Still EXD 20 Original Instructions Manual Download Page 127

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Hydraulic systems

Checking the hydraulic system for

leaks

–

Switch off the truck and disconnect the bat-

tery connector.

–

Remove the hood of the technical compart-

ment.

–

Inspect the hydraulic system: pipes, hoses

and connections between the pump unit

and the cylinders.

–

Check the cylinders for leaks.

–

Check that the hoses are attached correctly

and show no signs of friction wear.

–

Check the external pipes and hoses on the

technical compartment.

–

Refit the hood of the technical compart-

ment.

–

Return the truck to service.

CAUTION

Risk of damaging the truck
In the event of leakage, please contact the After-

Sales Service Centre.

Checking the hydraulic oil level

To check the hydraulic oil level, proceed as

follows:

–

Immobilise the truck.

–

Lower the forks.

–

Switch off the ignition and remove the key.

–

Press in the emergency off switch.

–

Disconnect the battery connector.



Maintenance

Hydraulic systems

117

11638011551 EN - 02/2021 - 06

Summary of Contents for EXD 20

Page 1: ...Double pallet stacker EXD 20 Original instructions 0307 0345 11638011551 EN 02 2021 06 ...

Page 2: ......

Page 3: ...of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de Preface I 11638011551 EN 02 2021 06 ...

Page 4: ......

Page 5: ...ion 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 Defi...

Page 6: ...ing up 35 Checks and actions prior to commissioning 37 Checking the anti crush safety device 37 Checking the emergency shutdown 38 Checking the brake 38 Checking the horn 39 Truck operating instructions 40 Using the display operating unit 42 Selection buttons 42 Operation of the display unit 42 Driving safety guidelines 46 Driving 47 Defining directions 47 Driving 47 Steering 48 Braking 49 Horn 50...

Page 7: ...ce system Dynamic Drive Control 75 Description of the Dynamic Drive Control 75 Cold store usage optional 76 Before leaving the truck 78 Handling the battery 79 Battery type 79 Order picking 79 Opening and closing the battery hood 80 Charging the battery using an external charger 81 On board charger 83 Using the on board charger 84 Adjusting the on board charger 86 Changing the vertical access batt...

Page 8: ...n 107 Chassis bodywork and fittings 108 Cleaning the truck 108 General information on battery maintenance 110 Checking the condition of the forks 111 Steering and wheels 112 Cleaning the pinion gear of the steering geared motor 112 Checking the condition of the wheels 113 Stabiliser maintenance 113 Electrical equipment 114 Cleaning and blowing air through the electrical components 114 Checking the...

Page 9: ...f the mast chains 120 Checking the protective screen 121 Storage and decommissioning 123 Storage of truck 123 Permanent Putting Out of Commission Destruction 124 6 Technical specifications EXD20 datasheet 126 EXD20 mast types 130 Table of contents VII 11638011551 EN 02 2021 06 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...w 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 Ther...

Page 13: ... addi 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 o...

Page 14: ...pliance 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 declarat...

Page 15: ...lar 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 con...

Page 16: ...et 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 i...

Page 17: ... or 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 11638011551 EN 02 2021 06 ...

Page 18: ...le 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 ...

Page 19: ...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...

Page 20: ...Introduction 1 Disposing of components and batteries 10 11638011551 EN 02 2021 06 ...

Page 21: ...2 Safety ...

Page 22: ...allets 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 instr...

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

Page 24: ...m 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 ac...

Page 25: ...only 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 r...

Page 26: ...ned 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 tions cannot be used to determine the actual load level of vibrations during operation This depends on the operating conditions state ...

Page 27: ...the 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 th...

Page 28: ...tion 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: ...is 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 11638011551 EN 02 2021 06 ...

Page 30: ...til 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 servi...

Page 31: ...3 Overviews ...

Page 32: ...uck Protective screen Tiller Key switch or electronic key Display Stabilisers Stabiliser wheel 1 2 3 4 5 6 Drive wheel Battery compartment Forks Load wheels or bogies Mast 7 8 9 10 11 Overviews 3 Overview 22 11638011551 EN 02 2021 06 ...

Page 33: ... view of the technical compartment Pump motor unit Tank Stabilisers Turntable 1 2 3 4 Stabiliser wheel Drive wheel Traction motor ES30 24 steering unit 5 6 7 8 Overviews 3 Overview 23 11638011551 EN 02 2021 06 ...

Page 34: ...l lowering of forks Proportional lifting of forks Horn Drive switch 1 2 3 4 5 6 Anti crush safety device Lowering the load arms Diagnostic connector Emergency stop button Display Key switch or electronic key 7 8 9 10 11 12 Overviews 3 Operating and display devices 24 11638011551 EN 02 2021 06 ...

Page 35: ...ngs indicator light Warning indicator light Drive programme indicator light 1 2 3 4 5 6 Activity indicator light Error Code menu Settings menu Truck status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 7 8 9 10 11 12 13 Overviews 3 Operating and display devices 25 11638011551 EN 02 2021 06 ...

Page 36: ...L ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key 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...

Page 37: ...wer switches off auto matically after 10 mi nutes 600 seconds by default 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 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 38: ...onsult operating instructions Brand label Model label Brand label 1 2 3 4 5 Cold store label Next inspection label Double pallet stacker label Double pallet stacker label loading unload ing Capacity label 6 7 8 9 10 Overviews 3 Markings 28 11638011551 EN 02 2021 06 ...

Page 39: ...number for all technical en quiries The serial number contains the following infor mation 1 Production location 2 Type 3 Year of production 4 Count number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 29 11638011551 EN 02 2021 06 ...

Page 40: ...Overviews 3 Markings 30 11638011551 EN 02 2021 06 ...

Page 41: ...4 Use ...

Page 42: ... 24 electric steering offers driving precision and easier manoeuvring The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled by a tiller Masts The mast is lifted using the proportional tiller control These masts are equipped with side lift cylin ders EXD20 trucks are equipped with S standard masts for heights ranging from 1574 to 2424 mm D duplex masts for he...

Page 43: ...itch A display A diagnostic connector Equipment available as standard or as additional options That can be added to the truck Load backrest Load wheels single wheels or bogies Lithium ion battery Slow speed Creep Speed Central refilling system Cold store 35 C Use 4 Technical description 33 11638011551 EN 02 2021 06 ...

Page 44: ...sion 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 T...

Page 45: ...r operation The brake is automatically dis engaged Lower the tiller then reposition in the rest position to unblock truck use Raise the load arms several centimetres NOTE Always adjust your speed to suit the route any dangers and the load Use the truck on ground that has the correct surface and hard ness DANGER Risk of sparks Using the truck with the battery hood open is prohibi ted WARNING Risk o...

Page 46: ... Tilt the tiller in the driving area 3 NOTE In areas 1 and 2 the electromagnetic brake is applied and it is not possible to drive the truck Use 4 Starting up 36 11638011551 EN 02 2021 06 ...

Page 47: ...ce on the tiller head 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 M...

Page 48: ...ff switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This adjustment influences braking ef fectiveness Checking the brake NOTE Perform this check on a flat surface Drive the machine forward Tilt the tiller in areas 1 and 2 In these two areas the machine is braked and the drive unit is no longer powered Releasing the tiller in the drive area 3 send...

Page 49: ...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 39 11638011551 EN 02 2021 06 ...

Page 50: ...k 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 truck...

Page 51: ...a 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 41 11638011551 EN 02 2021 06 ...

Page 52: ...or can refer to the battery icon 1 or 2 The number of bars shown indicates the bat tery charge level From 0 to 20 1 bar From 21 to 40 2 bars From 41 to 60 3 bars From 61 to 80 4 bars From 81 to 100 5 bars The Battery indicator light 3 comes on in the event of a deep discharge of the battery or in the event of a fault Two distinct warnings may be displayed if the battery charge is insufficient 1 Le...

Page 53: ...ate the date of the next maintenance A warning is shown on the display The Warning light 3 comes on in the event of a fault in a truck component Drive program The Drive program light 1 is permanently il luminated when a travel mode is selected There are three different drive modes Tortoise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desire...

Page 54: ...ttings menu It is possible to access different settings through the Settings menu Select the Settings menu 1 This menu allows access to a drop down menu 2 consisting of Language Unit Date format Date Time Adjustment of the Load Management warn ing sounds Adjustment of the contrast Adjustment of the brightness Select the desired option Use 4 Using the display operating unit 44 11638011551 EN 02 202...

Page 55: ...ll through several successive dis plays The number of error messages is indicated at the bottom of the display 2 Start up screen In addition to the various menus and lights mentioned above additional data is available The Truck status menu 1 displays the truck menu The Hourglass icon 2 indicates the oper ating time of the truck The Clock icon 3 indicates the time and date Use 4 Using the display o...

Page 56: ...the dash board is prohibited The operator must be rest ing against the seat These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the dashboard to drive the truck The truck must not be used as a stepladder The truck is not designed to transport peo ple Operators must always stay within the truck clearance Stay in the safety area work...

Page 57: ...tion key Lower the tiller in the 3 zone NOTE The truck is in the drive position in the 3 zone In the lower zone 2 or the upper zone 1 the brake is applied and the traction motor is switched off DANGER Risk of obstructing the use of the tiller Do not adjust the A4 sized support to a height that is too low This could hinder the forklift operator when driving the truck Forward travel Use 4 Driving 47...

Page 58: ...ery careful Make sure that the path behind is clear before travelling in reverse Reversing the direction of travel Push the drive switch in direction 1 or 2 Release the drive switch Operate it progressively in the opposite di rection until the required speed is reached Steering A long centred and balanced tiller fitted with 2 handles directly controls the drive wheel The length of the tiller is de...

Page 59: ...NING The quality of the floor surface affects the braking distance of the truck This should be taken into consideration when driving Electromagnetic braking The electromagnetic brake is activated auto matically if one of the following conditions is met The tiller is released It is then brought back to the braking position 1 by a gas spring The tiller is in the braking position 2 or 1 The drive swi...

Page 60: ...h Braking can be obtained by releasing the drive switch While travelling completely release the drive switch 1 or 2 The brake is automatically activated The truck is immobilised Horn The horn is positioned on the inner side of the tiller It is used On routes where there is poor visibility At junctions In the event of immediate danger Press the button 1 The horn sounds Use 4 Driving 50 11638011551 ...

Page 61: ... selected on the screen the truck operates at its maximum perform ance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck The travel speed of the truck is reduced 70 of maximum speed The speed of lifting and lowering the forks is reduced 90 of maximum speed This mode allows you to save battery Tortoise mode Selecting Tortoise mode allows you to reduce the ...

Page 62: ...can be set between 0 5 and 1 5 km h Contact the After Sales Service to change this The Creep Speed function cancels automati cally when the tiller is in the drive position CAUTION Danger 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...

Page 63: ... with great cau tion Never attempt a slope whose gradient is greater than that specified in the truck s da tasheet Make sure that the ground is clean and has a non slip surface and that the route is clear Travelling up slopes Always travel up slopes in reverse The load faces uphill Without a load we recommend that you go up a slope forwards Use 4 Driving 53 11638011551 EN 02 2021 06 ...

Page 64: ...e truck on a slope Never make a U turn or take shortcuts on a slope On a slope the operator must drive more slowly WARNING Risk of serious injury and or serious damage to equipment Driving on slopes steeper than 10 is prohibited due to braking capacity and stability The load being transported could tip over Starting on a slope Proceed as follows Move the drive switch in the required direc tion Rel...

Page 65: ...le 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 sp...

Page 66: ...nter 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 re...

Page 67: ...e 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 t...

Page 68: ... quickly 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 58 11638011551 EN 02 2021 06 ...

Page 69: ...n 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 sw...

Page 70: ... 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 switch the truck off completely Use 4 Operating the FleetManager option 60 11638011551 EN 02 2021 06 ...

Page 71: ...s 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 ...

Page 72: ...me 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 62 11638011551 EN 02 2021 06 ...

Page 73: ...the mast triggers an automatic slowing of the low ering action This detector prevents a violent impact at the end of travel Push the fork lowering control until the car riage is fully lowered The progressive shutoff device for the carriage prevents the buffer from being hit at the end of travel Use 4 Transporting loads 63 11638011551 EN 02 2021 06 ...

Page 74: ...pallet stacker mode 1000 kg In double pallet stacker mode 1000 kg on the forks main lift and 1000 kg on the load arms initial lift Reading the capacity plate Example with an EXD20 fitted with a duplex mast of 1844 mm 1 Maximum lift height 1930 mm 2 Maximum mast capacity 1200 kg with a height of 1930 mm centre of gravity 400 mm 3 Maximum mast capacity 1200 kg with a height of 1930 mm centre of grav...

Page 75: ... 10 Maximum capacity in pallet truck mode 2000 kg with a height of 210 mm 11 Model Use 4 Transporting loads 65 11638011551 EN 02 2021 06 ...

Page 76: ...t touch or stand on moving parts e g lifting de vice pushing devices work installations load lifting devices WARNING Risk of injury Never put your hands near the load lift system DANGER Risk of accident The mast protective screen must always be in place correctly fixed and clean to provide good visibility for the operator For safety reasons the lift and traction func tions are inhibited when the t...

Page 77: ...y it even if there is not much light Initial Lift Lifting the load arms Press the button 4 The load arms are raised Lowering the load arms Press the button 5 The load arms are lowered CAUTION Risk of the load swinging and loss of stability Do not drive with a load in the raised position with out load on the load arms The high load must be lowered as close as possible to the load in the low positio...

Page 78: ... that the load is not damaged CAUTION Risk of injury Safety shoes must be worn Transporting people is strictly prohibited Do not use the forks to lift a person DANGER Risk of tipping It is essential to slow down when approaching a cor ner or on wet ground CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads w...

Page 79: ...Do not travel across the slope or make a U turn Reverse travel is used for setting down the load Adjust your speed 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 Setting a l...

Page 80: ...to disengage the load from the stor age area Proceed as follows 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 rack Lower the load until the forks are free Withdraw the truck in a straight line Lower the forks again until they are several centimetres from the ground DANG...

Page 81: ... com pletely clear of the rack The forklift operator must re main vigilant and ensure that there are no obstacles preventing the lowering of the forks With the load on the forks lower the forks again until they reach the ground Lift the load arms to move the truck Before leaving the truck NOTE Always stop the truck on level ground away from traffic routes Proceed as follows Lower the forks to the ...

Page 82: ... height to load the upper pallet Carefully move the forks forward into the pallet Raise the forks 1 to lift the first upper load Move slowly in a straight line to withdraw the forks from the rack DANGER Risk of hooking the mast on the rack Do not start lowering the forks until they are com pletely clear of the rack The operator must remain vigilant and ensure that there are no obstacles pre ventin...

Page 83: ... forwards Always travel up or down slopes with the load facing uphill In the event of poor visibility move slowly and carefully and ask somebody to guide you 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 The heavier of the two loads Q2 must be placed on the bottom on the load arms Keep the upper load Q1 as close as possi ble to load ...

Page 84: ...e leaving the machine CAUTION Parking the truck Always stop the machine on level ground away from traffic routes Lower the forks unladen and the load arms to the lowered position Turn off the ignition with the key or the elec tronic key In the event of a prolonged standstill press the emergency off switch and disconnect the battery Use 4 Transporting loads 74 11638011551 EN 02 2021 06 ...

Page 85: ...ommunicated when present on the forks The load on the load arms Q2 4 must be greater than or equal to the load on the forks Q1 3 The maximum speed of the truck depends on the height of the forks The vertical bars 2 inform the operator of the speed configuration of the truck The diagram is displayed only when double stacking is in operation It indicates if the speed is high me dium or low The speed...

Page 86: ...es 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 b...

Page 87: ...d 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 77 11638011551 EN 02 2021 06 ...

Page 88: ...etely The forks must touch the ground Switch off the truck The automatic braking is activated Remove the switch key DANGER Danger of death It is prohibited to park the truck with a load in the raised position or the forks in the raised position Use 4 Before leaving the truck 78 11638011551 EN 02 2021 06 ...

Page 89: ... 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 ...

Page 90: ...orks Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood Close the hood 1 WARNING Risk of trapping fingers When closing the battery hood correctly position your fingers to avoid any risk of them being trapped Ensure that the battery hood is closed se curely CAUTION...

Page 91: ...cket on the truck 1 Connect the battery connector to the wall mounted connector WARNING Electrical risk Only unplug the battery connector from the battery charger when both the battery charger and the truck are switched off NOTE Follow the instructions provided by the manu facturer of the battery and the battery charger equalising charge WARNING Risk of damage short circuit or explosion Do not pla...

Page 92: ...are generated during battery charg ing Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging Use 4 Handling the battery 82 11638011551 EN 02 2021 06 ...

Page 93: ...used 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 tensio...

Page 94: ...utomatically 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 amb...

Page 95: ...bly Continuously lit Continuously lit Battery polarity reversed Off Off Selector in neutral position Flashing Flashing CAUTION Risk of damaging the equipment 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 handling Risk of electric shock and or burns The mains cable must be checked regularly as part of pe...

Page 96: ...he 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 battery with a capacity below 210 Ah GEL battery with a capacity greater than 210 Ah CAUTION The charger is supplied in the neutral position Changing the vert...

Page 97: ...advisable to wear gloves when changing the bat tery WARNING Risk of injury Safety shoes must be worn when changing the bat tery Before handling ensure that there is nobody around the truck 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 To change the battery proceed as follows Immobilise...

Page 98: ...fting the latch 1 Hold the door 2 to prevent it falling Remove the door 2 if this option is selec ted and put it to one side Position the truck with extraction rollers or the roller frame in the upright position near the battery compartment on level ground Use 4 Handling the battery 88 11638011551 EN 02 2021 06 ...

Page 99: ... Operate and pull the locking handle 2 in the direction indicated by the arrow Lift the locking bar 3 until the battery is freed Use 4 Handling the battery 89 11638011551 EN 02 2021 06 ...

Page 100: ...osition the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Push the battery into the compartment DANGER Risk of trapping fingers Push the battery from the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery Use 4 Handling the battery 90 11638011551 EN 02 2021 06 ...

Page 101: ...t is not yet locked Lower and lock the handle 2 of the locking bar 3 in the direction indicated by the ar row The locking bar must be horizontal and must be right up against the stop 5 CAUTION Risk of locking the battery incorrectly The locking bar must not in any circumstances be positioned under or on top of the stop It must be positioned against the stop Reconnect the battery connector Use 4 Ha...

Page 102: ...de of the battery must be correctly locked Refit the battery hood Return the truck to service WARNING Risk of injury Before restarting the truck ensure that the battery is correctly installed Check that the battery is locked and that the battery hood is closed Use 4 Handling the battery 92 11638011551 EN 02 2021 06 ...

Page 103: ...d of the technical compartment Loosen the screw 1 using an 8 mm open ended spanner 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 When the forks are fully lowered Tighten the screw 1 using an 8 mm open ended spanner Refit the front hood of the technical com partment Use 4 Handling the truck in an emergency 93 11...

Page 104: ... the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is then unlocked CAUTI...

Page 105: ... re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted be fore the machine is used 0252_003 110 3 2 Use 4 Handling the truck in an emergency 95 11638011551 EN 02 2021 06 ...

Page 106: ...ctions Shut off the truck and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device to the sling ring 1 NOTE Do not sling the truck by the tiller Do not sling the truck by the accessory support Carefully lift the truck DANGER Risk of falling Make sure no one is under or near the truck when sling...

Page 107: ... 3 As a safety precaution always insert a wood en chock WARNING Risk of truck falling Immobilise and chock the truck after lifting it Transporting the truck CAUTION Always switch off the ignition and disconnect the bat tery Never tie down or sling the truck by the control unit or other points not designed for this CAUTION Risk of damage to the truck Use a hoist and woven NON METALLIC slings with a...

Page 108: ...mobilised 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 observed Anyone transported with the truck must only enter the lift after the truck has been correctly immobilised and they must exit the lift first Driving on loading bridges Before crossing a loading bridge the operator must make sure it is properly...

Page 109: ...5 Maintenance ...

Page 110: ... the truck is used under harsh conditions extreme heat or 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 in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix differ...

Page 111: ...ow 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 person...

Page 112: ... 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 pr...

Page 113: ... oil 1 1 l Traction motor 1 5 kW 1F1 fuse Power 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 2 2 kW 1F1 fuse Power 300 A quantity 1 Control fuse 1F3 fuse Control 7 5 A quantity 1 Control fuse 1F4 fuse Control 5 A quantity 1 Battery Distilled water As required Joints Lithium soap grease As required Maintenance 5 Technical data for inspection and maint...

Page 114: ...roved by the manufacturer Us ing oil mixtures or hydraulic fluids that are not recommended can cause damage that may be expensive to rectify Transmission gear oil Recommended oil CLP PG220 DIN 51 517 3 Aerosol can for chains Standard chain spray A167 Multi purpose grease Lithium soap grease extreme pressure with anti wear additive Standard DIN 51825 KPF 2K 30 KPF 2K 20 KPF 2N 30 ENVIRONMENT NOTE U...

Page 115: ...llows Remove the four screws 3 from the top hood 1 Lift the top cover slightly Remove the two screws 4 from the front hood 2 Remove the front hood The technical compartment must be closed once the operation is finished Remove the front hood 2 Tighten the two screws 4 of the front hood Reposition the top hood 1 Tighten the four screws 3 of the top hood Return the truck to service Maintenance 5 Acce...

Page 116: ...ors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and the electronic components Check the fuses Check the battery acid level and the electrolyte level Hydraulics Check the hydraulic oil level Check the conditio...

Page 117: ...pplication environmental conditions and driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 10 000 hour service plan 107 11638011551 EN 02 2021 06 ...

Page 118: ...e sensitive to moisture par ticularly electric components must be protected when the truck is cleaned Observe the manufacturer s instructions when us ing the cleaning product Clean the truck with a non flammable clean ing product mixed with water a sponge and cloths Specifically clean the oil filling openings and surrounding areas as well as the lubricating nipples before lubrication NOTE A truck ...

Page 119: ...of compressed air It is advisable to wear protection goggles and a mask Restart the truck in accordance with the in structions NOTE If despite taking precautions traces of mois ture remain in the motor dry it using com pressed air After having eliminated any traces of moisture the truck may be reactivated Do not do so before then to prevent any corro sion Maintenance 5 Chassis bodywork and fitting...

Page 120: ...ible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging mainte nance and treatment instructions A non compatible charger may result in a battery failure Observe the manufacturer s recommendations NOTE The discharge indicators used to check the battery must also be suitable for the type of battery Contact the re...

Page 121: ...hat the forks 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 111 11638011551 EN 02 2021 06 ...

Page 122: ...h solvent if necessary then dry with compressed air CAUTION Use of compressed air It is advisable to wear protection goggles and a mask Then lubricate the pinion gear and ring gear with silicone aerosol spray Reconnect the battery connector Return the truck to service CAUTION Risk of dust clogging There is a risk of dust clogging if non recommended products are used for greasing CAUTION Risk of in...

Page 123: ...abilisers No significant damage to the superstruc ture The damper cylinder pins must not be twis ted No oil leakage must be present on the damper cylinder This cylinder must be in side the spiral spring No damage to the rollers The wheels must rotate freely No locking at the level of the upper bearing Ensure that the wheel nuts are correctly tightened Ensure that there is no oil leakage under the ...

Page 124: ...electrical component Press in the emergency off switch Disconnect the battery connector Open the technical compartment Blow the electrical components with com pressed air WARNING Use of compressed air It is advisable to wear protection goggles and a mask Check the condition of the harness connec tor pins Maintenance 5 Electrical equipment 114 11638011551 EN 02 2021 06 ...

Page 125: ...an 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 an...

Page 126: ...nd output terminals are not sulphated presence of white salt Check the condition of the battery connec tor contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious inci dents In the event of an incident contact our After Sales Service Centre as quickly as possible Maintenance 5 Electrical equipment 116 11638011551 EN 02 2021 06...

Page 127: ... of friction wear Check the external pipes and hoses on the technical compartment Refit the hood of the technical compart ment Return the truck to service CAUTION Risk of damaging the truck In the event of leakage please contact the After Sales Service Centre Checking the hydraulic oil level To check the hydraulic oil level proceed as follows Immobilise the truck Lower the forks Switch off the ign...

Page 128: ...battery connector Return the truck to service Checking the controlled stabiliser hydraulic system for leaks Switch off the truck and disconnect the bat tery connector Remove the hood of the technical compart ment Inspect the stabiliser hydraulic system Tank Rigid pipes Connections from the stabiliser directional control valve block to the cylinders Check the tank for leaks Tighten the swivel joint...

Page 129: ...el of the stabilisers is on the mark situated between the raised MIN and MAX 3 lettering on the tank 2 Top up the level if necessary after un screwing the plug 1 Screw the plug back in at the end of the op eration CAUTION Risk of damage to the truck Only use hydraulic oil that complies with the specifi cations See table of lubricants Refit the hood of the technical compart ment Return the truck to...

Page 130: ... lubricant CAUTION Risk of the equipment becoming worn or damaged Chains are safety components Use of cold cleaning agents chemical products acid or chlorinated prod ucts could destroy the chains NOTE Use of high pressure liquid cleaning devices is not advisable DANGER Danger of death and or risk of serious damage to equipment On trucks fitted with macrolon mast protection clean the translucent sc...

Page 131: ...ter Sales Serv ice Centre Checking the protective screen It is important to check the condition of the mast protective screens and to check that the mountings are tightened Check that the protective screen 1 is cor rectly attached and in good condition un damaged Replace the protective screen if it is dam aged Adhere to the number of mountings as de fined by the manufacturer WARNING Risk of seriou...

Page 132: ...ectly attached Do not attach anything to the screen that could affect the visibility of the forks When cleaning the fork carriage side only clean the screen when the fork carriage is in the lowered posi tion Maintenance 5 Lift mast 122 11638011551 EN 02 2021 06 ...

Page 133: ... must 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 tru...

Page 134: ...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 S...

Page 135: ...6 Technical specifications ...

Page 136: ...EXD20 datasheet Technical specifications 6 EXD20 datasheet 126 11638011551 EN 02 2021 06 ...

Page 137: ...1884 2 3 Load per unladen axle drive side load side 10 1 kg 889 292 WHEELS EXD20 3 1 Tyre polyurethane rubber drive side load side R P P 3 2 Drive wheel dimensions width at the ground Ø x L mm Ø230 x L90 3 3 Wheel sizes load side Ø x L mm Ø85 x L85 bogies Ø85 x L60 3 4 Additional wheels dimensions Ø x L mm 2 x Ø125 x L60 3 5 Number of wheels drive side load side x drive wheel 1X 2 2 1X 2 4 3 6 Tra...

Page 138: ...mm 210 230 4 32 Ground clearance at centre of wheelbase 2 mm m2 mm 20 4 33 Load dimension b12 x L6 b12 x L6 800 x 1200 4 34 Aisle width with predetermined load Ast mm 2730 3 4 34 2 Aisle width with a pallet 800 x 1200 crosswise Ast mm 2860 3 4 35 Turning radius minimum Wa mm 2060 PERFORMANCE DATA EXD20 5 1 Travel speed when laden unladen 5 km h 6 6 5 2 Initial lifting speed when laden unladen 10 m...

Page 139: ...0 6 5 Battery weight 10 kg Gel Lead bat tery 290 Battery weight with case 10 3 PzS side access Li ion 205 Ah 190 Battery weight with case 10 3 PzS side access Li ion 410 Ah 229 6 6 Energy consumption according to standardised VDI cycle kWh h 0 483 6 7 Turnover output T h 59 6 8 Energy consumption at turnover out put kWh h 1 5 MISCELLANEOUS EXD20 8 1 Speed monitor AC controller LAC 10 7 Noise level...

Page 140: ...1574T 2024T 2424T h1 1240 1465 1665 h1 1315 1540 1740 h2 150 150 150 h3 1574 2024 2424 h4 2094 2544 2944 Mast type Duplex 1924 N h1 1915 h1 h2 1395 h3 2924 h4 3444 Technical specifications 6 EXD20 mast types 130 11638011551 EN 02 2021 06 ...

Page 141: ...he controlled sta biliser circuit 119 Checking the protective screen 121 Checks prior to start up 34 Cleaning and lubricating the chains 120 Cleaning the truck 108 Climatic conditions 8 Closing the battery hood 80 cold store 76 Cold store usage 76 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact det...

Page 142: ...Labels 28 Lift control elements 66 Lifting the truck 97 Load handling safety rules 61 M Maintenance plan 100 5000 hours 106 Managing battery charging 42 Masts 32 Multi purpose grease 104 N Noise emission values 16 O Oils 13 On board charger Adjusting the on board charger 86 Charging curve selector 86 Using the on board charger 84 Opening the battery hood 80 Operating company 18 Ordering spare part...

Page 143: ...otor 112 Symbols used 9 T Technical data for inspection and mainte nance 103 Technical description 32 Transporting a load 69 Transporting the truck 97 Transporting the truck in the lift 98 Transporting two loads 73 Travelling down slopes 54 Travelling up slopes 53 Truck operating instructions 40 U Unauthorised use 9 Using the truck on a slope 53 V Vibrations Vibration characteristics for vibration...

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Still EXD 20, Original Instructions Manual

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