Still ECV 10 Page 5 Original Instructions Manual Download

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Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conformity marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration that reflects the content of the declaration of conformity . . . . . . . . . . . . . . .

Information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date of edition and latest update of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Place of use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special risks associated with using the truck and attachments. . . . . . . . . . . . . . . . . . . .

Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety

Definition of terms used for responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic principles for safe operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Insurance cover on company premises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Table of contents

III

50028011505 EN - 03/2022 - 06

Summary of Contents for ECV 10

Page 1: ...Electric Pallet Stacker ECV 10 C ECV 10i C ECV 10 Original instructions 0342 0343 0344 50028011505 EN 03 2022 06 ...

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 an...

Page 4: ......

Page 5: ...ponents and batteries 11 Series 11 Technical description 12 Use of the truck 13 Intended use of the trucks 13 Unauthorised use 14 Place of use 14 Residual risks 15 Residual risks 15 Special risks associated with using the truck and attachments 15 Overview of hazards and countermeasures 16 Danger to employees 18 2 Safety Definition of terms used for responsible persons 22 Operating company 22 Speci...

Page 6: ...32 Battery connection cables 32 EMC Electromagnetic compatibility 33 3 Views Main Components 36 Dataplate and safety labels 38 Load label 39 Nameplate variant 1 40 Identification plate 40 Nameplate variant 2 41 Identification plate 41 4 Operation Intended use of the trucks 44 First use 44 Daily checks before use 44 Checking the working environment 45 Cleaning the Forklift 46 General information on...

Page 7: ...General 70 Servicing and maintenance personnel training and qualification 70 Battery maintenance staff 71 Maintenance operations that do not require special training 71 Technical inspection and maintenance data 71 Maintenance 1000 hours every 12 months 71 Maintenance 2000 hours every 2 years 74 Maintenance work 75 Changing the battery 75 Lubrication point 77 Check the hydraulic oil level 78 Toppin...

Page 8: ...echnical data ECV 10 Technical Datasheet 88 ECV 10i C ECV 10 C Technical Datasheet 91 Eco design requirements for electric motors and variable speed drives 94 Table of contents VI 50028011505 EN 03 2022 06 ...

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: ... 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 Introduction 1 Your industrial truck 3 50028011505 EN 03...

Page 12: ...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 change or ...

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 50028011505 EN 03 2022 06 ...

Page 15: ... Betriebssicherheitsverordnung German implementation of the EU working 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 Be...

Page 16: ... compartment 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 eq...

Page 17: ...nieure 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 vehicle are forward 1 reverse 4 left 2 and right 3 Introduction 1 Information about documentation 9 50028011505 EN 03 2022 06 ...

Page 18: ...cedures 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 50028011505 EN 03 2022 06 ...

Page 19: ...nd 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 Series The electric Pallet Stacker is suitable for stacking operations in narrow aisles and con fined spaces This series of electric pallet stacker includes the following models...

Page 20: ...and lowering devices can be operated using one hand without changing grip The anti crush button 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 control of driving speed Jolt free starting and smooth acceleration to maximum speed Simply release or turn the drive direction switch to bra...

Page 21: ... 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 22: ...n be used in indoors The sites on which the truck is used must comply with the applicable regulations condi tion of the ground lighting etc The ground must have sufficient load capacity concrete asphalt The truck is suitable for indoor use tempera tures ranging from 5 C to 40 C The maxi mum operation altitude is up to 2000 m The operator see chapter entitled Definition of terms used for responsibl...

Page 23: ...afety 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 24: ... 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 and ...

Page 25: ...n 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 structi...

Page 26: ...ight 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 The operating company must identify and evaluate the dangers involved in using the truck It must also establish which occupation al health and...

Page 27: ...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 employers liability in surance...

Page 28: ...Introduction 1 Residual risks 20 50028011505 EN 03 2022 06 ...

Page 29: ...2 Safety ...

Page 30: ... and generally recognised technical directives and conven tions standards VDE regulations technical regulations of other European Union mem ber states or countries that are signatories to the treaty that established the European Economic Area This expertise allows him to assess the condition of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per so...

Page 31: ...tood the operating manual have familiarised himself with safe opera tion of the truck be physically and mentally able to drive the truck safely DANGER The use of drugs alcohol or medications that affect reactions impair the ability to drive the truck Individuals under the influence of the aforementioned substances are not permitted to perform work of any kind on or with the truck Prohibition of us...

Page 32: ...ck 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 desig...

Page 33: ...ible 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 must not be modified Work on the electric installation e g connect ing a radio additional lights or other accesso ries is permitted onl...

Page 34: ... 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 35: ...e 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 th...

Page 36: ...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 37: ...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 w...

Page 38: ...m 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 Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and consumption In case of injury seek medical advice immediately WARNING Battery ac...

Page 39: ...only be carried out in areas designated for this purpose Take care to minimise as far as pos sible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of battery acid must be neutral ised immediately Safety 2 Safety r...

Page 40: ...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 41: ...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 regu...

Page 42: ...Safety 2 EMC Electromagnetic compatibility 34 50028011505 EN 03 2022 06 ...

Page 43: ...3 Views ...

Page 44: ...inder Battery discharge indicator Battery charge connector Emergency brake switch Lift mechanism 1 2 3 4 5 6 7 8 9 Battery Chassis Balance wheel Cover nether Driving wheel Cover upper Tank Hydraulic Pump 10 11 12 13 14 15 16 17 Views 3 Main Components 36 50028011505 EN 03 2022 06 ...

Page 45: ...Tiller Lower button Lift button Travel switch 18 19 20 Warning signal button Collision safety switch 21 22 Views 3 Main Components 37 50028011505 EN 03 2022 06 ...

Page 46: ...n only Indicator label Truck slinging label Driving safety label Adjust position for ini tial lift version only 1 2 3 4 5 6 7 Company logo LOGO sticker Load curve Vehicle body number Warning label For initial lift version only Importer label for UK 8 9 10 11 12 13 Views 3 Dataplate and safety labels 38 50028011505 EN 03 2022 06 ...

Page 47: ...tionship between the position of the load centre and the maximum load Before loading check that the load and load centre distance are within the range permitted by the bearing capacity icons Views 3 Load label 39 50028011505 EN 03 2022 06 ...

Page 48: ...n permissible 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 Nameplate variant 1 40 50028011505 EN 03 2022 06 ...

Page 49: ...Refer to technical 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 Nameplate...

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 Nameplate variant 2 42 50028011505 EN 03 2022 06 ...

Page 51: ...4 Operation ...

Page 52: ...ated with this usage will enable him to put in place any necessary additional safety measures First use Carried out Check forward and reverse driving control functions Check lifting and lowering control functions Check meter status Check brake system function Check the emergency off switch Check horn Check safety reverser function Check battery status Check steering function Check for oil leakage ...

Page 53: ... route The driver must be vigilant about anything that could hinder safe operation There must not be any people in the vicinity of the vehicle There must not be any people under the forks after they have been lifted The driver must not use a media player or any other electronic device that may affect their peripheral awareness There must be no trace of grease on the floor The driver must be partic...

Page 54: ...battery manufacturer s instructions Refilling batteries with an electrolyte solu tion is prohibited if they are a type that does not require maintenance Batteries are recycled in accordance with national regulations please comply with the relevant regulations Open flames are prohibited when handling batteries as the gas may cause an explo sion Non flammable materials or liquids may be stored in lo...

Page 55: ...s After turning on the device with the key switch the remaining charge and total run time will be displayed The remaining charge indicator will change colour based on charge changes Indicator colour Remaining charge reference value Green 70 100 Orange 30 60 Red flashing 0 20 NOTE When 70 of the battery has been dis charged the indicator will start flashing red and give a Battery Low warning NOTE W...

Page 56: ...ce with charging requirements Park the truck as specified Unplug the mains plug 1 then plug it into a suitable power supply CAUTION There is a risk of damage to the equipment The charging voltage range is 100 240V Please do not exceed this voltage range Charging indicator 2 Charging indicator 2 Description Malfunction analysis Red light remains lit Charger is charging Normal status Green light rem...

Page 57: ...pment Charging equipment damaged remove battery Indicator lights fail to light up Charging equipment fault The input power cable is dis connected or the charging equipment is damaged Operation 4 Charging and discharging batteries 49 50028011505 EN 03 2022 06 ...

Page 58: ...eas and the load CAUTION To prevent the bottom of the lifting system from scraping the ground always raise the forks half way up before setting off Remember to turn off the power supply before leaving the equipment For effective protection wearing safety footwear is compulsory When travelling the mast must be tilted backward and the load must be in the lowered position CAUTION Driving safety instr...

Page 59: ...tarting Pull the emergency off switch 2 to the raised position Turn the key switch 1 to the ON position the battery indicator light will come on Operation 4 Drive operations 51 50028011505 EN 03 2022 06 ...

Page 60: ...vel Forward travel Use your thumb to press the drive switch gently and gradually increasing the force in the F direction The vehicle will accelerate and move forwards according to the pressure applied to the drive switch Reverse drive Use your thumb to press the drive switch gently and gradually increasing the force in the R direction The vehicle will accelerate and move back wards according to th...

Page 61: ...r supply will be cut off Automatic braking Releasing the tiller 1 will initiate forced braking Slackening the tiller 1 will cause it to move to the braking area B Alternatively lowering the tiller to the brake area B at the bottom will also initiate forced braking CAUTION If the tiller moves slowly into the brake position iden tify the cause and rectify the fault If necessary replace the gas sprin...

Page 62: ...elling brakes the vehicle by reverse current until it starts moving in the opposite direction Safety reverser To protect the driver from any risk of being trapped between an obstacle and the ma chine the end of the tiller is fitted with a safety reverser Once the safety reverser is triggered 1 the equipment will stop immediately then slowly move back in the direction of the fork Operation 4 Drive ...

Page 63: ...on routes with poor visibility and at junctions Press the horn button 1 located on the till er arm 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 Operation 4 Drive operations 55 50028011505 EN 03 2022 06 ...

Page 64: ... a load we recommend that you as cend slopes forwards Descending slopes Travel down slopes must always be forwards with the load uphill Without a load it is recommended that slopes are descended forwards In all cases you must travel at a very low speed and brake very gradually DANGER Risk to life and or risk of serious damage to equip ment Never park the truck on a slope Never make a U turn or tak...

Page 65: ...t exceeds the specified gradi ent is prohibited due to limited braking capacity Starting on a slope Activate the direction control button in the required direction Put the tiller in drive Release the control button in order to brake Operation 4 Drive operations 57 50028011505 EN 03 2022 06 ...

Page 66: ...he equipment immediately Only transport loads that have been positioned and secured in accordance with regulations Adopt appropriate protective measures if the load is at risk of tipping over or falling during transport Do not use damaged handling tools to handle a load Never stay under raised load components Personnel are prohibited from entering load com ponents This equipment must not be used t...

Page 67: ...load Ensure that its weight does not exceed the equipment s lift capacity Refer to the nominal capacity specified on the equipment s capacity rating plate Also make sure that the load is stable well balanced and centred between the forks to avoid dropping any part of the load Check that the width of the load is compati ble with the width of the forks CAUTION Safety footwear must be worn CAUTION Tr...

Page 68: ...ntimetres Carrying a load DANGER Personnel must not stand under or near the truck when the load is in the raised position DANGER Never transport a load with the forks in the raised position as the equipment may become unstable Always drive forwards for optimum visibility When carrying a load on a slope always climb and descend with the load uphill Nev er travel diagonally across the slope or make ...

Page 69: ...ouch nearby loads or loads positioned be hind the equipment CAUTION Before you remove the load ensure that there are no people in the vicinity Stacking a load Carefully drive the machine to the required location Raise the forks clearly above the level where the load is to be placed Drive the truck forward into the racking Lower the load until the fork arms are free Move the forks straight back Low...

Page 70: ... maintain maximum stability never use the initial lift control to avoid overloading the equipment Emergency lowering The solenoid valve is equipped with an emer gency lowering screw for manual emergency lowering This operation can be executed if the hydraulic system develops a fault The sole noid valve with the emergency lowering screw is located on the valve body of the hydraulic pump CAUTION Do ...

Page 71: ... Unscrew the two large flat head screws 1 and pull out the cover 2 The emergency lowering screw is located on the solenoid valve 2 Operation 4 Hydraulic operations 63 50028011505 EN 03 2022 06 ...

Page 72: ... 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 NOTE Precautions prior to decommissioning Thoroughly clean the truck Check the brakes Check the hydraulic oil level Top up if re quired Apply a thin layer of oil or grease to all un painted mechanical components Lubricate the truck in accordance with...

Page 73: ...Charge the battery Check whether the hydraulic oil contains condensation water Change the hydraulic oil according to requirements Put the equipment back into use 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 swi...

Page 74: ...ting de vice Correctly install the hook according to the lifting label shown in the figure Machine weight with battery See Technical Data sheet DANGER Personnel must not stand under or next to the truck when it is being lifted Do not sling the truck by the tiller Operation 4 Slinging 66 50028011505 EN 03 2022 06 ...

Page 75: ...cure the front and rear of the vehicle Standard mast tie points and position Lower the fork arms to the lowest position Use wooden chocks 1 to secure the front and rear of the vehicle Pass the tensioner through the inner and outer masts and secure the masts to the upper fixing points of the vehicle as indica ted by position 2 in the figure Tighten by pulling in the direction of the arrow Operation...

Page 76: ...Operation 4 Transporting the truck 68 50028011505 EN 03 2022 06 ...

Page 77: ...5 Maintenance ...

Page 78: ...hecklist 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 a...

Page 79: ...ed out by persons with no special training A specific qualification is not necessary Complicated maintenance operations such as replacing the battery replacing the wheels and so on should be carried out by the author ised service centre Refer to the maintenance section of this man ual for further information Technical inspection and maintenance data Assembly Item oil Capacity standard value Main h...

Page 80: ...ystem Check cylinders for damage and leakage and ensure that they are properly secured Check that the oil tank is fixed and check it for leaks Check the hydraulic oil level Check hoses pipes and interfaces for damage and ensure their tightness and seal ing Check overflow pressure Lifting system Check whether mast is damaged Check lifting and lowering speeds Clean and lubricate the rolling surface ...

Page 81: ...rs wear strips and stoppers Other Check chassis for cracks or damage Check cover for cracks Check connections between nuts and bolts Check that all support components are intact Check that labels are clear and complete Check caster for wear and tear Maintenance 5 Maintenance 1000 hours every 12 months 73 50028011505 EN 03 2022 06 ...

Page 82: ...s 2000 4000 6000 8000 10000 12000 14000 Carried out Note Perform all 1000 hour maintenance work Hydraulic system Change the hydraulic oil Replace oil tank air filter and filter Maintenance 5 Maintenance 2000 hours every 2 years 74 50028011505 EN 03 2022 06 ...

Page 83: ...according to regula tions and turn off the power before removing and installing batteries Removing batteries Unscrew the 2 screws 1 and remove the cover 2 Unscrew the 2 screws 3 and remove the battery cover 4 Maintenance 5 Maintenance work 75 50028011505 EN 03 2022 06 ...

Page 84: ... avoid short circuits Installing the battery Install the batteries in reverse order paying attention to the location where the batteries are installed and whether the wiring is cor rect NOTE Route the battery cable so that it is not trap ped when the battery is inserted Maintenance 5 Maintenance work 76 50028011505 EN 03 2022 06 ...

Page 85: ...Lubrication point Maintenance 5 Maintenance work 77 50028011505 EN 03 2022 06 ...

Page 86: ...ppropriate Sliding sur faces C Moly lithium grease no 3 100 g Transmis sion Table for lubrication of sliding surfaces Code Position used L1 Caster L2 Rollers L3 Channel and rollers L4 Chains L5 Steering bearing L6 Drive wheel Check the hydraulic oil level NOTE If there are popping noises coming from the tubing when lifting this indicates that the hy draulic oil is insufficient and should be prompt...

Page 87: ... marks NOTE You can lift again after you have finished add ing the oil You must continue checking the hydraulic oil level if there is still a banging noise Reinstall the disassembled parts in reverse order NOTE Only use hydraulic oil that meets the specifica tions Refer to Lubricants Topping up the gear oil CAUTION Do not add gear oil that contains impurities Maintenance 5 Maintenance work 79 5002...

Page 88: ...Fully lower the mast Press the emergency off switch Remove the front hood Check that all fuses are in working order If necessary replace them with fuses that match the parameters specified in the table below No Checking fuses for the fol lowing functions or compo nents Value 1 Traction lift motor fuse 150A 2 Control system fuses 10A Maintenance 5 Maintenance work 80 50028011505 EN 03 2022 06 ...

Page 89: ... 11 and drive wheel 12 by order Installation Install according to the reverse order of re moval CAUTION Tyre wear can affect the stability of the truck adjust the caster with minor wear on a regular basis or re place the caster with heavy wear Quality of tyres directly affects the stability and driv ing performance of the device If you need to replace the factory fitted tyres please use original s...

Page 90: ...ON When replacing wheels be sure that the truck won t tilt Remove the coiled elastic cylindrical pin 2 within the wheel bridge 1 with an ejector pin of 4mm in diameter Turn the wheel bridge to vertical direction knock out the wheel pin shaft 3 from side and remove the load wheel and bearing as sembly Remove the bearing 5 of load wheel 4 with hammer and jacking equipment Installation and Commission...

Page 91: ...k WARNING Make sure the lifting equipment is solid and secure and the load capacity should be greater than the total weight of the vehicle Lifting height of not more than 300mm to prevent the hazards to the maintenance personnel working under the vehicle for caster re moval and installation Unscrew four screws 1 then remove the caster 3 and adjustment shim 2 Installation Install according to the r...

Page 92: ...rmance of the device If you need to replace the factory fitted tyres please use original spare parts provided by the equipment manufacturer to reach the original design performance of the truck Upon maintenance or replacement for parts of the caster please refer to Figure 116702_04 006 Malfunction analysis Symptoms Possible reason Solution Unable to drive The key switch lock is in the OFF position...

Page 93: ...ion plate NOTE Please contact an authorised dealer if you have performed all of the steps listed in the ta ble above but are still unable to eliminate the fault Further fault identification and elimination operations must be performed by after sales service personnel who have undergone spe cial training Maintenance 5 Malfunction analysis 85 50028011505 EN 03 2022 06 ...

Page 94: ...Maintenance 5 Malfunction analysis 86 50028011505 EN 03 2022 06 ...

Page 95: ...6 Technical data ...

Page 96: ...ECV 10 Technical Datasheet Technical data 6 ECV 10 Technical Datasheet 88 50028011505 EN 03 2022 06 ...

Page 97: ...lly loaded drive side load side kg 596 1002 2 3 Axel load when unloaded drive side load side kg 446 152 Wheels ECV 10 3 1 Tyres drive side load side C solid rubber P polyur ethane PU PU 3 2 Tyre size drive side mm Ø210 X 70 3 3 Tyre size load side mm Ø80 X 60 3 5 Number of wheels front rear X drive 1x 1 4 Dimensions ECV 10 4 2 Lowered mast height h1 mm 2097 4 3 Free lift height h2 mm 150 4 4 Lift ...

Page 98: ...ormance ECV 10 5 1 Travel speed with without load km h 4 5 4 8 5 2 Lifting speed with without load m s 0 12 0 22 5 3 Lowering speed with without load m s 0 2 0 13 5 8 Climbing ability with without load 5 15 5 1 0 Brake type Electromagnetic brake Drive ECV 10 6 1 Drive motor 60 minutes kW 0 65 6 2 Lift motor 10 power kW 2 2 6 3 Battery to DIN 43 531 35 36 A B C no 6 4 Battery voltage capacity 5 hou...

Page 99: ...ECV 10i C ECV 10 C Technical Datasheet Technical data 6 ECV 10i C ECV 10 C Technical Datasheet 91 50028011505 EN 03 2022 06 ...

Page 100: ... ECV 10 C ECV 10i C 2 1 Service weight with battery kg 462 520 2 2 Axel load when fully loaded drive side load side kg 530 950 580 1140 2 3 Axel load when unloaded drive side load side kg 350 120 350 170 Wheels ECV 10 C ECV 10i C 3 1 Tyres drive side load side C solid rub ber P polyurethane PU PU PU PU 3 2 Tyre size drive side mm Ø210 X 70 Ø210 X 70 3 3 Tyre size load side mm Ø80 X 60 Ø80 X 60 3 5...

Page 101: ...nd clearance centre of wheelbase min max m2 m m 28 26 4 3 4 Aisle width 800 x 1200 pallet length wise Ast mm 2100 2260 4 3 5 Turning radius Wa mm 1337 1500 Performance ECV 10 C ECV 10i C 5 1 Travel speed with without load km h 4 4 5 4 4 5 5 2 Lifting speed with without load m s 0 10 0 17 0 10 0 14 5 3 Lowering speed with without load m s 0 2 0 13 0 2 0 13 5 8 Climbing ability with without load 5 1...

Page 102: ...ulation EU 2019 1781 because these motors do not meet the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variab...

Page 103: ...9 Driver rights duties and rules of behaviour 23 Drivers 22 Drive Wheel 81 E EC declaration of conformity in accordance with the Machinery Directive 4 EMC Electromagnetic compatibility 33 Emergency lowering 62 F First use 44 Forward travel reverse travel 52 Fuse checking 80 G Gear oil checking 79 General 2 70 H Hazards and countermeasures 16 Horn operation 55 Hydraulic fluid 30 I Identification pl...

Page 104: ... 51 Steering 55 T Technical datasheet 88 91 Technical description 12 Technical inspection and maintenance da ta 71 Transporting the truck 67 U Unauthorised use 14 Update of this manual 7 Use of the mast 58 Use on a slope 55 W Warning regarding non original parts 24 Working environment check 45 Working with loads 59 Index 96 50028011505 EN 03 2022 06 ...

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Page 106: ...STILL GmbH 50028011505 EN 03 2022 06 ...

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