Still EXP 14, Original Instructions Manual

Page 1: ...nal instructions Pallet stacker EXV 14 16 20 EXV 14i 16i 20i EXV SF 14 16 20 EXV SF 14i 16i 20i EXP 14 16 20 0301 0303 0305 0323 0324 0325 0326 0327 0328 0329 0330 0331 0332 0333 0334 45758043402 EN 02 2015 ...

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Page 3: ...ft 7 Applied equipment 8 User obligations 8 Environmental considerations 8 Disposal of components and batteries 8 Packaging 9 2 Safety Safety guidelines 12 General Precautions 12 General Safety Rules 12 Flooring requirements 12 Battery connection cables 13 Requirements for the traction battery charging area 13 Safety Regulations Relative to Forklift Use 13 Safety Regulations Relative to Operating ...

Page 4: ...esent on EXV and EXVi versions 42 Types of lifting masts 43 Side protection 45 Description 45 Platform 47 Description 47 Definition of directions 49 Markings 50 Location of labels 50 Serial number 52 Data plate 52 Capacity plate 53 Chassis frame labelling 54 Options and variants 55 List of options and variants 55 Straddle automatic lowering optional 56 Accessories mounting bar with data socket 57 D...

Page 5: ...Tiller always active Creep Speed function optional 75 Reverse drive 76 Truck brake systems 76 Parking and stopping the truck 77 Forklift Use in Cold Storage Rooms 78 Movement of the load 79 Safety guidelines for handling loads 79 Checks to be carried out before lifting a load 82 Adjusting the fork distance if present 83 Automatic speed reduction with forks raised above the safety sensors 84 Pickin...

Page 6: ...val from the top 102 Battery replacement with side removal 105 Putting out of commission 108 General Information 108 Forklift Towing 109 Temporary Putting Out of Commission 109 Checks and Inspections After a Long Period of Inactivity 109 Permanent Putting Out of Commission Demolition 109 6 Technical data EXV and EXVi overall dimensions 112 EXV SF and EXVi SF overall dimensions 113 Datasheet 114 EX...

Page 7: ...1 Introduction ...

Page 8: ... of industrial vehicles and on the labels and adhesive supplied to the forklift The forklift may not be put to any use other that than indicated in this manual The forklift must be used by appropriately trained operators only For the necessary operator training contact the authorised sales network Persons working near the forklift must also be instructed in the risks associated with use of the for...

Page 9: ...ghted with this symbol may cause damage to the forklift and in some cases result in warranty invalidity ENVIRONMENT NOTE Failure to observe the instructions highlighted with this symbol may cause environmental damage NOTE This symbol is used to provide additional information 45758043402 EN 3 ...

Page 10: ...n Ensure that the truck has all of the options requested and that it has been delivered with the following documentation Original instructions Rules for the compliant use industrial vehicles EC Declaration of Compliance Warranty book If the forklift has been delivered with a traction battery and or battery charger ensure that such products conform to the order and that the relative user and mainte...

Page 11: ... STILL GmbH Berzeliusstraße 10 D 22113 Hamburg Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH 45758043402 EN 5 ...

Page 12: ... with standard EN 13059 and declared in accordance with standard EN 12096 The limit values for the electromagnetic emissions and immunity relative to the forklift are those set out in the EN 12895 standard Type of use Normal use conditions of the forklift are understood as lifting and or transport of loads using forks with weight and load centre within the values provided see Chapter 6 Technical D...

Page 13: ...c fields etc appropriate equipment and or use precautions are necessary Contact the authorised sales network for more informa tion DANGER The forklift may not be used in environments in which there is a risk of explosion It may not be used to handle explosive loads For forklifts that must operate in environments in which there is a risk of explosion or must handle explosive loads appropriate equip ...

Page 14: ...ith applicable local legis lation governing forklift use and maintenance Environmental considerations Disposal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufact...

Page 15: ...ivery of the truck certain parts are packaged to provide protection during transport This packaging must be removed completely prior to initial start up ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck 45758043402 EN 9 ...

Page 16: ...1 Introduction Environmental considerations 10 45758043402 EN ...

Page 17: ...2 Safety ...

Page 18: ...es Never raise the load using just one fork Place the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork carriage The load must be placed on the fork arms so that the centre of gravity falls lengthwise on the mid point between the fork arms Do not drive with loads off centre laterally with respect to the forklift s median axis Lack...

Page 19: ...minate the gases produced EN 50272 3 Safety Regulations Relative to Forklift Use The operator must familiarize himself with the forklift to be able to better describe any defects and assist maintenance personnel The operator trained and authorized to use the forklift must be familiar with the controls and performances of the forklift Any defect squeaking leaks etc must be promptly reported because...

Page 20: ...the anti pollution laws ENVIRONMENT NOTE The incorrect or unlawful use of brake fluid is harmful to people s health and the environ ment Oils Do not allow to come into contact with the skin Do not inhale oil vapors Wear appropriate means of individual protection during forklift maintenance operations gloves goggles etc to prevent the oil from coming into contact with your skin ENVIRONMENT NOTE The ...

Page 21: ... Nevertheless even when the truck is used for its proper purpose and all instructions are followed some residual risks cannot be excluded Even outside the defined danger areas of the truck residual risk cannot be excluded Persons in this area around the truck must exercise a heightened degree of awareness so that they can react immediately in the event of any malfunction incident or breakdown etc W...

Page 22: ...h up to date technical regulations and is guaranteed if the truck is used correctly and in line with the intended purpose These standards only take into account the static and dynamic tipping forces that can arise during use in accordance with the operating standards and intended purpose In extreme cases there is a risk of exceeding the moment of tilt due to improper use or incorrect operation whi...

Page 23: ...oise Sound pressure level in driver s seat LpAZ 70 dB A Uncertainty factor KpA 4 dB A The value is determined in a test cycle in accordance with Harmonised European Standard EN 12053 and declared according to EN ISO 4871 with weighted time percentages of the Transport Lifting and Idling modes CAUTION The value expressed above can be used to com pare forklift trucks of the same category This can no...

Page 24: ...measuring vibration CAUTION The value expressed above can be used to com pare forklift trucks of the same category It cannot be used to determine the operator s daily expo sure to vibrations during real operation of the truck these vibrations depend on the conditions of use floor conditions method of use etc and therefore daily exposure must be calculated using data from the place of use 18 4575804...

Page 25: ...complete check of the technical condition of the truck must be performed with regard to accident safety In addition the truck must be thoroughly checked for damage that could potentially have been caused by improper use A test log must be created The results from the inspection must be retained until a further two inspections have been carried out The inspection date is indicated by an adhe sive l...

Page 26: ...k OM2308 10 1 2 3 3 4 5 6 7 8 9 10 11 12 11 13 14 1 Emergency shutdown handle 2 Tiller position sensor The truck will not move if the tiller is not in the correct usage position 3 Operator anti crush safety button Protects the operator from potential crushing by braking the truck 20 45758043402 EN ...

Page 27: ...ised approximately 500 mm above the ground 9 1500 mm sensor Automatic speed reduction with forks raised approximately 1500 mm above the ground 10 Automatic truck braking when the tiller is released by the operator 11 Horn Used to indicate the presence of the truck during travel 12 Combi tiller clasp closure sensor If the clasp is not closed properly the truck will not move 13 Fork stop latches Use...

Page 28: ... not functional or safe may not be used until they have been properly repaired Do not remove or deactivate safety devices and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g connecting a radio additional headlights etc is only permitted with the manufacturer s written approval All electrical system interventions must be document...

Page 29: ...3 Overview ...

Page 30: ...f lift mast Telescopic post two section telescopic post without free lifting and two side cylin ders NiHo post two section telescopic post with free lifting lateral chains and two lateral cylinders plus a central cylinder Triplex post three section telescopic post with free lifting lateral chains and two lateral cylinders plus a central cylinder Driving The 185 W electric steering motor operates t...

Page 31: ...device controlled by the release of the tiller safety electromagnetic controlled when the tiller arm reaches the lower end position service brake Electromagnetic parking device applied when there is a power cut On board equipment The on board equipment includes a glove compartment for storing adhesive tape gloves pens etc A switch for emergency shutdown located on the chassis A multifunction displ...

Page 32: ...gency stop handle 5 Helm 6 With operator side protective guards 7 Bonnet 8 Pivoting wheel 9 Operator s Platform 10 Drive wheel 11 Display 12 Straddles 13 Load rollers 14 Battery plug socket 15 Forks 16 Battery compartment hood 17 Anti shearing guard 18 Diagnostic test socket Service technical assistance 19 Digicode Numeric Keypad 20 Helm 26 45758043402 EN ...

Page 33: ...Overview 3 Instruments and controls Instruments and controls Start stop key The key has two positions 0 Stop No voltage to the circuit Key removal position I Start Circuit powered 45758043402 EN 27 ...

Page 34: ...d limited performance Other indicator lights 4 The light comes on depending on whether the operator is present The indicator light flashes when the truck does not detect the presence of the operator through the tiller or the platform The tiller is not tilted to the working position or the operator is not correctly positioned on the platform The indicator light is lit when the truck starts to detect...

Page 35: ...entries for each screen or backwards between one screen and the other By pressing the button C you move forwards between the items for each screen or forwards between one screen and the other By pressing the button D you confirm your selection of the item of the selected screen Status OM2296 05 12 2014 hrs 5242 8 93 11 05 STATUS The following are displayed on the Status screen Clock and date Batter...

Page 36: ...M2292 Visita di manutenzione prevista oggi 1 1 ERROR The message warns that the scheduled maintenance is due today The message is set by the technical service department authorised by the manufacturer according to the agreements with the customer OM2293 Prossima manutenzione 100 hrs 1 1 ERROR The message informs you of when the next maintenance work is due The message is set by the technical servi...

Page 37: ... to lift the forks and the load higher keep the first button on the right on the keypad D pressed for around three seconds OM2294 Altezza superata Avvertimento F The rectangle E on the display turns yellow and the word OK disappears The warning triangle that warns the operator to pay special attention when moving loads appears in its place OM2305 1 1 ERROR The message warns that for safety rea sons...

Page 38: ...ee Chapter Location of labels P 3 50 CAUTION The operator must assess whether to close the side protection before lifting the forks higher OM2303 Livello di carica della batteria basso 1 1 ERROR The message indicates that the battery charge level is low Charge the battery OM2304 Batteria scarica 0 Sollevamento limitato 1 1 ERROR If you continue to use the truck without recharging the battery the d...

Page 39: ... inside the truck Switch the truck off and on again If the message does not disappear contact the technical service department authorised by the manufacturer OM2299 LAC Temperatura elevata anormale 1 1 ERROR The message highlights that the electronic system has overheated Shut down the truck and wait for it to cool down If the message reappears contact the technical service department authorised b...

Page 40: ...t to cool down If the message reap pears contact the technical service depart ment authorised by the manufacturer CAUTION If the Error screen displays messages other than those mentioned above please contact the sales network authorised by the manufacturer Emergency shutdown handle Pushing the emergency shutdown handle will lock all of the functions on the truck 34 45758043402 EN ...

Page 41: ... the truck starts moving in the direction of the forks When the throttle 2 or 3 is turned in direction B the truck starts moving in the direction of the operator The truck speed increases or decreases according to the angular position of the throttle Releasing the throttle causes braking and subsequently the stopping of the truck Fork lowering button 4 Press the button 4 to lower the forks Fork mo...

Page 42: ...the horn This device allows the driver to signal his presence when necessary Anti crush button 7 Press the button 7 while the truck is trav elling towards the operator to automatically reverse the direction of travel When revers ing the truck travel speed is reduced for a few seconds The button 7 is a safety device Particularly useful in narrow areas it prevents the operator from being crushed bet...

Page 43: ...traddle lift function increases the ground clearance meaning that the truck can be used on uneven ground or slopes WARNING Risk of crushing feet Be careful not to put your feet under the straddles while using the initial lift function Straddle lifting button 9 Press the button 9 to lift the straddles when the button is released the straddles will stop in the position attained The straddle lifting ...

Page 44: ...his position the operator can begin lifting or lowering the forks using the appropriate throttle In this position the operator can raise or lower the straddles for versions with straddle initial lift only Position 2 braking position In this position the drive is locked and the parking brake is engaged NOTE In this position lifting and lowering of the forks and straddles if fitted is blocked NOTE Wh...

Page 45: ...he tiller always active function optional slow speed position This function is activated by pressing the slow speed button on the tiller 3 and rotating the traction control throttle 4 or by pressing the slow speed button and the fork lifting button The truck travels at limited speed 45758043402 EN 39 ...

Page 46: ...re starting the truck and only when the truck is stationary Carrying out the operation when the truck is moving is prohibited NOTE The preferred means of use with the combi tiller open is in pedestrian mode operated from the ground Open the clasp to release the tiller Use the handle to pull the tiller to open it 40 45758043402 EN ...

Page 47: ... the truck is stationary Carrying out the operation when the truck is moving is prohibited NOTE The preferred means of use with the combi tiller closed is in ride on mode operated from the platform Use the handle to push the tiller to fold it The clasp closes automatically to lock the tiller CAUTION Check that the tiller is locked correctly 45758043402 EN 41 ...

Page 48: ...e maximum authorised speed varies according to the tilt of the tiller The reference 5 represents the curve of the speed inside zone 2 In zone 3 the truck can reach its maximum speed The traction speed is proportional to the angular position of the throttle In zone 4 the brake is applied and the truck cannot be moved WARNING During use tilt the tiller and gradually change the speed of the throttle ...

Page 49: ...e h3 via the chains the lifting speed of the fork carriage is twice that of the internal mast CAUTION In locations with a low ceiling be aware that the load height may be greater than the mast height h3 h2 0252_003 099 V2 NiHo When the lift button is pressed the fork carriage is raised to the top of the internal mast h2 by the central cylinder then the lateral cylinders raise the internal mast up ...

Page 50: ...03 100 V2 Triplex The function is identical to that of the NiHo mast but has a greater lift height with the same mast height CAUTION In locations with a low ceiling be aware that the load height may be greater than the mast height 44 45758043402 EN ...

Page 51: ...f the truck will be au tomatically limited for safety reasons Position B side protection open Position used with the operator on board the truck standing on the platform Opening and closing the side protection To open pull the two operator side protec tive guards outwards To close push the two operator side protective guards inwards Adjusting the height of the side protection To adjust the height ...

Page 52: ...wer the side protection bars before re clo sing them Otherwise the side protective guards will not close and this may damage the hoods DANGER Do not sit on the side protection bars DANGER Do not climb on the side protection bars 46 45758043402 EN ...

Page 53: ...on B platform in the intermediate position in this position the truck traction is locked Position C platform in the operating position in ride on mode This position is used with the operator on board In this position the traction and truck speed depend on the position of the side protection Side protection open The truck can reach its maximum speed Side protection closed The truck speed is limited...

Page 54: ...of vibrations the platform must be adjusted according to the weight of the operator Adjust the pressure of the damping system based on the weight of the operator using the valve 1 Safety DANGER Risk of ejection from the platform Position yourself correctly on the platform between the two side protection bars standing up facing the forks with both feet inside the platform Turn corners at low speed ...

Page 55: ... 3 Preferred direction of travel Right 4 Definition of directions for EXV SF EXVi SF version with platform lowered and ride on mode operation Direction of movement defined by the regula tions Forward travel 1 Preferred direction of travel Left 4 Reverse travel 3 Right 2 Conclusion To make it easy for the reader to interpret the direction of travel will always be defined in the following manner 1 Dire...

Page 56: ...d maintenance manual label 6 Lifting danger label on initial lift chassis version only 7 Operating and maintenance manual label 8 Version set up for gel batteries 9 On board battery charger label 10 Annual checks label Germany only 11 Operator platform capacity diagram label 12 Maximum permissible pressure label 13 Cold store label on cold store version only 14 Danger of crushing feet label on ini...

Page 57: ...p for the gel battery version Do not use other types of battery 9 This label is only present on the version with the on board battery charger The label highlights the possibility of choosing the charging curve 10 This label is only present on trucks sold in Germany The label indicates the date of the truck s periodic safety inspection 11 This label is only present on the version with operator plat...

Page 58: ...Type 3 Year of production 4 Sequential number 1 Model 2 Manufacturer 3 Serial no 4 Year of manufacture 5 Unladen weight without battery in kg 6 Maximum battery weight 7 Minimum battery weight 8 Additional weight ballast in kg 9 Nominal power rating in kW 10 Battery voltage V 11 Rated capacity in kg 12 EC conformity symbol Data plate NOTE Please indicate the serial no for all technical enquiries 52...

Page 59: ...icated on the capacity plate refer to compact and homogeneous loads and must not be exceeded otherwise the stability of the truck and the load bearing capacity of the structures may be compromised The distances C of the load centre of gravity and the lifting height of the forks HS determine the maximum load capacity DANGER Risk of accident when forks are changed If the forks are changed and a diff...

Page 60: ...3 Overview Markings Chassis frame labelling OM2312 A The truck s serial number is marked A on the chassis frame 54 45758043402 EN ...

Page 61: ...old storage version Cold store Accessories mounting bar Accessories mounting bar with clipboard Accessories mounting bar with storage tray Accessories mounting bar with storage tray and clipboard Accessories mounting bar with data socket Pivoting wheel lubrication nipples Load roller lubrication nipples Various types of cables and plugs Various types of cables and additional plugs Built in rectifie...

Page 62: ...lay to warn that the operator must lower the straddles to be able to raise the forks any further see Chapter Display P 3 28 The forks are locked at 1500 mm from the ground until the operator lowers the straddles If the truck is equipped with the Straddle auto matic lowering option the truck automatically lowers the straddles if raised off the ground when the forks are raised above 1500 mm NOTE On ...

Page 63: ... the plug 4 to be connected to the customer s data terminal as follows Connect the positive to terminal 1 Connect the negative to terminal 2 DANGER Always respect the connections mentioned above 1 and 2 Reversing the polarity is dangerous and strictly prohibited WARNING The instructions provided are for information only Installation must be carried out precisely and in accordance with technical re...

Page 64: ...ration Key in LED status Warning THE ADMINIS TRATOR CODE IS IMPORTANT FOR ALL DIGI CODE SET TINGS 0 0 0 0 0 0 0 0 by default continuous red continuous green 3 Once the diodes have been switched off the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flashing 2 code accepted Example of a new operator code 45678 Allocating operator codes 2 5 4 3 2 1 ...

Page 65: ...h off 3 6 0 red off green flashing 2 value accepted Example automatically switches off after 1 min 60 s if not used Minimum setting 10 s maximum 3000 s Deactivating the automatic switch off 2 0 red off green flashing 2 command accepted Stand by NOTE The stand by function is only available with the Digicode option To prolong battery life the truck can be put into energy saving mode when it is not in ...

Page 66: ...e LED indicates whether it is necessary to top up the distilled water in the battery Operation If the LED 1 or 2 is green there is a sufficient level of electrolyte in the battery The battery must not be topped up with distilled water If the LED 1 or 2 is red there is an insufficient level of electrolyte in the battery The battery must be topped up with distilled water 60 45758043402 EN ...

Page 67: ...4 Use ...

Page 68: ...ny necessary additional safety measures Safety instructions relating to use of the truck Behaviour when driving The operator must obey the same rules within the plant as on the road The operator must drive at a speed appropriate for the driving conditions For example the operator should drive slowly around corners when entering and travelling through narrow passageways when driving through swing d...

Page 69: ...y There is a risk of physical injury inside the danger area Danger of death from falling loads Do not stand on the forks Standing or walking under the forks is strictly forbidden even when they are not loaded Danger area The danger area is the area in which people are in danger from the forklift truck move ments from its work equipment and from its load lifting devices e g accessories or from the ...

Page 70: ...nsure that no unauthorised person approaches the working area Hazards Hazards on the traffic routes must be signalled by standard road signs or possibly by addi tional warning notices Truck transport and lifting OM0747 Transporting the truck The forklift is normally transported by road and rail If the forklift s dimensions exceed the max clearance size allowed it is trans ported disassembled The sa...

Page 71: ...ctor Chocking the truck Secure the truck against rolling and sliding with chocks 1 Lashing down the truck Attach the lashing ropes 2 to the mast Climatic Conditions for Transport and Storage The forklift must be protected from atmo spheric agents during transport and storage 45758043402 EN 65 ...

Page 72: ... sling must have a capacity suitable for the weight of the truck The position is indicated by a hook symbol DANGER Use a crane with a suitable lifting capacity for the weight of the truck indicated on its data plate Also take into account the weight of the battery fitted if applicable referring to the relevant identification plate Lifting operations must be performed by qualified personnel DO NOT sta...

Page 73: ...ration of the wheels and rollers The wheels and the load rollers must roll freely The wheels must not show any sign of damage or heavy wear They must be correctly mounted The roller tracks of the column must be coated in a visible film of grease The chains must be undamaged and must be evenly and adequately tensioned Check that the battery cover is fully and properly closed Test that all of the hoo...

Page 74: ... Visually check that the operator platform is in good condition and that it is operating correctly EXV SF only Climb onto the operator platform and turn on the truck Test that the truck goes into forwards re verse travel using the control throttle Climb down from the step plate and visually check that the operator platform automatically moves to a rest position tilted slightly upwards Stand to the...

Page 75: ...rsion driving on the ground The operator should drive the truck using the driving and lifting controls located on the helm head DANGER All other positions should be considered incorrect and dangerous OM2278 Recommended position for pick up and deposit of the load Recommended position when in gear preferential gear 45758043402 EN 69 ...

Page 76: ...sed completely The platform is closed completely With standard tiller or combi tiller closed the maximum speed of travel is limited for safety reasons With combi tiller open the maximum authorised speed is slightly higher as the operator moves the truck from a greater safety distance CAUTION The truck may only be operated in pedestrian mode if the side protection and the side panels are fully clos...

Page 77: ...a safer situation restrained by the side protection CAUTION The truck may be operated in ride on mode with the side protection either open or closed CAUTION In ride on mode opening the combi tiller is prohibi ted If the clasp to close the tiller is not shut properly the truck will not start DANGER Risk of falling from the platform Position yourself correctly on the platform between the two operato...

Page 78: ...rgency shutdown handle by lifting it CAUTION This protective device must be used only in emer gencies the repeated use of this device may cause problems with the electronic equipment or break downs Starting the truck Carry out all of the daily checks to be per formed by the operator Pull the emergency shutdown handle Put the tiller in the vertical position To start the truck turn the switch key to...

Page 79: ...ruck do not persist but look for the cause Ride on drive mode version only for version with platform Grip the tiller head correctly Manually open the platform Manually open the operator protective guards Mount the platform Tilt the tiller to the working position Select the desired direction of movement using the throttle the truck speed is propor tional to the angular position of the throttle The ...

Page 80: ... G while travelling towards A the truck steers towards C When the tiller is turned anti clockwise G while travelling towards B the truck steers towards D When the tiller is turned clockwise H while travelling towards A the truck steers towards E When the tiller is turned clockwise H while travelling towards B the truck steers towards F 74 45758043402 EN ...

Page 81: ... disable this function To enable travel with the tiller in the vertical position Press and hold the button 3 Then turn the throttle 4 in the desired direction Creep speed of the truck 1 5 km h is enabled During creep speed with the tiller in the vertical position and the button 3 pressed if the operator tilts the tiller into the working position see Chapter Tiller positions P 3 38 the speed of tra...

Page 82: ...he drive control throttle During travel release the drive control throttle The truck will decelerate gently to a stop Braking by reversing the drive control throttle During travel turn the drive control throttle in the opposite direction to the direction of movement The truck will decelerate more forcefully but will come to a gradual stop When the truck has stopped release the drive control thrott...

Page 83: ...lose the platform and the operator s protective devices Switch off the truck by turning the key to position 0 and remove the key from the panel or alternatively if there is one switch off the truck by means of the numeric keypad Digicode DANGER Park the truck in such a way as not to obstruct pas sageways and or render unusable the emergency equipment e g fire extinguishers and fire hy drants 4575804...

Page 84: ...s CAUTION The forklift must always be turned off and parked outside the cold area cold storage room CAUTION If the truck has been working in environments at temperatures below 5 C and it is taken outside the cold storage room let it stand either for a sufficien tly long time to allow evaporation of any condensa tion at least 30 minutes or a sufficiently short time to prevent the formation of any con...

Page 85: ... there are people under or on top of the forks do not move the truck Do not move the forks and do not drive the truck DANGER Risk of accident when forks are changed If the forks are changed and a different type of forks to the original forks is fitted the residual load capacity changes When forks are changed a new residual capacity plate must be affixed If a truck is supplied without forks the resid...

Page 86: ...i mensions and weight fall within the truck specifi cations as indicated in the TECHNICAL DATA chapter DANGER The loads must be arranged so that they cannot slip or overturn and fall to the ground In order to guarantee load stability make sure that the load is balanced and centred on the forks DANGER Standing or walking under the raised load is strictly prohibited Make sure that nobody stands under...

Page 87: ... the load NOTE Further information on the general rules of truck use and taking up and depositing loads is provided in the Safety Regulations for Industrial Forklift Use manual attached to this manual 45758043402 EN 81 ...

Page 88: ... weight to the truck Never exceed the maximum loads shown Otherwise the stability of the truck can no longer be guaranteed Transporting people in order to increase the capa city of the truck is prohibited Example Weight of load to be lifted 1200 kg 3 Distance between the load centre of gravity fork carriage 600 mm 1 Permissible lift height 2600 mm 2 WARNING The illustrations are only examples Only...

Page 89: ...stalled on the forks Move the fork arms 3 in relation to the dimensions of the load to be lifted Ensure that the two forks are kept at an equal distance from the axle centre of the truck Lock the forks in position again by moving the lever 1 or knob 2 in the opposite direction and ensuring that the forks are locked in one of the notches on the fork carriage rail 45758043402 EN 83 ...

Page 90: ...riving speed reduction fully release the drive throttle after lowering the forks below the sensor height 500 mm and 1500 mm At this point if the throttle is turned again the truck will continue without the previous automatic speed reduction Picking up the load Load pick up from the ground Approach the load with caution and with as much precision as possible Lower the forks and the straddles so tha...

Page 91: ... pick up from shelving Approach the shelving at moderate speed Use the drive control throttles to gradually slow down and stop the truck perpendicular to the shelving with the tiller in the braking position Check that there is sufficient space between the forks and the shelving Raise the forks until you reach the correct fork insertion height Move the truck slowly forwards to insert the forks into ...

Page 92: ...ed up Raise the load a few centimetres until it is resting fully on the forks If the load is stable and secure on the forks proceed with the following steps In the event of uncertainty and or a load that is not properly secure or stable lower the forks and place the load back on the shelving Put the tiller in the driving position Look behind to check that the way is clear Turn the throttle in the ...

Page 93: ...Use 4 Movement of the load Lower the load to the transport position approximately 300 mm from the ground and read the Transporting loads section 45758043402 EN 87 ...

Page 94: ...ator s view a second person on foot must assist with manoeuvres in order to warn the driver of any obstacles In this case driving is only autho rised at walking speed and with the greatest care Stop the truck immediately if you lose contact with the person accompanying you DANGER Lower or raise the load until there is sufficient ground clearance approximately 300 mm Never transport loads with forks...

Page 95: ...he desired area and release the fork arms from the load Back up with the forklift DANGER Never leave the forklift with the forks raised whether loaded or not NOTE Further information on the general rules of forklift use is provided in the Rules for the Use of Industrial Vehicles Manual enclosed with this manual 45758043402 EN 89 ...

Page 96: ...truck on a lift Using the truck on lifts is only allowed if the lift has sufficient load capacity check the maximum weight of the truck including the traction battery and only with appropriate authorisation Slowly drive the truck onto the lift load first Secure the truck in the lift so that no part comes into contact with the walls of the lift A minimum distance of 100 mm from the walls of the lift ...

Page 97: ...iscon nect the battery plug and socket by means of the appropriate handle Closing the battery cover Close the battery cover WARNING Danger of crushing Be sure not to leave anything between the battery cover and the edge of the chassis when closing the cover DANGER It is absolutely forbidden to use the truck with the covers open In order to use the truck the covers for access to the inner parts mus...

Page 98: ...efore accessing the inner parts of the truck carefully follow the instructions given in Chapter 5 entitled Maintenance Access to the inner parts of the truck by personnel not authorised by the manufacturer is forbidden 92 45758043402 EN ...

Page 99: ... battery charger Connect plug the battery charger in to begin charging After the battery charging operation is completed turn off the battery charger Unplug the battery charger Replace the battery caps if removed previously Plug the battery in again Lower the battery compartment cover NOTE Refer to the battery charger manual for more information Charging curve selector only with on board battery c...

Page 100: ...ing pro cedures level checks etc checking the type of battery gel lead etc and the voltage and current delivered Excessive currents can damage batte ries and cause dangerous situations As regards safety precautions follow the instructions given in the battery manual and those included in the Sa fety Guidelines of this manual DANGER If the truck is fitted with an on board battery charger it is stric...

Page 101: ...nged by spe cially trained personnel in accordance with the manufacturer s instructions for the battery the battery charger and the truck The main tenance instructions for the battery must be observed Fire prevention measures WARNING Do not smoke or use a naked flame when handling batteries In the area designated for parking the truck to recharge the battery or battery charger there should be no fla...

Page 102: ...attery and the battery outlet is inserted If the truck is enabled for side removal of the battery the truck can only be operated once the battery is fixed in place properly using the battery locking system 96 45758043402 EN ...

Page 103: ...5 Maintenance ...

Page 104: ...rk authorised by the manufacturer in order to maintain the machine in perfect condition and compliant with technical specifications NOTE Contact the authorised service network for a maintenance contract appropriate to your forklift CAUTION When the forklift is used in dusty environments at below zero temperatures and for especially heavy uses it is necessary to reduce the interval between the vario...

Page 105: ...ear on the lift motor brushes and replace if necessary Check truck braking Check and adjust electromagnetic brake Check that the forks are in good condition Check condition of piping Check for oil leaks from cylinders and hydraulic connectors Check chain maintenance and adjust ment Lubricate fork and mast sliding track Grease the rods and levers i version only Check the bushings and replace if nec...

Page 106: ... unit 1000 a To be repeated every 1000 hours for example at 1000 2000 3000 4000 5000 etc or at least every 12 months whichever comes first 2000 b To be repeated every 2000 hours For example at 2000 4000 6000 8000 10 000 5000 c To be repeated every 5000 hours For example at 5000 10 000 15 000 20 000 Every 1000 hours or at least every 12 months whichever comes first unless local regulations require mo...

Page 107: ...of accident Load chains are safety components The use of cold chemical cleaning agents or fluids that are corrosive or contain acid or chlorine can damage the chains and is therefore prohibited Follow the manufacturer s guidelines before using a cleaning agent Place a collection vessel under the lift mast Clean with paraffin derivatives such as benzine If using a steam jet do not use any addi tional...

Page 108: ...battery cover Unplug the battery connector Remove the cover to gain access to the fuse holder The following fuses are found on the fuse holder Reference Name Description Value 1 1F1 fuse Main lifting and traction fuse 300 A 2 3F1 fuse Electric steering fuse 30 A 3 1F3 fuse Auxiliary supply fuse 7 5 A 4 1F4 fuse Pump unit solenoid valve fuse 5 A Battery replacement with removal from the top Turn of...

Page 109: ...personnel DO NOT stand within the crane s radius of action or near the truck Do not stand in the danger area beneath suspended loads Use NON METALLIC slings Make sure that the lifting capacity of the slings is suitable for the weight of the battery The slings must be pulled vertically To prevent short circuits it is recommended that batteries with polar terminals or unprotected connections be cove...

Page 110: ... When inserting and or extracting the battery from the top 2 the battery must be tilted as shown CAUTION Before using the truck refit the protective guard 1 Using the truck without the anti shearing protective guards is prohibited 104 45758043402 EN ...

Page 111: ...e arrow in the adjacent picture Labels written in English on the lever indicate Lock Battery i e the direction to lock the battery and Unlock Battery i e the direction to unlock the battery The spring of the battery lock lever will push the lever upwards This will release the battery Place the manufacturer approved battery side removal roller unit next to the truck position it so that it is still ...

Page 112: ...nnections be covered with a rubber mat Change the battery and refit it by following the above steps in reverse order When installing the new battery be partic ularly careful during the battery insertion stage Push the battery inwards sliding it along the rollers on the truck and positioning it on the previously prepared external roller unit DANGER Danger of crushing hands between the battery frame ...

Page 113: ...ng the battery cover take care to po sition the cables of the battery male connector correctly so as not to damage them NOTE After having positioned the battery holddown check that there is little or no clearance in the battery compartment 45758043402 EN 107 ...

Page 114: ...ce Putting out of commission Putting out of commission General Information The operations to be performed for Tem porary decommissioning and Permanent decommissioning are listed in this chapter 108 45758043402 EN ...

Page 115: ... Long Period of Inactivity DANGER Perform the following operations before using the forklift Clean forklift truck thoroughly Check the battery charge level and re assemble it in the forklift making sure to spread Vaseline on the terminals Lubricate all of the parts provided with lubricating nipples and the chains Carry out the fluid level checks Perform all of the functional maneuvers of the forkli...

Page 116: ...5 Maintenance Putting out of commission 110 45758043402 EN ...

Page 117: ...6 Technical data ...

Page 118: ...6 Technical data EXV and EXVi overall dimensions EXV and EXVi overall dimensions 112 45758043402 EN ...

Page 119: ...Technical data 6 EXV SF and EXVi SF overall dimensions EXV SF and EXVi SF overall dimensions 45758043402 EN 113 ...

Page 120: ...1 9 Wheelbase y mm 1311 4 1311 4 1233 3 4 WEIGHT EXV 14 EXV 16 EXV 14i EXV 16i 2 1 Service weight with battery kg 1178 1144 2 2 Axle load with load drive side load side kg 964 1614 983 1795 889 1655 896 1847 2 3 Axle load without load drive side load side kg 867 311 836 308 WHEELS EXV 14 EXV 16 EXV 14i EXV 16i 3 1 Tyres Polyurethane Polyurethane 3 2 Drive wheel sizes mm Ø 230 x L90 Ø 230 x L90 3 3...

Page 121: ...4 4 20 Length including fork shoulder l2 mm 800 2 4 800 2 4 4 21Total width b1 mm 800 800 4 22Fork dimensions s e l mm 55 8 182 1150 55 8 182 1150 4 24Fork carriage width b3 mm 780 780 4 25Fork spread b5 mm 560 680 560 680 4 26 b4 mm 255 375 255 375 4 32 Ground clearance centre of wheelbase m2 mm 30 9 20 9 150 3 4 34 Aisle width with pallets 800 x 1200 Ast mm 2465 4 2348 4 10 2448 3 4 11 2333 3 4 ...

Page 122: ...cycle kWh h 1 14 1 15 1 24 1 25 OTHER EXV 14 EXV 16 EXV 14i EXV 16i 8 1 Type of drive control AC control AC control 8 4 Noise level at operator s ear dB A 66 66 1 In brackets capacity on the forks for the version with fork initial lift i 2 Values for Tele or NiHo mast x value 26 mm l1 l2 26 mm with Triplex mast 3 Fork arms raised see the figure with apostrophe for dimensions 4 Value with battery su...

Page 123: ...aximum surmountable gradient with capacity of 2000 kg on the fork side with the initial lift option Datasheet VDI EXV SF 14 EXV SF 16 and EXV SF 14i EXV SF 16i CHARACTERISTICS EXV SF 14 EXV SF 16 EXV SF 14i EXV SF 16i 1 3 Power unit electric diesel petrol LPG Electric Electric 1 4 Drive type manual pedestrian stand on seated order picker Pedestrian Standing Pedestrian Standing 1 5 Load capacity Q ...

Page 124: ...m 534 534 3 7 Track width load side b11 mm 380 380 DIMENSIONS EXV SF 14 EXV SF 16 EXV SF 14i EXV SF 16i 4 2 Height of mast lowered h1 mm 1915 6 1915 6 4 3 Free lift h2 mm 150 6 150 6 4 4 Lift h3 mm 2844 6 2844 6 4 5 Height of mast extended h4 mm 3364 6 3364 6 4 6 Initial lift h5 mm 110 4 9 Height of tiller arm in driving position min max h14 mm 1175 1380 1175 1380 4 15Fork height lowered h13 mm 86...

Page 125: ... 0 35 14 0 40 0 35 0 40 0 35 14 5 8 Climbing ability KB 5 with without load 10 23 15 10 8 19 22 5 10Service brake Electric Electric TRANSMISSION EXV SF 14 EXV SF 16 EXV SF 14i EXV SF 16i 6 1 Traction motor S2 60 min kW 2 3 2 3 6 2 Lifting motor S3 15 kW 3 2 3 2 6 3 Battery acc to DIN 43 531 35 36 A B C no 2 PzS 2 PzS 6 4 Voltage Nominal capacity V Ah 24 230 24 230 6 5 Battery weight 5 kg 212 212 6...

Page 126: ...ddles lowered 42 mm 14 Value with straddles lowered 78 mm 15 5 16 Speed in pedestrian mode Speed standing without side protection Speed standing with side protection 16 On slopes with gentle start and forks raised geometric limit with start of slope at 9 2 17 Value with Tele mast h3 4644 mm 18 Rounded edge on the side with forks lowered geometric limit on slope 9 2 19 In brackets maximum surmounta...

Page 127: ...ive wheel sizes mm Ø 230 x L90 Ø 230 x L90 3 3 Wheel sizes load side mm Ø 85 x L85 Ø 85 x L60 4 Ø 85 x L105 Ø 85 x L80 4 3 4 Stabiliser wheels sizes mm Ø 150 x L50 Ø 150 x L50 3 5 Wheels number drive side load side x drive wheel 1x 1 2 1x 1 4 4 1x 1 2 1x 1 4 4 3 6 Track width drive side b10 mm 534 534 3 7 Track width load side b11 mm 370 370 DIMENSIONS EXV 20 EXV 20i 4 2 Height of mast lowered h1 ...

Page 128: ...500 8 2576 3 10 2461 3 8 10 4 35Turning radius Wa mm 1757 1640 8 1679 3 11 1564 3 8 11 PERFORMANCE EXV 20 EXV 20i 5 1 Travel speed with without load km h 6 0 6 0 13 6 0 6 0 13 5 2 Lifting speed with without load m s 0 15 0 30 12 0 15 0 30 12 5 3 Lowering speed with without load m s 0 31 0 31 12 0 31 0 31 12 5 8 Climbing ability KB 5 with without load 8 23 13 8 23 5 10Service brake Electric Electri...

Page 129: ...t table 6 With load rack mandatory for SF 7 Value with platform lowered 8 With forks fully lowered m2 13 mm 9 Values with fender 10 Value with straddles lowered 17 mm 11 Value with straddles lowered 42 mm 12 Value with straddles lowered 78 mm 13 5 14 Speed in pedestrian mode Speed standing without side protection Speed standing with side protection 15 Value with Tele mast h3 3584 mm 16 Rounded edg...

Page 130: ...ve side load side kg 1141 434 1096 412 WHEELS EXV SF 20 EXV SF 20i 3 1 Tyres Polyurethane Polyurethane 3 2 Drive wheel sizes mm Ø 230 x L90 Ø 230 x L90 3 3 Wheel sizes load side mm Ø 85 x L85 Ø 85 x L60 4 Ø 85 x L105 Ø 85 x L80 4 3 4 Stabiliser wheels sizes mm 2x Ø 140 x L50 2x Ø 140 x L50 3 5 Wheels number drive side load side x drive wheel 1x 2 2 1x 1 4 4 1x 2 2 1x 1 4 4 3 6 Track width drive si...

Page 131: ...Ast mm 2519 2909 6 2503 3 9 2892 3 6 9 4 34 1 Aisle width with pallets 1000 x 1200 Ast mm 2557 2947 6 2517 3 10 2906 3 6 10 4 35Turning radius Wa mm 1697 2087 6 1620 3 11 2009 3 6 11 PERFORMANCE EXV SF 20 EXV SF 20i 5 1 Travel speed laden un laden km h 4 0 4 0 6 0 6 0 8 0 10 0 13 14 4 0 4 0 6 0 6 0 8 0 10 0 13 14 5 2 Lifting speed with without load m s 0 15 0 30 12 0 15 0 30 12 5 3 Lowering speed ...

Page 132: ...apostrophe for dimensions 4 In brackets tandem rollers 5 Value with Tele mast h3 2684 mm For other values see mast table 6 With load rack mandatory for SF 7 Value with platform lowered 8 With forks fully lowered m2 13 mm 9 Values with fender 10 Value with straddles lowered 17 mm 11 Value with straddles lowered 42 mm 12 Value with straddles lowered 78 mm 13 5 14 Speed in pedestrian mode Speed stand...

Page 133: ...Technical data 6 EXP overall dimensions EXP overall dimensions 45758043402 EN 127 ...

Page 134: ...Wheelbase y mm 1406 5 WEIGHT EXP 14 EXP 16 EXP 20 2 1 Service weight with battery kg 1516 1556 1605 2 2 Axle load with load drive side load side kg 1146 2374 1160 2400 1187 2422 2 3 Axle load without load drive side load side kg 1072 444 1086 470 1113 492 WHEELS EXP 14 EXP 16 EXP 20 3 1 Tyres Polyurethane Polyurethane Polyurethane 3 2 Drive wheel sizes mm Ø 230 x L90 Ø 230 x L90 Ø 230 x L90 3 3 Wh...

Page 135: ...5 1265 4 15 Fork height lowered h13 mm 50 4 19 Overall length without load l1 mm 2071 2 2107 2 4 20 Length including fork shoulder l2 mm 921 2 6 4 957 2 6 4 4 21 Total width b1 mm 1170 1370 1570 4 22 Fork dimensions s e l mm 35x100x1150 45x120x1150 4 24 Fork carriage width b3 mm 820 4 25 Fork spread b5 mm 400 720 430 750 4 26 b4 mm 860 1060 1260 4 32 Ground clearance centre of wheelbase m2 mm 30 4...

Page 136: ...otor S3 15 kW 3 2 6 3 Battery acc to DIN 43 531 35 36 A B C no 3 PzS 10 6 4 Voltage Nominal capacity V Ah 24 345 6 5 Battery weight 5 kg 288 OTHER EXP 14 16 20 8 1 Type of drive control AC control 8 4 Noise level at operator s ear dB A 66 1 With Tele and NiHo mast 26 mm 2 With Tele and NiHo mast 26 mm 3 In brackets truck with tandem rollers 4 Value with Triplex mast h3 4266 mm 5 Value with Triplex...

Page 137: ...AL 7021 300 3 PzV gel 585 330 3 PzV gel 600 345 3 PzS lead 570 575 786 x 211 x 630 63 24 V 375 3 PzS lead 600 605 Silver metal lic 400 4 PzV gel 585 440 4 PzV gel 600 Side extrac tion 786 x 310 x 630 67 24 V 500 4 PzS lead 600 605 Silver metal lic Battery extrac tion type TROG Bat tery ca pac ity Ah Battery type Batteries per model of truck l STANDARD O OPTIONAL EXV 14 16 EXV 14i 16i EXV 20 EXV 20...

Page 138: ... PzV gel O l O l l 345 3 PzS lead O l O l l 375 3 PzS lead O l O l l 300 3 PzV gel O O 330 3 PzV gel O O 345 3 PzS lead O O 63 375 3 PzS lead O O 400 4 PzV gel O 440 4 PzV gel O Side ex traction 67 500 4 PzS lead O 132 45758043402 EN ...

Page 139: ... unit 1 1 ARAL DEGOL GS 220 General and mast lu brication 1 TUTELA MP02 Chain lubrication 1 STRUCTOVIS EHD Supply table for cold storage trucks Quantity Element to be supplied dm3 kg Lubricants Hydraulic system 9 EQUIVIS XV32 Reduction gear unit 1 1 ARAL DEGOL GS 220 General and mast lu brication 1 STATERMELF EP2 Chain lubrication 1 STRUCTOVIS FHD 45758043402 EN 133 ...

Page 140: ...6 Technical data Supply table 134 45758043402 EN ...

Page 141: ...irective 5 Emergency shutdown handle 34 F Fuses 102 I Intended use of the trucks 62 L Lashing down the truck 65 Location of labels 50 O Operator position 70 OptiSpeed 42 Overall dimensions 112 113 127 Overview 26 P Packaging 9 Platform 47 Preparation 95 R Residual dangers 15 Residual risks 15 S Safety Emergencies 72 Safety devices 20 Misuse 22 Safety guidelines for handling loads 79 Safety Inspect...

Page 142: ...Index g Types of lifting masts 43 Triplex 44 U Update of this manual 4 136 45758043402 EN ...

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Page 144: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 45758043402 EN ...