Still EXD-SF 20 Original Instructions Manual
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Still EXD-SF 20 Original Instructions Manual

Double pallet stacker
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Original instructions
Double pallet stacker
EXD-SF 20
0313 0346
11638011651 EN - 09/2019

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  • Page 1 Original instructions Double pallet stacker EXD-SF 20 0313 0346 11638011651 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 11638011651 EN - 09/2019...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... 2 General .
  • Page 6 Table of contents Overviews Overview ............20 General view of the truck .
  • Page 7 Table of contents Operating the FleetManager™ option ........59 Description of the FleetManager option .
  • Page 8 Table of contents Maintenance General maintenance information ........104 General .
  • Page 9 EXD-SF 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 Battery maximum weight Battery minimum weight Additional weight (ballast) in kg Nominal motor power (kW) Battery voltage V Rated capacity in kg EC conformity symbol...
  • Page 16 Rules for the operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 11638011651 EN - 09/2019...

  • Page 17: Proper Usage

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

  • Page 18: Unauthorised Use

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

  • Page 19: Safety

    Safety...

  • Page 20: Safety Regulations

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

  • Page 21: Safety Regulations For Handling Consumables

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

  • Page 22: Hydraulic Fluid

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

  • Page 23: Disposal Of Consumables

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

  • Page 24: Emissions

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

  • Page 25: Residual Dangers, Residual Risks

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

  • Page 26: Specialist

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

  • Page 27: Safety Tests

    Safety inspection based on time and extraordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must STILL GmbH Hamburg ensure that the truck is checked by a specialist at least once a year or after noteworthy Regelmäßige Prüfung incidents.
  • Page 28 Safety Safety tests 11638011651 EN - 09/2019...

  • Page 29: Overviews

    Overviews...

  • Page 30: Overview

    Overviews Overview Overview General view of the truck Mast Platform Tiller Stabiliser wheel Key switch or electronic key Drive wheel Safety protective guardrails Forks Stabilisers Load wheels or bogies 11638011651 EN - 09/2019...

  • Page 31: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump unit Traction motor Pump unit tank Servo stabilisers tank Stabilisers Horn ES30–24 steering unit 11638011651 EN - 09/2019...

  • Page 32: Control And Display Components

    Overviews Control and display components Control and display components Driver's compartment Handle Anti-crush safety device Lifting the load arms Lowering the load arms Proportional lowering of forks Diagnostic connector Proportional lifting of forks Emergency off switch Horn Display Drive switch Key switch or electronic key 11638011651 EN - 09/2019...

  • Page 33: Display-Operating Unit

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

  • Page 34: Battery Charging Indicator

    Overviews Control and display components Battery charging indicator COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES 91% - 100%: 10 bars 1% - 10%: 1 bar Full charge: 100% 0%: 1 flashing bar (lift Battery charge level Low charge: 10% Dis- function not permitted). represented by 10 bars charged: 0% NB: To protect the battery,...
  • Page 35 Overviews Control and display components COMMENTS/SCREEN DESCRIPTION EXPLANATION MESSAGES Switched off: truck switched Green indicator light Switched on: truck switched These codes will help the service department to decide Error code E3 294 on the appropriate response from the service engineer. Fault or brake wear (air gap) Do not operate the truck - The meter starts running...

  • Page 36: 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 37 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 38: Markings

    Overviews Markings Markings Labels Identification label Label to indicate the pressure of the com- Brand label pressor (platform) Model label Label to indicate the recommended pres- Danger instructions label for the battery lock sure of the compressor (platform) Danger instructions label. Consult the Next inspection label operating instructions Cold store label...

  • Page 39: 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 11638011651 EN - 09/2019...
  • Page 40 Overviews Markings 11638011651 EN - 09/2019...

  • Page 42: Technical Description

    Technical description Technical description Batteries EXD-SF 20 trucks are intended for stacking and double stacking pallets and/or containers. Power is supplied by: They allow you to transfer loads from one • A lead battery place to another and to pick orders.
  • Page 43 Technical description - an electric counter-current brake: The various models are equipped with: • When releasing the drive switch • An emergency off switch • By reversing the drive direction • A display • Controlled by the rear safety button •...

  • Page 44: 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 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 has been pressed.
  • 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. 11638011651 EN - 09/2019...

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

  • Page 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 upper part of the tiller. – The horn sounds. 11638011651 EN - 09/2019...

  • Page 50: 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 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 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 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 Using the display-operating unit flashes and the (4) icon remains on with a new warning message Operator presence The Operator present(1) indicator light comes on when the operator steps onto the detection platform. It turns off immediately afterwards. 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 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 55 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 56 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 57: 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 58: Driving

    Driving Driving Defining directions The drive directions on a ride-on double pallet stacker are as follows: • Forward travel: Fork direction (1) • Reverse travel: Opposite fork direction (2) The load is positioned at the front. NOTE The drive directions are modified when the truck is used in pedestrian mode.

  • Page 59: Braking

    Driving – Press the upper part (2) 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 travel – Press the lower part (1) of the drive switch (3) with your thumb.
  • Page 60 Driving Electromagnetic braking The electromagnetic brake is activated auto- matically if one of the following conditions is met: • The tiller is released It is then brought back to the braking position (1) by a gas spring • The tiller is in braking position (2) or (1) •...

  • Page 61: Horn

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

  • Page 62: Ride-On Driving

    Driving Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck: • The travel speed of the truck is reduced (70% of maximum speed) • The speed of lifting and lowering the forks is reduced (90% of maximum speed) This mode allows you to save battery.
  • Page 63 Driving NOTE When the side protection guardrails are folded and the platform is in the lower position, the speed of the truck is limited to 6 km/h. WARNING Driving safety guidelines The operator must not use the guardrails to push loads sideways.

  • Page 64: Pedestrian Driving

    Driving Pedestrian driving This double pallet stacker can be used in pedestrian mode to facilitate manoeuvring in narrow spaces. – Raise the platform (1). – Push on the tab (2) to unlock the side protection guardrails (3). – Fold down the side protection guardrails (3). –...
  • Page 65 Driving Unfolding the combi tiller – Pull on the lock (1) to unlock the tiller. – Pull the handle of the tiller (2) towards you to unfold it. 11638011651 EN - 09/2019...

  • Page 66: Using The Truck On A Slope

    Driving – Press one of the controls. The forklift operator can use the truck with an increased safety distance. The combi tiller controls are operated in the same way as the standard tiller controls. Folding the combi tiller – Push on the tiller handles (3) to fold it. The forklift operator uses the truck in a more standard configuration.
  • Page 67 Driving Slopes must always be approached with great caution: • Never attempt a slope whose gradient is greater than that specified in the truck's datasheet • Make sure that the ground is clean, has a non-slip surface and that the route is clear Travelling up slopes Always travel forwards when going up a slope.
  • Page 68 Driving WARNING Risk of serious injury and/or serious damage to equipment Driving on slopes steeper than 10% is prohibited due to braking capacity and stability. The load being transported could tip over. Starting on a slope Proceed as follows: – Move the drive switch in the required direction.

  • Page 69: 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 70: 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 71: 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 72 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 73: 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 74 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 75: Using The On-Board Compressor Option

    Using the on-board compressor option Using the on-board compres- sor option The on-board compressor option allows you to automatically pressurise the shock-absorbing platform bellows. This shock-absorbing platform reduces the vibrations felt within the truck while driving. It can be adjusted in accordance with the weight of the forklift operator.

  • Page 76: 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 77: 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 78: Reading The Capacity Plate

    (initial lift) if the truck is equipped with spring stabilisers Reading the capacity plate Example with an EXD-SF 20 fitted with a 1844-mm duplex mast: • 1: Maximum lift height: 1930 mm • 2: Maximum mast capacity: 1200 kg with...

  • Page 79: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads • 7: Mast capacity: 1200 kg with a height of 1930 mm (centre of gravity: 500 mm) • 8: Mast capacity: 1200 kg with a height of 1930 mm (centre of gravity: 600 mm) • 9: Maximum lift height: 210 mm with 2000 kg in pallet truck mode •...

  • Page 80: 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 81 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 82: 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 83 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 84 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 85 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 86: Handling Two Stacked Pallets

    Transporting loads Handling two stacked pallets Double pallet stackers enable two stacked loads to be transported: - One load on the load arms (initial lift). - One load on the forks. DANGER Risk of loss of stability The overall weight of the two loads must not exceed the maximum capacity of the machine (refer to the capacity plate).
  • Page 87 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 88 Transporting loads – Lower the forks again. WARNING Lifting and lowering the forks The initial lift or lowering operation (load arms) is matched by the forks. Before leaving the machine CAUTION Parking the truck Always stop the machine on level ground away from traffic routes.

  • Page 89: 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 90: 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 91 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 92: Before Leaving The Truck

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

  • Page 93: 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 94: 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 95: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an external 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. – Park the truck safely. –...
  • Page 96 Handling the battery WARNING Explosive gases are generated during battery charging. – Make sure that the area is well-ventilated. – Make sure that the battery hood remains open for the entire time the battery is charging. 11638011651 EN - 09/2019...

  • Page 97: On-Board Charger

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

  • Page 98: Using The On-Board Charger

    Handling the battery If the charger stays connected to the mains, If the cut-off period is longer than 13 minutes it restarts a charging cycle every 48 hours (the truck could have been used), a complete after the end of the previous charge in order to charging cycle is initialised.
  • Page 99 Handling the battery Do not pull the emergency stop handle. This operation cuts off the circuits and stops the battery from charging. – Connect the charger plug (1) to a mains socket. Phase Green LED Red LED Mains socket disconnected Charging Flashing phases...

  • Page 100: Adjusting The On-Board Charger

    Handling the battery CAUTION Risk of damage to the mains cable due to frequent operator handling. Risk of electric shock and/or burns! The mains cable must be checked regularly as part of periodic statutory checks and maintenance operations. NOTE The on-board charger is not compatible with the Cold Store option.

  • Page 101: Changing The Vertical Access Battery

    Handling the battery Changing the vertical access battery To change the battery, proceed as follows: – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. – Press in the emergency off switch. – Open the battery hood. –...
  • Page 102 Handling the battery extraction rollers (fitted with rollers) for easier handling of the battery. To change the battery, proceed as follows: – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. – Press in the emergency off switch. –...
  • Page 103 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. 11638011651 EN - 09/2019...
  • Page 104 Handling the battery – Pull the battery onto the truck with extraction rollers or the roller frame – Replace the battery. Remove the dis- charged battery and position a charged battery on the roller frame. – Position the truck with extraction rollers or the roller frame (4) in the upright position next to the battery compartment.
  • Page 105 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 106 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 107: 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 108: 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 109 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 110: 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 111: 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 112: 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 113: Maintenance

    Maintenance...

  • Page 114: 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 115: 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 116: 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 117: 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 118: Technical Data For Inspection And Maintenance

    Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Capacities/adjustment values Consumables/lubricants Minimum working capacity: 3.3 l Hydraulic system Hydraulic oil Maximum working capacity: 3.5 l Transmission gear Transmission gear oil 1.1 l Traction motor (2.3 kW) Power: 300 A, quantity: 1 1F1 fuse Steering unit ES30–24...

  • Page 119: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical compartment WARNING Risk of injury Before removing anything, turn the ignition off and press the emergency off switch. To access the technical compartment, it is necessary to lift the top hood (1) and remove the front hood (2).
  • Page 120 Maintenance Accessing the technical compartment – Remove the front hood. The technical compartment must be closed once the operation is finished. – Reposition the front hood (2). – Tighten the two screws (4) of the front hood. – Reposition the top hood (1). –...

  • Page 121: 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 122: 5000-Hour Maintenance Plan

    Maintenance 5000-hour maintenance plan Lubricate the forks and the mast guide rollers Check the condition and mounting of the guard grille 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 123: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Park the truck. – Press the emergency off switch. CAUTION Electrical hazards The battery must always be disconnected during cleaning procedures. Washing the outside of the truck WARNING Risk of damage to the truck –...
  • Page 124 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 125: 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 126: 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 127: Steering And Wheels

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

  • Page 128: Checking The Condition Of The Wheels

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

  • Page 129: 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 the emergency off switch. – Disconnect the battery connector. – Open the technical compartment. –...

  • Page 130: Checking The Battery Acid Level And Electrolyte Density

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

  • Page 131: Checking The Condition Of The Cables, Terminals And Battery Connector

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

  • Page 132: Hydraulic Systems

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

  • Page 133: Checking The Controlled Stabiliser Hydraulic System For Leaks

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

  • Page 134: Checking The Oil Level In The Controlled Stabiliser Circuit

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

  • Page 135: 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 136: 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 137: 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 138: 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 139: Technical Specifications

    Technical specifications...

  • Page 140: Exd-Sf 20 Datasheet

    Technical specifications EXD-SF 20 datasheet EXD-SF 20 datasheet 11638011651 EN - 09/2019...
  • Page 141 Technical specifications EXD-SF 20 datasheet DESCRIPTION 1.1 Manufacturer STILL 1.2 Model type EXD-SF 20 Drive type: battery, diesel, petrol, LPG, Battery mains power Driving mode: manual, pedestrian, standing, Standing seated, order picking Nominal capacity: main lift only Main lift/initial lift Q (kg) 0;...
  • Page 142 Technical specifications EXD-SF 20 datasheet 4.5 Extended mast height (±5 mm) h4 (mm) 2544 (2024T) 4.6 Initial lift (±5 mm) h5 (mm) Height of tiller in driving position h14 (mm) 4.9.1 1208/1402 min./max. (±5 mm) Height of tiller in driving position for the combi...
  • Page 143 Technical specifications EXD-SF 20 datasheet 5.8 Maximum gradient (0 kg, 1200 kg, 2000 kg) 20/15/12 Acceleration time (10 m) when laden/un- 7.6/6.7 laden electromagnetic 5.10 Service brake DRIVE SYSTEM EXD-SF 20 6.1 Traction motor, S2: 60 minutes 6.2 Lift motor, S3: at 10% utilisation...

  • Page 144: Exd-Sf 20 Mast Types

    Technical specifications EXD-SF 20 mast types EXD-SF 20 mast types Mast type Standard 1574T 1724T 2024T 2424T 1240 1315 1465 1665 1315 1390 1540 1740 1574 1724 2024 2424 2094 2244 2544 2944 Mast Duplex Triplex type 2424N 2924N 2136S...
  • Page 145 Index Checking the horn ....39 Checking the oil level in the controlled Accessing the technical compartment . . 109 stabiliser circuit ... . . 124 Address of manufacturer .
  • Page 146 Identification label ....5 EXD-SF 20 ..... 130 Initial Lift .
  • Page 147 Index Ordering spare parts and consumables . 105 Stacking a load ....74 Starting on a slope ....58 Starting up .
  • Page 150 STILL GmbH 11638011651 EN – 09/2019...

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