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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

10,000-hour service plan

11548011651 EN - 02/2021 - 09

Summary of Contents for FXH 20N

Page 1: ...Electric pallet truck FXH 20N FXH 25N Original instructions 1326 1327 2372 2373 11548011651 EN 02 2021 09 ...

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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 11548011651 EN 02 2021 09 ...

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Page 5: ... 8 Unauthorised use 9 Additional information on the conditions of use for pallet trucks in ride on mode 9 Explanation of symbols used 9 Disposing of components and batteries 9 2 Safety Safety regulations 12 Safety regulations for handling consumables 13 Permissible consumables 13 Oils 13 Hydraulic fluid 14 Battery acid 14 Disposal of consumables 15 Emissions 16 Noise emission values 16 Vibration c...

Page 6: ...perating unit 27 Markings 28 Labels 28 Serial number 29 4 Use Technical description 32 List of checks prior to start up 33 Starting the truck 34 Checks and actions prior to commissioning 35 Checking the emergency off switch 35 Checking the brakes 35 Checking the horn 36 Truck operating instructions 37 Stepping on off the truck 39 Operation of operator presence detection 40 Driver s compartment set...

Page 7: ...he LEDs 61 Disconnecting a truck equipped with the FleetManager option 63 Transporting loads 65 Load handling safety rules 65 Grabbing a loading unit 65 Transporting pallets or other containers 66 Lift control elements 67 Handling a single load 68 Cold store use 70 Cold store usage optional 70 Handling the battery 72 Battery type 72 Order picking 72 Opening and closing the battery hood 73 Charging...

Page 8: ...t 93 1000 hour maintenance plan 95 5000 hour maintenance plan 95 10 000 hour service plan 96 Chassis bodywork and fittings 97 Cleaning the truck 97 General information on battery maintenance 98 Checking the condition of the load arms 99 Steering and wheels 100 Checking the condition of the wheels 100 Electrical equipment 101 Cleaning and blowing out the electrical components 101 Checking the batte...

Page 9: ...6 Technical specifications FXH 20N datasheet 110 Table of contents VII 11548011651 EN 02 2021 09 ...

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 11548011651 EN 02 2021 09 ...

Page 18: ... advance is to limit danger as far as possible Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special meas ures for trucks equipped with Gel or Lead batteries U...

Page 19: ...e on using this truck Explanation of symbols used DANGER Compulsory procedure that must be followed to avoid life threatening danger or physical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To p...

Page 20: ...Introduction 1 Disposing of components and batteries 10 11548011651 EN 02 2021 09 ...

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: ...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 condi...

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

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

Page 29: ...is responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use Safety 2 Definition of responsible persons 19 11548011651 EN 02 2021 09 ...

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: ...t Seat Steering wheel Operator presence pedal Drive wheel Platform 1 2 3 4 5 6 Stabiliser wheels Battery compartment Load arms Load wheels or bogies Emergency off switch 7 8 9 10 11 Overviews 3 Truck overview 22 11548011651 EN 02 2021 09 ...

Page 33: ...General view of the technical compartment Pump motor unit Traction motor ES30 24 steering unit 1 2 3 Fuses Tank Button to adjust the floor 4 5 6 Overviews 3 Truck overview 23 11548011651 EN 02 2021 09 ...

Page 34: ...it or joystick depending on option selected Emergency off switch 1 2 3 Switch key or electronic key Control button Steering Knob device Steering wheel Handle for stepping on and off the truck 4 5 6 7 Overviews 3 Control and display components 24 11548011651 EN 02 2021 09 ...

Page 35: ... ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0 ...

Page 36: ...wer switches off auto matically after 10 mi nutes 600 seconds by default if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 37: ... Activity indicator light 1 2 3 4 5 6 7 Error Code menu Settings menu Drive wheel position menu Truck status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 8 9 10 11 12 13 14 For more information refer to Chapter 4 Using the display operating unit Overviews 3 Control and display components 27 11548011651 EN 02 2021 09 ...

Page 38: ...ication label Brand label Danger instructions label Consult operating instructions 1 2 3 Next inspection label Slinging label Consult operating instructions Model label 4 5 6 Overviews 3 Markings 28 11548011651 EN 02 2021 09 ...

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 11548011651 EN 02 2021 09 ...

Page 40: ...Overviews 3 Markings 30 11548011651 EN 02 2021 09 ...

Page 41: ...4 Use ...

Page 42: ...ers driving precision 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 mo tor that positions the turntable The steering motor is controlled by a variable speed transmission It receives information from the...

Page 43: ... specified by the manufacturer is observed Attachment parts special equipment must be properly secured and function according to their operating instructions Damaged or missing stickers must be re placed in compliance with the marking posi tion table The roller channels must be coated in a visible layer of grease The wheels must show no signs of defects or heavy wear They must be mounted cor rectl...

Page 44: ...closed correctly Enter the truck Sit on the seat and adjust it Adjust the floor Pull the emergency off switch 1 Turn the key 2 For models equipped with an electronic key enter the 5 digit PIN code to start the truck Press the operator presence pedal The display 3 switches on The truck is now ready for use Use 4 Starting the truck 34 11548011651 EN 02 2021 09 ...

Page 45: ...iliser wheels operate cor rectly This influences braking effectiveness Checking the brakes Braking by releasing the drive switch Drive the truck in direction 1 or 2 Release the drive switch The brake is activated until the truck stops completely Braking by reversing the drive direction Drive the truck in direction 1 or 2 Move the drive switch in the opposite direc tion The truck slows down and the...

Page 46: ...ocated 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 Use 4 Checks and actions prior to commissioning 36 11548011651 EN 02 2021 09 ...

Page 47: ... must be consistent with a maxi mum recommended height of 2 m For uses other than those shown above please consult the After Sales Service Centre It is important to use pallets that are in good condition Speed must be reduced when moving over obstacles to prevent the truck from becoming unbalanced and vibrations in the forklift opera tor s arms The trucks can drive across ramps and shal low inclin...

Page 48: ...CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 38 11548011651 EN 02 2021 09 ...

Page 49: ...njury or impact from the edges of the truck The chassis is narrow Be careful not to hit yourself on the truck when stepping onto it CAUTION Risk of damaging the equipment Never pull on the steering wheel or control unit when climbing onto the truck Excessive force on the steering wheel or the control unit can damage it and cause a malfunction DANGER Risk of injury To avoid accidental start up do n...

Page 50: ...ise from the chair in the event of poor visibility The truck then travels at 2 km h The forklift operator presence pedal must be kept depressed Before rising from the chair it is essential to slow down the truck to a very low pace and to check the working environment WARNING Risk of injury Do not rise from the chair when the truck is travelling at full speed NOTE Do not rise from the chair to slow...

Page 51: ...ng of controls If the operator presence pedal is released when moving The truck brake is automatically activated The controls no longer work Use 4 Operation of operator presence detection 41 11548011651 EN 02 2021 09 ...

Page 52: ...low This operation also enables you to adjust the hardness of the seat Adjusting the floor The floor is fitted with a pressure based height adjustment system To adjust the floor height proceed as follows Sit on the seat Press the floor unlocking button 2 and hold it down for the duration of the opera tion Exert pressure on the floor 3 by pushing it with your legs to obtain a good driving posi tion...

Page 53: ...or Put the truck into service Press the LED button 1 to activate the heating The LED button 1 illuminates to indicate that the heater is in operation NOTE When the driver gets up or leaves the seat the heating stops in order to conserve battery power No visual information is shown on the display Check whether the LED button 1 is on Press the LED button 1 to reactivate the heater Use 4 Driver s com...

Page 54: ...ition 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 1 The position of the drive wheel is then shown on the display 3 Operation of the display unit Operator presence For the truck to operate the operator must be de...

Page 55: ...t ing 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 illumi nated for two seconds and then goes out Use 4 Using the display operating unit 45 11548011651 EN 02 2021 09 ...

Page 56: ... and 4 icons flash and an audible beep sounds A warning message appears at the 4 icon and remains on until the battery is re charged 2 20 of charge remaining Three regular beeps sound lifting is restricted the 3 icon flashes and the 4 icon remains on with a new warning message Temperature settings and warning lights The temperature light 1 comes on in the event of overheating of the traction motor...

Page 57: ...he icon of the drive mode selected appears on the display Select the desired drive mode using the navigation keys Activity indicator The activity indicator light 1 flashes continu ously while the truck is in operation When the indicator is off the display unit is locked or frozen A warning is shown on the display Use 4 Using the display operating unit 47 11548011651 EN 02 2021 09 ...

Page 58: ...rast Adjustment of the brightness Select the desired option Error codes menu It is possible to access error messages that are disrupting the operation of the truck Select the Error messages menu 1 The operator can access the error codes If several codes are affecting the truck the oper ator can scroll through several successive dis plays The number of error messages is indicated at the bottom of t...

Page 59: ...ioned above additional data is available The Truck status menu 1 displays the truck menu The hourglass icon 2 indicates the operat ing time of the truck The clock icon 3 indicates the time and date Use 4 Using the display operating unit 49 11548011651 EN 02 2021 09 ...

Page 60: ...or low visibility areas Driving the truck while sitting on the dash board is prohibited The operator must be rest ing 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 peo ple The operator must always remain inside the driver s compartment of the truck Stay in the safety area working area...

Page 61: ...osition of the drive wheel Slowly start the truck Check the position of the drive wheel on the display NOTE Always operate the drive switch slowly as the truck reacts immediately Abrupt starts brak ing or reversal of drive direction must be avoi ded at all costs The drive switch is located on the control unit NOTE Always keep hands and feet inside the driver s compartment while the truck is moving...

Page 62: ...cally 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 opposite di rection until the required speed is reached Braking WARNING The quality of the floo...

Page 63: ...c brake is activated auto matically if one of the following conditions is met The operator releases the operator pres ence pedal The drive switch is in the neutral position The power supply is cut off The operator presses the emergency off switch Horn The horn is positioned on the rear side of the control module It is used On routes where there is poor visibility At junctions In the event of immed...

Page 64: ... selected on the screen the truck operates at its maximum perform ance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck The travel speed of the truck is reduced 70 of maximum speed The speed of lifting and lowering the forks is reduced 90 of maximum speed This mode allows you to save battery Tortoise mode Selecting Tortoise mode allows you to reduce the ...

Page 65: ...truck forwards or backwards Raise or lower the forks Forward travel Push the joystick to the left 1 to travel for wards opposite load arm direction Reverse travel Push the joystick to the right 2 to travel backwards load arm direction Rear of the joystick The rear of the joystick is used to Sound the horn Raise or lower the load arms Horn Press the button 3 on the joystick Raising the load arms in...

Page 66: ...at the zero point 1 the truck travels in a straight line Two stops one on the left 2 and one on the right 3 delimit the axis of rotation The oper ator adjusts the turning knob within this axis to drive In forward travel opposite to load arm direc tion Move the turning knob to the left anti clock wise 2 to turn to the left Move the turning knob to the right clock wise 2 to turn to the right In reve...

Page 67: ...aution 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 grad ually Travelling up slopes Always travel up slopes in reverse The load faces uphill Without a load it is recommended that you go up a slope forwards Use 4 Driving 57 11548...

Page 68: ...urn or take 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 switch in the required direc tion Release the drive switch to apply the ...

Page 69: ...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 70: ...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 71: ...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 72: ... quickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 62 11548011651 EN 02 2021 09 ...

Page 73: ...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 74: ... The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 64 11548011651 EN 02 2021 09 ...

Page 75: ...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 76: ...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 66 11548011651 EN 02 2021 09 ...

Page 77: ...nstallations load lifting devices Lifting of load arms Start the truck Push the control 1 upwards 2 When the control 1 is released the load arms stabilise at the required height Lowering of load arms Start the truck Pull the control 1 downwards 3 When the control 1 is released the load arms stabilise at the required height Use 4 Transporting loads 67 11548011651 EN 02 2021 09 ...

Page 78: ...k 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 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 handled Arrange the loads with a small space between ...

Page 79: ...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 Setting a load down on the ground Proceed as follows Drive the truck to the required location Carefully move the load into the unloading zone Lower the load until the fork arms are freed Withdraw the machine in a straight line Raise the fork arms again several ...

Page 80: ...be used alternately in side and outside of the cold store It can withstand 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 temperature zone may resu...

Page 81: ...king 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 Use 4 Cold store use 71 11548011651 EN 02 2021 09 ...

Page 82: ... 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 83: ...d arms Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood 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 CAUTI...

Page 84: ...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 the bat tery Smoking is prohi...

Page 85: ...are generated during battery charg ing Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging Use 4 Handling the battery 75 11548011651 EN 02 2021 09 ...

Page 86: ...end that you use a fixed roller frame or a truck with ex traction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise the truck Lower the 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 arms Disconnect the battery ...

Page 87: ...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 Use 4 Handling the battery 77 11548011651 EN 02 2021 09 ...

Page 88: ...lers or the roller frame Replace the battery Remove the dis charged battery and position a charged bat tery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Use 4 Handling the battery 78 11548011651 EN 02 2021 09 ...

Page 89: ...from the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Push it down to the end of the compart ment Use 4 Handling the battery 79 11548011651 EN 02 2021 09 ...

Page 90: ...ng 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 Use 4 Handling the battery 80 ...

Page 91: ...to pull and brake the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is th...

Page 92: ... re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted be fore the machine is used 0252_003 110 3 2 Use 4 Handling the truck in an emergency 82 11548011651 EN 02 2021 09 ...

Page 93: ... following instructions Switch off the truck and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device 1 NOTE Do not sling the truck by the steering wheel or the control module Carefully lift the truck DANGER Risk of falling Make sure no one is under or near the truck when slinging the truck Use...

Page 94: ... the truck CAUTION Always switch off the ignition and disconnect the bat tery Never tie down or sling the truck by the control unit or other points not designed for this CAUTION Risk of damage to the truck Use a hoist and woven NON METALLIC slings with an adequate lifting capacity Refer to the load weight shown on the truck s capacity plate The lifting operations must be performed by qualified per...

Page 95: ...ways 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 se cured and its load capacity is sufficient Cross the loading bridge slowly and carefully The driver must be sure that the veh...

Page 96: ...Use 4 Handling the truck in specific situations 86 11548011651 EN 02 2021 09 ...

Page 97: ...5 Maintenance ...

Page 98: ...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 differe...

Page 99: ...low the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by perso...

Page 100: ... personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pr...

Page 101: ...d 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 20 complying with the stand ard DIN 5182...

Page 102: ...r 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 Distilled water As required As required Joints Lithium soap grease...

Page 103: ...ical compartment Immobilise the truck Lower the load arms Switch off the truck key or electronic key Press the emergency off switch Disconnect the battery connector Move the seat all the way forwards Remove the mounting screw 1 at the bot tom of the door Maintenance 5 Accessing the technical compartment 93 11548011651 EN 02 2021 09 ...

Page 104: ... 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 hinges 3 Refit the mounting screw Reconnect the battery connector Return the truck to service Maintenance 5 Accessing the technical compartment 94 11548011651 EN 02 2021 09 ...

Page 105: ...eck 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 positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic co...

Page 106: ...d driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 10 000 hour service plan 96 11548011651 EN 02 2021 09 ...

Page 107: ... filler holes and sur rounding area as well as the lubricating nip ples 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 mo tors to direct jets NOTE Only use dry cleaning products Do not remove the cowlings Clean the electrical installations with a non ...

Page 108: ...tible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging mainte nance and treatment instructions A non compatible charger may result in a battery failure Observe the manufacturer s recommendations NOTE The discharge indicators used to check the battery must also be suitable for the type of battery Contact the r...

Page 109: ...t the load arms 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the fork carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 99 11548011651 EN 02 2021 09 ...

Page 110: ...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 Maintenance 5 Steering and wheels 100 11548011651 EN 02 2021 09 ...

Page 111: ... 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 Checking the battery acid level and electrolyte density NOTE Remove the battery from its compartment to ch...

Page 112: ...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 and clean Any spillage ...

Page 113: ...d 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 103 11548011651 EN 02 2021 09 ...

Page 114: ... friction wear Check the external pipes and hoses 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 a...

Page 115: ... 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 Close the technical compartment door Reconnect the battery connector Return the truck to service Maintenance 5 Hydraulic systems 105 11548011651 EN 02 2021 09 ...

Page 116: ... 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 117: ...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 118: ...Maintenance 5 Storage and decommissioning 108 11548011651 EN 02 2021 09 ...

Page 119: ...6 Technical specifications ...

Page 120: ...FXH 20N datasheet Technical specifications 6 FXH 20N datasheet 110 11548011651 EN 02 2021 09 ...

Page 121: ...xle drive side load side 10 kg 669 220 3 748 220 3 WHEELS FXH 20N FXH 25N 3 1 Tyre polyurethane rubber drive side load side P P P P P P 3 2 Drive wheel dimensions width at the ground Ø x L mm Ø254 x L102 Ø254 x L102 3 3 Wheel dimensions load side Ø x L mm Ø85 x L105 2 x Ø85 x L80 Ø85 x L105 2 x Ø85 x L80 3 4 Additional wheels dimensions Ø x L mm 2 x Ø140 x L50 2 x Ø140 x L50 3 5 Number of wheels a...

Page 122: ... 1 PERFORMANCE DATA FXH 20N FXH 25N 5 1 Travel speed laden unladen 5 km h 10 12 10 12 5 2 Lifting 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 15 20 12 20 5 9 Acceleration time 10 m s 5 9 4 5 6 2 4 5 5 10 Service brake electromagnetic electromagnetic DRIVE SYSTEM FXH 20N FXH 25N 6 1 Traction mo...

Page 123: ...trol AC controller LAC LAC 10 7 Noise level at operator s ears 2 5 dB A 68 71 Vibrations transmitted to the operator EN 13059 m s 0 5 0 5 1 Forks raised lowered 2 Calculation with Wa forks lowered 3 Weight according to line 2 1 4 With battery line 6 5 5 In lowered position 6 Add 100 mm for 4 PzS 7 Ast Wa L6 X a 8 Ast Wa R a Safety distance a 200 mm Technical specifications 6 FXH 20N datasheet 113 ...

Page 124: ...Technical specifications 6 FXH 20N datasheet 114 11548011651 EN 02 2021 09 ...

Page 125: ...sumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Defining directions 51 Description of use 8 Destruction 107 Display of the drive wheel position 44 Display operating unit 27 Display unit Activity indicator 47 Drive program 47 Error codes menu 48 Operator pres...

Page 126: ...ce plan 88 1000 hours 95 5000 hours 95 Managing battery charging 46 Multi purpose grease 91 N Noise emission values 16 O Oils 13 Operating company 18 Operator presence detection 40 Ordering spare parts and consumables 89 Order picking 72 Overview 22 P Permanent Putting Out of Commission 107 Permissible use 8 Picking up a load from the ground 68 Precautions to be taken during battery maintenance 98...

Page 127: ...uck 84 Transporting the truck in the lift 85 Travelling down slopes 58 Travelling up slopes 57 Truck operating instructions 37 U Unauthorised use 9 Using the truck on a slope 57 V Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Working on the electrical equipment 90 Index 117 11548011651 EN 02 2021 09 ...

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