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

Double pallet stacker
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Original instructions
Double pallet stacker
EXD 20
0307 0345
11638011551 EN - 02/2021 - 06

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Summary of Contents for Still EXD 20

  • Page 1 Original instructions Double pallet stacker EXD 20 0307 0345 11638011551 EN - 02/2021 - 06...
  • Page 3 Preface Address of manufacturer and  contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 11638011551 EN - 02/2021 - 06...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... General .
  • Page 6 Table of contents Overviews Overview ............General view of the truck .
  • Page 7 Table of contents Operating the FleetManager™ option ........Description of the FleetManager option.
  • Page 8 Table of contents Maintenance General maintenance information ........General .
  • Page 9 Table of contents Lift mast ............Cleaning and lubricating the chains.

  • 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 11638011551 EN - 02/2021 - 06...

  • 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 accordance with standard EN 12053. Acoustic pressure level in the driver's compartment Truck 62 dB (A) Uncertainty ± 2.5 dB (A) NOTE Lower or higher noise values may occur when using industrial trucks, e.g.

  • 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. 11638011551 EN - 02/2021 - 06...

  • 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: Overviews

    Overviews Overview Overview General view of the truck Protective screen Drive wheel Tiller Battery compartment Key switch or electronic key Forks Display Load wheels or bogies Stabilisers Mast Stabiliser wheel 11638011551 EN - 02/2021 - 06...

  • Page 33: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump-motor unit Stabiliser wheel Tank Drive wheel Stabilisers Traction motor Turntable ES30-24 steering unit 11638011551 EN - 02/2021 - 06...

  • Page 34: Operating And Display Devices

    Overviews Operating and display devices Operating and display devices Driver's compartment Handle Anti-crush safety device Lifting the load arms Lowering the load arms Proportional lowering of forks Diagnostic connector Proportional lifting of forks Emergency stop button Horn Display Drive switch Key switch or electronic key 11638011551 EN - 02/2021 - 06...

  • Page 35: Display-Operating Unit

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

  • Page 36: Electronic Key (Option)

    Overviews Operating and display devices Electronic key (option) 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 Comments ○ red off ● continuous (by de- green (1) (correct PIN) * 1 2 3 4 5 #...
  • Page 37 Overviews Operating and display devices PROGRAMMING (truck switch OFF only (2)) To reactivate the default Restoring the ini- administrator code tial administrator (00000000), please con- code tact your agent or nearest dealer. Power switches off auto- ● red flashing ● green matically after 10 mi- Activating the au- flashing (5) (5 seconds...

  • Page 38: Markings

    Overviews Markings Markings Labels Identification label Cold store label Danger instructions label. Consult operating Next inspection label instructions Double pallet stacker label Brand label Double pallet stacker label - loading/unload- Model label Brand label Capacity label 11638011551 EN - 02/2021 - 06...

  • 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 11638011551 EN - 02/2021 - 06...
  • Page 40 Overviews Markings 11638011551 EN - 02/2021 - 06...

  • Page 42: Technical Description

    Technical description Technical description Steering EXD20 trucks are intended for stacking and double stacking pallets and/or containers. The ES30–24 electric steering offers driving Model available: precision and easier manoeuvring. EXD20 with proportional lifting and lowering ● The truck is equipped with a 0,185 kW asyn- controls with initial lift chronous steering motor.
  • Page 43 Technical description Equipment available as standard or as traction, initial lift, horn and double throw safe- ty switch. additional options: The various models are equipped with: That can be added to the truck: An emergency off switch Load backrest ● ●...

  • 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: Starting Up

    Starting up Starting up NOTE Check that the battery hood is closed ● Check that the battery is locked ● – Check that the battery is connected – Check that the battery compartment hood is closed and locked correctly. – Release the emergency off switch (1) if it ...
  • Page 46 Starting up – Tilt the tiller in the driving area (3).  NOTE In areas (1) and (2), the electromagnetic brake is applied and it is not possible to drive the truck. 11638011551 EN - 02/2021 - 06...

  • Page 47: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning 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 Emergency Shutdown

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

  • Page 49: 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. 11638011551 EN - 02/2021 - 06...

  • Page 50: 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 51 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 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 ●...
  • Page 53 Using the display-operating unit restricted, the (3) icon flashes and the (4) icon remains illuminated with a new warning message. Temperature, settings and warning  lights The Temperature light (1) comes on in the event of overheating of the traction motor or the controller.
  • Page 54 Using the display-operating unit Activity indicator  The Activity indicator light (1) flashes continu- ously while the truck is in operation. When the indicator is off, the display unit is locked or frozen. A warning is shown on the display. Settings menu ...
  • Page 55 Using the display-operating unit Error codes menu  It is possible to access error messages that are disrupting the operation of the truck. – Select the Error messages menu (1) The operator can access the error codes. If several codes are affecting the truck, the oper- ator can scroll through several successive dis- plays.

  • Page 56: Driving Safety Guidelines

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

  • Page 57: Driving

    Driving Driving Defining directions  On a pedestrian-mode double pallet stacker, the conventional directions are: Forward travel (1): Tiller direction ● Reverse travel (2): Fork direction ● The load is positioned at the rear. Driving – Turn the ignition key. –...

  • Page 58: Steering

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

  • Page 59: Braking

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

  • Page 60: Horn

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

  • Page 61: Drive Program

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

  • Page 62: 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 63: Using The Truck On A Slope

    Driving Using the truck on a slope NOTE Incorrect use of the truck on a slope is not rec- ommended. It places particular stress on the traction motor, brakes and battery. Slopes must be approached with great cau- tion: Never attempt a slope whose gradient is ●...
  • Page 64 Driving Travelling down slopes  Always travel down slopes forwards. The load faces uphill. Without a load, we recommend that you de- scend 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...

  • Page 65: 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 66: 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 67: 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 68 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 69: 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 70 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 71: 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 72: 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 73: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads Progressive stopping of the carriage  in the lower position A detector (1) that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the low- ering action.

  • Page 74: Reading The Capacity Plate

    Transporting loads Reading the capacity plate  CAUTION Risk of loss of control Before picking up a load, make sure that its weight does not exceed the lifting capacity of the machine. Refer to the nominal capacity specified on the truck's capacity plate (1).
  • Page 75 Transporting loads 10: Maximum capacity in pallet truck mode: ● 2000 kg with a height of 210 mm 11: Model ● 11638011551 EN - 02/2021 - 06...

  • Page 76: Lift Control Elements

    Transporting loads Lift control elements WARNING Appropriate use of the equipment Only use the lifting device and the accessories for the work for which they are intended. The operator must receive instruction on the opera- tion of the load lift system. WARNING Risk of injury The safety instructions must be strictly adhered to.
  • Page 77 Transporting loads Raising/lowering the mast  Lifting the mast: – Press button (2). The forks are raised. Lowering the mast: – Press button (1). The forks are lowered. When the lifting control (1) is released, the forks stabilise at the required height. NOTE A groove (3) is present on each side of the button.

  • Page 78: 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 capacity of the truck. Refer to the nominal capacity specified on ●...
  • Page 79 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 There must be no one under or near the truck when the load is in the raised position.
  • Page 80 Transporting loads CAUTION Risk of falling Do not touch nearby loads or loads positioned be- hind the truck. CAUTION Risk of accident Before you set down the load, ensure that no one is around the truck or the load. Stacking a load ...
  • Page 81 Transporting loads Picking up a load at a height  Proceed as follows: – Drive the truck 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 82: Handling Two Stacked Pallets

    Transporting loads Handling two stacked pallets Double pallet stackers enable two stacked loads to be transported: - One load on the load arms (initial lift) - One load on the forks DANGER Risk of loss of stability The overall weight of the two loads must not ex- ceed the maximum capacity of the machine (refer to the capacity plate).
  • Page 83 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 84 Transporting loads – Slowly withdraw the truck in a straight line. – Lower the forks again. WARNING Lifting and lowering the forks The initial lift or lowering operation (load arms) is matched by the forks. Before leaving the machine CAUTION Parking the truck Always stop the machine on level ground away from traffic routes.

  • Page 85: 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 sys- tem that assists when driving and using the truck. The forklift operator must remain vigilant un- der all circumstances and adhere to the truck capacity plate.

  • Page 86: 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 87 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 88: Before Leaving The Truck

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

  • Page 89: 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 90: Opening And Closing The Battery Hood

    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 and closing the battery ...

  • Page 91: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an exter- nal charger CAUTION Deep discharging may damage the battery. – Charge the battery immediately. The fixed socket on the truck (1) is located above the battery and under the battery hood. –...
  • Page 92 Handling the battery WARNING Explosive gases are generated during battery charg- ing. – Make sure that the area is well-ventilated. – Make sure that the battery hood remains open for the entire time the battery is charging. 11638011551 EN - 02/2021 - 06...

  • Page 93: 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 94: 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 95 Handling the battery – Connect the charger plug (1) to a mains socket. Phase Green LED Red LED Mains socket disconnected Charging phases Flashing Stopped / Equalisation / Main- Continuously lit tenance phase Charging process too long Continuously lit Charger polarity reversed (+battery and -battery charger cables reversed, with the bat- Continuously lit...

  • Page 96: Adjusting The On-Board Charger

    Handling the battery 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. The charger does not flow and the two LEDs flash simultaneously to indicate that no curve has been selected.

  • Page 97: Changing The Side Access Battery

    Handling the battery – Attach the slinging hooks to the battery  compartment. NOTE Using secured hooks is recommended. – Lift the battery. Take care not to hook onto the upper bridge piece of the mast. – Replace the battery. –...
  • Page 98 Handling the battery – Place the connector on the battery cells. – Unlock the door that is not attached to the  side of the battery by lifting the latch (1). Hold the door (2) to prevent it falling. – Remove the door (2) (if this option is selec- ...
  • Page 99 Handling the battery – Operate and pull the locking handle (2) in  the direction indicated by the arrow. – Lift the locking bar (3) until the battery is  freed. 11638011551 EN - 02/2021 - 06...
  • Page 100 Handling the battery – Pull the battery onto the truck with extrac-  tion rollers or the roller frame – Replace the battery. Remove the dis- charged battery and position a charged bat- tery on the roller frame. – Position the truck with extraction rollers or the roller frame (4) in the upright position next to the battery compartment.
  • Page 101 Handling the battery – Push until a click is heard. The battery is  correctly installed. WARNING Risk of injury Ensure that the battery is in the end position and that the hook is correctly holding the battery. DANGER Risk of injury The battery is correctly positioned but is not yet locked.
  • Page 102 Handling the battery – Lower the latch of the battery compartment  door (if this option is selected). The door that is not attached to the side of the battery must be correctly locked. – Refit the battery hood. – Return the truck to service. WARNING Risk of injury Before restarting the truck, ensure that the battery is...

  • Page 103: 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 prob- lem. This operation is to be performed as follows: –...

  • Page 104: Truck Towing Procedure

    Handling the truck in an emergency Truck towing procedure It is not possible to tow the truck with no elec- trical function. The electromagnetic brake re- mains 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 105 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 be- fore the machine is used.

  • Page 106: Handling The Truck In Specific Situations

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

  • Page 107: Lifting The Truck

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

  • Page 108: 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 To load or unload the truck, use an inclined below the lifted truck.

  • Page 109: Maintenance

    Maintenance...

  • Page 110: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the infor- mation 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 re- mains valid.

  • Page 111: 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 112: 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 113: Technical Data For Inspection And Maintenance

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

  • Page 114: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants Transmission gear oil DANGER Toxic products. Recommended oil: Oils and other consumables are toxic products. It is CLP PG220 DIN 51 517–3 advisable to handle and use them with the utmost care. Aerosol can for chains Hydraulic oil Standard chain spray A167.

  • Page 115: Accessing The Technical Compartment

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

  • Page 116: 1000-Hour Service Plan

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

  • Page 117: 10,000-Hour Service Plan

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

  • Page 118: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Park the truck. – Press in the emergency off switch. CAUTION Electrical hazards The battery must always be disconnected during cleaning procedures. Washing the outside of the truck ...
  • Page 119 Maintenance Chassis, bodywork and fittings NOTE Only use dry cleaning products. ● Do not remove the cowlings. ● – Clean the electric installations with a non- metal brush and dry with lightly compressed air. After washing – Carefully dry the truck (e.g. with com- pressed air).

  • Page 120: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings General information on battery maintenance DANGER NOTE Risk of injury The discharge indicators used to check the ● Before carrying out any operations on the electric in- battery must also be suitable for the type of stallation, turn the truck power supply off.

  • Page 121: 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 122: Steering And Wheels

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

  • Page 123: Checking The Condition Of The Wheels

    Maintenance Steering and wheels Checking the condition of the  wheels – Raise the truck until the wheels are off the ground. – Check that the wheels rotate freely and re- move 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 124: Electrical Equipment

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

  • Page 125: 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 126: Checking The Condition Of The Cables, Terminals And Battery Connector

    Maintenance Electrical equipment Checking the condition of the ca-  bles, terminals and battery connec- – 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 127: Hydraulic Systems

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

  • Page 128: Checking The Controlled Stabiliser Hydraulic System For Leaks

    Maintenance Hydraulic systems – Remove the hood of the technical compart-  ment. To ensure correct operation of the truck func- tions, the oil level must be between the mini- mum mark (3) and maximum mark (2) on the tank. –...

  • Page 129: Checking The Oil Level In The Controlled Stabiliser Circuit

    Maintenance Hydraulic systems In the event of leakage, please contact the Af- ter-Sales Service Centre. Checking the oil level in the control-  led stabiliser circuit – Switch off the truck and disconnect the bat- tery connector. – Remove the hood of the technical compart- ment.

  • Page 130: Lift Mast

    Maintenance Lift mast Lift mast Cleaning and lubricating the chains NOTE NOTE If the lifting chain is too dirty, clean it. Use of high pressure liquid cleaning devices is not advisable. – Place a recipient underneath the lifting chain. DANGER –...

  • Page 131: Checking The Protective Screen

    Maintenance Lift mast – Fully lower the mast.  – Undo the locknut (2) – Place the chains under slight tension by tightening the nut (1). – Retighten the locknut (2). CAUTION Risk of the equipment becoming worn or damaged. After this adjustment, check that the fork carriage does not reach the mechanical stop at the top of the mast during the maximum lift.
  • Page 132 Maintenance Lift mast DANGER Poor visibility The screen must be installed and correctly attached. Do not attach anything to the screen that could affect the visibility of the forks. When cleaning the fork carriage side, only clean the screen when the fork carriage is in the lowered posi- tion.

  • Page 133: 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 134: 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 (cov- ers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.

  • Page 135: Technical Specifications

    Technical specifications...

  • Page 136: Exd20 Datasheet

    Technical specifications EXD20 datasheet EXD20 datasheet 11638011551 EN - 02/2021 - 06...
  • Page 137 Technical specifications EXD20 datasheet DESCRIPTION 1.1 Manufacturer STILL 1.2 Model type EXD20 Method of propulsion: battery, diesel, petrol, Battery LPG, mains power Driving: manual, pedestrian, standing, seat- Standing ed, order picking Nominal capacity: main lift only Main lift/initial lift Q (kg) 1200;...
  • Page 138 Technical specifications EXD20 datasheet Tiller height in driving position h14 (mm) 740/1230 min./max. (±5 mm) Load arm/ground height 4.10 h8 (mm) (0/+5 mm) Height at the ends of the fork 4.15 h13 (mm) in the lowered position (0/+5 mm) Total length 4.19 L1 (mm) 2185...
  • Page 139 Technical specifications EXD20 datasheet Acceleration time (10 m) when laden/unla- 7.6/6.7 5.10 Service brake electromagnetic DRIVE SYSTEM EXD20 6.1 Traction motor, S2: 60 minutes 6.2 Lift motor, S3: at 10% utilisation Battery type in accordance with DIN 3 PzS side access 43 535 Gel/Lead bat- 24/375...

  • Page 140: Exd20 Mast Types

    Technical specifications EXD20 mast types EXD20 mast types Mast type Standard 1574T 2024T 2424T 1240 1465 1665 1315 1540 1740 1574 2024 2424 2094 2544 2944 Mast type Duplex 1924 N 1915 1395 2924 3444 11638011551 EN - 02/2021 - 06...
  • Page 141 Index Closing the battery hood....cold store......76 Accessing the technical compartment.
  • Page 142 Index EXD20 datasheet....126 EXD20 mast types....130 Maintenance plan.
  • Page 143 Index Servicing and maintenance measures. . . 102 Transporting a load....Setting a load down on the ground..Transporting the truck.
  • Page 146 STILL GmbH 11638011551 EN - 02/2021 - 06...

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