Still EXD 18 User manual

Original instructions
Double pallet stacker
EXD-18
0285 0286 0294 0295
1160 801 15 51 EN - 09/2019

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
1160 801 15 51 EN - 09/2019 I

Table of contents
g
1 Introduction
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 3
Copyrightandpropertyrights ............................................ 3
EC declaration of conformity............................................. 4
Identification label .................................................... 5
Rules for the operating company of industrial trucks ........................... 5
Proper usage ....................................................... 7
Description of use and climatic conditions ................................... 7
Unauthorised use ..................................................... 8
Explanation of symbols used ............................................ 8
Disposing of components and batteries ..................................... 8
2Safety
Safety regulations ................................................... 10
Safety regulations for handling consumables ............................... 11
Permissibleconsumables ............................................. 11
Oils .............................................................. 11
Hydraulicfluid ...................................................... 12
Batteryacid ........................................................ 12
Disposalofconsumables .............................................. 13
Emissions ......................................................... 14
Noiseemissionvalues ................................................ 14
Vibration characteristics for vibrations to which the body is exposed . . . ............ 14
Residual dangers, residual risks ......................................... 15
Stability ........................................................... 15
Definition of responsible persons ........................................ 15
Operatingcompany .................................................. 15
Specialist .......................................................... 16
Drivers ........................................................... 16
Safety tests ........................................................ 17
Regular safety inspection of the truck ..................................... 17
1160 801 15 51 EN - 09/2019 III

Table of contents
g
3Overviews
Overview .......................................................... 20
Overview ......................................................... 20
Control and display components ......................................... 21
Tiller ............................................................. 21
Digicode (optional) .................................................. 22
Batterychargingindicator .............................................. 24
Markings .......................................................... 26
Locationofmarkings ................................................. 26
Serialnumber ...................................................... 27
4Use
Technical description ................................................. 30
List of checks prior to start-up ........................................... 32
Checks and actions prior to commissioning ................................. 33
Start-up ........................................................... 33
Checkingthebrake .................................................. 34
Checkemergencyshutdown ........................................... 34
Checkingtheanti-crushsafetydevice ..................................... 35
Checkingthehorn ................................................... 36
Truck operating instructions ............................................ 37
Driving ............................................................ 39
Driving safety instructions .............................................. 39
Driving ............................................................ 40
Optispeed ......................................................... 41
Braking ........................................................... 42
Parkingbrake ...................................................... 42
Creep Speed function ................................................ 43
Standby(optional) ................................................... 43
Driving on upward and downward slopes .................................. 44
Operating the FleetManager™ option ..................................... 45
Description of the FleetManager option .................................... 45
Commissioning a truck equipped with the FleetManager™ option ................ 46
FleetManager™ option: Colour code for the LEDs ........................... 47
Disconnecting a truck equipped with the FleetManager™ option ................. 49
Transporting loads ................................................... 51
Loadhandlingsafetyrules ............................................. 51
Grabbing a loading unit ............................................... 5
1
Transportingpalletsorothercontainers ................................... 52
IV 1160 801 15 51 EN - 09/2019

Table of contents
g
Liftcontrolelements ................................................. 53
Reading the capacity label ............................................. 55
Load handling ...................................................... 56
Handling two stacked pallets ........................................... 60
OptionAutolift ...................................................... 62
Cold store usage (optional) ............................................. 65
Stopping the truck ................................................... 67
Handling the battery .................................................. 68
Batterytype ........................................................ 68
Orderpicking ....................................................... 68
Opening/closingthebatterycover ........................................ 69
Battery charging using an externalcharger ................................. 71
On-board charger ................................................... 73
Using the on-board charger ............................................ 74
Adjusting the on-board charger .......................................... 76
Replacingtheverticalaccessbattery ..................................... 77
ReplacingaverticalaccessbatterywiththeAutoliftoption ...................... 78
Replacing the side accessbattery ....................................... 79
Handling the truck in an emergency ...................................... 83
Emergency mast lowering ............................................. 83
Towingthetruck ..................................................... 84
Handling the truck in specific situations .................................... 86
Slingingthetruck .................................................... 86
Hoistingthetruck .................................................... 87
Transportingthetruck ................................................ 88
Transportingthetruckinthelift .......................................... 88
Driving on loading bridges ............................................. 88
5 Maintenance
General maintenance information ........................................ 90
General ........................................................... 90
Servicing and maintenance personnel training and qualification . ................. 91
Battery maintenance staff .............................................. 91
Maintenance operations that do not require special training ..................... 91
Ordering spare partsandconsumables .................................... 91
Safety guidelines for maintenance ....................................... 92
Servicing and maintenance measures .................................... 92
Workingontheel
ectrical equipment ...................................... 92
Safetydevices ..................................................... 92
1160 801 15 51 EN - 09/2019 V

Table of contents
g
Recommended lubricants ............................................. 93
Technical data for inspection and maintenance .............................. 94
Access to the technical compartment ..................................... 95
Accessing the reducer and the brake ..................................... 97
Maintenance plan as required .......................................... 98
1000-hour/annual maintenance plan ..................................... 98
3000-hour maintenance plan ........................................... 99
Chassis, bodywork and fittings ..........................................100
Cleaning the truck ...................................................100
General information on battery maintenance ...............................101
Checktheconditionoftheforks .........................................102
Steering and wheels ..................................................103
Servicingthewheelsandrollers .........................................103
Stabiliser maintenance ...............................................104
Regular maintenance of thetransmissiongear ..............................105
Electrical equipment .................................................106
Servicingtheelectricalsystem ..........................................106
Fuses ........................................................... . 106
Checkingthebatteryacidlevelandelectrolytedensity ........................107
Checkingtheconditionofcables,terminalsandbatteryconnector ................108
Servicing the pump motor .............................................108
Service the on-board charger . ..........................................108
Cleaning the sensors for the Autolift option .................................109
Hydraulic systems ...................................................11
0
Checkingthehydraulicsystemforleaks ...................................110
Checkingtheoillevelandsealingofthehydraulicsystem ......................110
Draining the hydraulicsystem ...........................................111
Lift mast ...........................................................113
Liftingdevice .......................................................113
Servicing the lift mast .................................................113
Commissioning and storage ............................................115
Storageoftruck .....................................................115
Permanent Putting OutofCommission(Destruction) .........................116
6 Technical specifications
EXD18 datasheet ....................................................118
Mast types ........................................................123
VI 1160 801 15 51 EN - 09/2019

1
Introduction

1Introduction
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.
The driving permit must be obtained from the
appropriate office.
The truck has been fitted with state-of-the-
art technology. Following these operating
instructions will allow the truck to be handled
safely. By complying with the specifications in
these operating instructions, the functionality
and the approved features of the truck will be
retained.
Get to know the technology, understand it
and use it safely - these operating instructions
provide the necessary information and help to
avoid accidents and to keep the truck ready for
operation beyond the warranty period.
Therefore:
– Before commissioning the truck, read
the operating instructions and follow the
instructions.
– Always follow all of the safety information
contained in the operating instructions and
on the truck.
211
60 801 15 51 EN - 09/2019

Introduction 1
Your industrial truck
CE-Symbol
CE labelling
The manufacturer uses CE labellingtoindi-
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.
An independent structural change or an
addition to the tow tractor can compromise
safety, thereby invalidating the EC declaration
of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
Copyright and property rights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.
1160 801 15 51 EN - 09/2019 3

1Introduction
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.
Person authorised to compile the technical documents:
See EC compliance declaration
STILL S.A.S.
The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the EC labelling on the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
relevant authorities.
411
60 801 15 51 EN - 09/2019

Introduction 1
Identification label
1 Model
2 Manufacturer
3 Serial number
4 Year of manufacture
5 Unladen weight (without battery) in kg
6 Maximum battery weight
7 Minimum battery weight (for a lithium-ion
battery, the weight of the ballast container is
included)
8 Additional weight (ballast weight) in kg
9 Nominal motor power (kW)
10 Battery voltage in V
11 Nominal capacity in kg
12 EC conformity symbol
Identification label
NOTE
Indicate the serial number for all technical
enquiries.
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
•Inform
ation on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for the safe operation of
industrial trucks
• Information on the use of industrial trucks
•In
formation on transport, initial commis-
sioning and storage of industrial trucks
1160 801 15 51 EN - 09/2019 5

1Introduction
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.
611
60 801 15 51 EN - 09/2019

Introduction 1
Proper usage
Proper usage
The truck described in these operating in-
structions is suitable for lifting, transporting
and stacking loads.
The truck should only be used for the purposes
for which it was designed, as described in
these instructions.
If the truck needs to be used for purposes other
than those specified in these instructions, you
should first:
• Obtain permission from the manufacturer
• Obtain permission from the competent
authorities, if applicable
The purpose of obtaining these permissions in
advance is to limit danger as far as possible.
The capacity label specifies the maximum
load that can be raised. This limit must not be
exceeded.
Description of use and climatic conditions
Normal use
– Indoor and outdoor use.
– Ambient temperature in tropical and Nordic
regions ranging from -10°C to 45°C
– Start capability from -10°C to 45°C.
– Maximum start time of 20 seconds
– Use at up to 2000 metres above sea level.
Special use (partly with special mea-
sures) for trucks equipped with Gel or
Lead batteries
– Use, for example, in the event of abrasive
dust (such as AL203), lint, acid, leach, salt
and incombustible substances.
– Ambient temperature in tropical regions up
to 55 °C.
– Start capability at -25°C.
– Use at up to 3,500 metres above sea level.
1160 801 15 51 EN - 09/2019 7

1Introduction
Unauthorised use
Unauthorised use
Any danger caused as a result of unauthorised
use becomes the responsibility of the operator
or driver and not that of the manufacturer.
Use for purposes other than those described
in these operating instructions is prohibited.
Transporting people is prohibited.
The forklift truck should not be used in areas
where there is a risk of fire, explosion or
corrosion, or in areas that are particularly
dusty.
Stacking or unstacking is not permissible on
inclined surfaces or ramps.
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid life-threatening danger or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid damage to and/or destruction of equipment.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Disposing of components and batteries
The truck is made up of different materials.
If components or batteries must be replaced
and scrapped, they must be:
• disposed of
• treated or
• recycled in accordance with regional and
national regulations
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company when disposing of compo-
nents and batteries.
811
60 801 15 51 EN - 09/2019

2
Safety

2Safety
Safety regulations
Safety regulations
These operating instructions, which come
with the truck, must be communicated to all
those concerned and in particular to personnel
responsible for maintenance and driving.
The employer must make sure that the forklift
operator has properly understood all the safety
information.
Please observe the directives and safety
regulations attached, in particular:
• Information concerning the use of materials
handling trucks
• Regulations concerning traffic lanes and
working areas
• Appropriate behaviour, rights and responsi-
bilities of the driver
• Use in particular areas
• Information about the weight and dimen-
sions of pallets or any other container
• Information concerning starting, driving and
braking
• Information concerning maintenance and
repair
• Regular checks and technical inspections
• Recycling of lubricants, oils and batteries
• Residual risks.
Care is recommended both for the user and
the person in charge (employer) with regard to
adhering to all safety rules concerning the use
of material-handling trucks.
When instructing forklift operators, we recom-
mend the following points are emphasized:
• The features of the truck
• The special accessories
• The specific features of the working envi-
ronment.
Train the user in how to drive the truck, until it
is under proper control.
Then, and only then, proceed to transferring
pallets.
Forklift truck stability is guaranteed when the
unit is used correctly.
10 1160 801 15 51 EN - 09/2019

Safety 2
Safety regulations for handling consumables
Safety regulations for handling consumables
Permissible consumables
WARNING
Consumables can be dangerous.
It is necessary to follow the safety regulations when
handling these substances.
Refer to the maintenance data table for
the permissible substances necessary for
operation.
Oils
DANGER
Oils are flammable!
– Follow the statutory regulations
– Do not allow oils to come into
contact with hot motor parts.
– No smoking, fires or flames!
DANGER
Oils are toxic!
– Avoid contact and consumption
– In case of inhalation of steam or fu-
mes, breathe fresh air immediately.
– After contact with the eyes, rinse
thoroughly with water (for at least
10 minutes) and then consult an
eye specialist.
– If swallowed, do not induce
vomiting. Seek immediate medical
attention.
WARNING
Prolonged intensive contact with the
skin can result in loss of skin oils and
cause irritation.
– Avoid contact and consumption.
– Wear protective gloves!
– After any contact, wash the skin
with soap and water and then apply
askincareproduct.
– Immediately change soaked
clothing and shoes.
WARNING
There is a risk of slipping on spilled oil, particularly
when combined with water!
– Collect spilled oil immediately using an oil-
binding agent and dispose of it in accordance
with regulations.
ENVIRONMENT NOTE
Oils are water pollutants!
Always store oil in containers that comply with
the applicable regulations.
Avoid spilling oils.
Collect spilt oil immediately using an oil
binding agent and dispose of it in accordance
with regulations.
Dispose of old oils according to the applicable
regulations.
1160 801 15 51 EN - 09/2019 11

2Safety
Safety regulations for handling consumables
Hydraulic fluid
WARNING
During operation of the forklift truck,
hydraulic fluids are pressurised and
are hazardous to your health.
– Do not spill these fluids!
– Follow the statutory regulations
– Do not allow the fluids to come into
contact with hot motor parts.
– Do not allow to come into contact
with the skin.
– Avoid inhaling the spray
– Penetration of pressurised fluids
into the skin is particularly danger-
ous if these fluids escape at high
pressure due to leaks in the hydrau-
lic system. In case of such injury,
seek medical advice immediately.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
ENVIRONMENT NOTE
Hydraulic fluid is a water-polluting substance!
Always store hydraulic fluid in containers
complying with the regulations.
Avoid spilling.
Spilt hydraulic fluid should be removed with
oil-binding agents at once and disposed of
according to the regulations.
Dispose of old hydraulic fluid according to
regulations.
Battery acid
WARNING
Battery acid contains dissolved
sulphuric acid. This is toxic.
– Avoid contact and consumption.
–Incase
of injury, seek medical
advice immediately.
WARNING
Battery acid contains dissolved
sulphuric acid. This is corrosive.
–Whenwork
ingwithbatteryacid,
always wear protective clothing
and eye protection.
–Dono
t allow any acid to get onto
theclothingorskinorintothe
eyes; if this does happen, rinse
immediately with plenty of clean
water.
– In case of injury, seek medical
advice immediately.
– Immediately rinse away spilt
battery acid with plenty of water.
– Follow the statutory regulations
ENVIRONMENT NOTE
12 1160 801 15 51 EN - 09/2019