Still EXV-CB 06 Original Instructions Manual
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Still EXV-CB 06 Original Instructions Manual

Counterweight pallet stacker
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Original instructions
Counterweight pallet stacker
EXV-CB 06, EXV-CB 10, EXV-CB 12 and EXV-CB 16
2250 2251 2252 2253
11718011551 EN - 02/2021 - 05

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Summary of Contents for Still EXV-CB 06

  • Page 1 Original instructions Counterweight pallet stacker EXV-CB 06, EXV-CB 10, EXV-CB 12 and EXV-CB 16 2250 2251 2252 2253 11718011551 EN - 02/2021 - 05...
  • 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 11718011551 EN - 02/2021 - 05...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... General .
  • Page 6 Table of contents Overviews Overview ............General view of the truck.
  • 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 Datasheet Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 16....Mast types ............

  • Page 11: Introduction

    Introduction...

  • Page 12: 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 13: 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 14: 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 15: 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 16: 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 17: 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 18: 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 19: 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 20 Introduction Disposing of components and batteries 11718011551 EN - 02/2021 - 05...

  • Page 21: Safety

    Safety...

  • Page 22: 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 23: 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 24: 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 25: 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 26: Emissions

    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 EXV-CB 06 63 dB (A) EXV-CB 10/12/16 61 dB (A) Uncertainty ± 2.5 dB (A)

  • Page 27: 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 28: 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 29 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. 11718011551 EN - 02/2021 - 05...

  • Page 30: 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 31 Overviews...

  • Page 32: Overviews

    Overviews Overview Overview General view of the truck Protective screen Battery compartment Compartment for the hydraulic block Load wheels Tiller Forks Display Mast Drive wheel 11718011551 EN - 02/2021 - 05...

  • Page 33: General View Of The Technical Compartment With The Separate Hydraulic Block

    Overviews Overview General view of the technical compartment with the separate hydraulic block Controller Traction motor Steering unit ES30-24 Pump-motor unit Horn Tank 11718011551 EN - 02/2021 - 05...

  • Page 34: Operating And Display Devices

    Overviews Operating and display devices Operating and display devices Driver's compartment Handle Proportional lowering of forks Drive switch Diagnostic connector Anti-crush safety device Mast tilt Drive switch Ignition key or electronic key Horn Emergency off switch Proportional lifting of forks 11718011551 EN - 02/2021 - 05...

  • Page 35: 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 36: 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 37 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 38: Markings

    Overviews Markings Markings Labels Never touch with hands label Danger instructions label. Consult the oper- Do not climb on the hood label ating instructions Carrying of persons prohibited label Mast tilt label Slinging label. Consult the operating instruc- Cold store label tions Next inspection label Brand label...

  • Page 39: 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 11718011551 EN - 02/2021 - 05...
  • Page 40 Overviews Markings 11718011551 EN - 02/2021 - 05...

  • Page 42: Technical Description

    They can be used to transport pallets weigh- precision and easier manoeuvring. ing up to 600 kg (EXV-CB 06), 1000 kg (EXV- The truck is equipped with a 0,185 kW asyn- CB 10), 1200 kg (EXV-CB 12) and 1600 kg chronous steering motor.
  • Page 43 Technical description Equipment available as standard or as reverse traction, horn and double throw safety switch. additional options: The various models are equipped with: That can be added to the truck: An emergency off switch Load backrest ● ● A display Central refilling system ●...

  • Page 44: 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 forklift truck or at- tion table. tachments (special equipment) can result in acci- dents.

  • Page 45: Starting Up

    Starting up Starting up NOTE Check that the battery hood is closed. ● Check that the battery is locked. ● – Check that the battery is connected. – Check that the battery compartment hood is closed and locked correctly. – Release the emergency off switch (1) if it ...
  • Page 46 Starting up – Tilt the tiller into the drive area (2).  NOTE In areas (1) and (3), the electromagnetic brake is applied and it is not possible to drive the truck. 11718011551 EN - 02/2021 - 05...

  • Page 47: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning 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 48: Checking The Anti-Crush Safety Device

    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 49: 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. 11718011551 EN - 02/2021 - 05...

  • Page 50: 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 operator's +45°C and the relative humidity of the air less arms.
  • Page 51 Truck operating instructions WARNING CAUTION Driving safety guidelines: Risk of injury – The driver must drive slowly around corners and Before using a side access truck, check that the bat- when entering narrow passageways. tery is correctly locked. – The driver must always maintain a safe braking distance from vehicles or people in front of him.

  • Page 52: 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 53 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 54 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 55 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 56: 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 57: Driving

    Driving Driving Defining directions  On a pedestrian-mode counterweight pallet stacker, the conventional directions are: Forward travel (1): tiller direction ● Reverse travel (2): fork direction ● Driving – Turn the switch key. – Lower the tiller into zone (2). ...
  • Page 58 Driving Forward travel – 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 59: Steering

    Driving Steering Steering  The truck has electric steering controlled by a tiller (8). The electric power steering makes it possible to manoeuvre the truck gently and precisely with just one hand. WARNING Risk of serious injury and/or serious damage to the machine.

  • Page 60: Braking

    Driving Braking WARNING The quality of the floor surface affects the braking distance of the truck. This should be taken into consideration when driving. Electromagnetic braking  The electromagnetic brake is activated auto- matically if one of the following conditions is met: The tiller is released.

  • Page 61: Horn

    Driving Horn  The horn is positioned on the inner side of the tiller. It is used: On routes where there is poor visibility ● At junctions ● In the event of immediate danger ● – Press the button (1). The horn sounds.

  • Page 62: Drive Program

    Driving If the operator releases the Creep Speed but- ton and/or the drive switch, the vertical posi- tion of the tiller applies the emergency brake again. Drive program  The indicator light (1) is on during operation of the truck. The shape of the indicator light indi- cates the selected program.
  • Page 63 Driving Tortoise mode Selecting Tortoise mode allows you to reduce the performance of the truck: The travel speed of the truck is reduced to ● 6 km/h The speed of lifting and lowering the forks is ● considerably reduced The different speeds can be adjusted. Contact the After-Sales Service Centre to change these.

  • Page 64: Using The Truck On A Ramp

    Driving Using the truck on a ramp NOTE Incorrect use of the truck on a ramp is not rec- ommended. It places particular stress on the traction motor, brakes and battery. Ramps must always be approached with cau- tion: Never attempt a slope with a gradient that is ●...
  • Page 65 Driving Travelling down slopes  Always travel down slopes forwards. The load faces uphill. Without a load, we recommend that you go down a slope forwards. In all cases, you must travel at a very low speed and brake gradually. DANGER Danger of death and/or risk of serious damage to equipment...

  • Page 66: 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 67: 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 68: 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 69 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 70: 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 71 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 72: Transporting Loads

    Transporting loads Transporting loads Load handling safety rules  WARNING Carefully observe the following instructions before picking up loads. Never touch or stand on moving parts of the truck (e.g. lifting device, pushing devices, work installations or devices for picking up loads). WARNING Take care not to trap hands or feet when operating the truck.

  • Page 73: 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 74: Reading The Capacity Label

    Check that the pallet is in good condition. Nominal capacity EXV-CB 06: 600 kg with 500 mm centre of gravity. EXV-CB 10: 1000 kg with 500 mm centre of gravity.

  • Page 75: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads Adjusting the fork arm span NOTE The load centre of gravity must always be at an equal distance between the forks. – Move the locking lever (1) upwards.  – Set the fork arm span according to the load to be lifted.

  • Page 76: Lift Control Elements

    Transporting loads Lift control elements WARNING Appropriate use of the equipment Only use the lifting device and the accessories for the work for which they are intended. The operator must receive instruction on the opera- tion of the load lift system. WARNING Risk of injury The safety instructions must be strictly adhered to.
  • Page 77 Transporting loads Raising/lowering the mast  Raising the mast: – Press button (2). The forks are raised. Lowering the mast: – Press button (1). The forks are lowered. When the lifting control (1) is released, the forks stabilise at the required height. NOTE A groove (3) is present on each side of the button.

  • Page 78: Load Handling

    Transporting loads – Release the tilt control button (4) when the mast has returned to its original position. Load handling Before picking up a load Ensure that the load weight does not exceed the capacity of the truck. Refer to the nominal capacity specified on ●...
  • Page 79 Transporting loads Picking up a load from the ground – Use the forks to raise a load several centi- metres from the ground (observe the capacity of the truck). Transporting a load  DANGER Risk of accident There must be no one under or near the truck when the load is in the raised position.
  • Page 80 Transporting loads CAUTION Risk of falling Do not touch nearby loads or loads positioned be- hind the truck. CAUTION Risk of accident Before you set down the load, ensure that no one is around the truck or the load. Stacking a load ...
  • Page 81 Transporting loads Picking up a load at a height  Proceed as follows: – Drive the truck to the required location. – Lift the forks to the height of the pallet. – Carefully move the forks forward under the pallet. –...

  • Page 82: 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 83 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 84: 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 lower the forks com- DANGER pletely. Danger of death! The forks must touch the ground. It is prohibited to park the truck with a load in the –...

  • Page 85: 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 86: 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 87: Disconnecting/Connecting The Battery Connector

    Handling the battery Disconnecting/connecting the bat- tery connector WARNING Major risk of arcing and destruction of contacts Never connect or disconnect the connector if the truck is switched on. Regularly check the condition of the contacts of the connectors. Replace them if there are signs of arcing and carbonisation.

  • Page 88: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an exter- nal charger CAUTION Electrical hazards Make sure that the charger is compatible with the battery of the truck in terms of voltage and charging current (refer to the instructions for the charger). For a gel battery, use a gel battery charger or an ad- justable charger on the gel setting.
  • Page 89 Handling the battery WARNING Risk of sparks Always connect the battery connector before switch- ing on the battery charger and disconnect the con- nector after switching off the charger. NOTE The connectors are fitted with a keying pin. To avoid reversed connections, regularly check its presence and condition.

  • Page 90: Vertical Access Battery

    Handling the battery Vertical access battery  To change the battery, proceed as follows: – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. – Press the emergency off switch. – Open the battery hood. –...
  • Page 91 Handling the battery – Press the emergency off switch. – Open the battery hood. – Position the truck with extraction rollers or  the roller frame (2) in the upright position near the battery compartment on level ground. – Disconnect the battery connector. –...
  • Page 92 Handling the battery – Place the battery on the truck with extrac-  tion rollers or the roller frame (2). – Replace the battery on the truck with ex- traction rollers or the roller frame (2). – Gently push the battery inside the compart- ment.
  • Page 93 Handling the battery Improper handling could result in significant in-  jury. DANGER Risk of injury Do not position your fingers on the top of the chassis above the battery. The lever could trap your fingers when it swings down. –...
  • Page 94 Handling the battery Choice of opening side for battery com-  partment It is possible to remove the battery from its compartment to the left or right of the truck: – Reverse the battery mounting assembly (5) on the chassis and the hood. NOTE Regularly check that the battery mounting as- sembly (5) is always correctly positioned on...

  • Page 95: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Emergency lowering of the mast  Depending on the truck model, the pump-mo- tor unit can be found: In the technical compartment ● In the compartment for the hydraulic block ●...

  • Page 96: Truck Towing Procedure

    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 97 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 98: 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 (1). Refer to the technical specifications.

  • Page 99: 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 100: Transporting The Truck In The Lift

    Handling the truck in specific situations Trucks are generally transported by road or by DANGER rail. Danger of death. The truck must be suitably protected from the Do not stand within the hoist's operating radius or effects of the weather during transport and below the lifted truck.

  • Page 101: Maintenance

    Maintenance...

  • Page 102: 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 103: 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 104: 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 105: Technical Data For Inspection And Maintenance

    Power: 300 A, quantity: 1 Steering unit ES30–24 3F1 fuse Power: 40 A, quantity: 1 (0.185 kW S1) Pump motor 2.2 kW: EXV-CB 06 Fuse 1F1 Power: 300 A, quantity: 1 3.2 kW: EXV-CB 10/12/16 Control fuse 1F3 fuse Control: 7.5 A, quantity: 1...

  • Page 106: 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 107: 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 off switch. To access the technical compartment, it is necessary to lift the top hood (1) and remove the front hood (2).

  • Page 108: 1000-Hour Service Plan

    Maintenance 1000-hour service plan 1000-hour service 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 Check the condition and legibility of the labels Chassis and equipment Check the condition of the forks...

  • Page 109: 5000-Hour Maintenance Plan

    Maintenance 5000-hour maintenance plan Load lift system Mast: grease the support points Mast: grease Mast: check the mounting Lifting chains: clean, adjust and grease Check the condition and mounting of the guard grille Check the condition and the length of the mast chain Lift cylinders, chains, rollers and stroke-end stops: check the condition, mounting and operation Fork carriage: check 5000-hour maintenance plan...

  • Page 110: 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 111 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 112: 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 113: Checking The Condition Of The Forks

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

  • Page 114: Transmission

    Maintenance Transmission Transmission Cleaning the traction motor cooling  fins – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. – Press the emergency off switch. – Open the battery hood. – Disconnect the battery connector. –...

  • Page 115: Steering And Wheels

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

  • Page 116: 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 wheel...

  • Page 117: 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 the emergency off switch. – Disconnect the battery connector. – Open the technical compartment. –...

  • Page 118: 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 119: 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 120: 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 121 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 122: Lift Mast

    Maintenance Lift mast Lift mast Cleaning and lubricating the chains NOTE NOTE If the lifting chain is too dirty, clean it. Use of high pressure liquid cleaning devices is not advisable. – Place a recipient underneath the lifting chain. DANGER –...

  • Page 123: Checking The Protective Screen

    Maintenance Lift mast – Fully lower the mast.  – Undo the locknut (2) – Place the chains under slight tension by tightening the nut (1). – Retighten the locknut (2). CAUTION Risk of the equipment becoming worn or damaged. After this adjustment, check that the fork carriage does not reach the mechanical stop at the top of the mast during the maximum lift.

  • Page 124: 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 125: 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 126 Maintenance Storage and decommissioning 11718011551 EN - 02/2021 - 05...
  • Page 127 Datasheet...
  • Page 128 Datasheet Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 16 Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 11718011551 EN - 02/2021 - 05...
  • Page 129 Datasheet Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 16 NAME 1.1 Manufacturer STILL EXV-CB EXV-CB 1.2 Model type EXV-CB 10 EXV-CB 12 Method of propulsion: battery, diesel, Battery petrol, LPG, mains power Driving mode: manual, pedestrian, Pedestrian standing, seated, order picking 1.5 Nominal capacity...
  • Page 130 Datasheet Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 16 4.5 Extended mast height (mm) 4.6 Initial lift (mm) Height of tiller in driving po- sition 740/1230 (mm) Minimum/maximum Height of forks when low- 4.15 ered (mm) 4.19 Total length...
  • Page 131 Datasheet Datasheet for EXV-CB 06, EXV-CB 10, EXV-CB 12, EXV-CB 16 Maximum gradient when la- den/unladen 5 minutes 5.10 Service brake Electromagnetic EXV-CB DRIVE SYSTEM EXV-CB 10 EXV-CB 12 EXV-CB 16 Traction motor, hourly out- Lift motor at S3: 15% utilisa-...
  • Page 132 Datasheet Mast types Mast types EXV-CB 06 Standard 1924 S 2424 S 2924 S 3324 S Lift 1924 2424 2924 3324 (mm) Lift + fork h3+h13 height 1970 2470 2970 3370 (mm) Height HT Mast, retrac- 1515 1765 2015 2215...
  • Page 133 Datasheet Mast types Height HT Mast, ex- 2485 2985 3485 3885 4385 tended (mm) Free lift (mm) EXV-CB Duplex Triplex 1924 D 2424 D 2924 D 3324 D 3824 D 3516 T Lift 1924 2424 2924 3324 3824 3516 (mm) Lift + fork h3+h13 height...
  • Page 134 Datasheet Mast types Height Mast, 2485 2985 3485 3885 4385 4785 exten- (mm) Free lift (mm) EXV-CB Duplex 1924 D 2424 D 2924 D 3324 D 3824 D 4224 D Lift 1924 2424 2924 3324 3824 4224 (mm) Lift + fork h3+h13 height 1970...
  • Page 135 Datasheet Mast types Lift + fork h3+h13 1895 2395 2895 3295 3795 4195 height (mm) Height Mast, 1515 1765 2015 2215 2465 2665 retrac- (mm) Height Mast, 2405 2905 3405 3805 4305 4705 exten- (mm) Free lift (mm) EXV-CB Duplex 1844 D 2344 D 2844 D...
  • Page 136 Datasheet Mast types Height HT 4077 4827 Mast, extended (mm) Free lift (mm) 1129 1379 11718011551 EN - 02/2021 - 05...
  • Page 137 Copyright and property rights... Batteries......32 Datasheet for EXV-CB 06, EXV-CB 10, Battery EXV-CB 12, EXV-CB 16.
  • Page 138 Index Electronic key (option)....26 Managing battery charging... . Emergency lowering....Masts.
  • Page 139 Index Specialist......18 Transporting the truck in the lift..90 Stability.
  • Page 142 STILL GmbH 11718011551 EN - 02/2021 - 05...

This manual is also suitable for:

Exv-cb 10Exv-cb 12Exv-cb 16

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