Still EXD 20 User manual

Original instructions
Double pallet stacker
EXD 20
0307 0345
11638011551 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
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Table of contents
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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
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Table of contents
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3Overviews
Overview .......................................................... 20
General view of the truck .............................................. 20
General view of the technical compartment ................................ 21
Control and display components ......................................... 22
Driver'scompartment ................................................ 22
Display-operating unit ................................................ 23
Electronickey(option) ................................................ 24
Markings .......................................................... 26
Labels ............................................................ 26
Serialnumber ...................................................... 27
4Use
Technical description ................................................. 30
List of checks prior to start-up ........................................... 32
Starting up ........................................................ 33
Checks and actions prior to commissioning ................................. 35
Checkingtheanti-crushsafetydevice ..................................... 35
Checkingtheemergencyshutdown ...................................... 36
Checkingthebrake .................................................. 36
Checkingthehorn ................................................... 37
Truck operating instructions ............................................ 38
Using the display-operating unit ......................................... 40
Selectionbuttons .................................................... 40
Operationofthedisplayunit ............................................ 40
Driving safety guidelines .............................................. 44
Driving ............................................................ 45
Definingdirections ................................................... 45
Driving ............................................................ 45
Steering ........................................................... 46
Braking ........................................................... 47
Horn ............................................................. 48
Driveprogram ...................................................... 49
Creep Speed function ................................................ 50
Usingthetruckonaslop
e .............................................. 51
Operating the FleetManager™ option ..................................... 53
Description of the FleetManager option .................................... 53
Commissioning a truck equipped with the FleetManager™ option ................ 54
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FleetManager™ option: Colour code for the LEDs ........................... 55
Disconnecting a truck equipped with the FleetManager™ option ................. 57
Transporting loads ................................................... 59
Load handling safety rules ............................................. 59
Grabbing a loading unit ............................................... 59
Transporting pallets or othercontainers ................................... 60
Progressive stopping of the carriage in the lower position ...................... 61
Reading the capacity plate ............................................. 62
Liftcontrolelements ................................................. 64
Handling a single load . ............................................... 66
Handling two stacked pallets ........................................... 70
Driving assistance system: Dynamic Drive Control ........................... 73
DescriptionoftheDynamicDriveControl .................................. 73
Cold store usage (optional) ............................................. 74
Before leaving the truck ............................................... 76
Handling the battery .................................................. 77
Batterytype ........................................................ 77
Orderpicking ....................................................... 77
Opening and closing the battery hood ..................................... 78
Chargingthebatteryusinganexternalcharger .............................. 78
On-board charger ................................................... 80
Using the on-board charger ............................................ 81
Adjustingtheon-boardcharger .......................................... 83
Changing the vertical accessbattery ...................................... 83
Changing the side access battery ........................................ 84
Handling the truck in an emergency ...................................... 90
Emergency lowering of the mast ......................................... 90
Truck towing procedure ............................................... 91
Handling the truck in specific situations .................................... 93
Slingingthetruck .................................................... 93
Liftingthetruck ..................................................... 94
Transportingthetruck ................................................ 94
Transporting the truck inthelift .......................................... 95
Driving on loading bridges ............................................. 95
5 Maintenance
General maintenance information ........................................ 98
General .......................................................... 98
Servicing and maintenance personnel training and qualification . ................. 99
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Batterymaintenancestaff .............................................. 99
Maintenance operations that do not require special training ..................... 99
Ordering spare parts and consumables .................................... 99
Safety guidelines for maintenance .......................................100
Servicingandmaintenancemeasures ....................................100
Working on the electrical equipment ......................................100
Safetydevices .....................................................100
Technical data for inspection and maintenance ..............................101
Recommended lubricants .............................................10
2
Accessing the technical compartment ....................................103
1000-hour service plan ................................................104
5000-hour maintenance plan ...........................................105
10,000-hour service plan ..............................................105
Chassis, bodywork and fittings ..........................................106
Cleaning the truck ...................................................106
General information on battery maintenance ...............................108
Checkingtheconditionoftheforks .......................................109
Steering and wheels ..................................................11
0
Cleaning the pinion gear of the steering geared motor .........................110
Checking the condition of the wheels .....................................111
Stabiliser maintenance ...............................................111
Electrical equipment .................................................112
Cleaning and blowing air through the electrical components ....................112
Checking the battery acidlevelandelectrolytedensity ........................113
Checking the condition of the cables, terminals and battery connector . . . ..........114
Hydraulic systems ...................................................115
Checking the hydraulicsystemforleaks ...................................115
Checkingthehydraulicoillevel ..........................................115
Checkingthecontrolledstabiliserhydraulicsystemforleaks ....................116
Checking the oil levelinthecontrolledstabilisercircuit .........................117
Lift mast ...........................................................118
Cleaning and lubricating the chains .......................................118
Adjusting the lengthofthemastchains ....................................118
Checkingtheprotectivescreen ..........................................119
Storage and decommissioning ..........................................120
Storage of truck .....................................................120
Permanent Putting Out of Commission (Destruction) .........................121
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Table of contents
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6 Technical specifications
EXD20 datasheet ....................................................124
EXD20 mast types ...................................................128
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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.
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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.
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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.
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Introduction 1
Identification label
1 Model
2 Manufacturer
3 Serial number
4 Year of manufacture
5 Unladen weight (without battery) in kg
6 Battery maximum weight
7 Battery minimum weight
8 Additional weight (ballast) in kg
9 Nominal motor power (kW)
10 Battery voltage V
11 Rated 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:
•Informatio
n 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
•Inform
ation on transport, initial commis-
sioning and storage of industrial trucks
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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.
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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.
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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
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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.
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