originalinstructions handpallettruck - still
TRANSCRIPT
Original instructions
Hand pallet truck
HPS-20HPS-25
0051 0052
50988046007 EN - 06/2019
Prefaceg
Address of manufacturer andcontact detailsSTILL GmbHBerzeliusstraße 1022113 Hamburg, GermanyTel. +49 (0) 40 7339-0Fax: +49 (0) 40 7339-1622Email: [email protected]: http://www.still.de
Made in China
Rules for the operatingcompany of industrial trucksIn addition to these operating instructions,a code of practice containing additionalinformation for the operating companies ofindustrial trucks is also available.
This guide provides information for handlingindustrial trucks:• Information on how to select suitableindustrial trucks for a particular area ofapplication
• Prerequisites for the safe operation ofindustrial trucks
• Information on the use of industrial trucks• Information on transport, initial commis-sioning and storage of industrial trucks
50988046007 EN - 06/2019 I
Prefaceg
Internet address and QR codeThe information can be accessed at any timeby pasting the address https://m.still.de/vdmain a web browser or by scanning the QR code.
II 50988046007 EN - 06/2019
Table of contentsg
1 ForewordYour industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2EC conformity, CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2EC/EU declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Issue date and currentness of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Typical graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Disposal of units during repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 IntroductionProper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specific usage risks as a result of operating the industrial truck . . . . . . . . . . . . . . . . . . 16
3 SafetyDefinition of terms used for responsible persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Qualified person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Damage, defects and misuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Carrying out regular testing on the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Table of contentsg
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 OverviewsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Labelling points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 OperationChecks and tasks to be carried out prior to commissioning . . . . . . . . . . . . . . . . . . . . . . 32Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Fitting the tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Lifting system controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Braking the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Parking brake (special equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Safety regulations for handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Before the load pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Taking up loading units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cold store application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Cold store application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operation in special business situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Parking the industrial truck securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
IV 50988046007 EN - 06/2019
Table of contentsg
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Cleaning the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44After cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 MaintenanceGeneral maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Qualifications of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Intervals for maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Preparation for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Roller maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Servicing the lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Adjusting the lowering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintenance after 6 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Checking the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Checking the hydraulic oil level and hydraulic system for leaks . . . . . . . . . . . . . . . . . . . 57
7 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Technical datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
50988046007 EN - 06/2019 V
1
Foreword
1 ForewordYour industrial truck
Your industrial truckGeneralThe industrial trucks described in these op-erating instructions are built to the applicablestandards and safety regulations. The indus-trial trucks are fitted with the most up-to-datetechnology It is now a matter of handling thetrucks safely and maintaining their functional-ity.
These operating instructions provide thenecessary information to do this. Read andobserve theinformation provided beforecommissioning the industrial truck. Thiswill prevent accidents and ensure that thewarranty remains valid.
EC conformity, CE labellingWith the EC declaration of conformity, themanufacturer confirms that the industrial truckcomplies with the standards and regulationsvalid at the time ofmarketing. TheCE labellingis attached to the nameplate and indicatescompliance with the standards and regula-tions listed in the EC declaration of conformity.
An independent structural change or additionto the industrial truck can compromise safety,thus invalidating the EC declaration of confor-mity.
The EC declaration of conformity must becarefully stored and made available to theresponsible authorities.
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Foreword 1Your industrial truck
EC/EU declaration of conformity
EC/EU declaration of conformity
STILL GmbH
Berzeliusstraße 10
22113 Hamburg Germany
We hereby declare that the machine
Industrial truck type Hand pallet truck
Model HPS 20 / HPS 25
Serial number ST10000000 – ST99999999conforms to the most recent version of ECMachinery Directive 2006/42/EC and the most recentversion of EMC Directive 2014/30/EU for industrial trucks implemented in accordance with har-monised standard EN 12895:2015.The manufacturer is solely responsible for exhibiting this declaration of conformity.
Personnel authorised to compile the technical documents in accordance with the named direc-tives:Name Dirk Scharr
Address STILL GmbH, Berzeliusstraße 10, 22113 Hamburg
Hamburg, 1 October 2018.
Dirk ScharrHead of testing department
Rainer HardtProduct Audit Manager
.
50988046007 EN - 06/2019 3
1 ForewordInformation about the documentation
Information about the documentationDocumentation scopeThese operating instructions describe allmeasures necessary for the safe operationand proper maintenance of your industrialtruck in all possible variants at the time ofprinting. Special designs based on customerrequest are documented in separate operatinginstructions. If you have any questions, pleasecontact your service centre.
Please enter the production no. and year ofmanufacture from the nameplate ⇒ Chap-ter "Nameplate", P. 4-30 in the space pro-vided:
Production no. ...............................................
Year of manufacture ...................................................
Please quote these numbers during all techni-cal enquiries.
Operating instructions are provided with eachindustrial truck. These instructions must bestored carefully and must be available to theoperator and operating company at any time.
If the operating instructions are lost, the op-erating company must obtain a replacementfrom the manufacturer immediately.
The operating instructions can be reorderedas a spare part from the STILL service centre.
The personnel responsible for operating andmaintaining the equipment must be familiarwith these operating instructions.
The operating company (see ⇒ Chapter "Def-inition of terms used for responsible per-sons", P. 18) must ensure that all users havereceived, read and understood these instruc-tions.
Thank you for reading and complying withthese instructions. If you have any questionsor suggestions for improvements, or if youhave found any errors, please contact yourauthorised service centre.
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Foreword 1Information about the documentation
Issue date and currentness ofmanualThe issue date of this manual can be found onthe title page.
STILL is constantly engaged in the furtherdevelopment of industrial trucks. Theseoperating instructions are subject to change,and any claims based on the informationand/or illustrations contained in them cannotbe asserted.
If you require technical support for the indus-trial truck, please contact your authorisedservice centre.
Your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg
Copyright and trademark rightsThese instructions must not be reproduced,translated or made accessible to third par-ties—including as excerpts—except with theexpress written approval of the manufacturer.
Explanation of information symbolsused
DANGERIndicates procedures that must be strictly adheredto in order to prevent the risk of fatalities.
WARNINGIndicates procedures that must be strictly adheredto in order to prevent the risk of injuries.
CAUTIONIndicates procedures that must be strictly adheredto in order to prevent material damage and/ordestruction.
50988046007 EN - 06/2019 5
1 ForewordInformation about the documentation
NOTE
For technical requirements that requirespecial attention.
ENVIRONMENT NOTE
To prevent environmental damage.
HPS20_25_019
Typical graphicsThis documentation explains the (usuallysequential) chain of certain functions oroperations. Schematic views of an industrialtruck are used to illustrate these procedures.
NOTE
These schematic views are not representativeof the structural state of the documentedindustrial truck. The views are used solelyfor the purpose of clarifying procedures.
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Foreword 1Environmental considerations
Environmental considerationsPackagingDuring delivery of the industrial truck, certainparts are packaged to provide protectionduring transport. This packaging must beremoved completely prior to commissioning.
ENVIRONMENT NOTE
The packaging material must be properlydisposed of after delivery of the industrialtruck.
Disposal of units during repair workIt may be necessary to exchange units as partof maintenance work. Exchanged units mustthen be disposed of.
The industrial truck is made of differentmaterials. Each of these materials must be• disposed of,• treated or• recycled in accordance with regional andnational regulations.
ENVIRONMENT NOTE
We recommend working with a waste mana-gement company for disposalpurposes.
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1 ForewordEnvironmental considerations
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2
Introduction
2 IntroductionProper usage
Proper usageThe industrial truck described in these operat-ing instructions is suitable for lifting and trans-porting loads on pallets, see⇒Chapter "Safetyregulations for handing loads", P. 5-38.
The industrial truck must only be used for itsintended purpose as set out and described inthese operating instructions!
If the industrial truck is to be used for purposesother than those specified in the operatinginstructions, the approval of the manufacturerand, if applicable, the relevant regulatoryauthorities must be obtained beforehand toprevent hazards.
Themaximum load to be lifted (rated capacity)is specified on the nameplate and must not beexceeded.
The industrial truck must be used only at theplace of use stipulated, see ⇒ Chapter "Placeof use", P. 2-12.
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Introduction 2Impermissible use
Impermissible useThe operating company or operator, and notthe manufacturer, is liable for any hazardscaused by improper use (see also ⇒ Chap-ter "Definition of terms used for responsiblepersons", P. 18).
CAUTIONUse for purposes other than those described inthese operating instructions is prohibited.
• The industrial truck may not be operatedin areas where is a risk of fire, explosionor corrosion, or areas that are particularlydusty.
• The transport of unstable, poorly stackedloads or fluids is dangerous and not permis-sible.
• The industrial truck must not be used if theload capacity is exceeded.
• Foodstuffs must not come into directcontact with the industrial truck.
• It is not permissible to use the industrialtruck as a jack or lever.
• It is prohibited to transport persons or to usethe truck as a scooter.
• The industrial truck must not be used onslopes.
• The industrial truck must not be used inareas that are insufficiently lit.
• The tiller must not be turned at a right anglein order to stop the industrial truck.
• The industrial truck must not be used forhandling free-swinging loads.
• The industrial truckmust not be used if thereis a danger of unintentional movement.
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2 IntroductionPlace of use
Place of useThe industrial truck can be used in buildings.
The sites on which the industrial truck is usedmust comply with the current regulations(condition of the ground, lighting etc.).
The floor areas must have an adequate loadcapacity (concrete, asphalt) and should havea smooth surface.
The driveways, work areas and aisle widthsmust correspond with the specifications inthese operating instructions.
The industrial truck is suitable for interioruse in countries ranging from the Tropicsto Nordic regions (see temperature ranges⇒ Chapter "Technical datasheet", P. 7-61).
The operating company (see ⇒ Chapter "Def-inition of terms used for responsible per-sons", P. 18) must ensure suitable fire pro-tection in the surrounding area of the industrialtruck for the relevant application of the truck. Ifin doubt, contact the relevant authorities.
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Introduction 2Residual dangers, residual risks
Residual dangers, residualrisksDespite careful working and compliance withstandards and regulations, the occurrenceof other risks when using the industrial truckcannot be entirely excluded.
The industrial truck and all other systemcomponents comply with current safetyrequirements. Nevertheless, even when thetruck is used for its proper purpose and allinstructions are followed, some residual riskcannot be excluded.
Even beyond the narrow danger areas of theindustrial truck itself, a residual risk cannotbe excluded. Persons in this area around theindustrial truck must exercise a heighteneddegree of awareness, so that they can reactimmediately in the event of any malfunction,incident or breakdown etc.
WARNINGAll persons that are in the vicinity of the industrialtruck must be instructed regarding these dangersthat arise through use of the industrial truck.In addition, we draw attention to the safety regulati-ons in these operating instructions.
The risks can include:• Escape of consumables due to leakages,rupture of lines and containers etc.
• Falling, tripping etc. when moving theindustrial truck, especially if consumableshave leaked.
• The stability of the industrial truck hasbeen tested to the latest standards. Thesestandards only take into account the staticand dynamic tipping forces that can ariseduring specified use in accordance withthe operating rules and intended purpose.The risk of exceeding the moment of tiltthat arises from improper use or incorrectoperation cannot be excluded in extremecases, and will impact stability.
• Risk of feet being crushed under the loadwhen the load is lowered.
• Pinch and shear points between the load,industrial truck and surroundings.
50988046007 EN - 06/2019 13
2 IntroductionResidual dangers, residual risks
• Risk of accident when transporting loadsdue to slipping or falling.
• Loss of stability due to the load beingunstable or the load slipping etc.
• Human error - Disregarding safety regula-tions.
• Risk caused by unrepaired damage.• Risk caused by insufficient maintenance ortesting.
• Risk caused by using the wrong consum-ables.
• Risk caused by exceeding testing intervals.
The manufacturer is not held responsible foraccidents involving the industrial truck causedby the failure of the operating company tocomply with these regulations either intention-ally or carelessly.
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Introduction 2Danger to employees
Danger to employeesIn accordance with the German operatingsafety ordinance (BetrSichVO) and labourprotection law (ArbSchG), the operatingcompany (see "Definition of terms usedfor responsible persons") must determineand assess hazards during operation, andestablish what occupational health andsafety measures are required in respect ofemployees. The operating company musttherefore draw up appropriate operatinginstructions (§ 6 ArbSchG) and make themavailable to the operator. A responsibleperson must be appointed. The nationalregulations for the country of use must beobserved.
The construction and equipment of the indus-trial truck correspond to the Machinery Direc-tive 2006/42/EC and are therefore identifiedwith the CE label. These elements are there-fore not included in the hazard assessment.Attachments possess their own CE label andlikewise are not included for that reason. Theoperating company must, however, select thetype and equipment of the industrial trucks soas to comply with the local provisions for de-ployment.
The result must be documented (§ 6 Arb-SchG). In the case of industrial truck deploy-ments involving similar hazard situations it ispermitted to summarise the results.
The conditions of use for industrial trucksare broadly similar in many plants, so thatthe hazards can be summarised in oneoverview. Observe the information providedby the relevant employers' liability insuranceassociation on this subject.
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2 IntroductionSpecific usage risks as a result of operating the industrial truck
Specific usage risks as a resultof operating the industrial truckApproval from the manufacturer and, if appli-cable, the relevant authorities, must be ob-tained each time the truck is used in a mannerthat is different to how it is used normally, andin cases where the operator is not certain thathe can use the truck correctly and without therisk of accidents.
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3
Safety
3 SafetyDefinition of terms used for responsible persons
Definition of terms used for responsible personsOperating companyThe operating company is the natural or legalperson or group who uses the industrial truckor on whose authority the truck is used.
The operating company must ensure that theindustrial truck is used only for its proper pur-poses and in compliance with the safety reg-ulations in these operating and maintenanceinstructions.
The operating company must ensure thatall users read and understand the safetyinformation.
The operating company is responsible for thescheduling and correct performance of regularsafety checks.
We recommend that the national performancespecifications are adhered to.
Qualified personA qualified person is a fitter who works forthe manufacturer or is a person who meetsfollowing requirements:• A completed vocational qualification thatdemonstrably proves their professionalexpertise. This proof is to consist of a voca-tional qualification or a similar document.
• Professional experience indicating thatthe qualified person has gained practicalexperience of industrial trucks over aproven period during their career. Duringthis time, this person has become familiarwith a wide range of symptoms that requirechecks to be carried out, such as basedon the results of a hazard assessment or adaily inspection.
• Recent professional involvement in the fieldof the industrial truck test in question andan appropriate further qualification are es-sential. The qualified person must have ex-perience of carrying out the test in questionor of carrying out similar tests. Moreover,such a personmust also be aware of the lat-est technological developments regarding
18 50988046007 EN - 06/2019
Safety 3Definition of terms used for responsible persons
the industrial truck to be tested and the riskbeing assessed.
50988046007 EN - 06/2019 19
3 SafetyDefinition of terms used for responsible persons
OperatorThis industrial truck may be used only by per-sons who have received sufficient instructionon control and operation, and proven theirability to handle this industrial truck safely tothe operating company's responsible repre-sentative.
Rights, duties and rules of behaviour forthe operatorThe operator must be informed of his rightsand duties.
The operator must be granted the necessaryrights.
The operator must wear appropriate pro-tective equipment (protection suit, safetyfootwear, safety helmet, industrial goggles,gloves) for the application conditions, the joband the load to be lifted. Safety footwear mustalways be worn for safety.
The operator must be familiar with the operat-ing instructions and have access to them at alltimes.
The operator must:• have read and understood the operatinginstructions,
• have familiarised himself with safe opera-tion of an industrial truck,
• be physically and psychologically able todrive an industrial truck safely.
DANGERTaking drugs, alcohol or medications that affect theresponses of an individual limits the ability of thatindividual to drive an industrial truck!Individuals under the influence of the above-men-tioned substances are not permitted to perform anywork on or with an industrial truck.
20 50988046007 EN - 06/2019
Safety 3Basic principles for safe operation
Basic principles for safe operationChanges and retrofitting
NOTE
Changes and retrofitting are prohibited!
Warning regarding non-original partsOriginal parts, attachments and accessoriesare specially designed for this industrial truck.We specifically draw your attention to thefact that parts, attachments and accessoriessupplied by other companies have not beentested and approved by us.
CAUTIONInstallation and/or use of such products may there-fore have a negative impact on the design featuresof the industrial truck and thus impair active and/orpassive safety.We recommend that you obtain approval from themanufacturer and, if necessary, from the relevantregulatory authorities before installing such parts.The manufacturer accepts no liability for any da-mage caused by the use of non-original parts andaccessories without approval.
Damage, defects and misuse ofsafety systemsThe operator must report any damage or otherdefects to the industrial truck immediately tothe supervisory personnel.
Industrial trucks that are not functional mustnot be used until they have been properlyrepaired.
Do not remove or disable safety systems.
Fixed set valuesmay only be changedwith theapproval of the manufacturer.
50988046007 EN - 06/2019 21
3 SafetySafety tests
Safety testsCarrying out regular testing on theindustrial truck
Safety inspection based on time andextraordinary incidentsThe operating company must ensure that theindustrial truck is checked by a competentperson at least once a year or followingunusual incidents.
As part of this testing, a complete check ofthe technical condition of the industrial truckmust be performed with regard to accidentsafety. Furthermore, the industrial truck mustbe thoroughly checked for damage that couldhave been caused by improper use. A testlog must be created. The results of the testingmust be retained at least until a further twoinspections have been carried out.
The inspection date is indicated by an adhe-sive label on the industrial truck.
– Arrange for the authorised service centreto perform regular testing on the industrialtruck.
– Observe the guidelines regarding inspec-tion work on industrial trucks as specified byFEM 4.004.
The operating company is responsible forensuring any defects are remedied withoutdelay.
– Notify the authorised service centre.
NOTE
In addition, observe the national regulationsfor the country of use.
22 50988046007 EN - 06/2019
Safety 3Safety regulations for handling consumables
Safety regulations for handling consumablesPermissible consumables
WARNINGConsumables can be dangerous.Observe the safety regulations when handling suchmaterials.
Please refer to the maintenance data tablefor the permissible substances that are nec-essary for operation (see ⇒ Chapter "Mainte-nance data table", P. 6-49).
Oils
DANGEROils are flammable!– Follow the statutory regulations.– Do not allow oils to come into
contact with hot engine parts.– No smoking, fires or naked flames!
DANGEROils are toxic!– Avoid contact and consumption.– If vapour or fumes are inhaled,
move to fresh air immediately.– In the event of contact with the
eyes, rinse thoroughly (for at least10 minutes) with water and thenconsult an eye specialist.
– If swallowed, do not inducevomiting. Seek immediate medicalattention.
50988046007 EN - 06/2019 23
3 SafetySafety regulations for handling consumables
WARNINGProlonged intensive contact with theskin can result in dryness and irritatethe skin!– Avoid contact and consumption.– Wear protective gloves.– After any contact, wash the skin
with soap andwater, and thenapplya skin care product.
– Immediately change soakedclothing and shoes.
WARNINGThere is a risk of slipping on spilled oil, particularlywhen combined with water!– Spilt oil should be removed immediately with
oil-binding agents and disposed of according tothe regulations.
ENVIRONMENT NOTE
Oil is a water-polluting substance!• Always store oil in containers that complywith the applicable regulations.
• Avoid spilling oils.• Spilt oil should be removed immediatelywith oil-binding agents and disposed ofaccording to the regulations.
• Dispose of old oils according to the regula-tions.
Hydraulic fluid
WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous to your health.– Do not spill the fluids.– Follow the statutory regulations.– Do not allow the fluids to come into
contact with hot engine parts.
24 50988046007 EN - 06/2019
Safety 3Safety regulations for handling consumables
WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous to your health.– Do not allow the fluids to come into
contact with the skin.– Avoid inhaling spray.– Penetration of pressurised fluids
into the skin is particularly danger-ous if these fluids escape at highpressure due to leaks in the hydrau-lic system. In case of such injury,immediate medical assistance isrequired.
– To avoid injury, use appropriatepersonal protective equipment(e.g. protective gloves, industrialgoggles, skin protection and skincare products).
ENVIRONMENT NOTE
Hydraulic fluid is a water-polluting substance.• Always store hydraulic fluid in containersthat comply with regulations
• Avoid spills• Spilt hydraulic fluid should be removedimmediately with oil-binding agents anddisposed of according to the regulations
• Dispose of old hydraulic fluid according tothe regulations
Disposal of consumables
ENVIRONMENT NOTE
• Materials that accumulate during repair,maintenance and cleaning must be collec-ted properly and disposed of in accordancewith the national regulations for the countryin which the truck is being used. Work mustonly be carried out in areas designated forthe purpose. Care must be taken to mini-mise any environmental pollution.
– Soak up any spilt fluids such as hydraulic oilor gearbox oil using an oil-binding agent.
– Neutralise any spilt battery acid immedi-ately.
50988046007 EN - 06/2019 25
3 SafetySafety regulations for handling consumables
– Always observe national regulations con-cerning the disposal of used oil.
26 50988046007 EN - 06/2019
4
Overviews
4 OverviewsOverview
OverviewGeneral view
1
2
34
5
HPS_20_25_014
1 Tiller2 Hydraulic pump3 Steering rollers4 Forks5 Load castors
28 50988046007 EN - 06/2019
Overviews 4Labelling points
Labelling pointsOverview
HPS20_25_003
STILL GmbHBerzeliusstr. 10
D-22113 HAMBURG
Typ Type
BaujahrDate of Manuf.:
Serial - NrSerial - no
NenntragfähigkeitRated capacity
LeergewichtTare weight
HAND PALLET TRUCK
1
2
3
xxxxkgxxxxkg
DO NOT STOP THE TRUCK ON SLOPE
4
1 Decal information: Lower load / Transportload / Lift load / Do not drive on slopes
2 Capacity rating plate3 Nameplate4 Manufacturer's name
50988046007 EN - 06/2019 29
4 OverviewsNameplate
STILL GmbHBerzeliusstr. 10
D-22113 HAMBURG
Typ Type
BaujahrDate of Manuf.:
Serial - NrSerial - no
NenntragfähigkeitRated capacity
LeergewichtTare weight
HAND PALLET TRUCK
HPS20_25_027
1
2
3
4
5
6
7
1 CE labelling2 Model3 Year of manufacture4 Serial number5 Rated capacity6 Tare weight7 Manufacturer
NameplateIt is possible to identify the industrial truck fromthe information on the nameplate.
30 50988046007 EN - 06/2019
5
Operation
5 OperationChecks and tasks to be carried out prior to commissioning
Checks and tasks to be carried out prior to commissioningVisual inspections
WARNINGDamage or other defects on the industrial truck canresult in accidents.If damage or other defects are identified on theindustrial truck during the following inspections, donot use the industrial truck until it has been repairedproperly. Do not remove or disable safety systemsand controls. Do not change predefined set values.
Prior to start-up, ensure that the truck is safeto be operated:
– Fork arms or other load-carrying equipmentshould not show any noticeable damage(e.g. bends, cracks, significant wear).
– Check the area under the industrial truck forleaking consumables.
– Check whether all decal information ispresent and legible. Damaged or missingadhesive labelsmust be replacedaccordingto the overview of identification points, see⇒ Chapter "Overview", P. 4-29.
– Check the visible areas of the hydraulic sys-tem for damage and leakages. Damagedcomponents must be changed.
– Report defects to the supervisory person-nel.
32 50988046007 EN - 06/2019
Operation 5Commissioning
Fitting the tiller
NOTE
If the industrial truck is delivered withoutthe tiller fitted, it must be attached beforecommissioning.
HPS20_25_008
12
3
44
5
67
– Unscrew lock nut (7) on lever (5).
– Unscrew adjustment screw (6).
– Fit tiller (1) on the tiller foot.
– Insert bolt (3) and clamping sleeve (4) andfit to the tiller foot.
– Lift lever (5) and insert the pin at the end ofchain (2) into the groove in the lever.
– Screw in adjustment screw (6).
– Screw on lock nut (7) hand-tight.
Commissioning
HPS20_25_004
1
Wa
SteeringThe industrial truck can be steered by swivel-ling the tiller within the angle indicated (1).
At maximum steering lock, the industrialtruck can be turned in the smallest turn-ing radius (Wa), see ⇒ Chapter "Technicaldatasheet", P. 7-61.
50988046007 EN - 06/2019 33
5 OperationLifting
LiftingLifting systemThe following lifting system is fitted on thisindustrial truck:
h3
HPS20_25_017
Initial liftBy performing pumping actions, the fork islifted to the max. height (h3), see ⇒ Chap-ter "Technical datasheet", P. 7-61.
If the industrial truck is equipped with thefast-lift function, loads of up to approx. 200kg can be lifted faster.
Lifting system controls
DANGERDanger to life!Stay away from the area beneath the raised forks.Never exceed the rated capacity indicated onthe nameplate. Otherwise stability cannot beguaranteed!
DANGERRisk of accidents!Do not step onto the forks. Do not lift people.
34 50988046007 EN - 06/2019
Operation 5Lifting
Lifting the forks
HPT10_035
1– Push "lift-lower" operating lever downwards(1).
– Perform a pumping action with the tiller.
The forks are raised.
Lowering the forks
HPT10_036
2– Pull "lift-lower" operating lever upwards (2).
The forks are lowered.
50988046007 EN - 06/2019 35
5 OperationBrakes
BrakesBraking the industrial truckTo brake the industrial truck, with or without aload, proceed as follows:
HPS_20_25_021
1
– Move tiller (1) against the drive directionand use your muscular strength to reducethe speed of the industrial truck.
WARNINGRisk of crushing!If the truck is decelerated too quickly, the load couldslip forwards and lead to damage as a result ofcrushing.
Emergency stopIf the industrial truck is carrying a load andreaches a speed that is too high, it is possibleto perform an emergency stop.
CAUTIONRisk of tipping!The transportation speed must be adapted to suitthe ground conditions. Transport heavy loadsslowly and carefully.
36 50988046007 EN - 06/2019
Operation 5Brakes
HPT10_037
1– Pull operating lever (1) on the tiller upwards.
The pallet is lowered and is braked by theground.
– Also brake the industrial truck as usual,see ⇒ Chapter "Braking the industrialtruck", P. 5-36.
WARNINGRisk of injuryIf travelling at a high speed, the load could slipforwards and cause damage as a result of crushing.The industrial truck can continue to roll even if theload is braked.
Parking brake (special equipment)The industrial truck can be equipped with aparking brake as special equipment. Thisis intended solely for secure parking of theindustrial truck and is not to be used as aservice brake.
Operating the parking brake
HPS20_25_026
2
3
4
1
5
– Press right brake pedal (2) down with yourfoot.
Brake plate (3) is pushed against steeringrollers (4) and (5).
The parking brake is now applied.
Releasing the parking brake– Press left brake pedal (1) down with yourfoot.
Brake plate (3) is pushed away from steeringrollers (4) and (5).
The parking brake is released.
50988046007 EN - 06/2019 37
5 OperationHandling loads
Handling loadsSafety regulations for handing loadsThe safety regulations for handling loads areshown in the following sections.
DANGERDanger to life!Stay away from the area beneath the raised forks.Never exceed the rated capacity indicated onthe nameplate. Otherwise stability cannot beguaranteed!
DANGERRisk of accidents!Do not step onto the forks. Do not lift people.Never grab or climb onmoving parts of the industrialtruck.
Before the load pick-up
HPS20_25_018
Q
Load capacityThe load capacity (Q) indicated for the indus-trial truck must not be exceeded, see ⇒ Chap-ter "Technical datasheet", P. 7-61.
Taking up loading unitsTo make sure that the load is securely sup-ported, it must be ensured that the fork ispositioned as far as possible under the load.
If possible, the load should rest on the back ofthe fork.
38 50988046007 EN - 06/2019
Operation 5Handling loads
The load must not protrude too far over thefork tips.
Loads are to be picked up and transportedbetween the fork arms as close as possible tothe centre.
Taking up load– Only place those pallets into stock that donot exceed the specified maximum dimen-sions of 1000 x 1200mm. Damaged loadingequipment and improperly designed load-ing units may not be used.
– Attach or secure the load to the load-carrying equipment so that the load cannotmove or fall.
– Place the loading units into stock so thatthe defined aisle width is not reduced byprotruding parts.
6327_003-009
Transporting palletsAs a rule, loading units (e.g. pallets) are to betransported individually. Transporting severalloading units at a time is only permissible
• when instructed by the supervisor and• when the technical requirements have beenmet.
The operator must ensure proper conditionof the loading unit. Only safely and carefullypositioned loading units may be transported.
Driving on liftsFor this industrial truck, the operator may onlyuse lifts with a sufficient load capacity andwhich the operating company (see ⇒ Chap-ter "Definition of terms used for responsiblepersons", P. 18) has authorisation for use.
50988046007 EN - 06/2019 39
5 OperationHandling loads
HPT10_001
– Drive the industrial truck with the forksforwards into the lift without touching theshaft walls.
– Park the industrial truck securely in the lift,see ⇒ Chapter "Parking the industrial trucksecurely", P. 5-43 to prevent uncontrolledmovements of the load or the industrialtruck.
The distance from the shaft wall must be atleast 100 mm.
DANGERRisk of accidents!– Personnel accompanying the truck onto the
lift are only allowed to occupy the lift once theindustrial truck is secure andmust exit the lift firstafter the trip.
The maximum weight of the industrial truckcomprises the net weight and the max-imum load, see ⇒ Chapter "Technicaldatasheet", P. 7-61.
HPT10_010
Driving on loading bridges
DANGERRisk of accidents!– Before driving across a loading bridge, ensure
that it is properly attached and secured and hasadequate load capacity ( lorry, bridge etc.).
– Drive slowly and with care on the loading bridge.– Ensure that the lorry onto which you will be
driving is adequately secured to prevent itsshifting and can support the load of the industrialtruck.
The lorry driver and the operator of the industrialtruck must agree on the departure time.
40 50988046007 EN - 06/2019
Operation 5Cold store application
Cold store applicationCold store applicationThe industrial truck is suitable for use in coldstores, see temperature ranges ⇒ Chap-ter "Technical datasheet", P. 7-61.
CAUTIONChanging from a cold internal temperature toa warm outside temperature may result in theformation of condensation water. This water mayfreeze on re-entry to the cold store and blockmoving parts of the industrial truck.Close attention to the duration of deployment in thedifferent temperature ranges must be paid for bothtypes of application.The industrial truck must be dry before it can beused in the cold store.
WARNINGRisk of injury!If condensation water freezes in the cold store, donot try to free blocked parts with your hands.
– Always park the industrial truck outside thecold store.
50988046007 EN - 06/2019 41
5 OperationOperation in special business situations
Operation in special business situationsTransportWhen the industrial truck is driven onto ameans of transport, note the following:• The load/lifting capacity of the means oftransport, ramps and loading bridges mustbe greater than the loading weight of theindustrial truck.
• When turning the tiller, the industrial truckcould veer off the loading bridge towards theedge. This can cause the industrial truck tocrash.
– Park the industrial truck securely, see⇒ Chapter "Parking the industrial trucksecurely", P. 5-43.
CAUTIONIf the industrial truck is not secured against rolling,this could result in damage of the cargo or causeaccidents.– Lash the industrial truck to secure it.
Lashing
HPS_20_25_015
1
– Use tension belts (1) to secure the industrialtruck against slipping and rolling.
42 50988046007 EN - 06/2019
Operation 5Decommissioning
DecommissioningParking the industrial truck securely
WARNINGDo not park the industrial truck on a slope.Make sure that the industrial truck cannot roll awayunintentionally.Never park the industrial truck in areas where itcould create risks for other traffic.
– Lower the forks completely.
– Actuate the parking brake, (special equip-ment), see ⇒ Chapter "Parking brake (spe-cial equipment)", P. 5-37.
50988046007 EN - 06/2019 43
5 OperationCleaning
CleaningCleaning the industrial truck
WARNINGRisk of fire!Combustible fluids may not be used to clean thetruck.
CAUTIONFailure to follow these instructions could result indamaged components!– Follow themanufacturer's guidelines for working
with cleaning materials.
– Before lubrication, clean the oil fillingopenings and their surroundings, and thelubricating nipples.
NOTE
Please note: The more often the industrialtruck is cleaned, the more frequently it mustbe lubricated.
– Clean all parts of the industrial truck using adamp cloth.
– Under no circumstances should you use adirect water jet or steam for cleaning.
After cleaning– Dry the truck carefully (e.g. with com-pressed air).
– Put the industrial truck into operation inaccordance with regulations.
44 50988046007 EN - 06/2019
6
Maintenance
6 MaintenanceGeneral maintenance information
General maintenance informationQualifications of personnelOnly qualified and authorised personnelare allowed to perform maintenance work.The annual testing must be carried out bya qualified person. The examination andassessment by the qualified person mustnot be affected by operational and economicconditions and must be conducted solelyfrom a safety perspective. The qualifiedperson must have sufficient knowledge andexperience to be able to assess the conditionof an industrial truck and the effectivenessof the protective equipment according totechnical conventions and the principles fortesting industrial trucks.
Maintenance work for which no specialqualifications are necessarySimple maintenance work, such as checkingthe hydraulic oil level, may be carried out byuntrained personnel. This does not require thequalifications described above. Refer to theseoperating instructions for further information.
Information regarding performingmaintenanceThis section contains all the informationrequired to determine when your industrialtruck must be serviced. Be sure to performmaintenance within the time limit accordingto the maintenance overview; this is essentialto obtain the full operability, performance andservice life from the industrial truck, and is apre-condition for any warranty claims.
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Maintenance 6General maintenance information
Intervals for maintenance andinspectionTheworkmust be performed by the authorisedservice centre according to the maintenanceintervals listed below.
Servicing
Functiongroup Maintenance work Chapter
Chassisframe
Checking the condition, mounting andwear of the rollers "Roller maintenance"
Checking the function of the initial lift "Servicing the lifting system"Load liftsystem Adjusting the lowering device "Adjusting the lowering device"
Identificationpoints Checking the labelling for completeness "Overview"
.
Maintenance after 6 months
Functiongroup Maintenance work Chapter
- Carry out all servicing work
Load liftsystem Checking the forks "Check the forks"
Hydraulics Checking the hydraulic oil level andhydraulic system for leaks
"Check the hydraulic oil level andhydraulic system for leaks"
.
50988046007 EN - 06/2019 47
6 MaintenanceGeneral maintenance information
Ordering spare parts and wearingpartsSpare parts can be requested and orderedfrom the STILL service centre.
Only use spare parts as per the manufac-turer's instructions. The use of unapprovedspare parts can result in an increased risk ofaccidents due to insufficient quality or incor-rect assignment.
Anyone using unapproved spare parts shallassume unlimited liability in the event ofdamage or harm.
48 50988046007 EN - 06/2019
Maintenance 6General maintenance information
Maintenance data table
Unit Operating material Specification DimensionHydraulic system Hydraulic oil ISO VG32 Max. 0.4 l
Steering rollers ø 200 x 50 mm
Load castors, tandem ø 80 x 70 mm
Load castors, single ø 80 x 93 mm.
50988046007 EN - 06/2019 49
6 MaintenanceSafety regulations for maintenance
Safety regulations for maintenanceGeneral informationTo prevent accidents during maintenance andrepair work, all necessary safety measuresmust be taken, e.g.:• Ensuring that unintentional movement ofthe industrial truck is prevented.
• Ensuring that a raised lifting accessorycannot be lowered when work is beingcarried out beneath it.
Preparation for maintenanceJacking upThe industrial truck must be jacked up forsome maintenance work. Make sure thatthe industrial truck is only jacked up on levelsurfaces, and is secured against rolling anddropping.
HPS20_25_020
Jacking up at the chassis– Position the industrial truck with the fork tipsagainst a wall.
– Jack up the industrial truck until the steeringrollers are no longer in contact with theground.
– Secure the industrial truck.
50 50988046007 EN - 06/2019
Maintenance 6Servicing
ServicingRoller maintenanceThe bearing surfaces of the steering rollersand load castors must not be damaged.
– Change damaged or worn steering rollersand load castors for new ones of thesame size, see ⇒ Chapter "Technicaldatasheet", P. 7-61.
CAUTIONIncorrectly adjusted steering rollers or load castorscould lead to problems with stability.This adjustmentmust be carried out by your servicecentre.
Checking the mounting of the steeringrollers
HPS20_25_009
1
– Remove cover (1) on both sides.
50988046007 EN - 06/2019 51
6 MaintenanceServicing
2
HPS20_25_010
– Check snap ring (2) on both sides on thesteering rollers for damage and securepositioning, and change if necessary.
– Reattach cover (1).
HPS20_25_011
1 1
11
Checking the mounting of the loadcastors– Check clamping sleeve (1) on both sides onthe load castors for damage, and changeclamping sleeve as necessary.
52 50988046007 EN - 06/2019
Maintenance 6Servicing
Servicing the lifting systemCheck the initial lift for correct operation:
HPT10_035
1– Press operating lever (1) downwards andperform a pumping action with the tiller.The initial lift must extend to the maximumheight without jerking.
HPT10_036
2– Pull operating lever (1) upwards. The initiallift must retract again without jerking.
If the initial lift does not extend and retractwithout jerking:
– Check the hydraulic oil level
– Check the lift cylinder for leaks.
50988046007 EN - 06/2019 53
6 MaintenanceServicing
Adjusting the lowering device
Lowering position
HPS20_25_006
21
– Park the industrial truck securely, see⇒ Chapter "Parking the industrial trucksecurely", P. 5-43.
– Loosen lock nut (1).
– Lift the forks a little.
– Adjust adjustment screw (2) on the leveruntil the lowering function works.
HPS20_25_007
3– Move operating lever (3) to neutral position.
– Perform a pumping action.
This action must not lift the forks. If it does,rotate adjustment screw (2) clockwise until theforks are no longer lifted.
Neutral position– Lift the forks a little.
– Move operating lever (3) to neutral position.
– Check whether the forks are lowered to theneutral position.
If the forks are lowered, proceed as follows:
– Rotate adjustment screw (2) anti-clockwiseuntil the forks stop lowering.
Lifting position– Press operating lever (3) downwards.
– Perform a pumping action.
The forks must be lifted. If this is not the case,proceed as follows.
– Rotate adjustment screw (2) anti-clockwiseuntil the forks are lifted by the pumpingaction.
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Maintenance 6Servicing
– Tighten lock nut (1).
50988046007 EN - 06/2019 55
6 MaintenanceServicing
56 50988046007 EN - 06/2019
Maintenance 6Maintenance after 6 months
Maintenance after 6 monthsOther tasks– Perform all tasks required to maintainfull operability; see the chapter entitled"Remaining ready for operation".
Checking the forks
HPS_20_25_023
1
– Carry out a visual inspection of the forks (1)for excessive deformation or cracks, andhave them repaired as necessary.
CAUTION– Repairs and replacements on the frame must
only be carried out by your service centre.
Checking the hydraulic oil level andhydraulic system for leaks
HPS20_25_012
1Checking the hydraulic pump for leaks– Check the hydraulic pump for leaks.
– Check oil filler plug (1) for secure positioningand tighten as necessary.
Checking the oil level– Lower the forks.
– Swivel the tiller to the left.
– Unscrew oil filler plug (1).
The oil level must reach the thread of the oiltank.
– If necessary, top up with hydraulic oil of thecorresponding specification, see ⇒ Chap-ter "Maintenance data table", P. 6-49.
50988046007 EN - 06/2019 57
6 MaintenanceMaintenance after 6 months
– Screw the oil filler plug back on.
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7
Technical data
7 Technical dataDimensions
Dimensions
HPS20_25_005
Ast
Wa
100
390800
1019l1
100
102,5˚
102,5˚
eb1
327
173
327
h3s
121
Q
1230
c
850977
370
35
60 50988046007 EN - 06/2019
Technical data 7Technical datasheet
Technical datasheetNOTE
Values are valid for the standard devices.Variants may deviate from them.
Characteristics
HPS 20 HPS 25
Manufacturer STILL GmbH STILL GmbHOperation: manual, accompanied, stand-ing, seated, order picking
Manual Manual
Load capacity / Load Q (kg) 2000 2500
Load centre of gravity c (mm) 600 600.
Weight
HPS 20 HPS 25
Net weight kg 69.5 70.
Chassis frame
HPS 20 HPS 25
Front load castors, single 80x93 80x93
Front load castors, tandem 80x70 80x70
Rear steering rollers 200x50 200x50
Number of rollers (or castors), front/rear 4/2 4/2.
Basic dimensions
HPS 20 HPS 25
Lift height h3 (mm) 115 115
Total length l1 (mm) 1540 1540
Total width b1 (mm) 520 520
Fork arm dimensions s/e/l (mm) 85/160/1150 85/160/1150
Turning radius Wa (mm) 1335 1335Aisle width for pallet 1000x1200 longitudi-nal
Ast (mm) 1790 1790.
50988046007 EN - 06/2019 61
7 Technical dataTechnical datasheet
Temperature ranges
HPS 20 HPS 25
Temperature °C -12 to +50 -12 to +50.
62 50988046007 EN - 06/2019
Indexg
AAddress of manufacturer . . . . . . . . . . . . . IAfter cleaning . . . . . . . . . . . . . . . . . . . . . 44
BBefore the load pick-up . . . . . . . . . . . . . . 38
CCE labelling . . . . . . . . . . . . . . . . . . . . . . . 2Changes to the industrial truck . . . . . . . . 21Checking the hydraulic oil level and
hydraulic system for leaks . . . . . . . 57Cold store application . . . . . . . . . . . . . . . 41Consumables . . . . . . . . . . . . . . . . . . . . 23
Disposal . . . . . . . . . . . . . . . . . . . . . . 25Safety information for handling oils . . . 23Safety information for hydraulic fluid . . 24
Contact details . . . . . . . . . . . . . . . . . . . . . ICopyright and trademark rights . . . . . . . . . 5Currentness of manual . . . . . . . . . . . . . . . 5
DDamage . . . . . . . . . . . . . . . . . . . . . . . . 21Danger to employees . . . . . . . . . . . . . . . 15Defects . . . . . . . . . . . . . . . . . . . . . . . . . 21Dimensions . . . . . . . . . . . . . . . . . . . . . . 60Disposal
Units . . . . . . . . . . . . . . . . . . . . . . . . . . 7Documentation scope . . . . . . . . . . . . . . . 4Driving on lifts . . . . . . . . . . . . . . . . . . . . 39Driving on loading bridges . . . . . . . . . . . 40
EEC conformity . . . . . . . . . . . . . . . . . . . . . 2EC/EU declaration of conformity . . . . . . . . 3Emergency stop . . . . . . . . . . . . . . . . . . . 36
FForks
Checking . . . . . . . . . . . . . . . . . . . . . 57
GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 2General view . . . . . . . . . . . . . . . . . . . . . 28
HHydraulic fluid . . . . . . . . . . . . . . . . . . . . 24
IIdentification points
Overview . . . . . . . . . . . . . . . . . . . . . 29Impermissible use . . . . . . . . . . . . . . . . . 11Industrial truck
Cleaning . . . . . . . . . . . . . . . . . . . . . . 44Information symbols . . . . . . . . . . . . . . . . . 5Intervals for maintenance and
inspection . . . . . . . . . . . . . . . . . . 47Issue date of manual . . . . . . . . . . . . . . . . 5
JJacking up . . . . . . . . . . . . . . . . . . . . . . . 50
LLifting system . . . . . . . . . . . . . . . . . . . . . 34
Controls . . . . . . . . . . . . . . . . . . . . . . 34Initial lift . . . . . . . . . . . . . . . . . . . . . . 34Servicing . . . . . . . . . . . . . . . . . . . . . 53
Loadtaking up . . . . . . . . . . . . . . . . . . . . . . 39
Load capacity . . . . . . . . . . . . . . . . . . . . 38Load wheels
Checking . . . . . . . . . . . . . . . . . . . . . 52Lowering device
Adjusting . . . . . . . . . . . . . . . . . . . . . 54
MMaintenance data table . . . . . . . . . . . . . 49Maintenance intervals . . . . . . . . . . . . . . 47Maintenance schedule . . . . . . . . . . . . . . 47Maintenance work for which no special
qualifications are necessary . . . . . 46Misuse of safety systems . . . . . . . . . . . . 21
50988046007 EN - 06/2019 63
Indexg
NNameplate . . . . . . . . . . . . . . . . . . . . . . . 30
OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Operating company . . . . . . . . . . . . . . . . 18Operating material . . . . . . . . . . . . . . . . . 49Operating procedures . . . . . . . . . . . . . . . 6Operator . . . . . . . . . . . . . . . . . . . . . . . . 20
PPackaging . . . . . . . . . . . . . . . . . . . . . . . . 7Parking brake (special equipment) . . . . . 37Place of use . . . . . . . . . . . . . . . . . . . . . . 12Proper usage . . . . . . . . . . . . . . . . . . . . . 10
QQualifications of personnel . . . . . . . . . . . 46Qualified person . . . . . . . . . . . . . . . . . . . 18
RRegular testing . . . . . . . . . . . . . . . . . . . 22Representation of operating procedures . . 6Residual dangers, residual risks . . . . . . . 13Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 21Rights, duties and rules of behaviour
for the operator . . . . . . . . . . . . . . 20
Roller maintenance . . . . . . . . . . . . . . . . 51
SSafety inspection . . . . . . . . . . . . . . . . . . 22Safety regulations for handing loads . . . . 38Safety regulations for maintenance
General information . . . . . . . . . . . . . 50Specific usage risks as a result of
operating the industrial truck . . . . . 16Steering rollers
Checking . . . . . . . . . . . . . . . . . . . . . 51
TTaking up loading units . . . . . . . . . . . . . . 38Technical datasheet . . . . . . . . . . . . . . . . 61Tiller
Fitting . . . . . . . . . . . . . . . . . . . . . . . . 33Transport . . . . . . . . . . . . . . . . . . . . . . . . 42Transporting pallets . . . . . . . . . . . . . . . . 39Typical graphics . . . . . . . . . . . . . . . . . . . . 6
VVisual inspections . . . . . . . . . . . . . . . . . 32
WWarning regarding non-original parts . . . 21
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STILL GmbH
50988046007 EN – 06/2019