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Still FXD 20 N, Original Instructions Manual

The "Still FXD 20 N" Original Instructions Manual is essential for understanding and operating your equipment. Available for free download, this comprehensive manual ensures you maximize the product's potential. Access it today at manualshive.com and unleash the full capabilities of your Still FXD 20 N.

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Table of contents

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5 Maintenance

General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Servicing and maintenance personnel training and qualification . . . . . . . . . . . . . . . . . . 99
Battery maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance operations that do not require special training . . . . . . . . . . . . . . . . . . . . . 99
Ordering spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety guidelines for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Servicing and maintenance measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Technical data for inspection and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Accessing the technical compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5000-hour maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10,000-hour service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
General information on battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Checking the condition of the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Steering and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Checking the condition of the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cleaning and blowing out the electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Checking the battery acid level and electrolyte density . . . . . . . . . . . . . . . . . . . . . . . . 112
Checking the condition of cables, terminals and the battery connector . . . . . . . . . . . . . 113
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cleaning and lubricating the chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Adjusting the length of the mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Checking the protective screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Storage and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Storage of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Permanent Putting Out of Commission (Destruction) . . . . . . . . . . . . . . . . . . . . . . . . . 119

VI

11648011651 EN - 09/2019

Summary of Contents for FXD 20 N

Page 1: ...Original instructions Double pallet stacker FXD 20 N 1540 1546 11648011651 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 11648011651 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: ...ior to commissioning 34 Checking the emergency off switch 34 Checking the brakes 34 Checking the horn 35 Truck operating instructions 36 Stepping on off the truck 38 Operation of operator presence detection 39 Driver s compartment settings 41 Adjusting the seat 41 Adjusting the floor 41 Seat heater option 42 Using the display operating unit 43 Selection buttons 43 Display of the drive wheel positio...

Page 7: ...ive stopping of the carriage in the lower position 70 Handling a single load 71 Handling two stacked pallets 75 Driving assistance system Dynamic Drive Control 78 Description of the Dynamic Drive Control 78 Cold store usage optional 79 Parking the truck 81 Handling the battery 82 Battery type 82 Order picking 82 Opening and closing the battery hood 83 Charging the battery using an external charger...

Page 8: ... service plan 105 Chassis bodywork and fittings 106 Cleaning the truck 106 General information on battery maintenance 108 Checking the condition of the forks 109 Steering and wheels 110 Checking the condition of the wheels 110 Electrical equipment 111 Cleaning and blowing out the electrical components 111 Checking the battery acid level and electrolyte density 112 Checking the condition of cables t...

Page 9: ...Table of contents g 6 Technical specifications FXD 20N datasheet 122 FXD 20N mast types 126 11648011651 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 11648011651 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: ...The values were determined according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb 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 operat...

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 11648011651 EN 09 2019 ...

Page 29: ...3 Overviews ...

Page 30: ...ad guard 2 Protective screen 3 Control module 4 Seat 5 Lift cylinder 6 Platform 7 Drive wheel 8 Stabiliser wheel 9 Operator presence pedal 10 Battery compartment 11 Forks 12 Load wheels or bogies 13 Mast 14 Emergency off switch 20 11648011651 EN 09 2019 ...

Page 31: ...Overviews 3 Overview General view of the technical compartment 1 Pump motor unit 2 Fan 3 Horn 4 Traction motor 5 ES30 24 steering unit 6 Tank 7 Fuses 11648011651 EN 09 2019 21 ...

Page 32: ...nents Driver s compartment 1 Control unit or joystick depending on option selected 2 Emergency off switch 3 Switch key or electronic key 4 Display 5 Control button Steering Knob device 6 Steering wheel 7 Handle for stepping on and off the truck 22 11648011651 EN 09 2019 ...

Page 33: ... 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 34: ...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 35: ...rning indicator light 6 Drive programme indicator light 7 Activity indicator light 8 Error Code menu 9 Settings menu 10 Load Management and Drive wheel position menu 11 Status menu 12 Display of the operating time of the truck 13 Display of the battery charge 14 Display of the date and time For more information refer to chapter 4 Using the display operating unit 11648011651 EN 09 2019 25 ...

Page 36: ... of the truck label 4 Danger instructions label Consult operating instructions 5 Capacity label 6 Double pallet stacker label loading unload ing 7 Double pallet stacker label 8 Never touch with hands label 9 Mast safety label 10 Model label 11 Slinging label Consult operating instruc tions 26 11648011651 EN 09 2019 ...

Page 37: ...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 11648011651 EN 09 2019 27 ...

Page 38: ...3 Overviews Markings 28 11648011651 EN 09 2019 ...

Page 39: ...4 Use ...

Page 40: ...c steering offers driving precision and easier manoeuvring The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled with a steering wheel and a control module The drive unit is mounted on a turntable Steering is provided by an electric geared motor that positions the turntable The steering motor is controlled by a variable speed transmission It receives informa...

Page 41: ...description Electronic key Cold store 35 C Document holder Steering knob Joystick NOTE The operating instructions can be found in the document holder located on the technical compartment door 11648011651 EN 09 2019 31 ...

Page 42: ... 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 43: ...d Check that the battery compartment hood is closed and locked correctly Climb onto the truck using the handle Sit on the seat Press the operator presence pedal Release the emergency off switch 1 if it has been pressed Turn the key 2 For models equipped with an electronic key or the FleetManager option enter the PIN code The display 3 lights up The truck is ready for operation 11648011651 EN 09 20...

Page 44: ...tions are available again NOTE Ensure that the stabiliser wheels operate cor rectly This influences braking effectiveness Checking the brakes Braking by releasing the drive switch Drive the truck in direction 1 or 2 Release the drive switch The brake is activated until the truck stops completely Braking by reversing the drive direction Drive the truck in direction 1 or 2 Move the drive switch in th...

Page 45: ... to commissioning Checking the horn The horn is located on the rear side of the control module To check the operation of the horn proceed as follows Press the button 1 on the control module The horn sounds 11648011651 EN 09 2019 35 ...

Page 46: ...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 47: ...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 11648011651 EN 09 2019 37 ...

Page 48: ...on to your step CAUTION Risk of injury or impact from the edges of the truck The chassis is narrow Be careful not to hit yourself on the truck when stepping onto it CAUTION Risk of damaging the equipment Never pull on the steering wheel or control unit when climbing onto the truck Excessive force on the steering wheel or the control unit can damage it and cause a malfunction DANGER Risk of injury ...

Page 49: ...e travel fork direction it is possible to rise from the chair in the event of poor visibility The truck then travels at 2 km h The forklift operator presence pedal must be kept depressed Before rising from the chair it is essential to slow down the truck to a very low pace and to check the working environment WARNING Risk of injury Do not rise from the chair when the truck is travelling at full sp...

Page 50: ...on of operator presence detection CAUTION Disabling of controls If the operator presence pedal is released when moving The truck brake is automatically activated The controls no longer work 40 11648011651 EN 09 2019 ...

Page 51: ...if the weight setting is too high or too low This operation also enables you to adjust the hardness of the seat Adjusting the floor The floor is fitted with a pressure based height adjustment system To adjust the floor height proceed as follows Sit on the seat Press the floor unlocking button 2 and hold it down for the duration of the operation Exert pressure on the floor 3 by pushing it with your legs ...

Page 52: ... seat Adjust the weight of the operator Put the truck into service Press the LED button 1 to activate the heating The LED button 1 illuminates to indicate that the heater is in operation NOTE When the driver gets up or leaves the seat the heating stops in order to conserve battery power No visual information is shown on the display Check whether the LED button 1 is on Press the LED button 1 to rea...

Page 53: ...the screen Display of the drive wheel position The forklift operator can find out the position of the drive wheel by referring to the display Proceed as follows Press the left arrow or right arrow button to scroll through the menu Select the Wheel menu 2 Press the confirm button 1 The position of the drive wheel is then shown on the display 3 Operation of the display unit Operator presence For the t...

Page 54: ...the seat 1 is replaced by the light indicating the operator s presence on the pedal 2 which flashes Press the operator presence pedal with your left foot The light indicating the operator s presence on the pedal 2 remains continuously illuminated for two seconds and then goes out 44 11648011651 EN 09 2019 ...

Page 55: ...nsufficient 1 25 of charge remaining The 3 and 4 icons flash and an audible beep sounds A warning message appears at the 4 icon and remains on until the battery is recharged 2 20 of charge remaining Three regular beeps sound lifting is restricted the 3 icon flashes and the 4 icon remains on with a new warning message Temperature settings and warning lights The temperature light 1 comes on in the even...

Page 56: ...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 46 11648011651 EN 09 2019 ...

Page 57: ...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 58: ...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 48 11648011651 EN 09 2019 ...

Page 59: ... 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 60: ...ing WARNING Be aware of the position of the drive wheel Slowly start the truck Check the position of the drive wheel on the display NOTE Always operate the drive switch slowly as the truck reacts immediately Abrupt starts braking or reversal of drive direction must be avoided at all costs The drive switch is located on the control unit NOTE Always keep hands and feet inside the driver s compartmen...

Page 61: ...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 backwards 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 WARNING The quality of...

Page 62: ...ally if one of the following conditions is met The operator releases the operator pres ence pedal decelerates and then brakes The operator gets up from the seat decel erates and then brakes The drive switch is in the neutral position The power supply is cut off The operator presses the emergency off switch Horn The horn is positioned on the rear side of the control module It is used On routes wher...

Page 63: ...the truck he must remain vigilant Hare mode When Hare mode is selected on the screen the truck operates at its maximum perfor mance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck The travel speed of the truck is reduced 70 of maximum speed The speed of lifting and lowering the forks is reduced 90 of maximum speed This mode allows you to save battery To...

Page 64: ...mmediately Abrupt starts braking or reversal of drive direction must be avoided at all costs Front of the joystick The front of the joystick is used to Move the truck forwards or backwards Raise or lower the forks Forward travel Push the joystick to the left 1 to travel forwards opposite fork direction Reverse travel Push the joystick to the right 2 to travel backwards fork direction Fork lifting ...

Page 65: ...ant to handle the turning knob with caution The turning knob allows you to adjust the position of the wheel There is no need to reposition it when driving if the trajectory is straight When the button is positioned in the centre at the zero point 1 the truck travels in a straight line Two stops one on the left 2 and one on the right 3 delimit the axis of rotation The operator adjusts the turning k...

Page 66: ...4 Use Driving Move the turning knob to the left anti clockwise 2 to turn to the right Move the turning knob to the right clock wise 2 to turn to the left 56 11648011651 EN 09 2019 ...

Page 67: ...st be approached with great cau tion Never attempt a slope whose gradient is greater than that specified in the truck s datasheet Make sure that the ground is clean and has a non slip surface and that the route is clear Travelling up slopes Always travel up slopes in reverse The load faces uphill Without a load we recommend that you go up a slope forwards 11648011651 EN 09 2019 57 ...

Page 68: ...nt Never park the truck on a slope Never make a U turn or take shortcuts on a slope On a slope the operator must drive more slowly WARNING Risk of serious injury and or serious damage to equipment Driving on slopes steeper than 10 is prohibited due to braking capacity and stability The load being transported could tip over Starting on a slope Proceed as follows Move the drive switch in the require...

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 11648011651 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 11648011651 EN 09 2019 ...

Page 75: ... 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 76: ...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 66 11648011651 EN 09 2019 ...

Page 77: ...perator must lower the forks again before moving the truck The truck has two lift systems Main lift Lifting the fork arms Start the truck Push the fork lifting control 1 upwards A The fork arms are raised Lowering the fork arms Pull the fork lowering control 1 downwards B The fork arms are lowered When the lifting control 1 is released the forks stabilise at the required height NOTE The speed of l...

Page 78: ...ransporting loads Base lift Lifting the load arms Pull the control 2 downwards D The load arms are raised Lowering the load arms Push the control 2 upwards C The load arms are lowered 68 11648011651 EN 09 2019 ...

Page 79: ...condition FXD 20 N capacity 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 Reading the capacity plate Example with an FXD 20 N fitted with a 1844 mm duplex mast 1 Maximum lift height 1930 mm 2 Maximum mast capacity 1200 kg with a height of 1930 mm centre of gravity 400 mm 3 Maximum ma...

Page 80: ...r 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 the carriage prevents the buffer from being hit at the end of travel 70 116...

Page 81: ...with the width of the fork arms 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 ...

Page 82: ... 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 83: ...in maxi 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 to several centime...

Page 84: ...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 stop the machineon level ground away from traffic routes Proceed as follows Lower the f...

Page 85: ... forks to the correct height to load the upper pallet Carefully move the forks forward under the pallet Raise the forks 1 to lift the 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...

Page 86: ...avel is forwards Always travel up or down slopes with the load uphill In the event of poor visibility move slowly and carefully and work with guidance Do not travel with a load Q1 on the forks if there is no load Q2 on the load arms above 300 mm from the ground The heavier of the two loads Q2 must be placed down on the load arms Keep the upper load Q1 as close as possible to load Q2 at all times S...

Page 87: ...ving 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 using the ignition key or the elec tronic key In the event of a prolonged shutdown press the emergency off switch and disconnect the battery 11648011651 EN 09 2019 77 ...

Page 88: ...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 89: ...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 90: ...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 80 11648011651 EN 09 2019 ...

Page 91: ...a slope If absolutely necessary secure the truck with wedges Stopping the truck Immobilise the truck Lower the forks Switch off the ignition key or electronic key Press the emergency off switch Restarting work Switch on the ignition again key or elec tronic key Press the operator presence pedal Pull the emergency off switch 11648011651 EN 09 2019 81 ...

Page 92: ...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 93: ... 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 closed Charging the battery using an externa...

Page 94: ...k are switched off NOTE Follow the instructions provided by the battery and battery charger manufacturers equali sing charge WARNING Risk of damage short circuit or explosion Do not place any metallic objects or tools on the battery Smoking is prohibited WARNING The electrolyte diluted sulphuric acid is toxic and very caustic Follow the safety regulations when handling battery acid WARNING Explosi...

Page 95: ...ck To remove the battery we recommend that you use a fixed roller frame or a truck with extraction 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 Unclip the hood from the fixed screw 1 Place it on the forks Dis...

Page 96: ... battery cells Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment on level ground Operate and pull the locking handle 2 in the direction indicated by the arrow 86 11648011651 EN 09 2019 ...

Page 97: ...he truck with extraction rollers or the roller frame Replace the battery Remove the dis charged battery and position a charged battery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment 11648011651 EN 09 2019 87 ...

Page 98: ...ping 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 DANGER Risk of injury The battery is correctly positioned but is not yet locked Push it down to the end of the compartment 88 11648011651 EN 09 2019 ...

Page 99: ...attery incorrectly The locking bar should not in any circumstances be positioned under or on top of the stop It must be positioned against the stop Reconnect the battery connector 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 116...

Page 100: ...ration is to be performed as follows Open the technical compartment door 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 Loosen the screw 1 using an 8 mm open ended spanner Close the technical compartment door 90 11648011651 EN 09...

Page 101: ...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 102: ... 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 92 11648011651 EN 09 2019 ...

Page 103: ...fer to the technical features Observe the following instructions Shut off the truck and disconnect the battery 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 control module or the steering wheel Carefully lift the truck DANGER Risk of falling Make sure no on...

Page 104: ...e jack under the forks in the indi cated locations 3 As a safety precaution always insert a wooden 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 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 105: ...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 106: ...4 Use Handling the truck in specific situations 96 11648011651 EN 09 2019 ...

Page 107: ...5 Maintenance ...

Page 108: ...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 109: ...by 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 ...

Page 110: ...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 111: ...mum working capacity 5 9 l Transmission gear Transmission gear oil 0 98 l Traction motor 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 r...

Page 112: ... 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 113: ...onnect the battery connector Move the seat all the way forwards Remove the mounting screw 1 at the bottom of the door Open the technical compartment door 2 You must close the technical compartment after the operation is finished Close the door 2 CAUTION Risk of trapping fingers Take care not to trap your fingers between the door and the chassis Be careful not to trap your fingers in the external hinge...

Page 114: ...d locks correctly Check the transmission gear for noise and leaks Lubricate the gears Wheels Check the condition and tightness of the wheels Check the stabilisers Electrical equipment Clean the electric steering system and 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 th...

Page 115: ...e 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 Motor Drain ...

Page 116: ...ould lead to a short circuit All components that are sensitive to moisture particularly electric components must be protected when the truck is cleaned Follow the manufacturer s instructions when using the cleaning product Clean the truck with a non flammable cleaning product mixed with water a sponge and cloths Specifically clean the oil filler holes and surrounding area as well as the lubricating n...

Page 117: ... 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 corrosio...

Page 118: ...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 119: ...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 11648011651 EN 09 2019 109 ...

Page 120: ...that the wheels rotate freely and remove any objects that may prevent them from turning or may obstruct them CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the bearings and tyres of the wheels it is essential to remove any wires or plastic strips that may wind around the wheel hubs and bearings 110 11648011651 EN 09 2019 ...

Page 121: ...ector before working on an electrical component Press in the emergency off switch Disconnect the battery connector Open the technical compartment hood 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 cable harness connector pins 11648011651 EN 09 2019 111 ...

Page 122: ...kin or into the eyes If this does happen rinse 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 manuf...

Page 123: ...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 11648011651 EN 09 2019 113 ...

Page 124: ...ched correctly and show no signs of friction wear Check the external pipes and hoses on the technical compartment Close the technical compartment door 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 ...

Page 125: ...s on the tank Remove the plug 1 If necessary top up via the opening Refit the plug 1 afterwards CAUTION Risk of damage to hydraulic components Only use hydraulic oil that complies with the manu facturer s specifications see table of recommen ded lubricants Close the technical compartment door Reconnect the battery connector Return the truck to service 11648011651 EN 09 2019 115 ...

Page 126: ...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 127: ...er 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 When cl...

Page 128: ...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 129: ...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 130: ...5 Maintenance Storage and decommissioning 120 11648011651 EN 09 2019 ...

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

Page 132: ...6 Technical specifications FXD 20N datasheet FXD 20N datasheet 122 11648011651 EN 09 2019 ...

Page 133: ... unladen axle drive side load side 10 kg 992 459 1 WHEELS FXD 20N 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 Ø254 x L102 3 3 Wheel dimensions load side Ø x L mm Ø85 x L85 bogies Ø85 x L60 3 4 Additional wheels dimensions Ø x L mm 2 x Ø140 x L50 3 5 Number of wheels at drive side load side X drive wheel 1X 1 2 1X 1 4 3 6 Drive sid...

Page 134: ...ith predetermined load Ast mm 2684 3 4 34 2 Aisle width with an 800 x 1200 pallet crosswise Ast mm 2812 3 4 35 Turning radius minimum 20 mm initial lift raised lowered Wa mm 2012 PERFORMANCE DATA FXD 20N 5 1 Travel speed laden unladen 5 km h 10 10 Initial lift speed when laden unladen 10 m s 0 034 0 07 5 2 Main lift speed when laden unladen 10 m s 0 107 0 174 Initial lift lowering speed when laden...

Page 135: ...ht with tray 10 kg 4 PzS side access Li ion 410 Ah 351 6 6 Energy consumption according to standardised VDI cycle kWh 1h 1 08 6 7 Turnover output according to VDI cycle t h 48 6 8 Energy consumption at turnover output kWh 1h 1 7 MISCELLANEOUS FXD 20N 8 1 Speed control AC controller LAC 10 7 Noise level at operator s ears 2 5 dB A 69 Vibrations transmitted to the operator EN 13059 m s 0 56 1 Weight...

Page 136: ... mast types FXD 20N mast types Mast type Standard 1844S 2344S h1 1415 1665 h1 1490 1740 h2 150 150 h3 1844 2344 h4 2364 2864 Mast type Duplex 1844D 2344D h1 1415 1665 h1 h2 895 1145 h3 1844 2344 h4 2364 2864 126 11648011651 EN 09 2019 ...

Page 137: ...Checking the horn 35 Checking the protective screen 117 Checks prior to start up 32 Cleaning and lubricating the chains 116 Cleaning the truck 106 Climatic conditions 7 cold store 79 Cold store usage 79 Consumables 11 Battery acid safety instructions 12 Disposal 13 Oil Safety Information 11 Safety information for handling hydraulic fluid 12 Contact details I Copyright and property rights 3 D Definin...

Page 138: ... 20 General view of the technical compartment 21 Grade and quantity of lubricants and other consumables 98 Grease for pinion gear and steering ring 102 H Handling a single load 71 Handling two stacked pallets 75 Horn 52 Hydraulic fluid 12 Hydraulic oil 102 Hydraulic system Checking the hydraulic oil level 114 Checking the hydraulic system for leaks 114 I Identification label 5 J Joystick function Fr...

Page 139: ...ad down on the ground 72 Setting down two loads 76 Settings menu 47 Slinging the truck 93 Specialist 16 Stability 15 Stacking a load 73 Starting on a slope 58 Starting up 33 Steering 30 Steering knob option 55 Stepping on off the truck 38 Stopping the truck 81 Symbols used 8 T Technical data for inspection and maintenance 101 Technical description 30 Transmission oil 102 Transporting a load 72 Tra...

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