Still HPT-20 Original Instructions Manual Download

Page: 59 / 78

Preparation for maintenance

Jacking up

The industrial truck must be jacked up for

some maintenance work. Make sure that the

industrial truck is only jacked up on level sur-

faces, and is secured against rolling and drop-

ping.

Jacking up at the chassis

–

Position the industrial truck with the fork tips

against a wall.

–

Jack up the industrial truck until the steering

rollers are no longer in contact with the

ground.

–

Secure the industrial truck.

HPS20_25_020



Maintenance

Preparation for maintenance

50988046036 EN - 01/2021 - 01

Summary of Contents for HPT-20

Page 1: ...Hand pallet truck HPT 20 HPT 25 HPT 30 Original instructions 0053 0054 0055 0056 0057 50988046036 EN 01 2021 01 ...

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Page 3: ...strial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable indus trial trucks for a particular 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 Internet address and QR co...

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Page 5: ...ible use 11 Place of use 12 Residual dangers residual risks 13 Danger to employees 15 Specific usage risks as a result of operating the industrial truck 16 3 Safety Definition of terms used for responsible persons 18 Operating company 18 Qualified person 18 Operator 19 Basic principles for safe operation 20 Changes and retrofitting 20 Warning regarding non original parts 20 Damage defects and misu...

Page 6: ...ting system controls 34 Brakes 36 Braking the industrial truck 36 Emergency stop 36 Parking brake special equipment 37 Handling loads 38 Safety regulations for handing loads 38 Before the load pick up 38 Taking up loading units 38 Taking up load 39 Transporting pallets 39 Driving on lifts 39 Driving on loading bridges 40 Cold store application 41 Cold store application 41 Operation in special busi...

Page 7: ...intenance 50 General information 50 Preparation for maintenance 51 Jacking up 51 Preserving operational readiness 52 Roller maintenance 52 Servicing the lifting system 54 Adjusting the lowering device 55 Maintenance after 6 months 57 Other work that must be carried out 57 Checking the forks 57 Checking the hydraulic oil level and checking the hydraulic system for leak tightness 57 7 Technical data...

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Page 9: ...1 Foreword ...

Page 10: ...s and ensure that the warranty re mains valid EC conformity CE labelling With the EC declaration of conformity the manufacturer confirms that the industrial truck complies with the standards and regulations valid at the time of marketing The CE label ling is attached to the nameplate and indicates compliance with the standards and regulations listed in the EC declaration of conformity An independe...

Page 11: ... in the latest valid version This declaration of conformity is issued under the sole responsibility of the manufacturer Person authorised to compile the technical file in accordance with the named directives Name Paolo Campinoti EU Terry Dudley GB Address Loc Il Piano 53031 Casole d Elsa SI Italy Unit 4 Tunstall Arrow James Brindley Way Stoke on Trent ST6 5GF England Hamburg 01 01 2021 Fabio Mario...

Page 12: ...uctions must be stored carefully and must be available to the operator and operating company at any time If the operating instructions are lost the oper ating company must obtain a replacement from the manufacturer immediately The operating instructions can be reordered as a spare part from the STILL service centre The personnel responsible for operating and maintaining the equipment must be famil...

Page 13: ...usstr 10 22113 Hamburg Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third parties including as excerpts except with the ex press written approval of the manufacturer Explanation of information symbols used DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities WARNING Indicates procedures ...

Page 14: ...hain of certain functions or opera tions Schematic views of an industrial truck are used to illustrate these procedures NOTE These schematic views are not representative of the structural state of the documented in dustrial truck The views are used solely for the purpose of clarifying procedures HPS20_25_019 Foreword 1 Information about the documentation 6 50988046036 EN 01 2021 01 ...

Page 15: ... of the industrial truck Disposal of units during repair work It may be necessary to exchange units as part of maintenance work Exchanged units must then be disposed of The industrial truck is made of different materi als Each of these materials must be disposed of treated or recycled in accordance with regional and national regulations ENVIRONMENT NOTE We recommend working with a waste man agemen...

Page 16: ...Foreword 1 Environmental considerations 8 50988046036 EN 01 2021 01 ...

Page 17: ...2 Introduction ...

Page 18: ...tions If the industrial truck is to be used for purpo ses other than those specified in the operating instructions the approval of the manufacturer and if applicable the relevant regulatory au thorities must be obtained beforehand to pre vent hazards The maximum load to be lifted rated capacity is specified on the nameplate and must not be exceeded The industrial truck must be used only at the pla...

Page 19: ...is sible The industrial truck must not be used if the load capacity is exceeded Foodstuffs must not come into direct con tact with the industrial truck It is not permissible to use the industrial truck as a jack or lever It is prohibited to transport persons or to use the truck as a scooter The industrial truck must not be used on slopes The industrial truck must not be used in areas that are insu...

Page 20: ...nd with the specifications in these operating instructions The industrial truck is suitable for interior use in countries ranging from the Tropics to Nordic regions see temperature ranges Chapter Technical datasheet Page 65 The operating company see Chapter Defi nition of terms used for responsible persons Page 18 must ensure suitable fire protec tion in the surrounding area of the industrial truc...

Page 21: ...ust be instructed regarding these dangers that arise through use of the industrial truck In addition we draw attention to the safety regula tions in these operating instructions The risks can include Escape of consumables due to leakages rupture of lines and containers etc Falling tripping etc when moving the indus trial truck especially if consumables have leaked The stability of the industrial t...

Page 22: ...age Risk caused by insufficient maintenance or testing Risk caused by using the wrong consuma bles Risk caused by exceeding testing intervals The manufacturer is not held responsible for accidents involving the industrial truck caused by the failure of the operating company to comply with these regulations either intention ally or carelessly Introduction 2 Residual dangers residual risks 14 509880...

Page 23: ...o the Machinery Direc tive 2006 42 EC and are therefore identified with the CE label These elements are there fore not included in the hazard assessment Attachments possess their own CE label and likewise are not included for that reason The operating company must however select the type and equipment of the industrial trucks so as to comply with the local provisions for de ployment The result mus...

Page 24: ...rities must be ob tained each time the truck is used in a manner that is different to how it is used normally and in cases where the operator is not certain that he can use the truck correctly and without the risk of accidents Introduction 2 Specific usage risks as a result of operating the industrial truck 16 50988046036 EN 01 2021 01 ...

Page 25: ...3 Safety ...

Page 26: ... vocational qualification that demonstrably proves their professional ex pertise This proof is to consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven pe riod during their career During this time this person has become familiar with a wide range of symptoms that ...

Page 27: ...job and the load to be lifted Safety footwear must always be worn for safety The operator must be familiar with the operat ing instructions and have access to them at all times The operator must have read and understood the operating in structions have familiarised himself with safe opera tion of an industrial truck be physically and psychologically able to drive an industrial truck safely DANGER ...

Page 28: ...e and or pas sive safety We recommend that you obtain approval from the manufacturer and if necessary from the relevant regulatory authorities before installing such parts The manufacturer accepts no liability for any damage caused by the use of non original parts and accesso ries without approval Damage defects and misuse of safety systems The operator must report any damage or other defects to t...

Page 29: ...could have been caused by improper use A test log must be created The results of the testing must be retained at least until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the industrial truck Arrange for the authorised service centre to perform regular testing on the industrial truck Observe the guidelines regarding inspection work on ind...

Page 30: ...mes DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse thoroughly for at least 10 mi nutes with water and then consult an eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in dryness and irritate the...

Page 31: ...truck and are hazardous to your health Do not spill the fluids Follow the statutory regulations Do not allow the fluids to come into contact with hot engine parts WARNING These fluids are pressurised during op eration of the truck and are hazardous to your health Do not allow the fluids to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the skin is parti...

Page 32: ...ate during repair maintenance and cleaning must be collec ted properly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas designated for the purpose Care must be taken to mini mise any environmental pollution Soak up any spilt fluids such as hydraulic oil or gearbox oil using an oil binding agent Neutr...

Page 33: ...4 Overviews ...

Page 34: ...General view 1 3 2 4 5 Tiller Hydraulic pump Steering rollers 1 2 3 Forks Load castors 4 5 Overviews 4 General view 26 50988046036 EN 01 2021 01 ...

Page 35: ...er load Transport load Lift load Do not drive on slopes Decal information Load capacity Load cen tre of gravity Caution read the operating in structions 1 2 Nameplate Manufacturer s label text 3 4 Overviews 4 Overview 27 50988046036 EN 01 2021 01 ...

Page 36: ...al truck from the information on the nameplate 1 7 8 9 2 4 6 3 5 CE labelling Type Model Manufacturer s code Year of manufacture Tare weight Manufacturer Serial number Rated capacity 1 2 3 4 5 6 7 8 9 Overviews 4 Nameplate 28 50988046036 EN 01 2021 01 ...

Page 37: ...5 Operation ...

Page 38: ...ruck is safe to be operated Fork arms or other load carrying equipment should not show any noticeable damage e g bends cracks significant wear Check the area under the industrial truck for leaking consumables Check whether all decal information is present and legible Damaged or missing adhesive labels must be replaced according to the overview of identification points see Chapter Overview Page 27 ...

Page 39: ...1 on the pump unit 4 using the bolt 2 and the plug 3 included in de livery When positioning the tiller feed the chain 5 through the hole in the bolt 6 Turn the tiller a little and remove the secur ing pin 7 for the steering spring Lift the lowering lever 8 until the end of the chain can be hooked onto the lowering lev er Fully insert the pin at the end of the Operation 5 Checks and tasks to be car...

Page 40: ...chain into the holding fixture on the lower lever as shown in the illustration Operation 5 Checks and tasks to be carried out prior to commissioning 32 50988046036 EN 01 2021 01 ...

Page 41: ...by swivel ling the tiller within the angle indicated 1 At maximum steering lock the industrial truck can be turned in the smallest turning radius Wa see Chapter Technical datasheet Page 65 HPS20_25_004 1 Wa Operation 5 Commissioning 33 50988046036 EN 01 2021 01 ...

Page 42: ...l truck is equipped with the fast lift function loads of up to approx 200 kg can be lifted faster Lifting system controls DANGER Danger to life Stay away from the area beneath the raised forks Never exceed the rated capacity indicated on the nameplate Otherwise stability cannot be guaran teed DANGER Risk of accidents Do not step onto the forks Do not lift people h3 HPS20_25_017 Operation 5 Lifting...

Page 43: ...ting lever downwards 1 Perform a pumping action with the tiller The forks are raised Lowering the forks Pull lift lower operating lever upwards 2 The forks are lowered HPT10_035 1 HPT10_036 2 Operation 5 Lifting 35 50988046036 EN 01 2021 01 ...

Page 44: ...If the truck is decelerated too quickly the load could slip forwards and lead to damage as a result of crushing Emergency stop If the industrial truck is carrying a load and reaches a speed that is too high it is possible to perform an emergency stop CAUTION Risk of tipping The transportation speed must be adapted to suit the ground conditions Transport heavy loads slowly and carefully HPS_20_25_0...

Page 45: ... equipped with a parking brake as special equipment This is in tended solely for secure parking of the indus trial truck and is not to be used as a service brake Operating the parking brake Pull locking lever 2 and at the same time move operating lever 1 from lower position A to upper position B Release the locking lever 2 again The parking brake is now applied Releasing the parking brake Pull loc...

Page 46: ...ER Risk of accidents Do not step onto the forks Do not lift people Never grab or climb on moving parts of the industrial truck Before the load pick up Load capacity The load capacity Q indicated for the indus trial truck must not be exceeded see Chapter Technical datasheet Page 65 Taking up loading units To make sure that the load is securely suppor ted it must be ensured that the fork is posi tio...

Page 47: ...or fall Place the loading units into stock so that the defined aisle width is not reduced by pro truding parts Transporting pallets As a rule loading units e g pallets are to be transported individually Transporting several loading units at a time is only permissible when instructed by the supervisor and when the technical requirements have been met The operator must ensure proper condition of the...

Page 48: ...al truck is secure and must exit the lift first after the trip The maximum weight of the industrial truck comprises the net weight and the maximum load see Chapter Technical datasheet Page 65 Driving on loading bridges DANGER Risk of accidents Before driving across a loading bridge ensure that it is properly attached and secured and has adequate load capacity lorry bridge etc Drive slowly and with...

Page 49: ...n re en try to the cold store and block moving parts of the in dustrial truck Close attention to the duration of deployment in the different temperature ranges must be paid for both types of application The industrial truck must be dry before it can be used in the cold store WARNING Risk of injury If condensation water freezes in the cold store do not try to free blocked parts with your hands Alwa...

Page 50: ...er off the loading bridge towards the edge This can cause the industrial truck to crash Park the industrial truck securely see Chapter Parking the industrial truck se curely Page 43 CAUTION If the industrial truck is not secured against rolling this could result in damage of the cargo or cause ac cidents Lash the industrial truck to secure it Lashing Use tension belts 1 to secure the industrial tr...

Page 51: ...the industrial truck cannot roll away unintentionally Never park the industrial truck in areas where it could create risks for other traffic Lower the forks completely Actuate the parking brake special equip ment see Chapter Parking brake spe cial equipment Page 37 Operation 5 Decommissioning 43 50988046036 EN 01 2021 01 ...

Page 52: ... filling open ings and their surroundings and the lubri cating nipples NOTE Please note The more often the industrial truck is cleaned the more frequently it must be lubricated Clean all parts of the industrial truck using a damp cloth Under no circumstances should you use a direct water jet or steam for cleaning After cleaning Dry the truck carefully e g with com pressed air Put the industrial tr...

Page 53: ...6 Maintenance ...

Page 54: ...es for testing industrial trucks Maintenance work for which no special qualifications are necessary Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel This does not require the qualifications described above Refer to these operating instructions for further information Information regarding performing main tenance This section contains all th...

Page 55: ... the initial lift Servicing the lifting system Adjusting the lowering device Adjusting the lowering device Identification points Checking the labelling for completeness Overview Maintenance after 6 months Function group Maintenance work Chapter Carry out all servicing work Load lift sys tem Checking the forks Check the forks Hydraulics Checking the hydraulic oil level and hy draulic system for lea...

Page 56: ...he manufactur er s instructions The use of unapproved spare parts can result in an increased risk of acci dents due to insufficient quality or incorrect as signment Anyone using unapproved spare parts shall assume unlimited liability in the event of dam age or harm Maintenance 6 General maintenance information 48 50988046036 EN 01 2021 01 ...

Page 57: ...ite ø 200 x 50 mm HPT 25 HPT 30 Nylon grey PUR ø 200 x 45 mm HPT 25 HPT 30 Aluminium solid rubber ø 200 x 50 mm HPT 25 HPT 30 Aluminium PUR ø 200 x 50 mm HPT 25 HPT 30 Nylon white ø 200 x 50 mm Front load cas tors single Except HPT 20 FL Nylon white ø 82 x 82 mm Front load cas tors tandem HPT 20 FL Nylon ø 55 x 58 mm Except HPT 20 FL Nylon white ø 82 x 60 mm Maintenance 6 General maintenance infor...

Page 58: ... work all necessary safety measures must be taken e g Ensuring that unintentional movement of the industrial truck is prevented Ensuring that a raised lifting accessory can not be lowered when work is being carried out beneath it Maintenance 6 Safety regulations for maintenance 50 50988046036 EN 01 2021 01 ...

Page 59: ...n level sur faces and is secured against rolling and drop ping Jacking up at the chassis Position the industrial truck with the fork tips against a wall Jack up the industrial truck until the steering rollers are no longer in contact with the ground Secure the industrial truck HPS20_25_020 Maintenance 6 Preparation for maintenance 51 50988046036 EN 01 2021 01 ...

Page 60: ...ones of the same size see Chapter Technical datasheet Page 65 CAUTION Incorrectly adjusted steering rollers or load castors could lead to problems with stability This adjustment must be carried out by your service centre Checking the mounting of the steering rollers Remove cover 1 on both sides HPT 25 ST only HPT20_25_006 1 Maintenance 6 Preserving operational readiness 52 50988046036 EN 01 2021 0...

Page 61: ...itioning and change if necessary Reattach the cover HPT 25 ST only Checking the mounting of the load cas tors Check screws 1 for secure positioning and tighten if necessary 2 HPS20_25_010 HPT20_25_007 1 1 1 1 Maintenance 6 Preserving operational readiness 53 50988046036 EN 01 2021 01 ...

Page 62: ... lift must extend to the maximum height without jerking Pull operating lever 1 upwards The initial lift must retract again without jerking If the initial lift does not extend and retract without jerking Check the hydraulic oil level Check the lift cylinder for leaks HPT10_035 1 HPT10_036 2 Maintenance 6 Preserving operational readiness 54 50988046036 EN 01 2021 01 ...

Page 63: ... truck securely see Chapter Parking the industrial truck se curely Page 43 Loosen the lock nut 1 Lift the forks a little Adjust the adjustment screw 2 on the lever until the lowering function works Maintenance 6 Preserving operational readiness 55 50988046036 EN 01 2021 01 ...

Page 64: ... are lowered to the neutral position If the forks are lowered proceed as follows Turn the adjustment screw 2 anti clock wise until the forks are no longer lowered Lifting position Push the operating lever 3 downwards Perform a pumping action The forks must be lifted If this is not the case proceed as follows Turn the adjustment screw 2 anti clock wise until the forks are lifted by the pumping acti...

Page 65: ...on the frame must only be carried out by your service centre Checking the hydraulic oil level and checking the hydraulic system for leak tightness Checking the hydraulic pump for leak tightness Check the hydraulic pump for leak tight ness Checking the oil level Lift the fork to the maximum lift height Measure the maximum lift height from the floor to the top edge of the fork If the maximum lift he...

Page 66: ...n or der to gain access to the oil chamber of the hydraulic pump Check the oil volume and top up to 0 25 l if necessary Actuate the lowering operating lever on the tiller and insert the piston rod into the hydraulic pump Place the ball back onto the piston rod Tilt the hydraulic pump back into the chas sis and secure in place using the screw 2 and nut 1 Maintenance 6 Maintenance after 6 months 58 ...

Page 67: ... Carry out a function check Maintenance 6 Maintenance after 6 months 59 50988046036 EN 01 2021 01 ...

Page 68: ...Maintenance 6 Maintenance after 6 months 60 50988046036 EN 01 2021 01 ...

Page 69: ...7 Technical data ...

Page 70: ...Dimensions HPT 25 HPT 25 GA HPT 25 ST HPT 30 Technical data 7 Dimensions HPT 25 HPT 25 GA HPT 25 ST HPT 30 62 50988046036 EN 01 2021 01 ...

Page 71: ...Technical data 7 Dimensions HPT 25 HPT 25 GA HPT 25 ST HPT 30 63 50988046036 EN 01 2021 01 ...

Page 72: ...Dimensions HPT 20 FL Technical data 7 Dimensions HPT 20 FL 64 50988046036 EN 01 2021 01 ...

Page 73: ... 600 600 600 600 600 Weight HPT 20 FL HPT 25 HPT 25 GA HPT 25 ST HPT 30 Net weight with front load castors single kg 61 61 67 67 Net weight with front load castors tandem kg 71 63 63 69 69 Chassis frame HPT 20 FL HPT 25 HPT 25 GA HPT 25 ST HPT 30 Front load castors single mm 82 x 82 82 x 82 82 x 82 82 x 82 Front load castors tan dem mm 55 x 58 82 x 60 82 x 60 82 x 60 82 x 60 Rear steering rollers ...

Page 74: ...s of fork arm s e l mm 40 160 1150 55 150 1150 55 150 1150 55 150 1150 55 150 1150 Turning radius Wa mm 1367 1367 1367 1367 1367 Aisle width for pallets 1000 x 1200 lengthwise Ast mm 2048 2048 2048 2048 2048 Temperature ranges HPT 20 FL HPT 25 HPT 25 GA HPT 25 ST HPT 30 Temperature C 12 to 50 12 to 50 12 to 50 30 to 50 12 to 50 Technical data 7 Technical datasheet 66 50988046036 EN 01 2021 01 ...

Page 75: ...ion scope 4 Driving on lifts 39 Driving on loading bridges 40 E EC EU declaration of conformity 3 EC conformity 2 Emergency stop 36 F Forks Checking 57 G General 2 General view 26 H Hydraulic fluid 23 I Impermissible use 11 Industrial truck Cleaning 44 Information symbols 5 Intervals for maintenance and inspection 47 Issue date of manual 5 J Jacking up 51 L Labelling points Overview 27 Lifting sys...

Page 76: ...les of behaviour for the operator 19 Roller maintenance 52 S Safety 0 Safety inspection 21 Safety regulations for handing loads 38 Safety regulations for maintenance General information 50 Specific usage risks as a result of operat ing the industrial truck 16 Steering rollers Checking 52 T Taking up loading units 38 Technical datasheet 65 Tiller Fitting 31 Transport 42 Transporting pallets 39 Typi...

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Page 78: ...STILL GmbH 50988046036 EN 01 2021 01 ...

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