Page 1 Original instructions Double pallet stacker EXD-18 0285 0286 0294 0295 1160 801 15 51 EN - 02/2021 - 11...
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 - 02/2021 - 11...
Page 5: Table Of Contents
Table of contents Introduction Your industrial truck ........... General .
Page 6 Table of contents Overviews Overview ............Overview .
Page 7 Table of contents Transporting pallets or other containers ........Lift control elements .
Page 8 Table of contents Safety guidelines for maintenance........Servicing and maintenance measures .
Page 9 Table of contents Technical specifications EXD18 datasheet........... . . 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 Industrial truck according to these operating instructions Model according to these operating instructions 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 en- quiries. 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 16: Eco-Design Requirements For Electric Motors And Variable Speed Drives
Eco-design requirements for electric motors and variable speed drives 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. Eco-design requirements for electric motors and variable...
Page 17: Spare Parts List
Spare parts list  The spare parts list can be downloaded by en- tering the address https://sparepartlist.still.eu into a web browser or by scanning the QR code displayed to the side. When the web page is open, please type in...
Page 18: Proper Usage
Introduction Proper usage Proper usage The truck described in these operating instruc- The purpose of obtaining these permissions in tions is suitable for lifting, transporting and advance is to limit danger as far as possible. stacking loads. The capacity label specifies the maximum The truck should only be used for the purpo- load that can be raised.
Page 19: Unauthorised Use
Introduction Unauthorised use Unauthorised use Any danger caused as a result of unauthor- Transporting people is prohibited. ised use becomes the responsibility of the op- The forklift truck should not be used in areas erator or driver and not that of the manufactur- where there is a risk of fire, explosion or corro- sion, or in areas that are particularly dusty.
Page 20 Introduction Disposing of components and batteries 1160 801 15 51 EN - 02/2021 - 11...
Page 21: Safety
Safety...
Page 22: Safety Regulations
Safety Safety regulations Safety regulations Regular checks and technical inspections These operating instructions, which come with ● the truck, must be communicated to all those Recycling of lubricants, oils and batteries ● concerned and in particular to personnel re- Residual risks. ●...
Page 23: Safety Regulations For Handling Consumables
Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. It is necessary to follow the safety regulations when handling these substances.
Page 24: Hydraulic Fluid
Safety Safety regulations for handling consumables Hydraulic fluid WARNING ENVIRONMENT NOTE During operation of the forklift truck, hy- draulic fluids are pressurised and are Hydraulic fluid is a water-polluting substance! hazardous to your health. Always store hydraulic fluid in containers com- –...
Page 25: Disposal Of Consumables
Safety Safety regulations for handling consumables Disposal of consumables Any spillage of fluids such as hydraulic oil, ● ENVIRONMENT NOTE brake fluid or gear lubricant oil must be im- mediately soaked up with an oil-binding Materials that have to be disposed of following agent.
Page 26: Emissions
Safety Emissions Emissions Noise emission values Calculated during the test cycle performed in Acoustic pressure level on the driver's com- accordance with standard EN 12053 from the partment weighted values for the LIFT, IDLING and In the DRIVE oper- 66.55 dB DRIVE operating statuses.
Page 27: Residual Dangers, Residual Risks
Safety Residual dangers, residual risks Residual dangers, residual risks Falling, tripping etc. when moving on the in- Despite all operational precautions and com- ● dustrial truck, especially in the wet, with pliance with standards and rules, the possibili- leaking consumables or icy surfaces. ty of additional risks when using the truck can- Loss of stability due to the load being unsta- not be entirely excluded.
Page 28: Definition Of Responsible Persons
Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal The operating company is responsible for the person or group who operates the truck or on scheduling and correct performance of regular whose authority the truck is used.
Page 29 Safety Definition of responsible persons Prohibition of use by unauthorised per- When leaving the truck, the driver must secure it against unauthorised use. sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. 1160 801 15 51 EN - 02/2021 - 11...
Page 30: Safety Tests
Safety inspection based on time and ex-  traordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must en- STILL GmbH Hamburg sure that the truck is checked by a specialist at least once a year or after noteworthy inci- Regelmäßige Prüfung dents.
Page 31 Overviews...
Page 32: 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 - 02/2021 - 11...
Page 33: Operating And Display Devices
Overviews Operating and display devices Operating and display devices 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 - 02/2021 - 11...
Page 34: Digicode (Optional)
Overviews Operating and display devices 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 # green (1) (correct PIN) 0 0 0 0 0...
Page 35 Overviews Operating and display devices PROGRAMMING (truck switch OFF only (2)) Power switches off auto- ● red flashing ● green Activating the au- matically after 10 mi- flashing (5) (5 s before * * 2 * 1 # tomatic switch-off nutes (600 s by default) switch-off) if the truck is not in use.
Page 36: Battery Charging Indicator
Overviews Operating and display devices Battery charging indicator COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES 91% - 100%: 10 bars 1% - 10%: 1 bar Full charge: 100% 0%: 1 flashing bar (lift func- Battery charge level repre- Low charge: 10% Dis- tion not permitted). sented by 10 bars charged: 0% NB: To protect the battery,...
Page 37 Overviews Operating and display devices 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 38: Markings
Warranty label (for Germany only) on the in- Mast safety label side 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 - 02/2021 - 11...
Page 39: Serial Number
Overviews Markings Serial number  xx xxxx x xxxxx NOTE Indicate the serial number for all technical en- quiries. The serial number contains the following infor- mation: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 1160 801 15 51 EN - 02/2021 - 11...
Page 40 Overviews Markings 1160 801 15 51 EN - 02/2021 - 11...
Page 42: Technical Description
Technical description Technical description EXD18 trucks are designed for pallet stacking These masts are equipped with side lift cylin- and double pallet stacking. ders. This truck is a pedestrian version ACC model. EXD18 trucks are equipped with S (standard) masts for heights ranging from 1574 to 2024 mm.
Page 43 Technical description Equipment available as standard or as - Built-in charger (on versions of battery with vertical access only and non-cold store ver- additional options: sions) - Load backrest - Central refilling system. - Creep Speed (Creep Speed) - Cold store (-35°C). - Proportional speed (Proportionnal Speed).
Page 44: List Of Checks Prior To Start-Up
List of checks prior to start-up List of checks prior to start-up – Damaged or missing stickers must be re- WARNING placed in compliance with the marking posi- Damage or other defects on the forklift truck or at- tion table. tachments (special equipment) can result in acci- dents.
Page 45: 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 necessa- – Keep the tiller in the vertical position. – Place the drive direction selector in the neu- tral position (in the middle). –...
Page 46: 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 47: Checking The Anti-Crush Safety Device
Checks and actions prior to commissioning Checking the anti-crush safety de- vice 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 48: Checking The Horn
Checks and actions prior to commissioning Checking the horn  – Press the horn button (5) located on the up- per part of the tiller. – The horn sounds. 1160 801 15 51 EN - 02/2021 - 11...
Page 49: Truck Operating Instructions
Truck operating instructions Truck operating instructions The trucks are designed for indoor and out- Speed must be reduced when moving over door use in non-hazardous atmospheres. The obstacles to prevent the truck from becoming temperature should be between -10°C and unbalanced and vibrations in the operator's +45°C and the relative humidity of the air less arms.
Page 50 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 bat- when entering narrow passageways. tery is correctly locked. – The driver must always maintain a safe braking distance from vehicles or people in front of him.
Page 51: Driving
Driving Driving Driving safety instructions Never sit on the truck to drive it. Behaviour when driving ● The truck must not be used as a stepladder. ● The operator must obey the same rules within This truck is not designed to transport peo- ●...
Page 52: 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 53: Optispeed
Driving – Operate it progressively in the opposite di- rection until the required speed is reached. 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.
Page 54: 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 55: 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. –...
Page 56: Driving On Upward And Downward Slopes
Driving Timeout can be adjusted. Please call the Af- ter-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 ●...
Page 57: 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 man- cation agement system. Shock sensor You can access the system: Either by using a keypad This sensor allows you to record the shocks...
Page 58: 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 59: 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 dif- ferent 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...
Page 60 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has oc- Reset the shock Red colour Green colour curred The truck is The truck is con- switched on but is nected via a Blue- not moving.
Page 61: 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 ...
Page 62 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 de- vice (3). The LED (1) lights up for a second (red col- our).
Page 63: 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 64: Transporting Pallets Or Other Containers
Transporting loads Transporting pallets or other con-  tainers 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 author- ised: when the safety preconditions are fulfilled. ●...
Page 65: 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 in- stallations, load lifting devices). For safety reasons, the lift and traction func- tions are inhibited when the tiller is in the rest position.
Page 66 Transporting loads Base lift  Lifting the load arms – Press button (4). Lowering the load arms – Press button (5). 1160 801 15 51 EN - 02/2021 - 11...
Page 67: 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, homoge- neous loads.
Page 68: Load Handling
Transporting loads Load handling DANGER Risk of truck falling Do not stack the initial lift high. CAUTION Safety shoes must be worn. Transporting people is strictly prohibited. DANGER Risk of loss of stability It is essential to slow down when approaching a cor- ner or on wet ground.
Page 69 Transporting loads Transporting a load  DANGER Risk of accidents There must be no one 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 po- sition as the truck may become unstable.
Page 70 Transporting loads CAUTION Risk of falling Do not touch nearby loads or loads positioned be- hind the truck. CAUTION Risk of accidents Before you remove the load, ensure that there are no people around the truck or load. Stacking a load ...
Page 71 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 72: 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 73 Transporting loads – Then 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 Make sure that there is enough space above load (Q2) so as not to crush the top of the pallet.
Page 74 Transporting loads – Lower the forks again. WARNING The initial lift or lowering operation (load arms) is matched by the forks. 1160 801 15 51 EN - 02/2021 - 11...
Page 75: 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 ...
Page 76 Transporting loads Using the Autolift option  The unit that controls the Autolift option con- sists 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 ●...
Page 77 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 illumi- nating button lights up when the forks are moving.
Page 78: Cold Store Usage (Optional)
Cold store usage (optional) Cold store usage (optional)  CAUTION Standard trucks risk being subject to significant dam- age 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 79 Cold store usage (optional) 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 parts). CAUTION Do not leave discharged or unused batteries in the cold store.
Page 80: Stopping The Truck
Stopping the truck Stopping the truck – Switch off the ignition then remove the key WARNING or press the button on the digicode for Do not stop the truck on a slope, or if this is absolute- 2 seconds. ly necessary, make sure it is safely secured using chocks.
Page 81: Handling The Battery
Handling the battery Handling the battery Battery type Trucks can be fitted with different types of bat- tery. 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 sta- bility of the truck.
Page 82: Opening/Closing The Battery Cover
Handling the battery Parking the truck securely When the battery is being worked on, the truck must be parked safely. The truck can only be restarted when the covers and connectors have been put back in the operating position. Opening/closing the battery cover Opening ...
Page 83 Handling the battery – Guide it downwards. The cover will gradual-  ly 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. –...
Page 84: 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. –...
Page 85 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 86: On-Board Charger
Handling the battery On-board charger Precautions for installation and use CAUTION The on-board charger means you no longer Risk of damage to the mains cable resulting in elec- tric shock and/or burns. have to use a charging room. This charger can be connected to any 2P+T 230 V 16 A Park the truck very close to the wall-mounted mains socket to avoid tensioning the charger's mains cable...
Page 87: Using The On-Board Charger
Handling the battery The charger adapts automatically to the bat- Time protection tery discharge situation and therefore allows If the duration of phases I1 + P + U is more any type of partial charging to be carried out than 16 hours, the charger automatically ("opportunity charging").
Page 88 Handling the battery Phase Green LED Red LED Disconnected mains socket Charging Flashing phases Stopped / Equalisation / Continuously Maintenance phase Charging too Continuously long Charger po- larity reversed (+battery and -battery charger ca- bles reversed, Continuously Continuously with the bat- tery remain- ing normally connected to...
Page 89: Adjusting The On-Board Charger
Handling the battery 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 loca- ted on the front face of the charger. The curve selector is protected by a cap. The 4 fine lines indicate neutral positions.
Page 90: Replacing The Vertical Access Battery
Handling the battery Replacing the vertical access bat- tery 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 91: 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 92: Replacing The Side Access Battery
Handling the battery – Replace 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 93 Handling the battery – Open the battery hood (1). Position the sup-  port (2) in the opening provided for this pur- pose. – Position the truck in the upright position with extraction rollers or the roller frame (3) near the battery compartment on level ground.
Page 94 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 bat- tery hood. 1160 801 15 51 EN - 02/2021 - 11...
Page 95 Handling the battery – Pull the battery onto the truck with extrac-  tion rollers or the roller frame (3). – Replace the battery. – Push the battery to the end of the compart-  ment. – Fold the stop (7) down. –...
Page 96: 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 cir- cumstances.
Page 97: Towing The Truck
Handling the truck in an emergency Towing the truck It is not possible to tow the truck with no elec- trical function. The electromagnetic brake re- mains 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 98 Handling the truck in an emergency – Close the hood of the technical compart- ment. 1160 801 15 51 EN - 02/2021 - 11...
Page 99: 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.
Page 100: 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 bat- tery connector.
Page 101: Transporting The Truck
Handling the truck in specific situations Transporting the truck The truck must be suitably protected from the CAUTION effects of the weather during transport and Always switch off the ignition and disconnect the bat- storage. tery. To load or unload the truck, use an inclined Never tie down or sling the truck by the tiller or other plane or a mobile ramp.
Page 102 Handling the truck in specific situations 1160 801 15 51 EN - 02/2021 - 11...
Page 103: Maintenance
Maintenance...
Page 104: General Maintenance Information
Maintenance General maintenance information General maintenance information General The following instructions contain all the infor- mation required for servicing your truck. Carry out the various maintenance work in compli- ance with the maintenance plan. This will en- sure that your truck is reliable and in good working order and that the warranty remains valid.
Page 105: 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 in- by qualified and authorised personnel. spection must have sufficient knowledge and experience to be able to assess the condition The annual inspection for prevention of acci- of the truck and the efficiency of the protective dents at work must be carried out by a person...
Page 106: Safety Guidelines For Maintenance
Maintenance Safety guidelines for maintenance Safety guidelines for maintenance Servicing and maintenance measures To avoid accidents during servicing and main- – Ensure that there is no risk of the truck tenance operations, take all necessary safety moving or starting up unexpectedly. For this measures.
Page 107: Recommended Lubricants
Maintenance Recommended lubricants Recommended lubricants SAE 85W 90 API GL4 DANGER 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 ad- vice.
Page 108: Technical Data For Inspection And Maintenance
Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Consumables Capacities/Setting values 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 109: Access To The Technical Compartment
Maintenance Access to the technical compartment Access to the technical com- partment – 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 110 Maintenance Access to the technical compartment Opening the front cover  After removing the lower cover: – Unscrew the 4 screws (2) that hold the front hood in place. Opening the intermediate cover  After removing the lower cover then the front cover: –...
Page 111: 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 112: 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 113: 3000-Hour Maintenance Plan
Maintenance 3000-hour maintenance plan Checking the hydraulic system for leaks Checking the lift cylinders and pipes for leaks Lift mast Checking the condition and wear of the chains, and lubricating them Adjusting the length of the mast chain Checking the guard grille 3000-hour maintenance plan Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 3000, 6000 and 9000 hours...
Page 114: 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 ...
Page 115: General Information On Battery Maintenance
Maintenance Chassis, bodywork and fittings NOTE Only use dry cleaning products. ● Do not remove the protective covers. ● – 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).
Page 116: Check The Condition Of The Forks
Maintenance Chassis, bodywork and fittings – Open the battery hood. NOTE – Do not disconnect the battery plug. The discharge indicators used to check the ● battery must also be suitable for the type of CAUTION battery. Contact the relevant After-Sales Service Do not expose the charger to water, rain, oils, grease ●...
Page 117: Steering And Wheels
Maintenance Steering and wheels Steering and wheels Servicing the wheels and rollers  The tyre treads on the drive wheel (1), stabilis- ing wheels (2)and rollers (3) should show no signs of deterioration. – Replace damaged or worn wheels with new wheels.
Page 118: Stabiliser Maintenance
Maintenance Steering and wheels Stabiliser maintenance  EXD18 trucks are equipped with two damper stabilisers (1). They ensure the dynamic sta- bility 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 119: 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 man- ufacturer.
Page 120: 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 car- rying out the following checks. – Remove the front hood. – Check the condition of the fuses (1). –...
Page 121: 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 (indus- trial goggles, safety gloves) when working on a battery. – Never wear a watch or jewellery when handling battery acid.
Page 122: 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 123: Service The On-Board Charger
Maintenance Electrical equipment Service the on-board charger It is necessary to check the on-board charger. Proceed as follows: – Connect the cord to the 220 V mains. – Check that the green indicator light on the display is flashing and that the red one is off (charging in progress).
Page 124: 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 125: Draining The Hydraulic System
Maintenance Hydraulic systems – Remove the tank gauge (1).  – Check the hydraulic oil level. It must be lo- cated 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 126 Maintenance Hydraulic systems – Remove the bleed pipe (2) plug (3).  – Loosen the screw (1) using a 7 mm open- ended spanner. The oil will then flow. DANGER Do not stand under the forks. When the technician loosens the screws, the car- riage will gradually lower.
Page 127 Maintenance Hydraulic systems – Screw on the breather plug. – Bleed the hydraulic system by performing several fork and load arm lifting and lower- ing operations. CAUTION Only use hydraulic oil that complies with the specifi- cations (see lubrication table). 1160 801 15 51 EN - 02/2021 - 11...
Page 128: 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 resist- ance 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 129 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 retight- ened (2) and extended by no more than 3%.
Page 130: 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 131: 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 (cov- ers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.
Page 132 Maintenance Commissioning and storage 1160 801 15 51 EN - 02/2021 - 11...
Page 133 Technical specifications...
Page 134 Technical specifications EXD18 datasheet EXD18 datasheet DESCRIPTION 1.1 Manufacturer STILL GmbH 1.2 Model type EXD18 (K) EXD18 (L) 1160 801 15 51 EN - 02/2021 - 11...
Page 135 Technical specifications EXD18 datasheet Method of propulsion: battery, diesel, petrol, LPG, mains pow- Battery Battery Driving: manual, pedestrian, Pedestrian Pedestrian standing, seated, order picking LP/LI (LI 1.5 Nominal capacity only) & LP 800/1000 (1800) 800/1000 (1800) (kg) ≤ LI 1.6 Centre of gravity (mm) Distance from load wheel axle low/high...
Page 136 Technical specifications EXD18 datasheet h2 (m 4.3 Free lift (±5 mm) 2024 (S2024), 1724 4.4 Lift (±5 mm) without LI (mm) (S1724), 1574 (S1574) maximum overall 2652 (S2024), 2352 4.5 Extended mast height (±5 mm) (mm) height (with LI) (S1724), 2202 (S1574) 4.6 Initial lift (±5 mm) (mm) (brake minimum)
Page 137 Technical specifications EXD18 datasheet Aisle width for pallet 800 (L6) x 4.34 Ast (m 1200 (b12) crosswise (±20 mm) BS V 2PzS V 2444 2494 Aisle width for pallet 800 (b12) x Ast (m 1200 (L6) lengthwise (±20 mm) BS V 2PzS V 2364 2414...
Page 138 Technical specifications EXD18 datasheet 6.5 Battery weight (±10%) 2 PzS Energy consumption according kWh/1 BS V 2 PzS V 0.61 to standardised VDI cycle 6.7 Load transfer Energy consumption during a kWh/1 load transfer MISCELLANEOUS EXD18 (K) EXD18 (L) 8.1 Speed control LAC controller Noise level at operator's ears 2 PzS...
Page 139 Technical specifications Mast types Mast types Mast type Simplex Truck 1574S 1724S 2024S Lift (mm) 1574 1724 2024 h3 + h13 Lift + fork height (mm) 1660 1810 2110 Mast height HT retracted (mm) 1290 1365 1515 Mast height HT extended (mm) 2202 2352 2652...
Page 140 Technical specifications Mast types 1160 801 15 51 EN - 02/2021 - 11...
Page 141 Index Consumables..... . . 13 Battery acid safety instructions..14 Accessing the reducer and the brake. . . Disposal.
Page 142 Index General information on battery mainte- Operating company....18 nance......Optispeed.
Page 143 Index Using the Autolift option....66 Technical data for inspection and mainte- nance......Vibrations Technical description.
Page 146 STILL GmbH 1160 801 15 51 EN - 02/2021 - 11...

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