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Still EXD-SF 20, Original Instructions Manual

The Still EXD-SF 20 Original Instructions Manual is a comprehensive user guide essential for operating your EXD-SF 20 forklift effectively and safely. Download this manual for free from manualshive.com, ensuring you have all the necessary information at your fingertips. Master the manual to master your machine.

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Table of contents

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5 Maintenance

General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Servicing and maintenance personnel training and qualification . . . . . . . . . . . . . . . . . . 105
Battery maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance operations that do not require special training . . . . . . . . . . . . . . . . . . . . . 105
Ordering spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Safety guidelines for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Servicing and maintenance measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Technical data for inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Accessing the technical compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1000-hour service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10,000-hour service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
General information on battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Checking the condition of the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Steering and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cleaning the pinion gear of the steering geared motor . . . . . . . . . . . . . . . . . . . . . . . . . 117
Checking the condition of the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Stabiliser maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cleaning and blowing air through the electrical components . . . . . . . . . . . . . . . . . . . . 119
Checking the battery acid level and electrolyte density . . . . . . . . . . . . . . . . . . . . . . . . 120
Checking the condition of the cables, terminals and battery connector . . . . . . . . . . . . . 121
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking the controlled stabiliser hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . 123
Checking the oil level in the controlled stabiliser circuit . . . . . . . . . . . . . . . . . . . . . . . . . 124
Lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cleaning and lubricating the chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Adjusting the length of the mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Checking the protective screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

VI

11638011651 EN - 09/2019

Summary of Contents for EXD-SF 20

Page 1: ...Original instructions Double pallet stacker EXD SF 20 0313 0346 11638011651 EN 09 2019 ...

Page 2: ......

Page 3: ...g Address 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 11638011651 EN 09 2019 I ...

Page 4: ......

Page 5: ...sposing of components and batteries 8 2 Safety Safety regulations 10 Safety regulations for handling consumables 11 Permissible consumables 11 Oils 11 Hydraulic fluid 12 Battery acid 12 Disposal of consumables 13 Emissions 14 Noise emission values 14 Vibration characteristics for vibrations to which the body is exposed 14 Residual dangers residual risks 15 Stability 15 Definition of responsible pers...

Page 6: ...prior to start up 34 Starting 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 47 Driving 48 Defining directions 48 Driving 48 Braki...

Page 7: ...wo stacked pallets 76 Driving assistance system Dynamic Drive Control 79 Description of the Dynamic Drive Control 79 Cold store usage optional 80 Before leaving the truck 82 Handling the battery 83 Battery type 83 Order picking 83 Opening and closing the battery hood 84 Charging the battery using an external charger 85 On board charger 87 Using the on board charger 88 Adjusting the on board charge...

Page 8: ...g the truck 113 General information on battery maintenance 115 Checking the condition of the forks 116 Steering and wheels 117 Cleaning the pinion gear of the steering geared motor 117 Checking the condition of the wheels 118 Stabiliser maintenance 118 Electrical equipment 119 Cleaning and blowing air through the electrical components 119 Checking the battery acid level and electrolyte density 120...

Page 9: ...tents g Storage and decommissioning 127 Storage of truck 127 Permanent Putting Out of Commission Destruction 128 6 Technical specifications EXD SF 20 datasheet 130 EXD SF 20 mast types 134 11638011651 EN 09 2019 VII ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...these operating instructions will allow the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained Get to know the technology understand it and use it safely these operating instructions provide the necessary information and help to avoid accidents and to keep the truck ready for opera...

Page 13: ... nameplate An independent structural change or an addition to the tow tractor can compromise safety thereby invalidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the responsible authorities Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third pa...

Page 14: ...ed to compile the technical documents See EC compliance declaration STILL S A S The manufacturer declares that the truck complies with the requirements of the EC directives valid at the time of marketing This is confirmed by the EC declaration of conformity and by the EC labelling on the nameplate An independent structural change or addition to the truck can compromise safety thus invalidating the ...

Page 15: ...uiries Rules for the operating company of industrial trucks In addition to these operating instructions a code of practice containing additional information for the operating companies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for th...

Page 16: ...he operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https m still de vdma in a web browser or by scanning the QR code 6 11638011651 EN 09 2019 ...

Page 17: ...imit danger as far as possible The capacity label specifies the maximum load that can be raised This limit must not be exceeded Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special us...

Page 18: ...oid life threatening danger or physical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Disposing of components and batteries The truck is made up of different mater...

Page 19: ...2 Safety ...

Page 20: ... weight and dimen sions of pallets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of materia...

Page 21: ...n eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of...

Page 22: ...draulic fluid is a water polluting substance Always store hydraulic fluid in containers complying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of according to the regulations Dispose of old hydraulic fluid according to regulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact a...

Page 23: ...in accordance with regulations Observe the national regulations for your country Work may only be carried out in areas designated for this purpose Take care to minimise as far as possible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be immediately soaked up with an oil binding agent The regulations for disposal of used oil are appl...

Page 24: ...he values were determined according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb vibrations 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 operati...

Page 25: ...and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and ground conditions The stability of the truck has been tested to the latest standards These standards only take account of the static and dynamic tilting forces that can arise during operation that complies with the specifications and operating rules Risks c...

Page 26: ...n 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 be haviour The driver must be duly informed of his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety helmet industrial gog gles and protective gloves th...

Page 27: ...ents As part of this inspection A full check of the technical condition of the truck in terms of accident safety must be performed The truck must be thoroughly checked to detect any damage that may have been caused by improper use A test log must be created The results of the inspection must be retained until at least a further two inspections have been carried out The inspection date is indicated...

Page 28: ...2 Safety Safety tests 18 11638011651 EN 09 2019 ...

Page 29: ...3 Overviews ...

Page 30: ...rview General view of the truck 1 Mast 2 Tiller 3 Key switch or electronic key 4 Safety protective guardrails 5 Stabilisers 6 Platform 7 Stabiliser wheel 8 Drive wheel 9 Forks 10 Load wheels or bogies 20 11638011651 EN 09 2019 ...

Page 31: ...verviews 3 Overview General view of the technical compartment 1 Pump unit 2 Traction motor 3 Pump unit tank 4 Servo stabilisers tank 5 Stabilisers 6 Horn 7 ES30 24 steering unit 11638011651 EN 09 2019 21 ...

Page 32: ...ment 1 Handle 2 Lifting the load arms 3 Proportional lowering of forks 4 Proportional lifting of forks 5 Horn 6 Drive switch 7 Anti crush safety device 8 Lowering the load arms 9 Diagnostic connector 10 Emergency off switch 11 Display 12 Key switch or electronic key 22 11638011651 EN 09 2019 ...

Page 33: ...ndicator light 3 Temperature indicator light 4 Settings indicator light 5 Warning indicator light 6 Drive programme indicator light 7 Activity indicator light 8 Error Code menu 9 Settings menu 10 Truck status menu 11 Display of the operating time of the truck 12 Display of the battery charge 13 Display of the date and time 11638011651 EN 09 2019 23 ...

Page 34: ...ll charge 100 Low charge 10 Dis charged 0 91 100 10 bars 1 10 1 bar 0 1 flashing bar lift function not permitted NB To protect the battery 0 corresponds to max 80 discharge 2 Service alarm red 1 Flashing less than 50 hours truck operation until the next service 2 Constant Service date overdue 3 Red indicator light Switched on default or alarm 24 11638011651 EN 09 2019 ...

Page 35: ...er of operating hours of the machine The meter starts running when the machine is switched on and a control is used When counting the dot next to the tenths of an hour flashes The hour meter displays hours and tenths of an hour When the power supply is disconnected the hours are stored in the memory 8 STOP alarm red Miscellaneous problems Do not operate the truck 9 T alarm red Constant control modu...

Page 36: ... OFF only 2 ADMINISTRA TOR CODE ESSENTIAL FOR ALL ELEC TRONIC KEY SETTINGS 0 0 0 0 0 0 0 0 by default continuous red continuous 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 flashing 2 code accepted Example of new operator code 45678 Allocating operator codes 2 5 4 3 2 1 red off green flashing 2 code accepte...

Page 37: ...green flashing 5 5 seconds before switch off Power switches off automatically after 10 minutes 600 seconds by default if the truck is not in use Setting the time delay of the automatic switch off 3 6 0 red off green flashing 2 value accepted Example automatically switches off after 1 minute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off...

Page 38: ...structions label Consult the operating instructions 6 Double pallet stacker label loading unload ing 7 Label to indicate the pressure of the com pressor platform 8 Label to indicate the recommended pres sure of the compressor platform 9 Next inspection label 10 Cold store label 11 Serial number in the battery compartment 28 11638011651 EN 09 2019 ...

Page 39: ...xxxx x xxxxx 1 2 3 4 Serial number NOTE Indicate the serial number for all technical enquiries The serial number contains the following information 1 Production location 2 Type 3 Year of production 4 Count number 11638011651 EN 09 2019 29 ...

Page 40: ...3 Overviews Markings 30 11638011651 EN 09 2019 ...

Page 41: ...4 Use ...

Page 42: ...rises 2 3 kW traction motor LAC microprocessor controller to control traction and lift ES30 24 steering unit 2 2 kW pump unit Batteries Power is supplied by A lead battery A gel battery Or a lithium ion battery the truck therefore has specific characteristics The types of battery removal that are available are as follows Vertical access Side access These different battery types are not available on...

Page 43: ...lied when the power supply is cut Driver s compartment The tiller groups together control functions such as steering proportional lift forward and reverse traction initial lift horn and double throw safety switch The various models are equipped with An emergency off switch A display A diagnostic connector Side protection guardrails A driver s platform Equipment available as standard or as addition...

Page 44: ... the truck Do not restrict the field of vision 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 replaced in compliance with the marking position table The guard grille must be intact and securely mounted The roller guide rails must be...

Page 45: ...he truck is ready for operation The brake is automatically disengaged Lower the tiller then reposition it in the rest position to unblock truck use 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 hardness DANGER Risk of sparks Using the truck with the battery hood open is prohi b...

Page 46: ...4 Use Starting up 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 36 11638011651 EN 09 2019 ...

Page 47: ...n the op posite direction when the anti crush device on the tiller head comes into contact with the driver s body When the operator moves away from the anti crush safety device the ma chine stops even if a drive direction is selected again Normal operation may be resumed after releasing the drive switches Checking the anti crush safety device WARNING Ensure that the test zone is free of people and...

Page 48: ... no longer supplied with power Pull the emergency off switch 1 The functions are available again NOTE Ensure that the stabiliser wheels operate correctly This adjustment influences braking effectiveness 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 powere...

Page 49: ...Use 4 Checks and actions prior to commissioning Checking the horn Press the horn button 5 located on the upper part of the tiller The horn sounds 11638011651 EN 09 2019 39 ...

Page 50: ...ruck must also be reduced as the truck could tip over when breaking or cornering The loads must be consistent with a maximum 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 vibratio...

Page 51: ...ways The driver must always maintain 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 battery is correctly locked 11638011651 EN 09 2019 41 ...

Page 52: ...ows the battery charge level The operator can refer to the battery icon 1 or 2 The number of bars shown indicates the battery 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 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...

Page 53: ...It turns off immediately afterwards Temperature settings and warning lights The temperature light 1 comes on in the event of overheating of the traction motor or the controller A warning is shown on the display The settings light 2 comes on to indicate 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 116380...

Page 54: ...toise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desired drive mode using the navigation keys Activity indicator The activity indicator light 1 flashes continu ously while the truck is in operation When the indicator is off the display unit is locked or frozen A warning is shown on the display 44 11638011651 EN 09 2019 ...

Page 55: ...ent warning sounds Adjustment of the contrast Adjustment of the brightness Select the desired option Error codes menu It is possible to access error messages that are disrupting the operation of the truck Select the Error messages menu 1 The operator can access the error codes If several codes are affecting the truck the op erator can scroll through several successive displays The number of error ...

Page 56: ...tion 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 operat ing time of the truck The clock icon 3 indicates the time and date 46 11638011651 EN 09 2019 ...

Page 57: ... Driving the truck while sitting on the dashboard is prohibited The operator must be resting 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 people Operators must always stay within the truck clear...

Page 58: ...n the truck is used in pedestrian mode Driving Turn the switch key Lower the tiller into zone 3 NOTE The truck is in the driving position in zone 3 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 ...

Page 59: ...released the truck brakes electrically WARNING Restricted visibility During reverse travel visibility may be restricted Be very careful Make sure that the path behind is clear before travelling in reverse Reversing the drive direction 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 Braking WA...

Page 60: ...l position The power supply is cut off The operator presses the emergency off switch Braking by reversing the drive direction Braking can be achieved by reversing the drive direction Move the drive switch 1 or 2 in the opposite direction until the truck stops Braking by releasing the drive switch Braking can be obtained by releasing the drive switch While travelling completely release the drive sw...

Page 61: ... of the indicator light indicates the selected program The truck is equipped with three different drive programs Hare mode 3 BlueQ mode 4 Tortoise mode 2 NOTE When the operator restarts the truck the last mode selected is automatically activated NOTE The drive program is instantly changed If the operator changes mode while driving the truck he must remain vigilant Hare mode When Hare mode is selec...

Page 62: ...ring the forks is considerably reduced The different speeds can be adjusted Contact the After Sales Service Centre to change these Ride on driving WARNING Risk of the operator falling The side protection guardrails 1 prevent the operator from falling while driving Do not climb or sit on the side protection guardrails 1 Lower the platform 2 Raise the side protection guardrails 1 Lock the side prote...

Page 63: ...oads sideways NOTE To lower the side protection guardrails 1 the tab 3 must be pressed to unlock them Precautions for use in stacker and ride on modes When the operator uses the truck to stack a load it is necessary to lower the side protection guardrails when The forks are more than 1 8 metres from the ground H And the load height A is strictly greater than the height of the carriage B or the loa...

Page 64: ...Driving in pedestrian mode is possible when the platform is raised and the side protection guardrails are folded down The double throw safety switch is activated Maximum speed in pedestrian mode is reduced to 4 km h The maximum speed in pedestrian mode is reduced to 6 km h if the truck is fitted with a combi tiller Combi tiller A combi tiller is available as an option It increases the safety distan...

Page 65: ...Use 4 Driving Unfolding the combi tiller Pull on the lock 1 to unlock the tiller Pull the handle of the tiller 2 towards you to unfold it 11638011651 EN 09 2019 55 ...

Page 66: ...e same way as the standard tiller controls Folding the combi tiller Push on the tiller handles 3 to fold it The forklift operator uses the truck in a more standard configuration Using the truck on a slope NOTE Incorrect use of the truck on a slope is not recommended It places particular stress on the traction motor brakes and battery 56 11638011651 EN 09 2019 ...

Page 67: ...d faces uphill Without a load we recommend that you go up a slope forwards Travelling down slopes Always travel in reverse when going down a slope When the truck is used in pedestrian mode always travel forwards when going down a slope The load faces uphill Without a load we recommend that you go down a slope forwards In all cases you must travel at a very low speed and brake gradually DANGER Dang...

Page 68: ...ng 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 direction Release the drive switch to apply the parking brake 58 11638011651 EN 09 2019 ...

Page 69: ...ireless data management GSM 2 GPRS 1 module 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...

Page 70: ...lour No acoustic signal sounds Press the Enter 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 th...

Page 71: ...rect or not confirmed using the Enter key Re enter the PIN code The operator has been granted access authorisation But the period of validity has expired Use the interface to enter a new period of validity Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously ...

Page 72: ...A shock has occurred Reset the shock Flashes quickly Blue colour Off The truck is connected via a Bluetooth link The operating data is being read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the relevant data to be read As soon as the LEDs change to a different status resume work 62 11638011651 EN 09 2019 ...

Page 73: ... a keypad or electronic key Park the truck in a safe place Press the button 3 to log off Keep the button pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red colour The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flashes slowly at two second intervals green colour No acoustic signal sounds The truck is disabled Turn t...

Page 74: ...sponder 4 in front of the reading device 3 The LED 1 lights up for a second red colour The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flashes slowly at two second intervals green colour No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely 64 11638011651 EN 09 2019 ...

Page 75: ...rbing platform bellows This shock absorbing platform reduces the vibrations felt within the truck while driving It can be adjusted in accordance with the weight of the forklift operator To increase the shock absorbency Press the button 1 located on the dashboard To decrease the shock absorbency Press the button 2 located on the dash board 11638011651 EN 09 2019 65 ...

Page 76: ... devices for picking up loads 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 underneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms prot...

Page 77: ...e g pallets Transporting several loading units at a time is only autho rised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the loading unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety requirements 11638011651 EN 09 2019 67 ...

Page 78: ...20 model In pallet truck mode 2000 kg In 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 if the truck is equipped with controlled stabilisers In double pallet stacker mode 1000 kg on the forks main lift and 800 kg on the load arms initial lift if the truck is equipped with spring stabilisers Reading the capacity pla...

Page 79: ...height of 210 mm 11 Model 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 lowering action This detector prevents a violent impact at the end of travel Push the fork lowering control until the carriage is fully lowered The progressive shutoff device for t...

Page 80: ...e strictly adhered to Do not touch or stand on moving parts e g lifting device 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...

Page 81: ...l the button and to identify 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 without load on the load arms The high load must be lowered as close as possible to t...

Page 82: ...h of the forks Check 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 corner or on wet surfaces CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handle...

Page 83: ... uphill Never travel across the slope or make a U turn Reverse travel is used for depositing the load As visibility in reverse travel is restricted drive at creep speed Never drive with an unstable load If visibility is poor let someone guide you Be careful of low passageways low door ways scaffolding pipes etc To move past obstacles slightly raise the forks Check that the width of the load is not...

Page 84: ...i mum stability and to avoid any risk of overloading the truck Proceed as follows Drive the machine 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 storage area Lower the load until the forks are freed Withdraw the machine in a straight line Lower the forks again until they are several c...

Page 85: ...k 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 lowering of the forks Lower the forks again with the load to the ground Lift the load arms to move the truck Before leaving the machine NOTE Always stopthe machineonlevelgroundaway from traffic routes Proceed as follows Lower the for...

Page 86: ...se the forks to the correct 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 a...

Page 87: ...ravel 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 possible to load ...

Page 88: ...efore 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 electronic key In the event of a prolonged standstill press the emergency off switch and disconnect the battery 78 11638011651 EN 09 2019 ...

Page 89: ...nt on the forks is given Only the maximum weight 1 is communicated 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 i...

Page 90: ...ons the truck must be used alternately inside and outside of the cold store It can with stand temperatures 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 tempera...

Page 91: ...nent damage to the truck Parking The truck must be parked outside of the cold store Parking inside the cold 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 11638011651 EN 09 2019 81 ...

Page 92: ...e load and lower the forks completely 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 82 11638011651 EN 09 2019 ...

Page 93: ...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 maintenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that produce sparks within a minimum radiu...

Page 94: ...ergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood WARNING Risk of trapping fingers When closing the battery hood correctly position your fingers to avoid any risk of them being trapped Close the hood 1 Ensure that the battery hood is closed securely CAUTION Risk of sparks Never drive with the hood open or incorrectly clos...

Page 95: ...connect 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 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 circ...

Page 96: ...tery WARNING Explosive gases are generated during battery charging Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging 86 11638011651 EN 09 2019 ...

Page 97: ...circulation to the outside The charger is designed To be incorporated inside an industrial truck The charger must never be used alone out of the truck To stay permanently connected to the battery To operate in all positions Remain connected to the mains during periods of truck downtime to ensure the availability of the machine To tolerate opportunity charging CAUTION Risk of damage to the mains ca...

Page 98: ...an 13 minutes the truck could have been used a complete charging cycle is initialised Time protection If the duration of phases I1 P U is more than 16 hours the charger automatically 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 blocke...

Page 99: ...ion Mainte nance phase Continuously lit Off Charging process too long Off Continuously lit Charger polarity reversed battery and battery charger cables reversed with the battery remaining normally connected to the truck assembly Continuously lit Continuously lit Battery polarity reversed Off Off Selector in neutral position Flashing Flashing CAUTION Risk of damaging the battery It is strictly proh...

Page 100: ...ne lines indicate neutral positions The charger does not flow and the two LEDs flash simultaneously to indicate that no curve has been selected CAUTION Risk of premature damage to the battery Ensure that the charger setting corresponds to the type of battery If the battery is changed ensure that the setting corresponds to the type of battery The four thick lines indicate the four charging curves ope...

Page 101: ...are 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 Changing the side access battery DANGER Risk of trapping fingers It is advisable to wear gloves when changing the battery WARNING Risk of injury Safety shoes must be worn when ...

Page 102: ...itch 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 the battery by lifting the latch 1 Hold the door 2 to prevent it falling Remove the door 2 if this option is selected and put it to one side Position the truck with extraction rollers or the roller frame in the upright position near the battery co...

Page 103: ...Use 4 Handling the battery Operate and pull the locking handle 2 in the direction indicated by the arrow Lift the locking bar 3 until the battery is freed 11638011651 EN 09 2019 93 ...

Page 104: ...attery on the roller frame Position 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 therear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery 94 11638011651 EN 09 2019 ...

Page 105: ...y is correctly positioned but is not yet locked Lower and lock the handle 2 of the locking bar 3 in the direction indicated by the arrow 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...

Page 106: ...hat 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 is locked and that the battery hood is closed 96 11638011651 EN 09 2019 ...

Page 107: ...e performed as follows Remove the front hood 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 manually 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 11638...

Page 108: ...is sufficiently powerful to pull and brake 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 0252_003 109 1 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...

Page 109: ... 2 After towing chock the truck to prevent it from moving To re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted before the machine is used 11638011651 EN 09 2019 99 ...

Page 110: ...ing instructions Shut off the truck and disconnect the battery connector Raise the platform and lower the safety side protection guardrails 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 D...

Page 111: ...e jack under the forks in the indi cated locations 3 As a safety precaution always insert a wooden wedge 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 battery 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 ...

Page 112: ...m the operator Inside the lift the truck must be immobilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be 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...

Page 113: ...5 Maintenance ...

Page 114: ...tate work Maintenance intervals must be reduced if 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 specified in these operating instructions are authorised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mai...

Page 115: ...y specially trained personnel Personnel must follow the manufacturer s instructions of the battery the battery charger and the truck It is essential to follow the battery maintenance instructions and the battery charger operating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery e...

Page 116: ...supplied with voltage must only be carried out by 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 com prises electric components such as the trac tion controller b...

Page 117: ... VG68 HLP as per DIN 51524 2 Recommended 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 2...

Page 118: ...mum working capacity 3 5 l Transmission gear Transmission gear oil 1 1 l Traction motor 2 3 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 ...

Page 119: ...ff and press the emergency off switch To access the technical compartment it is necessary to lift the top hood 1 and remove the front hood 2 Proceed as follows Lower the platform and raise the side protections Unscrew the four screws 3 from the top hood 1 Lift the top hood slightly Remove the two screws 4 from the front hood 2 11638011651 EN 09 2019 109 ...

Page 120: ...hood The technical compartment must be closed once the operation is finished Reposition 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 110 11638011651 EN 09 2019 ...

Page 121: ...he platform Check the forklift operator side protection Wheels Check the condition and tightness of the wheels Check the stabilisers 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 Ch...

Page 122: ...res should be carried out every 5000 and 10 000 hours Information Carry out all 1000 hour maintenance 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 ...

Page 123: ...lead to a short circuit All components that are sensitive to moisture particularly electric components must be protected when the truck is cleaned Observe the manufacturer s instructions when using the cleaning product Clean the truck with a non flammable cleaning product mixed with water a sponge and cloths Specifically clean the oil filling openings and surrounding areas as well as the lubricating ...

Page 124: ...the truck e g with com pressed air WARNING Use of compressed air It is advisable to wear protection goggles and a mask Restart the truck in accordance with the instructions NOTE If despite taking precautions traces of moisture remain in the motor dry it using compressed air After having eliminated any traces of moisture the truck may be reactivated Do not do so before then to prevent any corrosion...

Page 125: ...es are used It is advisable to choose a compatible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging maintenance 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 sui...

Page 126: ...s Checking the condition of the forks Check that 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 116 11638011651 EN 09 2019 ...

Page 127: ...e ring gear 1 are free from dirt Clean 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...

Page 128: ...ically compensated However it is necessary to check the condition of the stabilisers No significant damage to the superstruc ture The damper cylinder pins must not be twisted No oil leakage must be present on the damper cylinder This cylinder must be inside 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 nut...

Page 129: ...attery connector before working on an 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 11638011651 EN 09 2019 119 ...

Page 130: ...inse immediately with plenty of clean water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immedia tely 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 manufac turer s recommendations The cell covers...

Page 131: ...p in the connections Check that the and output terminals are not sulphated presence of white salt Check the condition of the battery connector contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious incidents In the event of an incident contact our After Sales Service Centre as quickly as possible 11638011651 EN 09 2019 121 ...

Page 132: ...ached 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 Lo...

Page 133: ...nical compart ment Reconnect the battery connector Return the truck to service Checking the controlled stabiliser hydraulic system for leaks Switch off the truck and disconnect the battery 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 fo...

Page 134: ...t It is essential that the oil level 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 unscrew ing the plug 1 Screw the plug back in at the end of the operation CAUTION Risk of damage to the truck Only use hydraulic oil that complies with the speci fications See table of lubricants Refit the hood of the technical c...

Page 135: ...TE 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 screen thoroughly after lubrication operations Adjusting the length of the mast chains NOTE Depending on the use of the truck the chains are liable to stretch and as a result they have to be adjusted r...

Page 136: ...the number of mountings defined 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 equipment to the ground and disconnected the battery DANGER Poor visibility The screen must be installed and correctly atta ched Do not attach anything to the screen that could affect the visibility of the forks...

Page 137: ...ntacts Raise and chock the truck the wheels must not touch the ground in order to prevent irreversible deformation of the tyres Cover the truck with a cotton cover to protect 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...

Page 138: ...e pipes rubber components lubricants aluminium iron etc Before scrapping the truck notify the competent 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 irreg ularities he has committed during or after the scrapping of the truck s components an...

Page 139: ...6 Technical specifications ...

Page 140: ...6 Technical specifications EXD SF 20 datasheet EXD SF 20 datasheet 130 11638011651 EN 09 2019 ...

Page 141: ...24 2 2 Load per laden axle drive side load side 10 Load 2000 kg 1 kg 1383 2041 2 3 Load per unladen axle drive side load side 10 1 kg 1072 352 WHEELS EXD SF 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...

Page 142: ...dimensions s e L mm 75 150 1115 4 24 Fork carriage width 5 mm b3 mm 710 4 25 Fork arm external spread 5 mm b5 mm 540 560 4 26 Inside load arm spread 5 mm b4 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 3095 3 4 34 2 Aisle width with a pallet 800 x 1200 crosswise Ast mm 2913 3 4...

Page 143: ...capacity discharge in 5 hours V Ah 3 PzS side access Li ion 410 Ah 23 410 Battery weight 10 Gel lead battery 290 Battery weight with case 10 3 PzS side access Li ion 205 Ah 190 6 5 Battery weight with case 10 kg 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 output kWh h 1 5 MI...

Page 144: ...dard 1574T 1724T 2024T 2424T h1 1240 1315 1465 1665 h1 1315 1390 1540 1740 h2 150 150 150 150 h3 1574 1724 2024 2424 h4 2094 2244 2544 2944 Mast type Duplex Triplex 2424N 2924N 2136S h1 1165 1915 1165 h1 h2 1145 1395 645 h3 2424 2924 2136 h4 2944 3444 2662 134 11638011651 EN 09 2019 ...

Page 145: ... and battery connector 121 Checking the condition of the forks 116 Checking the controlled stabiliser hydraulic system for leaks 123 Checking the emergency shutdown 38 Checking the horn 39 Checking the oil level in the controlled stabiliser circuit 124 Checking the protective screen 126 Checks prior to start up 34 Cleaning and lubricating the chains 125 Cleaning the truck 113 Climatic conditions 7...

Page 146: ... reading device 64 Disconnecting the truck 63 Start up 60 G General 2 104 General information on battery maintenance 115 General view of the truck 20 Grade and quantity of lubricants and other consumables 104 Grease for pinion gear and steering ring 107 H Handling a single load 72 Handling two stacked pallets 76 Horn 51 Hydraulic fluid 12 Hydraulic oil 107 Hydraulic system Checking the hydraulic oi...

Page 147: ...n the ground 73 Setting down two loads 77 Settings menu 45 Slinging the truck 100 Specialist 16 Stabiliser maintenance 118 Stability 15 Stacking a load 74 Starting on a slope 58 Starting up 35 Steering 32 Steering geared motor Cleaning the pinion gear of the steering geared motor 117 Symbols used 8 T Technical compartment 21 Technical data for inspection and maintenance 108 Technical description 3...

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