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Original instructions Electric pallet truck ECH 12 0139 5001 801 1505 EN - 12/2019...
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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. 5001 801 1505 EN - 12/2019...
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.
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.
Introduction Your industrial truck EC declaration of conformity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the machine Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006/42/EC...
Introduction Information about documentation Information about documentation Documentation scope Operating instructions fully and must be available to the driver and ● operator at all times. Operating instructions for attachment parts ● (special equipment) If the operating instructions are lost, the oper- Spare parts list ●...
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.
Introduction Information about documentation Date of edition and latest update of this manual The publication date of these operating in- structions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks, and therefore re- serves the right to implement changes and to accept no claims concerning the information provided in this manual.
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Introduction Information about documentation Abbrevi- Meaning Explanation ation German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless net- GPRS General Packet Radio Service works ID no. Identification number International Organization for Standardi- International standardisation organisation zation...
Introduction Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.
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Introduction Environmental considerations 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. The composite construction tiller head pro- Brake system vides excellent impact resistance.
Introduction Use of the truck Use of the truck Intended use of the trucks The table of characteristics and performance attach- CAUTION ed to this user manual gives you the information you need to check that the equipment is suitable for the This machine was designed for the transport and work being carried out.
Introduction Use of the truck Unauthorised use Any danger caused as a result of unauthor- Transporting people is prohibited. ised use becomes the responsibility of the op- The forklift truck should not be used in areas erator or driver and not that of the manufactur- where there is a risk of fire, explosion or corro- sion, or in areas that are particularly dusty.
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 –...
Introduction Residual risks Overview of hazards and countermeasures 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.
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Introduction Residual risks Hazard Measure Check note Notes √ Complete - Not applicable German Health and la- bour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and Health (BetrSichV) and German Health and la- bour protection law (ArbSchG) Note the German Ordi-...
Introduction Residual risks Hazard Measure Check note Notes √ Complete - Not applicable (BetrSichV), employ- employers' liability in- ers' liability insurance surance association association regulation regulation 104 104 and the operating instructions When parking LPG Note the German Ordi- German Ordinance on trucks nance on Industrial Industrial Safety and...
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Introduction Residual risks as to comply with the local provisions for de- event of non-compliance. If other major opera- ployment. tional hazards are involved, they must also be taken into consideration. The results must be published. In the case of truck deployment involving similar hazard sit- The working conditions for the trucks are uations it is permitted to summarise the re-...
Safety Safety regulations Safety regulations Regular checks and technical inspections These operating instructions, which come with ● the truck, must be communicated to all those Recycling of lubricants, oils and batteries ● concerned and in particular to personnel re- Residual risks. ●...
Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Operating company The operating company is the natural or legal The operating company is responsible for the person or group who operates the truck or on scheduling and correct performance of regular whose authority the truck is used.
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Safety Definition of terms used for responsible persons When leaving the truck, the driver must secure it against unauthorised use, e.g. by pulling out the key. 5001 801 1505 EN - 12/2019...
Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company prem- ises The company premises are very often restric- ted public traffic areas. NOTE It is advisable to review the operational liability insurance so that insurance covers the truck with respect to third parties in the event of damage caused in restricted public traffic areas.
We recommend that you obtain approval from the by STILL. manufacturer and, if applicable, from the relevant regulatory authorities before installing such parts. The manufacturer accepts no liability for any damage caused by the use of non-original parts and non-orig- inal accessories.
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 compare forklift trucks of the same category. It cannot be used The following value is valid for all truck mod- to determine the operator's daily exposure to vibra- els: tions during real operation of the truck;...
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 condi- tion of the truck must be completely tested with regard to accident safety.
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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 batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values...
Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. It is necessary to follow the safety regulations when handling these substances.
Safety Safety regulations for handling consumables Hydraulic fluid WARNING ENVIRONMENT NOTE During operation of the forklift truck, hy- draulic fluids are pressurised and are Hydraulic fluid is a water-polluting substance! hazardous to your health. Always store hydraulic fluid in containers com- –...
Safety Safety devices Safety devices Damage, faults Any damage or faults observed on the truck or Work on the electric installation (e.g. connect- the accessories must be reported immediately ing a radio, additional lights or other accesso- to the responsible personnel. The truck and ries) is permitted only with the approval of the accessories must never be used before they manufacturer.
Safety EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key secondly checks it for sufficient resistance to quality feature of the truck. electromagnetic interference with reference to the planned usage location . A number of EMC involves electrical measures are taken to ensure the limiting the emission of electromagnetic in-...
Views Overview of main components Overview of main components Tiller Battery Hydraulics cowling Emergency stop switch Rollers Front protective panel 5001 801 1505 EN - 12/2019...
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. 5001 801 1505 EN - 12/2019...
Views Instrument display – Insert wire (6) and ball head wire (8) into bracket (7) (press the hydraulic pressure re- lease switch from the right side cover auxili- ary hole), release the pressed hydraulic re- lease switch, the ball head wire (8) will become taut and correctly installed.
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Views Instrument display Charge percentage display Motor temperature too high 5001 801 1505 EN - 12/2019...
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Views Instrument display Other battery faults Battery CAN signal not connected 5001 801 1505 EN - 12/2019...
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Views Instrument display Controller CAN signal not switched on F.X.X:Error code (X refers to a number) 5001 801 1505 EN - 12/2019...
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 operat- Unladen mass in kg ing instructions for more detailed information Max. permissible battery weight in kg (for CE label electric trucks only) Rated drive power in kW...
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...
Operation Handling of the Lithium-Ion battery Special lithium-ion safety rules Do not expose the battery unit to humidity DANGER ● or water (> 95%) There is a risk of fire. Install the batteries in a Level 2 pollution ● Have class D fire extinguishers or inert gas, carbon zone in accordance with standard EN dioxide, powder or foam fire extinguishers near the 60664-1...
Operation Handling of the Lithium-Ion battery What to do in the event of incorrect use Lithium-ion batteries present no chemical dan- – See a doctor as quickly as possible ger in the context of normal use. Batteries must not be opened or burned for example. In the event of a fire In the event of exposure to the internal com- If a fire breaks out, follow these instructions:...
Operation Handling of the Lithium-Ion battery DANGER DANGER Risk of explosion: release of gas that may create Risk of release of toxic products an explosive atmosphere After extinguishing the fire, establish a safety perime- ter of at least five metres around the battery. Personal protective measures following an incident WARNING Handle an open battery only in a well-ventilated...
Operation Handling of the Lithium-Ion battery What to do in the event of an accidental spillage Take the following precautions in the event of – Avoid pollution of the soil and atmosphere leakage: – Use absorbent materials (sand, earth) to absorb exudation Precautions for individuals –...
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 batter- ies.
Operation Handling of the Lithium-Ion battery Scrapping lithium-ion batteries Use packaging that complies with interna- ● ENVIRONMENT NOTE tional regulations Use the original packaging, if possible. Use Comply with current regulations for scrapping ● sturdy packaging capable of bearing the batteries.
Operation Handling of the Lithium-Ion battery Labels on the lithium-ion batterys Battery nameplate No collision No impact 5001 801 1505 EN - 12/2019...
Operation Handling of the Lithium-Ion battery Lithium-ion batteries: Long-term storage Storage of trucks for a period of less DANGER than two months Electrical danger If the truck is not used for a period of up to two We recommend that batteries are stored at a height between 60 and 120 cm.
Operation Operating instructions – Raise and chock the truck: the wheels must It is therefore necessary to check all points not touch the ground in order to prevent ir- and devices that are important for truck safety. reversible deformation of the tyres. Carry out the following operations: –...
Operation Checks before use WARNING WARNING Risk of serious injury and/or major equipment dam- Risk of serious injury and/or major equipment dam- age. age. Place both hands on the tiller and turn off the power Before driving forwards or backwards, carefully supply before touching moving parts and any equip- check in the direction of travel to ensure that it is safe ment.
Operation Break-in period precautions Break-in period precautions During the initial stage of putting the truck into – Change oil or lubricant promptly according use, it should be operated with low loads. to the instructions. Within the first 100 hours in particular, the fol- –...
Operation Drive system Drive system Drive system Instructions for driving – Insert the magnetic key into the key hole and switch on the power supply. – Tilt the control handle to the drive position. 5001 801 1505 EN - 12/2019...
Operation Drive system – 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 ve- hicle’s speed. NOTE Releasing the drive switch causes the vehicle to brake.
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Operation Drive system Manual lowering – Pull and hold the manual lowering switch (2). The forks will lower to the minimum height until they stop by themselves. CAUTION Before lifting a load, make sure that it has been prop- erly laid out on the pallet and that its weight does not exceed the rated load capacity of 1200 kg.
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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.
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 ve- hicle will begin to travel in the opposite di- rection.
Operation Drive system Emergency stop – Press the emergency switch (2). All power will be cut off and the vehicle will stop work- ing. 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.
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Operation Drive system Ascending slopes Always ascend slopes travelling in the reverse direction, with the load facing uphill. Without a load, it is recommend to ascend slopes forwards. Descending slopes Travel down slopes must always be forwards, with the load uphill. Without a load, it is recommended to descend slopes forwards.
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Operation Drive system – Stop on the slope by pressing the accelera- tor in the opposite direction until the ma- chine comes to a standstill. – Return the accelerator to the neutral posi- tion, then release the accelerator control button to apply the parking brake. –...
Operation Load handling Load handling Safety guidelines for handling loads DANGER WARNING Wear protective footwear. Always keep a suitable Closely observe the following instructions before distance between your feet and the truck. picking up loads.Never touch or stand on moving Risk of crushing feet when manoeuvring the truck.
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 pre- vent any partial spillage.
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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 visibili- –...
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, se- cure the truck with chocks. Never leave the truck with the load raised.
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. 5001 801 1505 EN - 12/2019...
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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 conduc- tive objects. WARNING If this happens, the battery may leak, emit heat or smoke, which may lead to a serious fire or explosion.
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Operation Battery use – The charging environment temperature should be 0°C to 40°C. WARNING If the battery fails, please contact an authorised deal- er to have it repaired. Do not disassemble the battery. 5001 801 1505 EN - 12/2019...
Operation Battery use Battery charger Battery LED light Charging stand 5001 801 1505 EN - 12/2019...
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Operation Battery use Battery charger – Remove the battery. – Plug into charging stand and charge (110/220V 50/60HZ). 5001 801 1505 EN - 12/2019...
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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. 5001 801 1505 EN - 12/2019...
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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. 5001 801 1505 EN - 12/2019...
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 according to the charging stand contact pins. NOTE Due to the characteristics of lithium batteries, battery capacity is reduced in low-temperature...
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.
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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.
Operation Cleaning the Forklift Cleaning the Forklift Cleaning depends on the type of use and the CAUTION workplace. Should the truck come into contact Do not clean the truck with direct jets of water; DO with highly aggressive elements such as salt NOT use solvents and petrols that could damage water, fertilizers, chemical products, cement, parts of the truck.
Maintenance General servicing information General servicing information General The following instructions contain all the infor- The forklift must undergo functional testing mation required for servicing your truck. Carry and a trial run after each inspection. out the various maintenance work in compli- ance with the maintenance plan.
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Maintenance General servicing information of the truck and the efficiency of the protective regulations and principles established for installations in accordance with the technical checking industrial trucks. 5001 801 1505 EN - 12/2019...
Maintenance Inspection and maintenance Inspection and maintenance Maintenance - 1000 hours / every 6 months At operating hours Carried 1000 3000 5000 7000 9000 11000 13000 15000 17000 19000 Functions and controls Check and fasten the controller and contactor. Check that cables are free from damage and that terminals are firmly attached.
Maintenance Inspection and maintenance Technical inspection and mainte- nance data Lubricants table Designation Model no. Amount added Position used Antifriction hydraulic oil L-HM46 0.16–0.18 L Hydraulics Antifriction hydraulic oil L-HV32 (cold stores) Multi-purpose lubricating Polylub GA352P As appropriate Sliding surfaces grease Moly lithium grease no.
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Maintenance Inspection and maintenance Diagram for lubrication and servicing Hydraulic oil filler port Gear oil filler port Lubrication surface 5001 801 1505 EN - 12/2019...
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Maintenance Inspection and maintenance Lubrication of sliding surfaces Steel stopper ball Drive wheel and drive chain Steering bearing Rollers Drive wheel 5001 801 1505 EN - 12/2019...
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). 5001 801 1505 EN - 12/2019...
Maintenance Essential maintenance – Loosen the six screws using a spanner, then remove the drive wheel (5) from the drive assembly (4). – Refit in reverse order to removal. Replacing the load wheels – Place a wooden block (1) under the load ...
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 –...
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Maintenance Essential maintenance – Remove the two screws on the left. – Remove the screw on the right. – Then remove the pump housing and motor. 5001 801 1505 EN - 12/2019...
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Maintenance Essential maintenance – Remove the plug and drain the old hydraul- ic fluid from this hole. – Add new oil. 5001 801 1505 EN - 12/2019...
Technical data Technical datasheet Technical datasheet Description Manufacturer Still Model ECH 12 Drive type:Battery, diesel, petrol, LP gas, mains Battery power Operation Pedestrian Nominal loading capacity Q (kg) 1200 Load centre c (mm) Axle centre to fork face x (mm)
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Technical data Technical datasheet Dimensions 4.34 Aisle width with 800 x 1200 mm pallet along forks Ast (mm) 2062 4.35 Turning radius Wa (mm) 1390 Performance data Driving speed, full load/no load km/h 4.0/4.5 Lifting speed, full load/no load 0.02/0.025 Lowering speed, full load/no load 0.06/0.03 Maximum climbing ability, with/without load...
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Index Incorrect use..... . . Information on the conformity of lithium-ion Address of manufacturer....batteries .
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Index Technical description....9 Transporting a lithium-ion battery..Safety guidelines for handling loads..Safety inspection.
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