Still EXD 20 User manual

Original instructions
Lithium-ion batteries
EXD 20
EXD 20 SF
EXH 20 SF
EXH 25
EXH 25 SF
EXH 30
0183 0184 0185 0186 0307
0313
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Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
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Table of contents
g
1 Introduction
Introduction ......................................................... 2
Information on the conformity of lithium-ion batteries ........................... 3
2Safety
Special lithium-ion safety rules ........................................... 6
What to do in the event of incorrect use ..................................... 7
Personal protective measures following an incident ........................... 8
What to do in the event of an accidental spillage .............................. 8
Transporting a lithium-ion battery ........................................ 10
Scrapping lithium-ion batteries .......................................... 11
3 General views
Lithium-ion battery types .............................................. 14
Labels on the top of lithium-ion batteries ................................... 15
Labels on the sides of lithium-ion batteries ................................. 16
4Use
Checking the charge status ............................................ 18
Connecting/disconnecting the battery connector ............................ 18
Commissioning a truck equipped with a side access lithium-ion battery ............ 19
Automatic battery shut-off ............................................. 20
Battery fitted with a compartment ........................................ 20
Specific features of the display .......................................... 21
Installing the external charger .......................................... 22
Charging lithium-ion batteries using an external charger ....................... 23
Using the side sockettochargethebattery ................................. 25
Battery charging times ................................................ 28
Using the on-board charger ............................................ 29
Changing the battery................................................. 32
Battery error codes .................................................. 33
Lithium-ion batteries: Long-term storage .................................. 34
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Table of contents
g
5 Maintenance
Maintenance plan for lithium-ion batteries ................................. 38
Chassis, bodywork and fittings .......................................... 39
Cleaning the lithium-ion battery .......................................... 39
Electrical equipment ................................................. 40
Harnessesandcables ................................................ 40
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1
Introduction

1Introduction
Introduction
Introduction
This supplement is specific to lithium-ion
batteries. It complements the operating
instructions. The latter describe the conditions
for using the lithium-ion battery in the truck
that you own. An Ion label affixed on the truck
allows you to differentiate from trucks fitted
with a Gel or Lead battery.
DANGER
Electrical risk
Refer to the specific lithium-ion safety rules.
Lithium-ion elements and batteries are on the
list of dangerous materials in accordance with
the United Nations recommendations on the
transport of dangerous goods.
The battery must not be opened.
It must be stored in a cool, dry and ventilated
place. High temperatures (above 40°C)
reduce the battery life.
DANGER
There is a risk of fire, leakage or explosion
Do not store lithium-ion batteries in bulk (risk of
short circuit). Keep the battery in its original pack-
aging until it is used.
Do not destroy or incinerate them.
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Introduction 1
Information on the conformity of lithium-ion batteries
Information on the conformity of lithium-ion batteries
The manufacturer of the lithium-ion battery
and Kion group provider declares that:
the lithium-ion battery
conforms with the provisions of the following
EU directive 2004/108/EC
in accordance with EN 61000–6–2:2006 and
EN 61000–6–3:2007.
This declaration of conformity with EC direc-
tives applies only to battery use that conforms
to the recommendations described in the op-
erating instructions.
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1Introduction
Information on the conformity of lithium-ion batteries
411
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2
Safety

2Safety
Special lithium-ion safety rules
Special lithium-ion safety rules
DANGER
There is a risk of fire.
Have class D fire extinguishers or inert gas, carbon
dioxide, powder or foam fire extinguishers near the
zone in which the lithium-ion batteries are used.
DANGER
Electrical danger
Do not open the battery. Electrical risk.
Only the After-Sales Service Centre technicians
can open the battery.
It is necessary to respect the following guide-
lines:
– Read the documents provided with the
battery carefully.
– Only persons who have been trained to
work with lithium-ion technology are per-
mitted to work on the batteries (for example
After-Sales Service Centre technicians).
– Do not place lithium-ion batteries on or near
flames or hot heat sources (> 70°C). This
may cause the batteries to overheat or burst
into flames. This type of use also impairs the
performance of the batteries and reduces
their service life.
– Improper use may cause overheating or
serious injury. Respect the following safety
rules:
• Never short circuit the battery terminals
• Do not reverse the battery polarity
• Do not open the battery
• Do not submit the battery to excessive
mechanical constraints
• Do not expose the battery unit to humidity or
water (> 95%)
• Install the batteries in a Level 2 pollution
zone in accordance with standard EN
60664-1
– Batteries must be installed in a room that
can be easily ventilated in the event of
incorrect use.
– The forklift operator must drive the truck
carefully to avoid any risk of piercing or
damaging the lithium-ion batteries.
DANGER
Risk of injury
In the event of an accident (shock, fall, collision),
the battery may be damaged, pierced or deformed.
Establish a 5-metre safety perimeter around the
battery. Contact the emergency services and tell
them that there is a lithium-ion battery fire. Contact
the after-sales service department.
– Store strapped batteries on pallets. Do
not store them too high to reduce any risk
of falling. Do not store on the ground to
reduce the risk of humidity and impacts. We
recommend that batteries are stored at a
height between 60 and 120 cm.
– If an unusual smell, change of shape or
any other anomaly is observed during
operation, immediately disconnect the
battery (using either the emergency stop or
the charger socket). Contact the after-sales
service department. If necessary, also
contact the emergency services and tell
them that there is a lithium-ion battery fire.
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Safety 2
What to do in the event of incorrect use
What to do in the event of incorrect use
Lithium-ion batteries present no chemical
danger in the context of normal use. Batteries
must not be opened or burned for example.
In the event of exposure to the internal com-
ponents or of their being burned, follow these
instructions.
In the event of contact with eyes
The content of an open batterycancauseeye
irritation.
Dust is likely to cause inflammation of the
eyelids.
– Rinse immediately and thoroughly with
water for at least 15 minutes
– See a doctor as quickly as possible
In the event of contact with skin
An open battery can lead to skin irritation and
allergies.
– Remove contaminated clothes
– Rinse the parts of the skin affected thor-
oughly for at least 15 minutes
– Wash the skin using soap and water
– See a doctor if the irritation persists
In the event of inhalation
An open battery can cause irritation of the
respiratory tracts and mucous membranes or
an allergic reaction.
During disassembly of the battery, a gas may
be released and irritate the throat.
– Carry the person into the open air
– See a doctor as quickly as possible
In the event of ingestion
– Rinse the mouth thoroughly with water
– Drink lots of water
– Do not make the person vomit
– See a doctor as quickly as possible
In the event of a fire
If a fire breaks out, follow these instructions:
For a small fire:
– Use class D fire extinguishers or inert
gas, carbon dioxide, powder or foam fire
extinguishers
– Establish a safety perimeter of five metres
around the battery
– Call the emergency services and tell them
that it is a lithium-ion battery fire
– After extinguishing the fire, do not reuse
the battery. Contact the after-sales service
department.
For a large fire:
– Establish a safety perimeter of five metres
around the battery
– Call the emergency services and tell them
that it is a lithium-ion battery fire
Special fire-fighting procedures (intervention
of firefighters):
•Firefightersmustw
ear self-contained
breathing apparatus
• Use an approved mask to avoid inhalation
of toxic fumes
• Wear protective clothing and equipment
to avoid accidental bodily contact with the
electrolyte solution
• All the types of extinguishing agents given
above can be used on the batteries
• Use a large amount of water to cool the
outside of the batteries if they are exposed
to fire to prevent them rupturing
– After extinguishing the fire, do not reuse
the battery. Contact the after-sales service
department.
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2Safety
Personal protective measures followinganincident
DANGER
Electrical risk
Do not use water on connected batteries in the
charging room.
DANGER
Risk of explosion: release of gas that may create
an explosive atmosphere
After extinguishing the fire, establish a safety
perimeter of at least five metres around the battery.
DANGER
Risk of release of toxic products
Personal protective measures
following an incident
WARNING
Handle an open battery only in a well-ventilated
place.
Respiratory protection
If an element is opened or if it leaks, use a gas mask covering the entire
face and fitted with ABEK filters or self-contained breathing apparatus
(escape mask-type).
Firefighters must wear self-contained breathing apparatus.
Hand protection Use polypropylene, polyethylene, rubber or Viton gloves to handle leaking
or broken elements.
Eye protection Wear safety goggles with side shields or a mask covering the face to
handle leaking or broken elements.
Other Wear a rubber apron and a protection suit to handle leaking or broken
elements.
.
What to do in the event of an accidental spillage
Take the following precautions in the event of
leakage:
Precautions for individuals
– Evacuate staff from the contaminated area
until the vapours have dispersed
–Avo
id inhaling the gas in the event of
electrolyte leakage from an element or a
battery
– Follow the instructions on What to do in the
event of incorrect use if there is contact with
the skin or eyes, or if there is inhalation or
ingestion
– Wear goggles and protective gloves
Precautions for the environment
–Avoid
pollution of wastewater, surface
water and groundwater
– Avoid pollution of the soil and atmosphere
– Use absorbent materials (sand, earth) to
absorb exudation
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Safety 2
What to do in the event of an accidental spillage
– Seal battery leakages
– Put the contaminated absorbent product
in a plastic bag and dispose of it as special
waste according to the local regulations in
force
DANGER
Environmental danger
Do not reuse a lithium-ion battery that has leaked.
Call the After-Sales Service Centre.
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2Safety
Transporting a lithium-ion battery
Transporting a lithium-ion
battery
Before transporting any lithium-ion battery,
check the current regulations on the transport
of dangerous goods. Comply with these
when preparing the packaging and transport.
Train authorised staff to dispatch lithium-ion
batteries.
NOTE
It is recommended that the original packaging
is kept for any subsequent dispatch.
A lithium-ion battery is a special product.
Special precautions should be taken when:
• Transporting a truck equipped with a
lithium-ion battery
• Transporting only the lithium battery
A class 9 danger label must be affixed to the
packaging for transport.
It is different if the battery is transported on
its own or in a truck. An example of a label
appears in this supplement. Refer to the latest
current regulations before dispatch as the
information might have changed since this
supplement was written.
Special documents must be sent with the
battery. Refer to the applicable standards or
regulations.
NOTE
Recharge the lithium-ion battery before trans-
porting it taking account of the transport mode
(plane, boat, road). Excessive discharge on
arrival could damage the performance of the
battery.
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Safety 2
Scrapping lithium-ion batteries
Scrapping lithium-ion batteries
ENVIRONMENT NOTE
Comply with current regulations for scrapping
batteries. Take care to minimise, as far as
possible, any impact on the environment.
Lithium-ion batteries must be sent to the
collection centre to be recycled. Contact the
After-Sales Service Centre to agree how to
send them.
Apply the following main rules for transport:
• Make sure that the battery is discharged
•AffixtheClass 9 transport label on the
battery
• Use packaging that complies with interna-
tional regulations
• Use the original packaging, if possible. Use
sturdy packaging capable of bearing the
weight of the batteries. Store it in a dry
place.
• Wedge the battery well in the packaging to
prevent it moving during transport
• Pack batteries individually in plastic bags.
Package them to prevent any risk of short-
circuit between terminals.
• Identify the type and number of batteries on
the outside of the packaging
• Do not store near to a heat source
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2Safety
Scrapping lithium-ion batteries
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3
General views

3General views
Lithium-ion battery types
Lithium-ion battery types
Dimensions
Battery type (1) Length
(mm)
Height
(mm) Depth (mm) Weight (kg)
Nominal
voltage (V)
Nominal
capacity
(Ah)
B1 (one module) 718 618 210 108 23.1 205
B2 (two modules) 718 618 210 139 23.1 410
.
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