Still ECH 12 Original Instructions Manual
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Still ECH 12 Original Instructions Manual

Electric pallet truck
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Original instructions
Electric pallet truck
ECH 12
0139
50018011505 EN - 10/2018

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  • Page 1 Original instructions Electric pallet truck ECH 12 0139 50018011505 EN - 10/2018...
  • Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de Made in China Rules for the operating company of industrial trucks In addition to these operating instructions,...
  • Page 4 Preface Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 50018011505 EN - 10/2018...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... 2 General .
  • Page 6 Table of contents Safety tests ............25 Carrying out regular inspections on the truck .
  • Page 7 Table of contents Operating instructions ..........53 Checks before use .

  • Page 9: Introduction

    Introduction...

  • Page 10: Your Industrial Truck

    Introduction Your industrial truck Your industrial truck General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used.

  • Page 11: Ce Labelling

    Introduction Your industrial truck CE labelling The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. This is confirmed by the issued EC declaration of conformity. The CE labelling is attached to the nameplate.

  • Page 12: Ec Declaration Of Conformity

    Introduction Information about documentation EC declaration of conformity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the machine according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC...

  • Page 13: Copyright And Property Rights

    Introduction Information about documentation proper maintenance of the truck in all possible If the operating instructions are lost, the oper- variants at the time of printing. Special de- ator must immediately request a replacement signs to meet customer requirements are doc- from the manufacturer.

  • Page 14: Explanation Of Symbols Used

    Introduction Information about documentation Explanation of symbols used DANGER Compulsory procedure that must be followed to avoid danger to life or physical harm. WARNING Compulsory procedure that must followed to avoid injury. CAUTION Compulsory procedure that must be followed to avoid material damage and/or destruction.

  • Page 15: Date Of Edition And Latest Update Of This Manual

    Introduction Information about documentation Date of edition and latest update of this manual The publication date of these operating instructions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks, and therefore reserves the right to implement changes and to accept no claims concerning the information provided in this manual.
  • Page 16 Introduction Information about documentation Abbrevi- Meaning Explanation ation European standard European Federation of Materials Han- Fédération Européene de la Manutention dling and Storage Equipment Maximum power maximum Force German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless GPRS...
  • Page 17 Introduction Information about documentation Abbrevi- Meaning Explanation ation Verein Deutscher Ingenieure German technical/scientific association Verband Deutscher Maschinen- und German Mechanical Engineering Industry VDMA Anlagenbau e.V. Association WLAN Wireless LAN Wireless local area network 50018011505 EN - 10/2018...

  • Page 18: Environmental Considerations

    Introduction Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during transport. This packaging must be removed completely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck. Disposal of components and batteries The truck is composed of different materials.

  • Page 19: Use Of The Truck

    Introduction Use of the truck A gas spring enables the tiller to quickly return Simply release or turn the drive direction to the vertical position after it is released. switch to brake. Booster circuit prevents the truck rolling back Tiller when starting on a gradient.

  • Page 20: Unauthorised Use

    Introduction Use of the truck Unauthorised use Any danger caused as a result of unauthorised The forklift truck should not be used in areas use becomes the responsibility of the operator where there is a risk of fire, explosion or or driver and not that of the manufacturer.

  • Page 21: Residual Risks

    Introduction Residual risks Residual risks Residual risks Despite careful operation and compliance with – Escape of consumables due to leakages or all applicable standards and regulations, the the rupture of lines, hoses or containers. possibility of other dangers when using the –...

  • Page 22: Overview Of Hazards And Countermeasures

    Introduction Residual risks Overview of hazards and counter- measures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
  • Page 23 Introduction Residual risks Hazard Measure Check note Notes √ Complete - Not applicable Impermissible usage Issuing of operating German Ordinance on (improper usage) instructions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of German Ordinance on instruction to driver Industrial Safety and...
  • Page 24 Introduction Residual risks Hazard Measure Check note Notes √ Complete - Not applicable When charging the Note the German Association for traction battery Ordinance on Electrical, Electronic Industrial Safety and and Information Health (BetrSichV), Technologies (VDE) the operating regulation 0510: In instructions and the particular German Engineering...

  • Page 25: Danger To Employees

    Introduction Residual risks Danger to employees The operating company must identify and The results must be published. In the case evaluate the dangers involved in using the of truck deployment involving similar hazard truck. It must also establish which occupa- situations it is permitted to summarise the tional health and safety measures are required results.
  • Page 26 Introduction Residual risks 50018011505 EN - 10/2018...

  • Page 27: Safety

    Safety...

  • Page 28: Safety Regulations

    Safety Safety regulations Safety regulations These operating instructions, which come • Regular checks and technical inspections with the truck, must be communicated to all • Recycling of lubricants, oils and batteries those concerned and in particular to personnel • Residual risks. responsible for maintenance and driving.

  • Page 29: Drivers

    Safety Definition of terms used for responsible persons ally recognised technical directives and signatories to the treaty that established the conventions (standards, VDE regulations, European Economic Area). This expertise technical regulations of other European allows him to assess the condition of indus- Union member states or countries that are trial trucks in terms of health and safety Drivers...

  • Page 30: Basic Principles For Safe Operation

    Original parts, attachments and accessories attachment parts and accessories supplied are specially designed for this truck. We by other companies have not been tested or draw your attention to the fact that parts, approved by STILL. 50018011505 EN - 10/2018...

  • Page 31: Damage, Faults

    Safety Basic principles for safe operation CAUTION The installation or use of such products may have a negative impact on the design of the truck and thus impair active or passive driving safety. We recommend that you obtain approval from the manufacturer and, if applicable, from the relevant regulatory authorities before installing such parts.

  • Page 32: Vibrations

    Safety Basic principles for safe operation Vibrations Vibrations to which the hands and arms CAUTION are exposed The value expressed above can be used to com- pare forklift trucks of the same category. It cannot The following value is valid for all truck models: be used to determine the operator's daily expo- •...

  • Page 33: Safety Tests

    Safety Safety tests Safety tests Carrying out regular inspections on the truck The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, the technical con- dition of the truck must be completely tested with regard to accident safety.
  • Page 34 Safety Safety tests The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck's electrical system and drive batte- ries must be checked separately. Test values for the drive battery Recommended Nominal voltage Component Measurements Test values...

  • Page 35: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Refer to the maintenance data table for the permissible substances necessary for Consumables can be dangerous. operation. It is necessary to follow the safety regulations when handling these substances.

  • Page 36: Hydraulic Fluid

    Safety Safety devices Hydraulic fluid WARNING Hydraulic fluid is a water-polluting substance! During operation of the forklift truck, Always store hydraulic fluid in containers hydraulic fluids are pressurised and complying with the regulations. are hazardous to your health. Avoid spilling. –...

  • Page 37: Battery Connection Cables

    Safety Battery connection cables The safety mechanisms and switches must Work on the electric installation (e.g. connect- never be removed or disabled. The predefined ing a radio, additional lights or other acces- setpoint values must not be modified. sories) is permitted only with the approval of the manufacturer.

  • Page 38: Emc - Electromagnetic Compatibility

    Safety EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key An EMC test thus firstly measures the electro- quality feature of the truck. magnetic interference emitted by the truck and secondly checks it for sufficient resistance to EMC involves electromagnetic interference with reference •...

  • Page 39: Views

    Views...

  • Page 40: Drive Directions

    Views Drive directions Drive directions The drive directions of the truck are forward (1) and reverse (2). 50018011505 EN - 10/2018...

  • Page 41: Overview Of Main Components

    Views Overview of main components Overview of main components Tiller Hydraulics cowling Rollers Front protective panel Battery Emergency stop switch 50018011505 EN - 10/2018...

  • Page 42: Control Handle

    Views Control handle Control handle Horn switch Lifting switch Power display Manual lowering handle Emergency reverse switch Drive switch Handle 50018011505 EN - 10/2018...

  • Page 43: Installing The Operating Handle

    Views Installing the operating handle Installing the operating handle Square operating tube Square tube harness Mounting base Wire Screw (M6x10) Bracket Control harness Ball head wire – Connect the square tube harness connector to the control harness. – Insert wire (6) and ball head wire (8) into bracket (7) (press the hydraulic pressure release switch from the right side cover aux- iliary hole), release the pressed hydraulic...

  • Page 44: Instrument Display

    Views Instrument display release switch, the ball head wire (8) will become taut and correctly installed. – Use 4 screws to install the square control tube on the mounting base (standard torque). Instrument display Normal display state Horn in normal working state Interlock switch status, acceleration status (flashing) Total operating time...
  • Page 45 Views Instrument display Charge percentage display Motor temperature too high 50018011505 EN - 10/2018...
  • Page 46 Views Instrument display Other battery faults Battery CAN signal not connected 50018011505 EN - 10/2018...
  • Page 47 Views Instrument display Controller CAN signal not switched on F.X.X:Error code (X refers to a number) 50018011505 EN - 10/2018...

  • Page 48: Safety Devices And Warning Labels

    Views Safety devices and warning labels Safety devices and warning labels “Forbid stampede” label "Pallet truck model" label "Anti-pinch" label "Instructions" label "Identification plate" label Slinging label "Filler port" label Chassis NO. 50018011505 EN - 10/2018...

  • Page 49: Identification Plate

    Views Identification plate Identification plate Type Own mass (self weight) in kg without battery Serial number Manufacturer Year of manufacture Refer to technical data listed in this operating Unladen mass in kg instructions for more detailed information Max. permissible battery weight in kg (for CE label electric trucks only) Rated drive power in kW...
  • Page 50 Views Identification plate 50018011505 EN - 10/2018...

  • Page 51: Operation

    Operation...

  • Page 52: Handling Of The Lithium-Ion Battery

    Operation Handling of the Lithium-Ion battery Handling of the Lithium-Ion battery Information on the conformity of lithium-ion batteries The manufacturer of the lithium-ion battery in accordance with EN 61000–6–2:2006 and and Kion group provider declares that: EN 61000–6–3:2007. the lithium-ion battery This declaration of conformity with EC direc- tives applies only to battery use that conforms conforms with the provisions of the following...

  • Page 53: Special Lithium-Ion Safety Rules

    Operation Handling of the Lithium-Ion battery Special lithium-ion safety rules DANGER • Do not submit the battery to excessive mechanical constraints There is a risk of fire. • Do not expose the battery unit to humidity or Have class D fire extinguishers or inert gas, carbon water (>...

  • Page 54: What To Do In The Event Of Incorrect Use

    Operation Handling of the Lithium-Ion battery What to do in the event of incorrect use Lithium-ion batteries present no chemical – Do not make the person vomit danger in the context of normal use. Batteries – See a doctor as quickly as possible must not be opened or burned for example.

  • Page 55: Personal Protective Measures Following An Incident

    Operation Handling of the Lithium-Ion battery DANGER DANGER Electrical risk Risk of explosion: release of gas that may create an explosive atmosphere Do not use water on connected batteries in the charging room. After extinguishing the fire, establish a safety perimeter of at least five metres around the battery.
  • Page 56 Operation Handling of the Lithium-Ion battery – Put the contaminated absorbent product DANGER in a plastic bag and dispose of it as special Environmental danger waste according to the local regulations in Do not reuse a lithium-ion battery that has leaked. force Call the After-Sales Service Centre.

  • Page 57: Transporting A Lithium-Ion Battery

    Operation Handling of the Lithium-Ion battery Transporting a lithium-ion battery Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train authorised staff to dispatch lithium-ion batteries.

  • Page 58: Scrapping Lithium-Ion Batteries

    Operation Handling of the Lithium-Ion battery Scrapping lithium-ion batteries • Use packaging that complies with interna- ENVIRONMENT NOTE tional regulations Comply with current regulations for scrapping • Use the original packaging, if possible. Use batteries. Take care to minimise, as far as sturdy packaging capable of bearing the possible, any impact on the environment.

  • Page 59: Labels On The Lithium-Ion Batterys

    Operation Handling of the Lithium-Ion battery Labels on the lithium-ion batterys Battery nameplate No impact No collision 50018011505 EN - 10/2018...

  • Page 60: Lithium-Ion Batteries: Long-Term Storage

    Operation Handling of the Lithium-Ion battery Lithium-ion batteries: Long-term storage Storage of trucks for a period of less than DANGER two months Electrical danger We recommend that batteries are stored at a height If the truck is not used for a period of up to between 60 and 120 cm.

  • Page 61: Operating Instructions

    Operation Operating instructions – Raise and chock the truck: the wheels must all points and devices that are important for not touch the ground in order to prevent truck safety. irreversible deformation of the tyres. Carry out the following operations: –...

  • Page 62: Checks Before Use

    Operation Checks before use CAUTION WARNING Equipment wear or damage Risk of serious injury and/or major equipment damage. Safety shoes must be worn to provide effective protection. Before driving forwards or backwards, carefully check in the direction of travel to ensure that it is safe to proceed.

  • Page 63: Break-In Period Precautions

    Operation Break-in period precautions • Visual check if there are any broken hoses If the truck is parked for too long, the wheels or broken electric wires. may become slightly flattened where they touch the ground.The flat areas will automat- •...
  • Page 64 Operation Drive system – Tilt the control handle to the drive position. – Rotate the drive button to drive the vehicle forward or backward. CAUTION Carry out a routine inspection on the vehicle before using it. NOTE The drive switch can be used to adjust the vehicle’s speed.

  • Page 65: Lifting, Lowering, Braking And Using The Horn

    Operation Drive system Lifting, lowering, braking and using the horn Lifting – Press and hold down the lift button on the control handle (1).The forks will be lifted to the maximum height until they stop by themselves. Manual lowering – Pull and hold the manual lower switch (2).The forks will lower to the minimum height until they stop by themselves.
  • Page 66 Operation Drive system Mechanical operating brake The truck is braked when the operating handle is released. The mechanical brake engages when the tiller is positioned in areas (1) and (3). Reverse braking – Braking can be accomplished by changing the direction of travel. –...

  • Page 67: Safety Reverse And Emergency Stop

    Operation Drive system Horn – Press the warning horn button (1). NOTE The horn must be used at junctions or places with poor visibility. Safety reverse and emergency stop Safety reverse – Press the safety reverse button (1). The vehicle will begin to travel in the opposite direction.

  • Page 68: Using The Truck On A Slope

    Operation Drive system Emergency stop – Press the emergency switch (2). All power will be cut off and the vehicle will stop working. CAUTION When the emergency stop button (2) is pressed, it will lock in position.Rotate the button clockwise half a turn to release it.Do not pull hard, as it will reset on its own.
  • Page 69 Operation Drive system Descending slopes Travel down slopes must always be forwards, with the load uphill. Without a load, it is recommended to descend slopes forwards. In all cases, travel at a very low speed and brake very gradually. DANGER Risk to life and/or risk of major equipment damage.

  • Page 70: Load Handling

    Operation Load handling Load handling Safety guidelines for handling loads WARNING DANGER Closely observe the following instructions before Risk of accident when forks are changed: picking up loads.Never touch or stand on moving If the forks are changed and a different type of parts of the truck (e.g.

  • Page 71: Loading

    Operation Load handling Loading Loading CAUTION Before lifting a load, ensure that its weight does not exceed the truck’s maximum load capacity. – Refer to the rated load capacity specified on the truck's identification plate. – Ensure that the load is stable and uniform to prevent any partial spillage.
  • Page 72 Operation Load handling – Raise the load a few centimetres above its support. – 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 visibility.

  • Page 73: Parking The Vehicle Safely

    Operation Parking the vehicle safely Parking the vehicle safely – Lower the forks to the lowest position. – Remove the magnetic key. WARNING Do not park the truck on slopes. If unavoidable, secure the truck with chocks. Never leave the truck with the load raised. CAUTION The forks must be fully lowered.

  • Page 74: Battery Use

    Operation Battery use Battery use Mounting the battery charger NOTE The charging stand can be secured to the wall using expansion screws (1). Battery precautions – Avoid the battery becoming corroded by water or corrosive liquid. 50018011505 EN - 10/2018...
  • Page 75 Operation Battery use – Keep the battery away from all fire sources, heat sources and flammable or explosive materials. – Do not place the battery on top of conductive objects. WARNING If this happens, the battery may leak, emit heat or smoke, which may lead to a serious fire or explosion.
  • Page 76 Operation Battery use – The charging environment temperature should be 0°C to 40°C. WARNING If the battery fails, please contact an authorised dealer to have it repaired. Do not disassemble the battery. 50018011505 EN - 10/2018...

  • Page 77: Battery Charger

    Operation Battery use Battery charger Battery Charging stand LED light 50018011505 EN - 10/2018...
  • Page 78 Operation Battery use Battery charger – Remove the battery. – Plug into charging stand and charge (110/220V 50/60HZ). 50018011505 EN - 10/2018...
  • Page 79 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. 50018011505 EN - 10/2018...
  • Page 80 Operation Battery use Charging complete – The battery will take approximately 2.5 hours to fully charge at a voltage of 100–240 V AC. – Insert the battery into the vehicle's battery holder. 50018011505 EN - 10/2018...

  • Page 81: Hoisting

    Operation Hoisting – A fully charged battery can last for three hours of continuous use. WARNING Before returning the battery to the vehicle, ensure that the vehicle is powered off. CAUTION Identify the positive and negative terminals accor- ding to the charging stand contact pins. NOTE Due to the characteristics of lithium batteries, battery capacity is reduced in low-temperature...

  • Page 82: Truck Transport

    Operation Truck transport – 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.
  • Page 83 Operation Truck transport – Make sure the forks are aligned with the pallet, 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.

  • Page 84: Cleaning The Forklift

    Operation Cleaning the Forklift Cleaning the Forklift Cleaning depends on the type of use and the Use water-dampened rags to clean the parts workplace. Should the truck come into contact of the body. with highly aggressive elements such as salt CAUTION water, fertilizers, chemical products, cement, etc., it should be cleaned as carefully as...

  • Page 85: Maintenance

    Maintenance...

  • Page 86: General Servicing Information

    Maintenance General servicing information General servicing information General The following instructions contain all the The forklift must undergo functional testing information required for servicing your truck. and a trial run after each inspection. Carry out the various maintenance work in compliance with the maintenance plan.

  • Page 87: Inspection And Maintenance

    Maintenance Inspection and maintenance with the technical regulations and principles established for checking industrial trucks. Inspection and maintenance Maintenance - 1000 hours / every 6 months At operating hours 1000 3000 5000 7000 9000 Carried out 11000 13000 15000 17000 19000 ...

  • Page 88: Maintenance - 2000 Hours / Every 12 Months

    Maintenance Inspection and maintenance At operating hours 1000 3000 5000 7000 9000 Carried out 11000 13000 15000 17000 19000   Check link mechanism for wear or damage. Check whether pin shaft is fixed securely. Check and lubricate moving parts on link mechanism. Other Check connections between nuts and bolts.

  • Page 89: Technical Inspection And Maintenance Data

    Maintenance Inspection and maintenance At operating hours 2000 4000 6000 8000 10000 Carried out 12000 14000 16000 18000 20000   Check lifting and lowering speeds. Other Check chassis for cracks or damage. Technical inspection and mainte- nance data Lubricants table Designation Model no.
  • Page 90 Maintenance Inspection and maintenance Diagram for lubrication and servicing Hydraulic oil filler port Lubrication surface Gear oil filler port 50018011505 EN - 10/2018...
  • Page 91 Maintenance Inspection and maintenance Lubrication of sliding surfaces Steel stopper ball Steering bearing Drive wheel Drive wheel and drive chain Rollers 50018011505 EN - 10/2018...

  • Page 92: Essential Maintenance

    Maintenance Essential maintenance Essential maintenance Replacing the drive wheel Replacing the drive wheel – Remove the drive cowling (1). – Remove the plate (2). – Remove the motor and cable mounting base and remove the motor cables (3). – Loosen the six screws using a spanner, then remove the drive wheel (5) from the drive assembly (4).

  • Page 93: Replacing The Load Wheels

    Maintenance Essential maintenance Replacing the load wheels – Place a wooden block (1) under the load wheels to raise them off the floor. Double load wheels – Remove the spiral slotted spring pin on the wheel frame (1). – Turn the wheel frame to the vertical direc- tion.

  • Page 94: Changing The Hydraulic Oil

    Maintenance Essential maintenance Single load wheels – Use a knockout pin to remove the spiral slotted spring pin (1). – Tap out the wheel pin spindle from the side. – Remove the wheel (2) and bearing assem- bly (3). Changing the hydraulic oil –...
  • Page 95 Maintenance Essential maintenance – Remove the two screws on the left. – Remove the screw on the right. – Then remove the pump housing and motor. 50018011505 EN - 10/2018...
  • Page 96 Maintenance Essential maintenance – Remove the plug and drain the old hydraulic fluid from this hole. – Add new oil. 50018011505 EN - 10/2018...

  • Page 97: Technical Data

    Technical data...

  • Page 98: Main Technical Data

    Technical data Main technical data Main technical data 50018011505 EN - 10/2018...

  • Page 99: Technical Datasheet

    Technical data Technical datasheet Technical datasheet Description 1.1 Manufacturer Still 1.2 Model ECH 12 Drive type:Battery, diesel, petrol, LP gas, mains Battery power 1.4 Operation Pedestrian 1.5 Nominal loading capacity Q (kg) 1200 c (mm) 1.6 Load centre x (mm) 950 (880) 1.8 Axle centre to fork face...
  • Page 100 Technical data Technical datasheet Dimensions m2 (mm) 4.32 Ground clearance at centre of wheelbase, with load 4.34 Aisle width with 800 x 1200 mm pallet along forks Ast (mm) 2062 4.35 Turning radius Wa (mm) 1390 Performance data 5.1 Driving speed, full load/no load km/h 4.0/4.5 5.2 Lifting speed, full load/no load...
  • Page 101 Index Address of manufacturer ... . . I Hazards and countermeasures ..14 Attachments Hydraulic fluid ....28 Special risks .
  • Page 102 Index Parking the vehicle safely ... . 65 Signals ......6 Personal protective measures Special lithium-ion safety rules .
  • Page 104 STILL GmbH 50018011505 EN – 10/2018...

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