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Still EXH 25 Original Instructions Manual Download Page 102

1000-hour maintenance plan

Depending on the application, environmental conditions and driving style, the following proce-

dures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours
 
Preparation
Clean the truck
Check the error codes using the diagnostic tool
Chassis and equipment
Check the condition of the load arms.
Check the electromagnetic brake and ensure that it is working correctly
Check and lubricate the hinges
Check the pump motor brushes for wear
Check the transmission gear for noise and leaks
Lubricate the gears
Wheels
Check the condition and tightness of the wheels
Check the stabilisers
Electrical equipment
Clean the electric steering system and the lifting motors
Check the condition of the cables and the battery sockets and ensure that they are positioned

correctly
Check the electrical insulation between the chassis and the electric components
Check the electrical insulation between the chassis and the electronic components
Check the fuses
Check the battery acid level and the electrolyte level
Hydraulics
Check the hydraulic oil level
Check the oil level of the controlled stabilisers

5000-hour maintenance plan 

Depending on the application, environmental conditions and driving style, the following proce-

dures should be carried out every 5000 and 10,000 hours
 
Information
Carry out all 1000-hour maintenance work
Hydraulics
Drain the hydraulic oil

Maintenance

5

1000-hour maintenance plan

 94

11538011551 EN - 02/2021  -  08

Summary of Contents for EXH 25

Page 1: ...Pallet truck EXH 25 EXH 30 Original instructions 0183 0184 2360 2361 11538011551 EN 02 2021 08 ...

Page 2: ......

Page 3: ...of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de Preface I 11538011551 EN 02 2021 08 ...

Page 4: ......

Page 5: ...ion of symbols used 9 Disposing of components and batteries 9 2 Safety Safety regulations 12 Safety regulations for handling consumables 13 Permissible consumables 13 Oils 13 Hydraulic fluid 14 Battery acid 14 Disposal of consumables 15 Emissions 16 Noise emission values 16 Vibration characteristics for vibrations to which the body is exposed 16 Residual dangers residual risks 17 Stability 17 Defi...

Page 6: ...hecks and actions prior to commissioning 35 Checking the anti crush safety device 35 Checking the emergency shutdown 36 Checking the brake 36 Checking the horn 37 Truck operating instructions 38 Using the display operating unit 40 Selection buttons 40 Operation of the display unit 40 Driving safety guidelines 44 Driving 45 Defining directions 45 Driving 45 Steering 46 Braking 47 Horn 48 Drive prog...

Page 7: ...picking 68 Opening and closing the battery hood 69 Charging the battery using an external charger 70 On board charger 72 Using the on board charger 73 Adjusting the on board charger 75 Changing the vertical access battery 76 Changing the side access battery 76 Handling the truck in an emergency 82 Truck towing procedure 82 Handling the truck in specific situations 84 Slinging the truck 84 Lifting ...

Page 8: ...and wheels 100 Cleaning the pinion gear of the steering geared motor 100 Checking the condition of the wheels 101 Stabiliser maintenance 101 Electrical equipment 102 Cleaning and blowing air through the electrical components 102 Checking the battery acid level and electrolyte density 103 Checking the condition of the cables terminals and battery connector 104 Hydraulic systems 105 Checking the hyd...

Page 9: ...1 Introduction ...

Page 10: ...w 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 pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Ther...

Page 11: ... addi tion to the tow tractor can compromise safety thereby invalidating the EC declaration of con formity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities 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 o...

Page 12: ...pliance declaration STILL S A S The manufacturer declares that the truck com plies with the requirements of the EC direc tives valid at the time of marketing This is confirmed by the EC declaration of conformity and by the EC labelling on the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declarat...

Page 13: ...lar area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Model Manufacturer Serial number Year of manufacture Unladen weight without battery in kg Maximum battery weight Minimum battery weight for a lithium ion battery the weight of the ballast con...

Page 14: ...et the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given i...

Page 15: ... or by scanning the QR code displayed to the side When the web page is open please type in the following password Spareparts24 On the next screen please enter your email address and truck serial number to receive the link by email Then download the spare parts list 2511 Introduction 1 Spare parts list 7 11538011551 EN 02 2021 08 ...

Page 16: ...le The capacity label specifies the maximum load that can be raised This limit must not be exceeded Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special meas ...

Page 17: ...physical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Disposing of components and batteries The truck is made up of different materials If components or batteries...

Page 18: ...Introduction 1 Disposing of components and batteries 10 11538011551 EN 02 2021 08 ...

Page 19: ...2 Safety ...

Page 20: ...allets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of material handling trucks When instr...

Page 21: ...Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined w...

Page 22: ...m plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the regulations Dispose of old hydraulic fluid according to reg ulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and consumption In case of injury seek medical advice immediately WARNING Battery ac...

Page 23: ...only be carried out in areas designated for this purpose Take care to minimise as far as pos sible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of battery acid must be neutral ised immediately Safety 2 Safety r...

Page 24: ...ned according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb vi brations Vibration characteristics 2 5 m s2 NOTE The vibration characteristics for bodily vibra tions cannot be used to determine the actual load level of vibrations during operation This depends on the operating conditions state ...

Page 25: ...the load being unsta ble or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and ground conditions The stability of the truck has been tested to the latest standards These standards only take account of the static and dynamic tilting forces th...

Page 26: ...tion of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per sons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of behav iour The driver...

Page 27: ...is responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use Safety 2 Definition of responsible persons 19 11538011551 EN 02 2021 08 ...

Page 28: ...til at least a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring that any defects are remedied immediately Contact your servi...

Page 29: ...3 Overviews ...

Page 30: ...iller Battery hood External charger socket hood Notepad clip Stabiliser wheels 1 2 3 4 5 Drive wheel Technical compartment Battery compartment Load arms Load wheels 6 7 8 9 10 Overviews 3 Overview 22 11538011551 EN 02 2021 08 ...

Page 31: ...Technical compartment Pump unit Traction motor ES30 24 steering unit 1 2 3 Stabiliser wheels Drive wheel Stabilisers 4 5 6 Overviews 3 Overview 23 11538011551 EN 02 2021 08 ...

Page 32: ...ay devices Driver s compartment Emergency stop button Electronic key or switch key Diagnostic connector 1 2 3 Display External charger socket hood 4 5 Overviews 3 Operating and display devices 24 11538011551 EN 02 2021 08 ...

Page 33: ...Tiller Horn Lifting the load arms Lowering the load arms Handle 1 2 3 4 Drive switch Anti collision device Creep Speed button 5 6 7 Overviews 3 Operating and display devices 25 11538011551 EN 02 2021 08 ...

Page 34: ...ngs indicator light Warning indicator light Drive programme indicator light 1 2 3 4 5 6 Activity indicator light Error Code menu Settings menu Truck status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 7 8 9 10 11 12 13 Overviews 3 Operating and display devices 26 11538011551 EN 02 2021 08 ...

Page 35: ...L ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0...

Page 36: ...wer switches off auto matically after 10 mi nutes 600 seconds by default if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 37: ...s Danger instructions label Consult operating instructions Brand label 1 2 3 4 Model label Slinging label Consult operating instructions Cold store label Next inspection label Danger instructions label Consult operating instructions 5 6 7 8 9 Overviews 3 Markings 29 11538011551 EN 02 2021 08 ...

Page 38: ...number for all technical en quiries The serial number contains the following infor mation 1 Production location 2 Type 3 Year of production 4 Count number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 30 11538011551 EN 02 2021 08 ...

Page 39: ...4 Use ...

Page 40: ... The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled by a tiller Braking The truck is equipped with two braking sys tems An electric counter current brake Upon releasing the drive switch By reversing the drive direction Controlled by the rear safety button An electromagnetic brake Electromagnetic safety brake controlled by the emergency off switch Electrom...

Page 41: ... and function according to their operating instructions Damaged or missing stickers must be re placed in compliance with the marking posi tion table The roller channels must be coated in a visible layer of grease The wheels must show no signs of defects or heavy wear They must be mounted cor rectly Check that there are no foreign objects that could hinder the operation of the wheels and rollers Th...

Page 42: ...w centimetres NOTE Always adjust the speed to suit the route any dangers and the load Use the truck on ground that has the correct surface and hardness WARNING Risk of accident or loss of load Driving on slopes steeper than 10 is prohibited due to braking capacity and stability The load being transported could tip over Tilt the tiller in the driving area 2 NOTE In areas 1 and 3 the electromagnetic...

Page 43: ...ce on the tiller head comes into contact with the driv er s body When the operator moves away from the anti crush safety device the machine stops even if a drive direction is selected again Normal operation may be resumed after re leasing the drive switches Checking the anti crush safety device WARNING Ensure that the test zone is free of people and ob jects both in front of and behind the truck M...

Page 44: ... switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This adjustment influences braking ef fectiveness Checking the brake NOTE Perform this check on a flat surface Drive the machine forward Tilt the tiller in areas 1 and 3 In these two areas the machine is braked and the drive unit is no longer powered Releasing the tiller in the drive area 2 sends ...

Page 45: ...Checking the horn Press the horn button 5 located on the up per part of the tiller The horn sounds Use 4 Checks and actions prior to commissioning 37 11538011551 EN 02 2021 08 ...

Page 46: ... must be consistent with a maxi mum recommended height of 2 m For uses other than those shown above please consult the After Sales Service Centre It is important to use pallets that are in good condition Speed must be reduced when moving over obstacles to prevent the truck from becoming unbalanced and vibrations in the forklift opera tor s arms The trucks can drive across ramps and shal low inclin...

Page 47: ...CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 39 11538011551 EN 02 2021 08 ...

Page 48: ...or can refer to the battery icon 1 or 2 The number of bars shown indicates the bat tery charge level From 0 to 20 1 bar From 21 to 40 2 bars From 41 to 60 3 bars From 61 to 80 4 bars From 81 to 100 5 bars The Battery indicator light 3 comes on in the event of a deep discharge of the battery or in the event of a fault Two distinct warnings may be displayed if the battery charge is insufficient 1 Le...

Page 49: ...ate the date of the next maintenance A warning is shown on the display The Warning light 3 comes on in the event of a fault in a truck component Drive program The Drive program light 1 is permanently il luminated when a travel mode is selected There are three different drive modes Tortoise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desire...

Page 50: ...ttings menu It is possible to access different settings through the Settings menu Select the Settings menu 1 This menu allows access to a drop down menu 2 consisting of Language Unit Date format Date Time Adjustment of the Load Management warn ing sounds Adjustment of the contrast Adjustment of the brightness Select the desired option Use 4 Using the display operating unit 42 11538011551 EN 02 202...

Page 51: ...ll through several successive dis plays The number of error messages is indicated at the bottom of the display 2 Start up screen In addition to the various menus and lights mentioned above additional data is available The Truck status menu 1 displays the truck menu The Hourglass icon 2 indicates the oper ating time of the truck The Clock icon 3 indicates the time and date Use 4 Using the display o...

Page 52: ...the dash board is prohibited The operator must be rest ing against the seat These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the dashboard to drive the truck The truck must not be used as a stepladder The truck is not designed to transport peo ple Operators must always stay within the truck clearance Stay in the safety area work...

Page 53: ...on key Lower the tiller into the 2 zone NOTE The truck is in the drive position in the 2 zone In the lower zone 1 or the upper zone 3 the brake is applied and the traction motor is switched off DANGER Risk of obstructing the use of the tiller Do not adjust the A4 sized support to a height that is too low This could hinder the forklift operator when driving the truck Forward travel Use 4 Driving 45...

Page 54: ...very careful Make sure that the path behind is clear before travelling in reverse Reversing the direction of travel Push the drive switch in direction 1 or 2 Release the drive switch Operate it progressively in the opposite di rection until the required speed is reached Steering A long centred and balanced tiller fitted with 2 handles directly controls the drive wheel The length of the tiller is d...

Page 55: ...NING The quality of the floor surface affects the braking distance of the truck This should be taken into consideration when driving Electromagnetic braking The electromagnetic brake is activated auto matically if one of the following conditions is met The tiller is released It is then brought back to the braking position 3 by a gas spring The tiller is in the braking position 3 or 1 The drive swi...

Page 56: ...h Braking can be achieved by releasing the drive switch While travelling completely release the drive switch 1 or 2 The brake is automatically activated The truck is immobilised Horn The horn is positioned on the inner side of the tiller It is used On routes where there is poor visibility At junctions In the event of immediate danger Press the button 1 The horn sounds Use 4 Driving 48 11538011551 ...

Page 57: ... selected on the screen the truck operates at its maximum perform ance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck The travel speed of the truck is reduced 70 of maximum speed The speed of lifting and lowering the forks is reduced 90 of maximum speed This mode allows you to save battery Tortoise mode Selecting Tortoise mode allows you to reduce the ...

Page 58: ...his The Creep Speed function cancels automati cally when the tiller is in the drive position CAUTION Danger of forklift operator being trapped by the truck Gently move the drive switch to adjust the truck speed This prevents it moving too quickly towards the operator NOTE If the operator releases the Creep Speed but ton and or the drive switch the vertical posi tion of the tiller applies the emerg...

Page 59: ...out a load it is recommended that you go up a slope forwards Travelling down slopes Always travel down slopes forwards The load faces uphill NOTE Without a load we recommend that you de scend a slope forwards In all cases you must travel at a very low speed and brake gradually DANGER Danger of death and or risk of serious damage to equipment Never park the truck on a slope Never make a U turn or t...

Page 60: ...per than 10 is prohibited due to braking capacity and stability The load being transported could tip over Starting on a slope Proceed as follows Move the drive switch in the required direc tion Release the drive switch to apply the park ing brake Use 4 Driving 52 11538011551 EN 02 2021 08 ...

Page 61: ...le with antenna The options available on the truck are Access control Access control and shock sensor Access control and GPRS module Access control shock sensor and GPRS module 1 GPRS General Packet Radio Service 2 GSM Global System for Mobile Communi cation Shock sensor This sensor allows you to record the shocks received by the truck If the truck receives a shock it is possible to configure a sp...

Page 62: ...nter key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or the RFID transponder 4 in front of the re...

Page 63: ...e enter the PIN code Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The operator has been granted ac cess authorisa tion But the peri od of validity has expired Use the interface to enter a new pe riod of validity The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously Green colour Memory is 80 full Clear t...

Page 64: ... quickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 56 11538011551 EN 02 2021 08 ...

Page 65: ...n a safe place Press the button 3 to log off Keep the but ton pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to sw...

Page 66: ... The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 58 11538011551 EN 02 2021 08 ...

Page 67: ... WARNING Take care not to trap hands or feet when operating the truck Grabbing a loading unit Watch out for the following elements the load must be well balanced and centred correctly between the fork arms the fork arms must be sufficiently slid un derneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms protrude too far out from the l...

Page 68: ...me is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 60 11538011551 EN 02 2021 08 ...

Page 69: ... on the tiller when lifting or lowering the load arms Lifting the load arms Press the control button 1 The load arms are raised Lowering the load arms Press the control button 2 The load arms are lowered Use 4 Transporting loads 61 11538011551 EN 02 2021 08 ...

Page 70: ...he width of the load is compati ble with the width of the load arms Check that the load is not damaged DANGER Risk of tipping It is essential to slow down when approaching a cor ner or on wet ground Picking up a load from the ground Proceed as follows Approach the load carefully Lower the load arms so that they can easily be inserted into the pallet Insert the load arms under the load For a load t...

Page 71: ...affolding pipes etc Check that the width of the load is not greater than the width of the aisle Setting a load down on the ground Proceed as follows Drive the truck to the required location Carefully move the load into the unloading zone Lower the load until the load arms are free Withdraw the truck in a straight line Raise the load arms again by a few centi metres CAUTION Risk of accident Before ...

Page 72: ... Switch off the ignition key or electronic key In the event of a prolonged shutdown press the emergency off switch Then disconnect the battery Use 4 Transporting loads 64 11538011551 EN 02 2021 08 ...

Page 73: ...es between 30 C and 45 C Specific rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room temperature zone may result in the formation of condensation water This water can freeze when the truck goes b...

Page 74: ...d store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged Use 4 Cold store usage optional 66 11538011551 EN 02 2021 08 ...

Page 75: ...the load arms The load arms must touch the ground Switch off the truck The automatic braking is activated Remove the switch key DANGER Risk of injury It is prohibited to park the truck with the load lift sys tem in the raised position Use 4 Before leaving the truck 67 11538011551 EN 02 2021 08 ...

Page 76: ... picking Maintenance personnel The battery must be replaced by specially trained personnel Personnel must follow the manufacturer s instructions for the battery the charger and the truck It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro ...

Page 77: ...d arms Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood Close the hood 1 WARNING Risk of trapping fingers When closing the battery hood correctly position your fingers to avoid any risk of them being trapped Ensure that the battery hood is closed se curely CAUTI...

Page 78: ...cket on the truck 1 Connect the battery connector to the wall mounted connector WARNING Electrical risk Only unplug the battery connector from the battery charger when both the battery charger and the truck are switched off NOTE Follow the instructions provided by the manu facturer of the battery and the battery charger equalising charge WARNING Risk of damage short circuit or explosion Do not pla...

Page 79: ...are generated during battery charg ing Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging Use 4 Handling the battery 71 11538011551 EN 02 2021 08 ...

Page 80: ...used alone out of the truck To stay permanently connected to the bat tery To operate in all positions Remain connected to the mains during peri ods of truck downtime to ensure the availa bility of the machine To tolerate opportunity charging CAUTION Risk of damage to the mains cable resulting in elec tric shock and or burns Park the truck very close to the wall mounted mains socket to avoid tensio...

Page 81: ...tically stops This can happen when a battery has a short circuited component Simply reset the mains to clear the fault Temperature safety As the charger is cooled by ventilation the air inlets and outlets must never be blocked The fan runs when the mains power is con nected It stops when charging is complete or when the mains power is disconnected The charger supplies reduced power if the ambient ...

Page 82: ...ualisation Maintenance phase Continuously lit Off Charging process too long Off Continuously lit Charger po larity reversed battery and battery charger ca bles reversed with the bat tery remain ing normally connected to the truck as sembly Continuously lit Continuously lit Battery polari ty reversed Off Off Selector in neutral posi tion Flashing Flashing CAUTION Risk of damaging the battery It is ...

Page 83: ...itions The charger does not flow and the two LEDs flash simultaneously to indicate that no curve has been selected CAUTION Risk of premature damage to the battery Ensure that the charger setting corresponds to the type of battery If the battery is changed ensure that the setting cor responds to the type of battery The four thick lines indicate the four charging curves open lead acid battery with a...

Page 84: ...lace the battery Position the new battery in the chassis Remove the slinging hooks Reconnect the battery connector Close the battery hood Return the truck to service Changing the side access battery DANGER Risk of trapping fingers It is advisable to wear gloves when changing the bat tery WARNING Risk of injury Safety shoes must be worn when changing the bat tery Before handling ensure that there i...

Page 85: ... Disconnect the battery connector Place the connector on the battery cells Unlock the door that is not attached to the side of the battery by lifting the latch 1 Hold the door 2 to prevent it falling Remove the door 2 if this option is selec ted and put it to one side Position the truck with extraction rollers or the roller frame in the upright position near the battery compartment on level ground...

Page 86: ... Operate and pull the locking handle 2 in the direction indicated by the arrow Lift the locking bar 3 until the battery is freed Use 4 Handling the battery 78 11538011551 EN 02 2021 08 ...

Page 87: ...osition the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Push the battery into the compartment DANGER Risk of trapping fingers Push the battery from the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery Use 4 Handling the battery 79 11538011551 EN 02 2021 08 ...

Page 88: ...t is not yet locked Lower and lock the handle 2 of the locking bar 3 in the direction indicated by the ar row The locking bar must be horizontal and must be right up against the stop 5 CAUTION Risk of locking the battery incorrectly The locking bar must not in any circumstances be positioned under or on top of the stop It must be positioned against the stop Reconnect the battery connector Use 4 Ha...

Page 89: ...de of the battery must be correctly locked Refit the battery hood Return the truck to service WARNING Risk of injury Before restarting the truck ensure that the battery is correctly installed Check that the battery is locked and that the battery hood is closed Use 4 Handling the battery 81 11538011551 EN 02 2021 08 ...

Page 90: ...to pull and brake the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is th...

Page 91: ... re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted be fore the machine is used 0252_003 110 3 2 Use 4 Handling the truck in an emergency 83 11538011551 EN 02 2021 08 ...

Page 92: ...ctor Lower the load arms the initial lift must be in the lowered position Remove any items that could fall Protect all parts that come into contact with the lifting device Hook the lifting device 1 onto the appropri ate locations as shown by the slinging hooks label NOTE Do not sling the truck by the tiller Do not sling the truck by the accessory support Carefully lift the truck DANGER Risk of fal...

Page 93: ...ed 3 As a safety precaution always insert a wood en chock WARNING Risk of truck falling Immobilise and chock the truck after lifting it Transporting the truck CAUTION Always switch off the ignition and disconnect the bat tery Never tie down or sling the truck by the control unit or other points not designed for this CAUTION Risk of damage to the truck Use a hoist and woven NON METALLIC slings with...

Page 94: ...city that are designed for this purpose and for which authorisation has been received from the operator Inside the lift the truck must be immobilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be observed Anyone transported with the truck must only enter the lift after the truck has been correctly immobili...

Page 95: ...5 Maintenance ...

Page 96: ...f the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix diffe...

Page 97: ...low the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by perso...

Page 98: ... personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pr...

Page 99: ...wer 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 1 5 kW for EXH25 2 2 KW for EXH30 1F1 fuse Power 300 A quantity 1 Control fuse 1F3 fuse Control 7 5 A quantity 1 Control fuse 1F4 fuse Control 5 A quantity 1 Battery Distilled water As required Joints Lithium soap grease As required Maintenance 5 Technical data for inspection and maintenance 91 1153801...

Page 100: ...proved by the manufacturer Us ing oil mixtures or hydraulic fluids that are not recommended can cause damage that may be expensive to rectify Transmission gear oil Recommended oil CLP PG220 DIN 51 517 3 Aerosol can for chains Standard chain spray A167 Multi purpose grease Lithium soap grease extreme pressure with anti wear additive Standard DIN 51825 KPF 2K 30 KPF 2K 20 KPF 2N 30 ENVIRONMENT NOTE ...

Page 101: ...llows Remove the four screws 3 from the top hood 1 Lift the top cover slightly Remove the two screws 4 from the front hood 2 Remove the front hood The technical compartment must be closed once the operation is finished Remove the front hood 2 Tighten the two screws 4 of the front hood Reposition the top hood 1 Tighten the four screws 3 of the top hood Return the truck to service Maintenance 5 Acce...

Page 102: ...cal equipment Clean the electric steering system and the lifting motors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic components Check the fuses Check the battery acid level and the electroly...

Page 103: ...d driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 10 000 hour service plan 95 11538011551 EN 02 2021 08 ...

Page 104: ... sensitive to moisture par ticularly electric components must be protected when the truck is cleaned Observe the manufacturer s instructions when us ing the cleaning product Clean the truck with a non flammable clean ing product mixed with water a sponge and cloths Specifically clean the oil filling openings and surrounding areas as well as the lubricating nipples before lubrication NOTE A truck t...

Page 105: ... of compressed air It is advisable to wear protection goggles and a mask Restart the truck in accordance with the in structions NOTE If despite taking precautions traces of mois ture remain in the motor dry it using com pressed air After having eliminated any traces of moisture the truck may be reactivated Do not do so before then to prevent any corro sion Maintenance 5 Chassis bodywork and fittin...

Page 106: ...tible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging mainte nance and treatment instructions A non compatible charger may result in a battery failure Observe the manufacturer s recommendations NOTE The discharge indicators used to check the battery must also be suitable for the type of battery Contact the r...

Page 107: ...at the load arms 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged it must be changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 99 11538011551 EN 02 2021 08 ...

Page 108: ...ean with solvent if necessary then dry with compressed air CAUTION Use of compressed air It is advisable to wear protection goggles and a mask Then lubricate the pinion and ring gear with silicone aerosol spray Reconnect the battery connector Return the truck to service CAUTION Risk of dust clogging There is a risk of dust clogging if non recommended products are used for greasing CAUTION Risk of ...

Page 109: ...abilisers No significant damage to the superstruc ture The damper cylinder pins must not be twis ted No oil leakage must be present on the damper cylinder This cylinder must be in side the spiral spring No damage to the rollers The wheels must rotate freely No locking at the level of the upper bearing Ensure that the wheel nuts are correctly tightened Ensure that there is no oil leakage under the ...

Page 110: ...electrical component Press in the emergency off switch Disconnect the battery connector Open the technical compartment Blow the electrical components with com pressed air WARNING Use of compressed air It is advisable to wear protection goggles and a mask Check the condition of the harness connec tor pins Maintenance 5 Electrical equipment 102 11538011551 EN 02 2021 08 ...

Page 111: ...an water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety information provided by the battery manufacturer Comply with the regulations in force Check the battery acid level and electrolyte density according to the battery manufactur er s recommendations The cell covers of the battery must be kept dry an...

Page 112: ...nd output terminals are not sulphated presence of white salt Check the condition of the battery connec tor contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious inci dents In the event of an incident contact our After Sales Service Centre as quickly as possible Maintenance 5 Electrical equipment 104 11538011551 EN 02 2021 08...

Page 113: ...f friction wear Check the external pipes and hoses on the technical compartment Refit the hood of the technical compart ment Return the truck to service CAUTION Risk of damaging the truck In the event of leakage please contact the After Sales Service Centre Checking the hydraulic oil level To check the hydraulic oil level proceed as follows Immobilise the truck Lower the load arms Switch off the i...

Page 114: ...battery connector Return the truck to service Checking the controlled stabiliser hydraulic system for leaks Switch off the truck and disconnect the bat tery connector Remove the hood of the technical compart ment Inspect the stabiliser hydraulic system Tank Rigid pipes Connections from the stabiliser directional control valve block to the cylinders Check the tank for leaks Tighten the swivel joint...

Page 115: ...el of the stabilisers is on the mark situated between the raised MIN and MAX 3 lettering on the tank 2 Top up the level if necessary after un screwing the plug 1 Screw the plug back in at the end of the op eration CAUTION Risk of damage to the truck Only use hydraulic oil that complies with the specifi cations See table of lubricants Refit the hood of the technical compart ment Return the truck to...

Page 116: ... must not touch the ground in order to prevent ir reversible deformation of the tyres Cover the truck with a cotton cover to pro tect it from dust CAUTION We recommend that you do not use a plastic sheet as this encourages condensation to form Consult the service department for further measures to take if the truck must be stored for a longer period of time Recommissioning after storage If the tru...

Page 117: ...um iron etc Before scrapping the truck notify the com petent authorities of your country in writing After receiving the authorisation from the competent authorities remove any compo nents according to national standards NOTE The client is solely responsible for any irregu larities he has committed during or after the scrapping of the truck s components and the removal of components Maintenance 5 S...

Page 118: ...Maintenance 5 Storage and decommissioning 110 11538011551 EN 02 2021 08 ...

Page 119: ...6 Technical specifications ...

Page 120: ...EXH datasheet Technical specifications 6 EXH datasheet 112 11538011551 EN 02 2021 08 ...

Page 121: ...7 3 1572 2246 3 2 3 Load per unladen axle drive side load side 10 kg 662 157 3 662 157 3 WHEELS EXH 25 EXH 30 3 1 Tyre polyurethane rubber drive side load side R P P 3 2 Drive wheel dimensions width at the ground Ø x L mm Ø230 x L90 3 3 Wheel dimensions load side Ø x L mm Ø85 x L85 bogies Ø85 x L60 3 4 Additional wheels dimensions Ø x L mm 2 x Ø125 x L60 3 5 Number of wheels at drive side load sid...

Page 122: ...MANCE DATA EXH 25 EXH 30 5 1 Travel speed laden unladen 5 km h 6 6 5 2 Lifting speed laden unladen 10 m s 0 028 0 036 0 026 0 036 5 3 Lowering speed laden unladen 10 m s 0 066 0 072 0 065 0 072 5 8 Maximum gradient laden unladen 12 20 10 20 5 9 Acceleration time 10 m s 7 4 6 56 7 7 6 56 5 10 Service brake electromagnetic DRIVE SYSTEM EXH 25 EXH 30 6 1 Traction motor hourly output kW 1 5 6 2 Lift m...

Page 123: ...d monitor AC controller LAC 10 7 Noise level at forklift operator s ears 2 5 dB A 60 Vibrations transmitted to the operator EN 13059 m s 1 Load arms lifted lowered 2 Calculation with Wa load arms lowered 3 Weight according to line 2 1 4 With battery line 6 5 5 In lowered position 6 Add 75 mm for 4 PzS 7 Ast Wa R a Safety distance a 200 mm Technical specifications 6 EXH datasheet 115 11538011551 EN...

Page 124: ...Technical specifications 6 EXH datasheet 116 11538011551 EN 02 2021 08 ...

Page 125: ...g the oil level in the controlled sta biliser circuit 107 Checks prior to start up 33 Cleaning the truck 96 Climatic conditions 8 Closing the battery hood 69 cold store 65 Cold store usage 65 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Defining direct...

Page 126: ...0 Multi purpose grease 92 N Noise emission values 16 O Oils 13 On board charger Adjusting the on board charger 75 Charging curve selector 75 Using the on board charger 73 Opening the battery hood 69 Operating company 18 Ordering spare parts and consumables 89 Order picking 68 P Permanent Putting Out of Commission 109 Picking up a load from the ground 62 Precautions to be taken during battery maint...

Page 127: ...k 85 Transporting the truck in the lift 86 Travelling down slopes 51 Travelling up slopes 51 Truck operating instructions 38 U Unauthorised use 9 Using the truck on a slope 50 V Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Wheels Checking the condition of the wheels 101 Working on the electrical equipment 90 Index 119 11538011551 EN 02 2021 08 ...

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