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3000-hour maintenance plan

Additional maintenance operations every 3000 hours
Depending upon use, environmental conditions and driving style, the following procedures must

be performed every 3000, 6000 and 9000 hours

Information
Carry out all 1000-hour maintenance work
Transmission
Drain the transmission gear oil
Hydraulic system
Clean the return line filter for the circuit
Replace the breather filter for the circuit
Drain the hydraulic system

Maintenance

5

3000-hour maintenance plan

96

1152 801 15 17 EN - 02/2021 - 14

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Summary of Contents for EXU-H-18

Page 1: ...Electric pallet truck EXU H 18 EXU H 20 Original instructions 0161 0162 2354 2356 1152 801 15 17 EN 02 2021 14 ...

Page 2: ......

Page 3: ... 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 1152 801 15 17 EN 02 2021 14 ...

Page 4: ......

Page 5: ...ised use 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 values for upper limbs 16 Residual dangers residual risks 17 Stability 17 Definition of responsi...

Page 6: ...ecking the horn 36 Checking the anti crush safety device 37 Truck operating instructions 38 Driving 40 Driving safety guidelines 40 Defining directions 41 Start up 41 Driving 43 Driving on upward and downward slopes 44 OptiSpeed 44 Braking 45 Parking brake 45 Creep Speed function 46 Standby optional 46 Operating the FleetManager option 48 Description of the FleetManager option 48 Commissioning a t...

Page 7: ...or Lead batteries Adjusting the on board charger 73 Changing the battery 73 Gel and lead side access batteries changing the battery using a trolley 75 Side access battery changing the battery using a moveable support 77 Handling the truck in an emergency 79 Towing the truck 79 Handling the truck in specific situations 81 Slinging the truck 81 Lifting the truck 81 Transporting the truck 82 Transpor...

Page 8: ...nance 99 Folding platform maintenance 100 Steering and wheels 101 Servicing wheels and rollers 101 Adjusting the height of the stabilisers 101 Maintaining the reinforced stabilisers option 102 Regular maintenance of the transmission gear 103 Electrical equipment 104 Servicing the electrical system 104 Fuses 104 Battery maintenance 105 Checking the condition of cables terminals and battery connecto...

Page 9: ...6 Technical specifications EXU H datasheet 118 Technical datasheet EXU H 20S option 122 Table of contents VII 1152 801 15 17 EN 02 2021 14 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...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 Theref...

Page 13: ...ddi 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 of ...

Page 14: ...liance 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 declarati...

Page 15: ...r 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 conta...

Page 16: ...t 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 in...

Page 17: ...r 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 1152 801 15 17 EN 02 2021 14 ...

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 Us...

Page 19: ...ysical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Disposing of components and batteries The truck is made up of different materials If components or batteries m...

Page 20: ...Introduction 1 Disposing of components and batteries 10 1152 801 15 17 EN 02 2021 14 ...

Page 21: ...2 Safety ...

Page 22: ...llets 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 instru...

Page 23: ...eek 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 wi...

Page 24: ... 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 aci...

Page 25: ...ly 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 reg...

Page 26: ...ined following tests using trucks with standard equipment accord ing to the datasheet driving over test course with humps Specified characteristics for upper limb vi brations Vibration values 2 5 m s2 NOTE The vibration characteristics for bodily vibra tions cannot be used to determine the actual vibration load level during operation This de pends on the operating conditions state of ground mode o...

Page 27: ... 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 dynamic...

Page 28: ...ion 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: ...s 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 1152 801 15 17 EN 02 2021 14 ...

Page 30: ...il 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 servic...

Page 31: ...3 Overviews ...

Page 32: ...er Ignition key Traction controller Fork arms Load wheels Stabiliser wheels 1 2 3 4 5 6 7 8 9 Drive wheel Traction motor Pump unit Electromagnetic brake Horn Lift cylinder Digicode Load arms Platform 10 11 12 13 14 15 16 17 18 Option Overviews 3 Truck overview 22 1152 801 15 17 EN 02 2021 14 ...

Page 33: ...g Proportional lowering of fork arms Proportional lifting of fork arms Horn 1 2 3 4 5 Travel throttle valve Anti crush safety feature Travel throttle valve Lowering the load arms 6 7 8 9 Overviews 3 Control and display components 23 1152 801 15 17 EN 02 2021 14 ...

Page 34: ... 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 Control and display components 24 1152 801 15 17 EN 02 2021 14 ...

Page 35: ... number of op erating hours of the machine The meter runs from when the truck is switched on and a control is used When counting the dot next to the tenths of an hour flashes The hourmeter displays hours and tenths of an hour When the power supply is disconnected the hours are stored in the memory 8 STOP alarm red Misc problems Do not operate the truck 9 T alarm red Constant control module overhea...

Page 36: ...s red con tinuous green 3 Once the diodes 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 to 9 Deleting operator codes 2 red off green flash ing 2 dele...

Page 37: ...t if the truck is not being used 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 min 60s when not used Minimum setting 10 s maximum 3000 s Deactivating the automatic switch off 2 0 red off green flash ing 2 command ac cepted Overviews 3 Control and display components 27 1152 801 15 17 EN 02 2021 14 ...

Page 38: ...bel ELECTRICAL DANGER label DANGER INSTRUCTIONS label 1 2 3 4 5 6 7 Warranty label for Germany only on the in side of the tiller Cold store label Capacity label Automatic lifting and lowering label option PIEK label option on the outside of the tiller 8 9 10 11 12 Overviews 3 Markings 28 1152 801 15 17 EN 02 2021 14 ...

Page 39: ...mber 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 1152 801 15 17 EN 02 2021 14 ...

Page 40: ...Overviews 3 Markings 30 1152 801 15 17 EN 02 2021 14 ...

Page 41: ...4 Use ...

Page 42: ...upplied by a 24 volt lead acid bat tery Two types of battery removal are available Vertical removal 2Pzs BS on EXU H18 and 2Pzs DIN on EXU H20 Side removal 2Pzs DIN available as an option on EXU H20 and EXU H20S Steering A long robust ergonomic tiller allows the op erator to direct the drive steering wheel effort lessly For safety reasons a gas spring automatically returns the tiller to the upper ...

Page 43: ... together a battery disconnection handle emergency stop located in the driver s place an hour meter discharge indicator a 3 position ignition key stop tortoise hare a tiller with the following controls forward reverse travel accelerator lifting lowering of the fork arms proportional control lift ing lowering of the load arms horn and safety reverser OptiSpeed variable speed according to till er po...

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 rectly...

Page 45: ...the wall mounted charger Checking the brake NOTE Perform this check on a flat surface Drive the machine forward Tilt the tiller in areas 1 and 3 In these two areas the machine is braked and the drive unit is no longer powered Releasing the tiller in the drive area 2 sends the tiller into the area 3 and cuts traction Use 4 Checks and actions prior to commissioning 35 1152 801 15 17 EN 02 2021 14 ...

Page 46: ...ectrical controls and motors are disa bled The electromagnetic brake is applied Reconnect the emergency stop handle 4 to restore the circuits 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 36 1152 801 15 17 EN 02 2021 14 ...

Page 47: ...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 switch 1...

Page 48: ...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 incline...

Page 49: ...CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 39 1152 801 15 17 EN 02 2021 14 ...

Page 50: ... low visibility areas Driving the truck while sitting on top of it is prohibited These trucks are designed to be used as a pallet truck Therefore Never sit on the truck to drive it The truck must not be used as a stepladder This truck is not designed to transport peo ple The operator must always stay within the truck clearance Stay in the safety area working area de fined by the manufacturer Ensur...

Page 51: ...ug if necessary Keep the tiller in the vertical position Put the throttle in neutral centre position Insert the ignition key 1 and turn it to the desired position or enter the 5 figure code then validate using the key on the digi code keyboard default code 00000 NOTE With the digicode option when the key is turned to the 0 position the truck is in tortoise mode The truck will still function if the...

Page 52: ...ation max speed 4 km h Hare position 3 strong acceleration and deceleration max speed 6 km h Check the battery charge with the combined indicator 4 and change or charge the bat tery if necessary Turn the ignition key 1 to the hare posi tion 3 for normal driving mode NOTE Perform a visual check on the truck before starting Use 4 Driving 42 1152 801 15 17 EN 02 2021 14 ...

Page 53: ...vel Press with your thumb on the lower part of the throttle The speed increases with the movement of the throttle speed is limited to 4 or 6 km h depending on the position of the key When the control throttle is released the truck brakes electrically Reverse travel Press with your thumb on the upper part of the throttle The speed increases with the movement of the throttle speed is limited to 4 or...

Page 54: ...en going down slopes Please observe the maximum gradients de fined as suitable for laden and unladen trans port OptiSpeed Lower the tiller NOTE The truck is only in a driving position in areas 2 3 In the lower 4 or upper 1 zone the brake is applied and the traction motor is switched off In zone 3 the truck can be used at full speed The traction speed is proportional to the throt tle activation In ...

Page 55: ...ring operation release throttle 2 or 3 Moderate braking Switch throttle 2 or 3 in the opposite di rection of travel Parking brake Release the drive direction switch 2 or 3 The truck is braked with the electromagnetic brake when its speed approaches 0 km h or when the tiller returns to the vertical position Use 4 Driving 45 1152 801 15 17 EN 02 2021 14 ...

Page 56: ...r of forklift operator being trapped by the truck Gently move the drive switch to adjust the truck speed This prevents it moving too quickly towards the operator NOTE If the operator releases the Creep Speed but ton and or the drive switch the vertical posi tion of the tiller applies the emergency brake again Standby optional The truck can be put in energy saving mode to prolong the service life o...

Page 57: ...Timeout can be adjusted Please call the Af ter Sales Service Centre Use 4 Driving 47 1152 801 15 17 EN 02 2021 14 ...

Page 58: ... 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 spee...

Page 59: ...er 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 read...

Page 60: ...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 the...

Page 61: ...uickly 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 51 1152 801 15 17 EN 02 2021 14 ...

Page 62: ...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 swit...

Page 63: ...he 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 53 1152 801 15 17 EN 02 2021 14 ...

Page 64: ...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 lo...

Page 65: ... 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 55 1152 801 15 17 EN 02 2021 14 ...

Page 66: ... a maximum height of 800 mm WARNING The illustrations are only examples Only the values shown on your truck s capacity label should be taken into consideration 2 Base lift load arms Maximum load EXU H18 1800 kg at a dis tance of 600 mm from the centre of the load Maximum load EXU H20 2000 kg at a dis tance of 600 mm from the centre of the load CAUTION The total load main lift base lift must not ex...

Page 67: ...on and to identify it even if there is not much light The fork arms are lowered to the lowest posi tion It is always possible to stop the move ment of the forks by releasing the buttons Base lift Lifting the load arms Press button 4 Lowering the load arms Press button 5 Load handling CAUTION Risk of injury Safety shoes must be worn Transporting people is strictly prohibited Use 4 Transporting load...

Page 68: ... load Check that the width of the load is compati ble with the width of the load arms Picking up a load 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 If the load is shorter than the load arms po sition it so that the end of the load over hangs the end of the load arms by a few centimetres in order to avoid ho...

Page 69: ...the unloading area Lower the load until the load arms are free Withdraw the truck in a straight line Raise the load arms again several centime tres CAUTION Risk of falling Be careful to keep clear of other loads at the side of or behind the truck Before leaving the truck NOTE Always stop the truck on level ground away from traffic routes Ensure the load arms are in the lower posi tion Switch off t...

Page 70: ...he pallet The truck is equipped with sensors A that enable the load on the forks to be detected and the height to be adjusted NOTE SAFETY When loading from a pallet the au tomatic lowering function is fitted with a sensor that stops the fork arms at a sufficient height to avoid crushing the operator s feet In addi tion an audible alarm B sounds for each au tomatic lifting or lowering operation WAR...

Page 71: ...or automatic lowering po sition A beep will then sound before the truck starts NOTE The lifting lowering controls of the tiller are de activated if the drive direction selector is not in the neutral position Automatic lowering Select the automatic lowering function with the button 3 Press the activation button 2 The pallet lowers automatically as the packets are loaded on to the forks NOTE SAFETY ...

Page 72: ...tton 2 The pallet lifts automatically as the packets are unloaded The upper level of the load is aligned at 800 mm from the ground Two gauges are used for the levelling Use 4 Transporting loads 62 1152 801 15 17 EN 02 2021 14 ...

Page 73: ...rrow 3 Once the job is complete it is necessary to raise the platform Raise the platform 1 in the direction indi cated by the arrow 2 Driving in pedestrian mode The platform 1 is raised The operator walks alongside the truck DANGER Risk of injury Ensure that the platform is raised correctly before walking alongside the truck Ensure that the platform is correctly in the vertical position DANGER Ris...

Page 74: ...ing outside the cold store This use re quires hydraulic oil for cold stores as given on the list of maintenance characteristics Use General The change in temperature between the cold indoors and the heat outside causes conden sation This water can freeze when the truck goes back into the cold store and jam the moving parts of the truck This is why the length of time the truck remains in the differ...

Page 75: ... 40 C The truck must not leave the cold area for more than 10 minutes because this length of time is not long enough for the for mation of condensation If the truck stays out side for longer than 10 minutes it must remain outside for long enough to allow the conden sation to run away This generally takes at least 30 minutes DANGER If the condensation freezes in the cold store the moving parts that...

Page 76: ...n Stopping the truck Bring truck to a controlled stop Lower the forks Switch off the ignition then remove the key or press the button on the digicode for 2 seconds Pull the emergency stop handle Restarting work Put the key back in the ignition or enter the 5 digit code on the electronic key default code 12345 Press the emergency stop handle Use 4 Stopping the truck 66 1152 801 15 17 EN 02 2021 14 ...

Page 77: ...picking Maintenance personnel The battery must be replaced by specially trained personnel Personnel must follow the manufacturer s instructions for the battery the charger and the truck It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro d...

Page 78: ...nd connectors have been put back in the operating position Opening closing the battery cover Opening Park the truck Lower the load arms Turn the key switch off Lift the cover 1 Closing CAUTION Keep fingers away from moving parts to avoid any risk of them being trapped Close the cover 1 Use 4 Handling the battery 68 1152 801 15 17 EN 02 2021 14 ...

Page 79: ... battery connector from the bat tery charger when both the battery charger and truck are switched off NOTE Follow the instructions provided by the battery and battery charger manufacturers equalising charge WARNING Risk of damage short circuit or explosion Do not place metal objects or tools on the battery No smoking WARNING The electrolyte diluted sulphuric acid is toxic and very caustic Follow t...

Page 80: ...be sufficient air circulation to the outside Electrical characteristics of the charger Mains voltage 190 V U 260 V Network frequency 50 60 Hz 1 au tomatic adaptation No inrush current to the mains connection Maximum output power 1040 W 3 Maximum output cur rent 35 A 2 Nominal battery volt age 24V Tolerance on the volt age of bearing U 1 Battery characteristics Battery type Gel or open lead acid ba...

Page 81: ...e stored in the mem ory for 13 minutes As soon as the mains pow er returns charging resumes from the point I U at which it was cut off with the number of Ah already injected stored in the memory If the cut off period is longer than 13 minutes the truck could have been used a complete charging cycle is initialised Time protection If during phases I1 P U 16H the charger becomes faulty This can happe...

Page 82: ...bles reversed with the bat tery remain ing normally connected to the truck as sembly Continuously lit Continuously lit Phase Green LED Red LED Battery polari ty reversed Off Off Selector in neutral posi tion Flashing Flashing Avoid interrupting the charging procedure until it is complete to optimise battery serv ice life CAUTION It is strictly prohibited to use an on board charger other than the o...

Page 83: ...that no curve has been selected The four thick lines indicate the four charging curves open lead acid battery with a capacity be low 210 Ah open lead acid battery with a capacity greater than 210 Ah gel battery with a capacity below 210 Ah gel battery with a capacity greater than 210 Ah If the battery is changed during the service life of the truck it is essential to ensure that the charger settin...

Page 84: ... Attach the lifting device 1 correctly to the battery 2 see the lifting device user man ual then remove it from the truck The lifting device must exercise vertical traction in order to avoid the boot being damaged The hooks must be placed so that they cannot fall on the battery cells when the lifting device is slackened CAUTION Use small hooks for slinging the battery Use 4 Handling the battery 74...

Page 85: ...lls Push the lever towards the battery A then lift the notch B Lift the lever C to release the battery Raise the opposite stop of the lever Pull the discharged battery onto the trolley 2 Turn the lock on the trolley to the closed position to lock the battery on the trolley 2 Connect the charged battery 3 to the truck using an extension lead NOTE Use a fairly long extension lead to allow the truck ...

Page 86: ...r CAUTION Place the cables correctly above the battery to pre vent them from being damaged when a battery is re moved from or inserted into its compartment CAUTION During operations to fit the battery keep your fingers away from moving parts to avoid any risk of them be ing trapped We recommend the use of gloves CAUTION Before using this machine ensure that the battery is correctly installed and t...

Page 87: ... the cells Push the lever towards the battery A then lift the notch B Lift the lever C to release the battery Lift the stop Pull the discharged battery onto the movea ble support Lock the discharged battery on the movea ble support using the hook Release the moveable support by lifting up the 2 wheel locks with your foot and take the discharged battery to the charging sta tion INSTALL THE CHARGED ...

Page 88: ...CAUTION Before using the machine ensure that the battery is correctly installed and that its cover is correctly locked Use 4 Handling the battery 78 1152 801 15 17 EN 02 2021 14 ...

Page 89: ... is possible to unlock the brake manually CAUTION Risk of damaging the truck This procedure must be carried out by authorised personnel Remove the load if necessary Disconnect the battery connector Remove the hood of the technical compart ment Two M5 X 30 screws are required Screw the screws into the brake 2 in the holes 3 This will unlock the brake Close the hood of the technical compart ment CAU...

Page 90: ... Unscrew and remove the two screws to re establish brake operation Close the hood of the technical compart ment Use 4 Handling the truck in an emergency 80 1152 801 15 17 EN 02 2021 14 ...

Page 91: ...by the tiller or other points not designed for this Wedge battens between the chassis and slings to prevent damage DANGER Danger to life No one should be under a raised load Lifting the truck To lift the truck its sub assemblies or addition al equipment lifting devices must be hooked only to the appropriate lifting points When jacking take appropriate measures using chocks or wooden blocks to prev...

Page 92: ...k until the wheels are no lon ger in contact with the ground Raise the truck with chocks 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 an adequate lifting capacity Refer to the load...

Page 93: ...ty 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 immobilise...

Page 94: ...Use 4 Handling the truck in specific situations 84 1152 801 15 17 EN 02 2021 14 ...

Page 95: ...5 Maintenance ...

Page 96: ...sh conditions extreme heat or extreme 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 during maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix different qualities of...

Page 97: ...w 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 persons...

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

Page 99: ...l 0 9 litre maximum Traction and pump motor Fuses Power 125 A Quantity 1 Control cable harness Fuses Control 7 5 A Quantity 1 Traction motor Maintenance free 1 2 kW AC Pump motor Maintenance free EXU H18 EXU H20 EXU H20S 1 2 kW Battery Distilled water As required Joints Lithium grease As required Maintenance 5 Technical specifications for inspection and maintenance 89 1152 801 15 17 EN 02 2021 14 ...

Page 100: ...ing anything from the truck Turn the key switch off Pull the battery connector handle emergency stop handle Opening the lower cover Unscrew the 2 screws 1 that hold the cov er in place Unclip the cover at both ends Raise and pull back the lower cover Maintenance 5 Access to the technical compartment 90 1152 801 15 17 EN 02 2021 14 ...

Page 101: ... screws 2 that hold the cov er in place Accessing the pump unit After removing the front cover Remove the plastic cover by unscrewing the 2 screws 3 to provide easy access to the pump unit Maintenance 5 Access to the technical compartment 91 1152 801 15 17 EN 02 2021 14 ...

Page 102: ... Then remove the mounting bracket 4 Maintenance 5 Access to the technical compartment 92 1152 801 15 17 EN 02 2021 14 ...

Page 103: ...r and the brake Turn the tiller to the right or left hand stop Unscrew the 2 screws 3 Unscrew the 2 screws 2 located either side of the two 1 2 covers Remove the two 1 2 covers Maintenance 5 Accessing the reducer and the brake 93 1152 801 15 17 EN 02 2021 14 ...

Page 104: ...rake operation Checking the condition of the roller frame Wheels Checking the wheels for wear Electrical equipment Checking the condition of the cables connections and battery connectors Check the battery acid level and the electrolyte level Checking the fuses Transmission Regularly checking the transmission gear Lift mast Checking the load lift system Maintenance 5 Maintenance plan as required 94...

Page 105: ...yre tread of the wheels Check the brake air gap Check the tightness of the nuts Electrical equipment Clean and blow out the electrical plate Check the mounting of the electrical connections Check the condition of the on board charger Check that the cables and fuses are secure Check and adjust the battery electrolyte level Check the lift height switch Clean the sensors for the automatic lifting fun...

Page 106: ...edures must be performed every 3000 6000 and 9000 hours Information Carry out all 1000 hour maintenance work Transmission Drain the transmission gear oil Hydraulic system Clean the return line filter for the circuit Replace the breather filter for the circuit Drain the hydraulic system Maintenance 5 3000 hour maintenance plan 96 1152 801 15 17 EN 02 2021 14 ...

Page 107: ...ic compo nents Observe the manufacturer s instructions for handling the cleaners Clean the truck exterior with water and cleaning agents soluble in water sponge rags Clean especially the oil filler openings and the surrounding area Grease the required assemblies mast con trols and joints Cleaning the electrical system WARNING Do not aim the steam cleaning device directly on electric motors and oth...

Page 108: ...ve gloves and industrial gog gles Follow the safety regulations described in previ ous chapters ENVIRONMENT NOTE Do not pour acid bearing wash water down the drain For more information see the bat tery instructions Gel battery Check for traces of sulphate in the compart ment and frame If there is only minimal sulphate build up just wipe the top of the cells with a damp cloth If sulphate build up i...

Page 109: ... battery The battery cover must remain open during charging See the chapter entitled Battery charging using an external charger Battery type Lead or gel batteries are used It is advisable to choose a compatible 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 comp...

Page 110: ...the truck Folding platform maintenance The folding platform must be checked regular ly The following operations must be carried out at least every three months or every 500 hours Check that the folding platform operates correctly Clean and lubricate the articulated parts of the platform Maintenance 5 Chassis bodywork and fittings 100 1152 801 15 17 EN 02 2021 14 ...

Page 111: ...gly adjusted stabilising wheel can lead to sta bility problems This adjustment must be carried out by our service department Adjusting the height of the stabilis ers NOTE Adjusting the clevis 1 with new drive wheel and stabiliser wheels R 22 mm PLEASE NOTE Lower the stabilisers to stabilise the truck Lift the stabilisers if the truck often encoun ters obstacles and if grip must be improved Follow ...

Page 112: ... is necessary to check the condi tion of the stabilisers No significant damage to the superstructure 2 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 3 The wheels must rotate freely No locking at the level of the upper bearing 4 Ensure that the wheel nuts are correctly tigh...

Page 113: ...fe of the transmission gear 2 grease nipples 1 have been added to its turntable It is therefore possible to regularly lubricate the transmission gear NOTE Use the lubricants recommended by the man ufacturer Maintenance 5 Steering and wheels 103 1152 801 15 17 EN 02 2021 14 ...

Page 114: ...s Fuses CAUTION Electricity danger Before carrying out any work on the electric installa tion turn the power supply off Disconnect the bat tery connector for this purpose Remove the front cover to gain access to the fuses Check that the following two fuses are cor rectly secured The 125A fuse 1 protects the traction and lift ing power circuit The 7 5 A fuse 2 protects the control circuits This ope...

Page 115: ...aked flames away from a battery which is being charged or has recently been charg ed To prevent the accumulation of hydrogen keep the battery cover open during charging Charge the battery in a well ventilated room Do not place metal objects on the battery there is a risk of creating a short circuit CAUTION Before commencing work unplug the battery con nector by pulling the emergency stop handle El...

Page 116: ... 80 discharged bat tery 1 14 High density battery 100 charged 1 29 to 1 32 depending on make We recommend a reading every 1 or 2 weeks Note down the values read in your battery monitoring logbook Lift the cover over each cell plug as descri bed above Carefully record the specific gravity of each cell with the hydrometer Close the various stoppers after measure ment NOTE If the density in the cells...

Page 117: ...The points mentioned above can cause serious inci dents In the event of a fault please contact the Af ter Sales Service Servicing the pump motor Checking the electrical connections Check the mounting condition and insula tion of the pump motor cables 1 Eliminate any traces of oxidation Replace faulty cables NOTE Oxidised connections and faulty cables will re sult in a drop in voltage leading to ma...

Page 118: ... connected to the 220 V supply Disconnect the mains cord NOTE In the event of a fault do not work on the charger Contact the After Sales Service Cen tre Cleaning the sensors for the Autolift option To ensure the correct operation of the Autolift option the sensors must be cleaned regularly Clean the sensors A thoroughly using a soft cloth Maintenance 5 Electrical equipment 108 1152 801 15 17 EN 02...

Page 119: ...ption in Access to the technical compartment The oil level must be in the centre between the minimum and maximum marks on the tank for correct use of the truck functions Top up if necessary Replace and tighten the plug afterwards CAUTION Only use hydraulic oil that complies with the specifi cations see lubrication table Maintenance 5 Hydraulic systems 109 1152 801 15 17 EN 02 2021 14 ...

Page 120: ...raulic unit Remove the unit s upper support and the filler tube breather Unscrew the tank s mounting clip Remove the tank Drain the oil Filling up Fit new seals on the tank and couplings Refit the unit in the technical compartment with its tube and upper support Connect the pipes and the power supply Unscrew the filler plug Fill up the tank through the filler hole Tighten the plug Operate the lift...

Page 121: ...retched by 3 or more Check the mounting flange of the cylinder on the mast Check the mechanical mast stops Check the mountings of the chain s two re turn pulleys Check the condition and mounting of the mast end of travel sensors Adjust the length of the mast chain NOTE Depending on the use of the truck the chains are liable to stretch and as a result they have to be adjusted regularly Lower the ma...

Page 122: ...g a paraffin based product pe troleum gas oil etc Observe the manufac turer s safety instructions If you use a steam jet do not use any addi tives Dry the chain 7 and its joints immediately with compressed air Move the chain fre quently during this operation Lubricate the chain 7 immediately using a special aerosol chain lubricant CAUTION Deterioration or destruction of the equipment The chain is ...

Page 123: ...l Check the condition of the mast protec tor mountings It is important to check the condition of the mast guard plate 3 and the tightness of its mountings 1 and 2 WARNING Risk of serious injury and or serious damage to equipment Keep hands away from moving parts and assemblies without first lowering the equipment to the ground and disconnecting the battery Maintenance 5 Lift mast 113 1152 801 15 1...

Page 124: ...ust 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 truck...

Page 125: ...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 C...

Page 126: ...Maintenance 5 Commissioning and storage 116 1152 801 15 17 EN 02 2021 14 ...

Page 127: ...6 Technical specifications ...

Page 128: ...EXU H datasheet Technical specifications 6 EXU H datasheet 118 1152 801 15 17 EN 02 2021 14 ...

Page 129: ...e load side 10 kg BS 856 1539 2 Pzs 937 1664 2 3 Load per unladen axle drive side load side 10 kg BS 411 145 2 Pzs 458 145 WHEELS EXU H 18 EXU H 20 3 1 Tyres polyurethane rubber C P P 3 2 Drive wheel dimensions width at the ground Øxl mm 230 x 75 POLYURETHANE 3 3 Wheel sizes load side Øxl mm Ø85 x 90 bogies 85 x 65 3 4 Additional wheels dimen sions Øxl mm Stabilisers 125 x 40 3 5 Number of wheels ...

Page 130: ...ttery EXU H 18 EXU H 20 BS 2045 2 Pzs 2120 4 34 Aisle width with an 800 x 1200 pallet lengthwise Ast m m BS 2095 2 Pzs 2170 4 35 Turning radius mini lowered raised forks Wa mm BS 1645 1585 2 Pzs 1720 1660 PERFORMANCE DATA EXU H 18 EXU H 20 5 1 Transfer speed when laden unla den 5 km h 6 6 5 2 Base lift lifting speed laden unla den 10 m s 0 035 0 041 0 035 0 041 Main lift lifting speed laden unlade...

Page 131: ... 160 2 Pzs 24 190 Li ion 82 Ah 24 82 Li ion 164 Ah 23 164 Li ion 205 Ah 23 205 Li ion 410 Ah 23 410 6 5 Battery weight 10 kg BS 144 2 Pzs 191 Li ion 82 Ah 150 Li ion 164 Ah 170 Li ion 205 Ah 110 Li ion 410 Ah 151 6 6 Energy consumption according to standardised VDI cycle kWh h 0 38 OTHER EXU H 18 EXU H 20 8 1 Speed control AC controller LAC 8 4 Noise level at operator s ears 5 dB A dB A 59 Technic...

Page 132: ...Technical datasheet EXU H 20S option Technical specifications 6 Technical datasheet EXU H 20S option 122 1152 801 15 17 EN 02 2021 14 ...

Page 133: ...EXU H 20S 3 1 Tyres polyurethane rubber C P P 3 2 Drive wheel dimensions width at the ground Øxl mm 230 x 75 POLYUR ETHANE 3 3 Wheel sizes load side Øxl mm Ø85 x 90 bogies 85 x 65 3 4 Additional wheels dimen sions Øxl mm Stabilisers 125 x 40 3 5 Number of wheels at drive side load side x drive wheel 1x 2 2 4 in bogies 3 6 Drive side track width 5 mm mm 482 3 7 Load side track width 5 mm mm Mobile ...

Page 134: ...s 20 mm Wa mm Pedestrian lowered forks raised forks 1760 1700 Ride on lowered forks raised forks 2132 2072 PERFORMANCE DATA EXU H 20S 5 1 Transfer speed when laden unladen 5 km h 6 00 6 00 5 2 Base lift lifting speed laden unladen 10 m s 0 035 0 041 Main lift lifting speed laden unladen 10 m s 0 115 0 184 5 3 Base lift lowering speed laden unladen 10 m s 0 062 0 031 Main lift lowering speed laden ...

Page 135: ...5 h V Ah 2 Pzs 24 190 6 5 Battery weight 10 kg 2 Pzs 191 6 6 Energy consumption according to standar dised VDI cycle kWh h 0 38 OTHER EXU H 20S 8 1 Speed control AC controller LAC 8 4 Noise level at operator s ears 5 dB A dB A 59 Technical specifications 6 Technical datasheet EXU H 20S option 125 1152 801 15 17 EN 02 2021 14 ...

Page 136: ...Technical specifications 6 Technical datasheet EXU H 20S option 126 1152 801 15 17 EN 02 2021 14 ...

Page 137: ...ning the electrical system 97 Cleaning the sensors for the Autolift op tion 108 Clean the truck 97 Climatic conditions 8 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 Definition of responsible persons 18 Description of the Autolift option 60 Description...

Page 138: ...th of the mast chain 111 Check the condition of the mast and the chain mountings 111 Check the condition of the mast protec tor mountings 113 Clean and lubricate the chain 112 Lubricate the mast 113 N Noise emission values 16 O Oil level check 109 Oils 13 Opening closing the battery cover 68 Operating company 18 Operating devices 23 Operator s seat 33 OptiSpeed 44 Ordering spare parts and consumab...

Page 139: ...option 122 Technical specifications for inspection and maintenance 89 Towing the truck 79 Transporting the machine 83 Transporting the truck 82 Transporting the truck in the lift 83 Truck operating instructions 38 U Unauthorised use 9 V Vibrations Vibration values for upper limbs 16 W Washing instructions 97 Washing the exterior of the truck 97 Working on the electrical equipment 88 Index 129 1152...

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Page 142: ...STILL GmbH 1152 801 15 17 EN 02 2021 14 ...

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