Still EXD–S 20 Original Instructions Manual
  1. Manuals
  2. Brands
  3. Still Manuals
  4. Forklifts
  5. EXD-S 20
  6. Original instructions manual

Still EXD–S 20 Original Instructions Manual

Double pallet stacker
Hide thumbs Also See for EXD–S 20:
Table of Contents

Advertisement

Quick Links

Download this manual
Original instructions
Double pallet stacker
EXD–S 20
0347
11638011751 EN - 02/2021 - 03

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EXD–S 20 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Still EXD–S 20

Summary of Contents for Still EXD–S 20

  • Page 1 Original instructions Double pallet stacker EXD–S 20 0347 11638011751 EN - 02/2021 - 03...
  • 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 11638011751 EN - 02/2021 - 03...

  • 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 FleetManager™ option: Colour code for the LEDs ......Disconnecting a truck equipped with the FleetManager™ option ....Using the on-board compressor 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 11638011751 EN - 02/2021 - 03...

  • 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. 11638011751 EN - 02/2021 - 03...

  • 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 Steering wheel Battery compartment Key switch or electronic key Forks Diagnostic connector Load wheels or bogies Stabiliser wheel Battery hood Platform Mast 11638011751 EN - 02/2021 - 03...

  • Page 33: General View Of The Technical Compartment

    Overviews Overview General view of the technical compartment Pump-motor unit Traction motor Tank Steering unit ES30-24 Servo stabilisers tanks Controller 11638011751 EN - 02/2021 - 03...

  • Page 34: Operating And Display Devices

    Overviews Operating and display devices Operating and display devices Truck controls Horn Control button for the on-board compressor Drive switch Ignition key or electronic key Load arms lifting control Diagnostic connector Load arms lowering control Display Brake Fork lifting and lowering controls (depending Emergency off switch on model) 11638011751 EN - 02/2021 - 03...

  • Page 35: 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 36 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 37: Display Operating Unit

    Overviews Operating and display devices Display operating unit Dipped beam (if available on the model) Right turn indicator (if available on the mod- Flashing beacons (if available on the model) Left turn indicator (if available on the model) BLUE-Q mode F1 - Indicator light (if available on the model) Tortoise mode Hour meter...

  • Page 38: Markings

    Overviews Markings Markings Labels Danger instructions label for the battery lock. Brand and model label Consult the operating instructions Next inspection label Double pallet stacker label Brand and model label Double pallet stacker label - loading/unload- Brand label Cold store label Brand label Truck steering and steering wheel label Model label...

  • 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 11638011751 EN - 02/2021 - 03...
  • Page 40 Overviews Markings 11638011751 EN - 02/2021 - 03...

  • Page 42: Technical Description

    Technical description Technical description EXD-S 20 double pallet stackers are equipped These different battery types are not available with a driver's platform. They are intended for on all models. stacking and double stacking pallets and/or containers inside shops, warehouses and fac- Steering tories.
  • Page 43 Technical description Stabilisers The side protection is fixed. ● The protection provides back support for ● The trucks are fitted with two suspended sta- the driver. bilisers, which compensate for ground irregu- The steering wheel comprises the controls ● larities. and the steering.

  • 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 is locked. ● – Check that the battery is connected. – Check that the battery compartment hood is closed and locked correctly. – Step onto the driver's platform. – Release the emergency off switch (1) if it ...

  • Page 46: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning 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 47: Horn

    Checks and actions prior to commissioning Horn  – Press the horn button (1). The horn sounds. 11638011751 EN - 02/2021 - 03...

  • Page 48: Operation Of The Display Operating Unit

    Operation of the display operating unit Operation of the display oper- ating unit Managing battery charging  The battery charge level indicator (1) has ten status bars. When the battery is fully charged (100%), the ten status bars are all lit. As the battery capacity falls, the battery status bars turn off.
  • Page 49 Operation of the display operating unit When the key (2) is pressed, creep speed is activated. The Tortoise symbol (1) will appear on the display. Tortoise mode remains active when the truck is switched off and on again. To deactivate Tortue mode: –...

  • 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: Adjusting The Steering Wheel Height

    Adjusting the steering wheel height Adjusting the steering wheel  height The steering wheel height can be adjusted. To adjust the handlebar height, proceed as follows: – Press and hold the button (1). – Pull the steering wheel (2) towards you or lower it until the required height is reached.

  • Page 53: 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 54: 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. Driving DANGER Risk of injury Always keep both feet and hands inside the driver's compartment while the truck is moving.

  • Page 55: Steering

    Driving – Gradually and slowly press the drive switch backwards (2) with your thumb. – When the drive switch is released, the truck brakes electrically. WARNING Restricted visibility During reverse travel, visibility may be restricted. Be very careful. Make sure that the path behind is clear before travelling in reverse.

  • Page 56: Emergency Off Switch

    Driving – Ensure that the steering movements are transmitted correctly and simultaneously. Steering angle: 180° The turning radius (Wa) depends on the length of the chassis. Safety when cornering: speed limitation Trucks with a platform are fitted with a safety device that automatically reduces the speed when cornering above a certain steering angle of the drive wheel.

  • Page 57: Braking

    Driving Braking Normal braking  It is recommended that the braking button (1) is used in order to stop the truck. The braking distance is respected. – Press the braking button (1). The truck comes to a standstill. Counter-current braking ...

  • Page 58: Horn

    Driving The forklift operator leaves the platform that ● detects the presence of the forklift operator The forklift operator presses the emergency ● off switch The drive switch is in the neutral position ● The power supply is cut off ●...
  • Page 59 Driving Blue Q mode Selecting Blue Q mode (3) allows you to slightly reduce the performance of the truck: The travel speed of the truck is reduced ● (70% of maximum speed) The lifting and lowering speed of the load lift ●...

  • Page 60: Using The Truck On A Ramp

    Driving Using the truck on a ramp NOTE Incorrect use of the truck on a ramp is not rec- ommended. It places particular stress on the traction motor, brakes and battery. Ramps must always be approached with cau- tion: Never attempt a slope with a gradient that is ●...
  • Page 61 Driving Travelling down slopes  Always travel in reverse when going down a slope. The load faces uphill. Without a load, we recommend that you go down a slope forwards. In all cases, you must travel at a very low speed and brake gradually.

  • Page 62: 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 63: 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 64: 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 65 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 66: 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 67 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 68: 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 vi- brations felt within the truck while driving. It can be adjusted in accordance with the weight of the forklift operator.

  • Page 69: Transporting Loads

    Transporting loads 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 70 Transporting loads 9: Maximum lift height: 210 mm with ● 2000 kg in pallet truck mode 10: Maximum capacity in pallet truck mode: ● 2000 kg with a height of 210 mm 11: Truck model ● 11638011751 EN - 02/2021 - 03...

  • Page 71: Load Handling Safety Rules

    Transporting loads Load handling safety rules  WARNING Carefully observe the following instructions before picking up loads. Never touch or stand on moving parts of the truck (e.g. lifting device, pushing devices, work installations or devices for picking up loads). WARNING Take care not to trap hands or feet when operating the truck.

  • Page 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: 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 74: Progressive Stopping Of The Carriage In The Lower Position

    Transporting loads Initial Lift  The initial lift controls are located on the steer- ing wheel. As an option, they can also be loca- ted behind the steering wheel. Raising the load arms: – Press the button (4). The load arms are raised. Lowering the load arms: –...

  • Page 75: 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 76 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 77 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 78 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 79: 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 80 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 81 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 82: 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- The maximum speed of the truck depends on tem that assists when driving and using the the height of the forks.

  • Page 83: 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 84 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 85: 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 86: 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 87: Charging The Battery Using An External Charger

    Handling the battery – Ensure that the battery hood is closed se- curely. CAUTION Risk of sparks Never drive with the hood open or incorrectly closed. Charging the battery using an exter- nal charger CAUTION Deep discharging may damage the battery. –...
  • Page 88 Handling the battery WARNING Risk of damage, short circuit or explosion. Do not place any metal objects or tools on the bat- tery. Smoking is prohibited. WARNING The electrolyte (diluted sulphuric acid) is toxic and very caustic. Follow the safety regulations when handling battery acid.

  • Page 89: 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 90: 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 91 Handling the battery The on-board charger is intended to recharge the battery. – Switch off the truck. 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.

  • Page 92: Order Picking

    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 regularly checked as part of periodic statutory checks and maintenance opera- tions. NOTE The on-board charger is not compatible with the Cold Store option.

  • Page 93: 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 bat- tery. WARNING Risk of injury Safety shoes must be worn when changing the bat- tery. Before handling, ensure that there is nobody around the truck.
  • Page 94 Handling the battery – Remove the door (2) (if this option is selec-  ted) and put it to one side. – Position the truck with extraction rollers or the roller frame in the upright position near the battery compartment on level ground. –...
  • Page 95 Handling the battery – Lift the locking bar (3) until the battery is  freed. – 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.
  • Page 96 Handling the battery – Push the battery into the compartment.  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. –...
  • Page 97 Handling the battery – Lower and lock the handle (2) of the locking  bar (3) in the direction indicated by the ar- row. 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 must not in any circumstances be positioned under or on top of the stop.

  • Page 98: Changing The Vertical Access Battery

    Handling the battery Changing the vertical access bat- tery To change the battery, proceed as follows: – Immobilise the truck. – Lower the forks. – Switch off the ignition and remove the key. – Press the emergency off switch. – Open the battery hood. –...

  • Page 99: 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 100: 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 101 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 102: 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 103: 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. – Raise the forks slightly. – Switch off the ignition and disconnect the battery connector.

  • Page 104: 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 105: Maintenance

    Maintenance...

  • Page 106: 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 107: 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 108: 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 109: 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 Hydraulic system Hydraulic oil Transmission gear Transmission gear oil 0.98 l Traction motor (2.3 kW) 1F1 fuse Power: 300 A, quantity: 1 Steering unit ES30–24 (0.185 kW 3F1 fuse Power: 40 A, quantity: 1 Pump motor (2.2 kW)

  • Page 110: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants SAE 85W 90 API GL4 CAUTION Damage to equipment if non-recommended lubri- Aerosol can for chains cants are used. Only use recommended lubricants. Only the lubri- Standard chain spray cants listed below are approved by the manufacturer. Do not mix lubricants.

  • Page 111: Easily Accessing The Technical Compartment

    Maintenance Easily accessing the technical compartment Easily accessing the technical compartment For some operations, it is not necessary to ac- cess all the components in the technical com- partment. In this case, simply remove the main front hood from the truck. –...

  • Page 112: 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 Enter the next maintenance interval Chassis and equipment Check the condition of the forks...

  • Page 113: 5000-Hour Maintenance Plan

    Maintenance 5000-hour maintenance plan 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 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...

  • Page 114: 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 115 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 116: 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 117: 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 118: 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 119: 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 obstruct them or prevent them from turning. CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the wheel...

  • Page 120: 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 121: Checking The Battery Acid Level And Electrolyte Density

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

  • Page 122: Checking The Condition Of 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 123: 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 124: 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 125: 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 126: 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 127: 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 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 (cov- ers, 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 11638011751 EN - 02/2021 - 03...

  • Page 131: Technical Specifications

    Technical specifications...

  • Page 132: Exd-S 20 Datasheet

    Technical specifications EXD-S 20 datasheet EXD-S 20 datasheet 11638011751 EN - 02/2021 - 03...
  • Page 133 Technical specifications EXD-S 20 datasheet DESIGNATION 1.1 Manufacturer STILL 1.2 Model type EXD-S 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) 1200;...
  • Page 134 Technical specifications EXD-S 20 datasheet Height at the ends of the fork 4.15 h13 (mm) in the lowered position (0/+5 mm) Total length 4.19 L1 (mm) 2585 (+5 mm) Length to load support 4.20 L2 (mm) 1395 (±5 mm) Total width 4.21 b1 (mm) (±5 mm)
  • Page 135 Technical specifications EXD-S 20 datasheet DRIVE SYSTEM EXD-S 20 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 tery 3 PzS - side Battery voltage and capacity access 23/205...
  • Page 136 Technical specifications EXD-S 20 datasheet 7) For side access and backrest version, add 55 mm 11638011751 EN - 02/2021 - 03...

  • Page 137: Exd20-S Mast Type

    Technical specifications EXD20-S mast type EXD20-S mast type Mast type Standard 1574S 1724S 2024S 2424S 1240 1315 1465 1665 1315 1390 1540 1740 1574 1724 2024 2424 2094 2244 2544 2944 Mast type Duplex 1574D 1724D 2024D 2424D 1240 1315 1465 1665 1145...
  • Page 138 Technical specifications EXD20-S mast type 11638011751 EN - 02/2021 - 03...
  • Page 139 Index Oil Safety Information....13 Safety information for handling hydraul- Address of manufacturer....ic fluid.
  • Page 140 Index FleetManager™ Masts......32 Colour code for the LEDs... 54 Multi-purpose grease.
  • Page 141 Index Stability......Travelling up slopes....50 Stacking a load.
  • Page 144 STILL GmbH 11638011751 EN - 02/2021 - 03...

Table of Contents