Still EXD 18 Original Instructions Manual
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Still EXD 18 Original Instructions Manual

Lithium-ion batteries
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Original instructions
Lithium-ion batteries
EXD 18
EXU 16, EXU 18, EXU 20
EXU-H
-
0153 0154 0155 0157 0161
0162 0285 0294 0295 1180
1182 1183 1184 1185 1186
11528011651 EN - 09/2019

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  • Page 1 Original instructions Lithium-ion batteries EXD 18 EXU 16, EXU 18, EXU 20 EXU-H 0153 0154 0155 0157 0161 0162 0285 0294 0295 1180 1182 1183 1184 1185 1186 11528011651 EN - 09/2019...
  • Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 11528011651 EN - 09/2019...

  • Page 5: Table Of Contents

    Table of contents Introduction Introduction ............2 Information on the conformity of lithium-ion batteries .
  • Page 6 Table of contents Vertical access battery: Changing the battery ....... 38 Side access battery: Changing the battery .
  • Page 7 Introduction...

  • Page 8: Introduction

    Introduction Introduction Introduction This supplement is specific to lithium-ion the United Nations recommendations on the batteries. It complements the operating transport of dangerous goods. instructions. The latter describe the conditions The battery must not be opened. for using the lithium-ion battery in the truck that you own.

  • Page 9: Information On The Conformity Of Lithium-Ion Batteries

    Introduction Information on the conformity of lithium-ion batteries Information on the conformity of lithium-ion batteries The manufacturer of the lithium-ion battery in accordance with EN 61000–6–2:2006 and and Kion group provider declares that: EN 61000–6–3:2007. the lithium-ion battery This declaration of conformity with EC direc- tives applies only to battery use that conforms conforms with the provisions of the following to the recommendations described in the op-...
  • Page 10 Introduction Information on the conformity of lithium-ion batteries 11528011651 EN - 09/2019...

  • Page 11: Safety

    Safety...

  • Page 12: Special Lithium-Ion Safety Rules

    Safety Special lithium-ion safety rules Special lithium-ion safety rules DANGER • Do not submit the battery to excessive mechanical constraints There is a risk of fire. • Do not expose the battery unit to humidity or Have class D fire extinguishers or inert gas, carbon water (>...

  • Page 13: What To Do In The Event Of Incorrect Use

    Safety What to do in the event of incorrect use What to do in the event of incorrect use Lithium-ion batteries present no chemical – Do not make the person vomit danger in the context of normal use. Batteries – See a doctor as quickly as possible must not be opened or burned for example.

  • Page 14: Personal Protective Measures Following An Incident

    Safety Personal protective measures following an incident DANGER DANGER Electrical risk Risk of explosion: release of gas that may create an explosive atmosphere Do not use water on connected batteries in the charging room. After extinguishing the fire, establish a safety perimeter of at least five metres around the battery.
  • Page 15 Safety What to do in the event of an accidental spillage – Seal battery leakages DANGER Environmental danger – Put the contaminated absorbent product in a plastic bag and dispose of it as special Do not reuse a lithium-ion battery that has leaked. Call the After-Sales Service Centre.

  • Page 16: Transporting A Lithium-Ion Battery

    Safety Transporting a lithium-ion battery Transporting a lithium-ion battery Before transporting any lithium-ion battery, check the current regulations on the transport of dangerous goods. Comply with these when preparing the packaging and transport. Train authorised staff to dispatch lithium-ion batteries. NOTE It is recommended that the original packaging is kept for any subsequent dispatch.

  • Page 17: Scrapping Lithium-Ion Batteries

    Safety Scrapping lithium-ion batteries Scrapping lithium-ion batteries • Use packaging that complies with interna- ENVIRONMENT NOTE tional regulations Comply with current regulations for scrapping • Use the original packaging, if possible. Use batteries. Take care to minimise, as far as sturdy packaging capable of bearing the possible, any impact on the environment.
  • Page 18 Safety Scrapping lithium-ion batteries 11528011651 EN - 09/2019...

  • Page 19: General Views

    General views...

  • Page 20: Differences Between Lithium-Ion Battery Types

    General views Differences between lithium-ion battery types Differences between lithium-ion battery types Dimensions Nominal Nominal Battery type (1) capacity Length Height voltage (V) Depth (mm) Weight (kg) (Ah) (mm) (mm) A1 (one module) 50.5 23.1 A2 (two modules) 70.5 23.1 Dimensions Nominal Nominal...

  • Page 21: Labels On The Top Of Lithium-Ion Batteries

    General views Labels on the top of lithium-ion batteries Labels on the top of lithium-ion batteries Identification label High Voltage label How to switch on the battery label + and - poles on the terminal board Recommendation pictograms label Tamper-proof label NOTE This illustration shows the location of labels on the A1 and A2 batteries.

  • Page 22: Labels On The Sides Of Lithium-Ion Batteries

    General views Labels on the sides of lithium-ion batteries Labels on the sides of lithium-ion batteries Identification label Recommendation pictograms label Transport label (check the regulations in High Voltage label force in your country) Tamper-proof label NOTE This illustration shows the location of labels on the A1 and A2 batteries.

  • Page 24: Checking The Charge Status

    Checking the charge status Checking the charge status DANGER Electrical danger The battery must be charged and serviced in accordance with the instructions provided with the battery and the external charger. – Before using the truck, check that the battery is correctly charged –...

  • Page 25: Vertical Access Lithium-Ion Batteries: Connecting/Disconnecting The Battery Connector

    Vertical access lithium-ion batteries: Connecting/disconnecting the battery connector Vertical access lithium-ion batteries: Connecting/discon- necting the battery connector WARNING 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.

  • Page 26: Starting A Truck Equipped With A Vertical Access Lithium-Ion Battery

    Starting a truck equipped with a vertical access lithium-ion battery Starting a truck equipped with a vertical access lithium-ion battery NOTE 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: –...

  • Page 27: Side Access Lithium-Ion Batteries: Connecting/Disconnecting The Battery Connector

    Side access lithium-ion batteries: Connecting/disconnecting the battery connector Side access lithium-ion batter- ies: Connecting/disconnect- ing the battery connector WARNING 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.
  • Page 28 Commissioning a truck equipped with a side access lithium-ion battery – 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.

  • Page 29: Automatic Battery Shut-Off

    Automatic battery shut-off Automatic battery shut-off It is not necessary to switch off the battery. Contact the After-Sales Service to configure If the truck is not used for a certain period of this. time, the battery is automatically switched off. When the battery is switched off, simply This period of time is normally 2 hours and 5 pressing the button for one second will switch...

  • Page 30: Display On A Truck Equipped With A Lithium-Ion Battery

    Display on a truck equipped with a lithium-ion battery Display on a truck equipped with a lithium-ion battery A 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 stan- dard display.

  • Page 31: Battery Charging Indicator

    Battery charging indicator Battery charging indicator COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES Full charge: 100% 91%–100%: 10 bars Battery charge level Low charge: 10% 1%–10%: 1 bar represented by 10 bars Discharged: 0% 0%: 1 flashing bar From 5% to 2%: reduction of traction speed.
  • Page 32 Battery charging indicator COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES Battery needs charging to 100% Red indicator light Flashing Causes: The battery has not been charged for a week and its charge level is below 90% Switched off: truck switched Green indicator light Switched on: truck switched These codes will help the After-Sales Service Centre...

  • Page 33: Installing The External Charger

    Installing the external charger Installing the external charger The lithium-ion battery must be recharged only DANGER with a special charger. Electrical danger Do not use a charger other than the one The charger must be installed and maintained only by electrical engineers or qualified staff. provided by the Kion group.

  • Page 34: Charging Lithium-Ion Batteries Using An External Charger

    Charging lithium-ion batteries using an external charger Charging lithium-ion batteries using an external charger Read the information in the documentation provided with the charger. It provides information on: • the various charger screens • possible error messages • precautions for use. CAUTION Risk of damage to the battery It is essential to use the charger supplied with the...
  • Page 35 Charging lithium-ion batteries using an external charger To recharge the lithium-ion battery, proceed as follows: – Park the truck close to the charging station. – Secure the truck. Lower the fork arms. – Switch off the ignition (2). – Open the battery compartment cover. –...
  • Page 36 Charging lithium-ion batteries using an external charger – Switch on the ignition (2) and check the charging status of the truck on the display (3). The truck is now ready for use. If the charger stops before charging is com- plete, follow these steps: –...
  • Page 37 Charging lithium-ion batteries using an external charger – Plug the socket of the charging station into the connector (3) located in the technical compartment. – Switch the charger on as directed in the specific instructions for the charger. A screen appears displaying the words Battery connected.

  • Page 38: Using The Side Socket To Charge The Battery

    Using the side socket to charge the battery Using the side socket to charge the battery A side socket (1) can be installed on the battery on the side of the truck. The socket allows you to charge the battery without removing the battery connector (emergency stop handle) of the truck.
  • Page 39 Using the side socket to charge the battery NOTE If the LED remains off, the connector is not detected. Please contact the After-Sales Service Centre. – When charging is complete and the charger has stopped, unplug the charger. NOTE It is possible to stop charging before the end of the complete cycle.

  • Page 40: Battery Charging Times

    Battery charging times Battery charging times The charging time for lithium-ion batteries depends on the charger used. There are two types of chargers. The charging times indicated in the table are provided for information only. They correspond to a complete battery recharge (from 0% to 100%).

  • Page 41: Using The On-Board Charger

    Using the on-board charger Using the on-board charger CAUTION Precautions for installation and use – The electric installation must comply with the standard applicable in your country. – The electric wall socket must be a 2-pole + earth 16-A, 230-V type socket that is correctly connected and protected.
  • Page 42 Using the on-board charger The on-board charger is intended to recharge 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. – Connect the charger plug to a mains wall socket.
  • Page 43 Using the on-board charger CAUTION Risk of damage to the equipment. It is strictly prohibited to use an on-board charger other than the one recommended. CAUTION Risk of damage to the mains cable resulting in electric shock and/or burns! 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.

  • Page 44: Vertical Access Battery: Changing The Battery

    Vertical access battery: Changing the battery Vertical access battery: Changing the battery It is not possible to change the vertical access lithium-ion battery. If the vertical access lithium-ion battery is faulty, please contact the After-Sales Service Centre. Only After-Sales Service Centre technicians are authorised to change the lithium-ion battery.

  • Page 45: Battery Error Codes

    Battery error codes Battery error codes Some errors require only a reset by pushing the ON/OFF button for more than ten seconds. The user does this first handling. If the error persists, contact the After-Sales Service Centre. 11528011651 EN - 09/2019...

  • Page 46: Lithium-Ion Batteries: Long-Term Storage

    Lithium-ion batteries: Long-term storage Lithium-ion batteries: Long-term storage Storage of trucks for a period of less than DANGER two months Electrical danger We recommend that batteries are stored at a height If the truck is not used for a period of up to between 60 and 120 cm.
  • Page 47 Lithium-ion batteries: Long-term storage – Raise and chock the truck: the wheels must all points and devices that are important for not touch the ground in order to prevent truck safety. irreversible deformation of the tyres. Carry out the following operations: –...
  • Page 48 Lithium-ion batteries: Long-term storage 11528011651 EN - 09/2019...

  • Page 49: Maintenance

    Maintenance...

  • Page 50: Maintenance Plan For Lithium-Ion Batteries

    Maintenance Maintenance plan for lithium-ion batteries Maintenance plan for lithium-ion batteries Lithium-ion batteries do not require any spe- cific maintenance. However, it is necessary to perform some maintenance operations. These operations are in addition to the stan- dard service plan for the truck. As required Clean the battery Check the battery connections and sockets...

  • Page 51: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the lithium-ion battery DANGER Electrical danger 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. CAUTION Always switch off the battery before working on an electrical component.

  • Page 52: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Harnesses and cables DANGER Risk of short circuit 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.

  • Page 53: Technical Specifications

    Technical specifications...

  • Page 54: Lithium-Ion Battery Weight Precision

    Technical specifications Lithium-ion battery weight precision Lithium-ion battery weight precision The lithium-ion battery can be installed in a ballast box by the manufacturer if necessary. The battery weight indicated on the identifica- tion label takes into account: • The lithium-ion battery weight •...
  • Page 55 Index Lithium-ion batteries Lithium-ion batteries: Long-term Address of manufacturer ... . . I storage ....40 Automatic battery shut-off .
  • Page 58 STILL GmbH 11528011651 EN – 09/2019...

This manual is also suitable for:

Exu 20Exu 18Exu 16Exu-h

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