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

Double pallet stacker
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Original instructions
Double pallet stacker
FXD 20 N
1540 1546
11648011651 EN - 09/2019

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  • Page 1 Original instructions Double pallet stacker FXD 20 N 1540 1546 11648011651 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 11648011651 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 Joystick function (option) ..........54 Steering Knob option .
  • Page 8 Table of contents Maintenance General maintenance information ........98 General .
  • Page 9 Table of contents Technical specifications FXD 20N datasheet ..........122 FXD 20N mast types .

  • Page 11: Introduction

    Introduction...

  • Page 12: Your Industrial Truck

    Introduction Your industrial truck Your industrial truck General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used.

  • Page 13: Ce Labelling

    Introduction Your industrial truck CE labelling The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. The supplied EC declaration of conformity confirms this. The CE labelling is attached to the nameplate.

  • Page 14: Ec Declaration Of Conformity

    Introduction EC declaration of conformity EC declaration of conformity Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY We declare that the machine 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. 11648011651 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 11648011651 EN - 09/2019...

  • Page 29: Overviews

    Overviews...

  • Page 30: Overview

    Overviews Overview Overview General view Overhead guard Stabiliser wheel Protective screen Operator presence pedal Control module Battery compartment Seat Forks Lift cylinder Load wheels or bogies Platform Mast Drive wheel Emergency off switch 11648011651 EN - 09/2019...

  • Page 31: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump-motor unit Horn Traction motor ES30-24 steering unit Tank Fuses 11648011651 EN - 09/2019...

  • Page 32: Control And Display Components

    Overviews Control and display components Control and display components Driver's compartment Control unit or joystick (depending on option Display selected) Control button (Steering Knob device) Emergency off switch Steering wheel Switch key (or electronic key) Handle for stepping on and off the truck 11648011651 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 Regular safety inspection of the truck label Mast safety label Danger instructions label. Consult operating Model label instructions Slinging label. Consult operating instruc- Capacity label tions Double pallet stacker label - loading/unload-...

  • 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 11648011651 EN - 09/2019...
  • Page 38 Overviews Markings 11648011651 EN - 09/2019...

  • Page 40: Technical Description

    Steering is provided by an electric geared motor that positions the turntable. Model available: • FXD 20 N: 1200 kg in pallet stacker mode, The steering motor is controlled by a variable 2000 kg in double pallet stacker mode speed transmission. It receives information...
  • Page 41 Technical description • Electronic key NOTE • Cold store (-35°C) The operating instructions can be found in • Document holder the document holder, located on the technical • Steering knob compartment door. • Joystick 11648011651 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: Starting Up

    Starting up Starting up NOTE Check that no controls are activated before • starting the truck. 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.

  • Page 44: 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 45: 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 46: 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 47 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 48: 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 (1) and the seat (2) to help when stepping on/off the truck. – Hold the handle (1) with one hand –...

  • Page 49: Operation Of Operator Presence Detection

    Operation of operator presence detection Operation of operator presence detection The truck is equipped with two operator presence detectors: • The chair (2) • The presence pedal (1) These two components are truck safety devices. First, the forklift operator must sit on the chair (2).
  • Page 50 Operation of operator presence detection CAUTION Disabling of controls If the operator presence pedal is released when moving: - The truck brake is automatically activated - The controls no longer work 11648011651 EN - 09/2019...

  • Page 51: Driver's Compartment Settings

    Driver's compartment settings Driver's compartment settings Adjusting the seat The seat is equipped with an operator pres- ence detector. The operator must adjust his weight by increments of 10 kg to trigger this detection. Proceed as follows: – Sit on the seat –...

  • Page 52: Seat Heater Option

    Driver's compartment settings Seat heater option The driver's seat may be equipped with the seat heater option. The heater turns on when the operator's presence on the seat is detected. To activate the heater, proceed as follows: – Sit on the seat –...

  • Page 53: 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 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 The light indicating the operator's presence on the pedal (2) remains continuously illuminated...
  • 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 Defining directions Names used in the text refer to the component installation position with respect to the driver's compartment. • Reverse travel (1) • Forward travel (3) • To the right (4) • To the left (2) The load is positioned at the rear. Driving WARNING Be aware of the position of the drive wheel...

  • Page 61: Braking

    Driving Forward travel – Using your thumb, push the drive switch to the left (2) to travel forwards (opposite fork direction). – When the drive switch is released, the truck brakes electrically. Reverse travel – Using your thumb, push the drive switch to the right (1) to travel backwards (fork direction).

  • Page 62: Horn

    Driving Braking by reversing the drive direction – Move the drive direction switches (2) or (3) in the opposite drive direction. Braking by releasing the drive switch – While travelling, completely release the drive switch. The brake is automatically activated. The truck is immobilised.

  • Page 63: Drive Program

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

  • Page 64: Joystick Function (Option)

    Driving The different speeds can be adjusted. Contact the After-Sales Service Centre to change these. Joystick function (option) The truck may be equipped with a joystick in place of the control unit. The operation is therefore different. NOTE Always operate the joystick slowly, as the truck reacts immediately.

  • Page 65: Steering Knob Option

    Driving Rear of the joystick The rear of the joystick is used to: • Sound the horn • Raise or lower the load arms Horn – Press the button (5) on the joystick. Raising the load arms (initial lift) – Press the button (6) on the joystick. Lowering the load arms (initial lift) –...
  • Page 66 Driving – Move the turning knob to the left (anti- clockwise) (2) to turn to the right – Move the turning knob to the right (clock- wise) (2) to turn to the left 11648011651 EN - 09/2019...

  • Page 67: Using The Truck On A Slope

    Driving Using the truck on a slope NOTE Incorrect use of the truck on a slope is not recommended. 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 greater than that specified in the truck's datasheet.
  • Page 68 Driving Travelling down slopes Always travel down slopes forwards. The load faces uphill. Without a load, we recommend that you descend 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 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: 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 76: 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 77: 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 78 Transporting loads Base lift Lifting the load arms – Pull the control (2) downwards (D). The load arms are raised. Lowering the load arms – Push the control (2) upwards (C). The load arms are lowered. 11648011651 EN - 09/2019...

  • Page 79: Reading The Capacity Plate

    (main lift) and 1000 kg on the load arms (initial lift) Reading the capacity plate Example with an FXD 20 N fitted with a 1844-mm duplex mast: • 1: Maximum lift height: 1930 mm • 2: Maximum mast capacity: 1200 kg with...

  • Page 80: Progressive Stopping Of The Carriage In The Lower Position

    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: Model 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...

  • Page 81: 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 82 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 83 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 84 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 85: 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 86 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 87 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 88: 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 89: 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 90 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 91: 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 92: 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 93: 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 94 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 95: 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 96 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 97 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 98 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 99 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 100: 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 101: 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 102 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 103: 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 104: 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 105: 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 106 Handling the truck in specific situations 11648011651 EN - 09/2019...

  • Page 107: Maintenance

    Maintenance...

  • Page 108: 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 109: 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 110: 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 111: 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 112: 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 113: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical compartment In order to perform maintenance on various truck components, it is necessary to access the technical compartment. – Immobilise the truck – Lower the forks – Switch off the truck (key or electronic key) –...

  • Page 114: 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 115: 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 116: 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 117 Maintenance Chassis, bodywork and fittings NOTE Only use dry cleaning products • Do not remove the cowlings • – Clean the electrical installations with a non-metal brush and dry with lightly compressed air. After washing – Carefully dry the truck (e.g. with com- pressed air).

  • Page 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125 Maintenance Hydraulic systems – Open the technical compartment door To ensure proper usage of the truck functions, the oil level must be between the minimum (3) and maximum (2) marks on the tank. – Remove the plug (1). If necessary, top up via the opening –...

  • Page 126: 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 127: 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 128: 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 129: 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 130 Maintenance Storage and decommissioning 11648011651 EN - 09/2019...
  • Page 131 Technical specifications...
  • Page 132 Technical specifications FXD 20N datasheet FXD 20N datasheet 11648011651 EN - 09/2019...
  • Page 133 Technical specifications FXD 20N datasheet DESCRIPTION FXD 20N 1.1 Manufacturer FENWICK-LINDE 1.2 Model type FXD 20N Method of propulsion: battery, diesel, petrol, LPG, Battery mains power Driving: manual, pedestrian, standing, seated, order Seated picking 1.5 Nominal capacity LP only: LP/LI; LI only Q (kg) 1200;...
  • Page 134 Technical specifications FXD 20N datasheet 4.10 Load arm/ground height h8 (mm) Height at the ends of the fork and on load mating h13 (mm) 4.15 face (±5 mm) 4.19 Total length (0/+5 mm) l1 (mm) 2187 4.20 Length to front of forks (±5 mm) l2 (mm) 1037 4.21 Total width (±5 mm)
  • Page 135 Technical specifications FXD 20N datasheet Gel/Lead battery 24/375 4 PzS side access Battery voltage and capacity (discharge 23/205 V/Ah Li-ion 205 Ah in 5 hours) 4 PzS side access 23/410 Li-ion 410 Ah Battery weight (±10%) Gel/Lead battery 4 PzS side access Battery weight with tray (±10%) (kg) Li-ion 205 Ah...
  • Page 136 Technical specifications FXD 20N mast types FXD 20N mast types Mast type Standard 1844S 2344S 1415 1665 1490 1740 1844 2344 2364 2864 Mast type Duplex 1844D 2344D 1415 1665 1145 1844 2344 2364 2864 11648011651 EN - 09/2019...
  • Page 137 Index cold store ......79 Cold store usage ....79 Accessing the technical compartment .
  • Page 138 Index Hydraulic fluid ....12 Hydraulic oil ..... 102 EC declaration of conformity .
  • Page 139 Index Starting on a slope ....58 Starting up ..... . . 33 Permanent Putting Out of Commission .
  • Page 142 STILL GmbH 11648011651 EN – 09/2019...

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