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Equipment scrappage and

disposal procedure

When the truck is eventually scrapped and

disposed of, this must be carried out in ac-

cordance with the laws and regulations in

force in the country of use. Special attention

should also be paid to regulations regarding

the disposal of used batteries, fuel, oil and

electronic and electrical equipment, as well as

local environmental protection regulations.

Operation

Equipment scrappage and disposal procedure

5001 801 1532 EN - 10/2021 - 03

Summary of Contents for ECH 12C

Page 1: ...Electric pallet truck ECH 12C ECH 15C Original instructions 2063 2065 5001 801 1532 EN 10 2021 03 ...

Page 2: ......

Page 3: ...f 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 and...

Page 4: ......

Page 5: ...ctions 9 Copyright and trademark rights 9 Explanation of information symbols used 9 List of abbreviations 10 Drive directions 12 Environmental considerations 13 Packaging 13 Disposal of components and batteries 13 2 Safety Safety regulations 16 Definition of responsible persons 17 Operating company 17 Specialist 17 Drivers 18 Basic principles for safe operation 20 Insurance cover on company premis...

Page 6: ...EMC Electromagnetic compatibility 34 3 Views Safety devices and warning labels 36 Overview of main components_plug model 37 Control handle_plug model 38 Indicator light 40 Identification plate 41 4 Operation Operating instructions 44 Checks before first commissioning 45 Break in period precautions 45 Daily inspection 45 Drive system 47 Driving steering and braking 47 Creep speed switch 49 Using th...

Page 7: ...6 Transportation 76 Troubleshooting common problems 77 Maintenance 77 Forklift truck transport 78 Cleaning the Forklift 79 Decommissioning and storing 80 Equipment scrappage and disposal procedure 81 5 Maintenance General Maintenance Information 84 Operational safety and environmental protection 84 Repairs and maintenance safety regulations 84 Maintenance and checks 85 General 85 Servicing and mai...

Page 8: ...il level 91 Topping up the gear oil 92 Troubleshooting 93 Troubleshooting 93 Battery malfunction information 93 Control unit error messages 94 6 Technical Data Technical datasheet 98 Eco design requirements for electric motors and variable speed drives 100 Table of contents VI 5001 801 1532 EN 10 2021 03 ...

Page 9: ...1 Foreword ...

Page 10: ...xtremely smooth steering makes the vehicle easier to manoeuvre in tight spaces A gas spring enables the tiller to quickly return to the vertical position after it is released Tiller The composite construction tiller head pro vides excellent impact resistance Ergonomic suitable for left and right handed operators The push buttons for the horn lift ing and lowering can be operated using one hand wit...

Page 11: ...standards and safety regulations The industrial truck is fitted with state of the art technology Following these operating in structions will allow the industrial truck to be handled safely By complying with the specifi cations in these operating instructions the functionality and the approved features of the industrial truck will be retained Get to know the technology understand it and use it saf...

Page 12: ...n Union EU UKCA in the United Kingdom UK EAC in the Eurasian Economic Union The conformity marking is applied to the nameplate A declaration of conformity is is sued for the EU and UK markets An unauthorised structural change or addition to the industrial truck can compromise safety thus invalidating the declaration of conformity conformity symbols Foreword 1 Your truck 4 5001 801 1532 EN 10 2021 ...

Page 13: ...1 For the markets of the European Union the EU candidate countries the EFTA States and Switzerland 2 For the United Kingdom market The declaration of conformity document is supplied with the industrial truck The declara tion shown explains the conformity with the provisions of the EC Machinery Directive and the Supply of Machinery Safety Regulation 2008 2008 No 1597 An unauthorised structural chan...

Page 14: ...gned for this purpose The dimensions and capacity of the pallet or contain er must be adapted 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...

Page 15: ...he 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 This truck is suitable for transporting goods over level surfaces This truck is suitable for use within tempera tures ranging from 5 C to 40 C and above If the truck is used for long periods in envi ronments below 5 C in freezers or where th...

Page 16: ...parts list 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 operating company see the chapter Def inition of responsible persons must ensure that all operators have received read and un derstood these instructions Thank you for reading and complying with these operating instructions If y...

Page 17: ...of trucks These operating instruc tions are subject to change and any claims based on the information and or illustrations contained in them cannot be asserted Please contact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third parties including as excerpts except ...

Page 18: ...chaft 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 regulations CE Communauté Européenne Confirms c...

Page 19: ...ompartment LSP Load centre of gravity Distance of the centre of gravity of the load from the front face of the fork backs MAK Maximum workplace concentration Maximum 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 equi...

Page 20: ...er Ingenieure German technical scientific association VDMA Verband Deutscher Maschinen und Anla genbau e V German Mechanical Engineering Industry Association WLAN Wireless LAN Wireless local area network Drive directions The drive directions of the truck are forward 1 and reverse 2 Foreword 1 Information about the documentation 12 5001 801 1532 EN 10 2021 03 ...

Page 21: ...sal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man a...

Page 22: ...Foreword 1 Environmental considerations 14 5001 801 1532 EN 10 2021 03 ...

Page 23: ...2 Safety ...

Page 24: ...llets 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 instru...

Page 25: ...cation that demonstrably proves their professional ex pertise This proof should consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven pe riod during their career During this time this person has become familiar with a wide range of symptoms that require checks to ...

Page 26: ...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 gloves that is ap propriate for the conditions the job and the load to be lifted Solid footwear should be worn to ensure safe driving and braking The driver must be familiar with the operating instructions...

Page 27: ... for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety 2 Definition of responsible persons 19 5001 801 1532 EN 10 2021 03 ...

Page 28: ...k 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 successor In this specific case you may plan a modifica tion or alteration to your truck provided that The modification or alteration is design...

Page 29: ...afe for operating or 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 Medical devices The operation of medical devices for example pacemakers or hearing aids can be i...

Page 30: ...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 for safe operation ...

Page 31: ...structed regarding these risks that arise through use of the truck In addition we draw attention to the safety regula tions in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Falling tripping etc whe...

Page 32: ... slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as cen trally as possible with the truck and trans port in this position Avoid turning and diagonally driving across slopes or gradients Never have the load facing downhill when travelling on slopes or gradients Pick up o...

Page 33: ...the truck correctly and without the risk of acci dents Safety 2 Residual risk 25 5001 801 1532 EN 10 2021 03 ...

Page 34: ...r s li cence Usage by unauthorised persons Access with key only for authorised persons O Truck not safe for op eration Periodic inspection and rectification of de fects 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 a...

Page 35: ...rman Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O When fuelling a Diesel German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in stru...

Page 36: ...cked Mark routes Keep roadways clear O German Ordinance on Industrial Safety and Health BetrSichV Routes intersect Announce right of way rule O German Ordinance on Industrial Safety and Health BetrSichV No person detection when placing goods in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the ...

Page 37: ... for deployment The result of the hazard assessment must be documented 6 ArbSchG In the case of truck applications involving similar hazard sit uations the results may be summarised Re fer to the chapter entitled Overview of haz ards and countermeasures which provides advice on complying with this regulation The overview specifies the primary hazards that in the event of non compliance are the mos...

Page 38: ... 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 the...

Page 39: ...age 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 Saf...

Page 40: ...eek 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 wi...

Page 41: ...uid 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 di...

Page 42: ...he 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 regul...

Page 43: ...3 Views ...

Page 44: ...ructions label STILL label Pallet truck model label Identification plate label 1 2 3 4 5 6 7 Battery indicator label Battery wrong insertion label Slinging label Anti pinch label Serial No Importer label for UK 8 9 10 11 12 13 Views 3 Safety devices and warning labels 36 5001 801 1532 EN 10 2021 03 ...

Page 45: ...nts_plug model Operating handle Joystick Hydraulic station Drive wheel Baffle 1 2 3 4 5 Fork Emergency off switch Lithium ion battery Handle 6 7 8 9 Views 3 Overview of main components_plug model 37 5001 801 1532 EN 10 2021 03 ...

Page 46: ...rol handle_plug model Horn button Lifting button Manual lowering button 1 2 3 Drive switch Emergency reverse button Creep speed button 4 5 6 Views 3 Control handle_plug model 38 5001 801 1532 EN 10 2021 03 ...

Page 47: ...switch 9 to turn off the truck s power supply Emergency off switch The vehicle s electrical system circuits will be disconnected when you press this switch 8 All electrical functions will be stopped and the vehicle will be forced to perform an emergen cy stop Views 3 Control handle_plug model 39 5001 801 1532 EN 10 2021 03 ...

Page 48: ...Remaining charge on standard battery Green 60 100 Yellow 30 60 Constantly illuminated in red 15 30 Flashing red 0 15 If the control unit detects a battery malfunc tion the power display light 2 will flash with an error code until the malfunction is elimina ted NOTE Please see the chapter Troubleshooting This chapter is intended to help users identify and eliminate simple faults or problems caused ...

Page 49: ...chnical data listed in this operat ing instructions for more detailed information 1 2 3 4 5 6 7 8 9 Conformity marking CE mark for the markets of the EU the EU candidate countries the EFTA States and Switzerland UKCA mark for the United Kingdom market EAC mark for the Eurasian Economic Union market Rated drive power in kW Battery voltage in V Rated capacity 10 11 12 13 Views 3 Identification plate...

Page 50: ...is possible for there to be multiple con formity markings on the nameplate The EAC mark may also be located in the immediate vicinity of the nameplate Views 3 Identification plate 42 5001 801 1532 EN 10 2021 03 ...

Page 51: ...4 Operation ...

Page 52: ...k areas and hazardous loads CAUTION Equipment wear or damage To avoid scraping the bottom of the lifting system on the floor keep the forks raised before starting CAUTION Equipment wear or damage The driver must turn off the ignition and remove the key before leaving the pallet truck DANGER Equipment wear or damage Safety shoes must be worn to provide effective pro tection WARNING Risk of serious ...

Page 53: ...e Break in period precautions During the initial stage of putting the truck into use it should be operated with low loads Within the first 100 hours in particular the fol lowing requirements should also be met Excessive discharge of a new battery dur ing initial use must be prevented It should generally be charged promptly when at 20 The specified preventive maintenance must be done thoroughly Avo...

Page 54: ...m system and safety devices Check the chassis frame and apply grease as required Check the position reset func tion of the operating handle Check the function of the emergency brake by activating the emergency button Check the tiller arm switch braking function Check the lifting and lowering functions by operating the buttons Visually inspect the bolts and nuts Visually inspect if there are any br...

Page 55: ... sur face raise the forks to prevent the bottom of the forks scraping against the ground Driving Place the drive handle in the driving area M and place the drive switch in the desired direc tion of travel forward or reverse When there is a large angle of rotation the speed will also be correspondingly large Operation 4 Drive system 47 5001 801 1532 EN 10 2021 03 ...

Page 56: ...cause and rectify the fault Regenerative braking Release the drive switch The drive switch will automatically return to the initial position speed is 0 The vehicle will enter the regen erative braking state and slow down When it decelerates to less than 1 km h the brake will bring the motor to a stop CAUTION Activate the drive switch If the drive switch cannot quickly return to the initial positio...

Page 57: ... speed switch 5 the truck will reduce its speed to 20 of the maxi mum speed 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 the ground is dry with...

Page 58: ...or equipment damage Never park the truck on a ramp Never make a U turn or take shortcuts on a ramp On a slope the op erator must drive very slowly WARNING Risk of serious injury and or serious damage to equipment Since braking force is limited a laden truck can climb a smooth gradient of 6 or less An unladen truck can climb a smooth gradient of 16 or less Starting on a slope If you have to stop an...

Page 59: ...eutral 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 51 5001 801 1532 EN 10 2021 03 ...

Page 60: ...k of tipping over or falling during transport You must not transport goods using dam aged transportation tools such as trucks pallets etc Never go under raised load bearing compo nents Personnel are prohibited from entering load components You must not use the truck to lift personnel Try to move the forks until they are com pletely under the goods CAUTION Before picking up a load the operator must...

Page 61: ... DANGER It is not permitted to walk under the forks It is not permitted to transport or lift people on the forks If there are people under or on top of the forks do not move the truck Do not move the forks and do not drive the truck DANGER Risk of accident when forks are changed If the forks are changed and a different type of forks to the original forks is fitted the residual load capaci ty chang...

Page 62: ...idth of the forks DANGER It is mandatory to wear safety footwear for pedes trian mode driving WARNING Transporting people is strictly prohibited CAUTION Take care not to disturb any adjacent loads or those which may be 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 CAUTIO...

Page 63: ...rt Back the truck away from the stack or any neighbouring loads gently and in a straight line Transporting loads Always carry loads in the forward direction of travel A in order to have the best visibili ty When carrying a load on a slope always ascend or descend with the load uphill Nev er drive sideways across a slope or perform a U turn Reverse travel B is to be used solely for unloading Since ...

Page 64: ... 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 CAUTION Take care not to disturb any adjacent loads or those which may be to the side or in front of the load being handled Operation 4 Load handling 56 5001 801 1532 EN 10 2021 03 ...

Page 65: ...must be parked correctly even if you only intend to leave it for a short time Pull the lowering lever 1 Lower the load bearing component Fully lower the forks Press the emergency off switch 3 Operation 4 Parking the vehicle safely 57 5001 801 1532 EN 10 2021 03 ...

Page 66: ... of lifting equipment to the truck and the hoisting operation itself must be per formed by personnel experienced in rigging DANGER Danger to life Personnel must not stand below or near the truck when the pallet truck is being lifted WARNING Lifting equipment of insufficient capacity can fail and cause severe injury or death Ensure that all lifting slings hardware or other equipment has sufficient ...

Page 67: ...y the hook symbol CAUTION Risk of major equipment damage It is strictly forbidden to attach the lifting slings to the operating handle or to other points not intended for this purpose Operation 4 Hoisting the Truck 59 5001 801 1532 EN 10 2021 03 ...

Page 68: ...value 5 6 7 8 Plug the connector of bend wire 5 into con troller wire 4 First touching hand operated value 8 The steel wire II 7 rising up buckle end of the steel I 6 into the steel wire II 7 from manual Release the steel wire II 7 and tighten the adjust screw 3 Operation 4 Handle and handle lever installation 60 5001 801 1532 EN 10 2021 03 ...

Page 69: ...Preventing electric shock Take note of the following two points for bat teries with high voltage and power Do not create a short circuit Keep tools away from the battery poles to prevent sparks or short circuits NOTE Metal or conductive objects must not be placed on top of the battery to prevent the bat tery from short circuiting Battery charging Charging precautions The truck must be parked in a ...

Page 70: ...e plug in lithium ion battery out before charging CAUTION The charging voltage range is 100 240 V 50 60 Hz Do not exceed this voltage range CAUTION When charging and maintaining the battery observe the manufacturer s maintenance instructions for the battery and battery charger Disassembling and installing the battery Before disassembling and installing the bat tery you must raise the forks to the ...

Page 71: ...stall the battery in reverse order paying at tention to the location where the battery is in stalled and whether the wiring is correct Route the battery cable so that it is not trap ped when the battery is inserted Mounting the battery charger NOTE The charging stand can be secured to the wall using expansion screws 1 Operation 4 Battery Use and Maintenance 63 5001 801 1532 EN 10 2021 03 ...

Page 72: ...d the battery becoming corroded by water or corrosive liquid Keep the battery away from all fire sources heat sources and flammable or explosive materials Operation 4 Battery Use and Maintenance 64 5001 801 1532 EN 10 2021 03 ...

Page 73: ... heat or smoke which may lead to a serious fire or explosion The charging 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 and Maintenance 65 5001 801 1532 EN 10 2021 03 ...

Page 74: ...Battery charger Battery Charging stand 1 2 LED light 3 Operation 4 Battery Use and Maintenance 66 5001 801 1532 EN 10 2021 03 ...

Page 75: ...Battery charger Remove the battery Plug into charging stand and charge 110 220V 50 60HZ Operation 4 Battery Use and Maintenance 67 5001 801 1532 EN 10 2021 03 ...

Page 76: ...t 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 and Maintenance 68 5001 801 1532 EN 10 2021 03 ...

Page 77: ...te 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 and Maintenance 69 5001 801 1532 EN 10 2021 03 ...

Page 78: ...slip in sulating mat NOTE To prevent static electricity from causing an explosion never use a dry cloth or fabric to wipe the surface of the battery Pull out the mains plug Wipe it with a damp cloth Wear protective eyewear rubber shoes and rubber gloves Battery waste disposal The disposal of used batteries must strictly comply with national environmental protection regulations or current waste dis...

Page 79: ...of the battery have a sig nificant impact on the operational safety of the truck Battery replacement equipment must be approved in advance by the company Li ion Battery waste disposal please contact your service dealer Operation 4 Battery Use and Maintenance 71 5001 801 1532 EN 10 2021 03 ...

Page 80: ...d period such as heat sources or direct sun light Do not disassemble crush puncture or heat the battery Lithium ion batteries must not be used by people who lack knowledge of how to use them safely Do not immerse the battery in water or oth er conductive liquids It is forbidden to use batteries in series or in parallel with other models or types of bat tery Serial and parallel operation of a compl...

Page 81: ...bidden to hot swap batteries Fire and electric shock are easily caused Be aware of corrosion It may cause battery damage and shorten the battery life Operation 4 Lithium ion battery appendix 73 5001 801 1532 EN 10 2021 03 ...

Page 82: ... is outside this permit ted range CAUTION Ambient usage temperature 0 C to 40 C 3 The lithium ion battery can be charged and reused at any time When the battery power is low charge it promptly to avoid over dis charge the replaced battery should also be charged promptly to avoid internal damage to the battery caused by over discharge of the battery after self discharge 4 Do not place metal objects...

Page 83: ...with soap and water Eye irritation can occur in the event of con tact with the eyes Immediately rinse eyes thoroughly with water for 15 minutes then consult a doctor Charging 1 The battery can only be charged using the vehicle specific charger Other chargers may cause battery damage 2 The normal charging temperature range of the battery is 5 C 40 C Do not charge in an environment that exceeds the ...

Page 84: ...her goods 5 Do not store under conditions whereby a load or a hidden load is connected that is it is prohibited to have any form of discharge be haviour during storage 6 If the battery is found to be swollen cracked or the voltage value is excessively low after long term storage the battery may be dam aged Please contact the company s technical department immediately for technical support 7 After ...

Page 85: ...otify the company s after sales service department to obtain technical support Maintenance Routine maintenance 1 The battery must be attended during charg ing especially when it is nearly full During the charging process make sure that the plug and socket are in good contact the charging de vice is working properly and the battery mod ule contacts are in good condition Should any abnormality be de...

Page 86: ...ions Observe the regional and national regulations Forklift truck transport Only use haulage equipment with sufficient load capacity For loading and unloading weights see the truck model nameplate and vehicle parameters 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...

Page 87: ...ring Do not use high pressure cleaners for cleaning Strictly adhere to the following steps Do not use combustible liquids to clean the truck You must take all safety precautions before you start cleaning and you must prevent sparks from being produced during work pro cesses such as from short circuits If the truck is powered by a battery you must dis connect it from the battery cable connections W...

Page 88: ...a suitable contact spray CAUTION Charge the battery every month If the truck is driven by the battery then the battery must be charged every month to avoid depletion of the battery through self discharge otherwise sulpha tion will destroy the battery Recommissioning after storage Clean the truck thoroughly Lubricate according to the truck s mainte nance schematic diagram Clean the battery apply sp...

Page 89: ...th the laws and regulations in force in the country of use Special attention should also be paid to regulations regarding the disposal of used batteries fuel oil and electronic and electrical equipment as well as local environmental protection regulations Operation 4 Equipment scrappage and disposal procedure 81 5001 801 1532 EN 10 2021 03 ...

Page 90: ...Operation 4 Equipment scrappage and disposal procedure 82 5001 801 1532 EN 10 2021 03 ...

Page 91: ...5 Maintenance ...

Page 92: ...When jacking up the truck appropriate tools such as chocks and wooden blocks must be used to secure the truck and prevent it from accidentally rolling or tipping over When working under a raised load bearing component sufficiently strong chains or safety devices must be used to secure the forks WARNING The battery connector must be disconnected before the industrial truck is jacked up WARNING Make...

Page 93: ... installing additional equipment on the forklift truck is prohibited without the agreement of the manufacturer NOTE If the data plates or affixed labels are incom plete or damaged they should be replaced with new ones For locations and reference numbers please see the spare parts cata logue CAUTION If the forklift truck is used in an extreme environment such as excessive heat excessive cold or are...

Page 94: ...son qualified to do so The person carrying out this inspection must provide their expertise and opinion without being influenced by economic factors or company internal issues Safety is the only critical deciding factor The person responsible for carrying out the in spection must have sufficient knowledge and experience to be able to assess the condition of the truck and the efficiency of the prot...

Page 95: ... the terminals are firmly attached Check the control unit Check the fastening of the cables and motor Drive system Check the gearbox for abnormal sound and leakage Check the wheels for wear and damage Check the wheel bearings and their mounting Hydraulics Check cylinder block and piston for damage and ensure that they are properly sealed and secured Check the oil level in the oil tank Other Check ...

Page 96: ...ut Drive system Adding gear oil Maintenance 2000 hours every 24 months At operating hours 2000 4000 6000 8000 10000 Carried out Notes Perform all 1000 hour maintenance work Hydraulics Change the hydraulic oil Maintenance 5 Inspection and Maintenance 88 5001 801 1532 EN 10 2021 03 ...

Page 97: ...Technical inspection and main tenance data Lubrication maintenance schematics Maintenance 5 Inspection and Maintenance 89 5001 801 1532 EN 10 2021 03 ...

Page 98: ... Designation Model no Amount added Position used Antifriction hydraulic oil L HM46 0 21L Hydraulics Moly lithium grease no 3 Grease contains MoS2 110 g Gearbox Moly lithium grease no 3 Grease contains MoS2 As appropriate Turning mecha nism Maintenance 5 Inspection and Maintenance 90 5001 801 1532 EN 10 2021 03 ...

Page 99: ...ping noises coming from the tubing when lifting this indicates that the hy draulic oil is insufficient and should be prompt ly replenished Park the truck as specified Pull the key switch out to prevent the truck from being accidentally started CAUTION If you need to work underneath a raised truck take effective measures to prevent accidents such as the truck overturning or slipping Remove the cove...

Page 100: ...ing up the gear oil Park the truck as specified Pull the key switch out to prevent the truck from being accidentally started CAUTION If you need to work underneath a raised truck take effective measures to prevent accidents such as the truck overturning or slipping Remove the cover Pour correct gear oil into the grease fitting 1 CAUTION Do not add gear oil that contains impurities Refit by followi...

Page 101: ...t after performing all the steps listed in Solutions please contact the company s customer serv ice department Further fault identification and elimination operations must be performed by after sales service personnel who have under gone special training Battery malfunction information If the control unit detects a battery malfunc tion the battery light 2 will flash with an er ror code until the e...

Page 102: ...reen light flashes 3 times the cycle is for 1 sec ond then stops for 2 seconds then flashes 4 times then stops for 3 seconds and re peats 8 For other malfunctions the yellow light will flash the cycle is for 1 second Control unit error messages Handheld unit diagnostic Connect the handheld unit to the control unit terminal Enter the Diagnostic menu and look for the error message LED malfunction li...

Page 103: ...Speed limit potentiometer open circuit UNDER VOLTAGE FAULT 1 4 Cell voltage too low 1 Cell voltage 17 V 2 Poor battery or control unit con nection OVERVOLT AGE FAULT 1 5 Cell voltage too high 1 Cell voltage 31 V 2 Battery charger is still connec ted when the vehicle is running 3 Poor battery contact MAIN OFF FAULT 2 1 Main contactor coil drive closed mal function 1 The main contactor coil was ac t...

Page 104: ...l operating sequence errors 2 Erroneously adjusting the accel erator CURRENT SENSE FAULT 4 1 Current check mal function 1 Electric motor or electric motor wiring short circuit 2 Control unit failure HARDWARE FAILSAFE 4 2 Electric motor volt age exceeds range 1 Electric motor voltage cannot match accelerator input 2 Electric motor or electric motor wiring coil short circuit EE CHECK SUM FAULT 4 3 E...

Page 105: ...6 Technical Data ...

Page 106: ...Technical datasheet Technical Data 6 Technical datasheet 98 5001 801 1532 EN 10 2021 03 ...

Page 107: ...front rear kg 100 15 100 15 Wheels 3 1 Tyres Pneumatic polyurethane rubber PU PU 3 2 Tyre size front mm Ф210x70 Ф210x70 3 3 Tyre size rear mm Ф80x60 Ф74x88 Ф80x60 Ф74x88 3 5 Wheels number front rear X drive 1x 4 1x 2 1x 4 1x 2 Dimensions 4 4 Lift height h3 mm 115 115 4 9 Height of tiller arm in driving position min max h14 mm 750 1190 750 1190 4 15 Fork height lowered h13 mm 80 80 4 19 Overall len...

Page 108: ...al capacity K5 V Ah 24 20 24 20 6 5 Battery weight kg 5 5 6 6 Energy consumption acc to VDI cycle kW h n a n a Other 8 1 Drive control method DC DC 8 4 Noise level dB A 74 74 Eco design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation EU 2019 1781 because these motors do not meet the description giv en in Article 2 Scope Item...

Page 109: ... these variable speed drives do not meet the description given in Article 2 Scope Item 1 b Technical Data 6 Eco design requirements for electric motors and variable speed drives 101 5001 801 1532 EN 10 2021 03 ...

Page 110: ...Technical Data 6 Eco design requirements for electric motors and variable speed drives 102 5001 801 1532 EN 10 2021 03 ...

Page 111: ...erations 13 G General 3 85 H Handle and handle lever installation 60 Hazards and countermeasures 26 Hoisting the truck 58 Hydraulic fluid 33 I Identification plate 41 Improper use 6 Indicator light 40 Information about the documentation 8 Information symbols 9 Insulation testing 30 Drive battery test values 31 Test values for the truck 31 Insurance cover on company premises 20 Issue date of the op...

Page 112: ...d maintenance personnel training and qualification 86 Special risks 24 Stability 24 T Technical datasheet 99 Technical description 2 Topicality of the operating instructions 9 U Using the truck 6 Using the truck on a slope 49 W Warning regarding non original parts 20 Y Your truck 2 Index 104 5001 801 1532 EN 10 2021 03 ...

Page 113: ......

Page 114: ...STILL GmbH 5001 801 1532 EN 10 2021 03 ...

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