUCK Four-way trucks Table 3. Lever-operated four-way truck Control Functionality Movements Lever Away from the truck Towards the truck driver driver Simultaneous Press the button and Lower Lift turning of the drive move control D away Mast out Mast in and steered from/...
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DESCRIPTION OF THE TRUCK 07 NOTE! If the truck is equipped with the wider fork spreading unit, it projects 213 mm out on each side of the truck. Settings Instrument panel and arm rest In order to increase comfort and driver ergonomics, there are a number of adjustment options.
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07 DESCRIPTION OF THE TRUCK When the backrest is in its tilt position (i.e. the lever is horizontal), its tilt can be adjusted to one of three positions using lever C. Tilt the backrest back, pull out the lever and place it in the desired position.
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DESCRIPTION OF THE TRUCK 07 Figure 9. Adjusting the head rest Figure 10. Mini steering wheel, armrest adjustment The neck support B can be adjusted up or down in steps. To remove the neck support from the seat backrest, press in latch A.
07 DESCRIPTION OF THE TRUCK Midi-wheel (option) depending on the height of the forks above the floor, the position of the reach carriage, and in cases where the drive The midi-wheel can be adjusted in three directions, height, wheel is turned more than 3 degrees in either direction. If the horizontally and turning.
DESCRIPTION OF THE TRUCK 07 situation, the S3-1 system immediately takes action by giving NOTE! new instructions to the control system for operation of the mast. The result of the weight measurement during lifting can be affected if the oil temperature of the truck is •...
07 DESCRIPTION OF THE TRUCK Premises and requirements Dynamic Curve Control (DCC) A measurement can only be taken when the forks have been Dynamic Curve Control (DCC) is an electronic auxiliary system lowered and stopped between the transport position switch and which reduces the risk of tipping accidents.
DESCRIPTION OF THE TRUCK 07 Fork Safe Zone System (option) The system is active when the forks are in transport mode (under 0.5 m). When the system prevents a fork movement, the symbol flashes on the truck display. To override the system and continue a fork movement, depress button 5 on the truck keypad.
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07 DESCRIPTION OF THE TRUCK Figure 12. Cabin Figure 13. Cover Cover The roof hatch can be opened from both the inside and the CAUTION! outside and is used as an emergency exit. The hatch can be The roof hatch may only be used as an emergency opened slightly and then completely unhooked.
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DESCRIPTION OF THE TRUCK 07 windows. The distribution of air outside and inside the cab can be adjusted by means of a control on the heater. Figure 15. Heating element, flap Beneath the heating element there is a flap which directs air to the floor level in the cab.
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07 DESCRIPTION OF THE TRUCK There is a panel directly in front of the driver with a display and Move the control down to close the flap. The air control buttons that control the heater. then circulates inside the cab. Move the control up to open the flap.
DESCRIPTION OF THE TRUCK 07 Other functions WARNING! The cab heater's casing gets hot during operation. To avoid burns, do not touch the heater. WARNING! If there is ice or misting up on the cab that reduces visibility, the truck must not be driven. Figure 17.
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07 DESCRIPTION OF THE TRUCK Options Descriptions NOTE! The user instructions for possible additional Camera system Colour system with a fork-mounted equipment items are supplied together with the camera and a 7 inch LCD screen equipment. Radio/CD/MP3 Information concerning options that are connected to the truck 12 V DC outlet Power supply, e.g.
BATTERY 08 Specifications WARNING! Always use protective glasses. Acid can cause Specifications serious burn injuries. Table 4. Battery as standard WARNING! Truck model Remaining battery Weight kg Explosive gas is generated during charging! Smoking capacity (V/Ah) or a naked flame can cause an explosion! UFW 200 48 / 465-930 712-1567...
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CAUTION! Do not pull out the battery plug by pulling on its cables. Figure 19. Battery charging (STILL-unique battery plug) Check that the battery electrolyte level is not above or below the cell plates. The battery can be damaged if the cell plates are dry Figure 18.
BATTERY 08 Disconnect the battery charger connector. CAUTION! Top up to the correct level with distilled water. Ensure that the battery wiring does not get trapped or incorrectly routed while inserting the battery. Dry off the battery to prevent leakage current and self discharging.
08 BATTERY Battery on motor-powered rollers WARNING! Position the truck. take care while driving the battery out or in, as there is a risk of pinching. Extend the mast completely and then switch off the truck. Pull out the 48 V battery plug. Battery servicing Release the battery locks on both sides.
TRUCK COMPUTER ATC 09 General Symbols and characters on the display The truck is fitted with a truck computer. In these cases, information is transmitted to the truck via the keyboard and is displayed on a panel. The truck is not equipped with a manual start key (option) as standard, but is started and stopped by pressing the ON/OFF buttons on the keyboard.
09 TRUCK COMPUTER ATC Keyboard Figure 21. Keyboard The keyboard consists of 13 keys with the following functions: Figure 20. Symbols and characters on the display Auxiliary system S3 Tilt centred (option) inactivated Side shift centred (option) Numeric key 0 and selection of level for picking out pallets Drive stop ...
TRUCK COMPUTER ATC 09 • When the last yellow segment extinguishes, (~25%), the text is shown Numeric key 7 and weight indication Low battery Numeric key 8, stepping up in the menu and restarting after a in the display. As an option, an audible signal can also be lift stop added.
09 TRUCK COMPUTER ATC • CAUTION! Left foot switch The error code is retained in the case of serious The driver has the left foot switch activated during start up. faults. If this occurs, contact authorised service • Battery lock personnel. The truck's battery is not correctly secured (option).
TRUCK COMPUTER ATC 09 Driver parameters Service menu 0: Exit NOTE! All operator parameters that concern the lift hydraulics return to the factory settings if any of the Press to step down through the menu. Press in the system's weight indication, S3-2 speed or S3-2 submenu 1 “Choose Language”.
09 TRUCK COMPUTER ATC User id: NOTE! It is only possible to set the parameters for the normal direction. The parameters for sideways driving cannot be altered. Enter your unique start code. When all the parameters have been gone through, press Code : to exit the Service menu.
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TRUCK COMPUTER ATC 09 Placement 001:0261 (0202) A. Selected level. B. The selected level's height (as When the control is in the neutral position and the level is standard 10 cm higher than when reached the display shows “Level reached!!”. withdrawal is selected) 001:0261 (0260) C.
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09 TRUCK COMPUTER ATC The display shows “Lower to floor!” 001:0261 (0202) Level CANCELLED The driver presses “I” for depositing. The display shows "Syst. not reset" for one second and then returns to "Lower to floor!". Ex.1: Retrieving a load The driver shall collect a load on level 3. Sys.
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TRUCK COMPUTER ATC 09 movement to less than approx. 80% of the maximum speed, the 005:0360 (0359) forks will automatically stop rising at the next pre-programmed Level reached!! level. When the truck reaches this state there are two short audible signals and the symbol flashes on the display.
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09 TRUCK COMPUTER ATC Use the function accumulated total weight, Weight The forks are centred to the middle when button is held indication pressed in. The operator can add the current load weight to an accumulated total of the load weight and view the total result in The symbol is shown on the display when the forks are in their middle position.
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TRUCK COMPUTER ATC 09 Shows the accumulated total weight, Weight indication weight by subtracting the weight of the container from the total weight. The operator can see the accumulated load weight total by To activate tare weight: pressing and holding down the button for longer than 1.5 seconds during normal operation.
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09 TRUCK COMPUTER ATC Service alarm Tare is reset on logging out or after each restart of the system, e.g. when the emergency stop button has been pressed. When the truck is in need of servicing a spanner symbol appears on the display and an audible signal sounds. The Other display messages service interval can be set between 1 and 10,000 hours.
DRIVING INSTRUCTIONS 10 Starting the truck The text "Enter code" will now be displayed. Enter your user password. The truck is delivered with the password Connect the battery plug. Check that the emergency stop “2222”. This should then be changed so that each driver function is disengaged.
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10 DRIVING INSTRUCTIONS When you place your left foot on the left foot pedal, select The truck is started when the direction of travel has been a driving direction and press the speed controller, the selected and the accelerator pedal (furthest to the right) parking brake is released.
DRIVING INSTRUCTIONS 10 The truck is equipped with a system which feeds power CAUTION! back to the battery when the motor brake is activated in The truck may be equipped with 360 degree the case of lower pressure on the acceleration pedal. You steering, which means that when the steering should work with minor movements on the acceleration wheel is turned the direction of travel may be...
10 DRIVING INSTRUCTIONS Trucks equipped with speed reduction again. If no keyboard key is pressed within 30 seconds, the display will shut down again. When a truck equipped with speed reduction lifts above a certain height (the default setting being 500 mm), its speed is NOTE! reduced to the crawl speed.
GENERAL LOADING AND UNLOADING INFORMATION 11 Responsibility for the load CAUTION! Do not drive with the load lifted. The driver of the truck is responsible for the load that is being carried during transport. There must not be any risk of the load tipping or sliding off during transport.
12 STACKING General When fetching a load from a stack, carry out these movements in reverse order. Approach the stack with the load in the lowered position. Trucks with mast tilt Lift the load sufficiently high that it clears the stack or shelf and then drive towards the stack.
MAINTENANCE OF THE TRUCK 13 Daily maintenance (before each shift) Check that the securing arrangements for the finger protection are intact and that there is a good view through Responsibility: Fork lift truck driver the protection. CAUTION! WARNING! Naked flames or smoking are prohibited when There is the danger of personal injury if the truck working on or near to the battery.
13 MAINTENANCE OF THE TRUCK Battery changing contact with electrical components is not covered by the factory guarantee. Check the battery voltage on the battery indicator. Charge the battery as necessary. The battery is charged in Manually check that the following bolts are not loose: accordance with the recommendation from the battery WARNING! manufacturer.
MAINTENANCE OF THE TRUCK 13 Preventive maintenance NOTE! Preventive maintenance must be carried out by specially appointed and trained personnel with a good working knowledge of the function and maintenance of the truck. To obtain the best results from your truck investment, we advise you to contact your service organisation and take out a service agreement for preventive maintenance.
14 SERVICING AND MAINTENANCE Service personnel • When dismantling parts of the hydraulic system the system must not be pressurised, e.g. the pump motor is shut off NOTE! and the forks are down. Servicing and maintenance must be carried out by •...
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SERVICING AND MAINTENANCE 14 Lubrication chart UFW • The gearbox oil should be changed every three years or every 3,000 hours of operation. • Hoses should be replaced after 5 years, since they are perishable.
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14 SERVICING AND MAINTENANCE Cab lubrication schematic diagram (option) The door hinge, cover and heater, along with the lock, must be lubricated at every routine service. Figure 24. Lubrication chart, UFW fork carriage Lubrication points Gear shaft Slide surfaces for fork carriage and forks Thrust rollers Figure 25.
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SERVICING AND MAINTENANCE 14 Symbol key lubrication chart Symbol Explanation Symbol Explanation Pos Lubrication points Hydraulic oil Hydraulic oil, oil filter Lift chains, all lift chains in the mast, height measurement chain and air filter, change Wheel tracks, springing Gearbox oil Gearbox oil, change Slide rails Grease...
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14 SERVICING AND MAINTENANCE Designation Table 6. Options Designation 300 Power fuse TMC 300 Power fuse PMC F13* 80 Main supply cold storage cab 10 B+ 3; Hydraulic valves; fans; DC/DC 5 Radio and internal cab lighting converter; electrically adjustable floor; camera 35 Power feed, battery changing system 10 B+ 4;...
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SERVICING AND MAINTENANCE 14 Chassis NOTE! In the case of demanding and/or dusty environments Description Service with humid or corrosive air, it is advisable to perform Lubrication maintenance more often. Reduce the periods between maintenance by one half (or one third). Driver seat Caster wheel/steered wheel First service (200 hours)
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14 SERVICING AND MAINTENANCE Mast system Hydraulic system Description Service Description Service Lift chains Couplings Forks, fork carriage Pump motor Bearings/Rollers Hydraulic pump Lubrication On/off valve proportional valve Mast profile Lift cylinders Reach carriage Description Service Fork locking Cylinders Steering Electrical system Description Service Description...
SERVICING AND MAINTENANCE 14 Electrical system Brake-System Description Service Description Service Fuses Brake function Battery plug Parking brake Video camera Brake disc Cooling fan Consumable materials Truck computer Only consumable materials (oils, grease, lubricants, etc.) that have been approved by UniCarriers should be used for Emergency stop engineering and maintaining trucks.
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14 SERVICING AND MAINTENANCE code is shown on the diver's display, this must be reported to Truck condition Possible cause Procedure your service organisation. The truck will not The truck is not ready Carry out all the actions lift the load for use under the heading "The Truck condition Possible cause...
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SERVICING AND MAINTENANCE 14 Slacken the screw (item 1), refer to Panels page 63 on the instrument panel (F). The screw does not need to be removed completely. Lift up the dashboard and secure it with the support strut. Remove the footplate (if the footplate is adjustable, it should be in its lowest position).
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14 SERVICING AND MAINTENANCE Dismantling and assembling wheels Pull or roll out the battery (depending on the type of battery). Safety regulations concerning wheel change Using pliers, squeeze the clips (item 2, 6 off) and push WARNING! them out. For safety reasons, UniCarriers recommends that wheel changing is only carried out by authorised Grasp the panel (C), refer to Panels page 63), lift it up service personnel.
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SERVICING AND MAINTENANCE 14 Fitting steered wheels (UFW) WARNING! Roll the wheel unit into the wheel fork and secure it. Ensure that the truck is unable to move while work is in progress. Connect the service wiring to release the brake. Release the battery plug Connect the battery plug to supply power to the truck.
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14 SERVICING AND MAINTENANCE Dismantling and assembling the drive wheel Tighten the screws (eight pcs) on the top of the straddle leg. The drive wheel must be replaced if its diameter is less than 320 mm. Fit the wiring for the electric brake. Undo the bolts and open the rear cover.
SAFETY REGULATIONS 15 The authority and obligations of the truck WARNING! driver It is not permitted to climb on to the truck. The driver has the authority and the responsibility to refuse to Driving the truck drive the truck in the following cases: •...
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15 SAFETY REGULATIONS Mast reach Reduced vision Slow down when approaching crossings and other places WARNING! where the line of vision is reduced. Avoid driving in the same Before using the mast reach function, ensure that direction as the forks if the load in front of you obstructs your neither yourself nor anyone else is at risk of being sight.
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SAFETY REGULATIONS 15 Transports When transporting loads, the truck should, if possible, be driven in the opposite direction to the direction the forks are pointing. This ensures that the driver has a better view if the load is high, and makes the truck easier to manoeuvre. When driving in the direction of the forks the truck is sensitive to sharp turns.
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15 SAFETY REGULATIONS Risk zones Do not drive near the edges of loading bays, gangways, etc. where there is a risk of the truck going over an edge. Be careful when operating close to colour marked risk zones. Overturning Keep hold of the steering wheel or a handle if the truck overturns.
SAFETY REGULATIONS 15 Awareness! Always be aware of personnel in the neighbourhood when operating the truck. Speed (UFW) Figure 29. Sideways driving on slopes WARNING! Take extra care when driving the truck sideways on an incline, as this can affect braking properties and steering.
15 SAFETY REGULATIONS Driving Conditions Maximum Direction speed Reach function in home position 6 km/h Reach function not in home position 4 km/h Reach function in home position 9.6 km/h Reach function not in home position 4 km/h Other limitations apply in all driving directions: •...
SAFETY REGULATIONS 15 Figure 31. Transportation security, mast, UFW Figure 32. Transportation security, fork carriage, UFW Moving the forks (UFW) See control E in table Control functions page 15. Manual fork spread, option, UFW If the forks are in a position where the locking pin is in a hole in the boom, the pin must be lifted using the eye so that the fork can be moved.
15 SAFETY REGULATIONS • If the working conditions are of a permanent nature, an CAUTION! agreement must be drawn up with the supervisory The forks should not be moved to positions that are authority and any other party concerned. different distances from the centre. •...
SAFETY REGULATIONS 15 If the truck is left unused for a prolonged period without it being recharged, e.g. between two shifts, the battery plug must be disconnected. CAUTION! Do not block access to fire fighting equipment or fire doors by parking the truck or placing goods in front of them.
15 SAFETY REGULATIONS When lifting the truck CAUTION! If the whole truck is to be lifted, lift points B must be used. Lift points A1 and A2 are used for stabilisation or when only the mast frame is to be lifted. Assembling and putting into service WARNING! Assembling, dismantling and putting the truck into...
SAFETY REGULATIONS 15 Actions before storage Carry out a weekly inspection in accordance with Weekly inspection page 52. Clean the truck. Clean and charge the battery in accordance with the WARNING! battery manufacturer's maintenance instructions. Putting the truck into service may only be carried out by authorised service personnel.
The operation and characteristics of the truck can be general, you must await the decision of the supervisor. negatively affected by starting in temperatures below zero. Bear in mind that the truck may still be frozen, Noise/Sound levels even if the ambient temperature has risen above Noise levels at the driving position are lower than 70 dB(A) zero.
Pull the seat to its furthest forward truck, STILL or its authorised representative must be contacted. Do not stand between position before Before the truck is assembled, it must have been approved by...
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15 SAFETY REGULATIONS Locations of safety and warning signs If the truck is equipped with a mini steering wheel. ...
DIMENSIONS 16 Dimensions NOTE! The following dimensional information applies to trucks equipped with the smallest possible battery and a fork length of 1150 mm. Figure 36. Dimensions UFW Measurements UFW200 UFW250 4350 - 8500 4500 - 9700 H+700 H+700...
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16 DIMENSIONS Cab dimensions (option) Measurements UFW200 UFW250 4300-8450 4450-9650 H/3+700 H/3+850 2215 2215 s x e 45 x 125 45 x 125 2473 2555 1323 1405 1942 2102 Figure 37. Cab dimensions 1772 1932 Table 7. Cab and dimensions in mm 1744/1498 1744/1498 Measurements...
WEIGHT 17 Weight NOTE! The following weights apply to standard trucks, including the smallest possible battery. If the truck has extra equipment fitted, there may be deviations from the table. Refer to the machine plate for the weight information for a particular truck. Table 8.
18 ORDERING HANDBOOKS AND MANUALS Ordering a Spare Parts Catalogue STILL does not automatically send out spare parts catalogues with delivery of your truck. It is possible to order a Master Manual via your local distributor, for a fee. Delivery time is...
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UniCarriers Manufacturing Sweden AB SE-435 82 Mölnlycke Phone +46 (0)31 98 40 00 info@atlet.se www.atlet.com...
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