Still ECU 15C, Original Instructions Manual

Page 1: ...Original instructions Electric pallet truck ECU 15C 0138 1133 801 16 01 EN 11 2018 ...

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Page 3: ...tructions a code of practice containing additional information for the operating companies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for the safe operation of industrial trucks Information on the use of industrial trucks Information ...

Page 4: ...Preface g 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 II 1133 801 16 01 EN 11 2018 ...

Page 5: ...0 Technical description 10 Use of the truck 12 Intended use of the trucks 12 Unauthorised use 13 Place of use 13 Residual risks 14 Residual dangers residual risks 14 Special risks associated with using the truck and attachments 14 Overview of hazards and countermeasures 16 Danger to employees 19 2 Safety Definition of terms used for responsible persons 22 Operating company 22 Specialist 22 Drivers ...

Page 6: ...ion of the pallet truck 34 Overview of the main components 34 Description of the safety devices and warning labels 35 Identification plate 36 4 Operation Cleaning the Forklift 38 Intended use of the trucks 38 Check and actions prior to use 38 Commissioning transporting decommissioning 38 List of checks prior to start up 41 Battery charging 42 Setup 44 Checking the safety belly button 44 Checking th...

Page 7: ...ial training 55 Maintenance safety instructions 55 List of inspections 55 Technical inspection and maintenance characteristics 57 Preparatory tasks for maintenance 58 Lubricating points 58 Check and refill hydraulic oil 59 Checking electrical fuses 60 Trouble shooting 61 6 Technical data Main technical data 64 Main technical data for standard version 64 1133 801 16 01 EN 11 2018 V ...

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Page 9: ...1 Introduction ...

Page 10: ...hese operating instructions will allow 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 provide the necessary information and help to avoid accidents and to keep the truck ready for operat...

Page 11: ... of marketing This is confirmed by the issued EC declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addition to the truck can compromise safety thus invalidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the responsible authorities 1133 801 16 01 EN 11 2018 3 ...

Page 12: ...declaration of conformity and by the CE labelling on the nameplate The EC declaration of conformity document is delivered with the truck The declaration shown explains the conformity with the re quirements of the EC machinery directive An independent structural change or addition to the truck can compromise safety thus invalidating the EC declaration of conformity The EC declaration of conformity ...

Page 13: ...r 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 maintaining the equipment must be familiar with these operating instructions The operating company see Chapter Def inition of terms used for responsible per sons P 22 must ensure that all op...

Page 14: ...id 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 NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage 6 1133 801 16 01 EN 11 2018 ...

Page 15: ...implementation of EU occupa tional health and safety directives Betr SichV 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 Ge...

Page 16: ... the workplace LpAZ Average continuous sound pressure level in the driver s 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 Iden...

Page 17: ...twork Defining directions The truck s directions define as the forwards 1 backwards 4 right 2 and left 3 Illustrations At many points in this documentation the mostly sequential operation of certain functi ons or operating procedures is explained To illustrate these operations schematic repre sentations of an truck are used NOTE These schematic representations do not represent the design state of th...

Page 18: ... with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispo sing of batteries ENVIRONMENT NOTE We recommend working with a waste mana gement company for disposal purposes Technical description The ECU 15C electric pallet trucks are de signed to handle pallets with a maximum weight of 1500 kg Design A modern functional design with ...

Page 19: ...ravel An electronic control unit with MOSFET tech nology ensures comfortable and economical usage Precise load independent travel Jerk free start up and acceleration to maxi mum speed Simply release or reverse the accelerator to brake During start up on a gradient drive is imme diately activated to avoid any uncontrolled reversing Hydraulic system Fully enclosed ventilated motor drives a gear pump...

Page 20: ...let or contai ner must be adapted to the load being transported and must ensure stability The table of characteristics and performance atta ched 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 associated with this usage will enabl...

Page 21: ...s Place of use The truck only can be used in indoors The sites on which the truck is used must com ply with the applicable regulations condition 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 Definitio...

Page 22: ... visibility etc Falling tripping etc when moving on the industrial truck especially in the wet with leaking consumables or icy surfaces Loss of stability due to the load being unstable or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and gro...

Page 23: ...Introduction 1 Residual risks 1133 801 16 01 EN 11 2018 15 ...

Page 24: ...y only for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when using working platforms Compliance with national regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability insurance associations Impaired visibil...

Page 25: ...and labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note Germa...

Page 26: ... Industrial Safety and Health BetrSichV employers liability insurance association regulation 104 and the operating instructions O German Ordinance on Industrial Safety and Health BetrSichV and employers liability insurance association regulation 104 With driverless transport systems Roadway quality inadequate Clean clear driveways O German Ordinance on Industrial Safety and Health BetrSichV Load c...

Page 27: ...pany must how ever select the type and equipment of the truck so as to comply with the local provisions for deployment The results must be published In the case of truck deployment involving similar hazard situations it is permitted to summarise the results This overview see chapter entitled Overview of hazards and countermeasures is intended to facilitate compliance with the conditions of these r...

Page 28: ...1 Introduction Residual risks 20 1133 801 16 01 EN 11 2018 ...

Page 29: ...2 Safety ...

Page 30: ...conomic Area This expertise allows him to assess the condition of indus trial trucks in terms of health and safety Drivers This truck may only be driven by suitable persons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary...

Page 31: ...ibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use 1133 801 16 01 EN 11 2018 23 ...

Page 32: ...al modification or transfor mation of your truck is forbidden without prior written permission from the manufacturer Authorisation from the relevant authority may also 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 tha...

Page 33: ...ies must be reported immediately to the responsible 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 ...

Page 34: ...ues do not indicate any danger as in this case CAUTION The value expressed above can be used to com pare forklift trucks of the same category It cannot be used to determine the operator s daily expo sure to vibrations during real operation of the truck these vibrations depend on the conditions of use floor conditions method of use etc and therefore daily exposure must be calculated using data from ...

Page 35: ...nts As part of this inspection A full check of the technical condition of the truck in terms of accident safety must be performed The truck must be thoroughly checked to detect any damage that may have been caused by improper use A test log must be created The results of the inspection must be retained until at least a further two inspections have been carried out The inspection date is indicated ...

Page 36: ...meter The insulation resistance is sufficient when it has a resistance of at least 50 Ohms multiplied by the nominal voltage of the truck circuit between the parts under voltage and the truck chassis Contact the After Sales Service Measuring the insulation resistance of the electrical system NOTE Test voltage battery nominal voltage The test voltage must not exceed 100 V or triple the value of the ...

Page 37: ...eye specialist If swallowed do not induce vomiting 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 s...

Page 38: ...aulic fluid is a water polluting substance Always store hydraulic fluid in containers complying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of according to the regulations Dispose of old hydraulic fluid according to regulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and...

Page 39: ...f used oil are applicable Any spillage of battery acid must be neu tralised immediately Safety devices Damage faults Any damage or faults observed on the truck or the accessories must be reported immediately to the responsible 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 me...

Page 40: ...ation at the planned usage location under the electromagnetic interference 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 compatib...

Page 41: ...3 General views ...

Page 42: ...e main components 1 Tiller 2 Battery discharge indicator 3 Emergency switch 4 Main cover 5 Fork 6 Load roller 7 Battery charging cable 8 Traction motor cover 9 Hydraulic cylinder 10 Drive wheel 11 Castors 12 Safety belly button 13 Butterfly switch MT15 Joystick MT15s 34 1133 801 16 01 EN 11 2018 ...

Page 43: ... fail safe electromagnetic brake when it is pushed By turning the pushed button 90 anti clock wise the push button can be removed and then prevent against unauthorized access Remove this button if you not operate the truck The truck is equipped with a safety belly button 12 which switches the driving function away from the operator if the truck travels towards the operator and the tiller is activa...

Page 44: ...ight in kg for electric trucks only 6 Min permissible battery weight in kg for electric trucks only 7 Own mass self weight in kg without battery 8 Manufacturer 9 Refer to technical data listed in this operating instructions for more detailed information 10 CE label 11 Rated drive power in kW 12 Battery voltage in V 13 Rated capacity 36 1133 801 16 01 EN 11 2018 ...

Page 45: ...4 Operation ...

Page 46: ...lets or in industrial containers de signed for this purpose The dimensions and capacity of the pallet or contai ner must be adapted to the load being transported and must ensure stability The table of characteristics and performance atta ched 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 autho...

Page 47: ...k safe with dedicated lifting gear Transportation CAUTION During transportation on a lorry or truck always fasten the truck securely Lower the forks and park the truck securely Fasten the truck according to figure by slinging dedicated lashing belts around both sides of the trucks torsion arms and fasten the other side at the transporting truck Decommissioning For storage Remove the load Lower the ...

Page 48: ...d actions prior to use For final decommissioning Hand the truck to a designated recycling company ENVIRONMENT NOTE Oil batteries and electric components must be recycled due to legal regulations 40 1133 801 16 01 EN 11 2018 ...

Page 49: ...acks significant wear Check that there are no signs of leaking consumables under the truck Do not restrict the field of vision Ensure the visible area specified by the manufacturer is observed Attachments special equipment must be properly secured and function according to their operating instructions Damaged or missing stickers must be replaced in compliance with the marking position table The rolle...

Page 50: ...ause explosion In the area of battery charging neither burning materials nor burning liquids are allowed Smoking is prohibited and the area must be ventilated Park the truck securely before starting charging or installing changing the batteries Before finishing the maintenance work make sure that all cables are connected correctly and that there are no disturbing towards other components of the tru...

Page 51: ...ptional voltage of 110V or 220V as referred The room where you are charging must be ventilated The exactly charge status can be only checked from the dischrge indicator To control the status the charging must be interrupted and the truck must be started Park the truck at a dedicated secured area with a dedicated power supply Lower the forks and remove the load Switch the truck off and connect the ...

Page 52: ...e operator and the tiller is activated in the tillers operating zone Normal operation may be resumed after releasing the drive direction switches Checking the safety belly button WARNING Ensure that the test zone is free of people and objects both in front of and behind the truck Operate the drive direction switch in back ward direction The truck moves backward Activate the safety belly button 12 ...

Page 53: ...osition CAUTION Perform these checks on a flat surface Turn the drive direction switch to the desired direction forward or backward If move the drive direction switch back to the neutral position B the controller should decelerates the truck until the truck stops 1133 801 16 01 EN 11 2018 45 ...

Page 54: ...ency switch 3 The power supply to the truck is cut off The electrical controls and motors are disabled The electromagnetic brake is applied Pull the emergency switch 3 to restore the circuits Checking the horn Press the horn button 14 located on the upper part of the tiller The horn sounds 46 1133 801 16 01 EN 11 2018 ...

Page 55: ...itudinal centre plane of the truck WARNING The working area of the industrial truck must be adequately lit If it is insufficiently lit working spotlights must be installed to ensure that the driver can see properly Insert the cap of the combined emergency switch 3 turn it 90 clockwise and pull the button up NOTE The cap can be used only on this kind of pedestrian power pallet truck NOTE Make sure t...

Page 56: ...ake Always lower the forks fully when parking Press the emergency switch 3 turn the cap 90 anti clockwise and remove the cap Lifting Lowering MT15 CAUTION The maximum capacity is 1500 kg Don t overload the truck Press the lifting button 15 carefully for lifting Press the lowering button 16 carefully for lowering Lifting Lowering MT15s CAUTION The maximum capacity is 1500 kg Don t overload the truc...

Page 57: ...he joystick 7 to the left B direction for lowering Travelling CAUTION Travel on inclines only with the load facing uphill Don t travel on inclines more than specified with the technical data After starting the truck by pulling the com bined emergency switch 3 1133 801 16 01 EN 11 2018 49 ...

Page 58: ...4 Operation Operation Move the tiller to the operating zone For MT15 turn the drive direction switch 13 to the desired driving direction forward or backwards 50 1133 801 16 01 EN 11 2018 ...

Page 59: ...he drive direction switch Steering Steer the truck by moving the tiller to the left or right side Braking NOTE The braking performance depends on the truck conditions and the load conditions of the truck The braking function can be activated on several ways By moving the drive direction control device 13 back to the initial 0 position or by releasing the button the regenerative braking is activate...

Page 60: ... operates if the truck is not travelling and the tiller is in the operating zone Malfunctions If there are any malfunctions or the truck is inoperative please stop using the truck and activate the emergency switch 3 by pushing it If possible park the truck on a safe area and remove the combined locking cap from the combined emergency switch 3 Inform immediately the manager and or call your service...

Page 61: ...5 Maintenance ...

Page 62: ... and a trial run after each inspection Service plan Maintenance work must be carried out accord ing to the maintenance checklist The service plan is followed by advice to facilitate 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 ot...

Page 63: ...xperience to be able to assess the condition of the truck and the efficiency of the protective installations in accordance with the technical regulations and principles established for checking industrial trucks Battery maintenance staff Batteries must only be recharged maintained and changed by specially trained personnel Personnel must follow the manufacturer s instructions of the battery the bat...

Page 64: ...rods for deformation and damages 10 Check the gearbox for noise and leakage 11 Check the wheels for deformation and damages 12 Lubricate the grease nipples Electrical system 13 Check the electric wiring for damage 14 Check the electric connections 15 Test the emergency switch function 16 Check the electric drive motor for noise and damages 17 Test the display 18 Check if the correct fuses are used...

Page 65: ...ck the steering function 34 Check the lifting and lowering function 35 Check the tiller arm switch function General 36 Check if all decals are legible and complete 37 Carry out a test run Technical inspection and maintenance characteristics Assembly Item Lubricant Capacities Setting Values Hydraulic Oil 0 7L to 1 0L Main hydraulic system Maximum pressure 130 bar Air gap of the electromagnetic brak...

Page 66: ... 1 Grease nipple 2 Shaft 3 Steering bearings 4 Joints Lubricate the marked points according to the maintenance checklist The required grease specification is DIN 51825 standard grease No 2 3 4 do not need to adding grease if these components are not main tained or replaced 58 1133 801 16 01 EN 11 2018 ...

Page 67: ... 1 0L ENVIRONMENT NOTE Waste material like oil used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company Loosen the 2 screws for the main cover and remove the cover The minimum and maximum allowed oil level can be checked on the oil tank If necessary add oil at the filling point 1133 801 16 01 EN 11 2018 59 ...

Page 68: ...5 Maintenance Preparatory tasks for maintenance Checking electrical fuses Fuse Rate FU 10A FU 01 60A FU 02 60A Remove the main cover Replace the fuses if necessary 60 1133 801 16 01 EN 11 2018 ...

Page 69: ...ce oil quantity Battery is charging Charge the battery completely and then remove the main power plug form the electrical socket Battery not connected Connect the battery correctly Fuse faulty Check and eventually replace fuses Low battery Charge the battery Combined emergency switch is activated De activate the combined emergency switch by insert and pull the knob Truck not starts operating Tille...

Page 70: ...5 Maintenance Trouble shooting 62 1133 801 16 01 EN 11 2018 ...

Page 71: ...6 Technical data ...

Page 72: ...ical data Main technical data Main technical data for standard version DESCRIPTION 1 1 Manufacturer Still 1 2 Model type ECU 15C 1 3 Method of propulsion battery diesel petrol LPG mains power Battery 64 1133 801 16 01 EN 11 2018 ...

Page 73: ...U Rubber1 3 2 Traction wheel sizes Ø x w mm Ø 200 x 70 Ø 230 x 73 1 3 3 Wheel sizes load end Ø x w mm Ø 80 x 70 3 4 Additional wheels dimensions Ø x w mm Ø 80 x 30 3 5 Number of wheels at traction end load end x traction wheel 1 X 2 4 3 6 Track traction end b10mm 410 3 7 Track load end b11mm 380 360 525 2 DIMENSIONS ECU 15C 4 4 Lift 5 mm h3 mm 115 4 9 Height of tiller in driving position min max h...

Page 74: ... 10 Operating brake Electromagnetic DRIVE ECU 15C 6 1 Drive motor rating S2 60 min kW 0 45 6 2 Lift motor rating at S3 10 kW 0 8 6 3 Type of battery according to DIN 43 531 35 36 A B C no No 6 4 Battery voltage and capacity discharge in 5 h V Ah 2 x 12V 853 6 5 Battery weight kg 52 2 x 26kg 6 6 Energy consumption according to VDI cycle kWh h 0 262 OTHER ECU 15C 8 1 Speed control DC Speed Control 8...

Page 75: ...te of edition of this manual 7 Decommissioning 39 Defining directions 9 Description of the safety devices and warning labels 35 Disposal Battery 10 Components 10 Documentation scope 4 Driver rights duties and rules of behaviour 22 Drivers 22 E EC declaration of conformity 4 Electrical insulation testing 28 EMC Electromagnetic compatibility 32 G General 2 54 H Hazards and countermeasures 16 Hydrauli...

Page 76: ...esidual dangers residual risks 14 S Safety Inspection 27 Servicing and maintenance personnel training and qualification 55 Signals 6 Special risks 14 Specialist 22 T Technical description 10 Technical inspection and maintenance characteristics 57 Trouble shooting 61 U Unauthorised use 13 Update of this manual 7 W Warning regarding non original parts 24 68 1133 801 16 01 EN 11 2018 ...

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