Still EXV-CB 06 Original Instructions Manual Download Page 109 | Manualshive

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Load lift system
Mast: grease the support points
Mast: grease
Mast: check the mounting
Lifting chains: clean, adjust and grease
Check the condition and mounting of the guard grille
Check the condition and the length of the mast chain
Lift cylinders, chains, rollers and stroke-end stops: check the condition, mounting and operation
Fork carriage: check

5000-hour maintenance plan

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

dures should be carried out every 5000 and 10,000 hours

Information
Carry out all 1000-hour maintenance work
Hydraulics
Drain the hydraulic oil

10,000-hour service plan

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

dures should be carried out every 10,000 hours

Information
Carry out all 1000-hour maintenance work
Carry out all 5000-hour maintenance work
Motor
Drain the transmission gear oil

Maintenance

5

5000-hour maintenance plan

99

11718011551 EN - 02/2021 - 05

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Summary of Contents for EXV-CB 06

Page 1: ...Counterweight pallet stacker EXV CB 06 EXV CB 10 EXV CB 12 and EXV CB 16 Original instructions 2250 2251 2252 2253 11718011551 EN 02 2021 05 ...

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 11718011551 EN 02 2021 05 ...

Page 4: ......

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

Page 6: ... start up 34 Starting up 35 Checks and actions prior to commissioning 37 Checking the emergency shutdown 37 Checking the brake 37 Checking the anti crush safety device 38 Checking the horn 39 Truck operating instructions 40 Using the display operating unit 42 Selection buttons 42 Operation of the display unit 42 Driving safety guidelines 46 Driving 47 Defining directions 47 Driving 47 Steering 49 ...

Page 7: ... the truck 74 Handling the battery 75 Battery type 75 Order picking 75 Opening and closing the battery hood 76 Disconnecting connecting the battery connector 77 Charging the battery using an external charger 78 Vertical access battery 80 Replacing the side access battery 80 Handling the truck in an emergency 85 Emergency lowering of the mast 85 Truck towing procedure 86 Handling the truck in speci...

Page 8: ...ssion 104 Cleaning the traction motor cooling fins 104 Steering and wheels 105 Cleaning the pinion gear of the steering geared motor 105 Checking the condition of the wheels 106 Electrical equipment 107 Cleaning and blowing air through the electrical components 107 Checking the battery acid level and electrolyte density 108 Checking the condition of the cables terminals and battery connector 109 H...

Page 9: ...6 Datasheet Datasheet for EXV CB 06 EXV CB 10 EXV CB 12 EXV CB 16 118 Mast types 122 Table of contents VII 11718011551 EN 02 2021 05 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...w the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained Get to know the technology understand it and use it safely these operating instructions pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Ther...

Page 13: ... addi tion to the tow tractor can compromise safety thereby invalidating the EC declaration of con formity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third parties without the express written permission o...

Page 14: ...pliance declaration STILL S A S The manufacturer declares that the truck com plies with the requirements of the EC direc tives valid at the time of marketing This is confirmed by the EC declaration of conformity and by the EC labelling on the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declarat...

Page 15: ...lar area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Model Manufacturer Serial number Year of manufacture Unladen weight without battery in kg Maximum battery weight Minimum battery weight for a lithium ion battery the weight of the ballast con...

Page 16: ...et the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given i...

Page 17: ... or by scanning the QR code displayed to the side When the web page is open please type in the following password Spareparts24 On the next screen please enter your email address and truck serial number to receive the link by email Then download the spare parts list 2511 Introduction 1 Spare parts list 7 11718011551 EN 02 2021 05 ...

Page 18: ...le The capacity label specifies the maximum load that can be raised This limit must not be exceeded Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special meas ...

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

Page 20: ...Introduction 1 Disposing of components and batteries 10 11718011551 EN 02 2021 05 ...

Page 21: ...2 Safety ...

Page 22: ...allets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of material handling trucks When instr...

Page 23: ...Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined w...

Page 24: ...m plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the regulations Dispose of old hydraulic fluid according to reg ulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and consumption In case of injury seek medical advice immediately WARNING Battery ac...

Page 25: ...only be carried out in areas designated for this purpose Take care to minimise as far as pos sible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of battery acid must be neutral ised immediately Safety 2 Safety r...

Page 26: ...lues were determined 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 ...

Page 27: ...the load being unsta ble or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and ground conditions The stability of the truck has been tested to the latest standards These standards only take account of the static and dynamic tilting forces th...

Page 28: ...tion of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per sons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of behav iour The driver...

Page 29: ...is responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use Safety 2 Definition of responsible persons 19 11718011551 EN 02 2021 05 ...

Page 30: ...til at least a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring that any defects are remedied immediately Contact your servi...

Page 31: ...3 Overviews ...

Page 32: ...eral view of the truck Protective screen Compartment for the hydraulic block Tiller Display Drive wheel 1 2 3 4 5 Battery compartment Load wheels Forks Mast 6 7 8 9 Overviews 3 Overview 22 11718011551 EN 02 2021 05 ...

Page 33: ...al view of the technical compartment with the separate hydraulic block Controller Steering unit ES30 24 Horn 1 2 3 Traction motor Pump motor unit Tank 4 5 6 Overviews 3 Overview 23 11718011551 EN 02 2021 05 ...

Page 34: ... crush safety device Drive switch Horn Proportional lifting of forks 1 2 3 4 5 6 Proportional lowering of forks Diagnostic connector Mast tilt Ignition key or electronic key Emergency off switch 7 8 9 10 11 Overviews 3 Operating and display devices 24 11718011551 EN 02 2021 05 ...

Page 35: ...ngs indicator light Warning indicator light Drive programme indicator light 1 2 3 4 5 6 Activity indicator light Error Code menu Settings menu Truck status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 7 8 9 10 11 12 13 Overviews 3 Operating and display devices 25 11718011551 EN 02 2021 05 ...

Page 36: ...L ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0...

Page 37: ...wer switches off auto matically after 10 mi nutes 600 seconds by default if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 38: ...g label Consult the operating instruc tions Brand label Model label 1 2 3 4 5 6 Danger instructions label Consult the oper ating instructions Mast tilt label Cold store label Next inspection label Identification label Locking and unlocking the battery label 7 8 9 10 11 12 Overviews 3 Markings 28 11718011551 EN 02 2021 05 ...

Page 39: ...number for all technical en quiries The serial number contains the following infor mation 1 Production location 2 Type 3 Year of production 4 Count number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 29 11718011551 EN 02 2021 05 ...

Page 40: ...Overviews 3 Markings 30 11718011551 EN 02 2021 05 ...

Page 41: ...4 Use ...

Page 42: ...able on all models Steering The ES30 24 electric steering offers driving precision and easier manoeuvring The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled by a tiller Masts The mast is lifted using the proportional tiller control These masts are equipped with side lift cylin ders EXV CB trucks are equipped with T masts for heights ranging from 1515 mm t...

Page 43: ...are equipped with An emergency off switch A display A diagnostic connector Equipment available as standard or as additional options That can be added to the truck Load backrest Central refilling system Cold store 35 C Use 4 Technical description 33 11718011551 EN 02 2021 05 ...

Page 44: ...sion Ensure the visible area 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 guard grille must be intact and securely mounted The roller guide rails must be coated in a visible layer of grease T...

Page 45: ...y for operation The brake is automatically dis engaged Lower the tiller then reposition 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 into the drive area 2 NOTE In areas 1 and 3 the electromagnetic brake is applied and it is not possible to drive the truck Use 4 Starting up 36 11718011551 EN 02 2021 05 ...

Page 47: ... power Pull the emergency off switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This influences braking effectiveness Checking the 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 dr...

Page 48: ... 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 ...

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 39 11718011551 EN 02 2021 05 ...

Page 50: ...k could tip over when break ing or cornering The loads 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 operator s arms The truck...

Page 51: ...a safe braking distance from vehicles or people in front of him The driver must avoid stopping suddenly making U turns too quickly and overtaking in dangerous areas with poor visibility CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 41 11718011551 EN 02 2021 05 ...

Page 52: ...or can refer to the battery icon 1 or 2 The number of bars shown indicates the bat tery charge level From 0 to 20 1 bar From 21 to 40 2 bars From 41 to 60 3 bars From 61 to 80 4 bars From 81 to 100 5 bars The Battery indicator light 3 comes on in the event of a deep discharge of the battery or in the event of a fault Two distinct warnings may be displayed if the battery charge is insufficient 1 Le...

Page 53: ...ate the date of the next maintenance A warning is shown on the display The Warning light 3 comes on in the event of a fault in a truck component Drive program The Drive program light 1 is permanently il luminated when a travel mode is selected There are three different drive modes Tortoise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desire...

Page 54: ...ttings menu It is possible to access different settings through the Settings menu Select the Settings menu 1 This menu allows access to a drop down menu 2 consisting of Language Unit Date format Date Time Adjustment of the Load Management warn ing sounds Adjustment of the contrast Adjustment of the brightness Select the desired option Use 4 Using the display operating unit 44 11718011551 EN 02 202...

Page 55: ...ll through several successive dis plays The number of error messages is indicated at the bottom of the display 2 Start up screen In addition to the various menus and lights mentioned above additional data is available The Truck status menu 1 displays the truck menu The Hourglass icon 2 indicates the oper ating time of the truck The Clock icon 3 indicates the time and date Use 4 Using the display o...

Page 56: ...the dash board is prohibited The operator must be rest ing against the seat These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the dashboard to drive the truck The truck must not be used as a stepladder The truck is not designed to transport peo ple Operators must always stay within the truck clearance Stay in the safety area work...

Page 57: ...key Lower the tiller into zone 2 NOTE The truck is in the driving position in zone 2 In the lower zone 1 or the upper zone 3 the brake is applied and the traction motor is switched off DANGER Risk of obstructing the use of the tiller Do not adjust the A4 sized support to a height that is too low This could hinder the forklift operator when driving the truck Use 4 Driving 47 11718011551 EN 02 2021 ...

Page 58: ...th the movement of the drive switch When the drive switch is released the truck brakes electrically 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 direction of travel Push the drive switch in direction 1 or 2 Release the drive switch Operate it progressively in the o...

Page 59: ...cause the truck to overturn Turning direction in forward travel Turn the tiller to the left 2 the truck turns to the left 2 Turn the tiller to the right 1 the truck turns to the right 1 Release the tiller it should return to the neutral position and the truck should move in a straight line Steering angle 180 The turning radius Wa depends on the length of the fork See technical specifica tions Safe...

Page 60: ...g position 1 or 3 The drive switch is in the neutral position The power supply is cut off The forklift operator presses the emergency off switch Braking by reversing the drive direction Braking can be achieved by reversing the drive direction Move the drive switch 1 or 2 in the oppo site direction until the truck stops Braking by releasing the drive switch Braking can be achieved by releasing the ...

Page 61: ...1 tortoise icon on the tiller Hold the button down Gently move the drive switch forwards or backwards depending on the manoeuvre to be performed NOTE The traction speed can be set between 0 5 and 1 5 km h Contact the After Sales Service to change this The Creep Speed function cancels automati cally when the tiller is in the drive position CAUTION Danger of forklift operator being trapped by the tr...

Page 62: ...tor restarts the truck the last mode selected is automatically activated NOTE The drive program is instantly changed If the operator changes mode while driving the truck he must remain vigilant Hare mode When Hare mode is 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 spee...

Page 63: ...ance of the truck The travel speed of the truck is reduced to 6 km h The speed of lifting and lowering the forks is considerably reduced The different speeds can be adjusted Contact the After Sales Service Centre to change these Use 4 Driving 53 11718011551 EN 02 2021 05 ...

Page 64: ...ed with cau tion Never attempt a slope with a gradient that is greater than that specified in the truck s da tasheet Make sure that the ground is clean and has a non slip surface and that the route is clear Travelling up slopes Always travel up slopes in reverse The load faces uphill Without a load we recommend that you go up a slope forwards Use 4 Driving 54 11718011551 EN 02 2021 05 ...

Page 65: ...ck on a slope Never make a U turn or take a short cut on a slope On a slope the forklift operator must drive more slowly WARNING Risk of serious injury and or serious damage to equipment Driving on slopes steeper than 10 is prohibited due to braking capacity and stability The load being transported could tip over Starting on a ramp Proceed as follows Move the drive switch in the required direc tio...

Page 66: ...le with antenna The options available on the truck are Access control Access control and shock sensor Access control and GPRS module Access control shock sensor and GPRS module 1 GPRS General Packet Radio Service 2 GSM Global System for Mobile Communi cation Shock sensor This sensor allows you to record the shocks received by the truck If the truck receives a shock it is possible to configure a sp...

Page 67: ...nter key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or the RFID transponder 4 in front of the re...

Page 68: ...e enter the PIN code Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The operator has been granted ac cess authorisa tion But the peri od of validity has expired Use the interface to enter a new pe riod of validity The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously Green colour Memory is 80 full Clear t...

Page 69: ... 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 59 11718011551 EN 02 2021 05 ...

Page 70: ...n a safe place Press the button 3 to log off Keep the but ton pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to sw...

Page 71: ... 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 61 11718011551 EN 02 2021 05 ...

Page 72: ...s 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 73: ...me is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 63 11718011551 EN 02 2021 05 ...

Page 74: ... gravity from the back of the fork and the lift height determine the maximum load to be lifted Check that the pallet is in good condition Nominal capacity EXV CB 06 600 kg with 500 mm centre of gravity EXV CB 10 1000 kg with 500 mm centre of gravity EXV CB 12 1200 kg with 500 mm centre of gravity EXV CB 16 1600 kg with 500 mm centre of gravity Reading the capacity label Example with an EXV CB 16 f...

Page 75: ...n the apron Progressive stopping of the carriage in the lower position A detector 1 that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the low ering action This detector prevents a violent impact at the end of travel Push the fork lowering control until the car riage is fully lowered The progressive shutoff device for the carriage ...

Page 76: ...dhered to Do not touch or stand on moving parts e g lifting de vice pushing devices work installations load lifting devices WARNING Risk of injury Never put your hands near the load lift system DANGER Risk of accident The mast protective screen must always be in place correctly fixed and clean to provide good visibility for the operator For safety reasons the lift and traction func tions are inhib...

Page 77: ...f gravity This adaption facilitates the lifting and moving of heavy loads Mast tilt Proceed as follows Lower the tiller move it into the driving po sition Pull the tilt control button 4 towards the till er in the 5 direction The forks tilt upwards and the mast tilts to wards the chassis Release the tilt control button 4 when the required mast tilt is reached Returning the mast to the vertical posi...

Page 78: ...idth of the fork arms Check that the load is not damaged CAUTION Risk of injury Safety shoes must be worn Transporting people is strictly prohibited Do not use the forks to lift a person DANGER Risk of tipping It is essential to slow down when approaching a cor ner or on wet ground CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being ...

Page 79: ...hill Do not travel across the slope or make a U turn Reverse travel is used for setting down the load Adjust your speed Do not drive with an unstable load If visibility is poor let someone guide you Raise the forks slightly in order to pass ob stacles Be careful of low passageways low door ways scaffolding pipes etc Check that the width of the load is not greater than the width of the aisle Settin...

Page 80: ...al lift control to disengage the load from the stor age area Proceed as follows Drive the truck to the required location Raise the forks clearly above the level where the load is to be placed Drive the truck forward into the rack Lower the load until the forks are free Withdraw the truck in a straight line Lower the forks again until they are several centimetres from the ground DANGER Risk of fata...

Page 81: ...ear of the rack The forklift operator must re main vigilant and ensure that there are no obstacles preventing the lowering of the forks With the load on the forks lower the forks again until they reach the ground Lift the forks to move the truck Before leaving the machine NOTE Always stop the machine on level ground away from traffic routes Proceed as follows Lower the forks to the lowered positio...

Page 82: ...es between 30 C and 45 C Specific rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room temperature zone may result in the formation of condensation water This water can freeze when the truck goes b...

Page 83: ...d store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged Use 4 Cold store usage optional 73 11718011551 EN 02 2021 05 ...

Page 84: ...etely The forks must touch the ground Switch off the truck The automatic braking is activated Remove the switch key DANGER Danger of death It is prohibited to park the truck with a load in the raised position or the forks in the raised position Use 4 Before leaving the truck 74 11718011551 EN 02 2021 05 ...

Page 85: ... picking Maintenance personnel The battery must be replaced by specially trained personnel Personnel must follow the manufacturer s instructions for the battery the charger and the truck It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro ...

Page 86: ...r 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 t...

Page 87: ... Each connector has a polarising pin Ensure that the connectors are present and in good condition They prevent any risk of reverse polarity Disconnecting the battery connector Immobilise the machine and switch off the ignition The fixed socket 1 on the truck is located in the battery compartment Open the battery hood Pull the handle of the battery connector 2 to disconnect it from the fixed socket...

Page 88: ...ine Lower the forks Press the emergency off switch 1 Switch off the ignition 2 key or electronic key Open the battery hood Disconnect the battery connector from the fixed socket on the truck Connect the battery connector to the charg ing station Switch the charger on as directed in the specific instructions for the charger When charging is complete and the charger has stopped unplug the battery co...

Page 89: ...TE The connectors are fitted with a keying pin To avoid reversed connections regularly check its presence and condition WARNING A battery produces explosive gases during charging 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 79 11718011551 EN 02 2021 05 ...

Page 90: ...onto the upper bridge piece of the mast Replace the battery Position the new battery in the chassis Remove the sling hooks Reconnect the battery connector Close the battery hood Return the truck to service Replacing the side access battery DANGER Risk of trapping fingers It is advisable to wear gloves when changing the bat tery To remove the battery we recommend that you use a fixed roller frame o...

Page 91: ...frame 2 in the upright position near the battery compartment on level ground Disconnect the battery connector Place the connector on the battery cells Actuate and pull the locking handle 3 to release the battery It will jut out slightly from its compartment Use 4 Handling the battery 81 11718011551 EN 02 2021 05 ...

Page 92: ...e compart ment Leave part of the battery a few centi metres outside of the compartment Lower the locking lever to insert the battery completely into the compartment DANGER Risk of rapid lowering of the lever Do not push the battery down to the bottom of the battery compartment suddenly Position your hands flat on the side of the battery Use 4 Handling the battery 82 11718011551 EN 02 2021 05 ...

Page 93: ...h it down to the bottom of the compart ment while holding the lever Lower and lock the handle 3 of the locking bar 4 Reconnect the battery connector Close the battery hood Return the truck to service WARNING Risk of losing the battery Before restarting the truck ensure that the battery is correctly installed and that the battery hood is fully locked Use 4 Handling the battery 83 11718011551 EN 02 ...

Page 94: ...the hood NOTE Regularly check that the battery mounting as sembly 5 is always correctly positioned on the machine This operation should preferably be carried out by the After Sales Service Centre If the battery mounting assembly is incorrectly posi tioned on the chassis and the hood the lock ing system of the battery cannot function cor rectly Use 4 Handling the battery 84 11718011551 EN 02 2021 0...

Page 95: ...e the front hood of the technical compartment or tilt the hood of the compart ment for the hydraulic block Loosen the screw 1 using an 8 mm open ended spanner DANGER Danger of death Do not walk underneath raised loads Check that no one is in the danger area before man ually lowering the mast When the forks are fully lowered Tighten the screw 1 using an 8 mm open ended spanner Refit the front hood ...

Page 96: ... 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 then unlocked CAUTI...

Page 97: ... 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 87 11718011551 EN 02 2021 05 ...

Page 98: ...and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Hook the slings onto the points intended for this purpose and indicated by the label 2 NOTE Do not sling the truck by the tiller Do not sling the truck by the handles of the hydraulics compartment Carefully lift the truck DANGER Risk of falling Make sure no one is...

Page 99: ...Risk of the equipment becoming worn or damaged Do not place the jack or the wedges under the plat form of the truck 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 t...

Page 100: ... 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 immobilised and they must exit the lift first Driving on loading bridges Before crossing a loading bridge the operator mus...

Page 101: ...5 Maintenance ...

Page 102: ...f the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix diffe...

Page 103: ...low the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by perso...

Page 104: ... personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pr...

Page 105: ...1 1 l Traction motor 2 3 kW 1F1 fuse Power 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 2 2 kW EXV CB 06 3 2 kW EXV CB 10 12 16 Fuse 1F1 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 d...

Page 106: ...proved by the manufacturer Us ing oil mixtures or hydraulic fluids that are not recommended can cause damage that may be expensive to rectify Transmission gear oil Recommended oil CLP PG220 DIN 51 517 3 Aerosol can for chains Standard chain spray A167 Multi purpose grease Lithium soap grease extreme pressure with anti wear additive Standard DIN 51825 KPF 2K 30 KPF 2K 20 KPF 2N 30 ENVIRONMENT NOTE ...

Page 107: ...ows 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 Remove the front hood The technical compartment must be closed once 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 Ac...

Page 108: ...heck the stops tipping protection Brake Check the brakes for wear Check for any damage and for any brake leaks Wheels Check the condition and tightness of the wheels Check the stabilisers Grease the load wheel bearings Electrical equipment Check the battery status Check the battery cables and sockets Check the condition and the positioning of the cables and connector Clean the electrical component...

Page 109: ...e application environmental conditions and driving style the following proce dures should be carried out every 5000 and 10 000 hours Information Carry out all 1000 hour maintenance work Hydraulics Drain the hydraulic oil 10 000 hour service plan Depending on the application environmental conditions and driving style the following proce dures should be carried out every 10 000 hours Information Car...

Page 110: ...e sensitive to moisture par ticularly electric components must be protected when the truck is cleaned Observe the manufacturer s instructions when us ing the cleaning product Clean the truck with a non flammable clean ing product mixed with water a sponge and cloths Specifically clean the oil filling openings and surrounding areas as well as the lubricating nipples before lubrication NOTE A truck ...

Page 111: ...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 fitting...

Page 112: ...ible 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 re...

Page 113: ...hat the forks 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 103 11718011551 EN 02 2021 05 ...

Page 114: ... battery connector Remove the hood of the technical compart ment Blow the motor 1 with compressed air WARNING It is advisable to wear protection goggles and a mask Check that there are no signs of heat build up in the connections of the power cables Refit the technical compartment hood Reconnect the battery connector Return the truck to service Maintenance 5 Transmission 104 11718011551 EN 02 2021...

Page 115: ... 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 gear and sprocket 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 inju...

Page 116: ...move any objects that may prevent them from turning or may obstruct them CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the wheel bearings and tyres any wires or plastic strips must be removed They can wind around the wheel bear ings and hubs Maintenance 5 Steering and wheels 106 11718011551 EN 02 2021 05 ...

Page 117: ...ical 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 pin contacts of the harness connectors Maintenance 5 Electrical equipment 107 11718011551 EN 02 2021 05 ...

Page 118: ...an water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety information provided by the battery manufacturer Comply with the regulations in force Check the battery acid level and electrolyte density according to the battery manufactur er s recommendations The cell covers of the battery must be kept dry an...

Page 119: ...nd output terminals are not sulphated presence of white salt Check the condition of the battery connec tor contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious inci dents In the event of an incident contact our After Sales Service Centre as quickly as possible Maintenance 5 Electrical equipment 109 11718011551 EN 02 2021 05...

Page 120: ...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 forks Switch off the igni...

Page 121: ...ug 1 If necessary top up via the opening Refit the plug 1 afterwards CAUTION Risk of damage to hydraulic components Only use hydraulic oil that complies with the manu facturer s specifications see table of recommended lubricants Refit the hood of the technical compart ment Reconnect the battery connector Return the truck to service Maintenance 5 Hydraulic systems 111 11718011551 EN 02 2021 05 ...

Page 122: ... lubricant CAUTION Risk of the equipment becoming worn or damaged Chains are safety components Use of cold cleaning agents chemical products acid or chlorinated prod ucts could destroy the chains NOTE Use of high pressure liquid cleaning devices is not advisable DANGER Danger of death and or risk of serious damage to equipment On trucks fitted with macrolon mast protection clean the translucent sc...

Page 123: ... and to check that the mountings are tightened Check that the protective screen 1 is cor rectly attached and in good condition un damaged Replace the protective screen if it is dam aged Adhere to the number of fastenings as de fined by the manufacturer WARNING Risk of serious injury and or serious damage to equipment Never touch moving parts and assemblies without first having lowered the equipmen...

Page 124: ... must not touch the ground in order to prevent ir reversible deformation of the tyres Cover the truck with a cotton cover to pro tect it from dust CAUTION We recommend that you do not use a plastic sheet as this encourages condensation to form Consult the service department for further measures to take if the truck must be stored for a longer period of time Recommissioning after storage If the tru...

Page 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 S...

Page 126: ...Maintenance 5 Storage and decommissioning 116 11718011551 EN 02 2021 05 ...

Page 127: ...6 Datasheet ...

Page 128: ...Datasheet for EXV CB 06 EXV CB 10 EXV CB 12 EXV CB 16 Datasheet 6 Datasheet for EXV CB 06 EXV CB 10 EXV CB 12 EXV CB 16 118 11718011551 EN 02 2021 05 ...

Page 129: ...atic tyres solid tyres inflatable tyres polyurethane tyres Polyurethane for slippery floors 3 2 Dimensions of the front wheel or drive wheel mm Dia 230 x 100 3 3 Dimensions of the front rear wheel or load side mm 4 x Ø 85 x 105 3 4 Additional wheel dimen sions mm 3 5 Number of front rear wheels or drive side load side 1x 4 3 6 Front track width drive side 5 mm mm 3 7 Rear track width load side 5 m...

Page 130: ...earance mast m1 mm 30 4 32 Ground clearance centre of truck m2 mm 38 4 33 Aisle width with a 1000 x 1200 pallet cross wise Ast m m 3077 3427 3427 3789 4 34 Aisle width with an 800 x 1200 pallet lengthwise Ast m m 2969 3319 3319 3681 4 35 Turning radius Wa mm 1510 1860 1860 2222 PERFORMANCE DATA EXV CB 06 EXV CB 10 EXV CB 12 EXV CB 16 5 1 Travel speed with without load km h Forward travel 6 Reverse...

Page 131: ...acity 5h V Ah 24 375 6 5 Battery weight 5 kg See DIN Battery type Capacity 6 6 Energy consumption ac cording to standardised cy cle kW h 0 72 1 19 1 19 1 45 6 7 Turnover output according to VDI cycle T h 26 4 50 4 50 4 67 6 8 Energy consumption at turn over output kWh h 1 27 1 66 1 66 1 89 MISCELLANEOUS EXV CB 06 EXV CB 10 EXV CB 12 EXV CB 16 8 1 Speed control LAC 8 4 Noise level at operator s ear...

Page 132: ...924 D 3324 D 3516 T h3 Lift mm 1924 2424 2924 3324 3516 h3 h13 Lift fork height mm 1970 2470 2970 3370 3562 h1 Height HT Mast re tracted mm 1440 1690 1940 2140 1690 h4 Height HT Mast ex tended mm 2485 2985 3485 3885 4077 h2 Free lift mm 879 1129 1379 1579 1129 EXV CB 10 Standard 1924 S 2424 S 2924 S 3324 S 3824 S h3 Lift mm 1924 2424 2924 3324 3824 h3 h13 Lift fork height mm 1970 2470 2970 3370 38...

Page 133: ...870 3562 h1 Height HT Mast re tracted mm 1440 1690 1940 2140 2390 1690 h4 Height HT Mast ex tended mm 2485 2985 3485 3885 4385 4077 h2 Free lift mm 879 1129 1379 1579 1829 1129 EXV CB 12 Standard 1924 S 2424 S 2924 S 3324 S 3824 S 4224 S h3 Lift mm 1924 2424 2924 3324 3824 4224 h3 h13 Lift fork height mm 1970 2470 2970 3370 3870 4270 h1 Height HT Mast retrac ted mm 1515 1765 2015 2215 2465 2665 Da...

Page 134: ...m 1440 1690 1940 2140 2390 2590 h4 Height HT Mast ex tended mm 2485 2985 3485 3885 4385 4785 h2 Free lift mm 879 1129 1379 1579 1829 2019 EXV CB 12 Triplex 3516 T 4266 T h3 Lift mm 3516 4266 h3 h13 Lift fork height mm 3562 4312 h1 Height HT Mast retracted mm 1690 1940 h4 Height HT Mast extended mm 4077 4827 h2 Free lift mm 1129 1379 EXV CB 16 Standard 1844 S 2344 S 2844 S 3244 S 3744 S 4144 S h3 L...

Page 135: ...D 3744 D 4144 D h3 Lift mm 1844 2344 2844 3244 3744 4144 h3 h13 Lift fork height mm 1895 2395 2895 3295 3795 4195 h1 Height HT Mast re tracted mm 1440 1690 1940 2140 2390 2590 h4 Height HT Mast ex tended mm 2405 2905 3405 3805 4305 4705 h2 Free lift mm 579 1129 1379 1579 1829 2029 EXV CB 16 Triplex 3516 T 4266 T h3 Lift mm 3516 4266 h3 h13 Lift fork height mm 3567 4317 h1 Height HT Mast retracted ...

Page 136: ...h4 Height HT Mast extended mm 4077 4827 h2 Free lift mm 1129 1379 Datasheet 6 Mast types 126 11718011551 EN 02 2021 05 ...

Page 137: ... Choice of opening side for battery com partment 84 Cleaning and lubricating the chains 112 Cleaning the truck 100 Climatic conditions 8 cold store 72 Cold store usage 72 Connecting the battery connector 77 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 ...

Page 138: ...safety rules 62 M Maintenance plan 92 5000 hours 99 Managing battery charging 42 Masts 32 Mast types 122 Multi purpose grease 96 N Noise emission values 16 Nominal capacity 64 O Oils 13 Operating company 18 Operation of the mast tilt 67 Ordering spare parts and consumables 93 Order picking 75 P Permanent Putting Out of Commission 115 Picking up a load at a height 71 Picking up a load from the grou...

Page 139: ... cooling fins 104 Transporting a load 69 Transporting the truck 89 Transporting the truck in the lift 90 Travelling down slopes 55 Travelling up slopes 54 Truck operating instructions 40 Turning direction in forward travel 49 U Unauthorised use 9 Using the truck on a ramp 54 V Vertical access battery 80 Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Wheels Ch...

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