Still ECU-25 User manual

Original instructions
Electric pallet truck
ECU-25
ECU-30
0168 0169
45628043431 EN - 04/2016

Table of contents
g
1 Introduction
Forklift data ........................................................ 2
General information .................................................. 2
How to Consult the Manual ............................................. 2
Delivery of the forklift and documentation .................................. 3
EC declaration of conformity in accordance with Machinery Directive .............. 4
Technical service and spare parts ........................................ 5
Normative References ................................................ 5
Type of use ........................................................ 5
Working conditions .................................................. 6
Modifications to Forklift ................................................ 6
Applied equipment ................................................... 7
User obligations ..................................................... 7
Environmental considerations .......................................... 7
Disposal of components andbatteries ..................................... 7
Packaging ......................................................... 8
2Safety
Safety regulations ................................................... 10
General Precautions ................................................. 10
GeneralSafetyRules ................................................. 10
Flooringrequirements ................................................ 10
Battery connectioncables ............................................. 11
Requirements for the traction-battery charging area .......................... 11
SafetyRegulationsRelativetoForkliftUse ................................. 11
Safety RegulationsRelativetoOperatingMaterials ........................... 11
Location of labels ................................................... 13
Description of labels .................................................. 13
Safety devices ...................................................... 15
Electromagnetic radiation .............................................. 16
Non-ionised radiation ................................................. 16
Safety tests ........................................................ 17
Regular safety inspection of the truck ..................................... 17
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Table of contents
g
3 Knowledge of the Truck
General Truck View .................................................. 20
Definition of direction of travel ........................................... 21
Instrumentation and Controls ........................................... 22
Start/stopkey ....................................................... 22
Tillercontrols ....................................................... 23
Tillerpositions ...................................................... 24
Batterystatusindicatorandhourmeter .................................... 25
Document holder .................................................... 26
List of available options ............................................... 27
Numerical keypad (optional) ............................................ 28
On-board battery charger (optional) ...................................... 29
Internal accessibility .................................................. 30
Truck Identification ................................................... 31
LocationofDataPlates ............................................... 3
1
Frame labelling ..................................................... 32
Forklift Identification Plate . . . .......................................... 32
Capacity rating plate ................................................. 33
4 Use and Operation
Truck Transport and Lifting ............................................. 36
Transportingthetruck ................................................ 36
Climatic ConditionsforTransportandStorage ............................... 36
Loadingandunloadingthetruck ......................................... 37
Breaking-In ........................................................ 37
Checks and Inspections ............................................... 38
Listofchecksbeforeuse .............................................. 38
Wheel Wear Check .................................................. 39
Use of the truck ..................................................... 40
Operatorposition .................................................... 40
Start-up ........................................................... 41
Truckoperation ..................................................... 4
1
Reversedrive ...................................................... 42
Forklift Braking/Stopping .............................................. 42
Parking and stoppingthetruck .......................................... 42
Leavingtheforklift,withnumericalkeypad(optional) .......................... 43
Stopping the truck in an emergency ...................................... 43
ForkliftUseinC
old-StorageRooms. ...................................... 44
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Table of contents
g
Usingthetruckoninclines,loadingbridgesandlifts. .......................... 45
Load Placement ..................................................... 46
Takingupload ...................................................... 46
Transportingpalletsorothercontainers ................................... 46
Deposit the load. .................................................... 46
Towingtrailers ...................................................... 47
Forklift Towing ...................................................... 48
Battery Recharging .................................................. 49
Recharging the battery using the on-board battery charger (optional) .............. 49
Recharging the battery, specific for batteries with electrolyte recirculation system ..... 51
5 Maintenance
General Information .................................................. 54
Preliminary maintenance operations ...................................... 54
Scheduled Maintenance .............................................. 55
Synoptic Table of Maintenance Operations . ................................ 55
Maintenance as required .............................................. 56
CleaningtheForklift .................................................. 56
Batteryrplacement ................................................... 56
Changing the battery from the side (optional) ................................ 58
Fusereplacement ................................................... 61
Decommissioning ................................................... 62
General Information .................................................. 62
TemporaryPuttingOutofCommission .................................... 62
Checks and Inspections After a Long Period of Inactivity ....................... 62
Permanent Putting OutofCommission(Demolition) .......................... 62
Supply Table ....................................................... 63
Resolution of Operating Defects ........................................ 64
6 Technical data
Technical data ...................................................... 6
6
Noise ............................................................. 71
Vibrations ......................................................... 72
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1
Introduction

1Introduction
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
• This manual contains "Original Instructions"
provided by the manufacturer.
• The "operator" is defined as the person
driving the forklift.
• The "user" is the physical or legal person
who has the forklift truck used by the
operators.
• For correct use of the forklift and in order
to avoid accidents, the operator is obliged
to read, understand and apply the contents
of this manual, the "Rules for the use of
industrial vehicles" and the labels and
plates applied to the forklift.
• This manual and the attached "Rules for
the use of industrial vehicles" must be kept
carefully and must always be on the forklift
for fast consultation.
• The manufacturer assumes no responsibil-
ity for any accidents to persons or damage
to things due to the failure to observe the
instructions in this manual, in the "Rules for
the use of industrial vehicles" and on the
labels and adhesive supplied to the forklift.
• The forklift may not be put to any use other
that than indicated in this manual.
• The forklift must be used by appropriately
trained operators only. For the necessary
operator training, contact the authorised
sales network.
• Persons working near the forklift must also
be instructed in the risks associated with
use of the forklift.
•Intheinterestsofc
lear information, some
illustrations in this manual show the forklift
without the safety equipment (guards,
panels, etc.). The forklift may not be used
without safety equipment.
How to Consult the Manual
There is a table of contents at the beginning
of the manual for ease of use. The manual is
divided into chapters with specific topics. The
name and title of the chapter are given at the
top of each page The following is found at the
bottom of each page: the type of manual, the
identifying code, the language and the manual
version.
Some general information is provided in this
manual. Please only consider the information
relevant for your specific forklift.
The following symbols have been used to
highlight some parts of this manual.
DANGER
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.
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Introduction 1
Delivery of the forklift and documentation
CAUTION
Failure to observe the instructions highlighted with
this symbol may cause damage to the forklift and,
in some cases, result in warranty invalidity.
ENVIRONMENT NOTE
Failure to observe the instructions highlighted
with this symbol may cause environmental
damage.
NOTE
This symbol is used to provide additional
information.
Delivery of the forklift and
documentation
Ensure that the forklift has all of the options
requested and that it has been delivered with
the following documentation:
• Instruction and maintenance manual;
• Rules for the compliant use industrial
vehicles;
• EC Declaration of Compliance;
• Spare parts catalogue CD.
If the forklift has been delivered with a traction
battery and/or an external battery charger,
ensure that such products conform to the
order and that the relevant instructions for
operation and maintenance are included, as
well as the EC declaration for the external
battery charger.
If applied equipment, other equipment or
devices are present, ensure that they conform
to the order and that the relative use and
maintenance manual and of the relative EC
declaration (if provided by regulations in
effect) are included.
All of the above documentation must be kept
for the entire operative life of the forklift. In the
event that the documentation is lost or dam-
aged, contact the authorised sales network for
copies of the original documentation.
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1Introduction
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
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
.
44
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Introduction 1
Technical service and spare parts
Technical service and spare parts
For scheduled maintenance and any repairs to
the forklift, contact only the authorised service
network.
The authorised service network has personnel
trained by the manufacturer, original spare
parts and the tools necessary to carry out
maintenance and repairs.
Servicing by the authorised service network
and the use of original spare parts maintain
the technical characteristics of the forklift over
time.
Only original spare parts provided by the man-
ufacturer may be used for forklift maintenance
and repairs. The use of non-original spare
parts invalidates the warranty and renders the
user responsible for any accidents due to the
inappropriateness of the non-original parts.
Normative References
This forklift complies with:
• The most recent version of Machine Direc-
tive 2006/42/EC in effect
• Electromagnetic Compatibility Directive
2014/30/EC and subsequent amendments,
relative to forklifts for handling in accor-
dance with the EN 12895 standard
The noise tests regarding the sound pressure
level at the driver’s seat were carried out
in accordance with the EN 12053 standard
and declared according to the EN ISO 4871
standard
The vibration tests were carried out in accor-
dance with standard EN 13059 and declared
in accordance with standard EN 12096.
The limit values for the electromagnetic
emissions and immunity relative to the forklift
are those set out in the EN 12895 standard.
Type of use
"Normal use conditions" of the forklift under-
stood as:
• lifting and/or transport of loads using forks
with weight and centre of gravity within the
values provided (see Chapter 6 - Technical
Data).
• transport and/or lifting on smooth, flat and
compact surfaces;
• transport and/or lifting of stable loads
uniformly distributed on the forks;
• transport and/or lifting with the load centre
of gravity approximately on the forklift’s
median longitudinal plane.
DANGER
The forklift must not be used for other purposes.
Any other use renders the user solely responsible
for injury/damage to persons and/or objects and
voids the warranty.
The following scenarios are examples of
improper use of the forklift truck:
• Transportation on uneven ground (irregular
or non-compacted surfaces)
• loads that exceed the weight and/or centre
of weight limits;
• transporting non-stable loads
• transporting loads not equally distributed on
the forks;
• transporting swinging loads;
• transporting loads whose centre of gravity
is considerably displaced with respect to
the forklift’s longitudinal median plane;
• transporting loads of dimensions such as to
block the view of the operator when driving;
• transporting loads piled so high that they
could fall on the operator;
• travelling with a load over 500 mm off the
ground;
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1Introduction
Working conditions
• transporting and/or lifting people;
• pushing or pulling loads;
• moving upwards or downwards on aslope
with the load facing downwards;
• turning at high speed;
• turning and/or moving in an oblique direc-
tion on slopes (upwards or downwards);
• colliding with stationary and/or movable
structures;
• inclining the lift unit forwards with the
forks lifted, except during the lifting and/or
depositing of the load.
DANGER
Improper use of the forklift could cause it and/or at
the load to overturn.
Working conditions
The forklift has been designed and built for
internal transport.
Do not use beyond the limits of the climatic
conditions indicated below:
• Maximum ambient temperature: +40°C
• Minimum ambient temperature: +5°C
• Altitude up to 2000 m
• Relative humidity between 30% and 95%
(without condensation).
CAUTION
Do not use the forklift in dusty areas.
Using the forklift in environments with high concen-
trations of salty air or water could interfere with its
proper operation and cause corrosion of metallic
parts.
If the forklift must be used in conditions that
exceed the limits indicated or, in any case,
under extreme conditions (extreme weather,
cold-storage rooms, presence of strong mag-
netic fields etc), appropriate equipment and/or
use precautions are necessary. Contact the
authorised sales network for more informa-
tion.
DANGER
The forklift may not be used in environments in
which there is a risk of explosion. It may not be
used to handle explosive loads.
For forklifts that must operate in environments
in which there is a risk of explosion or must
handle explosive loads, appropriate equip-
ment is necessary and must be accompanied
by a specific EC Declaration of Compliance
which replaces that of the standard forklift,
and by the relevant User and maintenance
manual.
Contact the authorised sales network for more
information.
Modifications to Forklift
No modifications may be made to the forklift,
otherwise the EC certificate and the warranty
will become invalid, with the exception of:
• assembly of the options provided by the
manufacturer
• assembly of applied equipment
for which it is necessary to refer exclusively to
the authorised sales network
DANGER
If the forklift is equipped at the factory or later with
devices that emit non-ionising radiation (such as
radio transmitters, RFID players, data terminals,
scanners, etc), the compatibility of such devices
must be verified with the presence of operators
using medical devices (such as heart pacemakers).
64
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Introduction 1
Applied equipment
Applied equipment
To use equipment that has not been applied,
please contact the authorised sales network,
in order to:
• verify feasibility
• install the equipment
• add a label with the new residual capacity is
• provide documentation on the equipment
(user and maintenance manual and EC
certificate).
User obligations
Users must comply with applicable local legis-
lation governing forklift use and maintenance.
Environmental considerations
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:
• disposed of,
• 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.
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1Introduction
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.
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2
Safety

2Safety
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
personnel to use the forklift.
• Do not install equipment on the forklift un-
less supplied or indicated by the manufac-
turer.
• Maintain the forklift in full working efficiency
in order to keep any type of risk to the
minimum.
• Do not use the forklift with hoods and doors
open.
• The data plates found on the forklift must
be kept in good condition and replaced if
damaged.
• Carefully read and follow all of the safety
indications found on the forklift.
• Make sure that the forklift has sufficient
overhead clearance.
• Do not park the forklift in front of fire-fighting
devices or fire escapes or anywhere that it
blocks traffic.
• If the forklift shows signs of failure or break-
age and there is reason to consider it un-
safe, stop, park it and notify the mainte-
nance manager.
• Pay attention to the distances from high
voltage overhead cables. Comply with
the safety distances established by the
competent authorities.
• Never raise the load using just one fork.
• Place the load on the fork carriage or in such
a way that the centre of gravity of the load is
as close as possible to the fork carriage.
• The load must be placed on the forks so
that the centre of gravity falls on the mid
point between the forks.
• Do not drive with loads decentralised
laterally with respect to the forklift’s median
axis. Lack of compliance with this regulation
can compromise forklift stability.
• Make sure that the surface on which the
load rests is able to support its weight.
• Always use safety clothing that complies
with the current regulations.
• Do not travel on loose or hilly ground or on
steps.
• Do not turn or stack on slopes.
• Do not overload the forklift beyond the
capacity limits indicated on the capacity
plates.
Flooring requirements
The work floor must be even and free of holes
or dips, which can be difficult to get around.
Any steps must be equipped with ramps to
prevent impacts with the wheels, which affect
the entire structure of the truck.
CAUTION
Passing over cracks or damaged parts of the floor
with the truck is prohibited. Dirt and any objects in
the work path must be removed immediately.
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Safety 2
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).
Safety Regulations Relative to Forklift Use
• The operator must familiarize himself with
the forklift to be able to better describe any
defects and assist maintenance personnel.
The operator, trained and authorized to use
the forklift, must be familiar with the controls
and performances of the forklift.
• Any defect (squeaking, leaks, etc.) must be
promptly reported because, if neglected, it
could cause more serious failures/defects.
• Carry out the inspections indicated in the
chapter on "Daily Inspections".
ENVIRONMENT NOTE
Report any oil and/or battery fluid leaks: they
are dangerous and highly polluting.
CAUTION
If you notice a burning smell, stop the forklift and
turn off the engine, then disconnect the battery.
Safety Regulations Relative to Operating Materials
Rules for handling and disposing of
operating materials
ENVIRONMENT NOTE
Improper use and disposal of operating and
cleaning materials can cause serious damage
to the environment.
Always use and handle the operating materi-
als in a suitable manner and follow the manu-
facturer’s instructions for the product’s use.
Keep the operating materials only in contain-
ers intended for this purpose and in a location
that satisfies the requirements.
The operating materials may be flammable, so
avoid contact with hot objects or open flames.
When topping up the operating materials, only
clean containers should be used.
Follow the manufacturer’s safety and disposal
instructions regarding the operating and
cleaning materials.
Do not disperse oils or other operating liquids!
Any spilt liquid must be immediately collected
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2Safety
Safety regulations
and neutralised with a binding material (such
as an oil binder) and then disposed of in
accordance with current regulations.
Always comply with anti-pollution regulations!
Before carrying out work that involves lubrica-
tion, filter replacement or hydraulic equipment
interventions, the area in question must be
thoroughly cleaned.
The replaced parts must always be disposed
of in accordance with the anti-pollution laws.
ENVIRONMENT NOTE
The incorrect or unlawful use of brake fluid is
harmful to people’s health and the environ-
ment.
Oils
• Do not allow to come into contact with the
skin.
• Do not inhale oil vapors.
• Wear appropriate means of individual
protection during forklift maintenance
operations (gloves, goggles, etc.) to
prevent the oil from coming into contact
with your skin.
ENVIRONMENT NOTE
The used oils and relative filters contain sub-
stances that are hazardous to the environment
and must be disposed of according to current
regulations. We advise you to contact the au-
thorised service network.
DANGER
The penetration in the skin of hydraulic oil that has
leaked under pressure from the forklift’s hydraulic
system is dangerous. If this type of lesion should
occur, contact a doctor immediately.
DANGER
Small high pressure jets of oil can penetrate the
skin. Look for any leaks using a piece of cardboard.
Battery Acid
• Do not inhale the vapor: it is poisonous.
• Use adequate means of individual protec-
tion to prevent contact with the skin.
• Battery acid is corrosive: if it should come
into contact with your skin, rinse abundantly
with water.
• Explosive gas mixtures can form when
charging the battery; therefore, the rooms
in which the battery is charged must be in
compliance with the specific regulations on
the subject (e.g. EN 50272-3 etc.).
• DO NOT smoke or use open flames and
lights within a 2 m radius from the charged
battery and in the battery charging area.
NOTE
For greater information, consult the specific
battery manual that comes with the battery.
ENVIRONMENT NOTE
The batteries contain substances that are ha-
zardous to the environment. The replacement
and disposal of the life-expired battery must
be carried out as required by law. We advise
you to contact the authorised service network
that is equipped for eco-friendly disposal in
accordance with current regulations.
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Safety 2
Location of labels
Location of labels
4
6
1
7
1841
3
2
5
1 Read the user and maintenance manual
2 Truck lifting point
3 Battery warning
4 Prohibition against carrying people
5 Cold-storage room version (optional)
6 Version set up for gel batteries
7 Position the plug correctly, as illustrated,
before removing the battery from the side
(only for the battery side removal version).
Description of labels
(1) This label indicates you should consult the
user and maintenance manual before using
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2Safety
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.
(5) This symbol, where present, indicates that
the truck is designed for the cold-storage room
version.
(6) This symbol, where present, indicates that
the truck is set up for the gel battery version.
Do not use other types of battery
(7) This symbol, if present, indicates that
the battery male connector must be moved
correctly, as illustrated, before removing the
battery from the side (only for the battery side
removal version). To avoid damaging the
battery male connector
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