Still FXD 20 Original Instructions Manual
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Still FXD 20 Original Instructions Manual

Double pallet stacker
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Original instructions
Double pallet stacker
FXD 20
1539 1545
11648011751 EN - 09/2019

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  • Page 1 Original instructions Double pallet stacker FXD 20 1539 1545 11648011751 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 11648011751 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 .
  • Page 7 Table of contents Parking brake ............59 Drive program .
  • Page 8 Table of contents Truck towing procedure ..........107 Handling the truck in specific situations .
  • Page 9 FXD 20 datasheet ........

  • 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 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 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. 11648011751 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

    62 dB (A) FXD 20 Uncertainty ± 2.5 dB (A) Vibration characteristics for vibrations to which the body is exposed load level of vibrations during operation. This...

  • 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 11648011751 EN - 09/2019...

  • Page 29: Overviews

    Overviews...

  • Page 30: Overview

    Overviews Overview Overview General view Emergency off switch Operator presence pedal Joystick Brake pedal Seat Forks Steering wheel Bogies Adjustable floor Battery compartment Platform Mast Drive wheel Protective screen Stabiliser wheel Overhead guard 11648011751 EN - 09/2019...

  • Page 31: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump-motor unit ES30-24 steering unit Tank Traction motor Fuses 11648011751 EN - 09/2019...

  • Page 32: Control And Display Components

    Overviews Control and display components Control and display components Driver's compartment Handle Display Switch key (or electronic key) Emergency off switch Joystick Parking brake Steering wheel 11648011751 EN - 09/2019...

  • Page 33: 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 34 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 35: Display Operating Unit

    Overviews Control and display components Display operating unit Operator presence indicator light Settings menu Battery indicator light Load Management and Drive wheel position Temperature indicator light menu Settings indicator light Status menu Warning indicator light Display of the operating time of the truck Drive programme indicator light Display of the battery charge Activity indicator light...

  • Page 36: Markings

    Overviews Markings Markings Location of markings Identification label Double pallet stacker label Brand label Never touch with hands label Truck regular safety inspection label Mast safety label Danger instructions label Consult the Model label operating instructions Slinging label Consult the operating instruc- Capacity label tions Double pallet stacker label —...

  • 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 11648011751 EN - 09/2019...
  • Page 38 Overviews Markings 11648011751 EN - 09/2019...

  • Page 40: Technical Description

    Model available: The steering motor is controlled by a variable • FXD 20: 1200 kg in pallet stacker mode, speed transmission. It receives information 2000 kg in double pallet stacker mode from the steering wheel and the wheel angle (1000 kg on the forks and 1000 kg on the position.
  • Page 41 Technical description Optional equipment available: NOTE • Electronic key The operating instructions can be found in • Cold store (-35°C) the document holder, located on the technical • Document holder compartment door. 11648011751 EN - 09/2019...

  • 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: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Checking the emergency off switch To check the operation of the emergency off switch, proceed as follows: – Drive the truck. – Press the emergency off switch (1). The truck stops immediately.
  • Page 44 Checks and actions prior to commissioning – Push the joystick to move the truck for- wards. – Push the joystick in the opposite direction. The truck brakes progressively and then moves off in the opposite direction until the desired speed has been reached. NOTE Also ensure that the stabiliser wheels operate correctly.
  • Page 45 Checks and actions prior to commissioning NOTE Also ensure that the stabiliser wheels operate correctly. This influences braking effective- ness. Braking with the dual-pedal option Braking using the brake pedal – Press the accelerator pedal (2) or (3) to move the truck forwards. –...

  • Page 46: Checking The Horn

    Checks and actions prior to commissioning Checking the horn The horn is located on the rear side of the control module. To check the operation of the horn, proceed as follows: – Press the button (1) on the control module The horn sounds.

  • Page 47: 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 48 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 49: Stepping On/Off The Truck

    Stepping on/off the truck Stepping on/off the truck WARNING Risk of falling, tripping or slipping when stepping on/off the truck. Use the handle and the seat when stepping on/off the truck. – Grip the handle (1) with your left hand. –...

  • Page 50: Driver's Compartment Settings

    Driver's compartment settings Driver's compartment settings Adjusting the seat The driver's seat has several settings, allowing you to adjust the driving position to suit you: • The lever (1) allows you to adjust the tilt of the backrest • The lever (2) allows you to adjust the horizontal position •...

  • Page 51: Adjusting The Floor

    Driver's compartment settings Adjusting the floor The floor is fitted with a pressure-based height adjustment system. To adjust the floor height, proceed as follows: – Sit on the seat. – Press the floor unlocking button (2) and hold it down for the duration of the operation. –...

  • Page 52: 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 53: Operation Of The Display Unit

    Using the display-operating unit Operation of the display unit Parking brake The parking brake indicator light (2) indicates the status of the parking brake. • Indicator light permanently illuminated: The parking brake is engaged, the controls are not available • Indicator light flashing: The parking brake is engaged, the controls are available •...
  • Page 54 Using the display-operating unit – Sit on the seat. The light indicating the operator's presence on the seat (1) is replaced by the light indicating the operator's presence on the pedal (2), which flashes. – Press the operator presence pedal with your left foot.
  • Page 55 Using the display-operating unit Managing battery charging The operating unit shows the battery charge level. The operator can refer to the battery icon (1) or (2). The number of bars shown indicates the battery charge level. • From 0 to 20%: 1 bar •...
  • Page 56 Using the display-operating unit Drive program The drive program light (1) is permanently illuminated when a travel mode is selected. There are three different drive modes: • Tortoise mode (2) • Hare mode (3) • Blue Q mode (4) The icon of the drive mode selected appears on the display.
  • Page 57 Using the display-operating unit Settings menu It is possible to access different settings through the Settings menu. – Select the Settings menu (1) This menu allows access to a drop-down menu (2) consisting of: • Language • Unit • Date format •...
  • Page 58 Using the display-operating unit Start-up screen In addition to the various menus and lights mentioned above, additional data is available: • The truck status menu (1) displays the truck menu • The hourglass icon (2) indicates the operat- ing time of the truck •...

  • Page 59: 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 60: Driving

    Driving Driving Definitions of steering directions On a ride-on double pallet stacker, the con- ventional directions for the drive direction are: • Forward travel (2): Opposite to fork direc- tion/forklift operator direction • Reverse travel (1): Fork direction The load is positioned at the rear. Operation of operator presence detection on the version without pedals...
  • Page 61 Driving The truck then travels at 2 km/h. The forklift operator presence pedal must be kept de- pressed. Before rising from the chair, it is essential to slow down the truck to a very low pace and to check the working environment. WARNING Risk of injury Do not rise from the chair when the truck is travelling...

  • Page 62: Starting The Truck

    Driving Starting the truck DANGER Risk of sparks It is prohibited to use the truck with the battery hood open. – Check that the battery hood is closed. – Check that the battery is locked. DANGER Risk of serious injury Always keep your body inside the driver's compart- ment while the truck is moving.

  • Page 63: Driving With The Version Without Pedals

    Driving NOTE Always adjust your speed to suit the route, any dangers and the load. Use the truck on ground that has the correct surface and hardness. Driving with the version without pedals DANGER Risk of serious injury Always keep your body inside the driver's compart- ment while the truck is moving.
  • Page 64 Driving The operator selects the direction of travel using the joystick. The joystick has two positions: • Forward travel (1) • Reverse travel (2) – Put the truck into service Forward travel – Push the joystick to the left (1) to travel forwards (in the opposite direction to the forks).

  • Page 65: Steering

    Driving Steering The steering wheel (1) allows precise, effort- less guidance of the truck thanks to the electric power steering. It is located on the left of the dashboard. Turning direction For forward travel (opposite fork direction) – Turn the steering wheel clockwise to steer the truck to the right.

  • Page 66: Horn

    Driving Horn The horn is positioned on the rear side of the control module. It is used: • On routes where there is poor visibility • At junctions • In the event of immediate danger – Press the button (1) on the joystick The horn sounds.

  • Page 67: Braking On The Version Without Pedals

    Driving Braking on the version without pedals WARNING The quality of the floor surface affects the braking distance of the truck. This should be taken into consideration when driving. NOTE Braking is progressive and increases as the brake pedal is depressed. Braking using the brake pedal –...
  • Page 68 Driving Progressive braking The progressive brake is activated automati- cally if one of the following conditions is met: • The operator presses the brake pedal (1) • The operator releases the operator pres- ence button or pedal • The joystick is released •...

  • Page 69: Parking Brake

    • After a period of time has elapsed (3 s by default) NOTE After a power failure or an emergency stop (emergency stop button), the truck still restarts with a brake in the locked status (indicator permanently on) (2). 11648011751 EN - 09/2019...
  • Page 70 Driving Parking brake status The parking brake indicator light (2) indicates the status of the parking brake. Parking brake status Permanently on Flashing indicator (2) Parking brake status Engaged Applied Released Stationary Stationary Moving Truck status Status of the traction Unavailable Available Available...

  • Page 71: Drive Program

    Driving – Press the accelerator pedal to start the truck moving. If the truck is a version without a pedal – Press the operator presence pedal. – Press the parking brake button (1). – Use the joystick to start the truck moving. Drive program The indicator light (1) is on during operation of the truck.

  • Page 72: Using The Truck On A Slope

    Driving Tortoise mode Selecting Tortoise mode allows you to reduce the performance of the truck: • The travel speed of the truck is reduced to 6 km/h • The speed of lifting and lowering the forks is considerably reduced The different speeds can be adjusted. Contact the After-Sales Service Centre to change these.
  • Page 73 Driving Travelling down slopes Always travel down slopes forwards. The load faces uphill. Without a load, we recommend that you go down 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 74: Driving: Single-Pedal Option

    Driving: Single-pedal option Driving: Single-pedal option Specific features of the single-pedal option The operation of a truck equipped with an accelerator pedal is identical to that of a truck without an accelerator pedal. The differences in operation relate to the following aspects: •...

  • Page 75: Driving With The Single-Pedal Option

    Driving: Single-pedal option Before rising from the chair, it is essential to slow down the truck to a very low pace and to check the working environment. WARNING Risk of injury Do not rise from the chair when the truck is travelling at full speed.
  • Page 76 Driving: Single-pedal option WARNING Be aware of the position of the drive wheel. Slowly start the truck. Check the position of the drive wheel on the display. NOTE Always depress the pedal slowly, as the truck reacts immediately. Abrupt starts or braking, or sudden reversal of the drive direction, must be avoided at all costs.

  • Page 77: Braking With The Single-Pedal Option

    Driving: Single-pedal option The truck brakes progressively and then moves off in the opposite direction until the desired speed has been reached. If the forklift operator has left their seat, the direction of travel cannot be reversed. Drive direction indicator On the display, the drive direction indicator light (1) or (2) lights up to indicate the direction of travel.
  • Page 78 Driving: Single-pedal option DANGER Do not rely on lift-off braking to stop the truck in an emergency. Always use the brake pedal in an emergency and press the emergency off switch if necessary. Braking by releasing the accelerator pedal – Push the drive switch and press the accel- erator pedal (2) to move the truck forwards.
  • Page 79 Driving: Single-pedal option NOTE Also ensure that the stabiliser wheels operate correctly. This influences braking effective- ness. 11648011751 EN - 09/2019...

  • Page 80: Driving: Dual-Pedal Option

    Driving: Dual-pedal option Driving: Dual-pedal option Specific features of the dual-pedal option The operation of a truck equipped with an accelerator pedal is identical to that of a truck without an accelerator pedal. The differences in operation relate to the following aspects: •...

  • Page 81: Driving With The Dual-Pedal Option

    Driving: Dual-pedal option Before rising from the chair, it is essential to slow down the truck to a very low pace and to check the working environment. WARNING Risk of injury Do not rise from the chair when the truck is travelling at full speed.
  • Page 82 Driving: Dual-pedal option WARNING Be aware of the position of the drive wheel. Slowly start the truck. Check the position of the drive wheel on the display. NOTE Always depress the pedal slowly, as the truck reacts immediately. Abrupt starts or braking, or sudden reversal of the drive direction, must be avoided at all costs.

  • Page 83: Braking With The Dual-Pedal Option

    Driving: Dual-pedal option If the forklift operator has left their seat, the direction of travel cannot be reversed. Braking with the dual-pedal option WARNING The quality of the floor surface affects the braking distance of the truck. This should be taken into consideration when driving.
  • Page 84 Driving: Dual-pedal option – Press the other accelerator pedal. The truck brakes progressively and then moves off in the opposite direction until the desired speed has been reached. Progressive braking The progressive brake is activated automati- cally if one of the following conditions is met: •...

  • Page 85: 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 86: 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 87: 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 88 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 89: 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 90 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 91: Transporting Loads

    (main lift) and 1000 kg on the load arms (initial lift) Reading the capacity plate Example with a FXD 20: • 1: Maximum lift height: 3330 mm • 2: Maximum mast capacity: 1200 kg with a height of 3330 mm (centre of gravity: 400 •...
  • Page 92 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: Truck model 11648011751 EN - 09/2019...

  • Page 93: Load Handling Safety Rules

    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 94: 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 95: Lift Control Elements

    Transporting loads Lift control elements WARNING Risk of injury The safety instructions must be strictly adhered to. Do not touch or stand on moving parts (e.g. lifting device, pushing devices, work installations, load lifting devices). CAUTION Risk of the load swinging and loss of stability Do not drive with a load in the raised position without load on the load arms.

  • Page 96: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads Base lift Lifting the load arms – Push the control (2) to the left (D). The load arms are raised. Lowering the load arms – Push the control (2) to the right (C). The load arms are lowered. Progressive stopping of the carriage in the lower position A detector (1) that senses when the position...

  • Page 97: 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 98 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 99 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 100 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 101: 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 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 102 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 103 Transporting loads 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 104: 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 105: 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 106 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 107: Parking The Truck

    Parking the truck. Parking the truck. WARNING – Switch off the ignition (key or electronic key). Risk of injury – Press the emergency off switch. Never leave the truck with the load in the raised position. Do not stop the truck on a slope. If absolutely Restarting work necessary, secure the truck with wedges.

  • Page 108: 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 109: 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 110 Handling the battery – Before charging, check the condition of the battery cable and the charger cable. Replace them if necessary. – Open the hood and leave open. – Remove the battery handle connector (1) from the truck plug (2). –...

  • Page 111: Changing The Side Access Battery

    Handling the battery Changing the side access battery DANGER Risk of trapping fingers It is advisable to wear gloves when changing the battery. WARNING Risk of injury Safety shoes must be worn when changing the battery. Before handling, ensure that there is nobody around the truck.
  • Page 112 Handling the battery – Place the connector on the battery cells. – Position the truck with extraction rollers or the roller frame (4) in the upright position next to the battery compartment on level ground. – Operate and pull the locking handle (2) in the direction indicated by the arrow.
  • Page 113 Handling the battery – Lift the locking bar (3) until the battery is freed. – 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.
  • Page 114 Handling the battery – Carefully push the battery into the compart- ment. DANGER Risk of trapping fingers Push the battery from the rear side (A) of the battery. Take care not to trap your fingers by pushing from the top or the side of the battery. DANGER Risk of injury The battery is correctly positioned but is not yet...
  • Page 115 Handling the battery – Lower and lock the handle (2) of the locking bar (3) in the direction indicated by the arrow. The locking bar must be horizontal and must be right up against the stop (5). CAUTION Risk of locking the battery incorrectly The locking bar should not in any circumstances be positioned under or on top of the stop.

  • Page 116: 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 117: 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 118 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 119: 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) to choose a suitable device. Refer to the technical features.

  • Page 120: Lifting The Truck

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

  • Page 121: 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 122 Handling the truck in specific situations 11648011751 EN - 09/2019...

  • Page 123: Maintenance

    Maintenance...

  • Page 124: 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 125: 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 126: 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 127: 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: 4.8 l Hydraulic system Hydraulic oil Maximum working capacity: 5.9 l Transmission gear Transmission gear oil 0.98 l Traction motor (3 kW) Power: 300 A, quantity: 1 1F1 fuse Steering unit ES30–24...

  • Page 128: 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 129: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical compartment To carry out maintenance on various truck components, it is necessary to access the technical compartment. – Immobilise the truck. – Lower the load arms. – Switch off the truck (key or electronic key). –...

  • Page 130: 1000-Hour Maintenance Plan

    Maintenance 1000-hour maintenance plan 1000-hour maintenance 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 131: 5000-Hour Maintenance Plan

    Maintenance 5000-hour maintenance plan Check the condition and mounting of the guard grille Check the pin clearance 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...

  • Page 132: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Disconnect the battery before cleaning the truck. Be very careful using steam jet cleaners or products with a strong degreasing effect. They dilute the grease inside the sealed-for-life bearings, and relubrication is impossible.

  • Page 133: 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 134: 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 135: Steering And Wheels

    Maintenance Steering and wheels 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 136: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Cleaning and blowing out 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 hood. –...

  • Page 137: Checking The Battery Acid Level And Electrolyte Density

    Maintenance Electrical equipment Checking the battery acid level and electrolyte density NOTE Remove the battery from its compartment to check the water level. WARNING The electrolyte (diluted sulphuric acid) is poisonous and corrosive. – Always wear suitable protective equipment (industrial protection goggles, safety gloves) when working on a battery.

  • Page 138: Checking The Condition Of Cables, Terminals And The Battery Connector

    Maintenance Electrical equipment Checking the condition of cables, terminals and the 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 139: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Checking the hydraulic system for leaks – Switch off the truck and disconnect the battery connector. – Move the seat all the way forwards. – Open the technical compartment door. – Inspect the hydraulic system: pipes, hoses and connections between the pump unit and the cylinders.
  • Page 140 Maintenance Hydraulic systems – Open the technical compartment door. 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 141: 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 142: 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 143: 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 144: 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 145: Technical Specifications

    Technical specifications...

  • Page 146: Fxd 20 Datasheet

    Technical specifications FXD 20 datasheet FXD 20 datasheet 11648011751 EN - 09/2019...
  • Page 147 Technical specifications FXD 20 datasheet DESCRIPTION FXD 20 1.1 Manufacturer STILL 1.2 Model type FXD 20 Method of propulsion: battery, diesel, petrol, LPG, Battery mains power Driving mode: manual, pedestrian, standing, Seated seated, order picking Nominal capacity, Main lift only;...
  • Page 148 Technical specifications FXD 20 datasheet Seat height relative to the SIP/height of support h7 (mm) 1166 (±5 mm) 4.10 Load arms/ground height h8 (mm) Height at the ends of the forks and on load mating h13 (mm) 4.15 face (±5 mm) 4.19 Total length (0/+5 mm)
  • Page 149 Technical specifications FXD 20 datasheet Battery type in accordance with DIN 3 PzS side access 43535 Gel/Lead battery 24 / 375 4 PzS side-access battery 23 / 205 Battery voltage and capacity (discharge V/Ah Li-ion 205 Ah in 5 hours)

  • Page 150: Fxd 20 Mast Types

    Technical specifications FXD 20 mast types FXD 20 mast types Mast type Standard 1844S 2344S 2844S 1415 1665 1915 1490 1740 1990 1844 2344 2844 2364 2864 3364 Mast type Duplex 1844D 2344D 2844D 1415 1665 1915 1145 1395 1844...
  • Page 151 Index Cleaning and lubricating the chains ..131 Cleaning the truck ....122 Accessing the technical compartment . . 119 Climatic conditions ....7 Address of manufacturer .
  • Page 152 Maintenance plan ....114 FXD 20 mast types ....140 1000 hours .
  • Page 153 Index Operating company ....15 Specific features of the dual-pedal option ..... 70 Operator presence detection Specific features of the single-pedal Dual-pedal option .
  • Page 156 STILL GmbH 11648011751 EN – 09/2019...

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