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1000-hour service plan

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

dures should be carried out every 1000, 2000, 3000, 4000, 6000, 7000, 8000 and 9000 hours

Preparation
Clean the truck
Check the error codes using the diagnostic tool
Enter the next maintenance interval
Chassis and equipment
Check the condition of the forks
Check the electromagnetic brake and ensure that it is working correctly
Check and grease the hinges
Check the transmission gear for noise and leaks
Grease the gears
Check the platform
Check the condition of the forklift operator detection function
Wheels
Check the condition and tightness of the wheels
Check the stabilisers
Grease the axles and the bearing of the load wheels and the stabiliser wheels (lubricated ver-

sion)
Electrical equipment
Clean the electric steering system and the lifting motors
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 electrical components
Check the electrical insulation between the chassis and the control unit components
Check the fuses
Check the battery acid level and the electrolyte level
Check the pump motor brushes for wear
Hydraulics
Check the pump-motor unit mounting
Check the hydraulic oil level
Check the condition of the pipe lines
Check the oil level of the controlled stabilisers
Load lift system
Check the condition and the length of the mast chain
Lubricate the forks and the mast guide rollers
Check the condition and mounting of the guard grille
Check the condition of the linkage of the initial lift

Maintenance

5

1000-hour service plan

102

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Summary of Contents for EXD-S 20

Page 1: ...Double pallet stacker EXD S 20 Original instructions 0347 11638011751 EN 02 2021 03 ...

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 11638011751 EN 02 2021 03 ...

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: ...ssioning 36 Checking the emergency shutdown 36 Checking the brakes 36 Horn 37 Operation of the display operating unit 38 Truck operating instructions 40 Adjusting the steering wheel height 42 Driving safety guidelines 43 Driving 44 Defining directions 44 Driving 44 Steering 45 Emergency off switch 46 Braking 47 Horn 48 Drive program 48 Using the truck on a ramp 50 Operating the FleetManager option...

Page 7: ...c Drive Control 72 Description of the Dynamic Drive Control 72 Cold store usage optional 73 Before leaving the truck 75 Handling the battery 76 Battery type 76 Opening and closing the battery hood 76 Charging the battery using an external charger 77 On board charger 79 Using the on board charger 80 Order picking 82 Changing the side access battery 83 Changing the vertical access battery 88 Handlin...

Page 8: ...103 Chassis bodywork and fittings 104 Cleaning the truck 104 General information on battery maintenance 106 Checking the condition of the forks 107 Steering and wheels 108 Cleaning the pinion gear of the steering geared motor 108 Checking the condition of the wheels 109 Stabiliser maintenance 109 Electrical equipment 110 Cleaning and blowing air through the electrical components 110 Checking the b...

Page 9: ...the mast chains 116 Checking the protective screen 117 Storage and decommissioning 118 Storage of truck 118 Permanent Putting Out of Commission Destruction 119 6 Technical specifications EXD S 20 datasheet 122 EXD20 S mast type 127 Table of contents VII 11638011751 EN 02 2021 03 ...

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 11638011751 EN 02 2021 03 ...

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 11638011751 EN 02 2021 03 ...

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 11638011751 EN 02 2021 03 ...

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: ...reen Steering wheel Key switch or electronic key Diagnostic connector Stabiliser wheel Platform 1 2 3 4 5 6 Drive wheel Battery compartment Forks Load wheels or bogies Battery hood Mast 7 8 9 10 11 12 Overviews 3 Overview 22 11638011751 EN 02 2021 03 ...

Page 33: ...General view of the technical compartment Pump motor unit Tank Servo stabilisers tanks 1 2 3 Traction motor Steering unit ES30 24 Controller 4 5 6 Overviews 3 Overview 23 11638011751 EN 02 2021 03 ...

Page 34: ...ms lowering control Brake Emergency off switch 1 2 3 4 5 6 Control button for the on board compressor Ignition key or electronic key Diagnostic connector Display Fork lifting and lowering controls depending on model 7 8 9 10 11 Overviews 3 Operating and display devices 24 11638011751 EN 02 2021 03 ...

Page 35: ...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 36: ...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 37: ...ble on the model Hour meter Warning signal if applicable F2 Indicator light if available on the model Service reminder 1 2 3 4 5 6 7 8 Right turn indicator if available on the mod el BLUE Q mode Tortoise mode Tortoise indicator Warning triangle Type of alarm Battery charge level indicator 9 10 11 12 13 14 15 Overviews 3 Operating and display devices 27 11638011751 EN 02 2021 03 ...

Page 38: ...bel loading unload ing Brand label Model label Capacity label Slinging label Consult the operating instruc tions 1 2 3 4 5 6 7 Brand and model label Next inspection label Brand and model label Brand label Cold store label Truck steering and steering wheel label Identification label 8 9 10 11 12 13 14 Overviews 3 Markings 28 11638011751 EN 02 2021 03 ...

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 11638011751 EN 02 2021 03 ...

Page 40: ...Overviews 3 Markings 30 11638011751 EN 02 2021 03 ...

Page 41: ...4 Use ...

Page 42: ...erent battery types are not available on all models Steering The ES30 24 electric steering offers driving precision and reduced effort during manoeu vres The truck is equipped with a 0 35 kW asyn chronous steering motor The steering is controlled by a steering wheel The drive unit is mounted on a turntable Steering lock is provided by an electric gear motor that positions the turntable The steerin...

Page 43: ...cornering to ensure maximum stability of the truck Driver s compartment An operator presence contact is incorporated into the suspended platform The side protection is fixed The protection provides back support for the driver The steering wheel comprises the controls and the steering An emergency off switch is located on the dashboard A display Use 4 Technical description 33 11638011751 EN 02 2021...

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: ...ay 3 switches on The truck is ready for operation The brake is automatically dis engaged Raise the load arms a few 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 of accident or loss of load Driving on s...

Page 46: ...supply is cut The electrical controls and motors are no longer supplied with power Pull the emergency off switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This influences braking effectiveness Checking the brakes To check the main brakes of the truck pro ceed as follows Press the braking button 1 The truck comes to a standstill Use 4 Checks and a...

Page 47: ...Horn Press the horn button 1 The horn sounds Use 4 Checks and actions prior to commissioning 37 11638011751 EN 02 2021 03 ...

Page 48: ...ance of the truck is automatically limited The triangle 2 remains permanently lit until the battery is re charged Performance modes See the chapter Drive Modes Blue Q mode Blue Q mode 3 ensures that battery con sumption is fully optimised To activate Blue Q mode Press the key 3 When the key 3 is pressed Blue Q mode is activated It remains active when the truck is switched off and on again To deact...

Page 49: ...y three num bers The Triangle light 2 turns on in the event of an error code on the truck It also comes on when the battery charge level is too low The hour meter light 4 indicates the number of operating hours for the truck When the symbol 3 is displayed the truck indicates the number of hours remaining before the battery is discharged The Adjustable Spanner indicator light 5 comes on to indicate...

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 11638011751 EN 02 2021 03 ...

Page 52: ...be adjusted To adjust the handlebar height proceed as follows Press and hold the button 1 Pull the steering wheel 2 towards you or lower it until the required height is reached Release the button 1 Use 4 Adjusting the steering wheel height 42 11638011751 EN 02 2021 03 ...

Page 53: ...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 54: ...e the driver s compartment while the truck is moving The drive switch is positioned on the steering wheel Forward travel Step onto the forklift operator detection plat form Pull the emergency off switch Gradually and slowly press the drive switch forwards 1 with your thumb When the drive switch is released the truck brakes electrically Reverse travel Step onto the forklift operator detection plat ...

Page 55: ...roceed as follows Turn the steering wheel to the left the truck turns to the left in forward travel 1 Turn the steering wheel to the right the truck turns to the right in forward travel 2 WARNING Risk of tipping Always slow down before negotiating a corner Ap proaching a tight corner too fast can cause the truck to overturn Optional Inverted steering may be selected You must therefore adapt your d...

Page 56: ...itation Trucks with a platform are fitted with a safety device that automatically reduces the speed when cornering above a certain steering angle of the drive wheel Emergency off switch During normal operation the emergency off switch 1 must be pulled out In case of danger Press the button 1 to break the electrical circuit and immobilise the truck Use 4 Driving 46 11638011751 EN 02 2021 03 ...

Page 57: ...2 While travelling move the switch in the op posite direction First the truck is braked electrically Release the drive switch The brake is automatically activated The truck is immobilised By releasing the drive switch While travelling completely release the drive switch The brake is automatically activated The truck is immobilised Electromagnetic braking The electromagnetic brake is activated auto...

Page 58: ...nt of immediate danger Press the button 1 The horn sounds Drive program The indicator light 1 is permanently on during operation of the truck The shape of the indi cator light indicates the selected program The truck is equipped with two different drive programs Tortoise mode 2 BlueQ mode 3 NOTE When the operator restarts the truck the last mode selected is automatically activated NOTE The drive p...

Page 59: ...system is reduced 90 of maximum speed This mode allows you to save battery Tortoise mode Selecting Tortoise mode 2 allows you to re duce the performance of the truck The travel speed of the truck is reduced The lifting and lowering speed of the load lift system is significantly reduced The speeds can be adjusted Contact the Af ter Sales Service to change these Use 4 Driving 49 11638011751 EN 02 20...

Page 60: ...th cau tion Never attempt a slope with a gradient that 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 forwards when going up a slope The load faces uphill Without a load we recommend that you go up a slope forwards Use 4 Driving 50 11638011751 EN 02 2021 03 ...

Page 61: ...the truck on a slope Never make a U turn or take a short cut on a slope On a slope the forklift 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 ramp Proceed as follows Move the drive switch in the required di...

Page 62: ...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 63: ...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 64: ...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 65: ... 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 55 11638011751 EN 02 2021 03 ...

Page 66: ...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 67: ... 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 57 11638011751 EN 02 2021 03 ...

Page 68: ...h board To decrease the shock absorbency Press the button 2 located on the dash board Using the foot protection op tion A foot protection option Active Foot Guard is available on the truck If the forklift operator removes his or her foot from the control area 1 the speed of the truck is automatically reduced The forklift op erator can accelerate again as soon as his or her feet are inside the driv...

Page 69: ...on Capacity of the EXD S 20 model In pallet truck mode 2000 kg In pallet stacker mode 1200 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 EXD S 20 model 1 Maximum lift height 2510 mm 2 Maximum mast capacity 1200 kg with a height of 2510 mm centre of gravity 400 mm 3 Maximum mast capacity 1200 kg w...

Page 70: ... Maximum lift height 210 mm with 2000 kg in pallet truck mode 10 Maximum capacity in pallet truck mode 2000 kg with a height of 210 mm 11 Truck model Use 4 Transporting loads 60 11638011751 EN 02 2021 03 ...

Page 71: ... 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 load Use ...

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 11638011751 EN 02 2021 03 ...

Page 73: ...llations 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 The truck has two lift systems Raising lowering the mast The control buttons are located behind the steering wheel Raising the mast Press button 1 The fork...

Page 74: ... be lowered as close as possible to the load in the low position The operator must lower the forks again be fore moving the truck Progressive stopping of the carriage in the lower position A detector 1 that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the low ering action This detector prevents a violent impact at the end of trave...

Page 75: ... 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 76: ... make a U turn Reverse travel is used for setting down the load Adjust your speed as the position of the forklift operator is now 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 th...

Page 77: ...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 78: ... 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 79: ... to load the upper pallet Carefully move the forks forward under 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 venting the ...

Page 80: ...vel is forwards Always travel up or down slopes with the load 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 Q...

Page 81: ...re 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 shutdown press the emergency off switch and disconnect the battery Use 4 Transporting loads 71 11638011751 EN 02 2021 03 ...

Page 82: ...t be observed The load on the load arms must be greater than or equal to the load on the forks The maximum speed of the truck depends on the height of the forks The speed varies depending on the load on the forks between 0 3 and 1 8 metres The heavier the load the lower the speed The forklift operator must remain cautious and adjust the speed to suit the environmental conditions CAUTION Risk of in...

Page 83: ...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 84: ...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 74 11638011751 EN 02 2021 03 ...

Page 85: ...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 75 11638011751 EN 02 2021 03 ...

Page 86: ... careful not to damage any wiring when replacing the battery Opening and closing the battery hood Opening the battery hood To open the battery hood Immobilise the truck Lower the forks 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 Ris...

Page 87: ...he condition of the battery cable and the charger cable Re place them if necessary Open the hood and leave it open Pull the handle of the battery connector 2 to disconnect it from the fixed socket 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 a...

Page 88: ...iluted sulphuric acid is toxic and very caustic Follow the safety regulations when handling battery acid WARNING Explosive gases 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 78 11638011751 EN 02 2021 03 ...

Page 89: ...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 90: ...tically 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 ...

Page 91: ...ualisation Maintenance phase Continuously lit Off Charging process too long Off Continuously lit Charger po larity reversed battery and battery charger ca bles reversed with the bat tery remain ing normally connected to the truck as sembly Continuously lit Continuously lit Battery polari ty reversed Off Off Selector in neutral posi tion Flashing Flashing CAUTION Risk of damaging the battery It is ...

Page 92: ...d 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 duce sparks within a minimum radius of 2 m around the truck and the battery charger The work area must be well ventilated Fire extinguishers must be provided and located near ...

Page 93: ...ame or a truck with ex traction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise the truck Lower the forks Switch off the ignition and remove the key Press in the emergency off switch Open the battery hood Disconnect the battery connector Place the connector on the battery cells Unlock the door that is not attached to the side of th...

Page 94: ...de Position the truck with extraction rollers or the roller frame in the upright position near the battery compartment on level ground Operate and pull the locking handle 2 in the direction indicated by the arrow Use 4 Handling the battery 84 11638011751 EN 02 2021 03 ...

Page 95: ...lers or the roller frame Replace the battery Remove the dis charged battery and position a charged bat tery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Use 4 Handling the battery 85 11638011751 EN 02 2021 03 ...

Page 96: ...shing from the top or the side of the battery Push until a click is heard The battery is correctly installed WARNING Risk of injury Ensure that the battery is in the end position and that the hook is correctly holding the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Use 4 Handling the battery 86 11638011751 EN 02 2021 03 ...

Page 97: ... It must be positioned against the stop Reconnect the battery connector Lower the latch of the battery compartment door if this option is selected The door that is not attached to the side 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...

Page 98: ...t the battery connector Attach the slinging hooks 1 to the battery compartment 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 in the chassis Remove the slinging hooks Reconnect the battery connector Close the battery hood Return the truck to service Use 4 Handling the battery 88 116...

Page 99: ...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 89 11...

Page 100: ... 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 101: ... 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 91 11638011751 EN 02 2021 03 ...

Page 102: ...ns 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 steering wheel Do not sling the truck by the accessory sup port Carefully lift the truck DANGER Risk of falling Make sure no one is under or near the truck when ...

Page 103: ...ons 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 wit...

Page 104: ...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 105: ...5 Maintenance ...

Page 106: ...f 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 diffe...

Page 107: ...low 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 perso...

Page 108: ... 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 109: ...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 maintenance 99 11638011751 EN 02 20...

Page 110: ... oil for the cold store version ISO L HM 32 as per ISO 6743 4 or ISO VG32 HLP as per DIN 51524 2 Transmission oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray Grease for pinion gear and steering ring CAUTION Follow the maintenance and safety guidelines Multi purpose grease Lithium soap grease with EP agents and MoS 2KPF 2N 20 complying with the stand ard DIN 51825...

Page 111: ...ess the emergency off switch Open the battery compartment Disconnect the battery connector Remove the four mounting screws 1 from the hood Carefully remove the hood The technical compartment can be accessed To refit the hood proceed as follows Position the tab inside the chassis Reposition the hood Refit and tighten the mounting screws 1 Return the truck to service Maintenance 5 Easily accessing t...

Page 112: ... stabiliser wheels lubricated ver sion Electrical equipment Clean the electric steering system and the lifting motors 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 electrical components Check the electrical insulation between the chassis and the control unit components Check the fu...

Page 113: ...ntenance work Hydraulics Drain the hydraulic oil 10 000 hour service plan Depending on the application 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 5000 hour maintenance plan 103 1163801175...

Page 114: ...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 115: ...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 116: ...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 117: ...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 107 11638011751 EN 02 2021 03 ...

Page 118: ...ean with 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 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 ...

Page 119: ...o 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 truck when ...

Page 120: ... electrical component Press 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 110 11638011751 EN 02 2021 03 ...

Page 121: ...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 122: ...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 112 11638011751 EN 02 2021 03...

Page 123: ...s 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 ig...

Page 124: ...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 125: ...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 126: ... 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 127: ...s 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 serious injury and or serious damage to equipment Never touch moving parts and assemblies without first having lowered the equipmen...

Page 128: ... 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 129: ...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 130: ...Maintenance 5 Storage and decommissioning 120 11638011751 EN 02 2021 03 ...

Page 131: ...6 Technical specifications ...

Page 132: ...EXD S 20 datasheet Technical specifications 6 EXD S 20 datasheet 122 11638011751 EN 02 2021 03 ...

Page 133: ...g 1 kg 1373 1963 1 2 3 Load per unladen axle drive side load side 10 1 kg 1033 303 1 WHEELS EXD S 20 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 Ø230 x L100 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 d...

Page 134: ... x L6 b12 x L6 800 x 1200 4 34 Aisle width with a pallet 800 x 1200 crosswise Ast mm 3005 4 5 7 4 35 Turning radius minimum forks raised lowered Wa mm 2293 2363 4 7 PERFORMANCE DATA EXD S 20 5 1 Travel speed when laden unladen 5 km h 10 10 6 5 2 Initial lifting speed when laden unladen 10 m s 0 050 0 061 Main lifting speed when laden unladen 10 m s 0 14 0 22 5 3 Initial lowering speed when laden u...

Page 135: ...eight with case 10 3 PzS side access Li ion 410 Ah 229 6 6 Energy consumption according to standardised VDI cycle kWh h 0 821 6 7 Turnover output T h 77 6 8 Energy consumption at turnover out put kWh h 1 37 MISCELLANEOUS EXD S 20 8 1 Speed monitor AC controller LAC 10 7 Noise level at forklift operator s ears 2 5 dB A 62 1 Weight according to line 2 1 2 With battery line 6 5 3 Forks lowered 4 Same...

Page 136: ...7 For side access and backrest version add 55 mm Technical specifications 6 EXD S 20 datasheet 126 11638011751 EN 02 2021 03 ...

Page 137: ...150 150 h3 1574 1724 2024 2424 h4 2094 2244 2544 2944 Mast type Duplex 1574D 1724D 2024D 2424D h1 1240 1315 1465 1665 h1 h2 720 795 945 1145 h3 1574 1724 2024 2424 h4 2094 2244 2544 2944 Mast type Triplex 1574T h1 1165 h1 h2 645 h3 2136 h4 2051 Technical specifications 6 EXD20 S mast type 127 11638011751 EN 02 2021 03 ...

Page 138: ...Technical specifications 6 EXD20 S mast type 128 11638011751 EN 02 2021 03 ...

Page 139: ...ruck 104 Climatic conditions 8 Closing the battery hood 76 cold store 73 Cold store usage 73 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 Counter current braking 47 D Defining directions 44 Description of the Dynamic Drive Control 72 Description of use 8...

Page 140: ...93 Load handling safety rules 61 M Maintenance plan 96 5000 hours 103 Masts 32 Multi purpose grease 100 N Noise emission values 16 O Oils 13 On board charger Using the on board charger 80 Opening the battery hood 76 Operating company 18 Operation of the display operating unit 38 Ordering spare parts and consumables 97 Order picking 82 P Permanent Putting Out of Commission 119 Picking up a load at ...

Page 141: ...he truck 93 Transporting the truck in the lift 94 Transporting two loads 70 Travelling down slopes 51 Travelling up slopes 50 Truck controls 24 Truck operating instructions 40 U Unauthorised use 9 Using the foot protection option 58 Using the on board compressor option 58 Using the truck on a ramp 50 V Vibrations Vibration characteristics for vibrations to which the body is exposed 16 W Wheels Che...

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