Still ECH 15 Page 6 Original Instructions Manual Download

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Modifications and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Wheels and tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Medical devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Electrical insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3 Views

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Operation

Cleaning the Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Checks and tasks before daily use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency off switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents

5001 801 1555 EN - 12/2020

Summary of Contents for ECH 15

Page 1: ...Pallet truck ECH 15 Original instructions 0195 5001 801 1555 EN 12 2020 ...

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: ...batteries 11 Technical description 11 Description of use and climatic conditions 13 Use of the truck 14 Intended use of the trucks 14 Unauthorised use 14 Place of use 14 Residual risks 15 Residual dangers residual risks 15 Residual dangers residual risks 16 Special risks associated with using the truck and attachments 17 Overview of hazards and countermeasures 18 Danger to employees 20 2 Safety De...

Page 6: ...missible consumables 32 Oils 32 Hydraulic fluid 33 Disposal of consumables 33 Safety devices 34 Damage faults 34 Safety guidelines 34 Battery connection cables 36 EMC Electromagnetic compatibility 37 3 Views Overview 40 Display element 42 Labels 44 Identification plate 45 Production number 46 4 Operation Cleaning the Forklift 48 Checks before use 48 Checks and tasks before daily use 48 Break in pe...

Page 7: ...ulations 66 Calendar of maintenance operations 68 1000 hour service plan 69 2000 hour service plan 69 Lubrication maintenance schematic view 70 Servicing 71 Decommissioning and storing the truck 73 Carrying out regular inspections on the truck 75 Equipment scrapping and disposal method 75 7 Troubleshooting Troubleshooting 78 8 Lithium ion battery use and maintenance Safety precautions 80 Battery i...

Page 8: ...rtation 84 Troubleshooting common problems 85 Maintenance 85 9 Technical data Technical datasheet 88 Eco design requirements for electric motors and variable speed drives 90 Table of contents VI 5001 801 1555 EN 12 2020 ...

Page 9: ...1 Introduction ...

Page 10: ... ready for operation beyond the warranty period Therefore Before commissioning the industrial truck read the operating instructions and follow the instructions Always follow all the safety information con tained in the operating instructions and on the industrial truck CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations valid at t...

Page 11: ...trial truck type corresponding to these operating instructions Type corresponding to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Person authorised to compile the technical file in accordance with the named directive See EC EU declaration of conformity STILL GmbH Introduction 1 Your industrial truck 3 5001 801 1555 EN 12 2020 ...

Page 12: ...year of manufacture from the nameplate in the space provided Production number Year of manufacture Please quote the production number in all technical enquiries Operating instructions are provided with each industrial truck These instructions must be stored carefully and must be available to the driver and operating company at all times The storage location is specified in the section en titled Ov...

Page 13: ...e Special sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documentation This may be in the form of an insert or separate operating instructions The original operating instructions for this in dustrial truck are valid for the operation of standard equipment and variants without re striction The operational and safety informa tion in...

Page 14: ...nual and any excerpts thereof may not be reproduced translated or transmitted in any form to third parties without the express written permission of the manufacturer Introduction 1 Information about documentation 6 5001 801 1555 EN 12 2020 ...

Page 15: ...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 7 5001 801 1555 EN 12 2020 ...

Page 16: ... 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 17: ...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 18: ...l operation of certain func tions or operating procedures is explained To illustrate these operations schematic repre sentations of an truck are used NOTE These schematic representations do not rep resent the design state of the documented truck They only serve to illustrate operating procedures Introduction 1 Information about documentation 10 5001 801 1555 EN 12 2020 ...

Page 19: ... 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 agement company for disposal purposes Technical description The Electric Pallet Trucks is used for handling pall...

Page 20: ...utton integrated into the tiller head protects the operator if the vehicle re coils Driving The electronic control unit ensures comforta ble use and lower costs Precise load 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 Hydraulic sy...

Page 21: ...prepared surfaces Driving with the horizontal load centre of gravity approximately on the longitudinal centre plane of the truck Ambient temperature ranging from 5 C to 40 C NOTE If the Forklift is used for a long time in an envi ronment lower than 5 in a cold storage or under extreme temperature and humidity changes special equipment must be installed additionally and the manufacturer s permissio...

Page 22: ...se for purposes other than those described in these operating instructions is prohibited Transporting people is prohibited The truck should not be used in areas where there is a risk of fire explosion or corrosion or in areas that are particularly dusty Stacking or unstacking is not permissible on inclined surfaces or ramps Place of use The truck only can be used in indoors The sites on which the ...

Page 23: ...cident when driving over difficult ground such as slopes soft or irregular sur faces or in poor visibility etc Falling tripping etc when moving on the in dustrial truck especially in the wet with leaking consumables or icy surfaces Loss of stability due to the load being unsta ble or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding ...

Page 24: ...ise 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 when moving on the truck especially in we...

Page 25: ... 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 only loads of ...

Page 26: ...ed 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 and employer s liability in surance associations Impaired visibility due to l...

Page 27: ...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 structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Safety and Health BetrSichV DGUV ...

Page 28: ...vided for the driver accordingly A person responsible for health and safety must be appointed Construction and equipment of the truck corre spond to the Machinery Directive 2006 42 EC and they are therefore identified with the CE symbol As a result these factors are not in cluded in the hazard assessment nor are the attachments which have their own CE label ling The operating company must however ...

Page 29: ...2 Safety ...

Page 30: ...ition of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per sons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of behav iour The drive...

Page 31: ...onsible 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 Safety 2 Definition of terms used for responsible persons 23 5001 801 1555 EN 12 2020 ...

Page 32: ... for the operating company and drivers when this in dustrial truck is equipped with a lithium ion battery variant in place of a conventional lead acid battery DANGER Risk of explosion Heating to over 80 C mechanical stress and incorrect use may lead to the battery exploding Never heat the battery to over 80 C or ex pose it to naked flames Do not subject the battery to excessive me chanical loads D...

Page 33: ... perform a separate hazard assessment in or der to assess the risks posed to the company by lithium ion batteries Observe the national regulations for the country in which the truck is being used Driver qualification In addition to the prerequisites set out in the chapter entitled Definition of responsible per sons in the section entitled Driver please observe the following The driver must be inst...

Page 34: ... 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 successor In this s...

Page 35: ...es 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 Wheels and tyres DANGER Risk to stability Failure to observe the following information and in structions can lead to a loss of stability The truck may tip ov...

Page 36: ...akers or hearing aids can be impaired Check with your doctor or manufacturer if the medical devices are sufficiently protected against electromagnetic interference Emissions Noise emission values Calculated during the test cycle performed in accordance with standard EN 12053 Acoustic pressure level on the driver s compartment ECH 15 LPAZ 70 NOTE Lower or higher noise values may occur when using in...

Page 37: ...lift 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 29 5001 801 1555 EN 12 2020 ...

Page 38: ...g must be created The results of the inspection must be retained at least until a fur ther two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the 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 responsib...

Page 39: ...sistance is sufficient when it has a resistance of at least 50 Ohms multi plied by the nominal voltage of the truck cir cuit between the parts under voltage and the truck chassis Contact the After Sales Service Measuring the insulation resistance of the electrical system NOTE Test voltage battery nominal voltage The test voltage must not exceed 100 V or triple the value of the nominal voltage Meas...

Page 40: ... 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 41: ...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 42: ...he operating company must ensure that the driver understands all the safety information Observe the relevant regulations and guide lines e g Operation of industrial trucks Rules for driveways and the area of opera tion Driver rights duties and rules of behaviour Special operating areas Information regarding setting off driving and braking Information for maintenance and repair Periodic checks Disp...

Page 43: ...l equip ment CAUTION Welding operations on other parts of the truck can cause damage to the electronics Therefore always disconnect the battery and all con nections to the electronic controls beforehand WARNING The working area of the industrial truck must be ade quately lit If it is insufficiently lit working spotlights must be in stalledto ensure that the driver can see properly CAUTION The func...

Page 44: ...onnection cables CAUTION Using sockets with NON ORIGINAL battery connec tion cables can be dangerous see purchase referen ces in the parts catalogue Safety 2 Battery connection cables 36 5001 801 1555 EN 12 2020 ...

Page 45: ... 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 46: ...Safety 2 EMC Electromagnetic compatibility 38 5001 801 1555 EN 12 2020 ...

Page 47: ...3 Views ...

Page 48: ...Overview Operating handle Tiller Hydraulic station Drive wheel 1 2 3 4 Battery Emergency off switch Fork 5 6 7 Views 3 Overview 40 5001 801 1555 EN 12 2020 ...

Page 49: ... Lifting lowering button Raises or lowers the load component 3 Drive switch Controls the direction and speed of travel 4 Collision protection button Protection function The truck will move away from the operator until this button is released Views 3 Overview 41 5001 801 1555 EN 12 2020 ...

Page 50: ...econd bars flash alter nately the battery charge is low and the battery needs to be recharged 2 Battery residual charge Displays the residual charge of the battery 100 indicates that the battery is fully charged 3 Forward indicator light Lights up when travelling forward normally Views 3 Display element 42 5001 801 1555 EN 12 2020 ...

Page 51: ...Lit solid interlock switch off Flashing interlock switch closed hour me ter starts counting 8 Information display area Displays the vehicle s total operating time Displays error messages Error code Error codes 1 Control unit co des 2 Drive control unit 6 Steering con trol unit 2 Error code The correspond ing error mes sage can be checked based on the error code Views 3 Display element 43 5001 801 ...

Page 52: ...ification plate Warning signs of emergency cut off switch Warning sticker Key switch sticker 1 2 3 4 5 Instructions sticker Model sticker Pinch hazard sticker Chassis NO Logo 6 7 8 9 10 Views 3 Labels 44 5001 801 1555 EN 12 2020 ...

Page 53: ...tery weight in kg for electric trucks only Own mass self weight in kg without battery 1 2 3 4 5 6 7 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 For QR code 8 9 10 11 12 13 14 Views 3 Identification plate 45 5001 801 1555 EN 12 2020 ...

Page 54: ...on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequential number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Views 3 Production number 46 5001 801 1555 EN 12 2020 ...

Page 55: ...4 Operation ...

Page 56: ... for too long the wheels may become slightly flattened where they touch the ground The flat areas will automati cally return to their former condition after the truck is driven for a short time Checks and tasks before daily use Visual inspections WARNING Damage or other defects on the industrial truck can result in accidents If damage or other defects are identified on the in dustrial truck during...

Page 57: ...ne 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 and bolts and refasten them if necessary Key switch The key switch 1 turns the...

Page 58: ...hicle will be forced to perform an emergen cy stop Driving the truck Daily checks and preparations that must be carried out before putting the truck into opera tion CAUTION Before putting the truck into use or lifting heavy ob jects the driver must ensure that no other people are within the hazard area Operation 4 Emergency off switch 50 5001 801 1555 EN 12 2020 ...

Page 59: ...e in the drive posi tion M and place the drive switch in the de sired drive direction 1 or 2 When there is a large angle of rotation the speed will also be correspondingly large Operation 4 Driving the truck 51 5001 801 1555 EN 12 2020 ...

Page 60: ...dle will force the brakes The operating handle will automatical ly move to the upper braking position B Al ternatively the brake can be forced by press ing the operating handle down to the lower braking position B CAUTION If the operating handle moves into the braking posi tion slowly identify the cause and rectify the fault Regenerative braking Release the drive switch which will automati cally r...

Page 61: ...nding on the actual situation CAUTION When using the vehicle on an incline or uneven sur face raise the fork to prevent the bottom of the fork scraping against the ground Using the truck on ramps CAUTION Excessive use of the truck on ramps is not recom mended Using the truck on ramps places particular stress on the traction motor and battery The truck s working range and safety factor will both be...

Page 62: ...aded Descending slopes DANGER Risk to life and or risk of serious damage to equip ment Never park the truck on a ramp Never make a U turn or take shortcuts on a ramp The operator must drive very slowly on ramps You must drive forwards to move a load down a slope with goods above the per son Operation 4 Using the truck on ramps 54 5001 801 1555 EN 12 2020 ...

Page 63: ... start the truck on a ramp first move the tiller into position B with the truck s brake applied then push the handle switch in the desired direction F or R Fi nally push the tiller into the operating position M Forward travel Reverse travel F R Operation 4 Using the truck on ramps 55 5001 801 1555 EN 12 2020 ...

Page 64: ...g ulations Adopt appropriate protective measures if the load is at risk of tipping over or falling during transport Do not transport goods using damaged equipment such as the truck pallets etc Never go under the raised load component Personnel are prohibited from entering the load component Do not use the truck to lift personnel Try to move the fork until it is completely under the goods Lifting P...

Page 65: ...Always park the truck correctly Never park the truck on a ramp The load component must be completely lowered Hold down the lowering button 1 to lower the load component Fully lower the fork arms Turn the key switch 3 to the OFF posi tion and pull out the key Press the emergency off switch 2 Operation 4 Truck parking 57 5001 801 1555 EN 12 2020 ...

Page 66: ...act with the lifting device Truck weight with battery see technical specifica tions Remove the load before hoisting the pallet truck Disconnect the power supply Attach slings in the positions identiﬁed by 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 Truck transpo...

Page 67: ...ck onto the pallet to prevent injuries caused by the forks Follow the prescribed steps and park the vehi cle correctly Make sure the forks are aligned with the pal let move slowly and stop after inserting the forks as far into the pallet as 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 Whe...

Page 68: ...Operation 4 Truck transport 60 5001 801 1555 EN 12 2020 ...

Page 69: ...5 Battery use and maintenance ...

Page 70: ...by the bat tery and charging station manufacturer must be strictly observed Charging procedure Ensure that charging requirements are complied with Park the truck correctly Open the swivelling hood 1 Unplug the power current plug 2 then plug it into a suitable power source CAUTION The charging voltage range is 100 240 V 50 60 Hz Do not exceed this voltage range Charging indicator light LED status p...

Page 71: ...wer line contacts well Yellow light re mains lit Battery fault battery reverse connection Troubleshooting the battery Battery fault battery not connec ted Troubleshooting the battery Flashing yellow light High ambient temperature Ambient tempera ture reduced to nor mal temperature Battery voltage too high Troubleshooting the battery Charger failure Charger fault return to factory for mainte nance ...

Page 72: ... the swivelling hood 1 b Pull out the battery 2 from above Install following the above steps in reverse or der Battery use and maintenance 5 Disassembling and installing the battery 64 5001 801 1555 EN 12 2020 ...

Page 73: ...6 Maintenance ...

Page 74: ...ned in this section must be carried out at the intervals set out in the maintenance checklist Modifying this truck especially its safety de vices is prohibited It is strictly forbidden to change the working speed of the truck Only original equipment and spare parts meet with company quality assurance re quirements To ensure the equipment s sta bility and operational performance you must only use o...

Page 75: ... ambient tempera tures or extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components Lifting and jacking equipment WARNING The battery connector must be disconnected before the industrial truck is jacked up WARNING Make sure that the industrial truck is only jacked up on level surfaces and is secured against roll...

Page 76: ...aintenance frequency should be greater in harsh and poor operating envi ronments such as high or low temperature environments and acidic or dusty environ ments There number of maintenance oper ations should also be increased Maintenance should be undertaken by qualified personnel using correct tools and procedures Maintenance and replacements should make use of genuine parts from the original manu...

Page 77: ... sound and leakage Check the wheels for wear and damage Check the wheel bearings and their mounting Overall structure Check the frame for damage Hydraulic system Check cylinder block and piston for damage and ensure that they are properly sealed and secured Check the oil level in the oil tank 2000 hour service plan At operating hours 2000 4000 6000 8000 10000 12000 14000 Carried out Servicing work...

Page 78: ... manufacturer s regulations when using and handling fluids Non standard operation may put the opera tor s health and life at risk and damage the en vironment Fluids should only be stored in the specified container Fluids may be flammable Maintenance 6 Lubrication maintenance schematic view 70 5001 801 1555 EN 12 2020 ...

Page 79: ...ure in accordance with regulations Code Designation Applies to Amount added A L HM32 Hydraulic system 0 48 L B Grease contains MoS2 Gearbox 100 g Servicing Pre service preparations Adopt all necessary safety measures to avoid accidents during servicing The procedure be low must be followed Park the truck correctly Pull the key switch and disconnect the bat tery plug out to prevent the truck from b...

Page 80: ...be prompt ly replenished CAUTION Do not add hydraulic oil that contains impurities Top up the hydraulic oil Carry out the pre service preparations prop erly Remove the cover If necessary top up with hydraulic oil of the correct specification After topping up lift the fork The oil level is fully topped up when you no longer hear pop ping noises continue to add oil if you still hear popping noises I...

Page 81: ...re detailed in the following subsections When storing the truck it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and wheel bearings are not damaged If the storage period is longer than six months the user must contact the company s service department to clarify other operational meas ures that need to be taken Precautions prior to...

Page 82: ...ge the battery Check whether the hydraulic oil contains condensation water Change the hydraulic oil if necessary Put the truck into operation If there are difficulties with operating electrical system switches you should apply contact spray to the exposed contact surfaces and re move the oxide layers on the surfaces of the operating component contacts by performing repeated switch operations After...

Page 83: ...d 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 Equipment scrapping and dis posal method When the ...

Page 84: ...Maintenance 6 Equipment scrapping and disposal method 76 5001 801 1555 EN 12 2020 ...

Page 85: ...7 Troubleshooting ...

Page 86: ...heck the battery charge and charge the battery if needed Check the fuse device Interrupt the charging process Unable to lift goods The hydraulic oil level is too low Load capacity exceeded Check the hydraulic oil level Pay attention to the rated load re fer to the model identification plate If you are still unable to resolve the fault after performing all the steps listed in Solutions please conta...

Page 87: ...8 Lithium ion battery use and maintenance ...

Page 88: ...ources 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 complete power supply system...

Page 89: ... hot swap batteries Fire and electric shock are easily caused Be aware of corrosion It may cause battery damage and shorten the battery life Lithium ion battery use and maintenance 8 Safety precautions 81 5001 801 1555 EN 12 2020 ...

Page 90: ...is 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 such as wrenc...

Page 91: ...ye 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 normal temper ature r...

Page 92: ... 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 the...

Page 93: ...ny 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 detected the issu...

Page 94: ...he event of dangerous situations such as short circuit or overcurrent once per month 5 Check the status of the insulation resist ance of the battery module and the bodywork and make sure that the resistance complies with the DIN 43539 VDE 0510 in order to prevent battery leakage once per month Disposing of used batteries In order to prevent environmental pollution used batteries should be sent to ...

Page 95: ...9 Technical data ...

Page 96: ...et The technical data given below complies with the VDI2198 standard The company reserves the right to make technical changes and addi tions Cod e Met ric Chinese Metric Features 1 1 Brand Still Technical data 9 Technical datasheet 88 5001 801 1555 EN 12 2020 ...

Page 97: ...dth mm Ф74 x 30 3 5 Wheels number driving caster loading x drive wheels mm 1 x 2 4 1 x 2 2 3 6 Track width front driving side b10 mm 450 3 7 Track width rear loading side b11 mm 390 Dimensions 4 4 Basic model maximum lift height h3 mm 115 4 9 Height of handle in operating po sition min max h14 mm 700 1200 4 15 Fork height lowered h13 mm 80 4 19 Overall length l1 mm 1550 4 20 Length to vertical fac...

Page 98: ...sumption according to VDI cycle kWh h 0 239 Other data 8 1 Type of drive control DC 10 5 Steering type Mechanical 10 7 Sound pressure level at the driv er s ear dB A 70 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 1 a a...

Page 99: ...meet the description given in Article 2 Scope Item 1 b Technical data 9 Eco design requirements for electric motors and variable speed drives 91 5001 801 1555 EN 12 2020 ...

Page 100: ...Technical data 9 Eco design requirements for electric motors and variable speed drives 92 5001 801 1555 EN 12 2020 ...

Page 101: ... 18 Hydraulic fluid 33 I Illustrations 10 Insurance cover on company premises 24 L List of abbreviations 8 Lithium ion batteries Declaring the use of 25 Driver qualification 25 Hazard assessment 25 Permissible batteries 25 Procedure in the event of a fire 25 Special features 24 Transport outside the premises 26 M Measuring battery insulation resistance 31 Measuring the insulation resistance of the...

Page 102: ...cial risks 17 Stability 17 T Transporting the lithium ion battery 26 U Unauthorised use 14 Update of this manual 8 W Warning regarding non original parts 26 Wheels and tyres Safety principles 27 Index 94 5001 801 1555 EN 12 2020 ...

Page 103: ......

Page 104: ...STILL GmbH 5001 801 1555 EN 12 2020 ...

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Still ECH 15, Original Instructions Manual

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