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Still EXH-S 20 Original Instructions Manual Download Page 104

1000-hour service 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
Enter the next maintenance interval
Chassis and equipment
Check the condition of the load arms
Check the electromagnetic brake and ensure that it is working correctly
Check and grease the hinges
Check the pump motor brooms for wear
Check the transmission gear for noise and leaks
Grease the gears
Check the platform
Check the condition of the forklift operator detection function
Wheels
Check the condition and tightness of the wheels
Check the stabilisers
Grease the axles and the bearing of the load wheels and the stabiliser wheels (lubricated ver-

sion)
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 electrical components
Check the electrical insulation between the chassis and the control unit components
Check the fuses
Check the battery acid level and the electrolyte level
Check the pump motor brushes for wear
Hydraulics
Check the pump-motor unit mounting
Check the hydraulic oil level
Check the condition of the pipe line
Check the oil level of the controlled stabilisers

Maintenance

5

1000-hour service plan

 94

11538011751 EN - 02/2021  -  03

Summary of Contents for EXH-S 20

Page 1: ...Pallet truck EXH S 20 EXH S 25 Original instructions 2364 2365 11538011751 EN 02 2021 03 ...

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 11538011751 EN 02 2021 03 ...

Page 4: ......

Page 5: ... 8 Unauthorised use 9 Additional information on the conditions of use for pallet trucks in ride on mode 9 Explanation 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 c...

Page 6: ...rating unit 27 Markings 28 Labels 28 Serial number 29 4 Use Technical description 32 List of checks prior to start up 34 Starting up 35 Checks and actions prior to commissioning 36 Checking the emergency shutdown 36 Checking the brakes 36 Horn 37 Operation of the display operating unit 38 Truck operating instructions 40 Adjusting the steering wheel height 42 Driving safety guidelines 43 Driving 44...

Page 7: ...iners 60 Using the load arms 61 Load handling 62 Cold store usage optional 65 Before leaving the truck 67 Handling the battery 68 Battery type 68 Opening and closing the battery hood 68 Charging the battery using an external charger 69 On board charger 71 Using the on board charger 72 Order picking 74 Changing the side access battery 75 Changing the vertical access battery 79 Handling the truck in...

Page 8: ... 96 General information on battery maintenance 98 Checking the condition of the load arms 99 Steering 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 ...

Page 9: ...6 Technical specifications EXH S 20 and EXH S 25 datasheet 112 Table of contents VII 11538011751 EN 02 2021 03 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...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 13: ... 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 14: ...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 15: ...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 16: ...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 17: ... 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 11538011751 EN 02 2021 03 ...

Page 18: ... advance is to limit danger as far as possible 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 ures for trucks equipped with Gel or Lead batteries U...

Page 19: ...e on using this truck Explanation of symbols used DANGER Compulsory procedure that must be followed to avoid life threatening danger or 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 p...

Page 20: ...Introduction 1 Disposing of components and batteries 10 11538011751 EN 02 2021 03 ...

Page 21: ...2 Safety ...

Page 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...of stability due to 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 dynam...

Page 28: ...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 29: ...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 11538011751 EN 02 2021 03 ...

Page 30: ...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 31: ...3 Overviews ...

Page 32: ... the truck Battery hood Steering wheel Key switch or electronic key Battery compartment Stabiliser wheel 1 2 3 4 5 Platform Drive wheel Load arms Load wheels or bogies 6 7 8 9 Overviews 3 Overview 22 11538011751 EN 02 2021 03 ...

Page 33: ... technical compartment ES30 24 steering unit Horn Traction motor Stabilisers Stabiliser wheels 1 2 3 4 5 Drive wheel Turntable Pump motor unit tank Pump motor unit 6 7 8 9 Overviews 3 Overview 23 11538011751 EN 02 2021 03 ...

Page 34: ...ms lowering control Brake Emergency off switch 1 2 3 4 5 6 Control button for the on board compressor Ignition key or electronic key Diagnostic connector Display Fork lifting and lowering controls depending on model 7 8 9 10 11 Overviews 3 Operating and display devices 24 11538011751 EN 02 2021 03 ...

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: ...ble on the model Hour meter Warning signal if applicable F2 Indicator light if available on the model Service reminder 1 2 3 4 5 6 7 8 Right turn indicator if available on the mod el BLUE Q mode Tortoise mode Tortoise indicator Warning triangle Type of alarm Battery charge level indicator 9 10 11 12 13 14 15 Overviews 3 Operating and display devices 27 11538011751 EN 02 2021 03 ...

Page 38: ...and label Model label Slinging label Consult the operating instruc tions Brand and model label 1 2 3 4 5 Next inspection label Brand and model label Brand label Truck steering and steering wheel label Identification label Cold store label 6 7 8 9 10 11 Overviews 3 Markings 28 11538011751 EN 02 2021 03 ...

Page 39: ...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 29 11538011751 EN 02 2021 03 ...

Page 40: ...Overviews 3 Markings 30 11538011751 EN 02 2021 03 ...

Page 41: ...4 Use ...

Page 42: ...of 1 2 kW EXH S 20 and 1 5 kW EXH S 25 Batteries Power is supplied by A lead battery Or a lithium ion battery Two types of battery removal are available Vertical access Side access on rollers These different battery types are not available on all models Steering The ES30 24 electric steering offers driving precision and reduced effort during manoeu vres The truck is equipped with a 0 35 kW asyn ch...

Page 43: ...Driver s compartment An operator presence contact is incorporated into the suspended platform The platform is fixed The protection provides back support for the driver The steering wheel comprises the controls and the steering An emergency off switch is located on the dashboard A display Use 4 Technical description 33 11538011751 EN 02 2021 03 ...

Page 44: ... specified by the manufacturer is observed Attachment parts special equipment must be properly secured 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 rectl...

Page 45: ...ay 3 switches on The truck is ready for operation The brake is automatically dis engaged Raise the load arms a few centimetres NOTE Always adjust your speed to suit the route any dangers and the load Use the truck on ground that has the correct surface and hard ness DANGER Risk of sparks Using the truck with the battery hood open is prohibi ted WARNING Risk of accident or loss of load Driving on s...

Page 46: ...supply is cut The electrical controls and motors are no longer supplied with power Pull the emergency off switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This influences braking effectiveness Checking the brakes To check the main brakes of the truck pro ceed as follows Press the braking button 1 The truck comes to a standstill Use 4 Checks and a...

Page 47: ...Horn Press the horn button 1 The horn sounds Use 4 Checks and actions prior to commissioning 37 11538011751 EN 02 2021 03 ...

Page 48: ...ance of the truck is automatically limited The triangle 2 remains permanently lit until the battery is re charged Performance modes See the chapter Drive Modes Blue Q mode Blue Q mode 3 ensures that battery con sumption is fully optimised To activate Blue Q mode Press the key 3 When the key 3 is pressed Blue Q mode is activated It remains active when the truck is switched off and on again To deact...

Page 49: ...y three num bers The Triangle light 2 turns on in the event of an error code on the truck It also comes on when the battery charge level is too low The hour meter light 4 indicates the number of operating hours for the truck When the symbol 3 is displayed the truck indicates the number of hours remaining before the battery is discharged The Adjustable Spanner indicator light 5 comes on to indicate...

Page 50: ... 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 51: ...CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 41 11538011751 EN 02 2021 03 ...

Page 52: ...adjusted To adjust the steering wheel height proceed as follows Press and hold the button 1 Pull the steering wheel 2 towards you or lower it until the required height is reached Release the button 1 Use 4 Adjusting the steering wheel height 42 11538011751 EN 02 2021 03 ...

Page 53: ...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 54: ...side the driver s compartment while the truck is moving The drive switch is positioned on the steering wheel Forward travel Step onto the forklift operator detection plat form Pull the emergency off switch Gradually and slowly press the drive switch forwards 1 with your thumb When the drive switch is released the truck brakes electrically Reverse travel Step onto the forklift operator detection pl...

Page 55: ...roceed as follows Turn the steering wheel to the left the truck turns to the left in forward travel 1 Turn the steering wheel to the right the truck turns to the right in forward travel 2 WARNING Risk of tipping Always slow down before negotiating a corner Ap proaching a tight corner too fast can cause the truck to overturn Optional Inverted steering may be selected You must therefore adapt your d...

Page 56: ...itation Trucks with a platform are fitted with a safety device that automatically reduces the speed when cornering above a certain steering angle of the drive wheel Emergency off switch During normal operation the emergency off switch 1 must be pulled out In case of danger Press the button 1 to break the electrical circuit and immobilise the truck Use 4 Driving 46 11538011751 EN 02 2021 03 ...

Page 57: ...2 While travelling move the switch in the op posite direction First the truck is braked electrically Release the drive switch The brake is automatically activated The truck is immobilised By releasing the drive switch While travelling completely release the drive switch The brake is automatically activated The truck is immobilised Electromagnetic braking The electromagnetic brake is activated auto...

Page 58: ...nt of immediate danger Press the button 1 The horn sounds Drive program The indicator light 1 is permanently on during operation of the truck The shape of the indi cator light indicates the selected program The truck is equipped with two different drive programs Tortoise mode 2 BlueQ mode 3 NOTE When the operator restarts the truck the last mode selected is automatically activated NOTE The drive p...

Page 59: ...is reduced The lifting and lowering speed of the load lift system is significantly reduced The speeds can be adjusted Contact the Af ter Sales Service to change these Using the truck on a ramp NOTE Incorrect use of the truck on a ramp is not rec ommended It places particular stress on the traction motor brakes and battery Ramps must always be approached with cau tion Never attempt a slope with a g...

Page 60: ... 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 take a short cut on a slope On a slope the forklift operator must drive more slowly WARNING Risk of serious injury and or serious damage to equipment Driving on slopes steeper than 10 is prohibited due to braking capacity and stabi...

Page 61: ... Move the drive switch in the required direc tion Release the drive switch to apply the park ing brake Use 4 Driving 51 11538011751 EN 02 2021 03 ...

Page 62: ...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 63: ...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 64: ...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 65: ... 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 55 11538011751 EN 02 2021 03 ...

Page 66: ...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 67: ... 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 57 11538011751 EN 02 2021 03 ...

Page 68: ...h board To decrease the shock absorbency Press the button 2 located on the dash board Using the foot protection op tion A foot protection option Active Foot Guard is available on the truck If the forklift operator removes his or her foot from the control area 1 the speed of the truck is automatically reduced The forklift op erator can accelerate again as soon as his or her feet are inside the driv...

Page 69: ... 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 70: ...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 11538011751 EN 02 2021 03 ...

Page 71: ...d to Do not touch or stand on moving parts e g lifting de vice pushing devices work installations load lifting devices WARNING Risk of injury Never put your hands near the load lift system The initial lift controls are located on the steer ing wheel As an option they can also be loca ted behind the steering wheel Raising the load arms Press the button 1 The load arms are raised Lowering the load a...

Page 72: ...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 73: ...low passageways low door ways scaffolding 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 ...

Page 74: ... 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 11538011751 EN 02 2021 03 ...

Page 75: ...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 76: ...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 11538011751 EN 02 2021 03 ...

Page 77: ...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 11538011751 EN 02 2021 03 ...

Page 78: ... careful not to damage any wiring when replacing the battery Opening and closing the battery hood Opening the battery hood To open the battery hood Immobilise the truck Lower the forks 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 Ris...

Page 79: ...he condition of the battery cable and the charger cable Re place them if necessary Open the hood and leave it open Pull the handle of the battery connector 2 to disconnect it from the fixed socket 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 a...

Page 80: ...iluted sulphuric acid is toxic and very caustic Follow the safety regulations when handling battery acid WARNING Explosive gases 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 70 11538011751 EN 02 2021 03 ...

Page 81: ...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 82: ...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 83: ...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 84: ...d 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 duce sparks within a minimum radius of 2 m around the truck and the battery charger The work area must be well ventilated Fire extinguishers must be provided and located near ...

Page 85: ...ame or a truck with ex traction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise the truck Lower the forks Switch off the ignition and remove the key Press in the emergency off switch Open the battery hood Disconnect the battery connector Place the connector on the battery cells Unlock the door that is not attached to the side of th...

Page 86: ...de Position the truck with extraction rollers or the roller frame in the upright position near the battery compartment on level ground Operate and pull the locking handle 2 in the direction indicated by the arrow Use 4 Handling the battery 76 11538011751 EN 02 2021 03 ...

Page 87: ...lers or the roller frame Replace the battery Remove the dis charged battery and position a charged bat tery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Use 4 Handling the battery 77 11538011751 EN 02 2021 03 ...

Page 88: ...shing from the top or the side of the battery Push until a click is heard The battery is correctly installed WARNING Risk of injury Ensure that the battery is in the end position and that the hook is correctly holding the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Use 4 Handling the battery 78 11538011751 EN 02 2021 03 ...

Page 89: ...his option is selected The door that is not attached to the side 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 Changing the vertical access bat tery To change the battery proceed as follow...

Page 90: ...cured hooks is recommended Lift the battery Replace 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 Use 4 Handling the battery 80 11538011751 EN 02 2021 03 ...

Page 91: ...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 92: ... 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 82 11538011751 EN 02 2021 03 ...

Page 93: ... the initial lift must be in the lowered position Switch off the truck and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device 1 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 falling Make sure no one is under o...

Page 94: ...tions 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 w...

Page 95: ...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 96: ...Use 4 Handling the truck in specific situations 86 11538011751 EN 02 2021 03 ...

Page 97: ...5 Maintenance ...

Page 98: ...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 99: ...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 100: ... 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 101: ...300 A quantity 1 Steering unit ES30 24 0 185 kW S1 Fuse 3F1 Power 40 A quantity 1 Pump motor 1 2 kW for EXH S 20 1 5 kW for EXH S 25 Fuse 1F1 Power 300 A quantity 1 Control fuse Fuse 1F3 Control 7 5 A quantity 1 Control fuse Fuse 1F4 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 11538...

Page 102: ...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 103: ...ress the emergency off switch Open the battery compartment Disconnect the battery connector Remove the four mounting screws 1 from the hood Carefully remove the hood The technical compartment can be accessed To refit the hood proceed as follows Position the tab inside the chassis Reposition the hood Refit and tighten the mounting screws 1 Return the truck to service Maintenance 5 Easily accessing ...

Page 104: ...eels Check the condition and tightness of the wheels Check the stabilisers Grease the axles and the bearing of the load wheels and the stabiliser wheels lubricated ver sion 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 ...

Page 105: ...intenance work Hydraulics Drain the hydraulic oil 10 000 hour service plan Depending on the application environmental conditions and 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 5000 hour maintenance plan 95 1153801175...

Page 106: ...re 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...

Page 107: ... 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 108: ...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 109: ...that the load arms 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 99 11538011751 EN 02 2021 03 ...

Page 110: ...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 111: ...o 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 truck when ...

Page 112: ... electrical component Press 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 11538011751 EN 02 2021 03 ...

Page 113: ...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 114: ...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 11538011751 EN 02 2021 03...

Page 115: ...of 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 ...

Page 116: ...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 117: ...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 118: ... 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 119: ...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 120: ...Maintenance 5 Storage and decommissioning 110 11538011751 EN 02 2021 03 ...

Page 121: ...6 Technical specifications ...

Page 122: ...EXH S 20 and EXH S 25 datasheet Technical specifications 6 EXH S 20 and EXH S 25 datasheet 112 11538011751 EN 02 2021 03 ...

Page 123: ... 3 Load per unladen axle drive side load side 10 kg 720 150 1 WHEELS EXH S 20 EXH S 25 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 Ø230 x L100 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 side X drive w...

Page 124: ... 10 m s 0 036 0 0046 0 028 0 0036 5 3 Initial lowering speed when laden unladen 10 m s 0 090 0 089 0 066 0 072 5 8 Maximum gradient laden unladen 13 20 11 20 5 9 Acceleration time 10 m s 5 9 5 1 6 1 5 1 5 10 Service brake electromagnetic DRIVE SYSTEM EXH S 20 EXH S 25 6 1 Traction motor S2 60 minutes kW 2 3 3 6 2 Lift motor at S3 10 utilisation kW 1 2 1 5 6 3 Battery type in accordance with DIN 43...

Page 125: ...1 Weight according to line 2 1 2 With battery line 6 5 3 Forks lowered 4 Same for Trog70 add 75 mm for 4 PzS add 150 mm for 5 PzS Value for rear access version For side access and backrest version add 75 mm 5 Forks raised Ast Wa R a Safety distance a 200 mm 6 Other speeds available 7 For side access and backrest version add 55 mm Technical specifications 6 EXH S 20 and EXH S 25 datasheet 115 11538...

Page 126: ...Technical specifications 6 EXH S 20 and EXH S 25 datasheet 116 11538011751 EN 02 2021 03 ...

Page 127: ...n for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 Counter current braking 47 D Defining directions 44 Description of use 8 Destruction 109 Display operating unit 27 Display unit Adjustable spanner 39 Error code lights 39 Hour meter 39 Managing battery charging 38 Performance modes 38 Triangle 39 Disposing of components and batteries 9 Drive program Blue Q mode 49...

Page 128: ...e ground 62 Precautions to be taken during battery maintenance 98 Prohibition of use by unauthorised persons 19 R Recommended lubricants 92 Residual dangers residual risks 17 S Safety devices 90 Safety Inspection 20 Serial number 29 Service plan 1000 hours 94 10 000 hours 95 Servicing and maintenance measures 90 Setting a load down on the ground 63 Slinging the truck 83 Spare parts list 7 Speciali...

Page 129: ...or option 58 Using the truck on a ramp 49 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 11538011751 EN 02 2021 03 ...

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