Original Original instruct instruction ions s
................................................... 2 Gene Genera rall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 EC decl declar arat atio ion n of conf confor ormi mity ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ......................................... 4 Docu Docume ment ntat atio ion n scop scope e
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Copy Copyri righ ghtt and and prop proper erty ty righ rights ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Expl Explan anat atio ion n of symb symbol ols s used used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 e feren ence ces s . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . .. . . .. . . . 5 Explan Explanat ation ion of the the crosscross-r r efer Date Date of issu issue e and and upda update te of this this manu manual al
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Defin Definin ing g dire direct ctio ions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ........................................... 6 Pack Packag agin ing g .......................................................... 6 Disp Dispos osin ing g of comp compon onen ents ts and and batt batter erie ies s ..................................... 6 ......................................................... 7 ......................................................... 8 Inte Intend nded ed use use of the the truc trucks ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Unau Unauth thor oris ised ed use use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Plac Place e of use use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Resi Residu dual al dang danger ers, s, resi residu dual al risk risks s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Spec Specia iall risk risks s asso associ ciat ated ed with with usin using g the the truc truck k and and atta attach chme ment nts s . . . . . . . . . . . . . . . . . . . 10 Over Overvi view ew of haza hazard rds s and and coun counte term rmea easu sure res s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dang Danger er to empl employ oyee ees s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Oper Operat atin ing g comp compan any y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Spec Specia iali list st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Driv Driver ers s
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
compan any y prem premis ises es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Insura Insurance nce cover cover on comp Modi Modific ficat atio ions ns and and refit refitti ting ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Warn Warnin ing g rega regard rdin ing g nonnon-or orig igin inal al part parts s Dama Damage ge,, faul faults ts
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Medi Medica call devi device ces s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Regu Regula larr safe safety ty insp inspec ecti tion on of the the truc truck k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 115 1152 807 80 01 [EN]
I
Electrical insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Permissible consumables
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Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Damage, faults
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Battery charge indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Digicode option (LFM Go) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Marking positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lithium-ion marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 List of checks prior to start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Charging a Gel or Lead battery (wall-mounted charger) . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Checking the anti-crush safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Checking the brake
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Checking the emergency stop
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Checking the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Description of the FleetManager option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Commissioning a truck equipped with the FleetManager™ option . . . . . . . . . . . . . . . . 48 FleetManager™ option: Colour code for the LEDs II
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1152 807 80 01 [EN]
Disconnecting a truck equipped with the FleetManager™ option . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Vertical access lithium-ion batteries: connecting/disconnecting the battery connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Commissioning a truck equipped with a vertical access lithium-ion battery . . . . . . . . . . 54 Side access lithium-ion batteries: connecting/disconnecting the battery connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Commissioning a truck equipped with a side access lithium-ion battery Display on a truck equipped with a lithium-ion battery
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Driving safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Using the folding platform (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 OptiSpeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Parking brake
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Standby (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Lift control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Load handling safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Before picking up a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Transporting pallets or other containers
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Driving on upward and downward slopes
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Transporting the truck in the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Driving on loading br idges
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Truck towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Slinging, lifting and setting the truck
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Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Opening/closing the battery cover
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Charging the battery using an external charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 On-board charger
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Using the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Gel or Lead batteries: Adjusting the on-board charger . . . . . . . . . . . . . . . . . . . . . . . . . 81 Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Gel and lead side access batteries: changing the battery using a trolley . . . . . . . . . . . . 83
1152 807 80 01 [EN]
III
Side access battery: changing the battery using a moveable support . . . . . . . . . . . . . . 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Charging lithium-ion batteries using an external charger . . . . . . . . . . . . . . . . . . . . . . . 87 Replacing the vertical access lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Side access lithium-ion battery: changing the battery
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Park the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Storage of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Permanent Putting Out of Commission (Destruction)
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Transporting a truck equipped with a lithium-ion battery Lithium-ion batteries: Long-term storage
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Servicing and maintenance personnel training and qualification . . . . . . . . . . . . . . . . . . 103 Battery maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Maintenance operations that do not require special training . . . . . . . . . . . . . . . . . . . . . 103 Ordering spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 List of inspections
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Technical inspection and maintenance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Servicing and maintenance measures
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Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Safety devices
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Slinging and jacking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Access to the technical compartment
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Accessing the reducer and the brake
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Servicing wheels and rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
IV
1152 807 80 01 [EN]
Regular maintenance of the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Folding platform maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Clean the battery and its compartment
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Checking the condition of cables, terminals and battery connector . . . . . . . . . . . . . . . . 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Cleaning the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Lithium-ion battery: harnesses and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Work that must also be carried out
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Checking the brake air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Adjusting the height of the stabilisers
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Checking the wear on collars and hinge pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 . . . . . . . . . . . . . . . . . . . . . . . . . 127 Checking the on-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Work that must also be carried out
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Hydraulic circuit, draining the circuit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Servicing the reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1152 807 80 01 [EN]
V
The truck described in these operating instructions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regulations for the country in which it is being used. The driving permit must be obtained from the appropriate office. The trucks have been fitted with state-of-theart technology. All that remains is to handle the truck safely and maintain its functionality. These operating instructions provide the necessary information to do this. Read and observe the information provided before commissioning the truck. This will prevent accidents and ensure that the warranty remains valid.
2
1152 807 80 01 [EN]
STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY
We declare that the machine
Industrial truck Model
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised 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 EC declaration of conformity. The EC declaration of conformity must be carefully stored and made available to the relevant authorities.
1152 807 80 01 [EN]
3
• Operating instructions document • Operating instructions for attachment parts (special equipment) • Spare parts catalogue • VDMA rules for the proper use of industrial trucks These operating instructions describe all measures necessary for the safe operation and proper maintenance of the truck in all possible variants at the time of printing. Special designs to meet customer requirements are documented in separate operating instructions. If you have any questions, please contact your service centre. Enter the production number and the year of manufacture located on the designation plate (see "Marking chapter") in the field provided:
Please quote these numbers for all technical enquiries. Operating instructions are provided with each truck. These instructions must be stored carefully and must be available to the driver and operator at all times. If the operating instructions are lost, the operator must immediately request a replacement from the manufacturer. Personnel responsible for operating and maintaining the equipment must be familiar with these operating instructions. The operating company (see "Definition of responsible persons" chapter) must ensure that all operators have received, read and understood these instructions. Thank you for reading and complying with these operating instructions. If you have any questions or suggestions for improvements, or if you have found any f aults, please contact your service centre.
This manual - and any excerpts thereof - may not be reproduced, translated or transmitted in any form to third parties without the express written permission of the manufacturer.
Compulsory procedure that must be followed to avoid damage to and/or destruction of equipment.
Compulsory procedure that must followed to avoid injury.
4
For technical requirements that require special attention.
1152 807 80 01 [EN]
To prevent environmental dama ge.
Cross references are used to direct the reader to the appropriate section or chapter. Examples: • Cross reference to another section: "Explanation of cross references" chapter • Cross reference to another chapter: "Definition of responsible persons" chapter
The publication date of these operating instructions is printed on the cover.
We hope you enjoy your driving
STILL makes continuous efforts to develop and improve its industrial trucks. For this reason, the manufacturer reserves the right to make changes and no claim will be accepted concerning the infor mation provided in this instruction manual. If you require technical assistance with your truck, please contact your nearest STILL service centre.
STILL GmbH Berzeliusstr. 4 22113 Hamburg Germany
.
Names used in the text: forward travel (1), reverse travel (3), to the right (2) and to the left (4) refer to component installation position with respect to the driver’s compartment. The load is positioned at the back.
1152 807 80 01 [EN]
5
When the truck is delivered, some parts are packaged to provide better protection during transport. This packaging must be removed completely prior to initial start-up.
The truck is made up of different materials. When components or batteries need to be changed, they must be:
The packaging material must be disposed of properly after delivery of the truck.
The documentation prov ided by the battery manufacturer must be c onsulted when dispo- sing of batteries.
• disposed of, • processed • recycled in accordance with the applicable regional and national regulations
We recommend working with a waste mana- gement company when disposing of compo- nents and batteries.
6
1152 807 80 01 [EN]
The electric pallet trucks EXU 16, EXU 18, EXU 20 and EXU 22 are designed to handle pallets or containers. Their small volume, their ease of driving and their performance make them very appropriate for loading and unloading operations. The range of these trucks covers capacities of 1600, 1800, 2000 and 2200 kg.
Power is supplied by either: – A lead battery – A gel battery – Or a lithium-ion battery (the truck therefore has specific characteristics). The types of battery removal that are available are as follows: • Vertical access (Types BS, 2Pzs, 3Pzs)
Drive is provided by a 1.2 kW asynchronous traction motor. The motor unit is driven by the truck controller, which incorporates the transistor speed controller.
• Side access on rollers (Types 2PzS and 3PzS). This system allows the battery to be changed quickly.
This controller offers excellent performance and enables optimum control of speed, acceleration and counter-current braking.
• counter-current, upon accelerator release
The power supply to the traction motor is controlled by an electronic controller with microprocessor, which provides complete control of speed, acceleration and braking.
• counter-current, controlled by rear safety inverter switch
• counter-current, by switching the direction of travel
• electromagnetic safety, controlled by the emergency stop handle • electromagnetic safety, controlled by the upper or lower position of the tiller
A long, robust, ergonomic tiller allows the operator to direct the drive/steering wheel effortlessly. The various controls: forward travel, reverse travel, lifting and lowering of the load arms, and the horn are grouped together at the end of the tiller. For safety reasons a gas spring automatically returns the tiller to the upper position when it is released. The speed of the truck is limited to 6 km/h in both directions of travel (key in the Hare position). The speed of the truck is limited to 4 km/h in both directions of travel (key in the Tortoise position).
• electromagnetic parking, applied when supply is cut.
The 5-point chassis has 2 suspended stabilisers which compensate for ground irregularities.
Capacity: • EXU 16: 1600 kg • EXU 18: 1800 kg • EXU 20: 2000 kg • EXU 22: 2200 kg • EXU 20 S* : 2000 kg • EXU 22 S* : 2200 kg * S : Folding platform.
1152 807 80 01 [EN]
7
The cylinder activates the lift shaft, which transmits the movement to the push rods.
• a battery disconnection handle (emergency stop) located in the driver’s compartment
These activate the wheel clevises, resulting in the load arms lifting.
• an hour meter/discharge indicator.
All the joint pins are treated f o r anti-wear and anti-corrosion properties. The joint rings are self-lubricating. Pump motor power:
• an ignition key with 3 positions (stop/Tortoise/Hare) • a tiller with the following controls: forward/reverse travel, accelerator, lifting/lowering of the load arms, horn and safety inverter • OptiSpeed (EXU16, EXU18, EXU20, EXU22) : : variable speed according to tiller position.
• EXU 16 and EXU 18: 1 kW • EXU 20: 1.2 kW • EXU 22: 1.4 kW • EXU 16-18-20 CS* : 1.2 kW • EXU 22 CS*: 1.4 kW
• backrest
* CS : Cold store (option)
• digicode (LFM Go) • cold-store version • Fleet Manager
The standard equipment in the driver’s compartment comprises:
• on-board charger • accessory holder
• an office compartment for storing rolls of film and adhesive, gloves, pens etc. • a clip for attaching documents together
This machine was designed for the transport and storage on racks (pallet stackers only) of loads packed on pallets or in industrial containers designed for this purpose. The dimensions and capacity of the pallet or container must be adapted to the load being transported and must ensure stability. The table of characteristics and performance attached to this user manual gives you the information you need to check that the equipment is suitable for the work being carried out. Any specific usage must be authorised by the site manager; an analysis of the potential risks associated with this usage will enable him to put in place any necessary additional safety measures.
8
1152 807 80 01 [EN]
Any danger caused as a result of unauthorised use becomes the responsibility of the operator or driver and not that of the manufacturer. Use for purposes other than those described in these operating instructions is prohibited. Transporting people is prohibited.
The truck can be used outdoors and in buildings. The truck must not be used outdoors in bad weather. Operation on public roads is permitted only if the special equipment specified in the Road Traffic Licensing Regulations is installed. The regulations applicable in different countries for driving on public roads must be observed. The sites on which the truck is used must comply with the applicable regulations (condition of the ground, lighting etc.). The ground must have sufficient load capacity (concrete, asphalt).
The forklift truck should not be used in areas where there is a risk of fire, explosion or corrosion, or in areas that are particularly dusty. Stacking or unstacking is not permissible on inclined surfaces or ramps.
The truck is suitable for indoor and outdoor use (temperatures ranging fr o m -20°C to +40°C). If your truck is to be used in a refrigerated storage area, it must be configured accordingly; an approval may be necessary for this environment (see chapter entitled "Description"). The operator (see chapter entitled "Definition of responsible persons") must ensure that appropriate fire protection is available in the vicinity of the truck during operation. Depending on the application,additional fire protection must be provided on the industrial truck. If in doubt, please contact the relevant authorities.
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9
Despite all operational precautions and compliance with standards and rules, the possibility of additional risks when using the truck cannot be entirely excluded.
• Falling, tripping etc. when moving on the industrial truck, especially in the wet, with leaking consumables or icy surfaces.
The truck and all its components comply with the regulations relating to current applicable safety rules.
• Loss of stability due to the load being unstable or the load slipping etc. • Risk of fire and explosion due to batteries and electrical voltages. • Human error - Disregarding safety regulations.
Persons in the vicinity of the truck must be particularly cautious and react immediately in the event of any malfunction, incident, breakdown etc.
It is important to adjust the speed of the truck depending on the load and ground conditions.
Personnel in contact with the truck must be informed of the risks related to using the truck. These operating instructions draw your attention to the safety rules.
The risks are: • Escape of consumables due to leaks, ruptured lines and tanks etc.
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 incorrect operation that jeopardise the stability cannot be ruled out in extreme situations.
• Risk of accident when driving over difficult ground such as slopes, soft or irregular surfaces or in poor visibility etc.
The manufacturer’s approval is required as soon as: • The truck is used differently from its normal use • The driver is not sure if he can use the truck correctly and without risk of accident
10
1152 807 80 01 [EN]
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11
This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete.
Observe the national re gulations for your country!
Truck equipment does Test not comply with local regulations
O
Lack of skills and qualification of driver
Driver training (sit-on and stand-on)
O
Usage by unauthorised persons
Access with key only for authorised persons
O
Truck not in a safe condition
Recurrent testing and rectification of defects
O
BetrSichVO (Workplace Safety Ordinance)
Risk of falling when using working platforms
Compliance with national regulations (different national laws)
O
Impaired visibility due to load
Resource planning
O
BetrSichVO (Workplace Safety Ordinance) and employer’s liability insurance associations BetrSichVO (Workplace Safety Ordinance)
Contamination of respiratory air
Assessment of diesel exhaust gases
O
TRGS 554 and BetrSichVO (Workplace Safety Ordinance)
Assessment of LPG exhaust gases
O
MAK (Maximum Workplace Concentrations) list and BetrSichVO (Workplace Safety Ordinance)
12
1152 807 80 01 [EN]
If in doubt, consult competent factory inspectorate or employers’ liability insurance association BGG 925 VDI 3313 driver permit
Impermissible usage (improper usage)
Issuing of operating instructions
O
BetrSichVO (Workplace Safety Ordinance) and ArbSchG (Health and Safety at Work Act)
Written notice of instruction to driver
O
BetrSichVO (Workplace Safety Ordinance) and ArbSchG (Health and Safety at Work Act)
Observe BetrSichVO (Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules
O
a) Diesel
Observe BetrSichVO (Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules
O
b) LPG
Observe BGV D34, operating instructions and VDMA rules Observe BetrSichVO (Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules
O
O
VDE 0510: In particular - Ensure ventilation - Insulation value within permissible range
Observe BetrSichVO (Workplace Safety Ordinance), BGR 104 and operating instructions Observe BetrSichVO (Workplace Safety Ordinance), BGR 104 and operating instructions
O
BetrSichVO (Workplace Safety Ordinance) and BGR 104
O
BetrSichVO (Workplace Safety Ordinance) and BGR 104
When fuelling
When charging the traction battery
When using battery chargers
When parking LPG trucks
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13
With driverless transport systems Roadway quality inadequate
Clean/clear driveways
Load carrier incorrect/slipped
Reattach load to pallet
Drive behaviour unpredictable
O
BetrSichVO (Workplace Safety Ordinance)
O
BetrSichVO (Workplace Safety Ordinance)
Employee training
O
BetrSichVO (Workplace Safety Ordinance)
Driveways blocked
Mark driveways Keep driveways clear
O
BetrSichVO (Workplace Safety Ordinance)
Driveways intersect
Announce right-ofway rule
O
BetrSichVO (Workplace Safety Ordinance)
No person detection during depositing and retrieval
Employee training
O
BetrSichVO (Workplace Safety Ordinance)
.
The operating company must identify and evaluate the dangers involved in using the truck. It must also establish which occupational health and safety measures are required to protect employees. Appropriate operating instructions must be drafted and provided for the driver accordingly. A person responsible for health and safety must be appointed. Construction and equipment of the truck correspond to the Machinery Directive 2006/42/EC and they are therefore identified with the CE symbol. As a result, these factors are not included in the hazard assessment; nor are the attachments, which have their own CE labelling. The operating company must, however, select the type and equipment of the truck so as to comply with the local provisions for deployment.
14
The results must be published. In the case of truck deployment involving similar hazard situations it is permitted to summarise the results. This overview (see chapter entitled "Overview of hazards and countermeasures") is intended to facilitate compliance with the conditions of these regulations. The overview indicates the main causes of accidents in the event of non-compliance. If other major operational hazards are involved, they must also be taken into consideration. The working conditions for the trucks are largely similar for many sites. The dangers can therefore be summarised in a single overview. It is recommended that the information provided by the relevant employers’ liability insurance association be observed in this respect.
1152 807 80 01 [EN]
The operating company is the natural or legal person or group who operates the truck or on whose authority the truck is used.
The operating company must ensure that all users read and understand the safety information in these instructions.
The operating company must ensure that the truck is only used for its intended purpose and in compliance with the safety guidelines set out in these operating instructions.
The operating company is responsible for the scheduling and correct performance of regular safety checks.
A specialist is deemed to be: • A person whose experience and technical training has allowed him to develop relevant knowledge of industrial trucks • A person who is also familiar with national health and safety regulations and generally recognised technical directives and
This truck may only be driven by suitable persons 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.
It is recommended that these checks comply with national performance specifications.
conventions (standards, VDE regulations, technical regulations of other European Union member states or countries that are signatories to the treaty that established the European Economic Area). This expertise allows him to assess the condition of industrial trucks in terms of health and safety
The driver must be familiar with the operating instructions and have access to them at all times. The driver must: • Have read and understood the operating instructions • Have familiarised himself with safe operation of the truck
The driver must be duly informed of his rights and duties.
• Be physically and mentally able to drive the truck safely
The driver must be granted the required rights. The driver must wear protective equipment (protection suit, safety helmet, industrial goggles and protective gloves) that is appropriate for the conditions, the task and the load to be lifted. The driver must also wear safety footwear to be able to drive and brake in complete safety.
16
Individuals under the influence of the above-mentioned substances are not permitted to perform work of any kindon or with the truck.
1152 807 80 01 [EN]
The driver is responsible for the truck during working hours. He must not allow unauthorised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use.
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17
The company premises are very often restricted public traffic areas.
It is advisable to review the operational liability insurance so that insurance covers the truck with respect to third parties in the event of damage caused in restricted public traffic areas.
If your truck is to be used in specific conditions (e.g. refrigerated warehouse or flameproof protection), it must be specially equipped and approved for this purpose, if applicable. If your truck is used for work that is not specified in the guidelines or in these instructions, and it must be modified or refitted for this purpose, it is important to remember that any structural modification could affect truck handling while driving as well as the stability of the truck, and could lead to accidents. You should therefore contact the manufacturer before carrying out any modification. Permission from the manufacturer is required for any modification that may affect the truck’s stability. Any constructional modification or transformation of your truck is forbidden without prior written permission from the manufacturer. Authorisation from the relevant authority may also be required.
Original parts, attachments and accessories are specially designed for this truck. We draw your attention to the fact that parts,
18
In this specific case, you may plan a modification or alteration to your truck provided that: • The modification or alteration is designed, tested and implemented by one or more engineers who are experts in the field of industrial trucks and their safety • A record is kept of the design, the different tests and the implementation of the modification or alteration • Appropriate changes are approved and made to the capacity plate, decals, labels and operating instructions • a permanent and clearly visible label is attached to the truck indicating the nature of the modification or alteration as well as the date of the modification or alteration, and the name and address of the company that carried out the work.
attachment parts and accessories supplied by other companies have not been tested or approved by STILL.
1152 807 80 01 [EN]
The installation or use of such products may have a negative impact on the design of the truck and thus impair active or passive driving safety. We recommend that you obtain approval from the manufacturer and, if applicable, 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 non-original accessories.
Any damage or faults observed on the truck or the accessories must be reported immediately to the responsible personnel. The truck and accessories must never be used before they are correctly reconditioned as they cannot be guaranteed to be safe for operating or driving.
The safety mechanisms and switches must never be removed or disabled. The predefined setpoint values must not be modified. Work on the electric installation (e.g. connecting a radio, additional lights or other accessories) is permitted only with the approval of the manufacturer.
The operation of medical devices, for example pacemakers or hearing aids, can be impaired. Check with your doctor or manufacturer if the medical devices are sufficiently protected against electromagnetic interference.
1152 807 80 01 [EN]
19
If you have a truck equipped with a lithiumion battery, special safety rules should be followed. A lithium-ion label will be displayed in the truck.
– The forklift operator must drive the truck carefully to avoid any risk of piercing or damaging the lithium-ion batteries.
It is necessary to respect the following guidelines: – Please take note of the infor mation on the lithium-ion supplement supplied with these operating instructions. – Only persons who have been trained to work with lithium-ion technology are permitted to work on the batteries (for example After-Sales Service Centre technicians). – Do not place lithium-ion batteries on or near flames or hot heat sources (> 70°C). This may cause the batteries to overheat or burst into flames. This type of use also impairs the performance of the batteries and reduces their service life. – Improper use may cause overheating or serious injury. Respect the following safety rules: • Never short circuit the battery terminals • Do not reverse the battery polarity
In the event of an accident (shock, fall, collision), the battery may be damaged, pierced or deformed. Set up a safety perimeter of five metres around the battery. Contact the emergency services and tell them that there is a lithium-ion battery fire. Contact the after-sales service department.
– Store strapped batteries on pallets. Do not store them too high to reduce any risk of falling. Do not store on the ground to reduce the risk of humidity and impacts. We recommend that batteries are stored at a height between 60 and 120 cm. – In the event of an unusual smell, change of shape or any other anomaly during operation, disconnect the battery immediately (using either the emergency stop socket or the charger socket). Contact the after-sales service department. If necessary, also contact the emergency services and tell them that there is a lithium-ion battery fire.
• Do not open the battery • Do not submit the battery to excessive mechanical constraints • Do not expose the battery unit to humidity or water (> 95%)
Have class D fire extinguishers or inert gas, carbon dioxide, powder or foam fire extinguishers near the zone in which the lithium-ion batteries are used.
• Install the batteries in a Level 2 pollution zone in accordance with standard EN 60664-1 – Batteries must be installed in a room that can be easily ventilated in the event of incorrect use.
20
Do not open the battery. Electrical risk. Only the After-Sales Service Centre technicians can open the battery.
1152 807 80 01 [EN]
The operating company (see chapter entitled "Definition of responsible persons") must ensure that the truck is checked by a specialist at least once a year or after noteworthy incidents. As part of this inspection: • A full check of the technical condition of the truck in terms of accident safety must be performed
STILL GmbH Hamburg Regelmäßige Prüfung (FEM 4.004) nach nationalen Vorschriften basierend auf den EG-Richtlinien: 95/63/EG, 99/92/EG, 2001/45/EG
Nächste Prüfung
• The truck must be thoroughly checked to detect any damage that may have been caused by improper use
9 1 0 1 9 3 4 4 3 6 5
• 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 by an adhesive 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.
Die Prüfplakette ersetzt nicht das Prüfprotokoll
Mitglied der: Fédération Européene de la Manutention 0000_003-001_V3
The operator is responsible for ensuring that any defects are remedied immediately. – Contact your service centre.
Observe the regulations in force in your country.
1152 807 80 01 [EN]
21
The truck’s electrical insulation must have sufficient insulation resistance. Insulation resistance must be tested in accordance with EN 1175–1 and ISO 20898 at least once a year.
between the parts under voltage and the truck chassis. Contact the After-Sales Service.
The truck’s electrical sy stem and drive batte- ries must be checked separ ately.
• Test voltage > battery nominal voltage • The test voltage must not exceed 100 V or triple the value of the nominal voltage – Check that there is no voltage before testing the circuit.
• Test voltage > battery nominal voltage • The test voltage must not exceed 100 V or triple the value of the nominal voltage
– Measure insulation resistance using a suitable meter.
– Measure insulation resistance using a suitable meter.
The insulation resistance is sufficient when it has a resistance of at least 1000 Ohms multiplied by the nominal voltage of the truck circuit, between the parts under voltage and the truck chassis.
The insulation resistance is sufficient when it has a resistance of at least 50 Ohms multiplied by the nominal voltage of the truck circuit,
Contact the After-Sales Service.
22
1152 807 80 01 [EN]
Consumables can be dangerous. It is necessary to follow the safety regulations when handling these substances.
– Follow the statutory regulations – Do not allow oils to come into contact with hot motor parts. – No smoking, fires or flames!
Refer to the maintenance data table for the permissible substances necessary for operation.
There is a risk of slipping on spilled oil, particularly when combined with water! – Collect spilled oil immediately using an oilbinding agent and dispose of it in accordance with regulations.
Oils are water pollutants! – Avoid contact and consumption
Always store oil in containers that comply with the applicable regulations.
– In case of inhalation of steam or fumes, breathe fresh air immediately.
Avoid spilling oils.
– After contact with the eyes, rinse thoroughly with water (for at least 10 minutes) and then consult an eye specialist. – If swallowed, do not induce vomiting. Seek immediate medical attention.
Collect spilt oil immediately using an oil binding agent and dispose of it in accordance with regulations. Dispose of old oils according to the applicable regulations.
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.
1152 807 80 01 [EN]
23
During operation of the forklift truck, hydraulic fluids are pressurised and are hazardous to your health.
Hydraulic fluid is a water-polluting substance! Always store hydraulic fluid in containers complying with the regulations.
– Do not spill these fluids! – Follow the statutory regulations – Do not allow the fluids to come into contact with hot motor parts. – Do not allow to come into contact with the skin. – Avoid inhaling the spray – Penetration of pressurised fluids into the skin is particularly dangerous if these fluids escape at high pressure due to leaks in the hydraulic system. In case of such injury, seek medical advice immediately.
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.
– To avoid injury, use appropriate personal protective equipment (e.g. protective gloves, industrial goggles, skin protection and skin care products).
Battery acid contains dissolved sulphuric acid. This is toxic.
Battery acid contains dissolved sulphuric acid. This is corrosive.
– Avoid contact and consumption.
– When working with battery acid, always wear protective clothing and eye protection.
– In case of injury, seek medical advice immediately.
– Do not allow any acid to get onto the clothing or skin or into the eyes; if this does happen, rinse immediately with plenty of clean water. – In case of injury, seek medical advice immediately. – Immediately rinse away spilt battery acid with plenty of water. – Follow the statutory regulations
24
1152 807 80 01 [EN]
– Dispose of used battery acid in line with the applicable regulations.
Materials that have to be disposed of following maintenance, repair and cleaning must be systematically collected and disposed of 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 damage or faults observed on the truck or the accessories must be reported immediately to the responsible personnel. The truck and accessories must never be used before they are correctly reconditioned as they cannot be guaranteed to be safe for operating or driving.
• 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 applicable. • Any spillage of battery acid must be neutralised immediately.
Work on the electric installation (e.g. connecting a radio, additional lights or other accessories) is permitted only with the approval of the manufacturer.
The safety mechanisms and switches must never be removed or disabled. The predefined setpoint values must not be modified.
1152 807 80 01 [EN]
25
26
1152 807 80 01 [EN]
1 2 3 4 5 6 7 8
Battery plug handle (emergency stop) Battery c over Switch key Traction control module Fork arms Load wheels Stabiliser wheels Drive wheel
9 10 11 12 13 14 15
Traction motor Pump unit Electromagnetic brake Lift cylinder Digicode (LFM Go)* Tiller Platform*
*Option
28
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1 2 3
Handle Lowering Raising
4 5 6
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Horn Throttle Anti-collision device
29
1
Battery charge level represented by 10 bars
2 Service alarm (red)
3 Red indicator light
30
Full charge: 100% Low charge: 10% Discharged : 0%
Flashing: less than 50 hours truck operation until the next service Constant: service date overdue Switched on: default or alarm
1152 807 80 01 [EN]
91% - 100%: 10 bars 1% - 10%: 1 bar 0%: 1 flashing bar (lift function not permitted). NB: To protect the battery, 0% corresponds to max. 80% discharge.
4
Switched off: truck switched off Switched on: truck switched on
Green indicator light
5
Breakdown code
6
Fault or brake wear (air gap)
These codes help the After Sales Service to decide on the appropriate response from the service engineer
E3 294
Do not operate the truck - The meter runs from when the truck is switched on and a control is used. - When counting, the dot next to the tenths of an hour flashes. -The hourmeter displays hours and tenths of an hour. - When the power supply is disconnected, the hours are stored in the memory.
7
Hourmeter
Indicates the number of operating hours of the machine
8
STOP alarm (red)
Misc. problems
Do not operate the truck
Constant: control module overheating
-> Truck is stopped In general, wait a few minutes and then continue.
9 T° alarm (red) .
1152 807 80 01 [EN]
31
1 2 3
Switch ON (operating mode) Switch OFF and awaiting code Programming mode active
Key in
Operation
* 0 0 0 0 0 #
ON
4 5
LED status
or * 1
2 3 4 5 # (by default)
# (3
OFF
seconds)
* 0 0 0 0 0 0 0 0 # (by
New operator code Allocating operator codes Deleting operator codes Modifying administrator codes
Key fault or incorrect code Time delayof automatic switch-off
default)
* 0 * 4 5 6 7 8 #
red off continuous green (1)(correct PIN) red flashing green off (4)(incorrect PIN) red off green flashing (2)
0 0 0 0 0
or 1 2 3 4 5 PIN code by default Truck power off
Once the diodes have gone out, the electronic continuous red key automatically continuous green (3) reverts to "operating mode" red off green flashing Example of new (2) (code accepted) operator code: 45678
* 2 * 5 4 3 2 1 #
red off green flashing *2*: operator reference (2) (code accepted) 10 options from 0 to 9
* 2 * #
red off green flashing *2*: operator reference (2) (deletion accepted) (between 0 and 9)
* * 9 * 1 2 3 4 5 6 7 8 #
red off green flashing (2) (code accepted) To reactivate the default administrator code (00000000), please contact your agent or nearest dealer.
Restoring the initial administrator code
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Notes
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Activating the automatic switch-off
* * 2 * 1 #
Setting the time delay of the automatic switch-off
* * 3 * 6 0 #
Deactivating the automatic switch-off
* * 2 * 0 #
red flashing green flashing (5) (5 s before switch-off)
Power switches off automatically after 10 mins (600 s by default) if the truck is not being used.
Example: automatically switches off after 1 min. red off green flashing (60s) when not used. (2) (value accepted) Minimum setting = 10 s / maximum = 3000 s red off green flashing (2) (command accepted)
.
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1 2 3 4 5 6 7 8
34
Manufacturer’s symbol EXU 16 model label EXU 18 model label EXU 20 model label EXU 22 model labe Identification label Slinging label Warranty label (for Germany only) on the inside of the truck
9 10 11
12
Cold storage area label ELECTRICAL HAZARD label (option) DANGER INSTRUCTIONS label (option): see chapter 4 "Adjusting the on-board charger" Label PIEK (option) on the outside of the truck
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Indicate the serial number for all technical enquiries.
1 2 3 4 5 6 7 8 9 10 11 12
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Model Manufacturer Serial number Year o f manufacture Unladen weight (without battery) in kg Battery maximum weight Battery minimum weight Additional weight (ballast) in kg Nominal motor power (kW) Battery voltage V Rated capacity in kg symbol EC conformity
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The FleetManager option allows you to control access to the truck. The option is a fleet management system. You can access the system: • Either by using a keypad
The fleet manager sets the access details via the web interface. This affects the transponder cards or PIN codes for the corresponding trucks. It is possible to change the amount of time for which the access authorisation is valid.
• Or by using a reading device f or a transponder or an RFID card
36
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1
Standard label for a truck equipped with a lithium-ion battery
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37
38
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This machine was designed for the transport and storage on racks (pallet stackers only) of loads packed on pallets or in industrial containers designed for this purpose. The dimensions and capacity of the pallet or container must be adapted to the load being transported and must ensure stability. The table of characteristics and performance attached to this user manual gives you the information you need to check that the equipment is suitable for the work being carried out. Any specific usage must be authorised by the site manager; an analysis of the potential risks associated with this usage will enable him to put in place any necessary additional safety measures.
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Damage or other defects on the forklift truck or attachments (special equipment) can result in accidents. If damage or other defects are noticed on the truck or attachments (special equipment) during the following inspections, do not use the truck until it has been properly repaired. Do not remove or disable the safety systems and switches. Do not change the pre-set values.
– Attachments (special equipment) must be properly secured and function according to their operating instructions. – Damaged or missing stickers must be replaced in compliance with the marking position table. – The roller guide rails must be coated in a visible layer of grease. – The wheels must show no signs of defects or heavy wear. The mounting must be correct.
Risk of falling! When working on high-level parts of the truck, do not use truck components for access or to stand on. – Use suitable access equipment.
– Check that there are no f o reign objects that could hinder the operation of the wheels and rollers. – The warning devices (horn etc.) must work.
Ensure that the truck is in good working condition prior to start-up.
– The battery cover must be closed.
To do this, carry out the following checks:
– Check that the covers are correctly positioned.
– Fork arms or other load-carrying equipment should not show any signs of noticeable damage (for example: bending, cracks, significant wear). – Check that there are no signs of leaking consumables under the truck. – Do not restrict the field of vision. Ensure the visible area specified by the manufacturer is observed.
– The operator must be qualified to drive the truck. The operator must be able to reach the controls and operate them (especially the anti-crush device). Do not obstruct access to the controls. Please inform your supervisor if you notice any defects.
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41
– Open the cover. – Leave it open. – Remove the battery disconnection handle (1) from the truck plug (2). – Connect the wall-mounted charger.
42
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– Connect the battery plug , if necessary – Keep the tiller in the vertical position. – Put the throttle in neutral (centre position). – Insert the ignition key (1) and turn it to the desired position or enter the 5-figure code then validate using the # key on the digicode keyboard (default code = 00000).
With the digicode optio n, when the key is turned to the 0 position the truck is in tortoise mode. The truck will sti ll function if the key is removed.
The ignition key may be turned to two different positions to choose the driving mode.
"Tortoise" position (2) : gentle acceleration and deceleration; max. speed: 4 km/h "Hare" position (3) : strong acceleration and deceleration; max. speed: 6 km/h – Check the battery charge with the combined indicator (4) and change or charge the battery if necessary. – Turn the ignition key (1) to the "hare" position (3) for normal driving mode.
Perform a visual check on the truck before starting.
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The truck moves in reverse when the anticrush button (2) is pressed. If the truck is being operated in narrow areas (such as in a lift for example), the operator may get stuck against the wall if care is not taken. Without an anti-crush safety device, the tiller could injure the operator. The truck automatically shifts into reverse when the anti-crush device on the tiller head comes into contact with the driver’s body. When the operator moves away from the anti-crush device, the vehicle stops even if forward travel is selected again. Normal operation may be resumed after releasing the drive direction switches.
Ensure that the test zone is free of people and objects, both in front of and behind the truck.
– Operate the drive direction selector (1) or (3) in forward travel. The truck moves forward. – Activate the anti-crush safety device (2).
The truck stops and shifts into fast reverse.
– Release the anti-crush safety device. The truck stops.
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Perform this check on a flat surface.
– While driving, tilt the tiller in areas (1) et (3), to test brake response. In these two areas, the truck is braked and the drive unit is no longer powered. Releasing the tiller in the drive area (2) sends the tiller into the (3) area and cuts traction.
– Pull the emergency stop handle (4) upwards. – The power supply to the machine is cut off. – The electrical controls and motors are disabled. – The electromagnetic brake is applied. – Reconnect the emergency stop handle (4) to restore the circuits.
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45
– Press the horn button (5) located on the upper part of the tiller. – The horn sounds.
46
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The Fleet Manager fleet management system allows access control and transmission of truck data.
This sensor allows you to record the shocks received by the truck.
The web interface allows data to be parameterised. The fleet manager parameterises the truck based on his chosen options.
If the truck receives a shock, it is possible to configure a speed reduction.
Software is also available.
The fleet manager is the only person who is able to change certain parameters.
Additional options: • Shock sensor • Tools for wireless data management: ▶ GSM
(2)
GPRS
(1)
Replace the sensor if it is faulty.
module with antenna
The options available on the truck are: • Access control and shock sensor
The module consists of a GSM modem and an antenna.
• Access control and GPRS module
The module allows you to:
• Access control, shock sensor and GPRS module
• Access truck information remotely
• Access control
(1) (2)
GPRS: General Packet Radio Service
GSM: Global System for Mobile Communication
• Use geolocation The data is stored on a server. Data is transmitted by Bluetooth (default) or by GSM module (optional).
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47
– Turn the switch key to start the truck. – Enter the PIN code on the keypad. The PIN code consists of five to eight digits. By default, no PIN code is given a s a factory setting. If the PIN code is correct, the LED (1) is not lit. The LED (2) flashes slowly at two-second intervals (green colour). No acoustic signal sounds. – Press the Enter key (3) to confirm. The truck is now ready for use.
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.
– Turn the switch key to start the truck. – Place the RFID transponder card or the RFID transponder (4) in front of the reading device (3). If the card is correct, the LED (1) is not lit. The LED (2) flashes slowly at two-second intervals (green colour). Two acoustic signals sound. The truck is now ready for use.
48
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The LEDs can have different statuses and different colours. Below is the list of the most common messages and their meanings.
no valid access authorisation
Lit continuously Red colour
Lit continuously Red colour
A long acoustic signal sounds
Off
Flashes once Green colour
Flashes quickly Yellow colour
Lit continuously Green colour
Flashes quickly Red colour
Flashes quickly Red colour
A long acoustic signal sounds
A long acoustic signal sounds upon activation
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: no valid access authorisation for the PIN code entered
Generate a valid access authorisation using the interface
: PIN code entered incorrect 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
The date of the truck is incorrect Memory is 80% full There are several possible causes: - Reading device or keypad not accessible - GPRS module not accessible - Built-in rechargeable battery flat - Memory full
Update the date of the truck Clear the memory
Contact the After-Sales Service Centre
49
Flashes quickly Red colour
Lit continuously Green colour
Flashes quickly Blue colour
Off
A shock has occurred
Reset the shock
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.
.
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Operators must not log off intentionally while driving.
Access to the truck must be disabled. Unauthorised users are not allowed to use thetruck.
– 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 the switch key to the off position to switch the truck off completely.
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– Park the truck in a safe place. – Briefly place the RFID card or the RFID transponder (4) in frontof 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.
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Electrical risk Regularly check the condition of the contacts of the connectors. Each ½ connector has a polarising pin. Ensure the polarising pin is present and in good condition. They prevent the risk of reverse polarity.
– Secure the truck. – Turn off the ignition and remove the key. There are two different ways to disconnect the battery. It is up to the operator to choose which one to use. – Pull the emergency stop handle (1) upwards to disconnect it. The emergency stop handle (1) is located at the front of the truck. – Alternatively, open the cover of the battery compartment. Next, disconnect the battery connector (2). It is not necessary to turn off the lithium-ion battery once the battery has been disconnected.
Check if the operator has disconnected the battery connector (2) or the emergency stop handle (1). – Press the emergency stop handle (1) into the fixed socket on the truck. – Alternatively, reconnect the battery connector (2).
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Do not connect any additional electrical devices on the truck. Contact the After-Sales Service if you want to add additional devices.
To commission a truck equipped with a vertical access lithium-ion battery, proceed as follows: – Open the cover of the battery compartment
– Connect the truck battery connector (2) – Turn on the battery To this end, check that the green indicator light (1) is on If the green indicator light is on, the battery is functioning. If the green indicator light is off, the battery is not turned on. Press the button for . Wait until the button lights up. The indicator light will then turn bright green. – Close the battery compartment cover. – Turn the truck off by turning the key or by typing in the PIN on the digicode. The truck is ready for operation.
– Turn the key or press and hold the # button on the digicode.
It is not necessary to turn off the battery. If the truck is not used for a certain period of time, the battery is automatically turned off. This period of time is normally 24 hours. It can be configured. Contact the After-Sales Service to configure this. If you want to turn it off, simply press on the button for . Wait for the button to turn off.
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Electrical risk. Regularly check the condition of the contacts of the connectors. Each ½ connector has a polarising pin. Ensure the polarising pins are present and in good condition. They prevent any risk of reverse polarity.
– Immobilise the machine. – Switch off the ignition and remove the key. – Pull the emergency stop handle (2) upwards to disconnect it. The emergency stop handle (2) is located at the front of the truck. It is not necessary to switch off the lithium-ion battery once the battery connector has been disconnected.
– Press the emergency stop handle (2) into the fixed socket on the truck.
Do not connect any additional electrical devices to the truck. Contact the After-Sales Service if you want to add additional devices.
To commission a truck equipped with a side access lithium-ion battery, proceed as follows: – Connect the truck battery connector (2).
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– Open the cover of the battery compartment. – Switch on the battery. To this end, check that the green indicator light (1) is on. If the green indicator light is on, the battery is functioning. If the green indicator light is off, the battery is not switched on. Press the button for . Wait until the button lights up. The indicator light will then turn bright green. – Close the battery compartment cover. – Switch on the truck by turning the key or by entering the PIN on the electronic key. The truck is ready for operation.
– Turn the key or press and hold the # button on the electronic key.
It is not necessary to switch off the battery. If the truck isnot used for a certain period of time, the battery is automatically switched off. This period of time is normally 24 hours. It can be configured. Contact the After-Sales Service to configure this. To switch off the battery, simply press on the button for . Wait for the button to turn off.
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An EXU truck equipped with a lithium-ion battery has a specific display (1). It is recognisable by its white screen. The other functions are identical to the standard display. They are described in chapter 3: .
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The operator must obey the same rules within the plant as he would on the road . He must drive at a speed appropriate for the driving conditions . For example, an operator should drive slowly around corners, when entering and passing through narrow passageways, when driving through swing doors, at blind spots, or on uneven surfaces . The operator must always maintain a safe braking distance from vehicles and persons in front of him and must always have the truck under control. He should avoid sudden stops, making fast U-turns, overtaking other vehicles in potentially dangerous areas or areas with poor visibility. Driving the truck while seated is prohibited.
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All EXU 16/18/20/22 models are designed to be operated in pedestrian mode, therefore : • Never sit on the truck to drive it. • The truck must notbe used as a stepladder. • The truck was not designed to transport people and must not be used for this purpose. • The operator must always stay within the truck clearance. • Stay in the safety area (wor king area defined by the manufactur er). Use of a telephone or radio in the truck is permitted , but avoid using these devices when driving as they may distract you. Take a test drive on an open surface .
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– Turn the ignition key to the Tortoise position (slow acceleration and deceleration) or the Hare position (faster acceleration and deceleration). – Lower the tiller in (2) zone.
The truck is in the drive position in the (2) position. In the lower (1) or upper (3) the brake is applied and the traction motor is switched off.
Always operate the travel throttle slowly, as the truck reacts immediately. Abrupt starts or braking or reversal of direction of travel must be avoided at all costs.
– Press with your thumb on the lower part of the throttle. – The speed increases with the movement of the throttle; speed is limited to 4 or 6 km/h depending on the position of the key. – When the control throttle is released, the truck brakes electrically.
– Press with your thumb on the upper part of the throttle. – The speed increases with the movement of the throttle; speed is limited to 4 or 6 km/h depending on the position of the key. – When the control throttle is released, the truck brakes electrically.
– Release the throttle. – Operate it progressively in the opposite direction until the required speed is reached.
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1
There are two positions for the folding platform (1): • Position A: platform raised
2
A 3
• Position B: platform lowered In pedestrian mode, the platform is raised. The maximum authorised speed is 6 km/h.
B 2276
In ride-on mode, the platform is lowered. The maximum authorised speed is 6 km/h.
To use the truck in ride-on mode, proceed as follows: – Lower the platform (1) in the direction indicated by the arrow (3) Once the job is complete, it is necessary to raise the platform. – Raise the platform (1) in the direction indicated by the arrow (2)
The platform (1) is raised. The operator walks alongside the truck.
Ensure that the platform is raised correctly before walking alongside the truck. Ensure that the platform is correctly in the vertical position.
In pedestrian mode, stay sufficiently far away from the truck. The truck must not be able to strike the operator’s feet. Wear safety shoes.
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– Lower the tiller.
The truck is only in a driving position in areas (2) & (3). In the lower (4) or upper (1) zone, the brake is applied and the traction motor is switched off.
In zone (3) the truck can be used at full speed. The traction speed is proportional to the throttle activation. In zone (2) the maximum authorised speed varies according to the angle of the tiller.
A B C D
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Braking range Unlimited driving range Driving range speed limiter Maximum speed charasteristic
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The quality of the floor surface affects the braking distance of the truck. To be taken into consideration when driving.
– During operation, release throttle (2) or (3).
– Switch throttle (2) or (3) in the opposite direction of travel.
– Release the drive direction switch (2) or (3). The truck is braked with the electromagnetic brake when its speed approaches 0 km/h or when the tiller returns to the vertical position.
The truck can be put in energy-saving mode to prolong the service life of the battery when it is not in use. After a certain period of inactivity, the truck switches off. To restart the truck, you must switch it off and then switch it on again, using the key. This time period can be configured between 0 and 10 minutes. This function is disabled by default. 62
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Timeout can be adjusted. Please call the After-Sales Service Centre.
– Activate the control switch (1)
– Activate the control switch (2)
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Closely follow the following instructions before picking up loads. Never touch or stand on moving parts of the truck (e.g. lifting device, pushing devices, work installations or devices for picking up loads).
Take care not to trap hands or feet when operating the truck.
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Safety footwear must be worn.
Transporting people is strictly prohibited.
Be careful not to touch adjacent loads or loads positioned at the side or in front of the load being handled. The loads are to be stacked so that they are aligned with a small space between each of them and so that they do not catch each other.
Ensure that the load weight does not exceed the truck’s capacity. – Refer to the nominal capacity specified on the truck’s capacity rating plate. – You must also make sure that the load is stable, well-balanced and centred between the load arms in order to avoid dropping any part of the load. – Check that the width of the load is compatible with the width of the load arms.
– Approach the load carefully. – Lower the load arms so that they can easily be inserted into the pallet. – Insert the load arms under the load. – If the load is shorter than the load arms, position it so that the end of the load overhangs the end of the load arms by a few centimetres, in order to avoid hooking the load in front. – Raise the load a few centimetres. – Withdraw the load slowly and in a straight line.
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– Always drive forwards for optimum visibility. – When carrying a load on a slope, always climb and descend with the load uphill. Never travel across the slope or make a U-turn. – Reverse travel must only be used for depositing a load. Since visibility in this direction is restricted, you should only travel at very low speed. – To facilitate movement over obstacles, increase the ground clearance.
– Carefully move the truck to the desired area. – Carefully move the load into the deposit area. – Lower the load until the load arms are free. – Withdraw the truck in a straight line. – Raise the load arms again several centimetres.
Be careful to keep clear of other loads at the side of or behind the truck.
Personnel must not stand under or near the truck when the load is in the raised position.
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As a general rule, loading units must be transported one by one (e.g. pallets). Transporting several loading units at a time is o nly authorised: • 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. 0252_003-103
0252_003-104
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Slope Slopes s shoul should d always always be approa approache ched d with with the load load faci facing ng towa toward rds s the the top top of the the slop slope. e. Only Only slopes slopes marked marked as clear clear traffi traffic c routes routes compat compat-ible with the truck’s technical specifications can be safely used.
Never travel across across slopes or make a U-turn on a slope! Do not not park park the the truc truck k on a slop slope e. Redu Reduce ce spee speed d when when goin going g down down slope slopes. s.
Please observe the maximum gradients defined as suitable for laden and unladen transport.
The truck must only be taken in lifts with an adequate adequate loading loading capacity capacity that are designed designed for this purpose, and for which authorisation has been received from the operator. Inside the lift, the the truck must be immobilised immobilised so that no part part is in cont contac actt with with the the wall wall of the the lift lift cage cage..
Befo Before re crossi crossing ng a loadi loading ng bridge bridge,, the the operat operator or must make sure it is properly attached and secured and its load capacity is sufficient. Cross Cross the loadi loading ng bridge bridge slowly slowly and carefu carefull lly. y. The driver must be sure that the vehicle to be entered is secured sufficiently against
68
A minimum minimu m safety distance of 100 10 0 mm from the the wall walls s of the the lift lift must must alwa always ys be obse observ rved ed.. Anyone transported with the truck must only ente enterr the the lift lift afte afterr the the truc truck k has has been been corr correc ectl tly y immo immobi bili lise sed d and and they they must must exit exit the the lift lift first first..
moveme movement nt and that that it can suppo support rt the load load of the forklift forklift truck. truck. The lorry driver and lift truck operator must coordi coordinat nate e the the depart departure ure time time of the the lorry. lorry.
1152 807 1152 807 80 01 [EN] [EN]
Your truck is fitted with special equipment for use in cold stores. It can be used for two operating ranges and carries a cold store label. The cold cold store store equipm equipment ent for the the truck truck consi consists sts of using specialised oils (for the hydraulic installation installation and the gears) suitable for cold stores.
Operating range 1: permanent use in areas with temperatures of –5 °C and for short periods of time down to –10 –10 °C. Parking outside outside the cold store. store.
1044_920-001
Operating range 2: alternating use indoors and outdoors in compliance with the rules belo below, w, temp temper erat atur ure e rang range e from from –32 –32 °C to +40 +40 °C. Parking outside the cold store. This use requires requires hydraulic hydraulic oil oil for for cold store stores s as given given on the the list list of mainte maintenan nance ce charac characte teris ristic tics. s.
The change in temperature between the cold indoors and the heat outside causes condensation. This water can freeze when the the truc truck k goes goes back back into into the the cold cold stor store e and and jam the the movi moving ng part parts s of the the truc truck. k. This This is why why the the leng length th of time time the the truc truck k rema remain ins s in the the diff differ eren entt temperature areas given below for the two operat operating ing ranges ranges must must be stric strictl tly y adhere adhered d to. to. e tract traction ion batter batteries ies must must The temp tempera eratur ture e of th of the erat atur ure e of the the cold cold stor store, e, neve neverr fall fall to the the temp temper otherw otherwise ise they they will will stop stop workin working. g.
The The truc truck k must must be dry dry and and at oper operat atin ing g temp temper erat atur ure e befo before re bein being g used used in the the cold cold store store..
115 1152 807 80 01 [EN]
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– Drive the truck for approximately approximate ly 5 minutes and operate the brakes several times to ensure ensure the truck truck operat operates es safel safely. y. – Operate all the lifting functions several times times.. This This warmi warming ng up phase phase is requir required ed to allow allow the oil to reach reach operat operating ing temper temperatu ature. re.
temperatures Permanent use in areas with with temperatures time e down down to of–5 °C and and for for short perio periods of tim –10 °C. °C .
Alternating use indoors with temperatures temperatur es down down to –32 –32 °C and and outs outsid ide e with with temp temper erat atur ures es up to +25 °C for short periods of time even up to +40 °C. The truck must not leave the cold area area for more than than 10 minutes, minutes, because because this length of time is not long enough for the formation formation of condensation. If the truck stays outside for longer than 10 minutes, it must remain outside for long enough to allow the condensation to run away. This generally takes takes at least least 30 minu minutes tes..
– Always park the truck outside the cold store.
The batteries must not remain discharged or unused used in the cold cold store store over overni nigh ght. t.
– Charge the battery ba ttery outside o utside the th e cold co ld store stor e and use a spare spare batte battery. ry.
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It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. Truck towing is authorised with a rigid connection (tow bar) if the truck to be towed can no longer be braked. Check that the towing vehicle is sufficiently powerful to pull and brake the truck being towed.
In the event of an electrical fault or no battery, it is possible to unlock the brake manually.
This procedure must be carried out by authorised personnel.
– Unload the fork arms, then disconnect the battery. – Remove the engine cover. – Two M5 X 35 screws (1) are required. – Screw the screws (1) to the brake (2) in the holes (3). The brake is then unlocked.
The truck must only be towed at low speeds.
1 0252_003-109
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71
– After towing, chock the truck to prevent it from moving. 2
– To re-establish brake operation, unscrew and remove the two screws (1). – Refit the covers.
It is essential that the covers are correctly refitted before the machine is used.
3
0252_003-110
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Use a hoist and hooks of sufficient capacity. Refer to the load weight shown on the truck’s data plate.
– Attach a sling or a hook to the 2 points indicated (3).
It is strictly prohibited to sling the truck by the tiller or other points not designed for this.
Wedge battens between the chassis and slings to prevent damage.
No-one should be under a raised load.
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The pallet stacker can be equipped with different types of batteries. Observe the information on the nattery type plate. Also refer to ⇒ Chapter "Technical Data", P. 133 for this purpose.
The weight and dimensions of the battery affect truck stability. Do not change the weight conditions when changing the battery. Do not remove nor change the position of additional weights.
Take care not to damage the battery leads when removing and installing the battery.
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– Park the truck. – Lower the load arms. – Turn the key switch off. – Lift the cover (1).
Keep fingers away from moving parts to avoid any risk of them being trapped.
– Close the cover (1).
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The battery may be damaged if discharged beyond a given limit. – Immediately charge the battery.
– Safely park the truck – Before charging, check the condition of the battery cable and the charging cable and replace these cables if necessary. – Disconnect the battery connector (4). – Connect the battery plug to the charge station connector.
Only disconnect the battery connector from the battery charger when both the battery charger and truck are switched off.
Follow the instructions provided by the battery and battery charger manufacturers (equali- sing charge)
Risk of damage, short circuit or explosion. Do not place metal objects or tools on the battery. No smoking!
The electrolyte (diluted sulphuric acid) is toxic and very caustic. Follow the safety regulations when handling battery acid.
Explosive gases are generated during battery charging. – Ensure the work area is well-ventilated.
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The on-board charger means you no longer have to use a charging room. In fact, this charger can be connected to any 2P+T 230 V 16 A socket. However, before charging this way, the user must ensure that the location selected for charging satisfies all the required safety guarantees: • The electrical installation must comply with standard NF C 15 100. • The electric wall socket must be a 2 pole + earth 16 A 230 V type that is correctly connected and protected. • Before charging, check the condition of the connections and cables (retighten, as required).
Mains voltage
Network frequency
• The charger must not be exposed to oil, grease and other similar substances. • Charging must be carried out with the truck stopped. • The increase in the temperature of the unit in relation to the ambient temperature is 10°C maximum. That of the expelled air is 25°C maximum. Wait 10 minutes after stopping the charger before touching the unit. • Since the charger is cooled by forced ventilation, do not block the air inlets and outlets. There must be sufficient air circulation to the outside.
Maximum output current Nominal battery voltage
190V
Tolerance on the voltage of bearing U
35 A +/-2% 24V 1%
.
Maximum output power
Battery type
• Charging must be carried out in an area where there is no condensation or pollution as well as sufficient ventilation.
1040 W +/-3%
Gel or open lead-acid battery
Number of components
12 2 V components
Capacity
140 Ah minimum to 375 Ah maximum (adaptation of the charging curve by a selector)
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Storage temperature -45° C to +80° C Operating temperature
-15° C to +40° C
Relative humidity
90%
Weight
2 kg
Volume
1.4 litres
If the charger stays connected to the mains, it restarts a charging cycle every 48 hours after the end of the previous charge in order to compensate for self-discharge.
.
• Protection against inversion of battery polarity: the charger is protected by an output relay. After reconnecting the battery in the right direction, the charger restarts charging without requiring human intervention. • Mains protection: by a 250 V 10 A 5x20 timed fuse. The mains fuse is fitted directly to the electronic card. The user is not authorised to replace this fuse. If this fuse is faulty, the charger must be returned to the service centre.
A 2x1.5 mm2 lead is used to connect the safety relay. The relay has a maximum cut-off power of 16 A. • Contact A: blue wire • Contact B: brown wire • When the charger is neither connected to the mains nor the battery, the "contact A" and "contact B" outputs are electrically insulated from one another.
• When the charger is connected to the mains and the battery, the "contact A" and "contact B" outputs are electrically insulated from one another. • When the charger is connected to the mains only, the "contact A" and "contact B" outputs are electrically insulated from one another.
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The overcharging calculation takes into account partial recharging. The mixture is always sufficient, without needless water consumption, which prevents premature wear of the batteries (often due to overlong charging periods) and reduces the need for maintenance.
If the mains power is cut off, all the charging parameters in progress are stored in the memory for 13 minutes. As soon as the mains power returns, charging resumes from the point (I, U) at which it was cut off, with the number of Ah already injected stored in the memory. If the cut-off period is longer than 13 minutes (the truck could have been used), a complete charging cycle is initialised.
• When the charger is connected to the battery only, the "contact A" and "contact B" outputs are electrically connected.
(see wiring diagram)
The charger adapts automatically to the battery discharge situation and therefore allows any type of partial charging to be carried out ("opportunity charging").
If during phases I1 + P + U > 16H, the charger becomes faulty. This can happen when a battery has a short-circuited component. Simply reset the mains to cancel the fault.
Since the charger is cooled by ventilation, the air inlets and outlets must never be blocked. The fan runs when the mains power is connected. It stops when charging is complete or when the mains power is disconnected.
1152 807 80 01 [EN]
The charger supplies reduced power if the ambient temperature exceeds the usage temperature range, in order to protect itself (the charging period will be extended in this case). The charger stops if the micro-controller detects a temperature measurement fault.
Before charging, it is necessary to ensure that the location selected for charging satisfies all of the safety requirements.
The charger is compatible with wet lead and gel batteries with a maximum capacity of 400 Ah.
The charger is designed: – To be incorporated in the truck – To stay permanently connected to the battery – To operate in all positions – To stay connected to the mains during periods when the truck is not being used to ensure the availability of the machine
Do not disconnect the battery connector during charging (green indicator light flashes). The truck cannot be operated during charging.
The on-board charger is intended for recharging the battery. – Switch off the truck. Do not pull the emergency stop handle. This operation cuts off the circuits and stops the battery from charging. – Open the cover of the battery compartment to ensure good ventilation. – Connect the cord to the mains socket. – Connect the charger plug to a mains wall socket.
Mains socket disconOff nected Charging Flashing phases
Off Off
Stopped / Equalisation / Continuously Off Maintenance lit phase Charging process too long
Off
Charger polarity reversed (+bat and -bat charger cables reversed, with the battery remaining normally connected to the truck assembly)
Continuously Continuously lit lit
Battery polarity reversed Selector in neutral position
Continuously lit
Off
Off
Flashing
Flashing
– Avoid interrupting the charging procedure until it is complete (to optimise battery service life).
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It is strictly prohibited to use an on-board charger other than the one recommended.
Risk of damage to the mains cable resulting in electric shock and/or burns!
Risk of damage to the mains cable due to frequent operator handling. Risk of electric shock and/or burns! The mains cable must be checked regularly as part of periodic statutory checks and maintenance operations.
Park the truck sufficiently close to the mains wall socket to ensure that the mains cable on the on-board charger is not taut when connected and charging.
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• When the truck is delivered with its battery, the charger settings are adjusted in the factory. • The adjustment depends on the selected battery.
The curve is selected using the selector located on the front face of the charger. The curve selector is protected by a cap. The four thin lines indicate neutral positions. The charger does not flow and the two diodes flash simultaneously to indicate that no curve has been selected. The four thick lines indicate the four charging curves: • open lead-acid battery with a capacity below 210 Ah • open lead-acid battery with a capacity greater than 210 Ah • gel battery with a capacity below 210 Ah • gel battery with a capacity greater than 210 Ah
If the battery is changed during the service life of the truck, it is essential to ensure that the charger settings correspond to the new battery type. Any modification to the settings must be carried out by a qualified technician.
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Maintain a safe distance for battery removal to avoid damaging the truck. – Open the battery compartment (1). – Unplug the battery connector (2). In order to avoid short-circuits, it is recommended that batteries with polar terminals or unprotected connections be covered with a rubber mat. – Unlock the battery.
– Attach the lifting device (1) correctly to the battery (2) (see the lifting device user manual), then remove it from the truck. – The lifting device must exercise vertical traction in order to avoid the boot being damaged. The hooks must be placed so that they cannot fall on the battery cells when the lifting device is slackened.
Use small hooks for slinging the battery.
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– On level ground, move the pallet truck close to the trolley (2). – Align the battery compartment with the empty space on the trolley (1). – Using the load arm lifting/lowering controls, adjust the heightof the battery compartment to that of the edge of the trolley (3). – Switch off the ignition and pull the emergency stop handle.
– Open the battery case cover. – Fit the battery connector on the cells. – Push the lever towards the battery(A) then lift the notch (B). – Lift the lever(C) to release the battery – Raise the opposite stop of the lever. – Pull the discharged battery onto the trolley (2). – Turn the lock on the trolley to the "closed" position to lock the battery on the trolley (2). – Connect the charged battery (3) to the truck using an extension lead.
Use a fairly long extension lead to allow the truck to move.
– Connect the battery connector and then switch on the ignition. – Move the truck forwards or backwards to align the batter y compartment with the charged battery (3). – Switch off the ignition and pull the emergency stop handle. – Disconnect and remove the extension lead.
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– Turn the retaining lock of the charged battery.
– Fully insert the charged battery in its compartment. – Fold the stop down. – Lift the lever slightly and then unlock the notch. – Fold the lever down to lock the battery. – Connect the recharged battery. – Close the battery cover.
Place the cables correctly above the battery to prevent them from being damaged when a battery is removed from or inserted into its compartment.
During operations to fit the battery, keep your fingers away from moving parts to avoid any risk of them being trapped. We recommend the use of gloves.
Before using this machine, ensure that the battery is correctly installed and that its cover is correctly locked.
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During operations to fit the battery, keep your fingers away from moving parts to avoid any risk of them being trapped. We recommend the use of gloves.
– On level ground, move the pallet truck close to the moveable support – Switch off the ignition and pull the emergency stop handle.
– Open the battery case cover. – Fit the battery connector on the cells. – Push the lever towards the battery(A) then lift the notch (B). – Lift the lever (C)to release the battery – Lift the stop – Pull the discharged battery onto the moveable support. – Lock the discharged battery on the moveable support using the hook. – Release the moveable support by lifting up the 2 wheel locks with your foot and take the discharged battery to the charging station.
– Fully insert the charged battery in its compartment. – Fold the stop down. – Lift the lever slightly and then unlock the notch. – Fold the lever down to lock the battery. – Connect the recharged battery. – Close the battery cover.
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Before using the machine, ensure that the battery is correctly installed and that its cover is correctly locked.
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Read the information in the documentation provided with the charger. It provides information on: • the various charger screens • possible error messages • precautions for use.
Risk of damage to the battery It is essential to use the charger supplied with the battery for charging lithium-ion batteries.
Do not touch the lithium-ion battery when it is charging and do not wear rings or jewellery. Do not place metal objects on or near the battery. Do not light a naked flame in the vicinity of the charging zone or near charging batteries.
To avoid any sparks, always connect the battery connector before switching the battery charger on and disconnect it after switching the charger off.
It is important to charge the lithium-ion battery fully at least once a week. The LED located on the display flashes red. You must therefore recharge the battery to 100%.
To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station.
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– Secure the truck. Lower the fork arms. – Switch off the ignition (2).
– Open the battery compartment cover. – Unplug the battery connector (1). – Plug the socket sock et of the charging charging station station into ocated d on the batter battery. y. the the conn connec ecto torr (1) (1) locate – Switch the charger c harger on as directed in the specific instructions instructions for the charger. charger. A screen appears displaying the words . Charging the battery is automatically automatically managed by the the on-board electr electroni onics cs of the batter battery. y. – When charging is complete and the charger has stoppe stopped, d, unplug unplug the the charge charger. r.
It is poss possib ible le to stop stop char chargi ging ng befo before re the the end end of the the comple complete te cycl cycle. e. The operat operator or can resume resume work work more more quick quickly ly.. It is advis advisabl able e to rechar recharge ge the battery after each use if possible. The batte battery ry charge charge percen percentag tage e is indic indicate ated d on the the disp display lay scree screen. n. The chargi charging ng time time is indic indicate ated d on the the scre screen en of the the char charge ger. r.
– Reconnect Reconnec t the battery connector (1) on the truck. – Then close the battery compartment cover. – Switch on the ignition (2) and check the charging status status of the truck on the the display (3). – The truck is now ready for use. 88
1152 807 1152 807 80 01 [EN] [EN]
To recharge the lithium-ion battery, proceed as follows: g station. station. – Park the truck close to the chargin charging – Secure the truck. Lower the fork arms. – Switch off the ignition (2) (key or electronic key). dle to discon – Pull the emergency emer gency stop han h andle (1). nect nect the the batter battery y connec connector tor (1).
– Plug the socket of the charging station into the connector (3) located in the technical compartment. – Switch the charge c hargerr on as directed in the specific instructions instructions for the charger. charger. A screen appears displaying the words . Charging the battery y manag managed ed by the on-boa on-board rd is automati automaticall cally battery. elect electron ronics ics of the battery. – When charging is complete and the charger has stopp stopped, ed, unplug unplug the charge charger. r.
stop char chargi ging ng befo before re the the end end of It is possi possibl bl e to stop cycl cle. e. The operat operator or can can resum resume e the complet complete e cy c kly.. It is advis advisabl able e to rechar recharge ge work work more more qui qui ckly the battery after each use if possible. The battery battery char ge g e perc percen enta tage ge is indi indica cate ted d on the the e n. The The charg charging ing time time is indic indicat ated ed display display scre en. of the the char charge ger. r. on the the scre screen en of
– Reconnect Reconnec t the emergency stop connector c onnector (1) to the truck truck..
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– Switch on the ignition (2) (2 ) (key or electronic key) and check the charging status of the truck truck on the display. display. – The truck is now ready for use.
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When handling batteries, make sure that the capacity of the equipment used (hoist, slings, hooks) is sufficientfor the weight of the battery. When installing a replacement battery, it is imperative to use the same model of lithiumion battery. Refer to the rating plate of the truck for the minimum and maximum acceptable weights.
The components of the lithium-ion battery should be handled with great care.
The battery is a heavy and fragile component that must be handled with care. Wearing gloves is recommended.
Risk of being trapped During operations to lock and insert the battery, keep your fingers away from moving parts to avoid any risk of them being trapped.
– Bring truck to a controlled stop. – Lower the forks. – Turn off the ignition and remove the key. – Pull the emergency stop handle (4) and remove it. – Open the battery hood. – Turn off the battery (5) (see chapter 4 Commissioning a truck equipped with a lithium-ion battery). – Unplug the battery connector (2).
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– Remove the screw (1) that holds the fastener on the side of the battery compartment.
– Attach the slinging hooks (3) to the battery case.
Using secured hooks is recommended.
– Lift the battery slowly. – Replace the battery. – Position the new battery carefully in the chassis. – Guide it to the end of travel. – Remove the sling hooks. – Refit the fastener (1) on the side of the battery compartment. Tighten the screw to torque. The torque is 17 Nm for an electrical tool. – Reconnect the battery connector (2). – Close the battery hood. – Reconnect the emergency stop handle (4). – Restart the truck.
There is a ballast plate at the bottom of the battery container. It is essential to leave this in place and not to move it. This plate is necessary and ensures the stability of the truck.
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It is not possible to change the side access lithium-ion battery. If the side access lithium-ion battery is faulty, please contact the After-Sales Service. Only After-Sales Service technicians are authorised to change the lithium-ion battery. . The tightening torque is 20 Nm.
If the mounting is loose, the battery can be dislodged from its compartment. Carefully check the tightening torque.
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The combined indicator may display an error code. When an error code is displayed, please call the After-Sales Service Centre.
Four error codes may be displayed. For example: • E1: 239
0.0 h
• E2: 212 • E3: 426 • E4: 320 Make a note of these error codes before switching off the truck. These error codes are stored, but are not necessarily displayed on the combined indicator.
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0252_003-065-V2
Do not park the truck on a slope or, if this is really necessary, make sure it is secured with chocks.
– Remove the ignition key or press the digicode # key for 2 seconds. – Press emergency stop button.
Never leave the truck with the load in the raised position.
– Push emergency stop button. – Lower the forks arms.
– Put the key back in the ignition or enter the 5-digit code on the electronic key (default code: 12345).
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Precautions should be taken if the truck must not be used for a reasonably long period. The operations depend on the length of time it is unused.
The following work must be carried out on the truck to prevent corrosion if it needs to be stored for a long period of time. If the truck is to be stored for more than two months, it must be positioned in a clean and dry area. The area must be well-ventilated with no risk of freezing. The following operations must be performed: – Clean the truck thoroughly. – Check the hydraulic oil level and refill if necessary.
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.
If the truck has been stored for more than six months, it must be checked carefully before being recommissioned. This check is similar to the workplace accident prevention inspection. It is therefore necessary to check all points and systems that are important for truck safety. Carry out the following operations:
– Lower the forks onto a suitable support (e.g. a pallet) until the chains are slack. – Coat any unpainted metal parts with a thin layer of oil or grease. – Grease all hinges and joints. – Check battery condition and electrolyte density. Maintain the battery in accordance with the manufactur er’s requirements. (Follow the instructions).
– Clean the truck thoroughly. – Grease all hinges and joints. – Check the condition and density of electrolyte, and, if necessary, recharge the battery. – Check that there are no traces of condensation water in the hydraulic oil. Drain if necessary. – Carry out the same maintenance work as for the first time it was commissioned.
– Spray contacts with an aerosol product designed for contacts. – 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.
– Commission the truck. – In particular, check the following during start-up: • traction, control and steering. • brakes (service brake and parking brake). • lifting device.
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When scrapping the truck, it is necessary to: – Remove the various parts of the truck (covers, battery, chains, motors etc.) – Sort out the components depending on their type: 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 components according to national standards.
The client is solely responsible for any irregularities he has committed during or after the scrapping of the truck’s components and the removal of components.
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A lithium-ion battery is a special product. Special precautions should be taken when: • transporting a truck equipped with a lithiumion battery • transporting only the lithium battery. A special label must be affixed for transport. This logo depends on the battery transport conditions (transported separately or in the truck). Refer to the specifications and rules in force in your country before transporting the truck and the lithium-ion battery.
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We recommend that batteries are stored at a height between 60 and 120 cm. Remain extremely vigilant when manoeuvring to avoid piercing the batteries.
If the truck is not used for a period of up to two months, it is necessary to perform certain operations: – Clean the truck carefully.
Special precautions should be taken when storing lithium-ion batteries.
– Check the hydraulic oil level and refill if necessary.
– Store the battery in a dry place at a temperature between 0 and 40° to preserve its service life. This area must not be hermetically sealed to allow air renewal.
– Coat any unpainted metal parts with a thin layer of oil or grease.
– Indicate the storage area. Access should be strictly limited to personnel who are aware of the risks and safety instructions.
– Spray contacts with a suitable aerosol product.
– It is strongly advisable to recharge the battery fully before storing it. – Batteries can be stored for a maximum period of 12 months if they are fully charged (100%). – Regularly check the charge level of the battery. Check the level at least every 3 months. Maintain the charge level above 30%. Recharge the battery if necessary. – Completely recharge the battery every 3 months to avoid impairing the performance of the battery. – Recharging could take up to 24 hours.
A battery that has reached an excessively low level cannot be recharged. Contact your After-Sales Service immediately.
Precautions should be taken if the truck must not be used for a reasonably long period. The operations depend on the length of time it is unused.
– Grease all hinges and joints.
– Place the truck on chocks to avoid the tyres becoming flat. – Cover the truck with a cotton cover to protect it from dust. Avoid using a plastic sheet.
The following work must be carried out on the truck to prevent corrosion if it needs to be stored for a long period of time. If the truck is to be stored for more than two months, it must be positioned in a clean and dry area. The area must be well-ventilated with no risk of freezing. The following operations must be performed: – Clean the truck carefully. – Check the hydraulic oil level and refill if necessary. – Coat any unpainted metal parts with a thin layer of oil or grease. – Grease all hinges and joints. – Recharge the lithium-ion battery every 3 months. Please observe the above instructions. – Spray contacts with an aerosol product designed for contacts.
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– Raise and chock the truck: the wheels must not touch the ground in order to prevent irreve irreversi rsible ble deform deformati ation on of the the tyres tyres.. – Cover the truck with a cotton cover to protect it from dust.
all points and devices that are important for truck truck safety. safety. Carry Carry out the the follo followin wing g operat operation ions: s: – Clean the truck carefully. – Grease all hinges and joints.
We reco recomm mmen end d that that you you do not not use use a plas plasti tic c shee sheett as this this encour encourage ages s conden condensati sation on to form. form.
– Check the battery charge status and rechar recharge ge the batter battery y if necess necessary ary.. – Check that there the re are no traces traces of condenoil. Drain if if sation water in the hydraulic hydraulic oil. necessary.
Consult the After-Sales Service for further measures to take if the truck must be stored for for a long longer er peri period od of time time..
– Carry out the same maintenance work as as for for the the first first time time it was was comm commis issi sion oned ed.. – Commission the truck.
If the truck has been stored for more than six months, it must be checked carefully before being recommissioned. This check is simil similar ar to the workpl workplace ace accid accident ent preven preventio tion n inspecti inspection. on. It is therefor therefore e necessary necessary to check
100 100
– In particular, p articular, check the following the following during start-up: • tract traction ion,, contro controll and steer steerin ing g • brak brakes es (ser (servi vice ce brak brake e and and park parkin ing g brak brake) e)..
1152 807 80 01 [EN]
The following instructions contain all the information information required for for servicing your truck. Carry out the various maintenance work in compliance with the maintenance maintenance plan. This will ensure that your truck is reliable and in good working order and that the warranty remains valid.
Maintenance work must be carried out accordi cording ng to the the hour hour meter meter.. Pleas Please e consul consultt the the truck’s truck’s maintena maintenance nce plan. plan. The service plan is followed followed by advice to facilitate work. Maint Maintena enance nce interv interval als s must must be reduce reduced d if the truck truck is used used under under harsh harsh condit conditio ions ns (extre (extreme me heat heat or extrem extreme e cold, cold, large large quant quantit ities ies of dust). dust).
Only lubricants and other consumables specified in these operating instructions are author authoris ised ed for for use durin during g mainte maintenan nance ce work. work. Lubricants and other consumables required for for truc truck k main mainte tena nanc nce e are are list listed ed in the the main mainte te-s tabl table. e. nance nance specificati specification ons Never Never mix differ different ent qualiti qualities es of grease grease or oil. If it is abso absolu lute tely ly nece necess ssar ary y to chan change ge bran brands ds,, make make sure sure to flush flush thorou thoroughl ghly y before beforehan hand. d. Before changing any filters or working on the hydraulic system, thoroughly clean the surf surfac ace e and and the the area areas s arou around nd the the part part.. pour oil oil must must be clea clean. n. All containers used used to pour
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0.0 h
0252_003-065-V2
Truck maintenance must only be carried out by qualified and authorised personnel. The annual inspection for prevention of accidents at work must be carried out by a person qualified to do so. The person carrying out this inspection must provide their expertise and opinion without being influenced by economic factors or company internal issues. Safety is the only critical deciding factor.
The person responsible for carrying out the inspection must have sufficient knowledge and experience to be able to assess the condition of the truck and the efficiency of the protective installations in accordance with the technical regulations and principles established for checking industrial trucks.
Batteries must only be recharged, maintained and changed by 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.
Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by persons with no special training.
A specific qualification is not necessary.
Spare parts are provided by our spare parts service department. You will find the information required to place an order in the spare parts and fitting catalogue.
Unauthorised spare parts may increase the risk of accidents due to faults relating to quality or incorrect choices. Anyone who uses non-compliant spare parts must assume full responsibility in the event of an accident.
Only use spare parts recommended by the manufacturer.
Refer to the maintenance section of this manual for further information.
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1. Every day 2. Carry out maintenance according to the hour meter (bold typeface) After hours of service, for example, it will be necessary, to carry out the maintenance and lubrication work for every "1000 hours". After hours of service, for example, it will be necessary to carry out the maintenance and lubrication work for every "1000 and 3000 hours". After hours of service, continue as above, therefore instead of 1000 hours: 10,000 hours of service. Truck: Type No:
1000
1000
1000 3000
1000
1000
1000 3000
1000
1000
1000 3000
1000
.
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Assembly
Item/Lubricant
Capacities/Setting values
Hydraulic oil
1,25 l
Filter element
Efficency : 300 µm
EXU16 maximum pressure
219 bar
EXU18 maximum pressure
219 bar
EXU20 maximum pressure
186 bar
EXU22 maximum pressure
201 bar
Reducer
Reducer oil
0.9 litre maximum
Drive wheel
Wheel nuts
Tightening torque: 80 Nm
Stabiliser wheels
Wheel pin bolt
Tightening torque: 35 Nm
Load wheels
Locking screw
Tightening torque: 50 Nm
Main hydraulic system
Traction and pump motor Control cable harness Traction motor
Fuses
Power 125A, Quantity: 1
Fuses
Control 7.5A, Quantity: 1
Maintenance free
1.2 kW (AC) EXU16, EXU18 : 1,0 kW
Pump motor
Battery Joints
Maintenance free
EXU16,18,20CF*, EXU20 : 1,2 kW EXU22, EXU22CF* : 1,4 kW
Distilled water
As required
Lithium grease
As required
*CF: Cold store
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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.
Operations on the truck’s electrical system must only be carried out when there is no voltage supply.
Rings, metal bracelets etc., must be removed before carrying out any operations on electric components.
Operating checks, testing and adjustment work on parts supplied with voltage must only be carried out by personnel:
Remove the electric equipment (which comprises electric components such as the traction controller) before carrying out any welding operations. This precaution prevents this electric equipment from being damaged.
• who have received detailed instructions • who have been authorised to perform this work • who have taken the necessary precautionary measures.
Operations on the electric system require the consent of the manufacturer.
After any repair or maintenance work, it is necessary: • to refit all safety devices • to check these for correct operation.
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To lift the truck, its sub-assemblies or additional equipment, lifting devices must be hooked only to the appropriate lifting points. When jacking, take appropriate measures (using chocks or wooden blocks) to prevent the truck from slipping or tipping over.
The truck must be jacked and chocked in order to perform certain maintenance operations. Always make sure: • To use a jack with an adequate lifting capacity, • Make sure that the truck is parked on level ground and is secured against rolling and tipping.
Disconnect the battery plug before lifting the truck!
– Position the truck so that the fork arms touch the wall. – Lift up the truck until the wheels are no longer in contact with the ground. – Raise the truck with chocks.
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– Fully raise the pallet truck’s load arms to facilitate these operations.
Before removing anything from the truck – Turn the key switch off. – Pull the battery connector handle (emergency stop handle).
– Unscrew the 2 screws (1) that hold the cover in place. – Unclip the cover at both ends – Raise and pull back the lower cover.
After removing the lower cover: – Unscrew the 4 screws (2) that hold the cover in place.
After removing the front cover:
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– Remove the plastic cover by unscrewing the 2 screws (3) to provide easy access to the pump unit.
– Then remove the mounting bracket (4)
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To access the reducer and the brake: – Turn the tiller to the right or left-hand stop. – Unscrew the 2 screws (3)
– Unscrew the 2 screws (2) located either side of the two 1/2 covers. – Remove the two 1/2 covers.
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1152 807 80 01 [EN]
The lithium ion battery does not require special maintenance. However, it is necessary to perform some maintenance operations, in addition to the usual maintenance plan for the truck.
Clean the battery. Check the battery connections and sockets. Fully charge the battery at least once a week. Check the tightness of the battery terminal. Retighten to the correct torque if necessary. The torque is 23 Nm. (For the vertical access battery only) Check the tightness of the battery mounting plate screw on the battery compartment. Retighten to the correct torque if necessary. The torque is 17 Nm. (For the side access battery only) Check the tightness of the battery mounting plate screw on the battery compartment. Retighten to the correct torque if necessary. The torque is 20 Nm.
Fully recharge the battery if it is in the storage area in or out of the truck
Visually check the battery .
1152 807 80 01 [EN]
111
– Always park the truck as specified. – Disconnect the battery connector (4).
– Disconnect the battery connector when washing the truck.
Do not use inflammable fluids for cleaning. Observe the above safety precautions for preventing sparks through shorts (disconnecting the battery connector). When the truck is being cleaned, carefully cover all vulnerable components, particularly electric components. Observe the manufacturer’s instructions for handling the cleaners.
– Clean the truck exterior with water and cleaning agents soluble in water (sponge, rags). – Clean especially the oil filler openings and the surrounding area. – Grease the required assemblies (mast, controls and joints).
Do not aim the steam cleaning device directly on electric motors and other electric components, brakes and bearings.
Use only dry cleaning agents as cleaning agents. Do not remove covers, etc.
– Clean electrical components with a nonmetallic brush and and blow dry with a weak jet of air.
112
1152 807 80 01 [EN]
– Dry the truck thoroughly (eg with compressed air). – Take the truck back into operation according to instructions. If moisture has penetrated the motors despite the precautionary measures, dry them first with compressed air; if not, there is the risk of short circuits! The truck must ONLY then be turned on and taken into operation to prevent any damage due to corrosion.
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113
The tyre tread on the drive wheel (1), the stabilising wheel (2) and the rollers (3) must not be damaged.
Drive wheel
230 x 75 mm
Stabiliser wheels
125 x 40 mm
Single rollers Dual rollers
85 x 100 mm 85 x 80 mm
– Replace damaged or wor n wheels with new wheels, and damaged or worn rollers with new ones.
A wrongly adjusted stabilising wheel can lead to stability problems. This adjustment must be carried out by our service department.
114
1152 807 80 01 [EN]
– Control fuses are accessed by removing the front hood. The 125 A fuse (1) protects the traction and lifting power circuit. The 7,5 A fuse (2) protects the control circuit. We recommend that this operation be carried out by our After-Sales Service Centre.
1152 807 80 01 [EN]
115
To increase the service life of the transmission gear, 2 grease nipples (1) have been added to its turntable. It is therefore possible to regularly lubricate the transmission gear.
Use the lubricants recommended by the manufacturer.
The folding platform must be checked regularly. The following operations must be carried out at least every three months or every 500 hours. – Check that the folding platform operates correctly – Clean and lubricate the articulated parts of the platform
116
1152 807 80 01 [EN]
This task must be carried out by a person wearing acid-resistant protective gloves and industrial goggles. Follow the safety regulations described in previous chapters.
Do not pour acid-bearing wash water down the drain. For more information, see the battery instructions.
– Check for traces of sulphate in the compartment and frame. – If there is only minimal sulphate build-up, just wipe the top of the cells with a damp cloth. – If sulphate build-up is heavy, you will need to take out the battery, jet wash it and clean the frame.
– Check that there are no electrolytes at the bottom of the compartment by connecting the rubber suction bulb supplied with the battery to the plastic pump tube. – Pump off any electrolyte that may have spilled between the cells. – Clean the top of the cells with a damp cloth.
In case of heavy sulphate build-up or excessive electrolyte spillage, please contact the After-Sales Service Centre.
1152 807 80 01 [EN]
117
– Check that the cable insulation is undamaged and that there are no signs of overheating at the connections. – Check that the "+" and "-" output terminals are not sulfated (presence of white salt). – Check the condition of the power outlet contacts and the presence of the keying pin. – Check the condition of the locking tab on the battery connector.
The points mentioned above can cause serious incidents. In the event of a fault, please contact the After-Sales Service.
118
1152 807 80 01 [EN]
Do not open the battery.
Lithium-ion batteries do not require any specific maintenance. However, it is advisable to clean it regularly depending on its use.
Always switch off the battery before working on an electrical component.
– Immobilise the truck. – Lower the forks. – Turn off the ignition and remove the key. – Pull the emergency stop handle. – Open the battery compartment cover. – Switch off the battery using the button (1). – Blow compressed air into the battery to remove dust and impurities.
It is advisable to wear industrial goggles and a mask.
– Check the condition of the terminals.
Do not wear jewellery or metal objects.
– Switch on the battery. – Close the battery compartment cover. – Restart the truck.
1152 807 80 01 [EN]
119
Do not use cables or harnesses other than those provided with the lithium-ion battery that was sold to you.
Using the cables provided with the vertical access lithium-ion battery with a side access lithium-ion battery is strictly forbidden. Using the cables provided with the side access battery with a vertical access battery is also strictly forbidden. A short circuit may occur and damage the cable harness and the connector.
120
1152 807 80 01 [EN]
– Carry out maintenance work as necessary. Refer to the chapter entitled .
Depending upon use, environmental conditions and driving style, the following procedures must be performed every 1000 hours.
Clean the truck (if necessary) Check the error codes (using the diagnostic tool)
Check that the cables and bundling are in good condition
Check for any possible oil leaks from the transmission gear Lubricate the ring gear
Check the wear on the tyre tread of the wheels Check the brake air gap Check that the nuts are tight
Clean and blow out the electrical plate Check the mounting of the electrical connections Check and adjust the battery electrolyte level Check the condition and mounting of the battery cables
Check the system oil level Check the system for leaks
1152 807 80 01 [EN]
121
Check the level of wear on the rings and clevis pins Oil or generously grease the rings and clevis pins
Check the general condition of the forks and the chassis .
122
1152 807 80 01 [EN]
IMPORTANT The mechanical braking torque is factory set. – The brake must be checked in the braked position, i.e. with the power supply cut. – Check the air gap on the brake using a set of wheel chocks. – The value of the original air gap is 0.2 mm. After partial wear of the disc, the maximum air gap is 0.5 mm. Above this value, there is a risk of not being able to release the brake fully and a risk of overheating. – If the air gap is close to the limit value of 0.5 mm, it must be adjusted. – Loosen the three fixing screws (3). – Adjust the three banjo bolts (4) to set the air gap to its original value of 0.20 mm. – Retighten the three mounting screws (3). – Check the air gap at 3 points at 120° intervals. – Make sure that the air gap is equal right around the brake.
We recommend that this operation be carried out by our After-Sales Service Centre.
1152 807 80 01 [EN]
123
Adjusting the clevis (1) with new drive wheel and stabiliser wheels R = 22 mm.
PLEASE NOTE: • Lower the stabilisers to stabilise the truck. • Lift the stabilisers if the truck often encounters obstacles and if grip must be improved. Follow the instructions below to adjust the height of the stabilisers: – Loosen the lock nut (2) (36 spanner) by holding the ball bearing (3) by its flat surface (36 spanner) – Tighten the clevis (1) using a 14 mm Allen key to lower the wheel or loosen the clevis (1) using a 14 mm Allen key to lift the wheel – After adjustment, lock the clevis (1) with the lock nut (2) tightened to a torque of
To screw, unscrew or lock the clevis (1) always hold the ball bearing (3) by its flat surface (36 spanner) during the procedure.
124
1152 807 80 01 [EN]
– Lower the load arms completely. – Switch off the ignition and pull the emergency stop handle. – Pull back ba ck the cover of the technical technical comAccess ss to the the partm partment ent (see (see descri descript ption ion in ″Acce technical compartment″). compartment″). – The oil level must be in the centre cent re between the minimum and maximum marks on the tank tank for for corr correc ectt use use of the the truc truck k func functi tion ons. s. – Top up if necessary. necessar y. afterwards. rds. – Replace and tighten the plug plug afterwa
Only Only use hydra hydraul ulic ic oil oil that that comp complie lies s with with the the speci specififications cations (see (see lubrica lubricatio tion n table) table)..
115 1152 807 80 01 [EN]
125
It is impo import rtan antt to chec check k the the cond condit itio ion n of the the colcollars lars and hinge hinge pins pins on the foll followi owing ng elemen elements ts of the lifting lifting system system : • (1) (1) Load Load arm arm shaf shaftt / supp suppor ortt roll roller er clev clevis is roller clevi clevis s • (2) (2) Push Push rod rod shaf shaftt / supp suppor or t roller • (3) (3) Mobi Mobile le chas chassi sis s shaf shaftt / lift lift shaf shaftt • (4) (4) Fixe Fixed d chas chassi sis s / lift lift shaf shaftt • (5) (5) Cyli Cylind nder er / fixed fixed chas chassi sis s • (6) (6) Lift Lift shaf shaftt / push push rods rods
If significant significant wear is f ound, replace the worn coll collars ars and pins pins befor befor e the the other other compo componen nents ts are damaged.
126 126
1152 807 80 01 [EN]
– Connect the cord to the 220 V mains. – Check that the green gree n indicator indic ator light on the disp displlay is flash flashin ing g and and that that the the red red one one is off off (charging (charging in progress) progress).. ised (tracti (traction on – Check that the truck is immobil immobilised as long as it is and lifting not permitted) permitted) as conn connec ecte ted d to the the 220 220 V supp supply ly.. – Disconnect the mains cord.
115 1152 807 80 01 [EN]
127
The operations described below relate to lead batteries with liquid electrolyte. For batteries with gel electrolyte, which are said to be "maintenance-free", please refer to the manufacturer’s instructions.
Avoid contact with the acid. Do not create a shortcircuit. Refer to the recommendations in the daily checks section. The electrolyte contains sulphuric acid, which is a hazardous product. Wear gloves and goggles when working on the battery. In case of contact with eyes or skin, rinse immediately with clean water, then seek medical advice if necessary. Charging the battery releases hydrogen, which can create an explosive mixture. Do not create sparks, do not smoke and keep naked flames away from a battery which is being charged or has recently been charged. To prevent the accumulation of hydrogen, keep the battery cover open during charging. Charge the battery in a well-ventilated room. Do not place metal objects on the battery: there is a risk of creating a short-circuit.
Before commencing work, unplug the battery connector by pulling the emergency stop handle.
– This check and any topping up required should be carried out every week, after charging an open lead battery only. – Turn off the key switch, open the cover and disconnect the battery connector. – Check the level, which should be up to the base of the plug, slightly above the splash guard. – Add demineralised water to top up cells with a low water level. – Then refit the plugs.
Only top up with demineralised water. Never top up before charging (risk of overflow). Do not overfill the cells.
128
1152 807 80 01 [EN]
For more information, refer to the instructions supplied with the battery.
Measuring the density gives an accurate indication of the charging status of each cell in an open lead battery only. This measurement can be taken before or after charging: • Minimum density of an 80% discharged battery: 1.14 • High density, battery 100% charged: 1.29 to 1.32 (depending on make) – We recommend a reading every 1 or 2 weeks. – Note down the values read in your battery monitoring logbook. – Lift the cover over each cell plug as described above. – Carefully record the specific gravity of each cell with the hydrometer. – Close the various stoppers after measurement.
If the density in the c e lls differs or it is very low in certain cells, con t act our service engineers. Allowing the battery charge to fall below the threshold of 1.14 is v ery detrimental to its service life.
1152 807 80 01 [EN]
129
– Carry out the required maintenance work. Refer to the chapter. – Carry out all 1000-hour maintenance work. Refer to the chapter.
Depending upon use, environmental conditions and driving style, the following procedures must be performed every 3000 hours.
Drain the transmission gear oil
Drain the hydraulic system .
130
1152 807 80 01 [EN]
– Lower the load arms to the ground to eliminate pressure in the hydraulic circuit. – Switch off the ignition and unplug the battery connector. – Disconnect the power supply to the solenoid valve (3). – Disconnect the cylinder supply hose (1). – Remove the 2 screws (2) that hold the upper support (angle bracket) in place. – Lift out the hydraulic unit. – Remove the unit’s upper support and the filler tube/breather. – Unscrew the tank’s mounting clip. – Remove the tank. – Drain the oil.
– Fit new seals on the tank and couplings. – Refit the unit in the technical compartment with its tube and upper support. – Connect the pipes and the power supply. – Unscrew the filler plug. – Fill up the tank through the filler hole. – Tighten the plug. – Operate the lifting system several times.
Always use hydraulic oil in accordance with the specifications (see lubrication table).
1152 807 80 01 [EN]
131
This operation must be carried out by the service centre.
132
1152 807 80 01 [EN]
134
1152 807 80 01 [EN]
DESIGNATION 1.1 Manufacturer
STILL GmbH
1.2 Model type
EXU16
EXU18
Method of propulsion: battery, diesel, petrol, LPG, mains power Driving: manual, pedestrian, standing, seated, 1.4 order picking Q (kg)
1.6 Centre of gravity
c (mm)
Distance from load wheel axle 1.8 to load mating face (±5 mm) Wheelbase 1.9 (±5 mm)
X(mm)
1150 lowered/raised
Y(mm)
1150 lowered/raised
Pedestrian 1600
1800
1304 / 1228
1381 / 1301 EXU18
Load per laden axle, 2.2 drive side/load side (±10%) Load per unladen axle, 2.3 drive side/load side (±10%)
kg
2 PzS - 1150
EXU22
/
/
495
82 Ah lithium-ion battery 164 Ah lithium-ion battery 205 Ah lithium-ion battery 410 Ah lithium-ion battery
kg
1449 / 1370
EXU20
430
2 Pzs
kg
2200
963 / 883
BS
Weight in 2.1 working order (±10%)
2000 600
EXU16
WEIGHT
EXU22
Battery
1.3
1.5 Rated capacity
EXU20
/
352
/
/
373
/
/
680 / 1350
2 PzS rollers / drive wheels
392
/
433
/
746 / 1542
789 / 1699
/
384/104
/
WHEELS
EXU16
EXU18
EXU20
EXU22
3.1 Tyres: polyurethane, rubber
C+P/P
C+P/P
C+P/P
C+P/P
Drive wheel dimensions 3.2 (width at the ground) Wheel sizes, load 3.3 side
Øxl (mm)
230 x 75
Øxl (mm)
Ø85 x 105 (bogies = 85 x 100)
1152 807 80 01 [EN]
135
Additional wheels Øxl Stabilisers (dimensions) (mm) Number of wheels at drive side/load side (x = 3.5 drive wheel) Drive side track mm 3.6 width (± 5 mm) Load side track Mobile chassis mm 3.7 width (± 5 mm) 52/56/68 3.4
DIMENSIONS 4.4
4.9
4.15
4.19 4.20
Lift unladen/laden (± 5 mm) Height of tiller in driving position, min/max. Height at the ends of the fork in the lower position (max) Total length (± 5 mm) Length to load mating face (±5 mm)
Dimensions of forks Outside fork 4.25 spread Ground clearance 4.32 at centre of wheelbase, min/max
482 355 / 395 / 515 EXU18
EXU20
h3 (mm)
130
h14 (mm)
740 / 1250
h13 (mm)
85
L1 (mm)
BS / 2 PzS
L2 (mm)
BS / 2 PzS
1660 / 1730
1660 / 1730
510 / 580
- / 1820
- / 580
- / 670
720
s/e/l (mm)
165 - 55 - 1150
b5 (mm)
520 - 560 - 680
m2 (mm)
36 / 166
Aisle width with an 800 x 1200 4.34 pallet lengthwise Ast (mm) (lowered/raised forks)
EXU16 BS
1947 / 1962
2 Pzs 3 Pzs BS
EXU20
EXU22
/
/
1997 / 2017
/
/
/
2060 / 2055
1997 / 2012
/
/
/
2 Pzs 3 Pzs
EXU18
EXU22
- / 1730
b1 (mm)
Aisle width with a 1000 x 1200 4.33 pallet crosswise Ast (mm) (lowered/raised forks)
136
1x+ 2 / 2 (4 in bogies)
EXU16
4.21 Total width 4.22
125 x 40
2047 / 2067 /
1152 807 80 01 [EN]
/
/ /
2110 / 2105
Turning radius (mini) 4.35 (lowered/raised forks)
1560 / 1495
BS Wa (mm)
1610 / 1550
2 Pzs
5.2 5.3 5.8 5.9
Transfer speed when laden/unladen (5%) Lifting speed when laden/unladen (10%) Lowering speed when laden/unladen (10%) Maximum gradient when laden/unladen, 5 minutes Acceleration time when laden/unladen (d = 10 m)
1670 / 1585
EXU16
EXU18
EXU20
EXU22
6 /6 0.04 / 0.06
0.03 / 0.04
m/s
0.071 / 0.065
0.07/0.06
%
14 / 24
s
7.58 / 6.5
13 / 24
10 / 24
Electromagnetic EXU16
kW
6.2 Lift motor at 15% utilisation
kW
Battery type in accordance with 6.3 DIN 46 531 / 35 /36 A, B, C, no
DIN 46 536 B
AC motor DC motor
BS
EXU18
EXU20
EXU22
1.2 1
1
1.2
1.4
BS/2 Pzs
BS/2 Pzs
2 Pzs
3 Pzs
/
/
2 Pzs
V/Ah
11 / 24
7.65 / 6.5 8.04 / 6.5 8.04 / 6.5
Traction motor, hourly output
Battery voltage and 6.4 capacity (discharge in 5 h)
/
m/s
DRIVE 6.1
/
/
km/h
5.10 Service brake
/
/
3 Pzs
PERFORMANCE DATA 5.1
/
82 Ah lithiumion battery 164 Ah lithiumion battery 205 Ah lithiumion battery 410 Ah lithiumion battery
1152 807 80 01 [EN]
24/160 24/220 /
24 / 375
/
23/82
/
/
23/164
/
/
/
23/205
/
/
23/410
/
137
BS 2 Pzs
6.5 Battery weight (±10%)
Energy consumption 6.6 according to standardised VDI cycle
kg
8.1 Speed control
63
/
/
84
/
/
kWh / h
110
/
151
/
0.38
EXU16 AC controller
.
138
/ /
213
82 Ah lithiumion battery 164 Ah lithiumion battery 205 Ah lithiumion battery 410 Ah lithiumion battery
OTHER
/
141
1152 807 80 01 [EN]
EXU18 LAC
EXU20
EXU22
1152 807 80 01 [EN]
139
140
1152 807 80 01 [EN]
DESIGNATION 1.1 Manufacturer
STILL GmbH
1.2 Model type 1.3
EXU 20S
Method of propulsion: battery, diesel, petrol, LPG, mains power
1.4 Driving: manual, pedestrian, standing, seated, order picking 1.5 Rated capacity
Q (kg)
1.6 Centre of gravity
c (mm)
EXU 22S
Battery
Pedestrian 2000
2200 600
Distance from load 1.8 wheel axle to load mating face (±5 mm)
x (mm)
1150 lowered/raised
962/895.5
1.9 Wheelbase (±5 mm)
y (mm)
1150 lowered/raised
1379/1312.5 1454/1387.5
WEIGHT
Battery
EXU 20S
BS 2.1
Weight in working order (±10%)
Load per laden axle, 2.2 drive side/load side (±10%) Load per unladen axle, 2.3 drive side/load side (±10%)
kg
kg
kg
EXU 22S /
2 Pzs
540
/
3 Pzs
/
585
2 Pzs
876/1664
/
3 Pzs
/
934/1851
2 Pzs
435/105
/
3 Pzs
/
460/125
EXU 20S
EXU 22S
WHEELS 3.1 Tyres: polyurethane, rubber
C+P/P
Drive wheel 3.2 dimensions (width at the ground)
Øxl (mm)
230 x 75 POLYURETHANE
3.3 Wheel sizes, load side
Øxl (mm)
Ø85 x 105 (bogies = 85 x 100)
3.4
Additional wheels (dimensions)
Øxl (mm)
Stabiliser s
3.5 Number of wheels at drive side/load side (x = drive wheel) Drive side track width (± 5 mm) Load side track width 3.7 (± 5 mm)
mm
3.6
mm
Mobile chassis 52/56/68
1152 807 80 01 [EN]
125 x 40 1x+ 2 / 2 (4 in bogies) 482 355/395/515
141
DIMENSIONS
EXU 20S
Lift unladen/laden (± 5 mm) Height of tiller in driving 4.9 position, min/max. Height at the ends of 4.15 the fork in the lower position (max)
h3 (mm)
4.4
4.19 Total length (± 5 mm) 4.20
Length to load mating face (±5 mm)
EXU 22S 125
h14 (mm)
740/1250
h13 (mm)
85
L1 (mm)
Pedestrian/ride-on
1896/2286
1980/2360
L2 (mm)
Pedestrian/ride-on
745/1135
830/1210
b1 (mm)
4.21 Total width
720
4.22 Dimensions of forks
s/e/l (mm)
165/55/1150
4.25 Outside fork spread
b5 (mm)
520/560/680
Ground clearance at 4.32 centre of wheelbase, min/max
m2 (mm)
4.33
Aisle width with a 1000 Ast (mm) x 1200 palletcrosswise
Aisle width with an 4.34 800 x 1200 pallet lengthwise
4.35 Turning radius (mini)
Ast (mm)
Wa (mm)
Pedestrian/ride-on
1975/2344
2058/2427
Pedestrian/ride-on
1908/2277
1996/2365
Pedestrian/ride-on
2175/2544
2265/2431
Pedestrian/ride-on
2108/2477
2195/2564
Pedestrian/ride-on
1737/2106
1824/2193
Pedestrian/ride-on
1670/2039
1757/2126
PERFORMANCE DATA
EXU 20S
5.1
Transfer speed when laden/unladen (5%)
km/h
5.2
Lifting speed when laden/unladen (10%)
m/s
5.3
Lowering speed when laden/unladen (10%)
m/s
142
34/159
EXU 22S
6/6 2 Pzs
0.04/0.06
/
3 Pzs
/
0.03/0.04
2 Pzs
0.07/0.06
/
3 Pzs
/
0.07/0.06
1152 807 80 01 [EN]
Maximum gradient when laden/unladen, 5 minutes Acceleration time when 5.9 laden/unladen (d = 10 m) 5.8
%
11/24
s
Electromagnetic
DRIVE
EXU 20S
6.1 Traction motor, hourly output
kW
6.2 Lift motor at 15% utilisation
kW DC motor
6.3
6.4
Battery type in accordance with DIN 46 531 / 35 /36 A, B, C, no Battery voltage and capacity (discharge in 5 h)
6.5 Battery weight (10%)
6.6
AC motor
V/Ah
EXU 22S 1.2
1.2
1.4
2 Pzs
3 Pzs
BS
/
/
2 Pzs
24/250
/
3 Pzs
/
24/375
BS
/
/
2 Pzs
219
/
3 Pzs
/
287
0.38
0.38
EXU 20S
EXU 22S
DIN 46 536 B
kg
Energy consumption according to standardised VDI cycle
kWh / h
OTHER 8.1 Speed control
8.04/6.5
5.10 Service brake
10/24
AC controller
LAC
.
1152 807 80 01 [EN]
143
Calculated in the test cycle in accordance with EN 12053 from the weighted values for the TRACTION, LIFT and IDLING operating states.
EXU 16, EXU 18, EXU 20, EXU 22 in the LIFT operating state
LPAZ
= 70 dB (A)
LPa
=
in the "Idling" operating status
LPb
=
in the DRIVE operating state
LPc
=
Insecurity
KPA
± 2,5 dB (A)
73 dB (A)
0 dB (A) 73,5 dB (A)
Lower or higher noise values may occur when using industrial trucks, due e.g. to the method of operation, environmental factors and other sources of noise.
144
1152 807 80 01 [EN]
The values were determined according to EN 13059 using trucks with standard equipment according to the data sheet (driving over test course with humps).
Measured vibration characteristic
aW.ZS
=
Insecurity
K
=
0,3 m/s2
< 2,5 m/s2
Vibration characteristic
0,80 m/s2
The vibration characte ristic for bodily vibrati- ons cannot be used to de termine the actual load level of vibratio ns during operation. This depends on the operati ng conditions (state of pathway, method of operation etc.) and should therefore be de termined on site, where appropriate. It is man datory to specify the hand-arm vibrations e v en where the values do not indicate any hazar d , as in this case.
1152 807 80 01 [EN]
145
146
1152 807 80 01 [EN]
Clean the truck . . . . . . . . . . . . . . . . . . . 112 Access to the technical compartment . . 108 Accessing the reducer and the brake . . 110
Cleaning the electrical system . . . . . . . 112 Consumables . . . . . . . . . . . . . . . . . . . . 23 Battery acid safety instructions . . . . . 24
Adjusting the height of the stabilisers
Disposal . . . . . . . . . . . . . . . . . . . . . . 25
Stabilisers . . . . . . . . . . . . . . . . . . . . 124
Oil Safety Information . . . . . . . . . . . . 23
Adjusting the on-board charger . . . . . . . . 81
Safety information for handling hydraulic fluid . . . . . . . . . . . . . . . . 24
After washing the truck . . . . . . . . . . . . . 113 Anti-crush safety device Checking . . . . . . . . . . . . . . . . . . . . . 44 Description of the function . . . . . . . . . 44
Copyright and property rights . . . . . . . . . . 4 Cross references . . . . . . . . . . . . . . . . . . . 5
Attachments Special risks . . . . . . . . . . . . . . . . . . . 10
Damage, faults . . . . . . . . . . . . . . . . 19, 25 Danger to employees . . . . . . . . . . . . . . . 14 Datasheet EXU . . . . . . . . . . . . . . . . . . 134
Battery Charging a Gel or Lead battery (wall-mounted charger) . . . . . . . . 42 Cleaning the battery . . . . . . . . . . . . 117 Disposal . . . . . . . . . . . . . . . . . . . . . . . 6 Battery acid . . . . . . . . . . . . . . . . . . . . . . 24 Battery charge indicator . . . . . . . . . . . . . 30 Battery electrolyte density . . . . . . . . . . 129
Datasheet EXU 20S - EXU 22S (option) . . . . . . . . . . . . . . . . . . . 140 Destruction . . . . . . . . . . . . . . . . . . . . . . 97 Digicode option (LFM Go) . . . . . . . . . . . . 32 Directions Defining directions . . . . . . . . . . . . . . . 5 Disposal Battery . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery maintenance . . . . . . . . . . . . . . 128 Battery type . . . . . . . . . . . . . . . . . . . . . . 74 Brake Checking the brake . . . . . . . . . . . . . . 45
Components . . . . . . . . . . . . . . . . . . . . 6 Documentation scope . . . . . . . . . . . . . . . 4 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Braking . . . . . . . . . . . . . . . . . . . . . . . . . 62
Driver rights,duties and rules of behaviour . . . . . . . . . . . . . . . . . . 16
Braking system . . . . . . . . . . . . . . . . . . . . 7
Driver’s compartment . . . . . . . . . . . . . . . . 8 Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Changing the battery . . . . . . . . . . . . . . . 82 Changing the battery using a hoist . . . . . 91 Charger Using the charger . . . . . . . . . . . . . . . 79
Driving on loading bridges . . . . . . . . . . . 68 Driving on upward and downward slopes . . . . . . . . . . . . . . . . . . . . . 68 Driving safety instructions . . . . . . . . . . . . 58
Check the tyres and the wear on the wheels and rollers . . . . . . . . . . . 114 Checking the brake air gap . . . . . . . . . . 123
EC declaration of conformity . . . . . . . . . . . 3
Checking the cables, terminals and battery connector . . . . . . . . . . . . 118
Electrical insulation testing . . . . . . . . . . . 22
Checking the emergency stop . . . . . . . . 45
Electrolyte level and battery water top-up . . . . . . . . . . . . . . . . . . . . 128
Checking the horn . . . . . . . . . . . . . . . . . 46
Error codes . . . . . . . . . . . . . . . . . . . . . . 94
Checks prior to start-up . . . . . . . . . . . . . 41 1152 807 80 01 [EN]
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Lead battery . . . . . . . . . . . . . . . . . . . . 117
Colour code for the LEDs . . . . . . . . . . 49
Lift control elements . . . . . . . . . . . . . . . . 63
Commissioning a truck equipped with a keypad or an electronic key . 48
Lifting system . . . . . . . . . . . . . . . . . . . . . . 7 Checking the wear on collars and hinge pins . . . . . . . . . . . . . . . . . 126
Commissioning a truck equipped with an RFID reading device . . . . . 48
List of inspections . . . . . . . . . . . . . . . . 104
Description . . . . . . . . . . . . . . . . . . . . 47
Lithium-ion batteries
Disconnecting a truck equipped with a keypad or electronic key . . . 51
Lithium-ion batteries: Long-term storage . . . . . . . . . . . . . . . . . . . . 99
Disconnecting a truck equipped with an RFID reading device . . . . . 52
Special lithium-ion safety rules . . . . . . 20
Disconnecting the truck . . . . . . . . . . . 51 Start-up . . . . . . . . . . . . . . . . . . . . . . 48 FleetManager™ option . . . . . . . . . . . . . . 36 Folding platform Driving in pedestrian mode . . . . . . . . 60
Lithium-ion battery Changing the side access lithium-ion battery . . . . . . . . . . . . . 93 Charging lithium-ion batteries using an external charger . . . . . . . . . . . 87
Driving in ride-on mode . . . . . . . . . . . 60
Charging using an external charger . . . . . . . . . . . . . . . . . 87, 89
Maintenance . . . . . . . . . . . . . . . . . . 116
Cleaning the lithium-ion battery . . . . 119
Use . . . . . . . . . . . . . . . . . . . . . . . . . 60
Display . . . . . . . . . . . . . . . . . . . . . . . 57
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 115
Harnesses and cables . . . . . . . . . . . 120 Maintenance plan for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . 111
Gel and lead side access batteries: changing the battery using a trolley . . . . . . . . . . . . . . . . . . . . . 83
Marking . . . . . . . . . . . . . . . . . . . . . . 37 Transporting a truck equipped with a lithium-ion battery . . . . . . . . . . . 98
Gel battery . . . . . . . . . . . . . . . . . . . . . . 117
Load handling safety rules . . . . . . . . . . . 64
General . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lowering the fork arms . . . . . . . . . . . . . . 63
Hazards and countermeasures . . . . . . . . 12
Maintenance schedule 1000 hours . . . . . . . . . . . . . . . . . . . 121
Hoisting the truck Lifting by the chassis . . . . . . . . . . . . 107
3000 hours . . . . . . . . . . . . . . . . . . . 130
Hydraulic circuit, draining the circuit . . . 131
Manual issue date . . . . . . . . . . . . . . . . . . 5
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 24
Markings . . . . . . . . . . . . . . . . . . . . . . . . 34 Measuring battery insulation resistance . 22
Identification label . . . . . . . . . . . . . . . . . 35
Measuring the insulation resistance of the electrical system . . . . . . . . . . . 22
Insurance cover on company premises . . 18
Medical devices . . . . . . . . . . . . . . . . . . . 19 Modifications and r efitting . . . . . . . . . . . . 18
Jacking . . . . . . . . . . . . . . . . . . . . . . . . 107
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Side access lithium-ion battery Commissioning a truck equipped with a lithium-ion battery . . . . . . . . 55
Noise Noise emission values . . . . . . . . . . . 144
Slinging and jacking the truck . . . . . . . . 107 Special risks . . . . . . . . . . . . . . . . . . . . . 10
Oil level check . . . . . . . . . . . . . . . . . . . 125 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 On-board charger Checking the charger . . . . . . . . . . . 127 Opening/closing the battery cover . . . . . . 75
Specialist . . . . . . . . . . . . . . . . . . . . . . . . 16 Stabilisers . . . . . . . . . . . . . . . . . . . . . . . . 7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . 43 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Symbols used . . . . . . . . . . . . . . . . . . . . . 4
Operating company . . . . . . . . . . . . . . . . 16 OptiSpeed . . . . . . . . . . . . . . . . . . . . . . . 61 Ordering spare parts and consumables . 103
Technical inspection and maintenance characteristics . . . . . . . . . . . . . . 105
Overviews . . . . . . . . . . . . . . . . . . . . . . . 28
Transporting the truck in the lift . . . . . . . . 68
Packaging . . . . . . . . . . . . . . . . . . . . . . . . 6
Unauthorised use . . . . . . . . . . . . . . . . . . . 9
Parking brake . . . . . . . . . . . . . . . . . . . . 62
Update of this manual . . . . . . . . . . . . . . . . 5
Permanent Putting Out of Commission . . 97 Place of use . . . . . . . . . . . . . . . . . . . . . . . 9 Prohibition of use by unauthorised persons . . . . . . . . . . . . . . . . . . . . 17
Vertical access lithium-ion batteries Connecting/disconnecting the battery connector . . . . . . . . . . . . . 53 Vertical access lithium-ion battery
Raising the fork arms . . . . . . . . . . . . . . . 63
Commissioning a truck equipped with a lithium-ion battery . . . . . . . . 54
Regular maintenance of the transmission gear . . . . . . . . . . . . . . . . . . 116 Residual dangers, residual risks . . . . . . . 10
Replacing the lithium-ion battery . . . . 91 Vibration characteristic values for bodily vibrations . . . . . . . . . . . . . 145
Safety devices . . . . . . . . . . . . . . . . . . . 106 Safety Inspection . . . . . . . . . . . . . . . . . . 21
Warning regarding non-original parts . . . 18
Selecting the driving mode . . . . . . . . . . . 43
Washing instructions . . . . . . . . . . . . . . 112
Servicing and maintenance measures . 106
Washing the exterior of the truck . . . . . . 112
Servicing wheels and rollers . . . . . . . . . 114
Work that must also be carried out . . . . . . . . . . . . . . . . . . . 121, 130
Side access battery: changing the battery using a moveable support . 85
Working on the electrical equipment . . . 106
Side access lithium-ion batteries Connecting/disconnecting the battery connector . . . . . . . . . . . . . 55
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