Still ECH 12 Original Instructions Manual Download Page 6

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Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrying out regular inspections on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposal of consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damage, faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMC – Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Views

Drive directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the operating handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety devices and warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Operation

Handling of the Lithium-Ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Information on the conformity of lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special lithium-ion safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to do in the event of incorrect use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal protective measures following an incident . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What to do in the event of an accidental spillage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scrapping lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Labels on the lithium-ion batterys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lithium-ion batteries: Long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checks before use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break-in period precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents

5001 801 1505 EN - 12/2019

Summary of Contents for ECH 12

Page 1: ...Electric pallet truck ECH 12 Original instructions 0139 5001 801 1505 EN 12 2019 ...

Page 2: ......

Page 3: ... of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable indus trial trucks for a particular area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Internet address a...

Page 4: ......

Page 5: ...ed use of the trucks 11 Unauthorised use 12 Precautions 12 Description of use 12 Residual risks 13 Residual risks 13 Special risks associated with using the truck and attachments 13 Overview of hazards and countermeasures 14 Danger to employees 16 2 Safety Safety regulations 20 Definition of terms used for responsible persons 21 Operating company 21 Specialist 21 Drivers 21 Basic principles for sa...

Page 6: ...splay 38 Safety devices and warning labels 42 Identification plate 43 4 Operation Handling of the Lithium Ion battery 46 Information on the conformity of lithium ion batteries 46 Special lithium ion safety rules 47 What to do in the event of incorrect use 48 Personal protective measures following an incident 49 What to do in the event of an accidental spillage 50 Transporting a lithium ion battery...

Page 7: ...aning the Forklift 80 Storing the truck for an extended period 80 5 Maintenance General servicing information 82 General 82 Servicing and maintenance personnel training and qualification 82 Inspection and maintenance 84 Maintenance 1000 hours every 6 months 84 Maintenance 2000 hours every 12 months 85 Technical inspection and maintenance data 86 Essential maintenance 89 Replacing the drive wheel 8...

Page 8: ......

Page 9: ...1 Introduction ...

Page 10: ...w the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained Get to know the technology understand it and use it safely these operating instructions pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Ther...

Page 11: ... declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities CE Symbol Introduction 1 Your industrial truck 3 5001 801 1505 EN 12 2019 ...

Page 12: ...ther EC directives if applicable that are valid at the time of placing on the market This is confirmed by the EC declaration of conformity and by the CE label ling on the nameplate The EC declaration of conformity document is delivered with the truck The declaration shown explains the conformity with the re quirements of the EC machinery directive An independent structural change or addition to th...

Page 13: ...must be available to the driver and operator at all times If the operating instructions are lost the oper ator must immediately request a replacement from the manufacturer The operating instructions are included in the spare parts list and can be reordered there as a spare part Personnel responsible for operating and main taining the equipment must be familiar with these operating instructions The...

Page 14: ...ulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid material damage and or destruction NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Introduction 1 Information about documentation 6 5001 801 1505 EN 12 2019 ...

Page 15: ... equipment directive BG Berufsgenossenschaft German insurance company for the com pany and employees BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulati...

Page 16: ...ximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without loose rim parts StVZO Straßenverkehrs Zulass...

Page 17: ...documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man agement company for disposal purposes Technical description This series of electric pallet trucks is used for handling pallets and has a maximum load ca pacity of 1200 kg Design The latest ergonomic and practical design adaptable to all operators a...

Page 18: ... independent travel Jolt free starting and smooth acceleration to maximum speed Simply release or turn the drive direction switch to brake Booster circuit prevents the truck rolling back when starting on a gradient Brake system The electromagnetic brake with dust protec tion function can be used as a safety brake and parking brake Braking is controlled by the drive controller the brake s electroma...

Page 19: ... to the load being transported and must ensure stability The table of characteristics and performance attach ed to this user manual gives you 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 associ ated with this usage will enable him to put in place any neces...

Page 20: ...rom slipping off The truck must be switched off when left unattended When using this truck pay attention to the surroundings and do not become distracted Please pay attention to the moving parts of the truck to prevent your hands from being crushed Description of use Due to the characteristics of the lithium bat tery use the vehicle at an ambient tempera ture of 10 C to 45 C The truck can climb ge...

Page 21: ...safety instructions Residual risks can include Escape of consumables due to leakages or the rupture of lines hoses or containers Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Risk of falling tripping or slipping during movement of the truck especially on wet or icy surfaces or in the event of consumable leaks Risk of...

Page 22: ... defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due to load Resource planning O German Ordinance on Industrial Safety and Health BetrSichV C...

Page 23: ...neer ing Federation VDMA rules O b LPG Note German Social Accident Insurance DGUV regulation D34 the operating in structions and the Ger man Engineering Fed eration VDMA rules O When charging the traction battery Note the German Ordi nance on Industrial Safety and Health BetrSichV the oper ating instructions and the German Engineer ing Federation VDMA rules O Association for Electri cal Electronic...

Page 24: ...ark driveways Keep driveways clear O German Ordinance on Industrial Safety and Health BetrSichV Driveways intersect Announce right of way rule O German Ordinance on Industrial Safety and Health BetrSichV No person detection during depositing and retrieval Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees The operating company must identify and evalu...

Page 25: ...ns of these regulations The overview indicates the main causes of accidents in the event of non compliance If other major opera tional hazards are involved they must also be taken into consideration The working conditions for the trucks are largely similar for many sites The dangers can therefore be summarised in a single over view It is recommended that the information provided by the relevant em...

Page 26: ...Introduction 1 Residual risks 18 5001 801 1505 EN 12 2019 ...

Page 27: ...2 Safety ...

Page 28: ...pallets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of material handling trucks When inst...

Page 29: ...shed the European Economic Area This expertise allows him to assess the condition of industrial trucks in terms of health and safety Drivers Driver rights duties and rules of behav iour The driver must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety hel met industrial goggles and glo...

Page 30: ...When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety 2 Definition of terms used for responsible persons 22 5001 801 1505 EN 12 2019 ...

Page 31: ... is required for any modifica tion that may affect the truck s stability Any constructional modification or transforma tion of your truck is forbidden without prior written permission from the manufacturer Au thorisation from the relevant authority may al so be required SPECIAL CASE if the manufacturer of the truck is no longer in business and its activity is unlikely to be taken over by a success...

Page 32: ...nal accessories Damage faults Any damage or faults observed on the truck or the accessories must be reported immediately to the responsible personnel The truck and accessories must never be used before they are correctly reconditioned as they cannot be guaranteed to be safe for operating or driving The safety mechanisms and switches must never be removed or disabled The predefined setpoint values ...

Page 33: ...e 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 vibra tions during real operation of the truck these vibra tions depend on the conditions of use floor condi tions method of use etc and therefore daily expo sure must be calculated using data from the place of use Safety 2 Basic principles...

Page 34: ...he authorised service centre to perform regular testing on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operating company is responsible for en suring that any defects are remedied without delay Notify your authorised service centre NOTE In addition observe the national regulations for the country of use Insulation testing The insulation of t...

Page 35: ...tage Measurements Nominal volt age UBatt Test values Battery 50 VDC Batt Batt Battery tray 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω 100 VDC 80 volts 4000 Ω Test values for the entire truck Nominal volt age Test voltage Test values for new trucks Minimum values over the duration of the service life 24 volts 50 VDC Min 50 kΩ 24 kΩ 48 volts 100 VDC Min 100 kΩ 48 kΩ 80 volts 100 VDC Min 200 kΩ 80 kΩ Sa...

Page 36: ... Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined ...

Page 37: ...fluid in containers com plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the regulations Dispose of old hydraulic fluid according to reg ulations Disposal of consumables ENVIRONMENT NOTE Materials that have to be disposed of following maintenance repair and cleaning must be systematically collected and ...

Page 38: ...driving The safety mechanisms and switches must never be removed or disabled The predefined setpoint values must not be modified Work on the electric installation e g connect ing a radio additional lights or other accesso ries is permitted only with the approval of the manufacturer Battery connection cables CAUTION Using sockets with NON ORIGINAL battery connec tion cables can be dangerous see pur...

Page 39: ... the electromagnetic in terference conditions to be expected there An EMC test thus firstly measures the electro magnetic interference emitted by the truck and secondly checks it for sufficient resistance to electromagnetic interference with reference to the planned usage location A number of electrical measures are taken to ensure the electromagnetic compatibility of the truck CAUTION The EMC reg...

Page 40: ...Safety 2 EMC Electromagnetic compatibility 32 5001 801 1505 EN 12 2019 ...

Page 41: ...3 Views ...

Page 42: ...Drive directions The drive directions of the truck are forward 1 and reverse 2 Views 3 Drive directions 34 5001 801 1505 EN 12 2019 ...

Page 43: ...Overview of main components Tiller Hydraulics cowling Rollers Front protective panel 1 2 3 4 Battery Emergency stop switch Key 5 6 7 Views 3 Overview of main components 35 5001 801 1505 EN 12 2019 ...

Page 44: ...e Horn switch Lifting switch Battery power display Manual lowering handle 1 2 3 4 Emergency reverse switch Drive switch Operating handle Creep speed switch 5 6 7 8 Views 3 Control handle 36 5001 801 1505 EN 12 2019 ...

Page 45: ...ing tube Mounting base Screw M6x10 Control harness 1 2 3 4 Square tube harness Wire Bracket Ball head wire 5 6 7 8 Connect the square tube harness connector to the control harness Views 3 Installing the operating handle 37 5001 801 1505 EN 12 2019 ...

Page 46: ...se 4 screws to install the square control tube on the mounting base standard tor que Instrument display Normal display state Horn in normal working state Interlock switch status acceleration status flashing Total operating time The display description includes forward backward fork lifting and fork lowering The display changes occasionally from time to time depending on the operation 1 2 3 4 Views...

Page 47: ...Charge percentage display Motor temperature too high Views 3 Instrument display 39 5001 801 1505 EN 12 2019 ...

Page 48: ...Other battery faults Battery CAN signal not connected Views 3 Instrument display 40 5001 801 1505 EN 12 2019 ...

Page 49: ...Controller CAN signal not switched on F X X Error code X refers to a number Views 3 Instrument display 41 5001 801 1505 EN 12 2019 ...

Page 50: ...rbid stampede label Anti pinch label Identification plate label Filler port label 1 2 3 4 Pallet truck model label Instructions label Slinging label Chassis NO 5 6 7 8 Views 3 Safety devices and warning labels 42 5001 801 1505 EN 12 2019 ...

Page 51: ...ble battery weight in kg for electric trucks only 1 2 3 4 5 6 Own mass self weight in kg without battery Manufacturer Refer to technical data listed in this operat ing instructions for more detailed information CE label Rated drive power in kW Battery voltage in V Rated capacity 7 8 9 10 11 12 13 Views 3 Identification plate 43 5001 801 1505 EN 12 2019 ...

Page 52: ...Views 3 Identification plate 44 5001 801 1505 EN 12 2019 ...

Page 53: ...4 Operation ...

Page 54: ...thium ion battery conforms with the provisions of the following EU directive 2004 108 EC in accordance with EN 61000 6 2 2006 and EN 61000 6 3 2007 This declaration of conformity with EC direc tives applies only to battery use that conforms to the recommendations described in the op erating instructions Operation 4 Handling of the Lithium Ion battery 46 5001 801 1505 EN 12 2019 ...

Page 55: ...ints Do not expose the battery unit to humidity or water 95 Install the batteries in a Level 2 pollution zone in accordance with standard EN 60664 1 Batteries must be installed in a room that can be easily ventilated in the event of in correct use The forklift operator must drive the truck carefully to avoid any risk of piercing or damaging the lithium ion batteries DANGER Risk of injury In the ev...

Page 56: ...e the person vomit See a doctor as quickly as possible In the event of a fire If a fire breaks out follow these instructions For a small fire Use class D fire extinguishers or inert gas carbon dioxide powder or foam fire extin guishers Establish a safety perimeter of five metres around the battery Call the emergency services and tell them that it is a lithium ion battery fire After extinguishing t...

Page 57: ... or if it leaks use a gas mask covering the entire face and fitted with ABEK filters or self contained breathing apparatus escape mask type Firefighters must wear self contained breathing apparatus Hand protection Use polypropylene polyethylene rubber or Viton gloves to handle leak ing or broken elements Eye protection Wear safety goggles with side shields or a mask covering the face to handle lea...

Page 58: ...r if there is inhalation or ingestion Wear goggles and protective gloves Precautions for the environment Avoid pollution of wastewater surface water and groundwater Avoid pollution of the soil and atmosphere Use absorbent materials sand earth to absorb exudation Seal battery leakages Put the contaminated absorbent product in a plastic bag and dispose of it as special waste according to the local r...

Page 59: ...nly the lithium battery A class 9 danger label must be affixed to the packaging for transport It is different if the battery is transported on its own or in a truck An example of a label ap pears in this supplement Refer to the latest current regulations before dispatch as the in formation might have changed since this sup plement was written Special documents must be sent with the bat tery Refer ...

Page 60: ... the Class 9 transport label on the bat tery Use packaging that complies with interna tional regulations Use the original packaging if possible Use sturdy packaging capable of bearing the weight of the batteries Store it in a dry place Wedge the battery well in the packaging to prevent it moving during transport Pack batteries individually in plastic bags Package them to prevent any risk of short ...

Page 61: ...Labels on the lithium ion batterys Battery nameplate No impact 1 2 No collision 3 Operation 4 Handling of the Lithium Ion battery 53 5001 801 1505 EN 12 2019 ...

Page 62: ...must not be used for a reasonably long period The operations depend on the length of time it is unused Storage of trucks for a period of less than two months If the truck is not used for a period of up to two months it is necessary to perform certain op erations Clean the truck carefully Check the hydraulic oil level and refill if nec essary Coat any unpainted metal parts with a thin layer of oil ...

Page 63: ...wing during start up traction control and steering brakes service brake and parking brake Operating instructions The pallet truck is designed for use in safe en vironments the ambient temperature must be between 10 C and 45 C and the altitude must not exceed 2000 metres NOTE The floor surface must be dry clean and level For braking and stability reasons the maxi mum permissible gradient over short...

Page 64: ...ing the forks WARNING The working area of the industrial truck must be ade quately lit If it is insufficiently lit working spotlights must be in stalled To ensure that the driver can see properly Checks before use WARNING The truck can only be driven by battery power After the truck has arrived or been transpor ted you must perform the following checks before putting it into use Check whether the ...

Page 65: ... charged promptly when at 20 The specified preventive maintenance must be done thoroughly Avoid sudden braking driving quickly or sharp turns Change oil or lubricant promptly according to the instructions Limit the load weight to 70 80 of the rated load CAUTION When the truck is in the running in stage approx 100 hours of operation the equipment user should check the fastening of the wheel nuts an...

Page 66: ...em Drive system Instructions for driving Insert the magnetic key into the key hole and switch on the power supply Tilt the control handle to the drive position Operation 4 Drive system 58 5001 801 1505 EN 12 2019 ...

Page 67: ... switch can be used to adjust the ve hicle s speed NOTE Releasing the drive switch causes the vehicle to brake Lifting lowering braking and using the horn Lifting Press and hold down the lift button on the control handle 1 The forks will be lifted to the maximum height until they stop by themselves Operation 4 Drive system 59 5001 801 1505 EN 12 2019 ...

Page 68: ... pallet and that its weight does not exceed the rated load capacity of 1200 kg CAUTION Make sure that the forks are completely under the load before the vehicle moves off Creep speed switch Keeping the handle in the vertical position simultaneously press the drive switch 4 and the creep speed switch 5 the truck will reduce its speed to 20 of the maxi mum speed Operation 4 Drive system 60 5001 801 ...

Page 69: ...ke engages when the tiller is positioned in areas 1 and 3 Reverse braking Braking can be accomplished by changing the direction of travel Press the reverse switch in the opposite di rection until the truck comes to a stop then release the drive switch Operation 4 Drive system 61 5001 801 1505 EN 12 2019 ...

Page 70: ...utton 1 The ve hicle will begin to travel in the opposite di rection CAUTION If the safety reverse switch resets slowly this indi cates a fault The cause of the fault must be identified and eliminated The spring can be replaced if neces sary NOTE The safety reverse button 1 can be pressed in various ways such as against the belly Operation 4 Drive system 62 5001 801 1505 EN 12 2019 ...

Page 71: ...ce affects the braking distance of the truck and should be taken into con sidered by the operator Using the truck on a slope NOTE Incorrect use of the truck on slopes is not rec ommended It places particular stress on the traction motor brakes and battery Be particularly careful near slopes Never attempt a slope with a gradient great er than that specified in the truck s data sheet Make sure that ...

Page 72: ...age Never park the truck on a slope Never make a U turn or take shortcuts on a slope On a slope the operator must drive very slowly WARNING Risk of serious injury and or serious damage to equipment Due to limited braking capacity the large drive ver sion must not be driven on a gradient of over 10 when unladen or on a gradient of more than 4 un der full load Small drive version must not be driven ...

Page 73: ...chine comes to a standstill Return the accelerator to the neutral posi tion then release the accelerator control button to apply the parking brake To restart press the accelerator button for the desired direction The truck will move off Operation 4 Drive system 65 5001 801 1505 EN 12 2019 ...

Page 74: ...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 capaci ty changes When forks are changed a new residual capacity plate must be affixed If a truck is supplied without forks the residual ca pacity plate for standard forks is affixed See chapter Technical Datasheet DANGER Wear protective footwear A...

Page 75: ... to the side or in front of the load being handled Loads should be laid out as follows Line up loads with a small space between each one and its neighbour to avoid any fouling CAUTION Only transport loads that have been positioned and secured in accordance with regulations Take appropriate protective measures if the load is at risk of tipping over or falling during transport Approach the load care...

Page 76: ...perform a U turn Reverse travel B is to be used solely for unloading Since visibility is reduced when travelling in this direction drive only at very slow speed Unloading Carefully drive the truck to the desired loca tion Carefully drive the truck to the unloading area Lower the load until the fork arms are free from the pallet Back the truck away in a straight line Raise the forks to mid height C...

Page 77: ...s Never leave the truck with the load raised CAUTION The forks must be fully lowered CAUTION Always park the truck on a level surface that does not interfere with traffic CAUTION If the vehicle is to be parked for an extended period remove the battery and refer to the servicing and maintenance instructions Operation 4 Parking the vehicle safely 69 5001 801 1505 EN 12 2019 ...

Page 78: ...attery charger NOTE The charging stand can be secured to the wall using expansion screws 1 Battery precautions Avoid the battery becoming corroded by water or corrosive liquid Operation 4 Battery use 70 5001 801 1505 EN 12 2019 ...

Page 79: ...es and flammable or explosive materials Do not place the battery on top of conduc tive objects WARNING If this happens the battery may leak emit heat or smoke which may lead to a serious fire or explosion Operation 4 Battery use 71 5001 801 1505 EN 12 2019 ...

Page 80: ... environment temperature should be 0 C to 40 C WARNING If the battery fails please contact an authorised deal er to have it repaired Do not disassemble the battery Operation 4 Battery use 72 5001 801 1505 EN 12 2019 ...

Page 81: ...Battery charger Battery Charging stand 1 2 LED light 3 Operation 4 Battery use 73 5001 801 1505 EN 12 2019 ...

Page 82: ...Battery charger Remove the battery Plug into charging stand and charge 110 220V 50 60HZ Operation 4 Battery use 74 5001 801 1505 EN 12 2019 ...

Page 83: ...w LED light WARNING Before removing the battery make sure the vehicle is completely powered off The figure on the right is a top view diagram of the charging contact pins 2 Correctly plug the battery into the charging stand NOTE If the battery is still not fully charged after five hours contact an authorised dealer Operation 4 Battery use 75 5001 801 1505 EN 12 2019 ...

Page 84: ...ng complete The battery will take approximately 2 5 hours to fully charge at a voltage of 100 240 V AC Insert the battery into the vehicle s battery holder Operation 4 Battery use 76 5001 801 1505 EN 12 2019 ...

Page 85: ...educed in low temperature environments Hoisting DANGER Danger to life Personnel must not stand below or near the truck when the pallet truck is being lifted WARNING Risk of serious injury and or major equipment dam age Use lifting hooks and a hoist with adequate lifting ca pacity Protect all components that come into contact with the lifting device Truck weight with battery see technical specifica...

Page 86: ... The load weight is greater than the net weight of the truck including battery weight The load weight does not just in clude the net weight of the truck it also in cludes the wooden pallet The pallet or wooden box should be large and strong enough to withstand the weight of the truck Pay attention to the fork blades when lifting the truck onto the pallet to prevent injuries caused by the fork blad...

Page 87: ... possible CAUTION Operate on open level ground and pay attention to ground conditions when lifting and lowering the pallet to prevent the truck from tipping When transporting the truck make sure it is fully secured and take precautionary meas ures against bad weather Operation 4 Truck transport 79 5001 801 1505 EN 12 2019 ...

Page 88: ...ms to the lowest position and unload the load Check the brakes Check the hydraulic oil level and top up if required Apply a thin layer of lubricating oil or grease to all non painted mechanical components Lubricate the truck in accordance with the lubrication schedule Remove the battery and recharge it at least once per month Clean the battery and apply specialised grease to the terminals Spay all...

Page 89: ...5 Maintenance ...

Page 90: ...checklist The service plan is followed by advice to facili tate work Maintenance intervals must be reduced if the truck is used under harsh conditions extreme heat or extreme cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use during maintenance work Lubricants ...

Page 91: ...he efficiency of the protective installations in accordance with the technical regulations and principles established for checking industrial trucks Maintenance 5 General servicing information 83 5001 801 1505 EN 12 2019 ...

Page 92: ...ridge is damaged or broken Check the gearbox for abnormal sound and leakage Check and lubricate the bearings between the drive motor and gearbox Check and lubricate the drive chain Hydraulics Check hoses pipes and interfaces for damage and ensure their tightness and seal ing Check cylinders for leaks Check valves for leaks Check the hydraulic oil level Brake system Check the electromagnetic brake ...

Page 93: ... message record and operating time Power and drive system Check bearing positions for noise Clean or add gearbox grease Check driving speeds Hydraulics Check cylinders for damage and ensure that they are properly secured Clean or change hydraulic oil Check overflow pressure Brake system Check that electromagnetic brakes are installed and connected Check braking distance of electromagnetic brakes L...

Page 94: ...n used Antifriction hydraulic oil L HM46 0 16 0 18 L Hydraulics Antifriction hydraulic oil cold stores L HV32 Multi purpose lubricating grease Polylub GA352P As appropriate Sliding surfaces Moly lithium grease no 3 100 g Transmission Maintenance 5 Inspection and maintenance 86 5001 801 1505 EN 12 2019 ...

Page 95: ...Diagram for lubrication and servicing Hydraulic oil filler port Lubrication surface A B Gear oil filler port C Maintenance 5 Inspection and maintenance 87 5001 801 1505 EN 12 2019 ...

Page 96: ...Lubrication of sliding surfaces Steel stopper ball Steering bearing Drive wheel L1 L2 L3 Drive wheel and drive chain Rollers L3 L4 Maintenance 5 Inspection and maintenance 88 5001 801 1505 EN 12 2019 ...

Page 97: ...acing the drive wheel Replacing the drive wheel Remove the drive cowling 1 Remove the plate 2 Remove the motor and cable mounting base and remove the motor cables 3 Maintenance 5 Essential maintenance 89 5001 801 1505 EN 12 2019 ...

Page 98: ...s Place a wooden block 1 under the load wheels to raise them off the floor Double load wheels Remove the spiral slotted spring pin on the wheel frame 1 Turn the wheel frame to the vertical direc tion Tap out the wheel pin spindle from the side Remove the load wheels 2 and bearing assembly 3 Maintenance 5 Essential maintenance 90 5001 801 1505 EN 12 2019 ...

Page 99: ... slotted spring pin 1 Tap out the wheel pin spindle from the side Remove the wheel 2 and bearing assem bly 3 Changing the hydraulic oil Remove the hydraulic station protective covers on both sides Maintenance 5 Essential maintenance 91 5001 801 1505 EN 12 2019 ...

Page 100: ... Remove the two screws on the left Remove the screw on the right Then remove the pump housing and motor Maintenance 5 Essential maintenance 92 5001 801 1505 EN 12 2019 ...

Page 101: ... Remove the plug and drain the old hydraul ic fluid from this hole Add new oil Maintenance 5 Essential maintenance 93 5001 801 1505 EN 12 2019 ...

Page 102: ...Maintenance 5 Essential maintenance 94 5001 801 1505 EN 12 2019 ...

Page 103: ...6 Technical data ...

Page 104: ...Main technical data Technical data 6 Main technical data 96 5001 801 1505 EN 12 2019 ...

Page 105: ... 20 Wheels 3 1 Tyres pneumatic polyurethane rubber PU PU 3 2 Drive wheel sizes Ø x w mm 210x70 3 3 Load wheel specifications Ø x w mm 80x60 3 5 Wheels number drive side load side x traction 1x 4 Dimensions 4 4 Lift height h3 mm 110 4 9 Tiller height travel position min max h14 mm 800 1190 4 15 Fork height lowered h13 mm 80 4 19 Overall length l1 mm 1540 4 20 Length to fork face l2 mm 390 4 21 Tota...

Page 106: ...load 4 10 5 9 Acceleration time with without load s n a 5 10 Brake type Electromagnetic Drive 6 1 Traction motor rating S2 60 min kW 0 65 6 2 Lifting motor rating at S3 15 kW 0 5 6 3 Battery according to DIN 43531 35 36 A B C no Lithium battery 6 4 Battery voltage nominal capacity K5 V Ah 24 20 6 5 Battery weight 10 kg 3 7 6 6 Energy consumption according to VDI cycle kW h n a Other 8 1 Drive cont...

Page 107: ...s 46 Instrument display 38 Insulation testing 26 Drive battery test values 27 Test values for the truck 27 Insurance cover on company premises 23 In the event of a fire 48 In the event of contact with eyes 48 In the event of contact with skin 48 In the event of ingestion 48 In the event of inhalation 48 L Lifting lowering braking and using the horn 59 List of abbreviations 7 Lithium ion batteries ...

Page 108: ...ls 6 Specialist 21 Special lithium ion safety rules 47 Special risks 13 Storing the truck for an extended period 80 T Technical datasheet 97 Technical description 9 Transporting a lithium ion battery 51 U Unauthorised use 12 Update of this manual 7 Using the truck on a slope 63 W Warning regarding non original parts 24 What to do in the event of an accidental spillage 50 Index 100 5001 801 1505 EN...

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Page 110: ...STILL GmbH 5001 801 1505 EN 12 2019 ...

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