Still SXD-20 Original Instructions Manual Download

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Double pallet stacker

SXD-20

Original instructions

1615 2366

11648011551 EN - 02/2021 - 07

Summary of Contents for SXD-20

Page 1: ...Double pallet stacker SXD 20 Original instructions 1615 2366 11648011551 EN 02 2021 07 ...

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 11648011551 EN 02 2021 07 ...

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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: ...ioning 35 Start up 35 Checking the emergency shutdown 35 Checking the brakes 36 Checking the horn 37 Truck operating instructions 38 Climbing on and off the truck 40 Operator presence pedal 41 Using the display operating unit 42 Selection buttons 42 Display of the drive wheel position 42 Operation of the display unit 43 Driving safety guidelines 47 Driving 48 Definition of directions 48 Start up 4...

Page 7: ... Parking the truck 75 Handling the battery 76 Battery type 76 Order picking 76 Opening and closing the battery hood 77 Changing the side access battery 78 Charging the battery using an external charger 84 Handling the truck in an emergency 86 Emergency mast lowering 86 Truck towing procedure 87 Handling the truck in specific situations 89 Slinging the truck 89 Lifting the truck 90 Transporting the...

Page 8: ... wheels 108 Maintaining the wheels and rollers 108 Electrical equipment 109 Cleaning and blowing out the electrical components 109 Checking the fuses 109 Checking the battery acid level and electrolyte density 110 Checking the condition of cables terminals and the battery connector 111 Hydraulic systems 112 Checking the hydraulic system for leaks 112 Check the hydraulic oil level 113 Lift mast 114...

Page 9: ...1 Introduction ...

Page 10: ...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 11: ... 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 12: ...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 13: ...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 14: ...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 15: ... 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 11648011551 EN 02 2021 07 ...

Page 16: ...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 17: ...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 18: ...Introduction 1 Disposing of components and batteries 10 11648011551 EN 02 2021 07 ...

Page 19: ...2 Safety ...

Page 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 11648011551 EN 02 2021 07 ...

Page 28: ...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 29: ...3 Overviews ...

Page 30: ...ronic key and display block Steering wheel Handle for climbing on and off Lift cylinder Platform 1 2 3 4 5 6 7 8 Drive wheel Stabiliser wheel Battery compartment Push rods Forks Load wheels Hood Mast Guard grille 9 10 11 12 13 14 15 16 17 Overviews 3 Overview 22 11648011551 EN 02 2021 07 ...

Page 31: ... view of the technical compartment Pump motor unit Fan Controller Electromagnetic brake 1 2 3 4 Traction motor Electric steering unit ES30 24 Horn Tank 5 6 7 8 Overviews 3 Overview 23 11648011551 EN 02 2021 07 ...

Page 32: ...h key or electronic key Control button Steering Knob device Display Control unit Display 1 2 3 4 5 Control unit Switch key or electronic key Emergency off switch Steering wheel 6 7 8 9 Overviews 3 Operating and display devices 24 11648011551 EN 02 2021 07 ...

Page 33: ...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 34: ...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 35: ...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 11648011551 EN 02 2021 07 ...

Page 36: ... the truck label Danger instructions label Consult operating instructions Capacity label 1 2 3 4 5 Double pallet stacker label loading unload ing Double pallet stacker label Never touch with hands label Mast safety label Model label 6 7 8 9 10 Overviews 3 Markings 28 11648011551 EN 02 2021 07 ...

Page 37: ...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 11648011551 EN 02 2021 07 ...

Page 38: ...Overviews 3 Markings 30 11648011551 EN 02 2021 07 ...

Page 39: ...4 Use ...

Page 40: ...truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled by A steering wheel and a control unit The Steering Knob device notched button which allows you to position the wheel The drive unit is mounted on a turntable Turn ing is provided by an electric geared motor that positions the turntable The steering motor is controlled by an impulse control system This system...

Page 41: ...the right Control unit on the left or the right depend ing on the position of the steering wheel Control button Steering Knob device Cold store 35 C Terminal support Document holder support Roller support Use 4 Technical description 33 11648011551 EN 02 2021 07 ...

Page 42: ...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 43: ...art the truck The display 3 lights up The truck is now ready for use Checking the emergency shutdown To check the operation of the emergency off switch proceed as follows Press the emergency off switch 1 The power supply to the machine is cut off The electrical controls and motors are no lon ger supplied with power The electromagnetic brake is applied Pull the emergency off switch 1 Enter the code...

Page 44: ...witch in the op posite direction First the truck is braked electrically Release the drive switch The brake is automatically activated The truck should slow down until it reaches a standstill Braking by releasing the drive switch To check the brakes proceed as follows Accelerate the unladen truck in a clear area While travelling completely release the drive switch The brake is automatically activat...

Page 45: ...Checking the horn To check the operation of the horn proceed as follows Press the horn 1 The horn sounds Use 4 Checks and actions prior to commissioning 37 11648011551 EN 02 2021 07 ...

Page 46: ...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 47: ...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 39 11648011551 EN 02 2021 07 ...

Page 48: ... Risk of injury To avoid accidental start up do not use the control module as a handle Please use the handle 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 Use 4 Climbing on and off the truck 40 11648011551 EN 02 2021 07 ...

Page 49: ... the truck is moving it brakes and slows to a stop Releasing the operator presence pedal 1 ac tivates the parking brake DANGER Risk of accident Do not keep the operator presence pedal pressed down with equipment or weights NOTE Use your left foot to press the operator pres ence pedal Use 4 Operator presence pedal 41 11648011551 EN 02 2021 07 ...

Page 50: ...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 51: ...om 61 to 80 4 bars From 81 to 100 5 bars The Battery indicator light 3 comes on in the event of a deep discharge of the battery or in the event of a fault Two distinct warnings may be displayed if the battery charge is insufficient 1 Less than 25 of charge remaining 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 rechar...

Page 52: ...is shown on the display The warning indicator light 3 comes on in the event of a fault in a truck component Drive programme The drive programme indicator light 1 is per manently illuminated when a travel mode is selected There are three different drive modes Tortoise mode 2 Hare mode 3 Blue Q mode 4 The icon of the drive mode selected appears on the display Select the desired drive mode using the ...

Page 53: ...n the display Settings menu It is possible to access different settings through the Settings menu Select the settings menu 1 This menu allows access to a drop down menu 2 consisting of Language Unit Date format Date Time Adjust the Load Management warning sounds Adjust the contrast Adjust the brightness Select the desired choice Use 4 Using the display operating unit 45 11648011551 EN 02 2021 07 ...

Page 54: ...rough several successive dis plays The number of error messages is indicated at the bottom of the display 2 The start up screen In addition to the various menus and lights mentioned above additional data is available The truck status menu 1 displays the truck menu The hourglass icon 2 indicates the operat ing time of the truck The clock icon 3 indicates the time and date Use 4 Using the display op...

Page 55: ...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 56: ...eck that the battery hood is closed Check that the battery is locked Check that the battery is connected Check that the battery compartment hood is closed and locked correctly Climb onto the truck using the handle 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 op tion enter th...

Page 57: ...d travel Using your thumb push the drive switch to the left 2 to travel forwards opposite fork direction When the drive switch is released the truck brakes electrically Reverse travel Using your thumb push the drive switch to the right 1 to travel backwards fork direc tion When the drive switch is released the truck brakes electrically WARNING Restricted visibility During reverse travel visibility...

Page 58: ...s braked electrically Release the drive switch at the required speed The truck comes to a standstill Braking by releasing the drive switch While travelling completely release the drive switch The truck is braked electrically The parking brake is applied automatically when the truck speed is close to zero The truck comes to a standstill Electromagnetic braking The electromagnetic parking brake is a...

Page 59: ...f the indicator light indi cates the selected program The truck is equipped with three different drive programs Hare mode 3 BlueQ mode 4 Tortoise mode 2 NOTE When the operator restarts the truck the last mode selected is automatically activated NOTE The drive program is instantly changed If the operator changes mode while driving the truck he must remain vigilant Hare mode When Hare mode is select...

Page 60: ...6 km h The speed of lifting and lowering the forks is considerably reduced The different speeds can be adjusted Contact the After Sales Service Centre to change these Using the truck on a slope NOTE Incorrect 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 great caution Never attempt a slope ...

Page 61: ... brake gradually DANGER Danger of death and or risk of serious damage to equipment 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 ...

Page 62: ...on 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 oper ator adjusts the turning knob within this axis to drive In forward travel opposite direction to the forks Move the turning knob to the left anti clock wise 2 to turn to the left Move the turning knob to the right clock wise...

Page 63: ...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 64: ...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 65: ...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 66: ... quickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 58 11648011551 EN 02 2021 07 ...

Page 67: ...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 68: ... The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 60 11648011551 EN 02 2021 07 ...

Page 69: ...s WARNING Take care not to trap hands or feet when operating the truck Grabbing a loading unit Watch out for the following elements the load must be well balanced and centred correctly between the fork arms the fork arms must be sufficiently slid un derneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms protrude too far out from the ...

Page 70: ...me is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 62 11648011551 EN 02 2021 07 ...

Page 71: ...ks 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 lifting and lowering moveme...

Page 72: ...ctor 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 Transporting lo...

Page 73: ...llet is in good condition SXD 20 capacity In pallet truck mode 2000 kg In pallet stacker mode 1200 kg In double pallet stacker mode 800 kg on the forks main lift and 1200 kg on the load arms initial lift Reading the capacity label Example for a truck equipped with a 1574 mm mast and initial lift 1 Model SXD 20 2 Maximum lift height 1660 mm 3 Maximum mast capacity 1200 kg with a height of 1660 mm c...

Page 74: ...e 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 DANGER Risk of tipping It is essential to slow down when approaching a cor ner or on wet ground CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads ...

Page 75: ... 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 76: ...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 77: ...verse the truck slowly to move the pallet Lower the forks again with the load to 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 lowered position Switch off the ignition key or electronic key In the event of a prolonged shutdown press the emergency off switch Then ...

Page 78: ...ier load must be placed on the load arms Picking up two loads Lower the load arms Raise the 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 upper load Reverse the truck slowly in a straight line to withdraw the first load Lower the forks to move the truck Lift the forks back to a suitable height to avoid all obsta...

Page 79: ...ravel is forwards 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 two loads Carefully move the truck to t...

Page 80: ...rking 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 72 11648011551 EN 02 2021 07 ...

Page 81: ...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 82: ...d store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged Use 4 Cold store usage optional 74 11648011551 EN 02 2021 07 ...

Page 83: ...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 75 11648011551 EN 02 2021 07 ...

Page 84: ... 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 85: ...orks Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood 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 86: ...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 the hood on the forks Disconnect the battery connector located under...

Page 87: ... the door 2 to prevent it falling Remove the door 2 if this option is selec ted and place it to one side Position the truck with extraction rollers or the roller frame 4 in the upright position near the battery compartment on level ground Use 4 Handling the battery 79 11648011551 EN 02 2021 07 ...

Page 88: ... Operate and pull the locking handle 2 in the direction indicated by the arrow Lift the locking bar 3 until the battery is freed Use 4 Handling the battery 80 11648011551 EN 02 2021 07 ...

Page 89: ...osition the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Push the battery into the compartment DANGER Risk of trapping fingers Push the battery from the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery Use 4 Handling the battery 81 11648011551 EN 02 2021 07 ...

Page 90: ... is not yet locked Lower and lock the handle 2 of the locking bar 3 in the direction indicated by the ar row The locking bar must be horizontal and must be right up against the stop 5 CAUTION Risk of locking the battery incorrectly The locking bar 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 Use 4 H...

Page 91: ...de of the battery must be correctly locked Refit the battery hood Return the truck to service WARNING Risk of injury Before restarting the truck ensure that the battery is correctly installed Check that the battery is locked and that the battery hood is closed Use 4 Handling the battery 83 11648011551 EN 02 2021 07 ...

Page 92: ...tor to the wall 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 f...

Page 93: ... generated during battery charg ing Make sure that the work 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 85 11648011551 EN 02 2021 07 ...

Page 94: ...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 86 11648011551 EN 02 202...

Page 95: ... the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is then unlocked CAUTI...

Page 96: ... 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 88 11648011551 EN 02 2021 07 ...

Page 97: ...forks Switch off the ignition and remove the key Press the emergency off switch Remove any items that could fall Protect all parts that come into contact with the lifting device 2 Hook the lifting device 2 onto the sling hook only 1 Lift the truck slowly and carefully NOTE Never sling the truck by the control unit or other points not designed for this DANGER Risk of falling Personnel must not stan...

Page 98: ...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 an adequate lifting capacity Refer to the load weight shown on the truck s capacity plate The lifting operations must be per...

Page 99: ...ways 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 attached and se cured and its load capacity is sufficient Cross the loading bridge slowly and carefully The driver must be sure that the veh...

Page 100: ...Use 4 Handling the truck in specific situations 92 11648011551 EN 02 2021 07 ...

Page 101: ...5 Maintenance ...

Page 102: ...f the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix diffe...

Page 103: ...low the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by perso...

Page 104: ... 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 105: ...d 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 5182...

Page 106: ...Traction motor 3 kW 1F1 fuse Power 300 A quantity 1 ES30 24 steering unit 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 2 2 kW 1F1 fuse Power 300 A quantity 1 Control fuse 1F3 fuse Control 7 5 A quantity 1 Control fuse 1F4 fuse Control 5 A quantity 1 Battery Distilled water As required Joints Lithium soap grease As required Maintenance 5 Technical data for inspection and maintenance 98 116...

Page 107: ...hnical compartment Immobilise the truck Lower the forks Switch off the truck key or electronic key Press the emergency off switch Disconnect the battery connector from the fixed socket on the truck Remove the mounting screw 1 at the bot tom of the door Maintenance 5 Accessing the technical compartment 99 11648011551 EN 02 2021 07 ...

Page 108: ...hed Close the technical compartment 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 hinges 3 Refit the mounting screw 1 Reconnect the battery connector Return the truck to service Maintenance 5 Accessing the technical compartment 100 11648011551 EN 02 2021 07 ...

Page 109: ...ld be carried out as required Chassis bodywork and fittings Clean the truck Wheels Check the condition of the wheels Electrical equipment Checking the condition of the battery and the battery cable Clean the battery and the battery compartment Check the fuses Maintenance 5 Maintenance plan as required 101 11648011551 EN 02 2021 07 ...

Page 110: ...g of the truck and battery cables Check the electrical insulation between the chassis and the electric components Check the battery acid level and the electrolyte level Hydraulics Check the hydraulic oil level Check the condition of the pipework Lift mast Check the condition and the length of the mast chain Lubricate the forks and the mast guide rollers Check the condition and the mounting for the...

Page 111: ...d driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 10 000 hour service plan 103 11648011551 EN 02 2021 07 ...

Page 112: ... are sensitive to moisture par ticularly 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 clean ing product mixed with water a sponge and cloths Specifically clean the oil filler holes and sur rounding area as well as the lubricating nip ples before lubrication NOTE A frequent...

Page 113: ...se of compressed air It is advisable to wear protection goggles and a mask Restart the truck in accordance with the in structions NOTE If despite taking precautions traces of mois ture remain in the motor dry it using com pressed air After having eliminated any traces of moisture the truck may be reactivated Do not move it forward to prevent any corrosion Maintenance 5 Chassis bodywork and fitting...

Page 114: ...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 115: ...the fork arms 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the fork carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 107 11648011551 EN 02 2021 07 ...

Page 116: ...igns of deterioration Raise the truck until the wheels are off the ground Check that the wheels rotate freely and re move any objects that may prevent them from turning or may obstruct them NOTE Contact the After Sales Service Centre re garding the replacement of wheels and rollers Maintenance 5 Steering and wheels 108 11648011551 EN 02 2021 07 ...

Page 117: ...ection goggles and a mask Check the condition of the cable harness connector pins Close the technical compartment door Return the truck to service Checking the fuses CAUTION Electricity danger Before carrying out any work on the electric installa tion turn the power supply off Disconnect the bat tery connector for this purpose Park the truck Switch off the truck and press the emergen cy off switch...

Page 118: ...n goggles safety gloves when work ing on a battery Never wear a watch or jewellery when handling battery acid Do not allow any acid to get onto the clothing or skin or into the eyes If this does happen rinse im mediately with plenty of clean water Immediately rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety informa...

Page 119: ...ild up in the connections Check that the and 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 Electric...

Page 120: ...en the connections if required Check the cylinders for leaks Check that the hoses are attached correctly and show no signs of friction wear Check that there are no signs of oil leakage under the truck CAUTION Risk of damaging the truck In the event of leakage contact the After Sales Serv ice Centre Maintenance 5 Hydraulic systems 112 11648011551 EN 02 2021 07 ...

Page 121: ...e truck functions the oil level must be between the minimum 3 and maximum 2 marks 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 recommended lubricants Close the technical compartment door Reconnect the battery conne...

Page 122: ... 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 123: ...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 124: ...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 116 11648011551 EN 02 2021 07 ...

Page 125: ... 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 126: ...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 127: ...6 Technical specifications ...

Page 128: ...SXD 20 datasheet Technical specifications 6 SXD 20 datasheet 120 11648011551 EN 02 2021 07 ...

Page 129: ...2000 kg kg 1273 2075 2 3 Load per unladen axle drive side load side 10 1 kg 943 405 WHEELS 3 1 Drive side load side tyres Polyurethane P Rub ber R Drive side load side R P P 3 2 Drive wheel dimensions Ø x l mm Ø 254 x l 102 3 3 Wheel dimensions load side Ø x l mm Ø 85 X l 85 Bogies Ø 85 X l 60 3 4 Additional wheels Ø x l mm 2 x Ø 140 X l 50 3 5 Number of wheels at drive side load side x drive whee...

Page 130: ... load 3 Ast mm 2640 4 34 2 Aisle width with a 800 x 1200 pallet crosswise Ast mm 2750 4 35 Turning radius minimum 20 mm Wa mm 1950 PERFORMANCE DATA 5 1 Travel speed laden unladen 5 km h 10 10 5 2 Initial lifting speed 10 m s 0 064 0 089 Main lifting speed 10 m s 0 013 0 023 5 3 Initial lowering speed 10 m s 0 073 0 075 Main lowering speed 10 m s 0 045 0 032 5 8 Maximum gradient 0 kg 1200 kg 2000 k...

Page 131: ...ation felt by the operator EN 13059 m s2 0 74 1 Weight according to line 2 1 2 With battery line 6 5 3 Ast Wa R a pallet stacker Safety distance a 200 mm 4 Load backrest mandatory for Standard Duplex 1924 2024 and 2124 masts Add 280 mm to the h4 mast values 5 With Standard Duplex 1724 mast 6 With Duplex 1724 mast Technical specifications 6 SXD 20 datasheet 123 11648011551 EN 02 2021 07 ...

Page 132: ...0 1590 h2 150 150 150 150 150 h3 1574 1724 1924 2024 2124 h4 2094 2244 2444 2544 2644 Mast type Duplex 1574D 1724D 1924D 2024D 2124D h1 1240 1315 1415 1465 1515 h1 h2 720 795 895 945 995 h3 1574 1724 1924 2024 2124 h4 2094 2244 2444 2544 2644 Technical specifications 6 Mast types 124 11648011551 EN 02 2021 07 ...

Page 133: ...ains 114 Cleaning the truck 104 Climatic conditions 8 Climbing on and off the truck 40 cold store 73 Cold store usage 73 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Dashboard elements 24 Definition of directions 48 Description of use 8 Destruction 118...

Page 134: ... lift 64 Main lift 63 Lifting the truck 90 Load handling safety rules 61 Location of markings 28 M Maintaining the wheels and rollers 108 Maintenance plan 94 1000 hour annual 102 5000 hours 102 As required 101 Managing battery charging 43 Mast 32 Mast types for trucks 124 Multi purpose grease 97 N Noise emission values 16 O Oils 13 Operating company 18 Operator presence pedal 41 Ordering spare par...

Page 135: ... data for inspection and mainte nance 98 Technical description 32 Transmission oil 97 Transporting a load 67 Transporting the truck 90 Transporting the truck in the lift 91 Transporting two loads 71 Travelling down slopes 53 Travelling up slopes 53 Truck operating instructions 38 Truck overview 22 U Unauthorised use 9 Using the truck on a slope 52 V Vibrations Vibration characteristics for vibrati...

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