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Still FXH 20, Original Instructions Manual

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5

Maintenance

Safety guidelines for maintenance

Safety guidelines for maintenance

Servicing and maintenance measures

To avoid accidents during servicing and

maintenance operations, take all necessary

safety measures. For example:

– Ensure that there is no risk of the truck

moving or starting up unexpectedly. For

this reason, remove the battery connector.

Working on the electrical equipment

Operations on the truck's electrical system

must only be carried out when there is no

voltage supply.
Operating checks, testing and adjustment

work on parts supplied with voltage must only

be carried out by personnel:
• who have received detailed instructions
• who have been authorised to perform this

work

• who have taken the necessary precaution-

ary measures.

Rings, metal bracelets etc., must be removed

before carrying out any operations on electric

components.
Remove the electric equipment (which com-

prises electric components such as the trac-

tion controller) before carrying out any welding

operations. This precaution prevents this

electric equipment from being damaged.
Operations on the electric system require the

consent of the manufacturer.

Safety devices

After any repair or maintenance work, it is

necessary:
• to refit all safety devices
• to check these for correct operation.

104

11548011751 EN - 10/2018

Summary of Contents for FXH 20

Page 1: ...Original instructions Electric pallet truck FXH 20 FXH 25 11548011751 EN 10 2018 ...

Page 2: ......

Page 3: ...g Address 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 11548011751 EN 10 2018 I ...

Page 4: ......

Page 5: ...isposing 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 Definition of responsible per...

Page 6: ...g the brakes 34 Checking the horn 37 Truck operating instructions 38 Stepping on off the truck 39 Driver s compartment settings 40 Adjusting the seat 40 Adjusting the floor 41 Seat heater option 41 Using the display operating unit 42 Selection buttons 42 Display of the drive wheel position 42 Operation of the display unit 43 Driving safety guidelines 49 Driving 50 Defining directions 50 Operation of...

Page 7: ...ck equipped with the FleetManager option 75 FleetManager option Colour code for the LEDs 76 Disconnecting a truck equipped with the FleetManager option 78 Transporting loads 80 Load handling safety rules 80 Grabbing a loading unit 80 Transporting pallets or other containers 81 Lift control elements 82 Handling a single load 83 Using the cold store 85 Cold store usage optional 85 Handling the batte...

Page 8: ... 5000 hour maintenance plan 109 10 000 hour service plan 109 Chassis bodywork and fittings 110 Cleaning the truck 110 General information on battery maintenance 111 Checking the condition of the load arms 112 Steering and wheels 113 Checking the condition of the wheels 113 Electrical equipment 114 Cleaning and blowing out the electrical components 114 Checking the battery acid level and electrolyte...

Page 9: ...1 Introduction ...

Page 10: ...these operating instructions will allow 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 provide the necessary information and help to avoid accidents and to keep the truck ready for opera...

Page 11: ... nameplate An independent structural change or an addition to the tow tractor can compromise safety thereby invalidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the responsible authorities Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third pa...

Page 12: ...ed to compile the technical documents See EC compliance declaration STILL S A S The manufacturer declares that the truck complies with the requirements of the EC directives 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 invalidating the ...

Page 13: ...uiries Rules for the operating company of industrial trucks In addition to these operating instructions a code of practice containing additional information for the operating companies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for th...

Page 14: ...he operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https m still de vdma in a web browser or by scanning the QR code 6 11548011751 EN 10 2018 ...

Page 15: ...Introduction 1 Rules for the operating company of industrial trucks 11548011751 EN 10 2018 7 ...

Page 16: ...obtaining these permissions in advance is to limit danger as far as possible Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special mea sures for trucks equippe...

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

Page 18: ...1 Introduction Disposing of components and batteries 10 11548011751 EN 10 2018 ...

Page 19: ...2 Safety ...

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

Page 21: ...n eye specialist If swallowed do not induce vomiting 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...

Page 22: ...draulic fluid is a water polluting substance Always store hydraulic fluid in containers complying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of according to the regulations Dispose of old hydraulic fluid according to regulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact a...

Page 23: ...in accordance with regulations Observe the national regulations for your country Work may only be carried out in areas designated for this purpose Take care to minimise as far as possible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be immediately soaked up with an oil binding agent The regulations for disposal of used oil are appl...

Page 24: ... exposed The values 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 vibrations 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 t...

Page 25: ...es 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 that can arise during operation that complies with the specifications and operating rules Risks caused by misuse or in...

Page 26: ...en specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of be haviour The driver must be duly informed of his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety helmet industrial gog gles and protective gloves that is appropriate for the conditions the...

Page 27: ...ents As part of this inspection A full check of the technical condition of the truck in terms of accident safety must be performed The truck must be thoroughly checked to detect any damage that may have been caused by improper use A test log must be created The results of the inspection must be retained until at least a further two inspections have been carried out The inspection date is indicated...

Page 28: ...2 Safety Safety tests 20 11548011751 EN 10 2018 ...

Page 29: ...3 Overviews ...

Page 30: ...trol unit 2 Seat 3 Steering wheel 4 Adjustable floor 5 Platform 6 Drive wheel 7 Operator presence button or pedal 8 Stabiliser wheels 9 Brake pedal 10 Battery compartment 11 Load wheels or bogies 12 Load arms 13 Emergency off switch 22 11548011751 EN 10 2018 ...

Page 31: ...Overviews 3 Truck overview General view of the technical compartment 1 Pump motor unit 2 Fuses 3 Tank 4 ES30 24 steering unit 5 Traction motor 11548011751 EN 10 2018 23 ...

Page 32: ...l and display components Control and display components Driver s compartment 1 Handle 2 Display 3 Switch key or electronic key 4 Emergency off switch 5 Joystick 6 Parking brake 7 Steering wheel 24 11548011751 EN 10 2018 ...

Page 33: ... OFF only 2 ADMINISTRA TOR CODE ESSENTIAL FOR ALL ELEC TRONIC KEY SETTINGS 0 0 0 0 0 0 0 0 by default continuous red continuous 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 flashing 2 code accepted Example of new operator code 45678 Allocating operator codes 2 5 4 3 2 1 red off green flashing 2 code accepte...

Page 34: ...green flashing 5 5 seconds before switch off Power switches off automatically after 10 minutes 600 seconds by default if the truck is not in use Setting the time delay of the automatic switch off 3 6 0 red off green flashing 2 value accepted Example automatically switches off after 1 minute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off...

Page 35: ...Warning indicator light 6 Drive programme indicator light 7 Activity indicator light 8 Error Code menu 9 Settings menu 10 Drive wheel position menu 11 Truck status menu 12 Display of the operating time of the truck 13 Display of the battery charge 14 Display of the date and time For more information refer to Chapter 4 Using the display operating unit 11548011751 EN 10 2018 27 ...

Page 36: ...els 1 Identification label 2 Brand label 3 Danger instructions label Consult operating instructions 4 Next inspection label 5 Slinging label Consult the operating instruc tions 6 Model label 7 Cold store label 28 11548011751 EN 10 2018 ...

Page 37: ...xxxx x xxxxx 1 2 3 4 Serial number NOTE Indicate the serial number for all technical enquiries The serial number contains the following information 1 Production location 2 Type 3 Year of production 4 Count number 11548011751 EN 10 2018 29 ...

Page 38: ...3 Overviews Markings 30 11548011751 EN 10 2018 ...

Page 39: ...4 Use ...

Page 40: ...and easier manoeuvring The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled with a steering wheel and a control module The drive unit is mounted on a turntable Steering is provided by an electric geared motor that positions the turntable The steering motor is controlled by a variable speed transmission It receives information from the steering wheel and the...

Page 41: ...ed in compliance with the marking position 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 correctly Check that there are no foreign objects that could hinder the operation of the wheels and rollers The warning devices horn etc must work The battery hood must be closed Check that the hoods are correct...

Page 42: ...top Braking by releasing the joystick Push the joystick to move the truck for wards Release the joystick The truck brakes progressively until the truck comes to a complete stop Braking by reversing the drive direction Push the joystick to move the truck for wards Push the joystick in the opposite direction The truck brakes progressively and then moves off in the opposite direction until the desire...

Page 43: ...edal 2 to move the truck forwards Release the accelerator pedal The truck brakes progressively until the truck comes to a complete stop Braking by reversing the drive direction Toggle the drive switch located on the joystick to set the direction of travel Press the accelerator pedal 2 to move the truck forwards Move the drive switch in the opposite direction Keep the accelerator pedal depressed Th...

Page 44: ...lerator pedal 2 or 3 to move the truck forwards Release the accelerator pedal The truck brakes progressively until the truck comes to a complete stop Braking by reversing the drive direction Press the accelerator pedal 2 or 3 to move the truck forwards Press the other accelerator pedal Keep the pedal depressed The truck brakes progressively and then moves off in the opposite direction until the de...

Page 45: ... to commissioning Checking the horn The horn is located on the rear side of the control module To check the operation of the horn proceed as follows Press the button 1 on the control module The horn sounds 11548011751 EN 10 2018 37 ...

Page 46: ...istent with a maximum 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 operator s arms The trucks can drive across ramps and shallow inclines With an initi...

Page 47: ...table floor 4 paying close attention to your step Be careful not to press the pedals Sit on the seat CAUTION Risk of injury or impact from the edges of the truck Be careful not to hit yourself on the edge of the floor when stepping onto the truck CAUTION Risk of damaging the equipment Never pull on the steering wheel when stepping onto the truck Excessive force on the steering wheel can damage it an...

Page 48: ... follows Sit on the seat Adjusting the backrest Pull the adjustment lever 1 to tilt the backrest Adjusting the depth Pull the adjustment lever 2 to move the seat forwards or backwards Weight setting The seat is equipped with an operator pres ence detector The operator must adjust his weight by increments of 10 kg to trigger this detection Turn the adjustment wheel 3 until the desired weight is rea...

Page 49: ...es not work at low temperatures Seat heater option The driver s seat may be equipped with the seat heater option The heater turns on when the operator s presence on the seat is detected To activate the heater proceed as follows Sit on the seat Adjust the weight of the operator Put the truck into service Press the LED button 1 to activate the heating The LED button 1 illuminates to indicate that th...

Page 50: ...he right arrow button 3 to scroll right through the drop down menu The confirm button 4 to confirm the highlighted choice on the screen Display of the drive wheel position The forklift operator can find out the position of the drive wheel by referring to the display Proceed as follows Press the left arrow or right arrow button to scroll through the menu Select the Wheel menu 2 Press the confirm button...

Page 51: ...is disengaged the truck is moving Drive direction indicator NOTE This feature is only present on the truck version with the single pedal option An indicator light indicates the direction of travel Forward travel 1 Reverse travel 2 When the operator selects a direction of travel the indicator for the chosen direction lights up Operator presence For the truck to operate the operator must be detected...

Page 52: ...the seat 1 is replaced by the light indicating the operator s presence on the pedal 2 which flashes Press the operator presence pedal with your left foot The light indicating the operator s presence on the pedal 2 remains continuously illuminated for two seconds and then goes out 44 11548011751 EN 10 2018 ...

Page 53: ...insufficient 1 Less than 25 of charge remaining the 3 and 4 icons flash and an audible beep sounds A warning message appears at the icon 4 and remains on until the battery is recharged 2 Less than 20 of charge remaining three regular beeps sound the icon 3 flashes and the icon 4 remains on with a new warning message Temperature settings and warning lights The temperature light 1 comes on in the event...

Page 54: ...toise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desired drive mode using the navigation keys Activity indicator The activity indicator light 1 flashes continu ously while the truck is in operation When the indicator is off the display unit is locked or frozen A warning is shown on the display 46 11548011751 EN 10 2018 ...

Page 55: ...ent warning sounds Adjustment of the contrast Adjustment of the brightness Select the desired option Error codes menu It is possible to access error messages that are disrupting the operation of the truck Select the Error messages menu 1 The operator can access the error codes If several codes are affecting the truck the op erator can scroll through several successive displays The number of error ...

Page 56: ...tion 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 operat ing time of the truck The clock icon 3 indicates the time and date 48 11548011751 EN 10 2018 ...

Page 57: ... overtaking in potentially hazardous or low visibility areas Driving the truck while sitting on the dashboard is prohibited The operator must be resting against the seat This truck is designed to be used as a pallet truck Therefore The truck must not be used as a stepladder The truck is not designed to transport people The operator must always remain inside the driver s compartment of the truck St...

Page 58: ...GER Risk of serious injury Always keep your body inside the driver s compart ment while the truck is moving The truck is equipped with two operator presence detectors The seat 1 The operator presence button on the adjustable floor 2 These two components are truck safety devices To activate the operator presence detection proceed as follows Sit on the seat 1 Press the operator presence button 2 Keep...

Page 59: ...or presence button is released when moving The parking brake is activated All controls are available CAUTION Disabling of controls When the operator leaves the seat after a time delay The parking brake is activated The controls are no longer available 11548011751 EN 10 2018 51 ...

Page 60: ...d and that the hood is closed correctly Step onto the truck Sit on the seat and adjust it Adjust the floor Pull the emergency off switch 2 Turn the key For models equipped with an electronic key enter the 5 digit PIN to start the truck 3 The display 4 switches on Press the operator presence button or pedal 5 or 6 depending on the version Select the direction of travel for the single pedal version P...

Page 61: ... avoided at all costs NOTE The truck accelerates in proportion to the pressure exerted on the joystick The forklift operator selects the direction of travel using the joystick The joystick has two positions Forward travel 1 Reverse travel 2 Put the truck into service Forward travel Push the joystick to the left 1 to travel forwards opposite load arm direction Reverse travel Push the joystick to th...

Page 62: ...pposite direction The truck brakes progressively and then moves off in the opposite direction until the required speed has been reached Steering The steering wheel 1 allows precise effort less guidance of the truck thanks to the electric power steering It is located on the left of the dashboard 54 11548011751 EN 10 2018 ...

Page 63: ... left Turn the steering wheel anti clockwise to steer the truck to the right WARNING Risk of incorrect operation Never use a truck with a faulty steering wheel Always slow down before negotiating a tight corner Approaching a tight corner too fast can cause the truck to overturn Horn The horn is positioned on the rear side of the control module It is used On routes where there is poor visibility At...

Page 64: ...ng by releasing the joystick DANGER Do not rely on lift off braking to stop the truck in an emergency Always use the brake pedal in an emergency and press the emergency off switch if necessary Push the joystick to move the truck for wards Release the joystick The truck brakes progressively until the truck comes to a complete stop The driving controls are available Braking by reversing the drive di...

Page 65: ...eleased The operator presses the emergency off switch The power supply is cut off WARNING Risk of the operator being thrown from the truck Activating the emergency off switch causes the truck to stop suddenly It should only be used in the event of an emergency and not for braking the truck under normal circum stances NOTE Also ensure that the stabiliser wheels operate correctly This influences brak...

Page 66: ... pedal pressed The brake is locked indicator permanently on 2 if one of the following conditions is met The operator presses the parking brake button 1 The operator leaves the seat and releases the presence pedal and the traction control at the same time When the truck is stopped and the brake is applied indicator flashing 2 the brake switches automatically to locked status indicator permanently on...

Page 67: ...Parking brake release NOTE A power failure or a emergency stop causes immediate application of the parking brake even if the truck is moving Put the truck into service The parking brake is in locked status indicator permanently on 2 If the truck is a dual pedal version Press the parking brake button 1 Press one of the accelerator pedals to start the truck moving If the truck is a single pedal vers...

Page 68: ...ueQ mode 4 Tortoise mode 2 NOTE When the operator 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 perfor mance Blue Q mode Selecting Blue Q mode allows you to slightly reduc...

Page 69: ...duce the performance 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 11548011751 EN 10 2018 61 ...

Page 70: ...hed with great caution Avoid slopes with a gradient greater than that specified in the datasheet for the truck Make sure that the ground is clean has a non slip surface and that the route is clear Always drive at a very low speed and brake gradually Travelling up slopes Laden Always travel up slopes in reverse The load faces uphill Unladen It is recommended that you go up a slope forwards 62 115480...

Page 71: ...ke shortcuts on a slope On a slope the 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 slope Proceed as follows Move the drive direction controls in the desired direction Release the drive direction controls ...

Page 72: ...ed in the sections below Operation of operator presence detection with the single pedal option DANGER Risk of serious injury Always keep your body inside the driver s compart ment while the truck is moving The truck is equipped with two operator presence detectors The seat 1 The operator presence button on the floor 2 These two components are truck safety devices To activate the operator presence d...

Page 73: ... Always keep your body inside the driver s compart ment while the truck is moving WARNING Be aware of the position of the drive wheel Slowly start the truck Check the position of the drive wheel on the display NOTE Always depress the pedal slowly as the truck reacts immediately Abrupt starts or braking or sudden reversal of the drive direction must be avoided at all costs NOTE The truck accelerate...

Page 74: ...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 Keep the accelerator pedal 4 depressed Push the drive switch down 1 or up 2 Push the drive switch 3 in the opposite direction The truck brakes progressively and then moves off in the opposite direction until the required speed has been r...

Page 75: ...f braking to stop the truck in an emergency Always use the brake pedal in an emergency and press the emergency off switch if necessary Braking by releasing the accelerator pedal Push the drive switch and press the accel erator pedal 2 to move the truck forwards Release the accelerator pedal 2 The truck brakes progressively until the truck comes to a complete stop The driving controls are available...

Page 76: ...n The accelerator pedal is released The operator presses the emergency off switch The power supply is cut off WARNING Risk of the operator being thrown from the truck Activating the emergency off switch causes the truck to stop suddenly It should only be used in the event of an emergency and not for braking the truck under normal circum stances NOTE Also ensure that the stabiliser wheels operate c...

Page 77: ...ons below Operation of operator presence detection with the dual pedal option DANGER Risk of serious injury Always keep your body inside the driver s compart ment while the truck is moving The truck is equipped with two types of operator presence detection The seat 1 The accelerator pedals 2 or 3 are used as operator presence pedals These two components are truck safety devices To activate the ope...

Page 78: ...ing with the dual pedal option DANGER Risk of serious injury Always keep your body inside the driver s compart ment while the truck is moving WARNING Be aware of the position of the drive wheel Slowly start the truck Check the position of the drive wheel on the display NOTE Always depress the pedal slowly as the truck reacts immediately Abrupt starts or braking or sudden reversal of the drive dire...

Page 79: ... to move backwards in the direction of the load arms 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 Press one of the accelerator pedals 1 or 2 Release the pedal Press the other accelerator pedal The truck brakes progressively and then moves off in...

Page 80: ...g controls are available DANGER Do not rely on lift off braking to stop the truck in an emergency Always use the brake pedal in an emergency and press the emergency off switch if necessary Braking by releasing the forwards pedal Press the accelerator pedal 2 or 3 to move the truck forwards Release the accelerator pedal The truck brakes progressively until the truck comes to a complete stop The dri...

Page 81: ...esses the emergency off switch The power supply is cut off WARNING Risk of the operator being thrown from the truck Activating the emergency off switch causes the truck to stop suddenly It should only be used in the event of an emergency and not for braking the truck under normal circum stances NOTE Also ensure that the stabiliser wheels operate correctly This adjustment influences braking effectiv...

Page 82: ...ireless data management GSM 2 GPRS 1 module 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...

Page 83: ...lour No acoustic signal sounds Press the Enter key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or th...

Page 84: ...rect or not confirmed using the Enter key Re enter the PIN code The operator has been granted access authorisation But the period of validity has expired Use the interface to enter a new period of validity Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously ...

Page 85: ...A shock has occurred Reset the shock Flashes quickly Blue colour Off The truck is connected via a Bluetooth link The operating data is being read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the relevant data to be read As soon as the LEDs change to a different status resume work 11548011751 EN 10 2018 77 ...

Page 86: ... a keypad or electronic key Park the truck in a safe place Press the button 3 to log off Keep the button pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red colour The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flashes slowly at two second intervals green colour No acoustic signal sounds The truck is disabled Turn t...

Page 87: ...sponder 4 in front of the reading device 3 The LED 1 lights up for a second red colour The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flashes slowly at two second intervals green colour No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely 11548011751 EN 10 2018 79 ...

Page 88: ... devices for picking up loads 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 underneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms prot...

Page 89: ...e g pallets Transporting several loading units at a time is only autho rised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the loading unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety requirements 11548011751 EN 10 2018 81 ...

Page 90: ...d lifting devices The lift control button has two positions Lifting the load arms 1 Lowering the load arms 2 Put the truck into service Lifting the load arms Press the button at position 1 When the button is released the load arms stabilise at the required height Lowering the load arms Press the button at position 2 When the control is released the load arms stabilise at the required height 82 115...

Page 91: ...width 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 DANGER Risk of tipping It is essential to slow down when approaching a corner or on wet surfaces CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads with a sma...

Page 92: ...low door ways scaffolding pipes etc To move past obstacles slightly raise the fork arms Check that the width of the load is not greater than the width of the aisle Setting a load down on the ground Proceed as follows Drive the machine to the required location Carefully move the load into the unloading area Lower the load until the fork arms are freed Withdraw the machine in a straight line Raise t...

Page 93: ...pplications the truck must be used alternately inside and outside of the cold store It can with stand temperatures 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...

Page 94: ...nt damage to the truck Parking The truck must be parked outside of the cold store Parking inside the cold 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 86 11548011751 EN 10 2018 ...

Page 95: ...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 maintenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that produce sparks within a minimum radiu...

Page 96: ...n key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood 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 securely CAUTION Risk of sparks Never drive wi...

Page 97: ...ttery connector to the wall mounted connector WARNING Electrical risk Only unplug the battery connector from the battery charger when both the battery charger and the truck are switched off NOTE Follow the instructions provided by the manu facturer of the battery and the battery charger equalising charge WARNING Risk of damage short circuit or explosion Do not place any metal objects or tools on t...

Page 98: ...tery WARNING Explosive gases are generated during battery 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 90 11548011751 EN 10 2018 ...

Page 99: ... remove the battery we recommend that you use a fixed roller frame or a truck with extraction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise the truck Lower the load arms Switch off the ignition and remove the key Press in the emergency off switch Open the battery hood Unclip the hood from the fixed screw 1 Place it onto the load arm...

Page 100: ... battery cells Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment on level ground Operate and pull the locking handle 2 in the direction indicated by the arrow 92 11548011751 EN 10 2018 ...

Page 101: ...he truck with extraction rollers or the roller frame Replace the battery Remove the dis charged battery and position a charged battery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment 11548011751 EN 10 2018 93 ...

Page 102: ...ping fingers Push the battery from therear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Push it down to the end of the compartment 94 11548011751 EN 10 2018 ...

Page 103: ...attery incorrectly The locking bar should not in any circumstances be positioned under or on top of the stop It must be positioned against the stop Reconnect the battery connector Refit the battery hood Return the truck to service WARNING Risk of injury Before restarting the truck ensure that the battery is correctly installed Check that the battery is locked and that the battery hood is closed 115...

Page 104: ... towing vehi cle is sufficiently powerful to pull and brake the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel 0252_003 109 1 Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw th...

Page 105: ... 2 After towing chock the truck to prevent it from moving To re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted before the machine is used 11548011751 EN 10 2018 97 ...

Page 106: ...evice Refer to the technical features Observe the following instructions Switch off the truck and disconnect the battery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device 1 NOTE Do not sling the truck by the steering wheel or the control module Carefully lift the truck DANGER Risk of falling Make sure no one is und...

Page 107: ...and chock the truck after lifting it Transporting the truck CAUTION Always switch off the ignition and disconnect the battery 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 weight shown on the truck s capacity plate The lifti...

Page 108: ...istance 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 must make sure it is properly attached and secured and its load capacity is sufficient Cross the loading bridge slowly a...

Page 109: ...5 Maintenance ...

Page 110: ...te work Maintenance intervals must be reduced if the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables specified in these operating instructions are authorised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the maint...

Page 111: ...y specially trained personnel Personnel must follow the manufacturer s instructions of the battery the battery charger and the truck It is essential to follow the battery maintenance instructions and the battery charger operating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery e...

Page 112: ...supplied with voltage must only be carried out by personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which com prises electric components such as the trac tion controller b...

Page 113: ... VG68 HLP as per DIN 51524 2 Recommended oil for the cold store version ISO L HM 32 as per ISO 6743 4 or ISO VG32 HLP as per DIN 51524 2 Transmission oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray Grease for pinion gear and steering ring CAUTION Follow the maintenance and safety guidelines Multi purpose grease Lithium soap grease with EP agents and MoS 2KPF 2N 2...

Page 114: ...l Traction motor 3 kW 1F1 fuse Power 300 A quantity 1 Power 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Power 40 A quantity 1 Pump motor 1F1 fuse 1 2 kW Power 300 A quantity 1 1 5 kW Power 300 A quantity 1 Control fuse 1F3 fuse Control 7 5 A quantity 1 Control 7 5 A quantity 1 Control fuse 1F4 fuse Control 5 A quantity 1 Control 5 A quantity 1 Battery Distille...

Page 115: ...t the battery connector Move the seat all the way forwards Remove the mounting screw 1 located at the bottom of the door Open the technical compartment door 2 The technical compartment must be closed after the operation is finished Close the door 2 CAUTION Risk of trapping fingers Take care not to trap your fingers between the door and the chassis Be careful not to trap your fingers in the external hi...

Page 116: ...sure that the floor adjusts and locks correctly Ensure that the seat adjusts and locks correctly Check the transmission gear for noise and leaks Lubricate the gears Wheels Check the condition and tightness of the wheels Check the stabilisers Electrical equipment Clean the electric steering system and lifting motors Check the condition of the cables and the battery sockets and ensure that they are p...

Page 117: ...urs 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 11548011751 ...

Page 118: ...a sponge and cloths Specifically clean the oil filler holes and surrounding area as well as the lubricating nipples before lubrication NOTE A frequently cleaned truck must be lubricated more regularly Cleaning the electrical installations WARNING Electrical hazards Do not expose electrical equipment especially motors to direct jets NOTE Only use dry cleaning products Do not remove the cowlings Clean...

Page 119: ...es 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 maintenance 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 sui...

Page 120: ...ecking the condition of the load arms Check that the load arms 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged have it changed by the After Sales Service Centre 112 11548011751 EN 10 2018 ...

Page 121: ...tate freely Then remove any objects that may prevent them from turning or that may obstruct them Check the level of wear on the tyre treads CAUTION Equipment damage In order to avoid any risk of damaging the bearings and tyres of the wheels it is essential to remove any wires or plastic strips that may wind around the wheel hubs and bearings 11548011751 EN 10 2018 113 ...

Page 122: ...ess in the emergency off switch Disconnect the battery connector Move the seat all the way forwards Open the technical compartment door 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 cable harness connector pins Close the technical compartment door Return the truck to service 114 115...

Page 123: ...kin or into the eyes If this does happen rinse immediately with plenty of clean water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immedia tely 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 manuf...

Page 124: ...p in the connections Check that the and output terminals are not sulphated presence of white salt Check the condition of the battery connector contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious incidents In the event of an incident contact our After Sales Service Centre as quickly as possible 116 11548011751 EN 10 2018 ...

Page 125: ... on the technical compartment Close the technical compartment door Return the truck to service CAUTION Risk of damaging the truck In the event of leakage please contact the After Sales Service Centre Checking the hydraulic oil level To check the hydraulic oil level proceed as follows Immobilise the truck Lower the load arms Switch off the ignition and remove the key Press the emergency off switch ...

Page 126: ...ug 1 afterwards CAUTION Risk of damage to hydraulic components Only use hydraulic oil that complies with the manu facturer s specifications see table of recommen ded lubricants Close the technical compartment door Reconnect the battery connector Return the truck to service 118 11548011751 EN 10 2018 ...

Page 127: ...ontacts Raise and chock the truck the wheels must not touch the ground in order to prevent irreversible deformation of the tyres Cover the truck with a cotton cover to protect 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 tim...

Page 128: ...e pipes rubber components lubricants aluminium iron etc Before scrapping the truck notify the competent 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 irreg ularities he has committed during or after the scrapping of the truck s components an...

Page 129: ...6 Technical specifications ...

Page 130: ...6 Technical specifications FXH 20 datasheet FXH 20 datasheet 122 11548011751 EN 10 2018 ...

Page 131: ... load side 10 3 kg 1188 1828 1589 2006 2 3 Load per unladen axle drive side load side 10 3 kg 751 246 830 246 WHEELS FXH 20 FXH 25 3 1 Tyre polyurethane rubber drive side load side R P P 3 2 Drive wheel dimensions width on the ground Ø x l mm Ø254 x l102 3 3 Wheel dimensions load side Ø x l mm Ø85 x l105 2 x Ø85 x l80 3 4 Additional wheels dimensions Ø x l mm 2 x Ø140 x l50 3 5 Number of wheels dr...

Page 132: ...Turning radius minimum 20 mm LI raised lowered 1 Wa mm 1760 1825 2205 2270 PERFORMANCE DATA FXH 20 FXH 25 5 1 Travel speed laden unladen 5 km h 10 12 10 12 5 2 Lift speed laden unladen 10 m s 0 039 0 048 0 024 0 033 5 3 Lowering speed laden unladen 10 m s 0 077 0 078 0 074 0 053 5 8 Maximum gradient laden unladen 17 20 15 20 5 9 Acceleration time 10 m s 5 6 4 3 5 7 4 3 5 10 Service brake electroma...

Page 133: ... output according to VDI cycle T h 148 6 8 Energy consumption at turnover output kWh h 1 62 MISCELLANEOUS FXH 20 FXH 25 8 1 Speed control AC controller LAC 10 7 Noise level at forklift operator s ears 2 5 dB A 68 Vibration transmitted to the operator EN 13059 m s 0 5 1 Load arms lifted lowered 2 Calculation with Wa load arms lowered 3 Weight according to line 2 1 4 With battery line 6 5 5 In lower...

Page 134: ...6 Technical specifications FXH 20 datasheet 126 11548011751 EN 10 2018 ...

Page 135: ...ecking the condition of the wheels 113 Checking the emergency off switch 33 Checking the horn 37 Checks prior to start up 33 Cleaning the truck 110 Climatic conditions 8 cold store 85 Cold store usage 85 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraulic fluid 14 Contact details I Copyright and property rights 3 D Defini...

Page 136: ...ty of lubricants and other consumables 102 Grease for pinion gear and steering ring 105 H Handling a single load 83 Horn 55 Hydraulic fluid 14 Hydraulic oil 105 Hydraulic system Checking the hydraulic oil level 117 Checking the hydraulic system for leaks 117 I Identification label 5 Indicator light Drive direction indicator 43 Parking brake 43 L Labels 28 Lift control elements 82 Lifting the truck 9...

Page 137: ...l option 69 Specific features of the single pedal option 64 Stability 17 Starting on a slope 63 Starting the truck 52 Steering 32 54 Stepping on off the truck 39 Symbols used 9 T Technical data for inspection and maintenance 106 Technical description 32 Transmission oil 105 Transporting a load 84 Transporting the truck 99 Transporting the truck in the lift 100 Travelling down slopes 63 Travelling u...

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