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Original instructions Pallet truck ECH 15 0195 5001 801 1555 EN - 12/2020...
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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 1555 EN - 12/2020...
Introduction Your industrial truck Your industrial truck General The industrial truck described in these operat- ing instructions conforms with the applicable standards and safety regulations. The industrial truck is fitted with state-of-the- art technology. Following these operating in- structions will allow the industrial truck to be handled safely.
Introduction Your industrial truck EC declaration of conformity in accordance with the Machinery Directive Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare herewith that the machine Industrial truck type corresponding to these operating instructions Type corresponding to these operating instructions conforms to the latest version of the Machinery Directive 2006/42/EC.
Introduction Information about documentation Information about documentation Scope of the documentation Original operating instructions for the indus- ● trial truck Operating instructions of the installed var- ● iants that are not mentioned in the afore- mentioned original operating instructions "UPA"Operating instructions or inserts (de- ●...
Introduction Information about documentation Safely store the complete documentation and pass it on to the subsequent operating compa- ny when transferring or selling the industrial truck. NOTE Please note the definition of the following re- sponsible persons: "operating company" and "driver".
Introduction Information about documentation Copyright and property rights This manual - and any excerpts thereof - may not be reproduced, translated or transmitted in any form to third parties without the express written permission of the manufacturer. 5001 801 1555 EN - 12/2020...
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 Information about documentation 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 func- tions or operating procedures is explained. To illustrate these operations, schematic repre- sentations of an truck are used.
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 Technical description The chassis is made of thick steel plate and is suitable for the harshest working conditions. Steering system Extremely smooth steering makes the vehicle easier to manoeuvre in tight spaces. A gas spring enables the tiller to quickly return to the vertical position after it is released.
Introduction Description of use and climatic conditions cuts off the power. Automatic braking is acti- vated when the tiller is in the horizontal or ver- tical position (end stop brake). Battery Equipped with lithium-ion battery. The display unit displays the battery's remain- ing charge.
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 Residual risks Residual risks Residual dangers, residual risks Falling, tripping etc. when moving on the in- Despite all operational precautions and com- ● dustrial truck, especially in the wet, with pliance with standards and rules, the possibili- leaking consumables or icy surfaces. ty of additional risks when using the truck can- Loss of stability due to the load being unsta- not be entirely excluded.
Introduction Residual risks Residual dangers, residual risks Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the truck cannot be en- tirely excluded. The truck and all other system components comply with current safety requirements. Nev- ertheless, even when the truck is used for its proper purpose and all instructions are fol- lowed, some residual risk cannot be excluded.
Introduction Residual risks Stability The stability of the truck has been tested to the latest technological standards and is guar- anteed provided that the truck is used properly and according to its intended purpose. These standards only take into account the dynamic and static tipping forces that can arise during specified use in accordance with the operating rules and intended purpose.
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 Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and la- bour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver...
Introduction Residual risks Hazard Course of action Check note Notes √ done - Not applicable When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal- German Ordinance on correct/slipped Industrial Safety and...
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 Prohibition of use by unauthorised per- When leaving the truck, the driver must secure it against unauthorised use. sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck.
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.
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Safety Basic principles for safe operation Permissible lithium-ion batteries – Use only lithium-ion batteries that have been approved by the manufacturer of this industrial truck. Declaring the use of lithium-ion batter- We recommend that the operating company informs the local fire brigade of the planned use of industrial trucks fitted with lithium-ion batteries.
Safety Basic principles for safe operation – Ventilate the location of the fire well, as the resulting combustion gases are corrosive if inhaled. – Inform the fire brigade that lithium-ion bat- teries are affected by the fire. – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire.
Basic principles for safe operation companies have not been tested or approved CAUTION by STILL. 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.
Noise emission values Calculated during the test cycle performed in accordance with standard EN 12053 Acoustic pressure level on the driver's compartment ECH 15 <70 NOTE Lower or higher noise values may occur when using industrial trucks, e.g. due to the mode of operation, environmental factors and other sources of noise.
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Safety Basic principles for safe operation NOTE It is mandatory to specify the hand-arm vibra- tions, even where the values do not indicate any danger, as in this case. 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;...
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.
Safety Safety tests Electrical insulation testing The truck's electrical insulation must have suf- cuit, between the parts under voltage and the ficient insulation resistance. Insulation resist- truck chassis. ance must be tested in accordance with EN Contact the After-Sales Service. 1175–1 and ISO 20898 at least once a year.
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.
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Safety Safety guidelines Safety information DANGER The truck must not be used by unauthorised per- sons. As the operating company, you must ensure that ac- cess to the truck is only possible for authorised per- sonnel. DANGER Safety systems are there for your safety. Safety systems - of any kind - must never be disa- bled.
Safety Battery connection cables Battery connection cables CAUTION Using sockets with NON-ORIGINAL battery connec- tion cables can be dangerous (see purchase referen- ces in the parts catalogue) 5001 801 1555 EN - 12/2020...
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 Overview Operating handle Battery Tiller Emergency off switch Hydraulic station Fork Drive wheel 5001 801 1555 EN - 12/2020...
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Views Overview Operating handle Name Description Horn button Emits an acoustic warning signal. Lifting/lowering button Raises or lowers the load component. Controls the direction and speed of Drive switch travel. Protection function: The truck will move Collision protection button away from the operator until this button is released.
Views Display element Display element Composition Function When all 10 bars are lit, the battery is fully charged. Charge display When the first and second bars flash alter- nately, the battery charge is low and the battery needs to be recharged. Displays the residual charge of the battery;...
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Views Display element Reverse indicator light Lights up when reversing normally. Lifting indicator light Lights up when lifting normally. Lowering indicator light Lights up when lowering normally. Lit solid, interlock switch off; Operating status indicator light Flashing, interlock switch closed, hour me- ter starts counting.
Views Identification plate Identification plate Type Manufacturer Serial number Refer to technical data listed in this operat- Year of manufacture ing instructions for more detailed information Unladen mass in kg CE label Max. permissible battery weight in kg (for Rated drive power in kW electric trucks only) Battery voltage in V Min.
Views Production number Production number xx xxxx x xxxxx NOTE The production number is used to identify the truck. It can be found on the nameplate and must be referred to in all technical questions. The production number contains the following coded information: (1) Production location (2) Model...
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.
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 Emergency off switch Emergency off switch The vehicle's electrical system circuits will be disconnected when you press this switch (1). All electrical functions will be stopped and the vehicle will be forced to perform an emergen- cy stop. Driving the truck Daily checks and preparations that must be carried out before putting the truck into opera-...
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Operation Driving the truck Driving Place the operating handle in the drive posi- tion (M) and place the drive switch in the de- sired drive direction (1 or 2). When there is a large angle of rotation, the speed will also be correspondingly large.
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Operation Driving the truck Tortoise speed Switch on the slow travel function Procedure: Press and hold down the "slow travel" but- ● ton (1). Rotate the drive switch (2) in the required ● travel direction. The brake is released. The truck travels at slow speed.
Operation Using the truck on ramps CAUTION Activate the drive switch. If the drive switch cannot quickly return to the initial position, or resets very slowly, identify the cause and rectify the fault. Re- place the armrest elbow if necessary. Reverse braking Turning the drive switch to the opposite direc- tion while travelling brakes the truck by re-...
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Operation Using the truck on ramps Ascending slopes – You must drive in reverse to move a load up a slope (with goods in front of the per- son). You can go up the slope forwards if no goods are loaded.
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Operation Using the truck on ramps – Going down slopes forwards is recommen- ded if no goods are loaded. Starting to move on a ramp If you need to start the truck on a ramp, first move the tiller into position (B) (with the truck's brake applied), then push the handle switch in the desired direction ((F) or (R)).
Operation Picking up and storing goods Picking up and storing goods CAUTION Before picking up a load, the operator must ensure that it has been correctly stacked. The weight must not exceed the truck's rated load capacity. Do not place long loads in a lateral direction across the fork.
Operation Truck parking Truck parking Whenever the driver leaves the truck, it must be parked correctly, even if it is only intended to be left for a short time. CAUTION Always park the truck correctly. Never park the truck on a ramp. The load component must be completely lowered.
Operation Hoisting Hoisting DANGER Danger to life! Personnel must not stand below or near the truck when the pallet truck is being lifted. WARNING Risk of serious injury and/or major equipment dam- age. Use lifting hooks and a hoist with adequate lifting ca- pacity.
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Operation Truck transport – Fix the truck to the pallet to prevent loosen- ing. NOTE Only use haulage equipment with sufficient load capacity. – The load weight includes the net weight of the truck(including battery weight) and the wooden pallet. –...
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Operation Truck transport 5001 801 1555 EN - 12/2020...
Battery use and maintenance Battery charger Battery charger Charging precautions – The truck must be parked in a well-ventila- ted room. – There must be no metal objects on the sur- face of the battery. – Before the start of the charging procedure, check all cable connections and plug con- nectors for obvious damage.
Battery use and maintenance Disassembling and installing the battery Green light remains Battery charging is Normal status complete Change in Indi- current / Indicator light fault Depot repair Battery fault cator voltage lights fail to No change The power input line is in good Charger fault, return light in current /...
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Battery use and maintenance Disassembling and installing the battery – a: Open the swivelling hood (1). – b: Pull out the battery (2) from above. Install following the above steps in reverse or- der. 5001 801 1555 EN - 12/2020...
Maintenance Cleaning Cleaning When cleaning electronics and electrical com- CAUTION ponents, you must use low-strength suction High-pressure cleaners, excessive water pressure or gas or compressed air. You should also use a water and steam that are too hot can damage com- non-conductive, anti-static brush to clean dust ponents.
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Maintenance Repairs and maintenance safety regulations Maintenance personnel for batteries Lifting and jacking equipment Batteries must only be charged, serviced, and WARNING replaced by personnel who have received ap- The battery connector must be disconnected before propriate training in accordance with the in- the industrial truck is jacked up.
Maintenance Calendar of maintenance operations equipment supplied by our company to meet left and right wheels should be replaced at the the data indicators for the model list. same time). When replacing wheels or tyres, you must en- sure that the truck will not tilt (for example, the Calendar of maintenance op- erations It is necessary to perform regular inspection...
Maintenance 1000 hour service plan 1000 hour service plan At operating hours Carried 1000 3000 5000 7000 9000 11000 13000 Servicing work to be performed every 1000 hours or every 12 months. Electrical system Check that cables are free from damage and that the terminals are firmly attached. Check the control unit.
Maintenance Lubrication maintenance schematic view Lubrication maintenance schematic view Hydraulic oil filler port Gear oil filler port Fluids Strictly follow the manufacturer's regulations when using and handling fluids. Non-standard operation may put the opera- tor’s health and life at risk and damage the en- vironment.
Maintenance Servicing so keep them away from hot components and naked flames. Clean utensils must be used when refilling flu- ids. It is strictly prohibited to mix different fluids together (except where specifically indicated in the operating instructions). Make sure to protect against fluid splashes. In the event of a fluid spillage, immediately cover the spillage using an appropriate adsorbent and dispose of the fluid/adsorbent mixture in...
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After topping up, lift the fork. The oil level is fully topped up when you no longer hear pop- ping noises; continue to add oil if you still hear popping noises. Install following the above steps in reverse or- der.
Maintenance Decommissioning and storing the truck – Top up with gear oil of the correct specifica- tion by pouring it into grease nipple "1". – Top up every 500 operating hours or annu- ally, whichever occurs first. CAUTION Do not add gear oil that contains impurities. Install following the above steps in reverse or- der.
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Maintenance Decommissioning and storing the truck – Charge the battery. NOTE – Check whether the hydraulic oil contains Please observe the instructions and regula- condensation water. Change the hydraulic tions provided by the battery manufacturer. oil if necessary. – Spray all exposed contacts with a suitable –...
Maintenance Carrying out regular inspections on the truck Carrying out regular inspec- tions 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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Maintenance Equipment scrapping and disposal method 5001 801 1555 EN - 12/2020...
- Pay attention to the rated load (re- - Load capacity exceeded fer to the model identification plate) If you are still unable to resolve the fault after performing all the steps listed in "Solutions", please contact the company's customer serv- ice department.
Lithium-ion battery use and maintenance Safety precautions Safety precautions – Do not short-circuit the positive and nega- tive terminals of the battery. – Do not bump the battery. Handle it gently and avoid subjecting it to excessive vibra- tion, external impact or falls from height. –...
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Lithium-ion battery use and maintenance Safety precautions – It is strictly forbidden to hot-swap batteries. – Fire and electric shock are easily caused. – Be aware of corrosion. – It may cause battery damage and shorten the battery life. 5001 801 1555 EN - 12/2020...
Lithium-ion battery use and maintenance Battery introduction and instructions – Smoking and naked flames are strictly pro- hibited. – They may cause the battery to explode. Battery introduction and instructions Battery introduction CAUTION Rated Battery Ambient usage temperature: 0°C to 40°C 48 V voltage material...
Lithium-ion battery use and maintenance First aid measures after a Li-ion accident 7. If the lithium-ion battery fails and cannot be ing installation and removal. When lifting, hook used, remove it from the vehicle. Trained per- two slings to the eyelets, gently lift and keep sonnel can use our BMS special reading in- the battery stable without tilting it;...
Lithium-ion battery use and maintenance Storage Storage 4. Stacking is prohibited for this product ser- NOTE ies; Lithium-ion batteries are classified as danger- ous goods according to class 9. CAUTION Store batteries secured against overturning. To pro- NOTE tect batteries against moisture, do not store them di- rectly on the floor.
Lithium-ion battery use and maintenance Troubleshooting common problems Troubleshooting common problems During the use and maintenance of lithium-ion cracks, splits in the insulation layer or burn power batteries, one or more of the following marks, immediately stop using the battery, find abnormal conditions may occur with the bat- and analyse the cause and fix it;...
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Lithium-ion battery use and maintenance Maintenance 3. Check the reliability of the charging device 5. Check the status of the insulation resist- and make sure that the charging device is ance of the battery module and the bodywork, charging in full compliance with the voltage and make sure that the resistance complies and current regulation signals from the BMS.
Technical datasheet Technical datasheet Technical datasheet The technical data given below complies with the VDI2198 standard. The company reserves the right to make technical changes and addi- tions. Met- Chinese Metric Features Brand Still 5001 801 1555 EN - 12/2020...
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Technical data Technical datasheet Model no. ECH15 Drive type Battery Operation type pedestrian rated capacity 1500 Load centre distance Load distance 946/883 Wheelbase 1200/1135 Weight Service weight (include. battery) Axle loading, laden driving side/ 606/1076 loading side Axle loading, unladen driving 145/35 side/loading side Tyres, Chassis...
Technical data Eco-design requirements for electric motors and variable speed drives Aisle width for pallets 800 × 1200 4.34.2 2208 lengthways 4.35 Turning radius 1390 Performance data Travel speed, laden/ unladen km/h 5/5.5 Lifting speed, laden/ unladen 0.028/0.031 Lowering speed, laden/ unladen 0.068/0.043 Max.
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Technical data Eco-design requirements for electric motors and variable speed drives meet the description given in Article 2 "Scope", Item (1) (b). 5001 801 1555 EN - 12/2020...
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Technical data Eco-design requirements for electric motors and variable speed drives 5001 801 1555 EN - 12/2020...
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Index Address of manufacturer....Illustrations......10 Attachments Insurance cover on company premises.
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Index Signals......7 Update of this manual....Specialist.
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