Still X-Line User manual

Lithium-ion batteries
X-Line/C-Line
Original instructions
50988012301EN-05/2023 - 04

Manufacturer and contact de-
tails
STILL GmbH
Berzeliusstrasse 10
22113 Hamburg, Germany
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.still.de
Preface

 I50988012301EN-05/2023 - 04

1 Foreword 
Before using the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information about these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dangerous incorrect use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product-specific dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compliance Information for lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Explanation of signal terms used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
User qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Danger area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Identifying the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13
Battery-Part-Number (B-P/N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 13
2 Safety 
Battery management system and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Information in the event of emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Firefighting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
Battery is becoming disproportionately hot and reporting an error . . . . . . . . . . . . . . . . .
 17
Gas escaping from the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 18
First-aid measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3Overviews 
Battery group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Battery group 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery group 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery group 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Battery group 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Battery group 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table of contents
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 III50988012301EN-05/2023 - 04

Battery group 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Battery group 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Battery group 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Battery group 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Battery group 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4 Operation 
Description of the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Condition of the battery on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the battery to the industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Switching on the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Modes of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Battery capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  45
Displaying the charge state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 45
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 46
Switching off the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Correcting battery faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Transporting the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  49
Safety information for transporting the battery outside the industrial truck . . . . . . . . . . .
 49
Safety information for transporting the industrial truck with a built-in battery . . . . . . . . .
 50
Safety information for transporting the battery by crane . . . . . . . . . . . . . . . . . . . . . . . . .
 50
Detecting potential damage to the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 51
5 Maintenance 
Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintaining the operational readiness of the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . .  54
Maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 54
Maintenance and inspection checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 55
Cleaning the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Transporting and storing the battery on company premises . . . . . . . . . . . . . . . . . . . . 57
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  57
Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 58
Disposing of the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table of contents
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 IV 50988012301EN-05/2023 - 04

6 Technical data 
Datasheet for lithium-ion batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Temperature ranges for lithium-ion batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table of contents
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 V50988012301EN-05/2023 - 04

1
Foreword

Before using the battery
DANGER
Failure to observe the safety informa-
tion poses a risk of fatal injury!
Failure to observe the safety information
can result in electric shock, burns, seri-
ous injury or death.
–Carefully read the operating instruc-
tions before using the battery.
The manufacturer accepts no liability for dam-
age caused by not observing these instruc-
tions or by improperly or incorrectly using the
lithium-ion battery. The battery complies with
the essential health and safety requirements
of the relevant European directives and the
directives applicable in the United Kingdom.
The country-specific guidelines and laws must
be observed.
Important information about
these instructions
Objective of these instructions
These instructions include information neces-
sary for the safe and error-free use of the lithi-
um-ion battery in an industrial truck.
Further information
For further information about using, handling
and replacing the battery, refer to the operat-
ing instructions of the industrial truck.
Target group for these instructions
These instructions are aimed at all users of
the battery.
Structure of these instructions
These instructions do not contain any informa-
tion regarding service and repair work. Service
and repair work must be carried out only by
competent persons and in accordance with
the service documents.
–Only carry out work on the battery that is
described in these instructions.
Foreword
1
Before using the battery
 2 50988012301EN-05/2023 - 04

Storing these instructions
To ensure safe use, these instructions must
be accessible to all users.
–Always store these instructions in the vicini-
ty of the battery.
–Notify all battery users of the storage loca-
tion for these instructions.
–Pass these instructions on to the next own-
er of the battery.
Foreword
1
Important information about these instructions
 350988012301EN-05/2023 - 04

Intended use
The lithium-ion battery is intended solely for
replacing the types of lead battery specified in
the manual for the relevant models of industri-
al truck. Any other use is improper use.
The battery corresponds to the latest techno-
logical standards and recognised safety regu-
lations. However, if the battery is used in a
way other than the intended use, dangerous
situations may arise.
The battery must be used only in accordance
with the following documents:
●
These operating instructions for the battery
●
Operating instructions for the industrial
truck
●
Operating instructions for the battery charg-
er
Use and charge the battery only when it is in
good working order:
●
The battery must be undamaged and func-
tional
●
The cables to the battery charger must not
be damaged
●
The cables to the industrial truck must not
be damaged
Use the battery only in industrial trucks de-
signed for this purpose with the operating volt-
age indicated on the identification plate.
Charge the battery only with battery chargers
approved by the manufacturer.
Use the battery (X-Line / C-Line) only in ac-
cordance with the approved ambient condi-
tions, see the chapter entitled"Ambient condi-
tions".
CAUTION
Reduced service life due to discharged cells.
The service life of the battery will be reduced if the
charge state of the battery falls below 10% for an
extended period of time.
–If the current charge state is less than 10%,
charge the battery as soon as possible.
–Take the battery out of operation for an extended
period of time only if it is fully charged. Recharge
the battery after three months.
Foreword
1
Intended use
 4 50988012301EN-05/2023 - 04

Dangerous incorrect use
Improper handling can cause an explosion or
start a fire!
●
Never use the battery in areas where there
is a risk of fire or a
risk of explosion .
●
Do not climb on the battery.
●
Use the battery (X-Line / C-Line) only in
accordance with the approved ambient con-
ditions, see the chapter entitled"Ambient
conditions".
Opened, destroyed or damaged batter-
ies
Opening or intentionally damaging the battery
can cause serious injuries.
●
Do not dismantle, open or break up the bat-
tery.
●
Do not disassemble, bridge or bypass the
safety systems.
●
Do not screw or solder anything to the bat-
tery or otherwise change the battery in any
way.
●
Do not pierce, drop or crush the battery.
●
Never touch damaged batteries with your
bare hands. Lithium can cause serious
burns to the skin.
●
Do not continue using a battery if it is un-
usually warm, is producing an odour, is dis-
coloured or is deformed.
The battery contains electrical and mechanical
components that are essential for preventing
hazards. Opening the battery invalidates the
warranty.
Heat
●
Never expose the battery to temperatures
of over 60C or an open flame.
External heat can cause the battery to ex-
plode.
Fluid
The ingress of liquids can cause short circuits
and fire.
●
Protect the battery from fluids and humidity.
Foreword
1
Dangerous incorrect use
 550988012301EN-05/2023 - 04

Short circuit
A short circuit can destroy the battery and
start a fire.
●
Do not short circuit the battery.
●
Keep the contacts away from metallic ob-
jects.
Misuse
Misuse can destroy the battery and result in
personal injury or property damage. Improper
use includes using the battery in an industri-
al truck that has not been approved for this
purpose. In this scenario, the safety systems
present in the battery cannot function as inten-
ded and perform actions such as shutting off
the battery in a dangerous situation. Other ex-
amples of improper or incorrect use include:
●
Failure to observe the temperature limits
●
Charging the battery using a different bat-
tery charger to the one approved by the
manufacturer
●
Making changes to the battery
●
Allowing an unqualified person to repair the
battery
●
Repairing the battery with components not
approved by the manufacturer
●
Allowing people who are not familiar with
how to handle the battery and/or who do not
understand the hazards involved to operate
or maintain the battery
Product-specific dangers
All lithium-ion batteries are safe when used for
their intended purpose.
If the batteries are used properly, no hazard-
ous substances escape from the closed tray.
No contact with toxic substances is possible.
There is a risk of contact only in the event of
incorrect use (mechanical, thermal, electrical)
that leads to activation of the safety valves or
to the housing cracking.
If not handled properly, liquid electrolyte may
escape or electrode materials may react with
humidity/water. The battery may vent and
cause a fire or explosion.
Touching live components can cause an elec-
tric shock, which can cause burns or paralysis.
Foreword
1
Product-specific dangers
 6 50988012301EN-05/2023 - 04

The latter can cause ventricular fibrillation,
cardiac arrest or respiratory paralysis, leading
to death.
Improper handling can arc faults and subse-
quently lead to burns.
If a battery combusts, the resulting smoke or
vapours can cause irritation of the eyes, skin
and respiratory system.
Compliance Information for
lithium-ion batteries
CE conformity
Compliance information for lithium-ion batter-
ies. The manufacturer of the lithium-ion bat-
tery and supplier of the KION Group declares
that: The lithium-ion battery complies with the
latest versions of the 2006/66/EC Battery Di-
rective, the 2006/42/EC Machinery Directive,
the 2014/30/EU EMC Directive and, if appli-
cable, the Low Voltage Directive 2014/35/EU.
This declaration of conformity with the EU di-
rectives applies only to use of the battery as
recommended in these operating instructions.
UKCA compliance
Compliance information for lithium-ion batter-
ies. The manufacturer of the lithium-ion bat-
tery and supplier of the KION Group declares
that: The lithium-ion battery complies with the
latest versions of the"Regulation for Supply of
Machinery (Safety) Regulations 2008","Regu-
lations for Batteries and Accumulators (Plac-
ing on the Market) Regulations 2008","Elec-
tromagnetic Compatibility Regulations 2016",
and, if applicable, the"Regulations for Elec-
trical Equipment (Safety) Regulations 2016".
This declaration of conformity with the UKCA
directives applies only to use of the battery as
recommended in these operating instructions.
Foreword
1
Compliance Information for lithium-ion batteries
 750988012301EN-05/2023 - 04

Explanation of signal terms
used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered to
in order to prevent the risk of injuries.
CAUTION
Indicates procedures that must be strictly adhered to
in order to prevent material damage and/or destruc-
tion.
NOTE
For technical requirements that require special
attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of signs and sym-
bols
General danger sign
Danger of electric shock
Warning of hot surface



Foreword
1
Explanation of signal terms used
 8 50988012301EN-05/2023 - 04

Not to be maintained by the user
Do not climb
Do not lift using a triangle cable guide
Use a lifting traverse
Do not burn the battery
Do not stack batteries
Do not immerse the battery in fluid
Observe instructions
Use air-supplied respiratory protection
The battery contains harmful substances. Do
not dispose of the battery in household waste




–+

–+
–+

–+




Foreword
1
Explanation of signs and symbols
 950988012301EN-05/2023 - 04

The product contains recyclable materials
User qualifications
The battery must only be used by adults.
Users must not have any physical or mental
disabilities that reduce their capacity to recog-
nise hazards and to intervene in dangerous
situations.
To use the battery in the industrial truck, the
user must have the following qualifications:
user training from the operating company
based on these operating instructions.
Persons with medical implants
For technical reasons, the electric cables emit
electromagnetic (non-ionising) radiation. This
radiation could affect users who have medical
implants, such as pacemakers or defibrillators.
CAUTION
Electromagnetic interference may occur on medical
devices!
–Only use devices that are sufficiently protected
against electromagnetic interference.
–The functionality of some medical equipment, for
example pacemakers or hearing aids, may be im-
paired when the battery is in operation.
–Ask your doctor or the manufacturer of the medi-
cal device to confirm that the medical device is
sufficiently protected against electromagnetic in-
terference.
Danger area
WARNING
Risk of burns due to hot surfaces!
–Do not touch the hot area on the surface of the
battery. The position of the hot area depends on
the battery model.

Foreword
1
User qualifications
 10 50988012301EN-05/2023 - 04

X-Line
The temperature of the brake resistor in the
battery can rise to over 100°C during opera-
tion. The surface of the battery in this area
can also become very hot. It can take several
hours for the components to cool down to a
temperature at which they pose no risk.
–For the location of the hot area, refer to the
chapter entitled"Overview" for the relevant
battery group.
C-Line
During normal use, the outside of the battery
does not become hot.
Foreword
1
Danger area
 1150988012301EN-05/2023 - 04

Ambient conditions
The ambient conditions in which the battery
groups may be operated are different.
●
If you have any questions regarding the
permitted ambient conditions for using the
battery, contact the authorised service cen-
tre.
●
Observe the instructions for using the bat-
tery in the operating instructions of the in-
dustrial truck.
X-Line
Permissible temperature ranges
(operation, charging, storage)
See the chapter entitled "Technical data" for the relevant bat-
tery group.
Moisture/humidity Protection class rating IP6K9K
The battery can be used both outside and in buildings.
Air humidity 0% - 100%
Storage conditions See the chapter entitled "Storage conditions".
Cold store suitability See temperature ranges in the chapter entitled "Technical da-
ta" for the respective battery group.
Areas where there is a risk of
fire or explosion No
Altitude Use is possible up to a height of 2000m.
C-Line
Permissible temperature ranges
(operation, charging, storage)
See the chapter entitled "Technical data" for the relevant bat-
tery group.
Moisture/humidity
Protection class: IP54
The battery may be used only in buildings or areas protected
from the weather.
The battery must not be used in areas exposed to rain, fog or
steam.
Air humidity 5% - 85%
Cold store suitability No
Storage conditions See the chapter entitled "Storage conditions".
Areas where there is a risk of
fire or explosion No
Altitude Use is possible up to a height of 2000m.
Foreword
1
Ambient conditions
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