Still EXD-18 Original Instructions Manual
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Still EXD-18 Original Instructions Manual

Still EXD-18 Original Instructions Manual

Double pallet stacker
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Original instructions
Double pallet stacker
EXD-18
0285 0286 0294 0295
1160 801 15 51 EN - 09/2019

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  • Page 1 Original instructions Double pallet stacker EXD-18 0285 0286 0294 0295 1160 801 15 51 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 1160 801 15 51 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 Overview .
  • Page 7 Table of contents Lift control elements ..........53 Reading the capacity label .
  • Page 8 Table of contents Recommended lubricants ..........93 Technical data for inspection and maintenance .

  • Page 9: Introduction

    Introduction...

  • Page 10: 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 11: 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 12: 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 13: 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 Maximum battery weight Minimum battery weight (for a lithium-ion battery, the weight of the ballast container is included) Additional weight (ballast weight) in kg Nominal motor power (kW)
  • Page 14 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. 1160 801 15 51 EN - 09/2019...

  • Page 15: 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 16: 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 17: Safety

    Safety...

  • Page 18: 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 19: 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 20: 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 21: 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 22: Emissions

    Safety Emissions Emissions Noise emission values Acoustic pressure level on the driver's Calculated during the test cycle performed compartment in accordance with standard EN 12053 from the weighted values for the LIFT, IDLING and In the DRIVE 66.55 dB DRIVE operating statuses. operating state Uncertainty 2.5 dB (A)

  • Page 23: 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 24: 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 25: 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 26 Safety Safety tests 1160 801 15 51 EN - 09/2019...

  • Page 27: Overviews

    Overviews...

  • Page 28: Overview

    Overviews Overview Overview Overview Lift mast Tank Guard grille Load arms Tiller Load wheels or bogies Emergency stop handle Pump unit Display On-board charger Traction controller Fork arms Stabiliser wheel Mast cylinder Drive wheel 1160 801 15 51 EN - 09/2019...

  • Page 29: Control And Display Components

    Overviews Control and display components Control and display components Tiller Handle Travel throttle valve Load arm lifting Anti-crush safety feature Proportional lowering of fork arms Travel throttle valve Proportional lifting of fork arms Lowering the load arms Horn 1160 801 15 51 EN - 09/2019...

  • Page 30: Digicode (Optional)

    Overviews Control and display components Digicode (optional) Switch ON (operating mode) Key fault or incorrect code Switch OFF and awaiting code Time delay of automatic switch-off Programming mode active Operation Enter Status of LEDs Notes ○ red off ● continuous * 0 0 0 0 0 # 0 0 0 0 0 1 2 3 4...
  • Page 31 Overviews Control and display components PROGRAMMING (truck switch OFF only (2)) Power switches off ● red flashing ● green Activating the automatically after flashing (5) (5 s before * * 2 * 1 # automatic 10 minutes (600 s by switch-off) switch-off default) if the truck is...

  • Page 32: Battery Charging Indicator

    Overviews Control and display components Battery charging indicator COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES 91% - 100%: 10 bars 1% - 10%: 1 bar Full charge: 100% 0%: 1 flashing bar (lift Battery charge level Low charge: 10% Dis- function not permitted). represented by 10 bars charged: 0% NB: To protect the battery,...
  • Page 33 Overviews Control and display components COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES Switched off: truck switched Green indicator light Switched on: truck switched These codes will help the service department to decide Error code E3 294 on the appropriate response from the service engineer. Fault or brake wear (air gap) Do not operate the truck - The meter starts running...

  • Page 34: Markings

    Double pallet stacker label Warranty label (for Germany only) on the Mast safety label inside of the tiller Still label on the mast cylinders at both sides Never touch with hands label Cold store label 1160 801 15 51 EN - 09/2019...

  • Page 35: 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 1160 801 15 51 EN - 09/2019...
  • Page 36 Overviews Markings 1160 801 15 51 EN - 09/2019...

  • Page 38: Technical Description

    Technical description Technical description EXD18 trucks are designed for pallet stacking These masts are equipped with side lift and double pallet stacking. cylinders. This truck is a pedestrian version ACC model. EXD18 trucks are equipped with S (stan- dard) masts for heights ranging from 1574 to 2024 mm.
  • Page 39 Technical description Equipment available as standard or as - Built-in charger (on versions of battery additional options: with vertical access only and non-cold store versions) - Load backrest - Central refilling system. - Creep Speed (Creep Speed) - Cold store (-35°C). - Proportional speed (Proportionnal Speed).

  • Page 40: 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 41: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Start-up – Connect the battery connector, if neces- sary. – Keep the tiller in the vertical position. – Place the drive direction selector in the neutral position (in the middle). –...

  • Page 42: Checking The Brake

    Checks and actions prior to commissioning Checking the brake CAUTION Perform this check on a flat surface. – Drive the truck and whilst tilting the tiller in areas (1) and (2), test the effectiveness of the brake. In these two areas, the truck is braked and the drive unit is no longer powered.

  • Page 43: Checking The Anti-Crush Safety Device

    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 44: 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. 1160 801 15 51 EN - 09/2019...

  • Page 45: 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 46 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 47: Driving

    Driving Driving Driving safety instructions Behaviour when driving • Never sit on the truck to drive it. • The truck must not be used as a stepladder. The operator must obey the same rules within • This truck is not designed to transport the plant as he would on the road.

  • Page 48: Driving

    Driving Driving – Turn the ignition key to the Tortoise sition (slow acceleration and deceleration) or the position (faster acceleration Hare and deceleration). – Lower the tiller in the (2) zone. NOTE The truck is in the drive position in the (2) zone.

  • Page 49: Optispeed

    Driving Optispeed – Lower the tiller. NOTE The machine is only in the driving position in zones (2) and (3). In the lower zone (4) or the upper zone (1), the brake is applied and the traction motor is switched off. In zone (3), the truck can be used at full speed.

  • Page 50: Braking

    Driving Braking WARNING The quality of the floor surface affects the braking distance of the truck. To be taken into consideration when driving. Gentle braking – Release the drive direction selector (2) or (3) during operation. Moderate braking – Move the drive direction selectors (2) or (3) in the opposite drive direction.

  • Page 51: Creep Speed Function

    Driving 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. Hold the button down. – Gently move the drive switch forwards or backwards depending on the manoeuvre to be performed.

  • Page 52: Driving On Upward And Downward Slopes

    Driving Timeout can be adjusted. Please call the After-Sales Service Centre. Driving on upward and downward slopes Slopes should always be approached with the load facing towards the top of the slope. Only slopes • marked as traffic routes • and compatible with the truck's technical specifications can be safely used.

  • Page 53: 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 54: 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 55: 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 56 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 57: 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 58 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 59: 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 60: 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 61: Lift Control Elements

    Transporting loads Lift control elements WARNING Risk of injury The safety regulations must be strictly adhered to. It is strictly forbidden to touch or stand on moving parts (e.g. lifting device, pushing devices, work installations, load lifting devices). For safety reasons, the lift and traction func- tions are inhibited when the tiller is in the rest position.
  • Page 62 Transporting loads Base lift Lifting the load arms – Press button (4). Lowering the load arms – Press button (5). 1160 801 15 51 EN - 09/2019...

  • Page 63: Reading The Capacity Label

    Transporting loads Reading the capacity label CAUTION 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 label (1). The values shown correspond to compact, homo- geneous loads.

  • Page 64: Load Handling

    Transporting loads Load handling DANGER Risk of truck falling Do not stack the initial lift high. CAUTION Safety footwear must be worn. Transporting people is strictly prohibited. DANGER It is essential to slow down when approaching a corner or on wet floors. CAUTION Do not touch nearby loads or loads positioned at the side or in front of the load being handled.
  • Page 65 Transporting loads Transporting a load DANGER Risk of accidents Personnel must not stand under or near the truck when the load is in the raised position. DANGER Risk of falling Never transport a load with the forks in the raised position as the truck may become unstable.
  • Page 66 Transporting loads CAUTION Risk of accidents Before you remove the load, ensure that there are no people around the truck or load. Stacking a load CAUTION Risk of loss of stability To disengage the load from the racking do not use the initial lift control in order to retain maximum stability and to avoid any risk of overloading the truck.
  • Page 67 Transporting loads Picking up a load at a height – 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 68: Handling Two Stacked Pallets

    Transporting loads Handling two stacked pallets EXD18 trucks enables two stacked loads to be transported: - one load on the load arms of the initial lift - one load on the fork arms. 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 69 Transporting loads Transporting two loads – The normal direction of travel is forwards. – In the event of poor visibility, move slowly and carefully and work with guidance. – Do not travel with a load (Q1) on the forks if there is no load (Q2) on the load arms above 300 mm from the ground.

  • Page 70: Option Autolift

    Transporting loads Option Autolift DANGER Do not use the Autolift option in double stacking mode. NOTE Training on how to use this option is required before use. WARNING Risk of accident Ensure that there is nobody in the work area. Description of the Autolift option The Autolift option enables automatic lifting and automatic lowering of the forks.
  • Page 71 Transporting loads Using the Autolift option The unit that controls the Autolift option consists of: • A green illuminating button (1) • A turning knob (2) to select the lift (4) or lower (5) position • Two emergency off switches (3) located at each end of the unit WARNING Risk of crushing fingers...
  • Page 72 Transporting loads – Turn the Autolift(2) turning knob to the Lift(4) position. – Press the green illuminating button (1). – The forks are raised to 800 mm. A beep sounds before activation. The green illuminating button lights up when the forks are moving.

  • Page 73: 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 74 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 75: Stopping The Truck

    Stopping the truck Stopping the truck WARNING – Switch off the ignition then remove the key or press the button on the digicode for Do not stop the truck on a slope, or if this is absolu- 2 seconds. tely necessary, make sure it is safely secured using chocks.

  • Page 76: 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 77: Opening/Closing The Battery Cover

    Handling the battery restarted when the covers and connectors have been put back in the operating position. Opening/closing the battery cover Opening – Bring truck to a controlled stop. – Lower the forks. – Turn off the ignition and remove the key. –...
  • Page 78 Handling the battery – Guide it downwards. The cover will gradu- ally close. – At the end of travel, be careful not to trap your fingers. With your second hand, hold the cover handle (2) and lower it slowly. – Return the cover to the horizontal position. CAUTION Keep fingers away from moving parts to avoid any risk of them being trapped.

  • Page 79: Battery Charging Using An External Charger

    Handling the battery – Subsequently, position the second axis in the opening (5) . The first side of the cover is back in place. – Position the rod (7) into the opening (6). The second side is in place. – Close the cover. Battery charging using an external charger CAUTION...
  • Page 80 Handling the battery – Remove the battery disconnection handle (1) from the truck plug (2). – Connect the battery connector to the wall-mounted connector. WARNING Only unplug the battery connector from the battery charger when both the battery charger and truck are switched off.

  • Page 81: 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 82: 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 83 Handling the battery – Connect the charger plug (1) to a mains wall socket. Phase Green LED Red LED Disconnected mains socket Charging Flashing phases Stopped / Equalisation / Continuously Maintenance phase Charging too Continuously long Charger polarity reversed (+battery and -battery charger cables...

  • Page 84: Adjusting The On-Board Charger

    Handling the battery NOTE The on-board charger is not compatible with the Cold Store option. 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.

  • Page 85: Replacing The Vertical Access Battery

    Handling the battery Replacing the vertical access battery Maintain a safe distance in order to remove the battery and not damage the truck. DANGER Risk to life Risk of the battery falling. No-one should be under a raised load. Changing the battery with a hoist –...

  • Page 86: Replacing A Vertical Access Battery With The Autolift Option

    Handling the battery Replacing a vertical access battery with the Autolift option If equipped with the Autolift option, replacing the vertical access battery involves an addi- tional step. – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. –...

  • Page 87: Replacing The Side Access Battery

    Handling the battery – Position the new battery carefully in the chassis. – Guide it to the end of travel. – Remove the sling hooks. – Reconnect the battery connector. – Close the battery hood. – Refit the Autolift unit and tighten the nuts (1) correctly.
  • Page 88 Handling the battery – Open the battery hood (1). Position the support (2) in the opening provided for this purpose. – Position the truck in the upright position with extraction rollers or the roller frame (3) near the battery compartment on level ground. –...
  • Page 89 Handling the battery – Fully raise the locking bar (6). – Lift the stop (7). The stop is magnetic so that it can be perfectly positioned in the battery hood. 1160 801 15 51 EN - 09/2019...
  • Page 90 Handling the battery – Pull the battery onto the truck with extraction rollers or the roller frame (3). – Replace the battery. – Push the battery to the end of the compart- ment. – Fold the stop (7) down. – Fully lower the locking bar (6). –...

  • Page 91: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Emergency mast lowering The drain screw allows the mast to be lowered manually in the event of a problem. CAUTION This operation is only carried out in exceptional circumstances.

  • Page 92: Towing The Truck

    Handling the truck in an emergency Towing the truck It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. You may tow the truck with a rigid connection (tow bar) if the truck to be towed can no longer be braked.
  • Page 93 Handling the truck in an emergency – Close the hood of the technical compart- ment. 1160 801 15 51 EN - 09/2019...

  • Page 94: 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 (2) or a hoist of sufficient quality. Check the weight of the truck (including battery) in order to choose a suitable device. Refer to the technical data.

  • Page 95: Hoisting The Truck

    Handling the truck in specific situations Hoisting the truck DANGER Danger of swinging The lifting action must be performed carefully. For some work it is necessary to lift the truck. – Raise the load arms. – Switch off the ignition and unplug the battery connector.

  • Page 96: Transporting The Truck

    Handling the truck in specific situations Transporting the truck CAUTION The truck must be suitably protected from the effects of the weather during transport and Always switch off the ignition and disconnect the storage. battery. Never tie down or sling the truck by the tiller or other To load or unload the truck, use an inclined points not designed for this.

  • Page 97: Maintenance

    Maintenance...

  • Page 98: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the information required for servicing 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 99: 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 100: 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 101: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants DANGER SAE 85W 90 API GL4 Toxic products. Aerosol can for chains Oils and other consumables are toxic products. It is advisable to handle and use them with the utmost Standard chain spray. care. If in doubt, please ask your local dealer for advice.

  • Page 102: Technical Data For Inspection And Maintenance

    Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Capacities/Setting values Consumables Hydraulic system Hydraulic oil Total quantity of oil: 2.5 litres Transmission gear Transmission gear oil 0.9 litre max. 125 A power circuit fuse Traction and pump motor Quantity: 1 7.5 A control circuit fuse...

  • Page 103: Access To The Technical Compartment

    Maintenance Access to the technical compartment Access to the technical compartment – Fully raise the truck's load arms to facilitate these operations. CAUTION Before removing anything from the truck: – Switch off the ignition. – Pull the emergency stop handle. Opening the lower cover –...
  • Page 104 Maintenance Access to the technical compartment Opening the intermediate cover After removing the lower cover then the front cover: – Unscrew the 2 screws (3) that hold the intermediate cover in place. 1160 801 15 51 EN - 09/2019...

  • Page 105: Accessing The Reducer And The Brake

    Maintenance Accessing the reducer and the brake Accessing the reducer and the brake To access the transmission gear and brake, it is necessary to remove the cover behind the tiller. – Turn the tiller to the right or left-hand stop. –...

  • Page 106: Maintenance Plan As Required

    Maintenance Maintenance plan as required Maintenance plan as required Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out as required Preparation Cleaning the truck Chassis and equipment Checking the brake operation Checking the condition of the roller frame Wheels Checking the wheels for wear Electrical equipment...

  • Page 107: 3000-Hour Maintenance Plan

    Maintenance 3000-hour maintenance plan Electrical equipment Check the condition and correct positioning of the truck and battery cables Checking the condition of the on-board charger Checking that the cables and fuses are secure Check the battery acid level and the electrolyte level Hydraulics Checking the oil level and sealing of the hydraulic system Checking the hydraulic system for leaks...

  • Page 108: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Park the truck. – Pull the emergency stop handle. CAUTION The battery must always be disconnected during cleaning procedures. Washing the outside of the truck WARNING –...

  • Page 109: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings – Clean the electrical installations with a non-metal brush and dry with lightly compressed air. After washing – Carefully dry the truck (e.g. with com- pressed air). – Restart the truck in accordance with the instructions.

  • Page 110: Check The Condition Of The Forks

    Maintenance Chassis, bodywork and fittings Charging the battery CAUTION Do not expose the charger to water, rain, oils, – Park the truck in an area without condensa- grease or any similar substances. tion or pollution and with sufficient ventila- The charger becomes hot during the operation. tion.

  • Page 111: Steering And Wheels

    Maintenance Steering and wheels Steering and wheels Servicing the wheels and rollers The tyre treads on the drive wheel (1), stabil- ising wheels (2)and rollers (3) should show no signs of deterioration. – Replace damaged or worn wheels with new wheels.

  • Page 112: Stabiliser Maintenance

    Maintenance Steering and wheels Stabiliser maintenance EXD18 trucks are equipped with two damper stabilisers (1). They ensure the dynamic stability of the truck. Stabilisers do not require any specific mainte- nance or adjustment work. Wheel wear (drive wheel and stabiliser wheel) is automatically compensated.

  • Page 113: Regular Maintenance Of The Transmission Gear

    Maintenance Steering and wheels Regular maintenance of the trans- mission gear To increase the service life of the transmission gear, 2 grease nipples (1) have been added to its turntable. It is therefore possible to regularly lubricate the transmission gear. NOTE Use the lubricants recommended by the manufacturer.

  • Page 114: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Servicing the electrical system Checking the cable and fuse connection mountings WARNING Stop the truck and disconnect the battery before carrying out the following checks. – Remove the front hood. – Check the condition of the fuses (1). –...

  • Page 115: 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 116: Checking The Condition Of Cables, Terminals And Battery Connector

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

  • Page 117: Cleaning The Sensors For The Autolift Option

    Maintenance Electrical equipment – Check that the green indicator light on the display is flashing and that the red one is off (charging in progress). – Check that the truck is immobilised (traction and lifting not permitted) as long as the cord is connected to the 220 V supply.

  • Page 118: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Checking the hydraulic system for leaks – Inspect the hydraulic system: pipes, hoses and connections between the pump unit and the cylinders. – Tighten the connections if required. – Check cylinders for leaks. – Check that the hoses are attached correctly and show no signs of friction wear.

  • Page 119: Draining The Hydraulic System

    Maintenance Hydraulic systems – Remove the tank gauge (1). – Check the hydraulic oil level. It must be located in the section indicated between the minimum mark (3) and the maximum mark (4). – If necessary, top up with oil recommended by the manufacturer NOTE The amount of oil in a full hydraulic system is...
  • Page 120 Maintenance Hydraulic systems – Remove the hood support mounting bracket (4). – Loosen the clip (5). – Loosen the tank mounting clip (6). – Carefully remove the tank (7) from below. – Drain any oil that may remain at the bottom of the tank.

  • Page 121: Lift Mast

    Maintenance Lift mast Lift mast Lifting device – Remove any dirt from the guide rails (1). – Lubricate the guide rails of the outer, central and inner masts using pressure high resistance adhesive lubricant to slow down wear. NOTE Lubricate the guide rails uniformly using an aerosol spray at a distance of 15 to 20 cm.
  • Page 122 Maintenance Lift mast Checking the condition and wear of the chains and lubrication – Lubricate the lift chains (1) using chain spray. Adjust the lift chains NOTE The forks should rest on the load arms in the lower position, with the chains slightly taut. If this is not the case, the chains must be retightened (2) and extended by no more than 3%.

  • Page 123: Commissioning And Storage

    Maintenance Commissioning and storage Commissioning and storage 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 124: Permanent Putting Out Of Commission (Destruction)

    Maintenance Commissioning and storage 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 125: Technical Specifications

    Technical specifications...

  • Page 126: Exd18 Datasheet

    Technical specifications EXD18 datasheet EXD18 datasheet DESCRIPTION 1.1 Manufacturer STILL GmbH 1.2 Model type EXD18 (K) EXD18 (L) Method of propulsion: battery, Battery Battery diesel, petrol, LPG, mains power Driving: manual, pedestrian, Pedestrian Pedestrian standing, seated, order picking 1160 801 15 51 EN - 09/2019...
  • Page 127 Technical specifications EXD18 datasheet LP/LI (LI 1.5 Nominal capacity Q (kg) 800/1000 (1800) 800/1000 (1800) only) & LP ≤ LI 1.6 Centre of gravity (mm) Distance from load wheel axle to low/high 928/862 924 / 858 load mating face (±5 mm) 1.9 Wheelbase (±5 mm) low/high 1479/1413...
  • Page 128 Technical specifications EXD18 datasheet Load arm height / ground (0 / +5 (mm) Height at the ends of the fork in 4.15 the lower position (0/+5 mm) (mm) BS V 2PzS 4.19 Total length (±5 mm) l1 (mm) 1150 V 1150 1899 1954 (1200)
  • Page 129 Technical specifications EXD18 datasheet EXD18 (K) EXD18 (L) PERFORMANCE DATA laden/un- 5.1 Travel speed (±5%) km/h 6.00/6.00 laden 5.1. laden/un- Reverse travel speed (±5%) km/h 6.00/6.00 laden laden/un- Initial lifting speed (LI) (±10%) 0.032 / 0.045 0.032 / 0.045 laden laden/un- Main lifting speed (LP) (±10%) 0.100 / 0.152...
  • Page 130 Technical specifications EXD18 datasheet 4) Ast pallet stacker 5) Ast pallet truck 6) With mast S2024 1160 801 15 51 EN - 09/2019...

  • Page 131: Mast Types

    Technical specifications Mast types Mast types Mast type Simplex Truck 1574S 1724S 2024S Lift (mm) 1574 1724 2024 Lift + fork height (mm) h3 + h13 1660 1810 2110 Mast height HT retracted (mm) 1290 1365 1515 Mast height HT extended (mm) 2202 2352 2652...
  • Page 132 Technical specifications Mast types 1160 801 15 51 EN - 09/2019...
  • Page 133 Index Cleaning the sensors for the Autolift option ....109 Access to the technical compartment . . . 95 Cleaning the truck ....100 Accessing the reducer and the brake .
  • Page 134 Index FleetManager™ Colour code for the LEDs ..47 Maintenance plan Commissioning a truck equipped 1000-hour/annual ....98 with a keypad or an electronic key .
  • Page 135 Index Refit the cover..... 70 Start-up ......33 Regular maintenance of the transmis- Symbols used .
  • Page 138 STILL GmbH 1160 801 15 51 EN – 09/2019...

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