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Still EXD 18C Original Instructions Manual
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Still EXD 18C Original Instructions Manual

Still EXD 18C Original Instructions Manual

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Original instructions
11628011551 EN - 11/2022  -  01

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Summary of Contents for Still EXD 18C

  • Page 1 Original instructions 11628011551 EN - 11/2022  -  01...
  • 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 11628011551 EN - 11/2022  -  01  I...
  • Page 5 Table of contents Introduction Your industrial truck ...........  2 General .
  • Page 6 General view of EXD 18C and EXD 20C trucks .......
  • Page 7 Table of contents Progressive stopping of the carriage in the lower position ..... . .  56 Handling a single load ...........  57 Handling two stacked pallets .
  • Page 8 Table of contents Steering and wheels .......... 87 Checking the condition of the wheels .
  • Page 9 Introduction...
  • Page 10 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 11 Introduction Conformity marking Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...
  • Page 12 Declaration that reflects the content of the declaration of conformity Declaration that reflects the content of the declaration of con- formity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the specified machine conforms to the most recent valid version of the directives specified below:  ...
  • Page 13 Introduction Declaration that reflects the content of the declaration of conformity handed over to the new owner if the industrial truck is sold on. 11628011551 EN - 11/2022  -  01  5...
  • Page 14 Introduction Identification label Identification label Version 1  Identification label Manufacturer CE symbol (this symbol means that the machine complies with European regulations for industrial trucks) Serial number/year Unladen weight Battery voltage Minimum battery weight (for a lithium- ion battery, the weight of the ballast container is included) Maximum battery weight Nominal capacity of the truck...
  • Page 15 Introduction List of abbreviations NOTE Several conformity markings may appear ● on the nameplate. The EAC marking can also be located in the ● immediate vicinity of the nameplate. List of abbreviations This list of abbreviations applies to all types of operating instructions.
  • Page 16 Introduction List of abbreviations Abbrevi- Meaning Explanation ation ID no. Identification number International Organization for Standardi- International standardisation organisation zation Uncertainty of measurement of sound pressure levels Local Area Network Local area network Light Emitting Diode Light emitting diode Sound pressure level at the workplace Average continuous sound pressure level in the driver's compartment Distance of the centre of gravity of the...
  • Page 17 ● ing and storage 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. 11628011551 EN - 11/2022  -  01  9...
  • Page 18 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 the following password: Spareparts24!.
  • Page 19 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 20 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 21 Safety...
  • Page 22 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 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 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 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 immediately soaked up with an oil-binding Materials that have to be disposed of follow- agent.
  • Page 26 Safety Emissions Emissions Vibration characteristics for vibrations to which the body is exposed The values were determined according to EN NOTE 13059 using trucks with standard equipment according to the datasheet (driving over test The vibration characteristics for bodily vibra- course with humps).
  • Page 27 Safety Residual dangers, residual risks Residual dangers, residual risks Falling, tripping etc. when moving on the Despite all operational precautions and com- ● industrial 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 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. 11628011551 EN - 11/2022  - ...
  • Page 30 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 Overview Overview General view of EXD 18C and EXD 20C trucks Mast Tiller Wheels or bogies Ignition key or electronic key (depending on Forks the model) Battery compartment Diagnostic connector Protective screen  24 11628011551 EN - 11/2022  -  01...
  • Page 33 Overviews Operating and display devices 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 ○...
  • Page 34 Overviews Operating and display devices PROGRAMMING (truck switch OFF only (2)) To reactivate the de- Restoring the ini- fault administrator code tial administrator (00000000), please con- code tact your agent or near- est dealer. Power switches off au- ● red flashing ● green tomatically after 10 mi- Activating the au- flashing (5) (5 seconds...
  • Page 35 Overviews Markings 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 11628011551 EN - 11/2022  - ...
  • Page 36 Overviews Markings  28 11628011551 EN - 11/2022  -  01...
  • Page 38 Technical description Technical description EXD 18C and EXD 20C trucks are designed arms, and forks are grouped together at the for pallet stacking and double pallet stacking. end of the tiller. Their small size, their ease of driving and their...
  • Page 39 Technical description Stabilisers It provides the steering for the truck. The various models are also equipped with: The 5-point chassis has 2 suspended stabil- isers which compensate for ground irregulari- – An emergency stop handle located on the ties. chassis, which completely shuts down the electrical system and brings the truck to a Masts standstill when it is pulled...
  • Page 40 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 tion table. attachments (special equipment) can result in acci- dents.
  • Page 41 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. – Pull the emergency off switch (1) if it has ...
  • Page 42 Starting up – Tilt the tiller into the driving zone (3).  NOTE In areas (1) and (2), the electromagnetic brake is applied and it is not possible to drive the truck.  34 11628011551 EN - 11/2022  -  01...
  • Page 43 Checks and actions prior to commissioning Checks and actions prior to commissioning Checking the emergency off  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 44 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. 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.
  • Page 45 Checks and actions prior to commissioning Checking the anti-crush safety device   WARNING Ensure that the test zone is free of people and ob- jects, both in front of and behind the truck. – Move the drive switch (1) or (3) to move the truck towards you.
  • Page 46 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 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 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 48 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 49 Driving Driving Defining directions  On a pedestrian-mode double pallet stacker, the conventional directions are: Forward travel (1): tiller direction ● Reverse travel (2): fork direction ● The load is positioned at the rear. Driving – Turn the ignition key. –...
  • Page 50 Driving – Press the lower part (1) of the drive switch  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 upper part (2) of the drive switch with your thumb.
  • Page 51 Driving – Turn the tiller clockwise: the truck turns to  the left (1) in forward travel. – Turn the tiller anti-clockwise: the truck turns to the right (2) in forward travel.  WARNING Risk of serious injury and/or serious damage to equipment Always slow down before negotiating a corner.
  • Page 52 Driving Braking by reversing the drive direction  Braking can be achieved by reversing the drive direction: – Move the drive switch (1) or (2) in the oppo- site direction until the truck stops. Braking by releasing the drive switch Braking can be achieved by releasing the drive switch: –...
  • Page 53 Driving Double throw safety switch  To protect the driver from any risk of being trapped between an obstacle and the ma- chine, the end of the tiller is fitted with a safety flap (1). This is the anti-crush safety device. As soon as the flap is pressed in, the machine stops immediately and moves off slowly in the direction of the fork.
  • Page 54 Driving Ramps must always be approached with cau- tion: Never attempt a slope with a gradient that ● is greater than that specified in the truck's datasheet. Make sure that the ground is clean and ● has a non-slip surface and that the route is clear.
  • Page 55 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 ramp Proceed as follows: – Move the drive switch in the required direc- tion.
  • Page 56 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 57 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 58 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 59 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 60 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 61 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 62 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 63 Transporting loads Transporting pallets or other  containers 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 64 Transporting loads Progressive stopping of the car-  riage in the lower position A detector (1) that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the lowering action. This detector prevents a violent impact at the end of travel.
  • Page 65 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 66 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 67 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 68 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 69 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 ex- ceed the maximum capacity of the machine (refer to the capacity plate).
  • Page 70 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 71 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 truck  CAUTION Parking the truck Always stop the machine on level ground away from traffic routes.
  • Page 72 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 73 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 74 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 75 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 76 Handling the battery – Check that the hood is closed securely. CAUTION Risk of sparks Never drive with the hood open or incorrectly closed. Order picking Maintenance personnel The battery must be replaced by specially trained personnel. Personnel must follow the manufacturer's instructions for the battery, the charger and the truck.
  • Page 77 Handling the battery Disconnecting/connecting the battery connector  WARNING Major risk of arcing and destruction of contacts Never connect or disconnect the connector if the truck is switched on. Regularly check the condition of the contacts of the connectors. Replace them if there are signs of arcing and carbonisation.
  • Page 78 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 79 Handling the battery any type of partial charging to be carried out Time protection ("opportunity charging"). If the duration of phases I1 + P + U is The overcharging calculation takes into ac- more than 16 hours, the charger automatically count partial recharging.
  • Page 80 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 the emergency off switch. – Open the battery hood. –...
  • Page 81 Handling the truck in an emergency 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 82 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 83 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 84 Handling the truck in specific situations Lifting the truck   DANGER Danger of truck tipping over Truck lifting must be performed carefully. For some work, it is necessary to lift the truck. – Lift the forks. – Switch off the ignition and disconnect the battery connector.
  • Page 85 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 86 Handling the truck in specific situations  78 11628011551 EN - 11/2022  -  01...
  • Page 87 Maintenance...
  • Page 88 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 89 Maintenance Technical specifications 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 condition The annual inspection for prevention of acci- of the truck and the efficiency of the protec- dents at work must be carried out by a person...
  • Page 90 Maintenance Technical specifications Assembly Consumables/lubricants Capacities/adjustment values Traction motor 1.2 kW for EXD 18C and EXD Fuse 1F1 Power: 300 A, quantity: 1 Pump motor 1.2 kW for EXD 18C and EXD Fuse 1F1 Power: 300 A, quantity: 1 Control fuse Fuse 1F3 Control: 7.5 A, quantity: 1...
  • Page 91 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 92 Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck  Disconnect the battery before cleaning the truck. Be very careful using steam jets or clean- ing products with a strong degreasing effect. They dilute the grease inside the sealed-for- life bearings.
  • Page 93 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 94 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 95 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 re- move any objects that may prevent them from turning or may obstruct them.
  • Page 96 Maintenance Electrical equipment 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. –...
  • Page 97 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 98 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 99 Maintenance Lift mast  DANGER Poor visibility The screen must be installed and correctly attached. Do not attach anything to the screen that could affect the visibility of the forks. When cleaning the fork carriage side, only clean the screen when the fork carriage is in the lowered posi- tion.
  • Page 100 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 101 Maintenance Storage and decommissioning Permanent Putting Out of Com- mission (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 102 Maintenance Storage and decommissioning  94 11628011551 EN - 11/2022  -  01...
  • Page 103 Technical specifications...
  • Page 104 Technical specifications Eco-design requirements for electric motors and variable speed drives Eco-design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation (EU) 2019/1781 because these motors do not meet the description giv- en in Article 2 "Scope", Item (1) (a) and be- cause of the provisions in Article 2 (2) (h) "Motors in cordless or battery-operated equip-...
  • Page 105 ......Oil Safety Information....15 General view of EXD 18C and EXD 20C Safety information for handling hydraul- trucks.
  • Page 106 Index Safety Inspection....22 Serial number..... . Handling a single load.
  • Page 108 STILL GmbH 11628011551 EN - 11/2022  -  01...

This manual is also suitable for:

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