STIER 904512 Platform Stacker

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FOREWORD
This original operating manual provides all the necessary knowledge for safe handling and maintaining the full functionality of the product described. Consequently, all instructions must be read carefully before using the product and then followed. This is the only way to avoid accidents and guarantee the warranty.
The manufacturer assumes no liability for any damage caused by improper or incorrect use. Keep the safety and operating instructions carefully for future use. However, the instructions in this manual do not replace standards or additional (even legal) regulations issued for safety reasons.

ABOUT THIS GUIDE

READ USER MANUAL:
Carefully read the user manual before setting up, operating or making any interventions to the product.

GENERAL SAFETY INSTRUCTIONS

Read this instruction manual carefully before operation in order to familiarize yourself with the  use to the full extent. Improper operation can cause a hazard. Only the complete observance of all safety instructions and information enables proper use.

DISPOSAL
This old equipment can be handed in to a disposal point, where it is disposed of in accordance with the national Circular Economy and Waste Act. The device and its accessories are made of a wide variety of materials. Defective components must be treated as hazardous waste and disposed of in accordance with legal requirements

Dispose of properly
Before disposing of the product, consider ways to avoid waste (e.g., disposing of functional products or repairing).
Remove all equipment from the product (oil, fuel). Remove batteries / rechargeable batteries and lamps / lamps from the product before disposal, if this is possible non-destructively Private end customers can hand in the product for disposal at a public collection or take-back point in their area. Addresses of suitable collection points can be obtained from the city or local administration. Commercial end customers can hand in the product for disposal at one of the following bodies: Manufacturer.

RESERVATION OF RIGHTS
STIER Industrial GmbH is not liable for the loss of data on sent devices. All indications known as trademarks or service marks are highlighted accordingly. The use of this information should not affect the validity or reputation of the trademarks or service marks. STIER Industrial GmbH reserves the right to make changes, deletions or additions to the information or data provided if necessary. Technical data, specifications and appearance are subject to change without notice and may differ in the representations from the actual product.
Copyright 2024 STIER Industrial GmbH. STIER and the STIER logo are registered trademarks of STIER Industrial GmbH.

ONLINE MANUAL
By scanning the following QR code, you will get to the digital version of the operating manual. Please enter the manufacturer number  (904207) in the search field.

Safety instructions and markings
Safety instructions and important explanations are marked by the following pictograms:

DANGER
Indicates indications that must be observed precisely in order to rule out a danger to life and limb lof persons.

CAUTION
Marks instructions that must be strictly adhered to in order to rule out injury to persons.

ATTENTION
Marks instructions that must be strictly adhered to in order to prevent material damage and/or destruction.
Identifies technical or material necessities that require special attention.

Foreword
Before using the hand-operated forklift, read this ORIGINAL OWNER’s MANUAL carefully and make sure you fully understand how to use the electric forklift. Improper operation can lead to potential hazards. This manual describes the use of the various hand-operated forklifts. During operation and maintenance, make sure that the manual applies to your type.
Keep this manual for future reference. If this or other information and warning signs are damaged or lost, please contact your dealer for a replacement.

This electric forklift meets the requirements of

• EN ISO 3691-5 (Industrial trucks – Safety requirements and verification – Part 5: Pedestrian-operated industrial trucks),
• EN 12895 (Industrial trucks – Electromagnetic compatibility),
• EN 12053 (Safety of industrial trucks – Test methods for the measurement of noise emissions),
• EN 1175 (Safety of industrial trucks – Electrical requirements), provided that the material handling equipment is used in accordance with the purpose described.

The noise level for this machine is 70 dB (A) according to EN 12053.

ATTENTION

• Environmentally hazardous waste, such as batteries, oil and electronics, leads to negative effects on health or the environment if not handled properly.
• The waste containers must be pre-sorted and disposed of, treated or recycled in solid waste bins separated by material in accordance with the regional or national regulations of the country of use. In order to avoid pollutant pollution, indiscriminate throwing away of waste is prohibited.
• To avoid leakage when using the products, materials that can be absorbed by the operator (wood residues or a dry duster) must be kept ready in order to absorb leaking oil in time. To avoid further environmental pollution, the absorbable materials must be disposed of in accordance with the regulations.
• Our products are subject to continuous development. This manual is for the sole purpose of operating and maintaining the hand-operated forklift. Therefore, please understand that no specific characteristics of the products are guaranteed for every specific application that is not described in this manual. We reserve the right to make changes and no claims can be made from the information and illustrations in this manual.

HINT
Check both the type designation on the last page of this document and on the nameplate. Keep the instruction manual for future reference.

Intended use

• The hand-operated forklift may only be used as intended as described and described in this operating manual. The industrial trucks described in this manual are self-propelled, pedestrian-guided hand forklifts with an electric lifting function. These industrial trucks are designed for lifting, lowering and transporting palletized loads. Incorrect use may result in injury or damage to equipment.
• The operator must ensure that the correct use is ensured. He must ensure that this industrial truck is only used by trained and authorised personnel. The industrial truck must be used on firm, smooth, appropriately prepared, level and suitable ground.
• The truck is intended for indoor use in ambient temperatures between +5°C and +40°C, as well as for intensive operation without driving over fixed obstacles or potholes. Operation on ramps is not permitted. During operation, the load must be placed approximately on the vertical longitudinal center plane of the industrial truck. Lifting or riding with people is prohibited. Use on lifting platforms or loading ramps is prohibited. The load capacity is noted on the load capacity diagram (load centre diagram) and on the nameplate. The operator must take the warnings and safety instructions into account. The lighting during operation must be at least 50 lux.

Changes

• No modifications or modifications may be made to this truck without the prior written permission of the original manufacturer of the machine, its authorized representative or their successors, which could affect the load capacity, stability or safety requirements of the truck, for example. This includes changes that affect things like brakes, steering, and visibility, as well as the attachment of removable attachments.
• If the modification or conversion is approved by the manufacturer or his successor, he must also make and approve the corresponding changes to the load-bearing capacity sign (load centre diagram), stickers, signs and operating and maintenance manuals. Failure to follow these instructions will void the warranty.

Product

Overview of the main components

1. Fork carriage
2. Baseplate
3. Stirrup
4. Cylinder components
5. Foot pedal
6. Swivel castor
7. Shaft

Technical description

Main data

Type sheet for industrial trucks according to VDI 2198
Mark	1.2	Type designation of the manufacturer		904512
	1.3	Drive		Manual
	1.4	Service		Pedestrian operation
	1.5	Load capacity / nominal load	Q (t)	0,4
	1.6	Load center distance	C (mm)	325
	1.8	Load spacing, center drive axle to forks	x (mm)	488
	1.9	Wheelbase	Y (mm)	809
Weight	2.1	Dead load	medical history	91
	2.2	Axle load with front/rear load	medical history	140/325
	2.3	Axle load without load front/rear	medical history	66/34
Wheels, chassis	3.1	Tyres		Nylon/PU
	3.2	Front Tire Size	Æ x w (mm)	Æ 128 x 40
	3.3	Rear tyre size	Æ x w (mm)	Æ 75 x 40
	3.4	Additional wheels (dimensions)	Æ x w (mm)	Æ 128 x 40
	3.5	Number of wheels, number of front/rear (x = driven)		2/2
	3.6	Front track gauge	B10 (mm)	480
	3.7	Rear track	B11 (mm)	415
Basic dimensions	4.2	Height of mast retracted	H1 (mm)	1725
	4.4	Lifting	H3 (mm)	1415
	4.5	Height of mast extended	H4 (mm)	1565
	4.15	Height, lowered t	H13 (mm)	85
	4.19	Overall length	L1 (mm)	1040
	4.20	Length incl. fork back	L2 (mm)	391
	4.21	Width	B1 (mm)	600
	4.22	Fork Dimensions	S/L (mm)	50/650
	4.25	Width over arms	B5 (mm)	576
	4.32	Ground clearance center wheelbase	m2 (mm)	28
	4.33	Aisle width for pallet 650 x 700 transverse	Branch (mm)	1500
	4.34	Aisle width for pallet 650 x 700 transverse	Branch (mm)	1500
	4.35	Turning radius	Wa (mm)	1020
Performan ce data	5.2	Lifting speed with/without load	M/s	0,026
	5.3	Lowering speed with/without load	M/s	0,1/0,05
	5.11	Parking brake		Manual

Nameplate

1. Designation, type
2. Serial number
3. Nominal Capacity
4. Supply voltage in V
5. Net mass (own weight) in kg
6. Name and address of the manufacturer
7. Minimum/Maximum Battery Weight
8. Rated power in kW
9. Load center distance
10.  Date
    
11. Option

Description of safety devices and warnings

(Europe and other countries, except USA)

ATTENTION

• F. CE marking
• G. Load Capacity Shield
• H. Warning sign: Do not place under the fork/do not stand on the fork
  I. Label: Residual Capacity/Lifting Capacity
• J. Sticker: Filling Point

Replace the stickers and signs if they are damaged or missing.

Warnings, residual risk and safety instructions

DANGER

• Do not drive outside the stacking operation with the load lifted higher than the lifting point.
• Do not place upper or lower limbs under or in the lifting device.
• Do not allow anyone other than the operator to be in front of or behind the truck when it is moving or lifting or lowering.
• Do not overload the industrial truck.
• Do not put your foot in front of the wheels or castors, as injuries could result.
• Do not lift people. People could fall and sustain serious injuries.
• Do not push or pull loads.
• Do not use this material handling equipment on ramps.
• Do not load the truck from the side or at the end. The load must be evenly distributed on the table.
• Do not use the truck with unstable and asymmetrical loads.
• Do not use the material handling equipment without prior written permission from the manufacturer.
• Lifted loads could become unstable in windy conditions. Even if wind does not lift the load, this can affect stability.

Pay attention to differences in altitude during the ride. Load could fall down or the industrial truck could become uncontrollable. Always keep an eye on the condition of the load. Stop operating the truck if the load becomes unstable. Brake the truck if the load shifts or threatens to slide off the truck. Follow the instructions in Chapter 8 if the truck is malfunctioning. Carry out the maintenance work according to the periodic inspection. This industrial truck is not waterproof. Use the material handling equipment in dry conditions. Prolonged continuous operation may cause damage to the Powerpack. Stop operation if the hydraulic oil temperature is too high.

ATTENTION

• The operator must wear safety shoes while operating the truck.
• The industrial truck is intended for indoor use at ambient temperatures between +5°C and +40°C.
• The lighting during operation must be at least 50 lux.
• The use of the industrial truck on ramps is prohibited.

Commissioning, transport, decommissioning

Commissioning
After receiving the new industrial truck or when recommissioning, carry out the following steps before the (first) commissioning:
Check that all parts are included and have not been damaged.
Carry out the work as part of your daily inspections and functional tests.

Type	904512
Commissioning weight [kg]	91
Lifting height [mm]	1415

Lifting/Transportation

Raise
Use a designated crane system and dedicated hoist. Do not stand under the swinging load. Do not go into the danger area during the lifting process.
Park the vehicle securely and lash the vehicle to the points shown in the figure.
Carefully lift the vehicle to the designated place and set it down safely before removing the hoist.

Transport

Always secure the vehicle securely when transporting it on a truck.
Lower the table and park the forklift safely.
Attach the truck as shown in the illustration by attaching designated lashing straps and attaching the ends of each strap to the transport vehicle.

Decommissioning
Lubricate all lubrication points listed in this manual (periodic inspection) and, if necessary, protect the material handling equipment against corrosion and dust. Jack up the forklift safely so that there is no flattening after storage.

For final decommissioning, take the truck to a designated recycling company. The recycling of oil must be carried out in accordance with national legislation and environmental protection regulations.

Daily inspection

This chapter describes the tests that must be carried out before each vehicle is put into service.
The daily inspection is an effective way to find faults or fault functions on the vehicle. Check the forklift at the following points before operating it.

ATTENTION
Remove the load from the truck and lower the forks.
Do not use the industrial truck if there is a fault or defect.

• Check for scratches, deformations or cracks.
• Check for oil leakage from the cylinder.
• Check the vertical creep of the truck.
• Check the chain and rollers for corrosion.
• Check the smooth movement of the wheels.
• Check the lowering and lifting function by pressing the foot pedal.
• Check all nuts and bolts for tightness.
• Perform a visual inspection for broken hoses or broken electrical wires.
• Check if the seat belt is being used.

Operating instructions

HINT
Please follow the safety instructions (Chapter 3) before using the vehicle. Before putting the vehicle into operation, make sure that there are No obstructions to the view from the load or other equipment!
Make sure the cargo is palletized, stable, and the daily inspection is carried out.

CAUTION
Do not park the forklift on sloping surfaces!
Always lower the platform completely and move the truck to a safe area.

Residual Load Capacity Diagram
The residual capacity diagram shows the maximum load capacity Q [kgl for a given load center c [mm] and the corresponding lifting height
H [mm] for the truck with horizontal loading. The white markings on the mast indicate whether the specific lifting limit has been reached.
For example, if the load center distance c is 350 mm and the maximum lifting height H is 1200 mm, the maximum load capacity Q is 400 kg.

Load center distance
Lifting height H (mm)	Load capacity Q (kg)
	A	B	C
1200	400	300	–
1500	400	250
The forklift may only be moved with a lifting height of less than 300 mm.

Lifting/lowering process

CAUTION

• Do not overload the vehicle! The maximum load capacity is 400 kg.
• Lift only loads according to the residual load capacity diagram.
• Avoid overloading and try to operate the truck within the rated load.
• The load should be distributed over at least 80 percent of the platform area. It is prohibited to place a load on both sides or on the leading edge of the platform. If the forks of the forklift are used to transport and stack pallets, the plate on the forks must be dismantled.
• Press the foot pedal until the desired lifting height is reached.
• Turn the drawbar counterclockwise to lower the fork.

Brake
Note: If the forklift is not moving, please brake to avoid accidents.
The brake is mounted on the left side of the swivel castor.

• Press the brake pedal to brake.
• Lift the brake pedal to release the brake.

Driving/Steering
DO NOT RIDE ON INCLINES. All driving and steering operations are controlled by the operator by manually operating the drawbar.

Dysfunction
In case of malfunction, please stop the industrial truck and park the industrial truck in a safe area if possible. Inform your supervisor
immediately and/or call the service department. If necessary, tow the truck out of the operating area using the towing equipment or hoist
provided for this purpose.

Behaviour in emergency situations
In emergency situations or in the event of tipping over (or falling), immediately maintain a safe distance.

Regular maintenance

• Maintenance of the industrial truck must be carried out exclusively by qualified and trained personnel.
• Before starting maintenance, the load must be removed and the forks lowered to the lowest position.
• Before starting work, place safety devices (such as lifting jacks, wedges or wooden blocks provided for this purpose) under the industrial truck to protect against accidental lowering, moving or slipping.
• Use genuine approved and approved parts from your dealer.
• Please note that leaking hydraulic oil can lead to malfunctions and accidents.
• The pressure valve may only be adjusted by trained service technicians.
• Check the parts that are pointed out in the maintenance checklist.

If the wheels need to be replaced, please follow the instructions above. The wheels must be round and they should not show any abnormal abrasion. Check the parts that are pointed out in the maintenance checklist.

Maintenance checklist

		Interval (month)
		1	3	6	12
	Hydraulics
1	Checking the hydraulic cylinder and piston for damage, noise and leaks		•
2	Checking the hydraulic connections and the hydraulic hose for damage and leaks		•
3	Checking the hydraulic oil level and topping it up if necessary		•
4	Hydraulic oil replenishment (every 12 months or 1500 operating hours)				•
5	Checking and adjusting the pressure valve (400 kg +0/ +10 %)				•
	Mechanical system
6	Checking the forks for deformations and cracks		•
7	Checking the chassis for deformations and cracks		•
8	Checking all screws for tightness		•
9	Check the lift mast and chain for corrosion, deformation or damage, replace if necessary	•
10	Checking the wheels for deformations and damage, replacing them if necessary		•
11	Checking and lubricating the joints		•
12	Lubricating the grease fittings	•
	Function
25	Testing the steering function
26	Checking the lowering and lifting function	•
	General
28	Checking all stickers and signs for legibility and completeness	•
29	Checking the roller, adjusting the height or replacing it in case of wear		•
30	Perform a test run	•

Lubrication points
Lubricate the marked areas according to the maintenance checklist. Required specification of grease: DIN 51825, standard grease.

1. Wheel bearing
2. 8Main frame of the mast
3. Chain
4. Hydraulic
5. Steering Bearing
6. Transmission

Testing and topping up hydraulic oil
It is recommended to use hydraulic oil in conjunction with the average temperature:

Ambient temperature	40°
Type	No. 32(GB11118-89)
Viscosity	32 cSt
Quantity	1.3 L

Waste materials such as oil, used batteries or other materials must be disposed of and recovered in accordance with national regulations and, if necessary, sent to a recycling company.
The oil level must not drop below the minimum fill level (line mark “Min.”) when lowered.
If necessary, add oil to the filling point.

Troubleshooting

ATTENTION
If the truck malfunctions, follow the instructions listed in Chapter 6.

ERROR	CAUSE	REMOVAL
The forks cannot be raisedto the maximum height.	There is not enough hydraulic oil.	Refill hydraulic oil.
The forks cannot be lifted.	No hydraulic oil.	Refill hydraulic oil.
	Contamination of hydraulic oil.	Change the hydraulic oil.
The forks cannot be lowered.	The large piston rod or cylinder is deformed because the loads tilt to the side or the forklift is overloaded.	Replace the large piston rod or cylinder.
	The forks were in the high position for a long period of time and the piston rod was bare for too long. As a result, rust has formed, which blocks the movement of the piston rod.	Move the forks to the lowest position when not in use and lubricate the piston rod in time.
	The hydraulic pump station relief valve cannot be opened due to wear or damage.	Replace the hydraulic pump station relief valve.
Oil leakage	Seals are subject to natural aging and wear.	Replace the part in question.
	Some parts have cracks.	Replace the part in question.
The forks are lowered by themselves.	Contamination of the hydraulic oil means that the relief valve is not fixed.	Change the hydraulic oil.
	Seals are subject to natural aging and wear.	Replace the part in question.
	The relief valve is damaged.	Replace the part in question

HINT
If the forklift has malfunctions that cannot be corrected in the work area, jack up the forklift and go under the forklift with a load handling device and secure the forklift reliably. Then move the truck out of the aisle.

STIER Industrial GmbH || info@stier.de

Documents / Resources

STIER 904512 Platform Stacker [pdf] Instruction Manual 904512, 904512 Platform Stacker, 904512, Platform Stacker, Stacker

References

• User Manual