Still EXH 25 Original Instructions Manual
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Still EXH 25 Original Instructions Manual

Pallet truck
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Original instructions
Pallet truck
EXH 25
EXH 30
0183 0184 2360 2361
11538011551 EN - 02/2021 - 08

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Summary of Contents for Still EXH 25

  • Page 1 Original instructions Pallet truck EXH 25 EXH 30 0183 0184 2360 2361 11538011551 EN - 02/2021 - 08...
  • 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 11538011551 EN - 02/2021 - 08...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... General .
  • Page 6 Table of contents Overviews Overview ............General views .
  • Page 7 Table of contents Operating the FleetManager™ option ........Description of the FleetManager option.
  • Page 8 Table of contents Maintenance operations that do not require special training ..... . Ordering spare parts and consumables ........Safety guidelines for maintenance.

  • Page 9: Introduction

    Introduction...

  • Page 10: Your Industrial Truck

    Introduction Your industrial truck Your industrial truck General The truck described in these operating instruc- tions 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 regula- tions for the country in which it is being used.

  • Page 11: Ce Labelling

    Introduction Your industrial truck CE labelling  The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. The supplied EC declaration of conformity confirms this. The CE labelling is attached to the nameplate.

  • Page 12: Ec Declaration Of Conformity

    Introduction EC declaration of conformity EC declaration of conformity Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY We declare that the machine 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.

  • Page 13: Identification Label

    Introduction Identification label Identification label  NOTE Indicate the serial number for all technical en- quiries. Model Manufacturer Serial number Year of manufacture Unladen weight (without battery) in kg Maximum battery weight Minimum battery weight (for a lithium-ion battery, the weight of the ballast container is included) Additional weight (ballast weight) in kg Nominal motor power (kW)

  • Page 14: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Eco-design requirements for electric motors and variable speed drives Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. Eco-design requirements for electric motors and variable...

  • Page 15: Spare Parts List

    Spare parts list  The spare parts list can be downloaded by en- tering the address https://sparepartlist.still.eu into a web browser or by scanning the QR code displayed to the side. When the web page is open, please type in...

  • Page 16: Proper Usage

    Introduction Proper usage Proper usage The truck described in these operating instruc- The purpose of obtaining these permissions in tions is suitable for lifting, transporting and advance is to limit danger as far as possible. stacking loads. The capacity label specifies the maximum The truck should only be used for the purpo- load that can be raised.

  • Page 17: Unauthorised Use

    Introduction Unauthorised use Unauthorised use Any danger caused as a result of unauthor- Transporting people is prohibited. ised use becomes the responsibility of the op- The forklift truck should not be used in areas erator or driver and not that of the manufactur- where there is a risk of fire, explosion or corro- sion, or in areas that are particularly dusty.
  • Page 18 Introduction Disposing of components and batteries 11538011551 EN - 02/2021 - 08...

  • Page 19: Safety

    Safety...

  • Page 20: Safety Regulations

    Safety Safety regulations Safety regulations Regular checks and technical inspections These operating instructions, which come with ● the truck, must be communicated to all those Recycling of lubricants, oils and batteries ● concerned and in particular to personnel re- Residual risks. ●...

  • Page 21: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. It is necessary to follow the safety regulations when handling these substances.

  • Page 22: Hydraulic Fluid

    Safety Safety regulations for handling consumables Hydraulic fluid WARNING ENVIRONMENT NOTE During operation of the forklift truck, hy- draulic fluids are pressurised and are Hydraulic fluid is a water-polluting substance! hazardous to your health. Always store hydraulic fluid in containers com- –...

  • Page 23: Disposal Of Consumables

    Safety Safety regulations for handling consumables Disposal of consumables Any spillage of fluids such as hydraulic oil, ● ENVIRONMENT NOTE brake fluid or gear lubricant oil must be im- mediately soaked up with an oil-binding Materials that have to be disposed of following agent.

  • Page 24: Emissions

    Safety Emissions Emissions Noise emission values Calculated during the test cycle performed in accordance with standard EN 12053. Acoustic pressure level in the driver's compartment Truck 60 dB (A) Uncertainty ± 2.5 dB (A) NOTE Lower or higher noise values may occur when using industrial trucks, e.g.

  • Page 25: Residual Dangers, Residual Risks

    Safety Residual dangers, residual risks Residual dangers, residual risks Falling, tripping etc. when moving on the in- Despite all operational precautions and com- ● dustrial truck, especially in the wet, with pliance with standards and rules, the possibili- leaking consumables or icy surfaces. ty of additional risks when using the truck can- Loss of stability due to the load being unsta- not be entirely excluded.

  • Page 26: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal The operating company is responsible for the person or group who operates the truck or on scheduling and correct performance of regular whose authority the truck is used.
  • Page 27 Safety Definition of responsible persons Prohibition of use by unauthorised per- When leaving the truck, the driver must secure it against unauthorised use. sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. 11538011551 EN - 02/2021 - 08...

  • Page 28: Safety Tests

    Safety inspection based on time and ex-  traordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must en- STILL GmbH Hamburg sure that the truck is checked by a specialist at least once a year or after noteworthy inci- Regelmäßige Prüfung dents.
  • Page 29 Overviews...

  • Page 30: Overviews

    Overviews Overview Overview General views Tiller Drive wheel Battery hood Technical compartment External charger socket hood Battery compartment Notepad clip Load arms Stabiliser wheels Load wheels 11538011551 EN - 02/2021 - 08...

  • Page 31: Technical Compartment

    Overviews Overview Technical compartment Pump unit Stabiliser wheels Traction motor Drive wheel ES30–24 steering unit Stabilisers 11538011551 EN - 02/2021 - 08...

  • Page 32: Operating And Display Devices

    Overviews Operating and display devices Operating and display devices Driver's compartment Emergency stop button Display Electronic key or switch key External charger socket hood Diagnostic connector 11538011551 EN - 02/2021 - 08...

  • Page 33: Tiller

    Overviews Operating and display devices Tiller Horn Drive switch Lifting the load arms Anti-collision device Lowering the load arms Creep Speed button Handle 11538011551 EN - 02/2021 - 08...

  • Page 34: Display-Operating Unit

    Overviews Operating and display devices Display-operating unit Operator present indicator light (depending Activity indicator light on the model of the truck) Error Code menu Battery indicator light Settings menu Temperature indicator light Truck status menu Settings indicator light Display of the operating time of the truck Warning indicator light Display of the battery charge Drive programme indicator light...

  • Page 35: Electronic Key (Option)

    Overviews Operating and display devices Electronic key (option) Switch ON (operating mode) Key fault or incorrect code Switch OFF and awaiting code Time delay of automatic switch-off Programming mode active Operation Enter Status of LEDs Comments ○ red off ● continuous (by de- green (1) (correct PIN) * 1 2 3 4 5 #...
  • Page 36 Overviews Operating and display devices PROGRAMMING (truck switch OFF only (2)) To reactivate the default Restoring the ini- administrator code tial administrator (00000000), please con- code tact your agent or nearest dealer. Power switches off auto- ● red flashing ● green matically after 10 mi- Activating the au- flashing (5) (5 seconds...

  • Page 37: Markings

    Overviews Markings Markings Labels Identification label Model label Electrical danger label Consult operating in- Slinging label. Consult operating instructions structions Cold store label Danger instructions label. Consult operating Next inspection label instructions Danger instructions label. Consult operating Brand label instructions 11538011551 EN - 02/2021 - 08...

  • Page 38: Serial Number

    Overviews Markings Serial number  xx xxxx x xxxxx NOTE Indicate the serial number for all technical en- quiries. The serial number contains the following infor- mation: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 11538011551 EN - 02/2021 - 08...

  • Page 40: Technical Description

    Driver's compartment ES30–24 steering unit ● 1.5 kW pump unit (EXH 25 models) and ● The tiller groups together control functions: 2.2 kW pump unit (EXH 30 models). steering, proportional lift, forward and reverse...

  • Page 41: List Of Checks Prior To Start-Up

    List of checks prior to start-up List of checks prior to start-up – Damaged or missing stickers must be re- WARNING placed in compliance with the marking posi- Damage or other defects on the truck or attachments tion table. (special equipment) can result in accidents. –...
  • Page 42 Starting up – Pull the emergency off switch (1) to the top  position. – Turn the switch key (2) or enter the PIN on the electronic key screen and start the truck. The display (3) switches on. The brake is automatically disengaged. –...

  • Page 43: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Checking the anti-crush safety de- vice Anti-crush safety function The machine moves in the opposite direction when the anti-crush 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.

  • Page 44: Checking The Emergency Shutdown

    Checks and actions prior to commissioning Checking the emergency shutdown  To check the operation of the emergency off switch, proceed as follows: – Start up the truck. – Drive the truck. – Press the emergency off switch (1). The truck stops immediately. ●...

  • Page 45: Checking The Horn

    Checks and actions prior to commissioning Checking the horn  – Press the horn button (5) located on the up- per part of the tiller. – The horn sounds. 11538011551 EN - 02/2021 - 08...

  • Page 46: Truck Operating Instructions

    Truck operating instructions Truck operating instructions The trucks are designed for indoor and out- Speed must be reduced when moving over door use in non-hazardous atmospheres. The obstacles to prevent the truck from becoming temperature should be between -10°C and unbalanced and vibrations in the forklift opera- +45°C and the relative humidity of the air less tor's arms.
  • Page 47 Truck operating instructions Before using a side access truck, check that the bat- CAUTION tery is correctly locked. Risk of injury 11538011551 EN - 02/2021 - 08...

  • Page 48: Using The Display-Operating Unit

    Using the display-operating unit Using the display-operating unit Selection buttons  The operator selects the menus using the four selection buttons: The Blue Q button (1) to select Blue Q ● mode, hare mode or tortoise mode The left arrow button (2) to scroll left ●...
  • Page 49 Using the display-operating unit restricted, the (3) icon flashes and the (4) icon remains illuminated with a new warning message. Temperature, settings and warning  lights The Temperature light (1) comes on in the event of overheating of the traction motor or the controller.
  • Page 50 Using the display-operating unit Activity indicator  The Activity indicator light (1) flashes continu- ously while the truck is in operation. When the indicator is off, the display unit is locked or frozen. A warning is shown on the display. Settings menu ...
  • Page 51 Using the display-operating unit Error codes menu  It is possible to access error messages that are disrupting the operation of the truck. – Select the Error messages menu (1) The operator can access the error codes. If several codes are affecting the truck, the oper- ator can scroll through several successive dis- plays.

  • Page 52: Driving Safety Guidelines

    Driving safety guidelines Driving safety guidelines Behaviour when driving Never sit on the dashboard to drive the ● truck Operators must obey the same rules within The truck must not be used as a stepladder ● the plant as on the road. They must drive at The truck is not designed to transport peo- ●...

  • Page 53: Driving

    Driving Driving Defining directions  On a pedestrian-mode pallet truck, the con- ventional directions are: Forward travel (1): tiller direction ● Reverse travel (2): load arms direction ● The load is positioned at the rear. Driving – Turn the ignition key. –...

  • Page 54: Steering

    Driving – Press the lower part (1) of the drive switch  (3) with your thumb. – The speed increases with the movement of the drive switch. – When the drive switch is released, the truck brakes electrically. Reverse travel –...

  • Page 55: Braking

    Driving – Turn the tiller clockwise: the truck turns to  the left in forward travel (1). – Turn the tiller anti-clockwise: the truck turns to the right in forward travel (2). WARNING Risk of serious injury and/or serious damage to equipment Always slow down before negotiating a corner.

  • Page 56: Horn

    Driving Braking by reversing the drive direction  Braking can be achieved by reversing the drive direction: – Move the drive switch (1) or (2) in the oppo- site direction until the truck stops. Braking by releasing the drive switch Braking can be achieved by releasing the drive switch: –...

  • Page 57: Drive Program

    Driving Drive program  The indicator light (1) is on during operation of the truck. The shape of the indicator light indi- cates the selected program. The truck is equipped with three different drive programs: Hare mode (3) ● BlueQ mode (4) ●...

  • Page 58: Creep Speed Function

    Driving Creep Speed function  This function makes it possible to manoeuvre the truck in confined spaces. The tiller remains in the vertical position. – Press the Creep Speed button (1) (tortoise icon) on the tiller. Hold the button down. –...
  • Page 59 Driving Slopes must be approached with great cau- tion: Never attempt a slope whose gradient is ● greater than that specified in the truck's da- tasheet. Make sure that the ground is clean, has a ● non-slip surface and that the route is clear. Travelling up slopes ...
  • Page 60 Driving WARNING Risk of serious injury and/or serious damage to equipment Driving on slopes steeper than 10% is prohibited due to braking capacity and stability. The load being transported could tip over. Starting on a slope Proceed as follows: – Move the drive switch in the required direc- tion.

  • Page 61: Operating The Fleetmanager™ Option

    Operating the FleetManager™ option Operating the FleetManager™ option Description of the FleetManager option The FleetManager option allows you to control GSM: Global System for Mobile Communi- access to the truck. The option is a fleet man- cation agement system. Shock sensor You can access the system: Either by using a keypad This sensor allows you to record the shocks...

  • Page 62: Commissioning A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Commissioning a truck equipped with the FleetManager™ option Commissioning a truck equipped with a  keypad or an electronic key – Turn the switch key to start the truck. – Enter the PIN code on the keypad. The PIN code consists of five to eight digits.

  • Page 63: Fleetmanager™ Option: Colour Code For The Leds

    Operating the FleetManager™ option FleetManager™ option: Colour code for the LEDs The LEDs can have different statuses and dif- ferent colours. Below is the list of the most common messages and their meanings. Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Reading device...
  • Page 64 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has oc- Reset the shock Red colour Green colour curred The truck is The truck is con- switched on but is nected via a Blue- not moving.

  • Page 65: Disconnecting A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Disconnecting a truck equipped with the FleetManager™ option NOTE Operators must not log off intentionally while driving. WARNING Access to the truck must be disabled. Unauthorised users are not allowed to use the truck. Disconnecting a truck equipped with a ...
  • Page 66 Operating the FleetManager™ option Disconnecting a truck equipped with an  RFID reading device – Park the truck in a safe place. – Briefly place the RFID card or the RFID transponder (4) in front of the reading de- vice (3). The LED (1) lights up for a second (red col- our).

  • Page 67: Transporting Loads

    Transporting loads Transporting loads Load handling safety rules  WARNING Closely follow the following instructions before pick- ing 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). WARNING Take care not to trap hands or feet when operating the truck.

  • Page 68: Transporting Pallets Or Other Containers

    Transporting loads Transporting pallets or other con-  tainers As a general rule, loading units must be trans- ported one by one (e.g. pallets). Transporting several loading units at a time is only author- ised: when the safety preconditions are fulfilled. ●...

  • Page 69: Lifting And Lowering The Load Arms

    Transporting loads Lifting and lowering the load arms  NOTE Keep your hands on the tiller when lifting or lowering the load arms. Lifting the load arms: – Press the control button (1). The load arms are raised. Lowering the load arms: –...

  • Page 70: Load Handling

    Transporting loads Load handling WARNING Risk of crushing feet Safety shoes must be worn. WARNING Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled. Arrange the loads with a small space between them to prevent them hooking onto one another.
  • Page 71 Transporting loads – Slowly withdraw the load in a straight line. Transporting a load  Observe the following recommendations: Drive forwards for optimum visibility ● Travel up or down slopes with the load up- ● hill. Do not travel across the slope or make a U-turn Reverse travel is used for setting down the ●...
  • Page 72 Transporting loads – Switch off the ignition (key or electronic key). – In the event of a prolonged shutdown, press the emergency off switch. Then disconnect the battery. 11538011551 EN - 02/2021 - 08...

  • Page 73: Cold Store Usage (Optional)

    Cold store usage (optional) Cold store usage (optional)  CAUTION Standard trucks risk being subject to significant dam- age if used in extreme conditions. Only trucks with the Cold Store option may be used inside cold storage. Specific oil designed for cold stores must be used.
  • Page 74 Cold store usage (optional) Parking The truck must be parked outside of the cold store. Parking inside the cold store could cause seri- ous damage to the electrical and mechanical equipment (seals, hoses, rubber and synthetic parts). CAUTION Do not leave discharged or unused batteries in the cold store.

  • Page 75: Before Leaving The Truck

    Before leaving the truck Before leaving the truck – Choose a safe and level location. – Remove the switch key. – Set down the load and fully lower the load DANGER arms. Risk of injury! The load arms must touch the ground. It is prohibited to park the truck with the load lift sys- –...

  • Page 76: Handling The Battery

    Handling the battery Handling the battery Battery type Trucks can be fitted with different types of bat- tery. Comply with the information indicated on your battery's type plate, as well as with its features. WARNING The weight and size of the battery influence the sta- bility of the truck.

  • Page 77: Opening And Closing The Battery Hood

    Handling the battery Parking the truck securely When the battery is being worked on, the truck must be parked safely. The truck can only be restarted when the covers and connectors have been put back in the operating position. Opening and closing the battery ...

  • Page 78: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an exter- nal charger CAUTION Deep discharging may damage the battery. – Charge the battery immediately. The fixed socket on the truck (1) is located above the battery and under the battery hood. –...
  • Page 79 Handling the battery WARNING Explosive gases are generated during battery charg- ing. – Make sure that the area is well-ventilated. – Make sure that the battery hood remains open for the entire time the battery is charging. 11538011551 EN - 02/2021 - 08...

  • Page 80: On-Board Charger

    Handling the battery On-board charger Precautions for installation and use CAUTION The on-board charger means you no longer Risk of damage to the mains cable resulting in elec- tric shock and/or burns. have to use a charging room. This charger can be connected to any 2P+T 230 V 16 A Park the truck very close to the wall-mounted mains socket to avoid tensioning the charger's mains cable...

  • Page 81: Using The On-Board Charger

    Handling the battery The charger adapts automatically to the bat- Time protection tery discharge situation and therefore allows If the duration of phases I1 + P + U is more any type of partial charging to be carried out than 16 hours, the charger automatically ("opportunity charging").
  • Page 82 Handling the battery 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 (1) to a mains socket.

  • Page 83: Adjusting The On-Board Charger

    Handling the battery CAUTION Risk of damage to the mains cable due to frequent operator handling. Risk of electric shock and/or burns! The mains cable must be regularly checked as part of periodic statutory checks and maintenance opera- tions. NOTE The on-board charger is not compatible with the Cold Store option.

  • Page 84: Changing The Vertical Access Battery

    Handling the battery Changing the vertical access bat- tery To change the battery, proceed as follows: – Immobilise the truck. – Lower the load arms. – Switch off the ignition and remove the key. – Press in the emergency off switch. –...
  • Page 85 Handling the battery extraction rollers (fitted with rollers) for easier handling of the battery. To change the battery, proceed as follows: – Immobilise the truck. – Lower the load arms. – Switch off the ignition and remove the key. – Press in the emergency off switch. –...
  • Page 86 Handling the battery – Operate and pull the locking handle (2) in  the direction indicated by the arrow. – Lift the locking bar (3) until the battery is  freed. 11538011551 EN - 02/2021 - 08...
  • Page 87 Handling the battery – Pull the battery onto the truck with extrac-  tion rollers or the roller frame – Replace the battery. Remove the dis- charged battery and position a charged bat- tery on the roller frame. – Position the truck with extraction rollers or the roller frame (4) in the upright position next to the battery compartment.
  • Page 88 Handling the battery – Push until a click is heard. The battery is  correctly installed. WARNING Risk of injury Ensure that the battery is in the end position and that the hook is correctly holding the battery. DANGER Risk of injury The battery is correctly positioned but is not yet locked.
  • Page 89 Handling the battery – Lower the latch of the battery compartment  door (if this option is selected). The door that is not attached to the side of the battery must be correctly locked. – Refit the battery hood. – Return the truck to service. WARNING Risk of injury Before restarting the truck, ensure that the battery is...

  • Page 90: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Truck towing procedure It is not possible to tow the truck with no elec- trical function. The electromagnetic brake re- mains in the closed position. Truck towing is authorised with a rigid connec- tion (tow bar) if the truck to be towed can no longer be braked.
  • Page 91 Handling the truck in an emergency – After towing, chock the truck to prevent it  from moving. – To re-establish brake operation, unscrew and remove the two screws (1). – Refit the covers. WARNING It is essential that the covers are correctly refitted be- fore the machine is used.

  • Page 92: Handling The Truck In Specific Situations

    Handling the truck in specific situations Handling the truck in specific situations Slinging the truck  DANGER Danger of truck falling Only use slings and a hoist of sufficient quality. Check the weight of the machine (including battery) in order to choose a suitable device. Refer to the technical features.

  • Page 93: Lifting The Truck

    Handling the truck in specific situations Lifting the truck  DANGER Danger of swinging Truck lifting must be performed carefully. For some work, it is necessary to lift the truck. – Lift the load arms. – Switch off the ignition and disconnect the battery connector.

  • Page 94: Transporting The Machine

    Handling the truck in specific situations The truck must be suitably protected from the DANGER effects of the weather during transport and Danger of death. storage. Do not stand within the hoist's operating radius or To load or unload the truck, use an inclined below the lifted truck.

  • Page 95: Maintenance

    Maintenance...

  • Page 96: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the infor- mation required for maintenance of your truck. Carry out the various maintenance work in compliance with the maintenance plan. This will ensure that your truck is reliable and in good working order and that the warranty re- mains valid.

  • Page 97: Servicing And Maintenance Personnel Training And Qualification

    Maintenance General maintenance information Servicing and maintenance personnel training and qualification Truck maintenance must only be carried out The person responsible for carrying out the in- by qualified and authorised personnel. spection must have sufficient knowledge and experience to be able to assess the condition The annual inspection for prevention of acci- of the truck and the efficiency of the protective dents at work must be carried out by a person...

  • Page 98: Safety Guidelines For Maintenance

    Maintenance Safety guidelines for maintenance Safety guidelines for maintenance Servicing and maintenance measures To avoid accidents during servicing and main- – Ensure that there is no risk of the truck tenance operations, take all necessary safety moving or starting up unexpectedly. For this measures.

  • Page 99: Technical Data For Inspection And Maintenance

    Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Consumables/lubricants Capacities/adjustment values Hydraulic system Hydraulic oil Transmission gear Transmission gear oil 1.1 l Traction motor (1.5 kW) 1F1 fuse Power: 300 A, quantity: 1 Steering unit ES30–24 (0.185 kW 3F1 fuse Power: 40 A, quantity: 1 Pump motor...

  • Page 100: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants Transmission gear oil DANGER Toxic products. Recommended oil: Oils and other consumables are toxic products. It is CLP PG220 DIN 51 517–3 advisable to handle and use them with the utmost care. Aerosol can for chains Hydraulic oil Standard chain spray A167.

  • Page 101: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical com- partment WARNING Risk of injury. Before removing anything, turn the ignition off and press the emergency stop button. To access the technical compartment, it is necessary to lift the top hood (1) and remove the front hood (2).

  • Page 102: 1000-Hour Maintenance Plan

    Maintenance 1000-hour maintenance plan 1000-hour maintenance plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours Preparation Clean the truck Check the error codes using the diagnostic tool Chassis and equipment Check the condition of the load arms.

  • Page 103: 10,000-Hour Service Plan

    Maintenance 10,000-hour service plan 10,000-hour service plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 10,000 hours Information Carry out all 1000-hour maintenance work Carry out all 5000-hour maintenance work Motor Drain the transmission gear oil 11538011551 EN - 02/2021 - 08...

  • Page 104: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Park the truck. – Press in the emergency off switch. CAUTION Electrical hazards The battery must always be disconnected during cleaning procedures. Washing the outside of the truck ...
  • Page 105 Maintenance Chassis, bodywork and fittings NOTE Only use dry cleaning products. ● Do not remove the cowlings. ● – Clean the electric installations with a non- metal brush and dry with lightly compressed air. After washing – Carefully dry the truck (e.g. with com- pressed air).

  • Page 106: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings General information on battery maintenance DANGER NOTE Risk of injury The discharge indicators used to check the ● Before carrying out any operations on the electric in- battery must also be suitable for the type of stallation, turn the truck power supply off.

  • Page 107: Checking The Condition Of The Load Arms

    Maintenance Chassis, bodywork and fittings Checking the condition of the load  arms – Check that the load arms (1) show no signs of deformation, splits, heavy wear or cracks. CAUTION Truck damage If the carriage is damaged, it must be changed by the After-Sales Service Centre.

  • Page 108: Steering And Wheels

    Maintenance Steering and wheels Steering and wheels Cleaning the pinion gear of the  steering geared motor – Immobilise the truck. – Lower the load arms. – Switch off the ignition and remove the key. – Press in the emergency off switch. –...

  • Page 109: Checking The Condition Of The Wheels

    Maintenance Steering and wheels Checking the condition of the  wheels – Raise the truck until the wheels are off the ground. – Check that the wheels rotate freely and re- move any objects that may prevent them from turning or may obstruct them. CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the bearings...

  • Page 110: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Cleaning and blowing air through  the electrical components CAUTION Electrical hazards Always disconnect the battery connector before working on an electrical component. – Press in the emergency off switch. – Disconnect the battery connector. –...

  • Page 111: Checking The Battery Acid Level And Electrolyte Density

    Maintenance Electrical equipment Checking the battery acid level and  electrolyte density WARNING The electrolyte (diluted sulphuric acid) is poisonous and caustic! – Always wear suitable protective equipment (indus- trial goggles, safety gloves) when working on a battery. – Never wear a watch or jewellery when handling battery acid.

  • Page 112: Checking The Condition Of The Cables, Terminals And Battery Connector

    Maintenance Electrical equipment Checking the condition of the ca-  bles, terminals and battery connec- – Check that the cable insulation is undam- aged. – Check that there are no signs of heat build- up in the connections. – Check that the "+" and "-" output terminals are not sulphated (presence of white salt).

  • Page 113: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Checking the hydraulic system for  leaks – Switch off the truck and disconnect the bat- tery connector. – Remove the hood of the technical compart- ment. – Inspect the hydraulic system: pipes, hoses and connections between the pump unit and the cylinders.

  • Page 114: Checking The Controlled Stabiliser Hydraulic System For Leaks

    Maintenance Hydraulic systems – Remove the hood of the technical compart-  ment. To ensure correct operation of the truck func- tions, the oil level must be between the mini- mum mark (3) and maximum mark (2) on the tank. –...

  • Page 115: Checking The Oil Level In The Controlled Stabiliser Circuit

    Maintenance Hydraulic systems In the event of leakage, please contact the Af- ter-Sales Service Centre. Checking the oil level in the control-  led stabiliser circuit – Switch off the truck and disconnect the bat- tery connector. – Remove the hood of the technical compart- ment.

  • Page 116: Storage And Decommissioning

    Maintenance Storage and decommissioning Storage and decommissioning Storage of truck Precautions should be taken if the truck must CAUTION not be used for a reasonably long period. The We recommend that you do not use a plastic sheet operations depend on the length of time it is as this encourages condensation to form.

  • Page 117: Permanent Putting Out Of Commission (Destruction)

    Maintenance Storage and decommissioning Permanent Putting Out of Commis- sion (Destruction) When scrapping the truck, it is necessary to: – Remove the various parts of the truck (cov- ers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.
  • Page 118 Maintenance Storage and decommissioning 11538011551 EN - 02/2021 - 08...

  • Page 119: Technical Specifications

    Technical specifications...

  • Page 120: Exh Datasheet

    Technical specifications EXH datasheet EXH datasheet 11538011551 EN - 02/2021 - 08...
  • Page 121 Technical specifications EXH datasheet DESCRIPTION 1.1 Manufacturer STILL 1.2 Model type EXH 25 EXH 30 Method of propulsion: battery, diesel, Battery petrol, LPG, mains power Driving mode: manual, pedestrian, Standing standing, seated, order picking 1.5 Nominal capacity 2500 3000 (kg) 1.6 Centre of gravity...
  • Page 122 Ast (m (2)(7) 2660 crosswise Turning radius (minimum) (±20 mm), 4.35 1790/1860 initial lift raised/lowered (mm) PERFORMANCE DATA EXH 25 EXH 30 5.1 Travel speed, laden/unladen (±5%) km/h 5.2 Lifting speed, laden/unladen (±10%) 0.028/0.036 0.026/0.036 Lowering speed, laden/unladen 0.066/0.072 0.065/0.072 (±10%)
  • Page 123 VDI cycle 6.7 Turnover output Energy consumption at turnover out- kWh/h 0.943 1.049 MISCELLANEOUS EXH 25 EXH 30 8.1 Speed monitor (AC controller) Noise level at forklift operator's ears 10.7 dB (A) (±2.5) Vibrations transmitted to the operator m/s²...
  • Page 124 Technical specifications EXH datasheet 11538011551 EN - 02/2021 - 08...
  • Page 125 Index Consumables..... . . 13 Battery acid safety instructions..14 Accessing the technical compartment..93 Disposal.
  • Page 126 Index FleetManager™ Colour code for the LEDs... 55 Oils....... 13 Commissioning a truck equipped with a On-board charger keypad or an electronic key.
  • Page 127 Index Technical compartment....23 Unauthorised use..... 9 Technical data for inspection and mainte- Using the truck on a slope.
  • Page 130 STILL GmbH 11538011551 EN - 02/2021 - 08...

This manual is also suitable for:

Exh 30

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