Still EXD 18 Original Instructions Manual Download Page 113 | Manualshive

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Checking the hydraulic system for leaks
Checking the lift cylinders and pipes for leaks
Lift mast
Checking the condition and wear of the chains, and lubricating them
Adjusting the length of the mast chain
Checking the guard grille

3000-hour maintenance plan

Depending on the application, environmental conditions and driving style, the following proce-

dures should be carried out every 3000, 6000 and 9000 hours

Information
Carry out all 1000-hour maintenance work
Transmission
Carrying out maintenance on the transmission gear
Hydraulics
Draining the hydraulic system
Lift mast
Carrying out maintenance on the lift mast

Maintenance

5

3000-hour maintenance plan

103

1160 801 15 51 EN - 02/2021 - 11

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Summary of Contents for EXD 18

Page 1: ...Double pallet stacker EXD 18 Original instructions 0285 0286 0294 0295 1160 801 15 51 EN 02 2021 11 ...

Page 2: ......

Page 3: ... 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 Preface I 1160 801 15 51 EN 02 2021 11 ...

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Page 5: ...on of symbols used 9 Disposing of components and batteries 9 2 Safety Safety regulations 12 Safety regulations for handling consumables 13 Permissible consumables 13 Oils 13 Hydraulic fluid 14 Battery acid 14 Disposal of consumables 15 Emissions 16 Noise emission values 16 Vibration characteristics for vibrations to which the body is exposed 16 Residual dangers residual risks 17 Stability 17 Defin...

Page 6: ...g the horn 38 Truck operating instructions 39 Driving 41 Driving safety instructions 41 Driving 42 Optispeed 43 Braking 44 Parking brake 44 Creep Speed function 45 Standby optional 45 Driving on upward and downward slopes 46 Operating the FleetManager option 47 Description of the FleetManager option 47 Commissioning a truck equipped with the FleetManager option 48 FleetManager option Colour code f...

Page 7: ...y 80 Replacing a vertical access battery with the Autolift option 81 Replacing the side access battery 82 Handling the truck in an emergency 86 Emergency mast lowering 86 Towing the truck 87 Handling the truck in specific situations 89 Slinging the truck 89 Hoisting the truck 90 Transporting the truck 91 Transporting the truck in the lift 91 Driving on loading bridges 91 5 Maintenance General main...

Page 8: ...d rollers 107 Stabiliser maintenance 108 Regular maintenance of the transmission gear 109 Electrical equipment 110 Servicing the electrical system 110 Fuses 110 Checking the battery acid level and electrolyte density 111 Checking the condition of cables terminals and battery connector 112 Servicing the pump motor 112 Service the on board charger 113 Cleaning the sensors for the Autolift option 113...

Page 9: ...6 Technical specifications EXD18 datasheet 124 Mast types 129 Table of contents VII 1160 801 15 51 EN 02 2021 11 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...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 pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Theref...

Page 13: ...ddi tion to the tow tractor can compromise safety thereby invalidating the EC declaration of con formity The EC declaration of conformity must be carefully stored and made available to the re sponsible 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 ...

Page 14: ...liance declaration STILL S A S The manufacturer declares that the truck com plies with the requirements of the EC direc tives 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 inva lidating the EC declaration of conformity The EC declarati...

Page 15: ...r area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks 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 conta...

Page 16: ...t the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given in...

Page 17: ...r by scanning the QR code displayed to the side When the web page is open please type in the following password Spareparts24 On the next screen please enter your email address and truck serial number to receive the link by email Then download the spare parts list 2511 Introduction 1 Spare parts list 7 1160 801 15 51 EN 02 2021 11 ...

Page 18: ...e 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 meas u...

Page 19: ...ysical 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 m...

Page 20: ...Introduction 1 Disposing of components and batteries 10 1160 801 15 51 EN 02 2021 11 ...

Page 21: ...2 Safety ...

Page 22: ...llets 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 instru...

Page 23: ...eek 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 a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined wi...

Page 24: ... plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the regulations Dispose of old hydraulic fluid according to reg ulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and consumption In case of injury seek medical advice immediately WARNING Battery aci...

Page 25: ...ly be carried out in areas designated for this purpose Take care to minimise as far as pos sible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of battery acid must be neutral ised immediately Safety 2 Safety reg...

Page 26: ...al factors and other sources of noise Vibration characteristics for vibrations to which the body is exposed The values were determined according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb vi brations Vibration characteristics 2 5 m s2 NOTE The vibration characteristics for bodily vibra tio...

Page 27: ...e load being unsta ble or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and ground conditions The stability of the truck has been tested to the latest standards These standards only take account of the static and dynamic tilting forces that...

Page 28: ...ion of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per sons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of behav iour The driver ...

Page 29: ...s responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use Safety 2 Definition of responsible persons 19 1160 801 15 51 EN 02 2021 11 ...

Page 30: ...il at least a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring that any defects are remedied immediately Contact your servic...

Page 31: ...3 Overviews ...

Page 32: ...rgency stop handle Display Traction controller Stabiliser wheel Drive wheel 1 2 3 4 5 6 7 8 Tank Load arms Load wheels or bogies Pump unit On board charger Fork arms Mast cylinder 9 10 11 12 13 14 15 Overviews 3 Overview 22 1160 801 15 51 EN 02 2021 11 ...

Page 33: ...g Proportional lowering of fork arms Proportional lifting of fork arms Horn 1 2 3 4 5 Travel throttle valve Anti crush safety feature Travel throttle valve Lowering the load arms 6 7 8 9 Overviews 3 Operating and display devices 23 1160 801 15 51 EN 02 2021 11 ...

Page 34: ...uous red con tinuous green 3 Once the diodes have gone out the digicode automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0 to 9 Deleting operator codes 2 red off green flash ing 2 deletio...

Page 35: ...ult if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 s if not in use Minimum setting 10 s maximum 3000 s Deactivating the automatic switch off 2 0 red off green flash ing 2 command ac cepted Overviews 3 Operating and display devices 25 1160 801 15 51 EN 02 2021 11 ...

Page 36: ...00 10 bars 1 10 1 bar 0 1 flashing bar lift func tion not permitted NB To protect the battery 0 corresponds to max 80 discharge 2 Service alarm red 1 Flashing less than 50 hours truck operation until the next service 2 Constant Service date overdue 3 Red indicator light Switched on default or alarm Overviews 3 Operating and display devices 26 1160 801 15 51 EN 02 2021 11 ...

Page 37: ...starts running when the machine is switch ed on and a control is used When counting the dot next to the tenths of an hour flashes The hour meter displays hours and tenths of an hour When the power supply is disconnected the hours are stored in the memory 8 STOP alarm red Miscellaneous problems Do not operate the truck 9 T alarm red Constant control module overheating Truck is stopped In general wa...

Page 38: ...y only on the in side of the tiller Never touch with hands label 01 02 03 04 Sling hook label see operating instructions Double pallet stacker label Mast safety label Still label on the mast cylinders at both sides Cold store label 05 06 07 08 09 Overviews 3 Markings 28 1160 801 15 51 EN 02 2021 11 ...

Page 39: ...mber 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 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 29 1160 801 15 51 EN 02 2021 11 ...

Page 40: ...Overviews 3 Markings 30 1160 801 15 51 EN 02 2021 11 ...

Page 41: ...4 Use ...

Page 42: ...sts for heights ranging from 1574 to 2024 mm The cylinders are equipped with end of travel dampers which enables the carriage to be lowered gradually Braking The truck is equipped with two braking sys tems an electric counter current brake upon accelerator release by reversing the drive direction controlled by the rear safety button an electromagnetic brake electromagnetic safety controlled by the...

Page 43: ...ckrest Creep Speed Creep Speed Proportional speed Proportionnal Speed Built in charger on versions of battery with vertical access only and non cold store ver sions Central refilling system Cold store 35 C Use 4 Technical description 33 1160 801 15 51 EN 02 2021 11 ...

Page 44: ...ion Ensure the visible area specified by the manufacturer is observed Attachment parts special equipment must be properly secured and function according to their operating instructions Damaged or missing stickers must be re placed in compliance with the marking posi tion table The guard grille must be intact and securely mounted The roller guide rails must be coated in a visible layer of grease Th...

Page 45: ...rtoise mode The truck will function even if the key is removed Selecting the driving mode NOTE The switch key can rotate to two different posi tions These two positions choose the operat ing mode Tortoise position 2 gentle acceleration and deceleration maximum speed 4 km h Hare position 3 strong acceleration and deceleration maximum speed 6 km h Check the battery charge on the combined indicator 4...

Page 46: ... 1 area and cuts traction Check emergency shutdown Pull the emergency stop handle 1 The power supply to the machine is cut off The electrical controls and motors are no longer supplied The electromagnetic brake is applied Press in the emergency stop handle 1 then enter the code or turn the switch key to have the functions available again NOTE Ensure the stabiliser wheels operate correctly This inf...

Page 47: ...comes into contact with the driv er s body When the operator moves away from the anti crush safety device the machine stops even if a drive direction is selected again Normal operation may be resumed after re leasing the drive switches 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...

Page 48: ...Checking the horn Press the horn button 5 located on the up per part of the tiller The horn sounds Use 4 Checks and actions prior to commissioning 38 1160 801 15 51 EN 02 2021 11 ...

Page 49: ... could tip over when break ing or cornering The loads must be consistent with a maxi mum recommended height of 2 m For uses other than those shown above please consult the After Sales Service Centre It is important to use pallets that are in good condition Speed must be reduced when moving over obstacles to prevent the truck from becoming unbalanced and vibrations in the operator s arms The trucks...

Page 50: ...safe braking distance from vehicles or people in front of him The driver must avoid stopping suddenly making U turns too quickly and overtaking in dangerous areas with poor visibility CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 40 1160 801 15 51 EN 02 2021 11 ...

Page 51: ...ibility Driving the truck while sitting on top of it is prohibited These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the truck to drive it The truck must not be used as a stepladder This truck is not designed to transport peo ple The operator must always stay within the truck clearance Stay in the safety area working area de fine...

Page 52: ...travel Press the lower part of the drive direction selector with your thumb The speed increases with the movement of the drive direction selector The speed is limited to 4 or 6 km h depending on the po sition of the key When the drive direction selector is re leased the truck brakes electrically Reverse travel Press the upper part of the drive direction selector with your thumb The speed increases...

Page 53: ...ke is applied and the traction motor is switched off In zone 3 the truck can be used at full speed The traction speed is proportional to the drive direction selector activation In zone 2 the maximum authorised speed varies according to the position of the tiller Brake action zone Maximum speed authorisation zone Maximum speed automatic authorisation zone Maximum speed curve A B C D Use 4 Driving 4...

Page 54: ...irection selector 2 or 3 during operation Moderate braking Move the drive direction selectors 2 or 3 in the opposite drive direction Parking brake Release the drive direction switch 2 or 3 The truck is braked with the electromagnetic brake when its speed approaches 0 km h or when the tiller returns to the vertical position Use 4 Driving 44 1160 801 15 51 EN 02 2021 11 ...

Page 55: ...r of forklift operator being trapped by the truck Gently move the drive switch to adjust the truck speed This prevents it moving too quickly towards the operator NOTE If the operator releases the Creep Speed but ton and or the drive switch the vertical posi tion of the tiller applies the emergency brake again Standby optional The truck can be put in energy saving mode to prolong the service life o...

Page 56: ... and compatible with the truck s technical specifications can be safely used The operator must ensure that the ground is clean and has a non slip surface Never travel across slopes or make a U turn on the slope Do not park the truck on a slope Reduce speed when going down slopes Please observe the maximum gradients de fined as suitable for laden and unladen trans port 0252_003 015 Use 4 Driving 46...

Page 57: ... with antenna The options available on the truck are Access control Access control and shock sensor Access control and GPRS module Access control shock sensor and GPRS module 1 GPRS General Packet Radio Service 2 GSM Global System for Mobile Communi cation Shock sensor This sensor allows you to record the shocks received by the truck If the truck receives a shock it is possible to configure a spee...

Page 58: ...er key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or the RFID transponder 4 in front of the read...

Page 59: ...enter the PIN code Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The operator has been granted ac cess authorisa tion But the peri od of validity has expired Use the interface to enter a new pe riod of validity The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously Green colour Memory is 80 full Clear the...

Page 60: ...uickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 50 1160 801 15 51 EN 02 2021 11 ...

Page 61: ...a safe place Press the button 3 to log off Keep the but ton pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to swit...

Page 62: ...he LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 52 1160 801 15 51 EN 02 2021 11 ...

Page 63: ... WARNING Take care not to trap hands or feet when operating the truck Grabbing a loading unit Watch out for the following elements the load must be well balanced and centred correctly between the fork arms the fork arms must be sufficiently slid un derneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms protrude too far out from the l...

Page 64: ... is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 54 1160 801 15 51 EN 02 2021 11 ...

Page 65: ...er is in the rest position The truck has two lift systems Main Lift Fork arms lifting Press the proportional control button 2 Fork arms lowering Press the proportional control button 1 NOTE A groove 3 is present on each side of the button This helps you to feel the button and to identify it even if there is not much light The fork arms are lowered to the lowest posi tion It is always possible to s...

Page 66: ...Base lift Lifting the load arms Press button 4 Lowering the load arms Press button 5 Use 4 Transporting loads 56 1160 801 15 51 EN 02 2021 11 ...

Page 67: ... the lift height determine the maximum load weight Check the pallet is in good condition EXD18 capacity in stacker and pallet truck mode EXD18 800 kg EXD18 capacity in double stacker mode EXD18 800 kg on the fork arms and 1000 kg on the load arms Reading the capacity label with initial lift Example using a EXD18 with initial lift fitted with a 2024 mm standard mast 1 Model EXD18 2 Maximum lift hei...

Page 68: ...d CAUTION Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads with a small space between them to prevent them hooking onto one another Picking up a load from the ground Use the initial lift to raise a load of up to 1800 kg several centimetres from the ground DANGER Ensure that the pallet is in good condition before commencing any operat...

Page 69: ...w less comfortable Do not drive with an unstable load If visibility is poor let someone guide you Raise the forks slightly in order to pass ob stacles Be careful of low passageways low door ways scaffolding pipes etc Check that the width of the load is not greater than the width of the aisle To facilitate movement over obstacles in crease the ground clearance Check that the width of the load is no...

Page 70: ... lift control to disengage the load from the stor age area Drive the truck to the required location Lower the load arms completely Raise the forks clearly above the level where the load is to be placed Drive the truck forward into the racking Lower the load until the forks are freed Withdraw the machine in a straight line Lower the forks again to several centime tres from the ground DANGER Risk of...

Page 71: ...m the racking Reverse the truck slowly to move the pallet Lower the forks again with the load a few centimetres from the ground Before leaving the machine CAUTION Always stop the machine on level ground away from traffic routes Lower the forks to the lowered position Switch off the ignition In the case of a prolonged standstill pull the emergency stop handle and disconnect the battery Use 4 Transp...

Page 72: ...y of the machine refer to the capacity plate The heavier load must be placed on the load arms Picking up two loads Lower the load arms Raise the forks to the correct height to load the upper pallet Carefully move the forks forward under the pallet Raise the forks 1 to lift the upper load Reverse the truck slowly in a straight line to withdraw the first load Move forward slowly to pick up the secon...

Page 73: ...of poor visibility move slowly and carefully and work with guidance Do not travel with a load Q1 on the forks if there is no load Q2 on the load arms above 300 mm from the ground It is imperative that the heavier of the two loads Q2 be placed down on the load arms Keep the upper load Q1 as close as possi ble to load Q2 at all times Setting down two loads Carefully move the truck to the desired are...

Page 74: ... Lower the forks again WARNING The initial lift or lowering operation load arms is matched by the forks Use 4 Transporting loads 64 1160 801 15 51 EN 02 2021 11 ...

Page 75: ...ifting and automatic lowering of the forks The forks are adjusted to the ideal height depending on the load added or removed from the pallet The truck is equipped with sensors 1 that en able the load on the forks to be detected and the height to be adjusted Automatic lifting and lowering occurs between 300 mm and 800 mm WARNING Risk of crushing feet It is advisable to wear safety shoes Do not put ...

Page 76: ...s When using Autolift nobody should lean on the mast or the sensor guard plate Loading goods DANGER In case of danger press one of the two emergency off switches 3 located on either side of the unit It is also possible to pull the truck s emergency stop han dle When loading goods the load must be cen tred on the forks in order for the sensors to de tect it accurately To load the forks proceed as f...

Page 77: ...the height of the forks The forklift oper ator can load until the forks are lowered to 300 mm Unloading goods Turn the Autolift 2 turning knob to the Lift 4 position Press the green illuminating button 1 A beep sounds before activation The green button is illuminated Remove the goods on the forks The rest of the goods must be distributed evenly so that the sensors work correctly The Autolift funct...

Page 78: ... between 30 C and 45 C Specific rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room temperature zone may result in the formation of condensation water This water can freeze when the truck goes bac...

Page 79: ... 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 They could be permanently damaged Use 4 Cold store usage optional 69 1160 801 15 51 EN 02 2021 11 ...

Page 80: ...n Stopping the truck Bring truck to a controlled stop Lower the forks Switch off the ignition then remove the key or press the button on the digicode for 2 seconds Pull the emergency stop handle Restarting work Put the key back in the ignition or enter the 5 digit code on the electronic key default code 12345 Press the emergency stop handle Use 4 Stopping the truck 70 1160 801 15 51 EN 02 2021 11 ...

Page 81: ...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 It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro d...

Page 82: ...sition Opening closing the battery cover Opening Bring truck to a controlled stop Lower the forks Turn off the ignition and remove the key Pull the emergency stop handle Open the battery cover by lifting the plastic cover towards the mast Lock the cover in the vertical position using the support 1 Closing Lift the support 1 to unlock it Use 4 Handling the battery 72 1160 801 15 51 EN 02 2021 11 ...

Page 83: ...er it slowly Return the cover to the horizontal position CAUTION Keep fingers away from moving parts to avoid any risk of them being trapped Restart the truck Refit the battery cover To put the battery cover on the truck proceed as follows Position the axis 4 of the support 1 in the corresponding slot 3 Use 4 Handling the battery 73 1160 801 15 51 EN 02 2021 11 ...

Page 84: ...e the cover Battery charging using an external charger CAUTION The battery may be damaged if discharged beyond a given limit Immediately charge the battery Park the truck safely Before charging check the condition of the battery cable and the charger cable Re place them if necessary Open the cover and leave open Use 4 Handling the battery 74 1160 801 15 51 EN 02 2021 11 ...

Page 85: ...acturers equalising charge WARNING Risk of damage short circuit or explosion Do not place any metallic objects or tools on the bat tery Do not smoke WARNING The electrolyte diluted sulphuric acid is toxic and very caustic Follow the safety regulations when handling battery acid WARNING Explosive gases are generated during battery charg ing Ensure the work area is well ventilated Make sure that the...

Page 86: ...ed alone out of the truck To stay permanently connected to the bat tery To operate in all positions Remain connected to the mains during peri ods of truck downtime to ensure the availa bility of the machine To tolerate opportunity charging CAUTION Risk of damage to the mains cable resulting in elec tric shock and or burns Park the truck very close to the wall mounted mains socket to avoid tensioni...

Page 87: ...stops This can happen when a battery has a short circuited component Simply reset the mains to clear the fault Temperature safety As the charger is cooled by ventilation the air inlets and outlets must never be blocked The fan runs when the mains power is con nected It stops when charging is complete or when the mains power is disconnected The charger supplies reduced power if the ambient temperat...

Page 88: ...truck as sembly Continuously lit Continuously lit Polarity inver sion of the battery Off Off Selector in neutral posi tion Flashing Flashing CAUTION It is strictly prohibited to use an on board charger other than the one recommended 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 checked regularly as part of pe...

Page 89: ...d CAUTION Risk of premature damage to the battery Ensure that the charger setting corresponds to the type of battery If the battery is changed ensure that the setting cor responds to the type of battery The four thick lines indicate the four charging curves open lead acid battery with a capacity less than or equal to 210 Ah open lead acid battery with a capacity equal to or exceeding 210 Ah GEL ba...

Page 90: ...dle and re move it Open the battery hood Place the battery connector on the battery cells Remove the battery hood 1 Attach the slinging hooks to the battery case NOTE Using secured hooks is recommended Lift the battery Take care not to hook onto the upper bridge piece of the mast Replace the battery Position the new battery carefully in the chassis Guide it to the end of travel Remove the sling ho...

Page 91: ... 1 to release the Autolift unit Remove the Autolift unit 2 on the side of the truck A cable 3 holds it in place and prevents it from falling Handle the Autolift unit carefully Ensure that the detection cam is not pressed in Open the battery hood Place the battery connector on the battery cells Attach the slinging hooks to the battery case NOTE Using secured hooks is recommended Lift the battery Ta...

Page 92: ...The battery is a heavy and fragile component which must be handled with care Wearing gloves is recom mended Replacing the side access battery WARNING Risk of trapping Wear safety shoes and gloves to replace the battery To remove the battery we recommend that you use a fixed roller frame or a truck with ex traction rollers fitted with rollers for easier handling of the battery Immobilise the truck ...

Page 93: ...ion the truck in the upright position with extraction rollers or the roller frame 3 near the battery compartment on level ground Press the lever 4 with one hand and raise the joystick 5 with the other hand The locking bar 6 raises slightly Use 4 Handling the battery 83 1160 801 15 51 EN 02 2021 11 ...

Page 94: ... Fully raise the locking bar 6 Lift the stop 7 The stop is magnetic so that it can be perfectly positioned in the bat tery hood Use 4 Handling the battery 84 1160 801 15 51 EN 02 2021 11 ...

Page 95: ...d of the compart ment Fold the stop 7 down Fully lower the locking bar 6 Close the battery hood Reconnect the battery connector Return the truck to service WARNING Before restarting the truck ensure that the battery is correctly installed and that it is properly locked Use 4 Handling the battery 85 1160 801 15 51 EN 02 2021 11 ...

Page 96: ...tion is to be performed as follows Remove the plug 3 from the white pipe Place a large container under the white pipe 2 Loosen the screw 1 using a 7 mm span ner The oil will then flow and the mast will lower gradually DANGER Danger of death Do not walk underneath raised loads Check that no one is in the danger area before man ually lowering the mast Use 4 Handling the truck in an emergency 86 1160...

Page 97: ...Risk of damaging the truck This procedure must be carried out by authorised personnel Remove the load if necessary Disconnect the battery connector Remove the hood of the technical compart ment Two M5 X 30 screws are required Screw the screws into the brake 2 in the holes 3 This will unlock the brake Close the hood of the technical compart ment CAUTION Risk of injury The truck must only be towed a...

Page 98: ... Close the hood of the technical compart ment Use 4 Handling the truck in an emergency 88 1160 801 15 51 EN 02 2021 11 ...

Page 99: ... Lower the forks Turn off the ignition and remove the key Pull the emergency stop handle Remove any items that could fall Protect all parts that come into contact with the lifting device 2 Hook the lifting device 2 onto the sling hook only 1 Lift the truck slowly and carefully NOTE Never sling the truck by the tiller or other points not designed for this DANGER Risk of falling Personnel must not s...

Page 100: ... lifting capacity To lift the front section of the truck place a jack under the chassis 1 For safety rea sons chock with a piece of wood For work on the lifting device the jack must be placed under the battery frame 2 To service the load wheels the jack must be fitted under the load arms as illustrated 3 WARNING Immobilise and chock the machine after lifting it Use 4 Handling the truck in specific...

Page 101: ...ck Transporting the truck in the lift The truck must only be taken in lifts with an adequate loading capacity that are designed for this purpose and for which authorisation has been received from the operator Inside the lift the truck must be immobilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be observ...

Page 102: ...Use 4 Handling the truck in specific situations 92 1160 801 15 51 EN 02 2021 11 ...

Page 103: ...5 Maintenance ...

Page 104: ...sh conditions extreme heat or extreme cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use during maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix different qualities of...

Page 105: ...w the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by persons...

Page 106: ...personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pre...

Page 107: ...mage that may be expensive to rectify Transmission gear oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray If in doubt please ask your local dealer for ad vice You should also consult your local dealer if a representative of an oil company offers you an oil product that is not specified in these operating instructions Multi purpose grease Lithium soap grease extreme...

Page 108: ...n gear oil 0 9 litre max Traction and pump motor 125 A power circuit fuse Quantity 1 Control cable harness 7 5 A control circuit fuse Quantity 1 Traction motor Maintenance free 1 2 kW AC Pump motor Maintenance free 1 2 kW Battery Distilled water As required Joints Lithium soap grease As required Maintenance 5 Technical data for inspection and maintenance 98 1160 801 15 51 EN 02 2021 11 ...

Page 109: ...ore removing anything from the truck Switch off the ignition Pull the emergency stop handle Opening the lower cover Unscrew the 2 screws 1 that hold the hood in place Unclip the cover at both ends Raise and pull back the lower cover Maintenance 5 Access to the technical compartment 99 1160 801 15 51 EN 02 2021 11 ...

Page 110: ...rews 2 that hold the front hood in place Opening the intermediate cover After removing the lower cover then the front cover Unscrew the 2 screws 3 that hold the in termediate cover in place Maintenance 5 Access to the technical compartment 100 1160 801 15 51 EN 02 2021 11 ...

Page 111: ...essary to remove the cover behind the tiller Turn the tiller to the right or left hand stop Release the 2 screws 3 Unscrew the 2 screws 2 located either side of the two 1 2 covers Remove the two 1 2 covers Maintenance 5 Accessing the reducer and the brake 101 1160 801 15 51 EN 02 2021 11 ...

Page 112: ...ng on the application environmental conditions and driving style the following proce dures should be carried out every 1000 2000 4000 7000 and 8000 hours Preparation Cleaning the truck Check the error codes using the diagnostic tool Chassis and equipment Checking the condition of the forks Checking that the brake system operates correctly Checking the condition of the pump motor unit Wheels Checki...

Page 113: ...tenance plan Depending on the application environmental conditions and driving style the following proce dures should be carried out every 3000 6000 and 9000 hours Information Carry out all 1000 hour maintenance work Transmission Carrying out maintenance on the transmission gear Hydraulics Draining the hydraulic system Lift mast Carrying out maintenance on the lift mast Maintenance 5 3000 hour mai...

Page 114: ...to moisture par ticularly electric components must be protected when the truck is cleaned Follow the manufacturer s instructions when using the cleaning product Clean the truck with a non flammable clean ing product mixed with water a sponge and cloths Specifically clean the oil filler holes and sur rounding area as well as the lubricating nip ples before lubrication NOTE A frequently cleaned truc...

Page 115: ...enance The plugs on the battery cells must always be dry and clean Neutralise any spilt battery acid immediately The battery terminals and lugs must be clean lightly covered with grease for terminals and securely tightened Charging the battery During the charging process the surface of the battery cells must be clear to ensure suffi cient ventilation Do not place metal objects on the battery The b...

Page 116: ... not expose the charger to water rain oils grease or any similar substances The charger becomes hot during the operation CAUTION Do not obstruct the ventilation Allow the charger to cool down for 10 minutes after charging is complete before touching it Do not use the charger out of the truck Check the condition of the forks Check that the fork arms 1 show no signs of deformation splits heavy wear ...

Page 117: ... 2 and rollers 3 should show no signs of deterioration Replace damaged or worn wheels with new wheels Replace damaged or worn rollers with new rollers NOTE Contact the After Sales Service Centre re garding the replacement of wheels and rollers Maintenance 5 Steering and wheels 107 1160 801 15 51 EN 02 2021 11 ...

Page 118: ...e damper cylinder This cylinder must be in side the spiral spring no damage to the rollers 3 The wheels must rotate freely no locking at the level of the upper bearing 4 ensure that the wheel nuts are correctly tightened WARNING Risk of loss of dynamic stability The dynamic behaviour of the device must be moni tored particularly when taking bends The behaviour of the truck must be the same when co...

Page 119: ...fe of the transmission gear 2 grease nipples 1 have been added to its turntable It is therefore possible to regularly lubricate the transmission gear NOTE Use the lubricants recommended by the man ufacturer Maintenance 5 Steering and wheels 109 1160 801 15 51 EN 02 2021 11 ...

Page 120: ...s Fuses CAUTION Electricity danger Before carrying out any work on the electric installa tion turn the power supply off Disconnect the bat tery connector for this purpose Remove the front cover to gain access to the fuses Check that the following two fuses are cor rectly secured The 125A fuse 1 protects the traction and lift ing power circuit The 7 5 A fuse 2 protects the control circuits This ope...

Page 121: ... water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety information provided by the battery manufacturer Comply with the regulations in force Check the battery acid level and electrolyte density according to the battery manufactur er s recommendations The cell covers of the battery must be kept dry and ...

Page 122: ...ition of the spindles of the mains socket No oxidation must be present and the wires must not be dam aged CAUTION The points mentioned above can cause serious inci dents In case of an incident contact our service en gineers as quickly as possible Servicing the pump motor Checking the electrical connections Check the mounting condition and insula tion of the pump motor cables 1 Eliminate any traces...

Page 123: ...bilised traction and lifting not permitted as long as the cord is connected to the 220 V supply Disconnect the mains cord NOTE In the event of a fault do not work on the charger Contact the After Sales Service Cen tre Cleaning the sensors for the Autolift option To ensure the correct operation of the Autolift option the sensors must be cleaned regularly Clean the sensors 1 thoroughly using a soft ...

Page 124: ...l leakage under the truck CAUTION In the event of a leakage contact the After Sales Service Centre Checking the oil level and sealing of the hydraulic system The hydraulic system includes a main tank located under the pump unit an additional tank located in the battery compartment The Drop of oil label 2 indicates that it is im portant to follow the indications in the manual The oil level is check...

Page 125: ...the battery hood Draining the hydraulic system A full hydraulic system contains 2 5 litres of oil To drain the hydraulic system the additional tank and the main tank must be drained Pro ceed as follows Keep the mast and the load arms in the raised position Switch off the ignition Pull the emergency stop handle Remove the front hoods to access the tech nical compartment Place a large container unde...

Page 126: ...rain any oil that may remain at the bottom of the tank Collect the oil in compliance with environ mental standards Remove any residual impurities from the bottom of the tank Filling up WARNING Do not operate the pump without oil Risk of destroying the pump Replace the tank O ring Fit the tank 7 into the technical compart ment Retighten clips 5 and 6 Remove the hood support mounting bracket 4 Pour ...

Page 127: ...raulic system by performing several fork and load arm lifting and lower ing operations CAUTION Only use hydraulic oil that complies with the specifi cations see lubrication table Maintenance 5 Hydraulic systems 117 1160 801 15 51 EN 02 2021 11 ...

Page 128: ...m Wait approximately 15 minutes before restart ing the truck Coat the chain 2 with spray for chains Lubricate the various bearings and friction points with oil Servicing the lift mast Raise the fork carriage and ensure that it cannot lower unexpectedly Checking the lift cylinders and connec tions for leaks Visually check the hydraulic connections and cylinders for leaks Tighten any leaking connect...

Page 129: ...be replaced Checking the guard grille Check that the guard grille 3 is correctly attached and in good condition Replace the guard grille if it is damaged Adhere to the number of fastenings as de fined by the manufacturer DANGER Risk of injury The grille must be installed and correctly attached Do not attach anything to the grille that could affect the visibility of the forks When cleaning the fork...

Page 130: ...ust not touch the ground in order to prevent ir reversible deformation of the tyres Cover the truck with a cotton cover to pro tect it from dust CAUTION We recommend that you do not use a plastic sheet as this encourages condensation to form Consult the service department for further measures to take if the truck must be stored for a longer period of time Recommissioning after storage If the truck...

Page 131: ...um iron etc Before scrapping the truck notify the com petent authorities of your country in writing After receiving the authorisation from the competent authorities remove any compo nents according to national standards NOTE The client is solely responsible for any irregu larities he has committed during or after the scrapping of the truck s components and the removal of components Maintenance 5 C...

Page 132: ...Maintenance 5 Commissioning and storage 122 1160 801 15 51 EN 02 2021 11 ...

Page 133: ...6 Technical specifications ...

Page 134: ...EXD18 datasheet DESCRIPTION 1 1 Manufacturer STILL GmbH 1 2 Model type EXD18 K EXD18 L Technical specifications 6 EXD18 datasheet 124 1160 801 15 51 EN 02 2021 11 ...

Page 135: ...g BS V 2PzS V 938 1716 949 1799 2 3 Load per unladen axle drive side load side 10 2 kg BS V 2PzS V 615 239 674 274 WHEELS EXD18 K EXD18 L 3 1 Tyres solid full soft inflatable polyurethane rubber Polyurethane 3 2 Drive wheel sizes Ø x L mm 230 x 75 3 3 Wheel sizes load side Ø x L mm 85 x 85 bogies 85 x 60 3 4 Additional wheels Ø x L mm Stabilisers 2x 125 x 40 3 5 Number of wheels at drive side load...

Page 136: ...m l2 mm BS V 2PzS V 709 764 4 21 Total width 5 mm b1 mm 720 4 22 Fork arm dimensions s e l mm 60 180 1190 4 23 Load arm dimensions s e l mm 60 107 1112 4 24 Fork carriage width 5 mm b3 m m 711 4 25 Outside fork spread b5 mm 540 560 540 560 4 26 Inside load arm spread b4 mm 540 560 210 230 4 32 Ground clearance at centre of wheelbase 2 mm m2 mm minimum maxi mum 20 145 4 33 Load dimension b12 x L6 c...

Page 137: ...5 2 Initial lifting speed LI 10 m s laden unla den 0 032 0 045 0 032 0 045 Main lifting speed LP 10 m s laden unla den 0 100 0 152 0 100 0 152 5 3 Initial lowering speed LI 10 m s laden unla den 0 081 0 075 0 081 0 075 Main lowering speed LP 10 m s laden unla den 0 251 0 171 0 251 0 171 5 7 Gradient laden unla den 5 8 Maximum gradient 5 minutes laden unla den 13 25 5 9 Acceleration time d 10 m s l...

Page 138: ...EOUS EXD18 K EXD18 L 8 1 Speed control LAC controller LAC 8 4 Noise level at operator s ears 5 dB A BS V 2 PzS V 65 Level of vibration felt by the op erator EN 13059 BS V 2 PzS V 2 5 1 In brackets pallet truck capacity on load arms 2 Weight according to line 2 1 3 With battery line 6 5 4 Ast pallet stacker 5 Ast pallet truck 6 With mast S2024 Technical specifications 6 EXD18 datasheet 128 1160 801...

Page 139: ...3 Lift mm 1574 1724 2024 h3 h13 Lift fork height mm 1660 1810 2110 h1 Mast height HT retracted mm 1290 1365 1515 h4 Mast height HT extended mm 2202 2352 2652 h2 Free lift mm 150 150 150 Technical specifications 6 Mast types 129 1160 801 15 51 EN 02 2021 11 ...

Page 140: ...Technical specifications 6 Mast types 130 1160 801 15 51 EN 02 2021 11 ...

Page 141: ...imatic conditions 8 Closing the battery cover 72 cold store 68 Cold store usage 68 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Description of the Autolift option 65 Description of use 8 Destruction 121 Digicode optional 24 Disposing of components and ...

Page 142: ...dering spare parts and consumables 95 Order picking 71 Overview 22 P Parking brake 44 Permanent Putting Out of Commission 121 Picking up a load from the ground 58 Picking up two loads 62 Precautions to be taken during battery maintenance 105 Prohibition of use by unauthorised persons 19 Proper usage 8 R Recommended lubricants 97 Refit the cover 73 Regular maintenance of the transmission gear 109 R...

Page 143: ...uck 91 Transporting the truck in the lift 91 Transporting two loads 63 Truck operating instructions 39 U Unauthorised use 9 Using the Autolift option 66 V Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Working on the electrical equipment 96 Index 133 1160 801 15 51 EN 02 2021 11 ...

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Page 146: ...STILL GmbH 1160 801 15 51 EN 02 2021 11 ...

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