Still ECV 10 C User manual

Original instructions
Electric Pallet Stacker
ECV 10 C
ECV 10i C
ECV 10
0342 0343 0344
50028011505 EN - 03/2018

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
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 thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
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.
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Table of contents
g
1 Introduction
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 3
ECdeclarationofconformity ............................................. 4
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Copyrightandpropertyrights ............................................ 5
Explanation of symbols used ............................................ 6
Date of edition and latest update of this manual ............................... 7
Listofabbreviations ................................................... 7
Drivedirections ...................................................... 9
Illustrations ......................................................... 9
Environmental considerations .......................................... 10
Packaging ......................................................... 10
Disposal of components and batteries ..................................... 10
Series ............................................................ 10
Technical description ................................................. 1
1
Use of the truck ..................................................... 12
Intended use of the trucks .............................................. 12
Unauthorised use .................................................... 13
Placeofuse ........................................................ 13
Residual risks ...................................................... 14
Residualrisks ...................................................... 14
Specialrisksassociatedwithusingthetruckandattachments ................... 14
Overviewofhazardsandcountermeasures ................................. 16
Danger to employees . . ............................................... 19
2Safety
Definition of terms used for responsible persons ............................. 22
Operatingcompany .................................................. 22
Specialist .......................................................... 22
Drivers ........................................................... 22
Basic principles for safe operation ....................................... 24
Insurance cover on companypremises .................................... 24
Modificationsandrefitting .............................................. 24
Warning regarding non-original parts ..................................... 24
Damage, faults ..................................................... 25
Medicaldevices ..................................................... 25
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Table of contents
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Vibrations ......................................................... 26
Safety tests ........................................................ 27
Carrying out regular inspectionsonthetruck ................................ 27
Insulationtesting .................................................... 27
Safety regulations for handling consumables ............................... 29
Permissibleconsumables ............................................. 29
Oils .............................................................. 29
Hydraulicfluid ...................................................... 30
Batteryacid ........................................................ 30
Disposalofconsumables .............................................. 31
Safety devices ...................................................... 31
Damage, faults ..................................................... 31
Battery connection cables ............................................. 31
EMC – Electromagnetic compatibility ..................................... 32
3Views
Drive directions ..................................................... 34
Main Components ................................................... 35
Dataplate and safety labels ............................................ 37
Load label ......................................................... 38
Identification plate ................................................... 38
4 Operation
Intended use of the trucks .............................................. 42
First use .......................................................... 42
Daily checks before use ............................................... 43
Checking the working environment ....................................... 43
General information on batteries ......................................... 44
Charging and discharging batteries ...................................... 44
Drive operations .................................................... 46
Description ........................................................ 46
Starting ........................................................... 47
Forwardtravel/reversetravel ........................................... 49
Brake ............................................................ 49
Safetyreverser ..................................................... 51
Steering ........................................................... 51
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Table of contents
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Horn operation ...................................................... 52
Usingthetruckonaslope .............................................. 52
Hydraulic operations ................................................. 54
Useofthemast ..................................................... 54
Workingwithloads ................................................... 55
Emergency lowering . . ............................................... 58
Before leaving the equipment ........................................... 60
Putting the equipment back into operation .................................. 61
Slinging ........................................................... 61
Transporting the truck ................................................ 62
5 Maintenance
General maintenance information ........................................ 64
General ........................................................... 64
Servicing and maintenance personnel training and qualification . ................. 64
Battery maintenance staff .............................................. 65
Maintenance operations that do not require special training ..................... 65
Technical inspection and maintenance data ................................ 65
Maintenance - 1000 hours / every 12 months ................................ 65
Maintenance - 2000 hours / every 2 years .................................. 67
Maintenance work ................................................... 67
Changing the battery . . ............................................... 67
Lubricationpoint .................................................... 70
Checkthehydraulicoillevel ............................................ 71
Topping up the gear oil . ............................................... 72
Checkingthefuses ................................................... 73
Tyre operation ...................................................... 74
Drive Wheel ........................................................ 74
Load Wheels - Removal and Installation ................................... 75
Caster-RemovalandInstallation ........................................ 76
Malfunction analysis ................................................. 78
6 Technical data
ECV 10 Technical Datasheet ........................................... 80
ECV 10i C / ECV 10 C Technical Datasheet ................................. 83
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1
Introduction

1Introduction
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.
The driving permit must be obtained from the
appropriate office.
The truck has been fitted with state-of-the-
art technology. Following these 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
operation beyond the warranty period.
Therefore:
– Before commissioning the truck, read
the operating instructions and follow the
instructions.
– Always follow all of the safety information
contained in the operating instructions and
on the truck.
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Introduction 1
Your industrial truck
CE-Symbol
CE labelling
The manufacturer uses CE labellingtoindi-
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.
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.
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1Introduction
Information about documentation
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
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
EC declaration of conformity
The manufacturer declares that the truck com-
plies with the requirements of the EC machin-
ery directive and any other EC directives, if
applicable, that are valid at the time of plac-
ing on the market. This is confirmed by the
EC 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 must be
carefully stored and made available to the
responsible authorities if applicable. It must
also be handed over to the new owner if the
truckissoldo
n.
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks (EU countries only)
These operating instructions describe all mea-
sures necessary for the safe operation and
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Introduction 1
Information about documentation
proper maintenance of the truck in all possible
variants at the time of printing. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year of
production located on the nameplate in the
field provided:
Production no. ...........................................
Year of production ..........................................
.........
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructionsmustbestored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the oper-
ator must immediately request a replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
asparepart.
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 operators
have received, read and understood these
instructions.
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
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.
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1Introduction
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.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
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Introduction 1
Information about documentation
Date of edition and latest update of
this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
List of abbreviations
NOTE
This list of abbreviations applies to all types
of operating instructions. Not all of the abbre-
viations that are listed here will necessarily
appear in these operating instructions.
Abbrevi-
ation Meaning Explanation
ABE Display operating unit
ArbSchG Arbeitsschutzgesetz German 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 German rules and recommendations for
occupational health and safety
DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations
CE Communauté Européenne Confirms conformity with product-specific
European directives (CE mark)
CEE Commission on the Rules for the Approval
of the Electrical Equipment
International commission on the rules for
the approval of electrical equipment
DC Direct Current Direct current
DFÜ Datenfernübertragung Remote data transmission
DIN Deutsches Institut für Normung German standardisation organisation
EG European Community
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1Introduction
Information about documentation
Abbrevi-
ation Meaning Explanation
EN European standard
FEM Fédération Européene de la Manutention European Federation of Materials Han-
dling and Storage Equipment
Fmax maximum Force Maximum power
GAA Gewerbeaufsichtsamt
German authority for monitoring/issuing
regulations for worker protection, environ-
mental protection, and consumer protec-
tion
GPRS General Packet Radio Service Transfer of data packets in wireless
networks
ID no. ID number
ISO International Organization for Standard-
ization International standardisation organisation
LAN Local Area Network Local area network
KpA Uncertainty of measurement of sound
pressure levels
LED Light Emitting Diode Light emitting diode
LpSound pressure level at 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 Identification Number Personal identification number
PPE Personal protective equipment
SE Super-Elastic Superelastic tyres (solid rubber tyres)
SIT Snap-In Tyre Tyres for simplified assembly, without
loose rim parts
StVZO Straßenverkehrs-Zulassungs-Ordnung German regulations for approval of vehi-
cles on public roads
TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli-
cable in the Federal Republic of Germany
VDE Verband der Elektrotechnik Elektronik
Informationstechnik German technical/scientific association
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Introduction 1
Information about documentation
Abbrevi-
ation Meaning Explanation
VDI Verein Deutscher Ingenieure German technical/scientific association
VDMA Verband Deutscher Maschinen- und
Anlagenbau e.V.
German Mechanical Engineering Industry
Association
WLAN Wireless LAN Wireless local area network
.
Drive directions
The drive directions of the vehicle are forward
(1), reverse (4), left (2) and right (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 the documented
truck. They only serve to illustrate operating
procedures.
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1Introduction
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
•disposedof,
• treated or
• recycled in accordance 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.
Series
The electric Pallet Stacker is suitable for
stacking operations in narrow aisles and
confined spaces.
This series of electric pallet stacker includes
the following models:
• 0342_ECV 10 C: simplex narrow electric
pallettruckwithratedloadof1000kg.
• 0343_ECV 10i C: simplex narrow electric
pallet truck with initial lift and rated load of
1000 kg.
• 0344_ECV 10 duplex narrow electric pallet
truck with rated load of 1000 kg.
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Introduction 1
Technical description
Technical description
This product has a compact chassis, 4-point
ground contact, balanced tiller and a micropro-
cessor electronic control system.The machine
is lightweight, highly efficient and easy to han-
dle.
Design
The latest ergonomic and practical design,
adaptable to all operators and working condi-
tions.
The polyurethane cowling provides superior
stability and shock resistance, and has a
variety of storage spaces.
The frame 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.
Tiller
The composite construction tiller head pro-
vides excellent impact resistance.
The ergonomic control layout is suitable for
left-handed and right-handed operators.
The horn, lifting and lowering devices can be
operated using one hand without changing
grip.
The walking, lifting and lowering devices,
harnesses and components are IP65 dust-
and water-resistant.
The anti-crush button integrated into the
tiller head protects the operator if the vehicle
recoils.
Driving
The MOSFET electronic control unit ensures
comfortable use and lower costs.
Precise control of driving speed.
Jolt-free starting and smooth acceleration to
maximum speed.
Simply release or turn the drive direction
switch to brake.
Booster circuit prevents the truck rolling back
when starting on a gradient.
Hydraulics
Gear pump driven by fully enclosed air-cooled
motor.
Safety valve and lowering brake protect the
hydraulic system.
Brake system
The electromagnetic brake with dust protec-
tion function can be used as a safety brake
and parking brake.Braking is controlled by the
drive controller, the brake's electromagnet
acts on the motor shaft and automatic braking
is activated when the tiller is in the horizontal
or vertical position (end stop brake).
Battery
2 x 12 V/85 Ah batteries. The display instru-
ment indicates the battery’s remaining charge.
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1Introduction
Use of the truck
Use of the truck
Intended use of the trucks
CAUTION
This machine was designed for the transport and
storage on racks (pallet stackers only) of loads
packedonpalletsorinin
dustrial 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 authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
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