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Still EXH-SF 20, Original Instructions Manual

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Summary of Contents for EXH-SF 20

Page 1: ...Pallet truck EXH SF 20 EXH SF 25 Original instructions 0185 0186 2362 2363 11538011651 EN 02 2021 ...

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 11538011651 EN 02 2021 ...

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Page 5: ...nation 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 D...

Page 6: ... up 36 Starting up 37 Checks and actions prior to commissioning 39 Checking the emergency shutdown 39 Checking the brake 39 Checking the anti crush safety device 40 Checking the horn 41 Truck operating instructions 42 Using the display operating unit 44 Selection buttons 44 Operation of the display unit 44 Driving safety guidelines 49 Driving 50 Defining directions 50 Driving 50 Horn 51 Drive prog...

Page 7: ...Battery type 74 Order picking 74 Opening and closing the battery hood 75 Charging the battery using an external charger 76 On board charger 78 Using the on board charger 79 Adjusting the on board charger 81 Changing the vertical access battery 82 Changing the side access battery 82 Handling the truck in an emergency 88 Truck towing procedure 88 Handling the truck in specific situations 90 Slinging...

Page 8: ...ion of the load arms 107 Steering and wheels 108 Cleaning the pinion gear of the steering geared motor 108 Checking the condition of the wheels 109 Stabiliser maintenance 109 Electrical equipment 110 Cleaning and blowing air through the electrical components 110 Checking the battery acid level and electrolyte density 111 Checking the condition of the cables terminals and battery connector 112 Hydr...

Page 9: ...1 Introduction ...

Page 10: ...ow 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 The...

Page 11: ...n 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 ...

Page 12: ...ompliance 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 declar...

Page 13: ...ular 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 co...

Page 14: ...meet 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...

Page 15: ...r 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 11538011651 EN 02 2021 ...

Page 16: ...in 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...

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 batterie...

Page 18: ...Introduction 1 Disposing of components and batteries 10 11538011651 EN 02 2021 ...

Page 19: ...2 Safety ...

Page 20: ... pallets 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 ins...

Page 21: ...g 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...

Page 22: ...com 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 ...

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 ...

Page 24: ...ined 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: ... 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 dyna...

Page 26: ...dition 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 driv...

Page 27: ...r 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 11538011651 EN 02 2021 ...

Page 28: ...until 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 ser...

Page 29: ...3 Overviews ...

Page 30: ...ew of the truck Emergency off switch Key switch or electronic key Display Stabilisers Drive wheel 1 2 3 4 5 Platform Stabiliser wheel Load arms Load wheels or bogies 6 7 8 9 Overviews 3 Overview 22 11538011651 EN 02 2021 ...

Page 31: ...eneral view of the technical compartment Pump unit Traction motor Pump unit tank Servo stabilisers tank 1 2 3 4 Stabilisers Horn ES30 24 steering unit 5 6 7 Overviews 3 Overview 23 11538011651 EN 02 2021 ...

Page 32: ...rtment Handle Lowering the load arms Lifting the load arms Horn Drive switch 1 2 3 4 5 Anti crush safety device Display Emergency off switch Key switch or electronic key 6 7 8 9 Overviews 3 Operating and display devices 24 11538011651 EN 02 2021 ...

Page 33: ...ings 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 25 11538011651 EN 02 2021 ...

Page 34: ...1 100 10 bars 1 10 1 bar 0 1 flashing bar lift func tion not permitted NB To protect the battery 0 corresponds to max 80 discharge 2 Service alarm red 1 Flashing less than 50 hours truck operation until the next service 2 Constant Service date overdue 3 Red indicator light Switched on default or alarm Overviews 3 Operating and display devices 26 11538011651 EN 02 2021 ...

Page 35: ...er starts running when the machine is switch ed on and a control is used When counting the dot next to the tenths of an hour flashes The hour meter displays hours and tenths of an hour When the power supply is disconnected the hours are stored in the memory 8 STOP alarm red Miscellaneous problems Do not operate the truck 9 T alarm red Constant control module overheating Truck is stopped In general...

Page 36: ...LL 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 ...

Page 37: ...Power 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...

Page 38: ...tery lock Danger instructions label Consult the oper ating instructions 1 2 3 4 5 6 Label to indicate the pressure of the com pressor platform Label to indicate the recommended pressure of the compressor platform Next inspection label Cold store label Serial number in the battery compartment 7 8 9 10 11 Overviews 3 Markings 30 11538011651 EN 02 2021 ...

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 31 11538011651 EN 02 2021 ...

Page 40: ...Overviews 3 Markings 32 11538011651 EN 02 2021 ...

Page 41: ...4 Use ...

Page 42: ...access Side access These different battery types are not available on all models Steering The electric steering ES30 24 offers driving precision and easier manoeuvres 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 brake systems an electric counter current brake When releasing the drive switch By rever...

Page 43: ... Cold store 35 C Side protection guardrails Use 4 Technical description 35 11538011651 EN 02 2021 ...

Page 44: ...ea 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 rec...

Page 45: ...or operation The brake is automatically dis engaged Lower the tiller then reposition it in the rest position to unblock truck use 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...

Page 46: ... Tilt the tiller in the driving area 3 NOTE In areas 1 and 2 the electromagnetic brake is applied and it is not possible to drive the truck Use 4 Starting up 38 11538011651 EN 02 2021 ...

Page 47: ...r Pull the emergency off 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 2 In these two areas the machine is braked and the drive unit is no longer powered Releasing the tiller in...

Page 48: ...ad 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 Move the drive switc...

Page 49: ...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 41 11538011651 EN 02 2021 ...

Page 50: ...ds 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 incl...

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 43 11538011651 EN 02 2021 ...

Page 52: ...ator 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 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 Less than ...

Page 53: ...Temperature settings and warning lights The temperature light 1 comes on in the event of overheating of the traction motor or the controller A warning is shown on the display The settings light 2 comes on to indicate 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 Use 4 Using the display operating unit 45 ...

Page 54: ...The icon of the drive mode selected appears on the display Select the desired drive mode using the navigation keys Activity indicator The activity indicator light 1 flashes continu ously while the truck is in operation When the indicator is off the display unit is locked or frozen A warning is shown on the display Use 4 Using the display operating unit 46 11538011651 EN 02 2021 ...

Page 55: ...ntrast Adjustment of the brightness Select the desired option Error codes menu It is possible to access error messages that are disrupting the operation of the truck Select the Error messages menu 1 The operator can access the error codes If several codes are affecting the truck the oper ator can scroll through several successive dis plays The number of error messages is indicated at the bottom of...

Page 56: ...ntioned above additional data is available The truck status menu 1 displays the truck menu The hourglass icon 2 indicates the operat ing time of the truck The clock icon 3 indicates the time and date Use 4 Using the display operating unit 48 11538011651 EN 02 2021 ...

Page 57: ... 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 wor...

Page 58: ...ck is used in pedestrian mode Driving Turn the switch key Lower the tiller into zone 3 NOTE The truck is in the driving position in zone 3 In the lower zone 2 or the upper zone 1 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 driv...

Page 59: ...WARNING Restricted visibility During reverse travel visibility may be restricted Be very careful Make sure that the path behind is clear before travelling in reverse Reversing the drive direction 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 Horn The horn is positioned on the inner side of ...

Page 60: ...s 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 61: ...form Tilt the tiller in the driving area DANGER Risk of falling Only one operator can stand on the platform at once The truck is not designed to transport two people NOTE When the side protection guardrails are folded and the platform is in the lower position the speed of the truck is limited to 6 km h WARNING Driving safety guidelines The operator must not use the guardrails to push loads sideway...

Page 62: ... mode is possible when the platform is raised and the side protec tion guardrails are folded down The double throw safety switch is activated Maximum speed in pedestrian mode is re duced to 4 km h The maximum speed in pedestrian mode is reduced to 6 km h if the truck is fitted with a combi tiller Combi tiller A combi tiller is available as an option It in creases the safety distance between the tr...

Page 63: ...Unfolding the combi tiller Pull on the lock 1 to unlock the tiller Pull the handle of the tiller 2 towards you to unfold it Use 4 Driving 55 11538011651 EN 02 2021 ...

Page 64: ...he standard tiller controls Folding the combi tiller Push on the tiller handles 3 to fold it The forklift operator uses the truck in a more standard configuration Using the truck on a slope NOTE Incorrect use of the truck on a slope is not rec ommended It places particular stress on the traction motor brakes and battery Use 4 Driving 56 11538011651 EN 02 2021 ...

Page 65: ...l Without a load we recommend that you go up a slope forwards Travelling down slopes Always travel in reverse when going down a slope When the truck is used in pedestrian mode al ways travel forwards when going down a slope The load faces uphill Without a load we recommend that you go down a slope forwards In all cases you must travel at a very low speed and brake gradually DANGER Danger of death ...

Page 66: ...eeper 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 58 11538011651 EN 02 2021 ...

Page 67: ...ule 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 s...

Page 68: ...Enter 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 r...

Page 69: ...Re 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 ...

Page 70: ...s 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 62 11538011651 EN 02 2021 ...

Page 71: ...in 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 s...

Page 72: ...3 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 64 11538011651 EN 02 2021 ...

Page 73: ...platform reduces the vi brations felt within the truck while driving It can be adjusted in accordance with the weight of the forklift operator To increase the shock absorbency Press the button 1 located on the dash board To decrease the shock absorbency Press the button 2 located on the dash board Use 4 Using the on board compressor option 65 11538011651 EN 02 2021 ...

Page 74: ...ds 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...

Page 75: ...ime 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 67 11538011651 EN 02 2021 ...

Page 76: ...oad arms Press the control button 2 The load arms are lowered Load handling WARNING Risk of crushing feet Safety shoes must be worn WARNING Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads with a small space between them to prevent them hooking onto one another Use 4 Transporting loads 68 11538011651 EN 02 2021 ...

Page 77: ...oaching 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 that is shorter than the load arms position it so that the load overhangs the end of the load arms by a few centime tres This will prevent the load hooking onto the ...

Page 78: ... 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 you set down the load ensure that no one is around the truck or the load Before leaving the truck NOTE Always stop the truck on l...

Page 79: ...res 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 ...

Page 80: ...old 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 72 11538011651 EN 02 2021 ...

Page 81: ... 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 73 11538011651 EN 02 2021 ...

Page 82: ...er 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 pr...

Page 83: ...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 WARNING Risk of trapping fingers When closing the battery hood correctly position your fingers to avoid any risk of them being trapped Close the hood 1 Ensure that the battery hood is closed se curely CAUTION Risk of sparks Never drive with ...

Page 84: ...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 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 p...

Page 85: ... 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 77 11538011651 EN 02 2021 ...

Page 86: ... 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 tensi...

Page 87: ...matically 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 ambien...

Page 88: ...qualisation 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 89: ...ositions 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...

Page 90: ...eplace 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...

Page 91: ...d 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 groun...

Page 92: ... 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 84 11538011651 EN 02 2021 ...

Page 93: ...Position 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 85 11538011651 EN 02 2021 ...

Page 94: ...ut 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 H...

Page 95: ...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 Use 4 Handling the battery 87 11538011651 EN 02 2021 ...

Page 96: ...l 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 ...

Page 97: ...o 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 89 11538011651 EN 02 2021 ...

Page 98: ...he initial lift must be in the lowered position Raise the platform and lower the safety side protection 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 lif...

Page 99: ...ns 3 As a safety precaution always insert a wood en wedge 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 100: ...acity 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 immobil...

Page 101: ...5 Maintenance ...

Page 102: ...if 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 diff...

Page 103: ...llow 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 pers...

Page 104: ...by 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 ...

Page 105: ...25 1F1 fuse Power 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 1 2 kW for EXH SF 20 1 5 kW for EXH SF 25 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 ...

Page 106: ...pproved 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 107: ...ed in these operating instructions Only the oils listed above are approved by the manufacturer Us ing oil mixtures or hydraulic fluids that are not recommended can cause damage that may be expensive to rectify Transmission oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray Multi purpose grease Lithium soap grease extreme pressure with anti wear additive Standard DIN...

Page 108: ...e technical compartment it is necessary to lift the top hood 1 and remove the front hood 2 Proceed as follows Lower the platform and raise the side pro tections Unscrew the four screws 3 from the top hood 1 Lift the top hood slightly Remove the two screws 4 from the front hood 2 Maintenance 5 Accessing the technical compartment 100 11538011651 EN 02 2021 ...

Page 109: ... the operation is finished Reposition 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 Accessing the technical compartment 101 11538011651 EN 02 2021 ...

Page 110: ...ck 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 electrical components Check the electrical insulation between the chassis and the control unit components Check the fuses Check the batter...

Page 111: ...ental 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 10 000 hour service plan 103 11538011651 EN 02 2021 ...

Page 112: ... are 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 grease nipples before lubrication NOTE A truck th...

Page 113: ...se 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 fitt...

Page 114: ...atible 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 ...

Page 115: ... 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 107 11538011651 EN 02 2021 ...

Page 116: ...lean 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 117: ... 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 truck whe...

Page 118: ...an 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 110 11538011651 EN 02 2021 ...

Page 119: ...ean 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 a...

Page 120: ... and 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 112 11538011651 EN 02 2021 ...

Page 121: ...s 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 th...

Page 122: ...e 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 joi...

Page 123: ...evel 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 ...

Page 124: ...s 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 tr...

Page 125: ...nium 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...

Page 126: ...Maintenance 5 Storage and decommissioning 118 11538011651 EN 02 2021 ...

Page 127: ...6 Technical features ...

Page 128: ...EXH SF 20 and EXH SF 25 datasheet Technical features 6 EXH SF 20 and EXH SF 25 datasheet 120 11538011651 EN 02 2021 ...

Page 129: ...3 Load per unladen axle drive side load side 10 kg 682 168 1 773 187 1 WHEELS EXH SF 20 EXH SF 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 sid...

Page 130: ...EXH SF 25 5 1 Travel speed laden unladen 5 km h 6 6 12 10 5 2 Initial lifting speed when laden unla den 10 m s 0 050 0 0061 5 3 Initial lowering speed when laden unladen 10 m s 0 102 0 082 5 8 Maximum gradient laden unladen 20 15 12 5 9 Acceleration time 10 m s 7 6 6 7 5 9 4 7 5 10 Service brake electromagnetic DRIVE SYSTEM EXH SF 20 EXH SF 25 6 1 Traction motor S2 60 minutes kW 2 3 3 6 2 Lift mot...

Page 131: ...91 1 68 MISCELLANEOUS EXH SF 20 EXH SF 25 8 1 Speed monitor AC controller LAC 10 7 Noise level at forklift operator s ears 2 5 dB A 64 Vibrations transmitted to the operator EN 13059 m s 1 Weight according to line 2 1 2 With battery line 6 5 3 Ast Wa R a Safety distance a 200 mm Technical features 6 EXH SF 20 and EXH SF 25 datasheet 123 11538011651 EN 02 2021 ...

Page 132: ...Technical features 6 EXH SF 20 and EXH SF 25 datasheet 124 11538011651 EN 02 2021 ...

Page 133: ...g the oil level in the controlled sta biliser circuit 115 Checks prior to start up 36 Cleaning the truck 104 Climatic conditions 8 cold store 71 Cold store usage 71 Combi tiller 54 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 directions 50 Des...

Page 134: ...102 Managing battery charging 44 Multi purpose grease 98 99 N Noise emission values 16 O Oils 13 On board charger Adjusting the on board charger 81 Charging curve selector 81 Using the on board charger 79 Operating company 18 Ordering spare parts and consumables 95 Order picking 74 P Pedestrian driving 54 Permanent Putting Out of Commission 117 Permissible use 8 Picking up a load from the ground 6...

Page 135: ...ansporting the machine 92 Transporting the truck 91 Transporting the truck in the lift 92 Travelling down slopes 57 Travelling up slopes 57 Truck operating instructions 42 U Unauthorised use 9 Using the on board compressor option 65 Using the truck on a slope 56 V Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Wheels Checking the condition of the wheels 109 W...

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Page 138: ...STILL GmbH 11538011651 EN 02 2021 ...

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