Still EXD 20 Original Instructions Manual
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Still EXD 20 Original Instructions Manual

Double pallet stacker
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Original instructions
Double pallet stacker
EXD 20
0307 0345
11638011551 EN - 09/2019

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  • Page 1 Original instructions Double pallet stacker EXD 20 0307 0345 11638011551 EN - 09/2019...
  • Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 11638011551 EN - 09/2019...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... 2 General .
  • Page 6 Table of contents Overviews Overview ............20 General view of the truck .
  • Page 7 Table of contents FleetManager™ option: Colour code for the LEDs ......55 Disconnecting a truck equipped with the FleetManager™ option ....57 Transporting loads .
  • Page 8 Table of contents Battery maintenance staff ..........99 Maintenance operations that do not require special training .
  • Page 9 Table of contents Technical specifications EXD20 datasheet ........... . 124 EXD20 mast types .

  • Page 11: Introduction

    Introduction...

  • Page 12: Your Industrial Truck

    Introduction Your industrial truck Your industrial truck General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used.

  • Page 13: Ce Labelling

    Introduction Your industrial truck CE labelling The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. The supplied EC declaration of conformity confirms this. The CE labelling is attached to the nameplate.

  • Page 14: Ec Declaration Of Conformity

    Introduction EC declaration of conformity EC declaration of conformity Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY We declare that the machine according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 15: Identification Label

    Introduction Identification label Identification label NOTE Indicate the serial number for all technical enquiries. Model Manufacturer Serial number Year of manufacture Unladen weight (without battery) in kg Battery maximum weight Battery minimum weight Additional weight (ballast) in kg Nominal motor power (kW) Battery voltage V Rated capacity in kg EC conformity symbol...
  • Page 16 Rules for the operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 11638011551 EN - 09/2019...

  • Page 17: Proper Usage

    Introduction Proper usage Proper usage The truck described in these operating in- If the truck needs to be used for purposes other structions is suitable for lifting, transporting than those specified in these instructions, you and stacking loads. should first: •...

  • Page 18: Unauthorised Use

    Introduction Unauthorised use Unauthorised use Any danger caused as a result of unauthorised The forklift truck should not be used in areas use becomes the responsibility of the operator where there is a risk of fire, explosion or or driver and not that of the manufacturer. corrosion, or in areas that are particularly dusty.

  • Page 19: Safety

    Safety...

  • Page 20: Safety Regulations

    Safety Safety regulations Safety regulations These operating instructions, which come • Regular checks and technical inspections with the truck, must be communicated to all • Recycling of lubricants, oils and batteries those concerned and in particular to personnel • Residual risks. responsible for maintenance and driving.

  • Page 21: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Refer to the maintenance data table for the permissible substances necessary for Consumables can be dangerous. operation. It is necessary to follow the safety regulations when handling these substances.

  • Page 22: Hydraulic Fluid

    Safety Safety regulations for handling consumables Hydraulic fluid WARNING Hydraulic fluid is a water-polluting substance! During operation of the forklift truck, Always store hydraulic fluid in containers hydraulic fluids are pressurised and complying with the regulations. are hazardous to your health. Avoid spilling.

  • Page 23: Disposal Of Consumables

    Safety Safety regulations for handling consumables – Dispose of used battery acid in line with the applicable regulations. Disposal of consumables • Any spillage of fluids such as hydraulic oil, ENVIRONMENT NOTE brake fluid or gear lubricant oil must be Materials that have to be disposed of following immediately soaked up with an oil-binding maintenance, repair and cleaning must be...

  • Page 24: Emissions

    Safety Emissions Emissions Noise emission values Calculated during the test cycle performed in NOTE accordance with standard EN 12053. Lower or higher noise values may occur when Acoustic pressure level in the driver's com- using industrial trucks, e.g. due to the mode partment of operation, environmental factors and other sources of noise.

  • Page 25: Residual Dangers, Residual Risks

    Safety Residual dangers, residual risks Residual dangers, residual risks Despite all operational precautions and • Falling, tripping etc. when moving on the compliance with standards and rules, the industrial truck, especially in the wet, with possibility of additional risks when using the leaking consumables or icy surfaces.

  • Page 26: Specialist

    Safety Definition of responsible persons in compliance with the safety guidelines set The operating company is responsible for the out in these operating instructions. scheduling and correct performance of regular safety checks. The operating company must ensure that all users read and understand the safety It is recommended that these checks comply information in these instructions.

  • Page 27: Safety Tests

    Safety inspection based on time and extraordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must STILL GmbH Hamburg ensure that the truck is checked by a specialist at least once a year or after noteworthy Regelmäßige Prüfung incidents.
  • Page 28 Safety Safety tests 11638011551 EN - 09/2019...

  • Page 29: Overviews

    Overviews...

  • Page 30: Overview

    Overviews Overview Overview General view of the truck Protective screen Drive wheel Tiller Battery compartment Key switch or electronic key Forks Display Load wheels or bogies Stabilisers Mast Stabiliser wheel 11638011551 EN - 09/2019...

  • Page 31: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump-motor unit Stabiliser wheel Tank Drive wheel Stabilisers Traction motor Turntable ES30-24 steering unit 11638011551 EN - 09/2019...

  • Page 32: Control And Display Components

    Overviews Control and display components Control and display components Driver's compartment Handle Anti-crush safety device Lifting the load arms Lowering the load arms Proportional lowering of forks Diagnostic connector Proportional lifting of forks Emergency stop button Horn Display Drive switch Key switch or electronic key 11638011551 EN - 09/2019...

  • Page 33: Display-Operating Unit

    Overviews Control and display components Display-operating unit Operator present indicator light (depending Activity indicator light on the model of the truck) Error Code menu Battery indicator light Settings menu Temperature indicator light Truck status menu Settings indicator light Display of the operating time of the truck Warning indicator light Display of the battery charge Drive programme indicator light...

  • Page 34: Electronic Key (Option)

    Overviews Control and display components Electronic key (option) Switch ON (operating mode) Switch OFF and awaiting code Programming mode active Key fault or incorrect code Time delay of automatic switch-off Operation Enter Status of LEDs Comments ○ red off ● continuous green (1) (correct PIN) * 1 2 3 4 5 # default PIN...
  • Page 35 Overviews Control and display components PROGRAMMING (truck switch OFF only (2)) To reactivate the default Restoring administrator code the initial (00000000), please administrator contact your agent or code nearest dealer. Power switches off ● red flashing ● green Activating the automatically after 10 flashing (5) (5 seconds automatic...

  • Page 36: Markings

    Overviews Markings Markings Labels Identification label Cold store label Danger instructions label. Consult operating Next inspection label instructions Double pallet stacker label Brand label Double pallet stacker label - loading/unload- Model label Brand label Capacity label 11638011551 EN - 09/2019...

  • Page 37: Serial Number

    Overviews Markings Serial number xx xxxx x xxxxx NOTE Indicate the serial number for all technical enquiries. The serial number contains the following information: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 11638011551 EN - 09/2019...
  • Page 38 Overviews Markings 11638011551 EN - 09/2019...

  • Page 40: Technical Description

    Technical description Technical description EXD20 trucks are intended for stacking and These different battery types are not available double stacking pallets and/or containers. on all models. Model available: Steering • EXD20 with proportional lifting and lowering controls with initial lift The ES30–24 electric steering offers driving precision and easier manoeuvring.
  • Page 41 Technical description Driver's compartment Equipment available as standard or as additional options: The tiller groups together control functions: steering, proportional lift, forward and reverse That can be added to the truck: traction, initial lift, horn and double throw • Load backrest safety switch.

  • Page 42: List Of Checks Prior To Start-Up

    List of checks prior to start-up List of checks prior to start-up WARNING – Damaged or missing stickers must be replaced in compliance with the marking Damage or other defects on the forklift truck or position table. attachments (special equipment) can result in accidents.

  • Page 43: Starting Up

    Starting up Starting up NOTE Check that the battery hood is closed • Check that the battery is locked • – Check that the battery is connected – Check that the battery compartment hood is closed and locked correctly. – Release the emergency off switch (1) if it has been pressed.
  • Page 44 Starting up – Tilt the tiller in the driving area (3). NOTE In areas (1) and (2), the electromagnetic brake is applied and it is not possible to drive the truck. 11638011551 EN - 09/2019...

  • Page 45: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Checking the anti-crush safety device Anti-crush safety function The machine moves in the opposite direction when the anti-crush button (2) is pressed. If the truck is being operated in narrow areas (such as in a lift for example), the operator may get stuck against the wall if care is not taken.

  • Page 46: Checking The Emergency Shutdown

    Checks and actions prior to commissioning Checking the emergency shutdown To check the operation of the emergency off switch, proceed as follows: – Start up the truck. – Drive the truck. – Press the emergency off switch (1). • The truck stops immediately. •...

  • Page 47: Checking The Horn

    Checks and actions prior to commissioning Checking the horn – Press the horn button (5) located on the upper part of the tiller. – The horn sounds. 11638011551 EN - 09/2019...

  • Page 48: Truck Operating Instructions

    Truck operating instructions Truck operating instructions The trucks are designed for indoor and It is important to use pallets that are in good outdoor use in non-hazardous atmospheres. condition. The temperature should be between -10°C Speed must be reduced when moving over and +45°C and the relative humidity of the air obstacles to prevent the truck from becoming less than 95%.
  • Page 49 Truck operating instructions WARNING CAUTION Driving safety guidelines: Risk of injury – The driver must drive slowly around corners and Before using a side access truck, check that the when entering narrow passageways. battery is correctly locked. – The driver must always maintain a safe braking distance from vehicles or people in front of him.

  • Page 50: Using The Display-Operating Unit

    Using the display-operating unit Using the display-operating unit Selection buttons The operator selects the menus using the four selection buttons: • The Blue Q button (1) to select Blue Q mode, hare mode or tortoise mode • The left arrow button (2) to scroll left through the drop-down menu •...
  • Page 51 Using the display-operating unit stricted, the (3) icon flashes and the (4) icon remains illuminated with a new warning message. Temperature, settings and warning lights The Temperature light (1) comes on in the event of overheating of the traction motor or the controller.
  • Page 52 Using the display-operating unit Activity indicator The Activity indicator light (1) flashes continu- ously while the truck is in operation. When the indicator is off, the display unit is locked or frozen. A warning is shown on the display. Settings menu It is possible to access different settings through the Settings menu.
  • Page 53 Using the display-operating unit Error codes menu It is possible to access error messages that are disrupting the operation of the truck. – Select the Error messages menu (1) The operator can access the error codes. If several codes are affecting the truck, the op- erator can scroll through several successive displays.

  • Page 54: Driving Safety Guidelines

    Driving safety guidelines Driving safety guidelines Behaviour when driving • Never sit on the dashboard to drive the truck • The truck must not be used as a stepladder Operators must obey the same rules within • The truck is not designed to transport the plant as on the road.

  • Page 55: Driving

    Driving Driving Defining directions On a pedestrian-mode double pallet stacker, the conventional directions are: • Forward travel (1): Tiller direction • Reverse travel (2): Fork direction The load is positioned at the rear. Driving – Turn the ignition key. – Lower the tiller in the (3) zone. NOTE The truck is in the drive position in the (3) zone.

  • Page 56: Steering

    Driving – Press the lower part (1) of the drive switch (3) with your thumb. – The speed increases with the movement of the drive switch. – When the drive switch is released, the truck brakes electrically. Reverse gear – Press the upper part (2) of the drive switch (3) with your thumb.

  • Page 57: Braking

    Driving – Turn the tiller clockwise: the truck turns to the left in forward travel (1). – Turn the tiller anti-clockwise: the truck turns to the right in forward travel (2). WARNING Risk of serious injury and/or serious damage to equipment Always slow down before negotiating a corner.

  • Page 58: Horn

    Driving Braking by reversing the drive direction Braking can be achieved by reversing the drive direction: – Move the drive switch (1) or (2) in the opposite direction until the truck stops. Braking by releasing the drive switch Braking can be obtained by releasing the drive switch: –...

  • Page 59: Drive Program

    Driving Drive program The indicator light (1) is on during operation of the truck. The shape of the indicator light indicates the selected program. The truck is equipped with three different drive programs: • Hare mode (3) • BlueQ mode (4) •...

  • Page 60: Creep Speed Function

    Driving The different speeds can be adjusted. Contact the After-Sales Service Centre to change these. Creep Speed function This function makes it possible to manoeuvre the truck in confined spaces. The tiller remains in the vertical position. – Press the Creep Speed button (1) (tortoise icon) on the tiller.

  • Page 61: Using The Truck On A Slope

    Driving Using the truck on a slope NOTE Incorrect use of the truck on a slope is not recommended. It places particular stress on the traction motor, brakes and battery. Slopes must be approached with great cau- tion: • Never attempt a slope whose gradient is greater than that specified in the truck's datasheet.
  • Page 62 Driving Travelling down slopes Always travel down slopes forwards. The load faces uphill. Without a load, we recommend that you descend a slope forwards. In all cases, you must travel at a very low speed and brake gradually. DANGER Danger of death and/or risk of serious damage to equipment Never park the truck on a slope.

  • Page 63: Operating The Fleetmanager™ Option

    Operating the FleetManager™ option Operating the FleetManager™ option Description of the FleetManager option The FleetManager option allows you to control GSM: Global System for Mobile Communi- access to the truck. The option is a fleet cation management system. Shock sensor You can access the system: •...

  • Page 64: Commissioning A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Commissioning a truck equipped with the FleetManager™ option Commissioning a truck equipped with a keypad or an electronic key – Turn the switch key to start the truck. – Enter the PIN code on the keypad. The PIN code consists of five to eight digits.

  • Page 65: Fleetmanager™ Option: Colour Code For The Leds

    Operating the FleetManager™ option FleetManager™ option: Colour code for the LEDs The LEDs can have different statuses and different colours. Below is the list of the most common messages and their meanings. Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Reading device variant: no...
  • Page 66 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has Reset the shock Red colour Green colour occurred The truck is The truck is switched on but connected via a is not moving.

  • Page 67: Disconnecting A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Disconnecting a truck equipped with the FleetManager™ option NOTE Operators must not log off intentionally while driving. WARNING Access to the truck must be disabled. Unauthorised users are not allowed to use the truck. Disconnecting a truck equipped with a keypad or electronic key –...
  • Page 68 Operating the FleetManager™ option Disconnecting a truck equipped with an RFID reading device – Park the truck in a safe place. – Briefly place the RFID card or the RFID transponder (4) in front of the reading device (3). The LED (1) lights up for a second (red colour). The LED (2) is not lit.

  • Page 69: Transporting Loads

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

  • Page 70: Transporting Pallets Or Other Containers

    Transporting loads Transporting pallets or other contain- As a general rule, loading units must be trans- ported one by one (e.g. pallets). Transporting several loading units at a time is only autho- rised: • when the safety preconditions are fulfilled. •...

  • Page 71: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads Progressive stopping of the carriage in the lower position A detector (1) that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the lowering action. This detector prevents a violent impact at the end of travel.

  • Page 72: Reading The Capacity Plate

    Transporting loads Reading the capacity plate CAUTION Risk of loss of control Before picking up a load, make sure that its weight does not exceed the lifting capacity of the machine. Refer to the nominal capacity specified on the truck's capacity plate (1). The values shown correspond to compact, homo- geneous loads.
  • Page 73 Transporting loads • 9: Maximum lift height: 210 mm with 2000 kg in pallet truck mode • 10: Maximum capacity in pallet truck mode: 2000 kg with a height of 210 mm • 11: Model 11638011551 EN - 09/2019...

  • Page 74: Lift Control Elements

    Transporting loads Lift control elements WARNING Appropriate use of the equipment Only use the lifting device and the accessories for the work for which they are intended. The operator must receive instruction on the opera- tion of the load lift system. WARNING Risk of injury The safety instructions must be strictly adhered to.
  • Page 75 Transporting loads Raising/lowering the mast Lifting the mast: – Press button (2). The forks are raised. Lowering the mast: – Press button (1). The forks are lowered. When the lifting control (1) is released, the forks stabilise at the required height. NOTE A groove (3) is present on each side of the button.

  • Page 76: Handling A Single Load

    Transporting loads Handling a single load DANGER Risk of truck falling Do not stack the initial lift high. Before picking up a load Ensure that the load weight does not exceed the truck's capacity. • Refer to the nominal capacity specified on the truck's capacity label •...
  • Page 77 Transporting loads Picking up a load from the ground – Use the initial lift to raise a load of up to 2000 kg several centimetres from the ground. Transporting a load DANGER Risk of accident No one should be under or near the truck when the load is in the raised position.
  • Page 78 Transporting loads CAUTION Risk of falling Do not touch nearby loads or loads positioned behind the truck. CAUTION Risk of accident Before you remove the load, ensure that no one is around the truck or load. Stacking a load DANGER Risk of loss of stability Do not use the initial lift control to disengage the load from the storage area, in order to retain maxi-...
  • Page 79 Transporting loads Picking up a load at a height Proceed as follows: – Drive the machine to the required location. – Lower the load arms completely. – Lift the forks to the height of the pallet. – Carefully move the forks forward under the pallet.

  • Page 80: Handling Two Stacked Pallets

    Transporting loads Handling two stacked pallets Double pallet stackers enable two stacked loads to be transported: - One load on the load arms (initial lift) - One load on the forks DANGER Risk of loss of stability The overall weight of the two loads must not exceed the maximum capacity of the machine (refer to the capacity plate).
  • Page 81 Transporting loads – Raise the load arms (2) to lift the load from the ground. – Lower load (Q1) again as close as possible to load (Q2) before driving. CAUTION Risk of crushing goods Make sure that there is enough space above load (Q2) so as not to crush the top of the pallet.
  • Page 82 Transporting loads – Lower the forks again. WARNING Lifting and lowering the forks The initial lift or lowering operation (load arms) is matched by the forks. Before leaving the machine CAUTION Parking the truck Always stop the machine on level ground away from traffic routes.

  • Page 83: Driving Assistance System: Dynamic Drive Control

    Driving assistance system: Dynamic Drive Control Driving assistance system: Dynamic Drive Control Description of the Dynamic Drive Control The Dynamic Drive Control option is a system that assists when driving and using the truck. The forklift operator must remain vigilant under all circumstances and adhere to the truck capacity plate.

  • Page 84: Cold Store Usage (Optional)

    Cold store usage (optional) Cold store usage (optional) CAUTION Standard trucks risk being subject to significant damage if used in extreme conditions. Only trucks with the Cold Store option may be used inside cold storage. Specific oil designed for cold stores must be used.
  • Page 85 Cold store usage (optional) DANGER If the condensation freezes in the cold store, it is prohibited to operate the jammed parts. This could cause permanent damage to the truck. Parking The truck must be parked outside of the cold store. Parking inside the cold store could cause seri- ous damage to the electrical and mechanical equipment (seals, hoses, rubber and synthetic...

  • Page 86: Before Leaving The Truck

    Before leaving the truck Before leaving the truck – Choose a safe and level location. – Remove the switch key. – Set down the load and lower the forks DANGER completely. Danger of death! The forks must touch the ground. It is prohibited to park the truck with a load in the raised position or the forks in the raised position.

  • Page 87: Handling The Battery

    Handling the battery Handling the battery Battery type Trucks can be fitted with different types of battery. Comply with the information indicated on your battery's type plate, as well as with its features. WARNING The weight and size of the battery influence the stability of the truck.

  • Page 88: Opening And Closing The Battery Hood

    Handling the battery restarted when the covers and connectors have been put back in the operating position. Opening and closing the battery hood Opening the battery hood To open the battery hood: – Immobilise the truck. – Lower the forks. –...
  • Page 89 Handling the battery – Park the truck safely. – Before charging, check the condition of the battery cable and the charger cable. Replace them if necessary. – Open the hood and leave it open. – Pull the handle of the battery connector (2) to disconnect it from the fixed socket on the truck (1).

  • Page 90: On-Board Charger

    Handling the battery On-board charger Precautions for installation and use expelled air is 25°C maximum. Wait 10 minutes after stopping the charger before The on-board charger means you no longer touching the unit. have to use a charging room. This charger •...

  • Page 91: Using The On-Board Charger

    Handling the battery If the charger stays connected to the mains, If the cut-off period is longer than 13 minutes it restarts a charging cycle every 48 hours (the truck could have been used), a complete after the end of the previous charge in order to charging cycle is initialised.
  • Page 92 Handling the battery Do not press the emergency off switch. This operation cuts off the circuits and stops the battery from charging. – Connect the charger plug (1) to a mains socket. Phase Green LED Red LED Mains socket disconnected Charging phases Flashing Stopped / Equalisation /...

  • Page 93: Adjusting The On-Board Charger

    Handling the battery Adjusting the on-board charger Charging curve selector The curve is selected using the selector located on the front face of the charger. The curve selector is protected by a cap. The 4 fine lines indicate neutral positions. The charger does not flow and the two LEDs flash simultaneously to indicate that no curve has been selected.

  • Page 94: Changing The Side Access Battery

    Handling the battery – Attach the slinging hooks to the battery compartment. NOTE Using secured hooks is recommended. – Lift the battery. Take care not to hook onto the upper bridge piece of the mast. – Replace the battery. – Position the new battery in the chassis. –...
  • Page 95 Handling the battery – Place the connector on the battery cells. – Unlock the door that is not attached to the side of the battery by lifting the latch (1). Hold the door (2) to prevent it falling. – Remove the door (2) (if this option is selected) and put it to one side.
  • Page 96 Handling the battery – Operate and pull the locking handle (2) in the direction indicated by the arrow. – Lift the locking bar (3) until the battery is freed. 11638011551 EN - 09/2019...
  • Page 97 Handling the battery – Pull the battery onto the truck with extraction rollers or the roller frame – Replace the battery. Remove the dis- charged battery and position a charged battery on the roller frame. – Position the truck with extraction rollers or the roller frame (4) in the upright position next to the battery compartment.
  • Page 98 Handling the battery – Push until a click is heard. The battery is correctly installed. WARNING Risk of injury Ensure that the battery is in the end position and that the hook is correctly holding the battery. DANGER Risk of injury The battery is correctly positioned but is not yet locked.
  • Page 99 Handling the battery – Lower the latch of the battery compartment door (if this option is selected). The door that is not attached to the side of the battery must be correctly locked. – Refit the battery hood. – Return the truck to service. WARNING Risk of injury Before restarting the truck, ensure that the battery is...

  • Page 100: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Emergency lowering of the mast The emergency control (1) allows the mast to be lowered manually in the event of a problem. This operation is to be performed as follows: –...

  • Page 101: Truck Towing Procedure

    Handling the truck in an emergency Truck towing procedure It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. Truck towing is authorised with a rigid connec- tion (tow bar) if the truck to be towed can no longer be braked.
  • Page 102 Handling the truck in an emergency – After towing, chock the truck to prevent it from moving. – To re-establish brake operation, unscrew and remove the two screws (1). – Refit the covers. WARNING It is essential that the covers are correctly refitted before the machine is used.

  • Page 103: Handling The Truck In Specific Situations

    Handling the truck in specific situations Handling the truck in specific situations Slinging the truck DANGER Danger of truck falling. Only use slings and a hoist of sufficient quality. Check the weight of the machine (including battery) in order to choose a suitable device. Refer to the technical features.

  • Page 104: Lifting The Truck

    Handling the truck in specific situations Lifting the truck DANGER Danger of swinging You must take care when lifting the truck. For some work, it is necessary to lift the truck. – Lift the load arms. – Switch off the ignition and disconnect the battery connector.

  • Page 105: Transporting The Truck In The Lift

    Handling the truck in specific situations The truck must be suitably protected from the DANGER effects of the weather during transport and Danger of death. storage. Do not stand within the hoist's operating radius or below the lifted truck. To load or unload the truck, use an inclined plane or a mobile ramp.
  • Page 106 Handling the truck in specific situations 11638011551 EN - 09/2019...

  • Page 107: Maintenance

    Maintenance...

  • Page 108: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the information required for maintenance of your truck. Carry out the various maintenance work in compliance with the maintenance plan. This will ensure that your truck is reliable and in good working order and that the warranty remains valid.

  • Page 109: Servicing And Maintenance Personnel Training And Qualification

    Maintenance General maintenance information Servicing and maintenance personnel training and qualification Truck maintenance must only be carried out The person responsible for carrying out the by qualified and authorised personnel. inspection must have sufficient knowledge and experience to be able to assess the The annual inspection for prevention of condition of the truck and the efficiency of accidents at work must be carried out by a...

  • Page 110: Safety Guidelines For Maintenance

    Maintenance Safety guidelines for maintenance Safety guidelines for maintenance Servicing and maintenance measures To avoid accidents during servicing and – Ensure that there is no risk of the truck maintenance operations, take all necessary moving or starting up unexpectedly. For safety measures.

  • Page 111: Technical Data For Inspection And Maintenance

    Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Capacities/adjustment values Consumables/lubricants Minimum working capacity: 3.3 l Hydraulic system Hydraulic oil Maximum working capacity: 3.5 l Transmission gear Transmission gear oil 1.1 l Traction motor (1.5 kW) Power: 300 A, quantity: 1 1F1 fuse Steering unit ES30–24...

  • Page 112: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants CAUTION SAE 85W 90 API GL4 Damage to equipment if non-recommended lubri- Aerosol can for chains cants are used Only use recommended lubricants. Only the lu- Standard chain spray. bricants listed below are approved by the manu- facturer.

  • Page 113: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical compartment WARNING Risk of injury. Before removing anything, turn the ignition off and press the emergency stop button. To access the technical compartment, it is necessary to lift the top hood (1) and remove the front hood (2).

  • Page 114: 1000-Hour Service Plan

    Maintenance 1000-hour service plan 1000-hour service plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours Preparation Clean the truck Check the error codes using the diagnostic tool Chassis and equipment Check the condition of the forks Check the electromagnetic brake and ensure that it is working correctly...

  • Page 115: 5000-Hour Maintenance Plan

    Maintenance 5000-hour maintenance plan 5000-hour maintenance plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 5000 and 10,000 hours Information Carry out all 1000-hour maintenance work Hydraulics Drain the hydraulic oil 10,000-hour service plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 10,000 hours...

  • Page 116: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Park the truck. – Press in the emergency off switch. CAUTION Electrical hazards The battery must always be disconnected during cleaning procedures. Washing the outside of the truck WARNING Risk of damage to the truck –...
  • Page 117 Maintenance Chassis, bodywork and fittings NOTE Only use dry cleaning products. • Do not remove the cowlings. • – Clean the electric installations with a non- metal brush and dry with lightly compressed air. After washing – Carefully dry the truck (e.g. with com- pressed air).

  • Page 118: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings General information on battery maintenance DANGER CAUTION Risk of injury Gel batteries are subject to specific charging, maintenance and treatment instructions. A non- Before carrying out any operations on the electric compatible charger may result in a battery failure. installation, turn the truck power supply off.

  • Page 119: Checking The Condition Of The Forks

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

  • Page 120: Steering And Wheels

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

  • Page 121: Checking The Condition Of The Wheels

    Maintenance Steering and wheels Checking the condition of the wheels – Raise the truck until the wheels are off the ground. – Check that the wheels rotate freely and remove any objects that may prevent them from turning or may obstruct them. CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the bearings...

  • Page 122: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Cleaning and blowing air through the electrical components CAUTION Electrical hazards Always disconnect the battery connector before working on an electrical component. – Press in the emergency off switch. – Disconnect the battery connector. – Open the technical compartment. –...

  • Page 123: Checking The Battery Acid Level And Electrolyte Density

    Maintenance Electrical equipment Checking the battery acid level and electrolyte density WARNING The electrolyte (diluted sulphuric acid) is poisonous and caustic! – Always wear suitable protective equipment (industrial goggles, safety gloves) when working on a battery. – Never wear a watch or jewellery when handling battery acid.

  • Page 124: Checking The Condition Of The Cables, Terminals And Battery Connector

    Maintenance Electrical equipment Checking the condition of the cables, terminals and battery connector – Check that the cable insulation is undam- aged. – Check that there are no signs of heat build-up in the connections. – Check that the "+" and "-" output terminals are not sulphated (presence of white salt).

  • Page 125: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Checking the hydraulic system for leaks – Switch off the truck and disconnect the battery connector. – Remove the hood of the technical compart- ment. – Inspect the hydraulic system: pipes, hoses and connections between the pump unit and the cylinders.

  • Page 126: Checking The Controlled Stabiliser Hydraulic System For Leaks

    Maintenance Hydraulic systems – Remove the hood of the technical compart- ment. To ensure correct operation of the truck functions, the oil level must be between the minimum mark (3) and maximum mark (2) on the tank. – Remove the plug (1). If necessary, top up via the opening.

  • Page 127: Checking The Oil Level In The Controlled Stabiliser Circuit

    Maintenance Hydraulic systems In the event of leakage, please contact the After-Sales Service Centre. Checking the oil level in the con- trolled stabiliser circuit – Switch off the truck and disconnect the battery connector. – Remove the hood of the technical compart- ment.

  • Page 128: Lift Mast

    Maintenance Lift mast Lift mast Cleaning and lubricating the chains CAUTION NOTE Risk of the equipment becoming worn or damaged. If the lifting chain is too dirty, clean it. Chains are safety components. Use of cold clea- – Place a recipient underneath the lifting ning agents, chemical products, acid or chlorinated chain.

  • Page 129: Checking The Protective Screen

    Maintenance Lift mast Checking the protective screen It is important to check the condition of the mast protective screens and to check that the mountings are tightened. – Check that the protective screen (1) is correctly attached and in good condition (undamaged).

  • Page 130: Storage And Decommissioning

    Maintenance Storage and decommissioning Storage and decommissioning Storage of truck Precautions should be taken if the truck must CAUTION not be used for a reasonably long period. The We recommend that you do not use a plastic sheet operations depend on the length of time it is as this encourages condensation to form.

  • Page 131: Permanent Putting Out Of Commission (Destruction)

    Maintenance Storage and decommissioning Permanent Putting Out of Commis- sion (Destruction) When scrapping the truck, it is necessary to: – Remove the various parts of the truck (covers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.
  • Page 132 Maintenance Storage and decommissioning 11638011551 EN - 09/2019...
  • Page 133 Technical specifications...

  • Page 134: Exd20 Datasheet

    Technical specifications EXD20 datasheet EXD20 datasheet 11638011551 EN - 09/2019...
  • Page 135 Technical specifications EXD20 datasheet DESCRIPTION 1.1 Manufacturer STILL 1.2 Model type EXD20 Method of propulsion: battery, diesel, petrol, Battery LPG, mains power Driving: manual, pedestrian, standing, Standing seated, order picking Nominal capacity: main lift only Main lift/initial lift Q (kg) 1200;...
  • Page 136 Technical specifications EXD20 datasheet 4.5 Extended mast height (±5 mm) h4 (mm) 2544 (2024T) 4.6 Initial lift (±5 mm) h5 (mm) Tiller height in driving position h14 (mm) 740/1230 min./max. (±5 mm) Load arm/ground height h8 (mm) 4.10 (0/+5 mm) Height at the ends of the fork h13 (mm) 4.15...
  • Page 137 Technical specifications EXD20 datasheet Acceleration time (10 m) when laden/un- 7.6/6.7 laden electromagnetic 5.10 Service brake DRIVE SYSTEM EXD20 6.1 Traction motor, S2: 60 minutes 6.2 Lift motor, S3: at 10% utilisation Battery type in accordance with DIN 3 PzS side access 43 535 Gel/Lead 24/375...

  • Page 138: Exd20 Mast Types

    Technical specifications EXD20 mast types EXD20 mast types Mast type Standard 1574T 2024T 2424T 1240 1465 1665 1315 1540 1740 1574 2024 2424 2094 2544 2944 Mast type Duplex 1924 N 1915 1395 2924 3444 11638011551 EN - 09/2019...
  • Page 139 Index Checking the protective screen ..119 Checks prior to start-up ... . . 32 Accessing the technical compartment . . 103 Cleaning and lubricating the chains ..118 Address of manufacturer .
  • Page 140 Index Driving ......45 Driving on loading bridges ... 95 Handling a single load .
  • Page 141 Index Starting on a slope ....52 Starting up ..... . . 33 Permanent Putting Out of Commission .
  • Page 144 STILL GmbH 11638011551 EN – 09/2019...

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