Still HPS-20 User manual

Original instructions
Hand pallet truck
HPS-20
HPS-25
0051 0052
50988046007 EN - 09/2013

Table of contents
g
1 Foreword
Your industrial truck .................................................. 2
General ........................................................... 2
ECconformity,CElabelling ............................................ 2
ECdeclarationofconformity ............................................ 3
Information about documentation ........................................ 4
Documentationscope ................................................ 4
Issuedateandcurrentnessofmanual ..................................... 5
Copyright and trademark rights .......................................... 5
Explanation of information symbols used . . ................................ 5
Typical graphics ..................................................... 6
Environmental considerations .......................................... 7
Packaging ......................................................... 7
Disposal of units during repair work ....................................... 7
2 Introduction
Proper 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
3Safety
Definition of terms used for responsible persons ............................. 18
Operatingcompany .................................................. 18
Qualifiedperson .................................................... 18
Operator .......................................................... 20
Essentials for safe operation ........................................... 20
Changes and retrofitting ............................................... 20
Warning regardingnon-originalparts ..................................... 21
Damage, defects and misuse of safety systems .............................. 21
Safety inspections ................................................... 22
Periodic safety inspection of the industrial truck .............................. 22
Safety regulations for handling consumables ............................... 23
Permissibleconsumables ............................................. 23
Oils .............................................................. 23
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Table of contents
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Hydraulicfluid ...................................................... 24
Disposalofconsumables .............................................. 25
4Overviews
General view ....................................................... 28
General view ....................................................... 28
Identification points .................................................. 29
Overview .......................................................... 29
Nameplate ......................................................... 30
5 Operation
Checks and operations prior to commissioning .............................. 32
Visualinspections ................................................... 32
Fittingthetiller ...................................................... 33
Commissioning ..................................................... 33
Steering ........................................................... 33
Lifting ............................................................ 34
Liftingsystem ....................................................... 34
Lifting system controls ................................................ 34
Brakes ............................................................ 36
Brakingtheindustrialtruck ............................................. 36
Emergency stop ..................................................... 36
Parking brake (special equipment) ....................................... 37
Workingwithloads ................................................... 38
Safety regulations for handing loads ...................................... 38
Beforetheloadpick-up ................................................ 38
Takinguploadingunits ................................................ 38
Takingupload ...................................................... 39
Transportingpallets .................................................. 39
Drivingonlifts ...................................................... 39
Driving on loadingbridges ............................................. 40
Cold store application ................................................. 41
Coldstoreapplication ................................................. 41
Operation in special business situations ................................... 42
Transport .......................................................... 42
Decommissioning ................................................... 43
Parking the industrialtrucksecurely ...................................... 43
II 50988046007 [EN]

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Cleaning .......................................................... 44
Cleaning the industrial truck ............................................ 44
After cleaning ....................................................... 44
6 Maintenance
General maintenance information ........................................ 46
Qualifications of personnel ............................................. 46
Intervals for maintenance andinspection .................................. 47
Orderingsparepartsandwearingparts .................................... 48
Maintenance data table ............................................... 49
Safety regulations for maintenance ....................................... 50
Generalinformation .................................................. 50
Preparation for maintenance ........................................... 50
Jackingup ......................................................... 50
Maintenance ....................................................... 51
Rollermaintenance .................................................. 51
Servicing the lifting system ............................................. 53
Adjustingtheloweringdevice ........................................... 54
Maintenance after 6 months ............................................ 57
Othertasks ........................................................ 57
Checkingtheforks ................................................... 57
Checkingthehydraulicoillevelandhydraulicsystemforleaks ................... 57
7 Technical data
Dimensions ........................................................ 60
Technical datasheet .................................................. 61
50988046007 [EN] III

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The industrial trucks described in these op-
erating instructions are built to the applicable
standards and safety regulations. The indus-
trial trucks are fitted with the most up-to-date
technology It is now a matter of handling the
trucks safely and maintaining their functional-
ity.
These operating instructions provide the
necessary information to do this. Read and
observe theinformation provided before
commissioning the industrial truck. This
will prevent accidents and ensure that the
warranty remains valid.
EC conformity, CE labelling
With the EC declaration of conformity, the
manufacturer confirms that the industrial truck
complies with the standards and regulations
valid at the time of marketing. The CE labelling
is attached to the nameplate and indicates
compliance with the standards and regula-
tions listed in the EC declaration of conformity.
An independent structural change or addition
to the industrial truck can compromise safety,
thus invalidating the EC declaration of confor-
mity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
25
0988046007 [EN]

Foreword 1
Your industrial truck
EC declaration of conformity
50988046007 [EN] 3

1Foreword
Information about documentation
Information about documentation
Documentation scope
These operating instructions describe all
measures necessary for the safe operation
and proper maintenance of your industrial
truck in all possible variants at the time of
printing. Special designs based on customer
request are documented in separate operating
instructions. If you have any questions, please
contact your service centre.
Please enter the production no. and year of
manufacture 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 each
industrial truck. These instructions must be
stored carefully and must be available to the
operator and operating company at any time.
If the operating instructions are lost, the op-
erating company must obtain a replacement
from the manufacturer immediately.
The operating instructions can be reordered
as a spare part from the STILL service centre.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 18) must ensure that all users have
received, read and understood these instruc-
tions.
Thank you for reading and complying with
these instructions. If you have any questions
or suggestions for improvements, or if you
have found any errors, please contact your
authorised service centre.
45
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Foreword 1
Information about documentation
Issue date and currentness of
manual
The issue date of this manual can be found on
the title page.
STILL is constantly engaged in the further
development of industrial trucks. These
operating instructions are subject to change,
and any claims based on the information
and/or illustrations contained in them cannot
be asserted.
If you require technical support for the indus-
trial truck, please contact your authorised
service centre.
Your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of information symbols
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
destruction.
50988046007 [EN] 5

1Foreword
Information about documentation
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
HPS20_25_019
Typical graphics
This documentation explains the (usually
sequential) chain of certain functions or
operations. Schematic views of an industrial
truck are used to illustrate these procedures.
NOTE
These schematic views are not representative
of the structural state of the documented
industrial truck. The views are used solely
for the purpose of clarifying procedures.
65
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Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the industrial truck, certain
parts are packaged to provide protection
during transport. This packaging must be
removed completely prior to commissioning.
ENVIRONMENT NOTE
The packaging material must be properly
disposed of after delivery of the industrial
truck.
Disposal of units during repair work
It may be necessary to exchange units as part
of maintenance work. Exchanged units must
then be disposed of.
The industrial truck is made of different
materials. Each of these materials must be
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposalpurposes.
50988046007 [EN] 7

1Foreword
Environmental considerations
85
0988046007 [EN]

2
Introduction

2Introduction
Proper usage
Proper usage
The industrial truck described in these operat-
ing instructions is suitable for lifting and trans-
porting loads on pallets, see ⇒ Chapter "Safety
regulations for handing loads", P. 5-38.
The industrial truck must only be used for its
intended purpose as set out and described in
these operating instructions!
If the industrial truck is to be used for purposes
other than those specified in the operating
instructions, the approval of the manufacturer
and, if applicable, the relevant regulatory
authorities must be obtained beforehand to
prevent hazards.
The maximum load to be lifted (rated capacity)
is specified on the nameplate and must not be
exceeded.
The industrial truck must be used only at the
place of use stipulated, see ⇒ Chapter "Place
of use", P. 2-12.
10 50988046007 [EN]

Introduction 2
Impermissible use
Impermissible use
The operating company or operator, and not
the manufacturer, is liable for any hazards
caused by improper use (see also ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 18).
CAUTION
Use for purposes other than those described in
these operating instructions is prohibited.
• The industrial truck may not be operated
in areas where is a risk of fire, explosion
or corrosion, or areas that are particularly
dusty.
• The transport of unstable, poorly stacked
loads or fluids is dangerous and not permis-
sible.
• The industrial truck must not be used if the
load capacity is exceeded.
• Foodstuffs must not come into direct
contact with the industrial truck.
• It is not permissible to use the industrial
truckasajackorlever.
• It is prohibited to transport persons or to use
the truck as a scooter.
• The industrial truck must not be used on
slopes.
• The industrial truck must not be used in
areas that are insufficiently lit.
• The tiller must not be turned at a right angle
in order to stop the industrial truck.
• The industrial truck must not be used for
handling free-swinging loads.
• The industrial truck must not be used if there
is a danger of unintentional movement.
50988046007 [EN] 11

2Introduction
Place of use
Place of use
The industrial truck can be used in buildings.
The sites on which the industrial truck is used
must comply with the current regulations
(condition of the ground, lighting etc.).
The floor areas must have an adequate load
capacity (concrete, asphalt) and should have
a smooth surface.
The driveways, work areas and aisle widths
must correspond with the specifications in
these operating instructions.
The industrial truck is suitable for interior
use in countries ranging from the Tropics
to 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 industrial
truck for the relevant application of the truck. If
in doubt, contact the relevant authorities.
12 50988046007 [EN]

Introduction 2
Residual dangers, residual risks
Residual dangers, residual
risks
Despite careful working and compliance with
standards and regulations, the occurrence
of other risks when using the industrial truck
cannot be entirely excluded.
The industrial truck and all other system
components comply with current safety
requirements. Nevertheless, even when the
truck is used for its proper purpose and all
instructions are followed, some residual risk
cannot be excluded.
Even beyond the narrow danger areas of the
industrial truck itself, a residual risk cannot
be excluded. Persons in this area around the
industrial truck must exercise a heightened
degree of awareness, so that they can react
immediately in the event of any malfunction,
incident or breakdown etc.
WARNING
All persons that are in the vicinity of the industrial
truck must be instructed regarding these dangers
that 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 the
industrial truck, especially if consumables
have leaked.
• The stability of the industrial truck has
been tested to the latest standards. These
standards only take into account the static
and dynamic tipping forces that can arise
during specified use in accordance with
the operating rules and intended purpose.
The risk of exceeding the moment of tilt
that arises from improper use or incorrect
operation cannot be excluded in extreme
cases, and will impact stability.
• Risk of feet being crushed under the load
when the load is lowered.
• Pinch and shear points between the load,
industrial truck and surroundings.
50988046007 [EN] 13

2Introduction
Residual dangers, residual risks
• Risk of accident when transporting loads
due to slipping or falling.
• Loss of stability due to the load being
unstable or the load slipping etc.
• Human error - Disregarding safety regula-
tions.
• Risk caused by unrepaired damage.
• Risk caused by insufficient maintenance or
testing.
• Risk caused by using the wrong consum-
ables.
• Risk caused by exceeding testing intervals.
The manufacturer is not held responsible for
accidents involving the industrial truck caused
by the failure of the operating company to
comply with these regulations either intention-
ally or carelessly.
14 50988046007 [EN]