Related Manuals for Still ECU-25
Summary of Contents for Still ECU-25
- Page 1 Original instructions Electric pallet truck ECU-25 ECU-30 0168 0169 45628043431 EN - 04/2016...
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Page 3: Table Of Contents
Table of contents Introduction Forklift data ............General information . - Page 4 Table of contents Knowledge of the Truck General Truck View ..........20 Definition of direction of travel .
- Page 5 Table of contents Using the truck on inclines, loading bridges and lifts......45 Load Placement ........... . . 46 Taking up load .
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Page 7: Introduction
Introduction... -
Page 8: Forklift Data
Introduction Forklift data Forklift data We recommend that you record the principal forklift data in the following table so that they are available if required by the sales network or authorised service centre. Type Serial number Date of delivery General information •... -
Page 9: Delivery Of The Forklift And Documentation
Introduction Delivery of the forklift and documentation CAUTION NOTE Failure to observe the instructions highlighted with This symbol is used to provide additional this symbol may cause damage to the forklift and, information. in some cases, result in warranty invalidity. ENVIRONMENT NOTE Failure to observe the instructions highlighted with this symbol may cause environmental... -
Page 10: Ec Declaration Of Conformity In Accordance With Machinery Directive
Introduction EC declaration of conformity in accordance with Machinery Directive EC declaration of conformity in accordance with Machinery Di- rective Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the 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 11: Technical Service And Spare Parts
Introduction Technical service and spare parts Technical service and spare parts For scheduled maintenance and any repairs to the technical characteristics of the forklift over the forklift, contact only the authorised service time. network. Only original spare parts provided by the man- The authorised service network has personnel ufacturer may be used for forklift maintenance trained by the manufacturer, original spare... -
Page 12: Working Conditions
Introduction Working conditions • transporting and/or lifting people; • colliding with stationary and/or movable structures; • pushing or pulling loads; • inclining the lift unit forwards with the • moving upwards or downwards on a slope forks lifted, except during the lifting and/or with the load facing downwards;... -
Page 13: Applied Equipment
Introduction Applied equipment Applied equipment To use equipment that has not been applied, • add a label with the new residual capacity is please contact the authorised sales network, • provide documentation on the equipment in order to: (user and maintenance manual and EC •... -
Page 14: Packaging
Introduction 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. 45628043431 EN - 04/2016... -
Page 15: Safety
Safety... -
Page 16: Safety Regulations
Safety Safety regulations Safety regulations General Precautions NOTE Some safety regulations to be followed when using the forklift are listed below. These regulations integrate those in the manual "Rules for approved use of industrial vehicles". General Safety Rules • Only allow qualified, trained and authorised the safety distances established by the personnel to use the forklift. -
Page 17: Battery Connection Cables
Safety Safety regulations Battery connection cables CAUTION Using sockets with NON-ORIGINAL battery con- nection cables can be dangerous (see purchase references in the parts catalogue) Requirements for the traction-battery charging area When the traction battery is being charged, the area must be sufficiently ventilated in order to download or eliminate the gases produced (EN 50272-3). - Page 18 Safety Safety regulations and neutralised with a binding material (such DANGER as an oil binder) and then disposed of in The penetration in the skin of hydraulic oil that has accordance with current regulations. leaked under pressure from the forklift’s hydraulic system is dangerous.
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Page 19: Location Of Labels
Safety Location of labels Location of labels 1841 Read the user and maintenance manual Version set up for gel batteries Truck lifting point Position the plug correctly, as illustrated, Battery warning before removing the battery from the side Prohibition against carrying people (only for the battery side removal version). - Page 20 Safety Description of labels the truck or performing any maintenance work on it. (2) This label indicates where to attach the truck’s lifting hook. (3) This plate indicates that only the on-board battery should be connected. (4) This label indicates that it is prohibited to carry people on the truck.
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Page 21: Safety Devices
Safety Safety devices Safety devices OM1759 The operator must be aware of the presence of the following safety devices: • Anti-crush button(1) • Horn (2) • Start/stop key(3) • E(4)lectromagnetic brake • EMERGENCY battery warning light (5) 45628043431 EN - 04/2016... -
Page 22: Electromagnetic Radiation
Safety Electromagnetic radiation NOTE These devices most be checked daily, as described in Chapter 4. Electromagnetic radiation The limit values for electromagnetic emissions and for immunity relative to the forklift are those provided by the EN 12895 standard. Non-ionised radiation If the forklift is equipped at the factory or later with devices that emit non-ionising radiation (such as radio transmitters, RFID... -
Page 23: Safety Tests
Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents STILL GmbH Hamburg The operating company must ensure that the truck is checked at least once a year, or Regelmäßige Prüfung following noteworthy incidents. - Page 24 Safety Safety tests 45628043431 EN - 04/2016...
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Page 25: Knowledge Of The Truck
Knowledge of the Truck... -
Page 26: General Truck View
Knowledge of the Truck General Truck View General Truck View 1842 On / off key Flat battery indicator Tiller Battery plug-outlet Horn button Drive Wheel Fork arm lifting push button Load castors Fork arm lowering push-button Fork arms Battery cover Motor compartment cover Tiller head Pivot wheels... -
Page 27: Definition Of Direction Of Travel
Knowledge of the Truck Definition of direction of travel Definition of direction of travel OM1761 The direction of travel is defined in the follow- ing manner: A = Direction of travel towards the fork arms (Backwards travel) B = Direction of travel towards the driver (Forwards travel) The preferred direction of travel is "B"... -
Page 28: Instrumentation And Controls
Knowledge of the Truck Instrumentation and Controls Instrumentation and Controls Start/stop key Key 1 has two positions: 0 =No circuit powered (key removal posi- tion); I =Circuit powered. NOTE All of the controls described on the following pages work with the key in position "1" OM1767 45628043431 EN - 04/2016... -
Page 29: Tiller Controls
Knowledge of the Truck Instrumentation and Controls Tiller controls Anti-crush button (1) • Pressing the button (1) while the truck is travelling towards the operator will reverse the direction of travel and, after six seconds, stop the truck. • If the button (1) is released after the direc- tion of travel is reversed the truck will stop. -
Page 30: Tiller Positions
Knowledge of the Truck Instrumentation and Controls fork lifting only if the tiller is in vertical position. • The button (7) does not work if pressed when the tiller is inclined. WARNING The truck is blocked when the button (7) is pressed while the tiller is moved from vertical position to inclined working position and vice versa In this case, switch off the truck and start it again... -
Page 31: Battery Status Indicator And Hour Meter
Knowledge of the Truck Instrumentation and Controls Battery status indicator and hour meter Battery charging status indicator • Indicates the battery charge level; it is subdivided into ten sectors with respective coloured LEDs. • When the battery is 100% charged, LED 1 remains lit up. -
Page 32: Document Holder
Knowledge of the Truck Document holder Document holder – There are two elastic bands under the bat- tery cover (1) for holding the documentation provided with the forklift(2). OM1768 45628043431 EN - 04/2016... -
Page 33: List Of Available Options
Knowledge of the Truck List of available options List of available options 1840 • On/Off numerical keypad (1). • Roll holder (2). • Equipment for cold climates (3). See Chapter 4 for more information on use of the truck thus equipped. •... -
Page 34: Numerical Keypad (Optional)
Knowledge of the Truck Numerical keypad (optional) CAUTION Contact the technical service network authorised by the manufacturer for information on the assembly of the options. Numerical keypad (optional) warning signal, after which the green LED (A) lights up and remains lit. The forklift is turned off by pressing key (C). -
Page 35: On-Board Battery Charger (Optional)
Knowledge of the Truck On-board battery charger (optional) Entering a password (Pin Code) for the • Enter the operator’s password to be can- operator celled (Pin Code) and press the key (OK). • The four-digit user password for the first •... -
Page 36: Internal Accessibility
Knowledge of the Truck Internal accessibility Internal accessibility DANGER It is prohibited to use the truck with the covers open. In order to use the truck, the covers for access to the inner parts must be closed and secured properly. DANGER Before accessing the inner parts of the truck, carefully follow the instructions given in Chapter... -
Page 37: Truck Identification
Knowledge of the Truck Truck Identification Truck Identification Location of Data Plates XXXX 2320 Truck identification plate Capacity rating plate 45628043431 EN - 04/2016... -
Page 38: Frame Labelling
Knowledge of the Truck Truck Identification Frame labelling The truck’s serial number is marked on the chassis frame (1). The serial number is not visible when the truck forks are lowered. To view the serial number, raise the forks, as the truck serial number (1) is positioned in the lower part of the fixed chassis in an area specifically protected from damage during use. -
Page 39: Capacity Rating Plate
Knowledge of the Truck Truck Identification Capacity rating plate Only one of the four plates shown in the illustration is affixed to the forklift. 2500 The plate indicates the maximum load capac- ity of the truck. The truck is available in the following versions: 3000 •... - Page 40 Knowledge of the Truck Truck Identification 45628043431 EN - 04/2016...
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Page 41: Use And Operation
Use and Operation... -
Page 42: Truck Transport And Lifting
Use and Operation Truck Transport and Lifting Truck Transport and Lifting Transporting the truck The forklift is normally transported by road and rail. If the forklift’s dimensions exceed the max. clearance size allowed, it is trans- ported disassembled. The sales network is in charge of the disassembly and reassembly operations. -
Page 43: Loading And Unloading The Truck
Use and Operation Breaking-In Loading and unloading the truck Use a lifting crane to load and unload the truck, or use an inclined plane or a movable platform with a slope and structural strength compatible with the truck’s performance and weight (see "Technical Data"... -
Page 44: Checks And Inspections
Use and Operation Checks and Inspections Checks and Inspections List of checks before use WARNING • Check that NO stickers are missing or damaged. Replace damaged or missing Damage or other faults to the truck or attachments stickers in compliance with the marking (special equipment) can result in accidents. -
Page 45: Wheel Wear Check
Use and Operation Checks and Inspections • Test that the electromagnetic brake works • Check and test the battery electrolyte level effectively. and density as indicated in the battery instructions. • Check that the battery harness is in good condition. •... -
Page 46: Use Of The Truck
Use and Operation Use of the truck Use of the truck Operator position The driving position is on the "Ground", and the operator should drive the truck using the driving and lifting controls located on the tiller head. DANGER All other positions should be considered incorrect and dangerous. -
Page 47: Start-Up
Use and Operation Use of the truck Start-up After having performed the daily checks, turn the ignition key to the I position to start the truck. Truck operation • Grip the tiller head correctly • Tilt the tiller in the working position (1). •... -
Page 48: Reverse Drive
Use and Operation Use of the truck Reverse drive Reverse of direction without load on forks Reverse of direction with load on forks • To reverse direction when travelling without • To reverse direction with a load on the fork a load on the fork arms, turn the traction arms, release the traction control throttle control throttle in the opposite direction of... -
Page 49: Leaving The Forklift, With Numerical Keypad (Optional)
Use and Operation Use of the truck DANGER Parking on ramps is strictly prohibited! Park on flat surfaces only. Leaving the forklift, with numerical keypad (optional) Follow the operations listed below in the order given when leaving the forklift: • Lower the forks to the ground. •... -
Page 50: Forklift Use In Cold-Storage Rooms
Use and Operation Use of the truck Forklift Use in Cold-Storage Rooms. A truck specifically equipped for cold-storage CAUTION rooms must be used when working at temper- If the truck has been working in environments at atures below +5°C. temperatures below -5°C and it is taken outside the cold-storage room, let it stand either for a sufficien- Forklifts equipped for working in cold climates tly long time to allow evaporation of any condensa-... -
Page 51: Using The Truck On Inclines, Loading Bridges And Lifts
Use and Operation Use of the truck Using the truck on inclines, loading bridges and lifts. Driving on inclines Using the truck on a lift When driving the truck up or down inclines, Using the truck on lifts is only allowed if the you must not exceed the values for inclines lift has sufficient load capacity (check the indicated in the chapter "Technical data". -
Page 52: Load Placement
Use and Operation Load Placement Load Placement Taking up load – Approach the load with caution and with as inserted far enough in that the load is resting much precision as possible. against the fork carriage. The load centre of gravity must be centred between the forks. -
Page 53: Towing Trailers
Use and Operation Load Placement NOTE Further information on the general rules of forklift use is provided in the Rules for the Use of Industrial Vehicles Manual enclosed with this manual. Towing trailers The forklift is not qualified to tow trailers. 45628043431 EN - 04/2016... -
Page 54: Forklift Towing
Use and Operation Forklift Towing Forklift Towing The forklift may not be towed in the case of breakdown. The forklift must be lifted with due caution, as described on the preceding pages. 45628043431 EN - 04/2016... -
Page 55: Battery Recharging
Use and Operation Battery Recharging Battery Recharging CAUTION • Turn on the external battery charger. • Connect plug the battery charger in to begin The battery is recharged with the forklift off. charging. • After the battery charging operation is DANGER completed, turn off the battery charger. - Page 56 Use and Operation Recharging the battery using the on-board battery charger (optional) DANGER If the truck is fitted with an on-board battery charger, it is strictly prohibited to connect the battery to an external battery charger. Instructions for recharging Follow the instructions below: •...
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Page 57: Recharging The Battery, Specific For Batteries With Electrolyte Recirculation System
Use and Operation Recharging the battery, specific for batteries with electrolyte recirculation system Recharging the battery, specific for batteries with electrolyte recirculation system CAUTION The battery is recharged with the forklift off. DANGER The battery must be charged in rooms that comply with the specific regulations on the subject. - Page 58 Use and Operation Recharging the battery, specific for batteries with electrolyte recirculation system Lower the battery compartment cover. NOTE Refer to the battery charger manual for more information. 45628043431 EN - 04/2016...
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Page 59: Maintenance
Maintenance... -
Page 60: General Information
Maintenance General Information General Information To keep your forklift in good condition, carry NOTE out the servicing indicated regularly, within the times indicated and using the consumption Contact the authorised service network for materials provided for that purpose, as speci- a maintenance contract appropriate to your fied on the following pages. -
Page 61: Scheduled Maintenance
Maintenance Scheduled Maintenance Scheduled Maintenance Synoptic Table of Maintenance Operations Operations Completed Intervals in hours 1000 3000 Check wheel tightness Grease the reducer fifth wheel Check the condition of the piping Check hydraulic system oil level Check reducer oil level Check bushes and levers Check pivot wheels Check the condition of battery and truck wiring... -
Page 62: Maintenance As Required
Maintenance Maintenance as required Maintenance as required 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 63 Maintenance Maintenance as required Instructions for ECU 16–18–20 version • Turn off the truck and perform the prelimi- nary maintenance operations. • Raise the battery compartment hood (1). • Disconnect the plug (2) from the outlet (3). • Insert the sling hooks in the two battery points (4).
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Page 64: Changing The Battery From The Side (Optional)
Maintenance Maintenance as required Changing the battery from the side (optional) OM2250 DANGER Before changing the battery, park the truck. Ensure that the truck is on a flat surface and cannot move accidentally. Ensure that the unlocked battery cannot slide off and fall onto the ground. - Page 65 – Place the manufacturer-approved battery side removal roller unit next to the truck; position it so that it is still and stable; adjust the height of the roller unit so that it is level with the underside of the battery at the battery compartment.
- Page 66 Maintenance Maintenance as required – Hook the battery at the two points (8) with a sling or chain. – Lift the battery and remove it. DANGER Use a crane with a suitable lifting capacity for the weight of the battery. The lifting operations must be performed by qualified personnel.
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Page 67: Fuse Replacement
Maintenance Maintenance as required Fuse replacement • Turn off the truck and perform the prelimi- nary maintenance operations. CAUTION Before replacing the fuse, eliminate the cause that led to its blowing. The blown fuse must only be replaced with a fuse of the same amperage. Do not tamper with the truck’s electrical system. -
Page 68: Decommissioning
Maintenance Decommissioning Decommissioning General Information The operations to be performed for "Tem- porary decommissioning" and "Permanent decommissioning" are listed in this chapter. Temporary Putting Out of Commission The following operations must be performed • Perform the lubrication operations indicated when the forklift is not going to be used for a in the maintenance chapter. -
Page 69: Supply Table
Maintenance Supply Table Supply Table Supply table for standard trucks Element to be supplied Lubricants Hydraulic system HLF 32 Reduction gear unit Tutela MATRIX General lubrication Tutela MP02 Supply table for cold-storage trucks Element to be supplied Lubricants Hydraulic system Tutela GI/M Reduction gear unit Tutela MATRIX... -
Page 70: Resolution Of Operating Defects
Maintenance Resolution of Operating Defects Resolution of Operating Defects The operating defects which can occur during forklift use are indicated in this section, with relative causes and solutions. If the defects should persist even after having carried out all of the checks indicated, contact the manufacturer’s authorised service network. - Page 71 Technical data...
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Page 72: Technical Data
Technical data Technical data Technical data OM1781 Characteristics Power Electric unit type 1.4 Drive type Tiller Load capacity / Load Centre of (mm) gravity 45628043431 EN - 04/2016... - Page 73 Technical data Technical data Load distance from load (mm) wheel axle Wheel- 1342 1414 1342 1414 (mm) base Weights Tare weight (including battery) Load per axle when loaded 992 / 2053 1031 / 2112 1109 / 2436 1142 / 2501 (front / rear) Load per...
- Page 74 Technical data Technical data Tiller height in operating 800 / 1240 position (mm) (min / max) Lowered fork arms 4.15 (mm) height Total 4.19 1727 1799 1727 1799 length (mm) Length including 4.20 shoulder (mm) of fork arms Total 4.21 (mm) width Fork arm...
- Page 75 Technical data Technical data Lifting speed 0.046 / 0.06 0.044 / 0.06 (loaded/empty) Lowering speed 0.045 / 0.046 (loaded/empty) Sur- mount- able 4.7 / 25 3.9 / 25 gradient KB 30 (loaded/empty) Max. sur- mount- able gra- 8.0 / 25 6.7 / 25 dient with/with-...
- Page 76 Technical data Technical data Control Electronic type Noise level in <70 driver’s If not stated, the values in the table are for forks where l = 1150 mm and a 24 V / 250 Ah battery (1) Excluding versions with standard wheel- base rod (2) With fork length l >...
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Page 77: Noise
Technical data Noise Levers with short wheelbase rods DIN Standard Battery DIN Wide Battery Forks 1980 1000 1491 1919 2557 2255 1991 2629 2327 2160 1100 1618 2046 2737 2382 2118 2809 2454 2400 1200 1744 2172 2977 2508 2244 3049 2580 dimensions expressed in millimetres... -
Page 78: Vibrations
Technical data Vibrations Vibrations Value of the vibrations to which the hands- CAUTION arms are exposed: The value expressed above can be used to com- pare forklift trucks of the same category. It cannot ā < 2.5 m/s be used to determine the operator’s daily expo- The value complies with Harmonised Euro- sure to vibrations during real operation of the truck;... - Page 79 Index Battery EC declaration of conformity in accordance with Machinery Disposal ..... . Directive ....before use .
- Page 82 STILL GmbH 45628043431 EN – 04/2016...
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