Still FXD 20 Original Instructions Manual Download Page 131

Page: 131 / 162

Technical data for inspection and maintenance

Assembly

Consumables/lubricants

Capacities/adjustment values

Hydraulic system

Hydraulic oil

Minimum working capacity:

4.8 l

Maximum 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 required

Maintenance

Technical data for inspection and maintenance

121

11648011751 EN - 02/2021 - 06

Summary of Contents for FXD 20

Page 1: ...Double pallet stacker FXD 20 Original instructions 1539 2378 11648011751 EN 02 2021 06 ...

Page 2: ......

Page 3: ...of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de Preface I 11648011751 EN 02 2021 06 ...

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

Page 6: ...he brakes 35 Checking the horn 38 Truck operating instructions 39 Stepping on off the truck 41 Driver s compartment settings 42 Adjusting the seat 42 Adjusting the floor 43 Seat heater option 43 Using the display operating unit 45 Selection buttons 45 Display of the drive wheel position 45 Operation of the display unit 46 Driving safety guidelines 52 Driving 53 Definitions of steering directions 5...

Page 7: ...sioning a truck equipped with the FleetManager option 79 FleetManager option Colour code for the LEDs 80 Disconnecting a truck equipped with the FleetManager option 82 Transporting loads 84 Reading the capacity plate 84 Load handling safety rules 86 Grabbing a loading unit 86 Transporting pallets or other containers 87 Lift control elements 88 Progressive stopping of the carriage in the lower posi...

Page 8: ...ance 120 Servicing and maintenance measures 120 Working on the electrical equipment 120 Safety devices 120 Technical data for inspection and maintenance 121 Recommended lubricants 122 Accessing the technical compartment 123 1000 hour maintenance plan 125 5000 hour maintenance plan 126 10 000 hour service plan 126 Chassis bodywork and fittings 127 Cleaning the truck 127 General information on batte...

Page 9: ...d lubricating the chains 136 Adjusting the length of the mast chains 136 Checking the protective screen 137 Storage and decommissioning 139 Storage of truck 139 Permanent Putting Out of Commission Destruction 140 6 Technical specifications FXD 20 datasheet 142 FXD 20 mast types 146 Table of contents VII 11648011751 EN 02 2021 06 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ...w the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained Get to know the technology understand it and use it safely these operating instructions pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Ther...

Page 13: ... addi tion to the tow tractor can compromise safety thereby invalidating the EC declaration of con formity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third parties without the express written permission o...

Page 14: ...pliance declaration STILL S A S The manufacturer declares that the truck com plies with the requirements of the EC direc tives valid at the time of marketing This is confirmed by the EC declaration of conformity and by the EC labelling on the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declarat...

Page 15: ...lar area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Model Manufacturer Serial number Year of manufacture Unladen weight without battery in kg Maximum battery weight Minimum battery weight for a lithium ion battery the weight of the ballast con...

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

Page 17: ... or by scanning the QR code displayed to the side When the web page is open please type in the following password Spareparts24 On the next screen please enter your email address and truck serial number to receive the link by email Then download the spare parts list 2511 Introduction 1 Spare parts list 7 11648011751 EN 02 2021 06 ...

Page 18: ...le The capacity label specifies the maximum load that can be raised This limit must not be exceeded Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special meas ...

Page 19: ...physical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Disposing of components and batteries The truck is made up of different materials If components or batteries...

Page 20: ...Introduction 1 Disposing of components and batteries 10 11648011751 EN 02 2021 06 ...

Page 21: ...2 Safety ...

Page 22: ...allets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of material handling trucks When instr...

Page 23: ...Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined w...

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

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

Page 26: ...ned according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb vi brations Vibration characteristics 2 5 m s2 NOTE The vibration characteristics for bodily vibra tions cannot be used to determine the actual load level of vibrations during operation This depends on the operating conditions state ...

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

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

Page 29: ...is responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use Safety 2 Definition of responsible persons 19 11648011751 EN 02 2021 06 ...

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

Page 31: ...3 Overviews ...

Page 32: ...ering wheel Adjustable floor Platform Drive wheel Stabiliser wheel 1 2 3 4 5 6 7 8 Operator presence pedal Brake pedal Forks Bogies Battery compartment Mast Protective screen Overhead guard 9 10 11 12 13 14 15 16 Overviews 3 Overview 22 11648011751 EN 02 2021 06 ...

Page 33: ...General view of the technical compartment Pump motor unit Fan Traction motor 1 2 3 ES30 24 steering unit Tank Fuses 4 5 6 Overviews 3 Overview 23 11648011751 EN 02 2021 06 ...

Page 34: ...lay devices Driver s compartment Handle Display Switch key or electronic key Emergency off switch 1 2 3 4 Joystick Parking brake Steering wheel 5 6 7 Overviews 3 Operating and display devices 24 11648011751 EN 02 2021 06 ...

Page 35: ...L ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0...

Page 36: ...wer switches off auto matically after 10 mi nutes 600 seconds by default if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 37: ...Activity indicator light Error Code menu 1 2 3 4 5 6 7 8 Settings menu Load Management and Drive wheel position menu Status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 9 10 11 12 13 14 For more information refer to chapter 4 Using the display operating unit Overviews 3 Operating and display devices 27 11648011751 EN 02 2021 06 ...

Page 38: ...ons label Consult the operat ing instructions Capacity label Double pallet stacker label loading unloading 1 2 3 4 5 6 Double pallet stacker label Never touch with hands label Mast safety label Model label Slinging label Consult the operating instruc tions 7 8 9 10 11 Overviews 3 Markings 28 11648011751 EN 02 2021 06 ...

Page 39: ...number for all technical en quiries The serial number contains the following infor mation 1 Production location 2 Type 3 Year of production 4 Count number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 29 11648011751 EN 02 2021 06 ...

Page 40: ...Overviews 3 Markings 30 11648011751 EN 02 2021 06 ...

Page 41: ...4 Use ...

Page 42: ...tric 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 mo tor that positions the turntable The steering motor is controlled by a variable speed transmission It receives inf...

Page 43: ...vailable Electronic key Cold store 35 C Document holder NOTE The operating instructions can be found in the document holder located on the technical compartment door Use 4 Technical description 33 11648011751 EN 02 2021 06 ...

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

Page 45: ...y This adjustment influences braking ef fectiveness Checking the brakes NOTE Braking is progressive and increases as the brake pedal is depressed Braking on the version without pedals Braking using the brake pedal Push the joystick to move the truck for wards Press the brake pedal 1 The truck brakes progressively until the truck comes to a complete stop Braking by releasing the joystick Push the j...

Page 46: ...mplete stop Braking by releasing the accelerator pedal Use the drive switch located on the joystick to set the direction of travel Press the accelerator pedal 2 to move the truck forwards Release the accelerator pedal The truck brakes progressively until the truck comes to a complete stop Braking by reversing the drive direction Toggle the drive switch located on the joy stick to set the direction...

Page 47: ...lerator pedal 2 or 3 to move the truck forwards Release the accelerator pedal The truck brakes progressively until the truck comes to a complete stop Braking by reversing the drive direction Press the accelerator pedal 2 or 3 to move the truck forwards Press the other accelerator pedal Keep the pedal depressed The truck brakes progressively and then moves off in the opposite direction until the de...

Page 48: ...ocated 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 Use 4 Checks and actions prior to commissioning 38 11648011751 EN 02 2021 06 ...

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

Page 50: ...a safe braking distance from vehicles or people in front of him The driver must avoid stopping suddenly making U turns too quickly and overtaking in dangerous areas with poor visibility CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 40 11648011751 EN 02 2021 06 ...

Page 51: ...o your step Be careful not to press the pedals Sit on the seat CAUTION Risk of injury or impact from the edges of the truck Be careful not to hit yourself on the edge of the floor when stepping onto the truck CAUTION Risk of damaging the equipment Never pull on the steering wheel when stepping onto the truck Excessive force on the steering wheel can damage it and cause a malfunction DANGER Risk of...

Page 52: ...e backrest Pull the adjustment lever 1 to tilt the back rest Adjusting the depth Pull the adjustment lever 2 to move the seat forwards or backwards Weight setting The seat is equipped with an operator pres ence detector The operator must adjust his weight by incre ments of 10 kg to trigger this detection Turn the adjustment wheel 3 until the de sired weight is reached NOTE The seat s operator pres...

Page 53: ...k at low temperatures Seat heater option The driver s seat may be equipped with the seat heater option The heater turns on when the operator s pres ence on the seat is detected To activate the heater proceed as follows Sit on the 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 ...

Page 54: ... Press the LED button 1 to reactivate the heater Use 4 Driver s compartment settings 44 11648011751 EN 02 2021 06 ...

Page 55: ...ough the drop down menu The confirm button 4 to confirm the high lighted choice on 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 ...

Page 56: ...irection indicator NOTE This feature is only present on the truck ver sion with the single pedal option An indicator light indicates the direction of travel Forward travel 1 Reverse travel 2 When the operator selects a direction of trav el the indicator for the chosen direction lights up Operator presence For the truck to operate the operator must be detected on the seat and then on the pedal When...

Page 57: ...t ing 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 illumi nated for two seconds and then goes out Use 4 Using the display operating unit 47 11648011751 EN 02 2021 06 ...

Page 58: ...aining the 3 and 4 icons flash and an audible beep sounds A warning message appears at the icon 4 and remains on until the battery is recharged 2 Less than 20 of charge remaining three regular beeps sound the icon 3 flashes and the icon 4 remains on with a new warning message Temperature settings and warning lights The temperature light 1 comes on in the event of overheating of the traction motor ...

Page 59: ...he 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 Use 4 Using the display operating unit 49 11648011751 EN 02 2021 06 ...

Page 60: ...rast 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 oper ator can scroll through several successive dis plays The number of error messages is indicated at the bottom of t...

Page 61: ...ioned 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 Use 4 Using the display operating unit 51 11648011751 EN 02 2021 06 ...

Page 62: ...the dash board is prohibited The operator must be rest ing against the seat These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the dashboard to drive the truck The truck must not be used as a stepladder The truck is not designed to transport peo ple Operators must always stay within the truck clearance Stay in the safety area work...

Page 63: ... DANGER Risk of serious injury Always keep your body inside the driver s compart ment while the truck is moving The truck is equipped with two operator pres ence detectors The chair 1 The operator presence button on the adjust able floor 2 These two components are truck safety devi ces To activate the operator presence detection proceed as follows Sit on the seat 1 Press the operator presence butt...

Page 64: ... not rise from the chair to slow down the truck If the forklift operator sits down again the truck continues to travel at a limited speed The drive switch must be released When the forklift operator presses the drive switch the truck returns to its normal speed CAUTION Releasing the operator presence button When the operator presence button is released when moving The parking brake is activated Al...

Page 65: ...is connected and locked and that the hood is closed correctly To start the truck proceed as follows Step onto the truck Sit on the seat and adjust it Adjust the floor Pull the emergency off switch 2 Turn the key For models equipped with an electronic key enter the 5 digit PIN to start the truck 3 The display 4 switches on Press the operator presence pedal 5 or 6 depending on the version Select the...

Page 66: ...r s compart ment while the truck is moving 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 joystick slowly as the truck reacts immediately Abrupt starts brak ing or reversal of drive direction must be avoi ded at all costs NOTE The truck accelerates in proportion to the pressure exerted on the j...

Page 67: ... the forks 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 direction of travel Push the joystick to the left 1 or to the right 2 Push the joystick in the opposite direction The truck brakes progressively and then moves off in the opposite direction until the desired s...

Page 68: ... Turn the steering wheel anti clockwise to steer the truck to the left For reverse travel in fork direction Turn the steering wheel clockwise to steer the truck to the left Turn the steering wheel anti clockwise to steer the truck to the right WARNING Risk of incorrect operation Never use a truck with a faulty steering wheel Always slow down before negotiating a tight cor ner Approaching a tight c...

Page 69: ...on the rear side of the control module It is used On routes where there is poor visibility At junctions In the event of immediate danger Press the button 1 on the joystick The horn sounds Use 4 Driving 59 11648011751 EN 02 2021 06 ...

Page 70: ... the joystick DANGER Do not rely on lift off braking to stop the truck in an emergency Always use the brake pedal in an emergency and press the emergency off switch if necessary Push the joystick to move the truck for wards Release the joystick The truck brakes progressively until the truck comes to a complete stop The driving controls are available Braking by reversing the drive direction Push th...

Page 71: ...ator presses the emergency off switch The power supply is cut off WARNING Risk of the operator being thrown from the truck Activating the emergency off switch causes the truck to stop suddenly It should only be used in the event of an emergency and not for braking the truck under normal circum stances NOTE Also ensure that the stabiliser wheels operate correctly This influences braking effective n...

Page 72: ...d down The brake is locked indicator permanently on 2 if one of the following conditions is met The forklift operator presses the parking brake button 1 The forklift operator leaves the seat and re leases the presence pedal and the traction controller at the same time When the truck is stopped and the brake is applied indicator flashing 2 the brake switches automatically to locked status indi cato...

Page 73: ...release NOTE A power failure or an emergency stop causes immediate application of the parking brake even if the truck is moving Put the truck into service The parking brake is in locked status indicator permanently on 2 If the truck is a dual pedal version Press the parking brake button 1 Press one of the accelerator pedals to start the truck moving If the truck is a single pedal version Press the...

Page 74: ...toise 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 selected on the screen the truck operates at its maximum perform ance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performa...

Page 75: ...orrect use of the truck on a slope is not rec ommended It places particular stress on the traction motor brakes and battery Slopes must always be approached with cau tion Never attempt a slope with a gradient that is greater than that specified in the truck data sheet Make sure that the ground is clean has a non slip surface and that the route is clear Travelling up slopes Always travel up slopes ...

Page 76: ... a U turn or take a short cut 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 direction controls in the re quired direction Release the drive ...

Page 77: ...eep your body inside the driver s compart ment while the truck is moving The truck is equipped with two operator pres ence detectors The chair 1 The operator presence button on the floor 2 These two components are truck safety devi ces To activate the operator presence detection proceed as follows Sit on the seat 1 Press the operator presence button 2 Keep the pedal depressed before and whilst the...

Page 78: ...forklift operator presses the drive switch the truck returns to its normal speed CAUTION Releasing the operator presence button When the operator presence button is released when moving The parking brake is activated All controls are available CAUTION Disabling of controls When the operator leaves the seat after a time de lay The parking brake is activated The controls are no longer available Driv...

Page 79: ... 1 Reverse travel 2 Put the truck into service Forward travel Push the drive switch down 1 to travel for wards in the opposite direction to the forks Press the accelerator pedal 4 Reverse travel Push the drive switch up 2 to travel back wards in the direction of the forks Press the accelerator pedal 4 WARNING Restricted visibility During reverse travel visibility may be restricted Be very careful ...

Page 80: ...ith the single pedal option WARNING The quality of the floor surface affects the braking distance of the truck This should be taken into consideration when driving NOTE Braking is progressive and increases as the brake pedal is depressed Braking using the brake pedal Push the drive switch and press the accel erator pedal 2 to move the truck forwards Press the brake pedal 1 The truck brakes progres...

Page 81: ...n Keep the accelerator pedal 2 depressed The truck brakes progressively and then moves off in the opposite direction until the desired speed has been reached The driving controls are available Progressive braking The progressive brake is activated automati cally if one of the following conditions is met The operator presses the brake pedal 1 The operator releases the operator pres ence button The ...

Page 82: ...NOTE Also ensure that the stabiliser wheels operate correctly This influences braking effective ness Use 4 Driving Single pedal option 72 11648011751 EN 02 2021 06 ...

Page 83: ...inside the driver s compart ment while the truck is moving The truck is equipped with two types of opera tor presence detection The seat 1 The accelerator pedals 2 or 3 are used as operator presence pedals These two components are truck safety devi ces To activate the operator presence detection proceed as follows Sit on the seat 1 Press and hold the accelerator pedal 2 or 3 before and whilst the ...

Page 84: ...he forklift operator presses the drive switch the truck returns to its normal speed CAUTION Releasing the operator presence pedal When the operator presence pedal is released when moving The parking brake is activated All controls are available CAUTION Disabling of controls When the operator leaves the seat after a time de lay The parking brake is activated The controls are no longer available Dri...

Page 85: ... travel 2 Forward travel Press the accelerator pedal 1 to travel for wards in the opposite direction to the forks Reverse travel Press the accelerator pedal 2 to travel backwards in the direction of the forks 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 direction o...

Page 86: ...kes progressively until the truck comes to a complete stop The driving controls are available DANGER Do not rely on lift off braking to stop the truck in an emergency Always use the brake pedal in an emergency and press the emergency off switch if necessary Braking by releasing the forwards pedal Press the accelerator pedal 2 or 3 to move the truck forwards Release the accelerator pedal The truck ...

Page 87: ... released The operator presses the emergency off switch The power supply is cut off WARNING Risk of the operator being thrown from the truck Activating the emergency off switch causes the truck to stop suddenly It should only be used in the event of an emergency and not for braking the truck under normal circum stances NOTE Also ensure that the stabiliser wheels operate correctly This adjustment i...

Page 88: ...le with antenna The options available on the truck are Access control Access control and shock sensor Access control and GPRS module Access control shock sensor and GPRS module 1 GPRS General Packet Radio Service 2 GSM Global System for Mobile Communi cation Shock sensor This sensor allows you to record the shocks received by the truck If the truck receives a shock it is possible to configure a sp...

Page 89: ...nter key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or the RFID transponder 4 in front of the re...

Page 90: ...e enter the PIN code Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The operator has been granted ac cess authorisa tion But the peri od of validity has expired Use the interface to enter a new pe riod of validity The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously Green colour Memory is 80 full Clear t...

Page 91: ... quickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 81 11648011751 EN 02 2021 06 ...

Page 92: ...n a safe place Press the button 3 to log off Keep the but ton pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to sw...

Page 93: ... The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 83 11648011751 EN 02 2021 06 ...

Page 94: ... is in good condition FXD 20 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 a FXD 20 1 Maximum lift height 3330 mm 2 Maximum mast capacity 1200 kg with a height of 3330 mm centre of gravity 400 mm 3 Maximum mast capacity 1200 kg with a...

Page 95: ... Maximum lift height 210 mm with 2000 kg in pallet truck mode 10 Maximum capacity in pallet truck mode 2000 kg with a height of 210 mm 11 Truck model Use 4 Transporting loads 85 11648011751 EN 02 2021 06 ...

Page 96: ... Take care not to trap hands or feet when operating the truck Grabbing a loading unit Watch out for the following elements the load must be well balanced and centred correctly between the fork arms the fork arms must be sufficiently slid un derneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms protrude too far out from the load Use ...

Page 97: ...me is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 87 11648011751 EN 02 2021 06 ...

Page 98: ...in be fore moving the truck The truck has two lift systems Main lift Lifting the fork arms Start the truck Pull the fork lifting control 1 backwards A The fork arms are raised Lowering the fork arms Push the fork lowering control 1 forwards B The fork arms are lowered When the lifting control 1 is released the forks stabilise at the required height NOTE The speed of lifting and lowering movements ...

Page 99: ...detector 1 that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the low ering action This detector prevents a violent impact at the end of travel Push the fork lowering control until the car riage is fully lowered The progressive shutoff device for the carriage prevents the buffer from being hit at the end of travel Use 4 Transportin...

Page 100: ... 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 cor ner or on wet ground CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled...

Page 101: ... make a U turn Reverse travel is used for setting down the load Adjust your speed as the position of the forklift operator is now less comfortable Do not drive with an unstable load If visibility is poor let someone guide you Raise the forks slightly in order to pass ob stacles Be careful of low passageways low door ways scaffolding pipes etc Check that the width of the load is not greater than th...

Page 102: ...to disengage the load from the stor age area Proceed as follows Drive the truck to the required location Lower the load arms completely Raise the forks clearly above the level where the load is to be placed Drive the truck forward into the rack Lower the load until the forks are free Withdraw the truck in a straight line Lower the forks again until they are several centimetres from the ground DANG...

Page 103: ... com pletely clear of the rack The forklift operator must re main vigilant and ensure that there are no obstacles preventing the lowering of the forks With the load on the forks lower the forks again until they reach the ground Lift the load arms to move the truck Before leaving the truck NOTE Always stop the truck on level ground away from traffic routes Proceed as follows Lower the forks to the ...

Page 104: ...ht to load the upper pallet Carefully move the forks forward under the pallet Raise the forks 1 to lift the first upper load Move slowly in a straight line to withdraw the forks from the rack DANGER Risk of hooking the mast on the rack Do not start lowering the forks until they are com pletely clear of the rack The operator must remain vigilant and ensure that there are no obstacles pre venting th...

Page 105: ...s 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 possi ble to load Q2 at all times Setting down tw...

Page 106: ...e 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 Use 4 Transporting loads 96 11648011751 EN 02 2021 06 ...

Page 107: ...ommunicated when present on the forks The load on the load arms Q2 4 must be greater than or equal to the load on the forks Q1 3 The maximum speed of the truck depends on the height of the forks The vertical bars 2 inform the operator of the speed configuration of the truck The diagram is displayed only when double stacking is in operation It indicates if the speed is high me dium or low The speed...

Page 108: ...es between 30 C and 45 C Specific rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room temperature zone may result in the formation of condensation water This water can freeze when the truck goes b...

Page 109: ...d store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged Use 4 Cold store usage optional 99 11648011751 EN 02 2021 06 ...

Page 110: ...s sary 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 Use 4 Parking the truck 100 11648011751 EN 02 2021 06 ...

Page 111: ... picking Maintenance personnel The battery must be replaced by specially trained personnel Personnel must follow the manufacturer s instructions for the battery the charger and the truck It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro ...

Page 112: ...rks Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood 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 se curely CAUTION ...

Page 113: ...all mounted connector WARNING Electrical risk Only unplug the battery connector from the battery charger when both the battery charger and truck are switched off NOTE Follow the instructions provided by the battery and battery charger manufacturers equalising charge WARNING Risk of damage short circuit or explosion Do not place any metallic objects or tools on the bat tery Smoking is prohibited WA...

Page 114: ...re generated during battery charg ing Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging Use 4 Handling the battery 104 11648011751 EN 02 2021 06 ...

Page 115: ...commend that you use a fixed roller frame or a truck with ex traction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise 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 Disconnect the battery connec...

Page 116: ...ruck 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 Use 4 Handling the battery 106 11648011751 EN 02 2021 06 ...

Page 117: ...lers or the roller frame Replace the battery Remove the dis charged battery and position a charged bat tery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Use 4 Handling the battery 107 11648011751 EN 02 2021 06 ...

Page 118: ...rom the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Push it down to the end of the compart ment Use 4 Handling the battery 108 11648011751 EN 02 2021 06 ...

Page 119: ...g 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 Use 4 Handling the battery 109 ...

Page 120: ...he 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 man ually 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 Use 4 Handling the truck in an emergency 110 11648011751 EN 02...

Page 121: ...the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is then unlocked CAUTIO...

Page 122: ...re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted be fore the machine is used 0252_003 110 3 2 Use 4 Handling the truck in an emergency 112 11648011751 EN 02 2021 06 ...

Page 123: ...structions Shut off the truck and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device to the sling ring 1 NOTE Do not sling the truck by the control module or the steering wheel Carefully lift the truck DANGER Risk of falling Make sure no one is under or near the truck when slinging the truck ...

Page 124: ... 3 As a safety precaution always insert a wood en chock WARNING Risk of truck falling Immobilise and chock the truck after lifting it Transporting the truck CAUTION Always switch off the ignition and disconnect the bat tery Never tie down or sling the truck by the control unit or other points not designed for this CAUTION Risk of damage to the truck Use a hoist and woven NON METALLIC slings with a...

Page 125: ...obilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be observed Anyone transported with the truck must only enter the lift after the truck has been correctly immobilised and they must exit the lift first Driving on loading bridges Before crossing a loading bridge the operator must make sure it is properly ...

Page 126: ...Use 4 Handling the truck in specific situations 116 11648011751 EN 02 2021 06 ...

Page 127: ...5 Maintenance ...

Page 128: ... the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix differ...

Page 129: ...ow the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by person...

Page 130: ... personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pr...

Page 131: ...r 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 required Maintenance 5 Technical data for inspection and maint...

Page 132: ... oil for the cold store version ISO L HM 32 as per ISO 6743 4 or ISO VG32 HLP as per DIN 51524 2 Transmission oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray Grease for pinion gear and steering ring CAUTION Follow the maintenance and safety guidelines Multi purpose grease Lithium soap grease with EP agents and MoS 2KPF 2N 20 complying with the stand ard DIN 51825...

Page 133: ...mpartment Immobilise the truck Lower the load arms Switch off the truck key or electronic key Press the emergency off switch Disconnect the battery connector Move the seat all the way forwards Remove the mounting screw 1 located at the bottom of the door Maintenance 5 Accessing the technical compartment 123 11648011751 EN 02 2021 06 ...

Page 134: ... 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 hinges 3 Refit the mounting screw Reconnect the battery connector Return the truck to service Maintenance 5 Accessing the technical compartment 124 11648011751 EN 02 2021 06 ...

Page 135: ...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 the electric components Check the electrical insulation between the chassis and th...

Page 136: ...ntenance work Hydraulics Drain the hydraulic oil 10 000 hour service plan Depending on the application environmental conditions and driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 5000 hour maintenance plan 126 1164801175...

Page 137: ...G Use of compressed air It is advisable to wear protection goggles and a mask If using compressed air first remove stubborn dirt with a cold cleaning agent Before carrying out lubrication operations thoroughly clean The oil filling openings and the areas around them The grease nipples Dry the truck after cleaning If despite taking all of these precautions wa ter enters the motors the truck must be...

Page 138: ...ible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging mainte nance and treatment instructions A non compatible charger may result in a battery failure Observe the manufacturer s recommendations NOTE The discharge indicators used to check the battery must also be suitable for the type of battery Contact the re...

Page 139: ...hat the forks 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 129 11648011751 EN 02 2021 06 ...

Page 140: ... move 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 Maintenance 5 Steering and wheels 130 11648011751 EN 02 2021 06 ...

Page 141: ...ttery 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 Checking the battery acid level and electrolyte density NOTE Remove the battery from its compartment to check the water level Maintenance 5 Electrical equip...

Page 142: ...rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety information provided by the battery manufacturer Comply with the regulations in force Check the battery acid level and electrolyte density according to the battery manufactur er s recommendations The cell covers of the battery must be kept dry and clean Any spillage ...

Page 143: ...d output terminals are not sulphated presence of white salt Check the condition of the battery connec tor contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious inci dents In the event of an incident contact our After Sales Service Centre as quickly as possible Maintenance 5 Electrical equipment 133 11648011751 EN 02 2021 06 ...

Page 144: ...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 forks Switch off the ignition and...

Page 145: ...g 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 recommended lubricants Close the technical compartment door Reconnect the battery connector Return the truck to service Maintenance 5 Hydraulic systems 135 11648011751 EN 02 2021 06 ...

Page 146: ... lubricant CAUTION Risk of the equipment becoming worn or damaged Chains are safety components Use of cold cleaning agents chemical products acid or chlorinated prod ucts could destroy the chains NOTE Use of high pressure liquid cleaning devices is not advisable DANGER Danger of death and or risk of serious damage to equipment On trucks fitted with macrolon mast protection clean the translucent sc...

Page 147: ...After Sales Serv ice Centre Checking the protective screen It is important to check the condition of the mast protective screens and to check that the mountings are tightened Check that the protective screen 1 is cor rectly attached and in good condition un damaged Replace the protective screen if it is dam aged Adhere to the number of mountings defined by the manufacturer WARNING Risk of serious ...

Page 148: ...ectly attached Do not attach anything to the screen that could affect the visibility of the forks When cleaning the fork carriage side only clean the screen when the fork carriage is in the lowered posi tion Maintenance 5 Lift mast 138 11648011751 EN 02 2021 06 ...

Page 149: ... must not touch the ground in order to prevent ir reversible deformation of the tyres Cover the truck with a cotton cover to pro tect it from dust CAUTION We recommend that you do not use a plastic sheet as this encourages condensation to form Consult the service department for further measures to take if the truck must be stored for a longer period of time Recommissioning after storage If the tru...

Page 150: ...um iron etc Before scrapping the truck notify the com petent authorities of your country in writing After receiving the authorisation from the competent authorities remove any compo nents according to national standards NOTE The client is solely responsible for any irregu larities he has committed during or after the scrapping of the truck s components and the removal of components Maintenance 5 S...

Page 151: ...6 Technical specifications ...

Page 152: ...FXD 20 datasheet Technical specifications 6 FXD 20 datasheet 142 11648011751 EN 02 2021 06 ...

Page 153: ...ive side load side 10 1 kg 1052 509 WHEELS FXD 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 Ø254 x l102 3 3 Wheel dimensions load side Ø x L mm 2 x 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 4 3 6 Drive side track width 5 mm mm 699 3 7 Load s...

Page 154: ...pallet crosswise 3 AST mm 2823 4 35 Turning radius minimum Wa mm 2021 PERFORMANCE DATA FXD 20 5 1 Travel speed laden unladen 5 km h 10 12 5 2 Initial lifting speed Initial lift laden unladen 10 m s 0 034 0 07 Main lifting speed Main lift laden unladen 10 1200 kg m s 0 107 0 174 5 3 Initial lowering speed Initial Lift laden unladen 10 m s 0 084 0 084 Main lowering speed Main lift laden unladen 10 1...

Page 155: ...n according to standardised VDI cycle kWh 1h 1 1 6 7 Turnover output according to VDI cycle t h 45 6 6 8 Energy consumption at turnover output kWh 1h 1 68 MISCELLANEOUS FXD 20 8 1 Speed control AC controller LAC 10 7 Noise level at forklift operator s ears 2 5 dB A 62 Vibrations transmitted to the operator EN 13059 m s 0 4 1 Weight according to line 2 1 2 With battery line 6 5 3 Ast Wa R a pallet ...

Page 156: ... 1665 1915 h1 1490 1740 1990 h2 150 150 150 h3 1844 2344 2844 h4 2364 2864 3364 Mast type Duplex 1844D 2344D 2844D h1 1415 1665 1915 h1 h2 895 1145 1395 h3 1844 2344 2844 h4 2364 2864 3364 Technical specifications 6 FXD 20 mast types 146 11648011751 EN 02 2021 06 ...

Page 157: ...cks prior to start up 34 Cleaning and lubricating the chains 136 Cleaning the truck 127 Climatic conditions 8 cold store 98 Cold store usage 98 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Definitions of steering directions 53 Description of the Dynami...

Page 158: ...he hydraulic system for leaks 134 I Identification label 5 Indicator light Drive direction indicator 46 Parking brake 46 L Lift Base lift 89 Main lift 88 Lift control elements 88 Lifting the truck 114 Load handling safety rules 86 Location of markings 28 M Maintenance plan 118 1000 hours 125 5000 hours 126 Managing battery charging 48 Mast 32 Multi purpose grease 122 N Noise emission values 16 O O...

Page 159: ...ck 55 Steering 32 58 Stepping on off the truck 41 Stopping the truck 100 Symbols used 9 T Technical data for inspection and mainte nance 121 Technical description 32 Transmission oil 122 Transporting a load 91 Transporting the truck 114 Transporting the truck in the lift 115 Transporting two loads 95 Travelling down slopes 66 Travelling up slopes 65 Truck operating instructions 39 Turning directio...

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