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  Original instructions Electric pallet truck ECU 15C 0138 1133 801 16 01 EN — 11/2018…
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  Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de Made in China Rules for the operating company of industrial trucks In addition to these operating instructions,…
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  Preface Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 1133 801 16 01 EN — 11/2018…

• Page 5: Table Of Contents

  Table of contents Introduction Your industrial truck ……….. 2 General .

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  Table of contents Safety tests …………27 Regular safety inspection of the truck .
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  Table of contents Daily inspection ……….. . . 54 Servicing and maintenance personnel training and qualification .

• Page 9: Introduction

  Introduction…

• Page 10: Your Industrial Truck

  Introduction Your industrial truck Your industrial truck General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used.

• Page 11: Ce Labelling

  Introduction Your industrial truck CE labelling The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. This is confirmed by the issued EC declaration of conformity. The CE labelling is attached to the nameplate.

• Page 12: Ec Declaration Of Conformity

  Introduction Information about documentation EC declaration of conformity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the machine according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC…

• Page 13: Copyright And Property Rights

  Introduction Information about documentation proper maintenance of the truck in all possible If the operating instructions are lost, the oper- variants at the time of printing. Special de- ator must immediately request a replacement signs to meet customer requirements are doc- from the manufacturer.

• Page 14: Explanation Of Symbols Used

  Introduction Information about documentation Explanation of symbols used DANGER Compulsory procedure that must be followed to avoid danger to life or physical harm. WARNING Compulsory procedure that must followed to avoid injury. CAUTION Compulsory procedure that must be followed to avoid material damage and/or destruction.

• Page 15: Date Of Edition And Latest Update Of This Manual

  Introduction Information about documentation Date of edition and latest update of this manual The publication date of these operating instructions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks, and therefore reserves the right to implement changes and to accept no claims concerning the information provided in this manual.

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  Introduction Information about documentation Abbrevi- Meaning Explanation ation European standard European Federation of Materials Han- Fédération Européene de la Manutention dling and Storage Equipment Maximum power maximum Force German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless GPRS…

• Page 17: Defining Directions

  Introduction Information about documentation Abbrevi- Meaning Explanation ation Verein Deutscher Ingenieure German technical/scientific association Verband Deutscher Maschinen- und German Mechanical Engineering Industry VDMA Anlagenbau e.V. Association WLAN Wireless LAN Wireless local area network Defining directions The truck’s directions define as the forwards (1), backwards (4), right(2) and left(3).

• Page 18: Environmental Considerations

  We recommend working with a waste mana- gement company for disposal purposes. Technical description The ECU 15C electric pallet trucks are de- In addition, the polyurethane hoods offer signed to handle pallets with a maximum excellent stability and shock resistance and weight of 1500 kg.
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  Introduction Technical description Steering Jerk-free start-up and acceleration to maxi- mum speed. Extremely smooth steering makes for easier manoeuvring in tight spaces. Simply release or reverse the accelerator to brake. A gas spring immediately returns the tiller to the vertical position on its release. During start-up on a gradient, drive is imme- diately activated to avoid any uncontrolled reversing.

• Page 20: Use Of The Truck

  Introduction Use of the truck Use of the truck Intended use of the trucks CAUTION This machine was designed for the transport and storage on racks (pallet stackers only) of loads packed on pallets or in industrial containers de- signed for this purpose. The dimensions and capacity of the pallet or contai- ner must be adapted to the load being transported and must ensure stability.

• Page 21: Unauthorised Use

  Introduction Use of the truck Unauthorised use Any danger caused as a result of unauthorised The forklift truck should not be used in areas use becomes the responsibility of the operator where there is a risk of fire, explosion or or driver and not that of the manufacturer.

• Page 22: Residual Risks

  Introduction Residual risks Residual risks Residual dangers, residual risks Despite all operational precautions and • Falling, tripping etc. when moving on the compliance with standards and rules, the industrial truck, especially in the wet, with possibility of additional risks when using the leaking consumables or icy surfaces.

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  Introduction Residual risks 1133 801 16 01 EN — 11/2018…

• Page 24: Overview Of Hazards And Countermeasures

  Introduction Residual risks Overview of hazards and counter- measures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.

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  Introduction Residual risks Hazard Measure Check note Notes √ Complete — Not applicable Impermissible usage Issuing of operating German Ordinance on (improper usage) instructions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of German Ordinance on instruction to driver Industrial Safety and…
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  Introduction Residual risks Hazard Measure Check note Notes √ Complete — Not applicable When charging the Note the German Association for traction battery Ordinance on Electrical, Electronic Industrial Safety and and Information Health (BetrSichV), Technologies (VDE) the operating regulation 0510: In instructions and the particular German Engineering…

• Page 27: Danger To Employees

  Introduction Residual risks Danger to employees The operating company must identify and The results must be published. In the case evaluate the dangers involved in using the of truck deployment involving similar hazard truck. It must also establish which occupa- situations it is permitted to summarise the tional health and safety measures are required results.

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  Introduction Residual risks 1133 801 16 01 EN — 11/2018…

• Page 29: Safety

  Safety…

• Page 30: Definition Of Terms Used For Responsible Persons

  Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Operating company The operating company is the natural or legal The operating company must ensure that person or group who operates the truck or on all users read and understand the safety whose authority the truck is used.

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  Safety Definition of terms used for responsible persons Prohibition of use by unauthorised persons The driver is responsible for the truck during working hours. He must not allow unautho- rised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use.

• Page 32: Basic Principles For Safe Operation

  Original parts, attachments and accessories attachment parts and accessories supplied are specially designed for this truck. We by other companies have not been tested or draw your attention to the fact that parts, approved by STILL. 1133 801 16 01 EN — 11/2018…

• Page 33: Damage, Faults

  Safety Basic principles for safe operation CAUTION The installation or use of such products may have a negative impact on the design of the truck and thus impair active or passive driving safety. We recommend that you obtain approval from the manufacturer and, if applicable, from the relevant regulatory authorities before installing such parts.

• Page 34: Vibrations

  Safety Basic principles for safe operation Vibrations Vibrations to which the hands and arms CAUTION are exposed The value expressed above can be used to com- pare forklift trucks of the same category. It cannot The following value is valid for all truck models: be used to determine the operator’s daily expo- •…

• Page 35: Safety Tests

  Safety inspection based on time and extraordinary incidents The operating company (see chapter entitled «Definition of responsible persons») must STILL GmbH Hamburg ensure that the truck is checked by a specialist at least once a year or after noteworthy Regelmäßige Prüfung incidents.

• Page 36: Electrical Insulation Testing

  Safety Safety tests Electrical insulation testing The truck’s electrical insulation must have by the nominal voltage of the truck circuit, sufficient insulation resistance. Insulation between the parts under voltage and the truck resistance must be tested in accordance with chassis. EN 1175–1 and ISO 20898 at least once a Contact the After-Sales Service.

• Page 37: Safety Regulations For Handling Consumables

  Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Refer to the maintenance data table for the permissible substances necessary for Consumables can be dangerous. operation. It is necessary to follow the safety regulations when handling these substances.

• Page 38: Hydraulic Fluid

  Safety Safety regulations for handling consumables Hydraulic fluid WARNING Hydraulic fluid is a water-polluting substance! During operation of the forklift truck, Always store hydraulic fluid in containers hydraulic fluids are pressurised and complying with the regulations. are hazardous to your health. Avoid spilling.

• Page 39: Disposal Of Consumables

  Safety Safety devices – Dispose of used battery acid in line with the applicable regulations. Disposal of consumables • Any spillage of fluids such as hydraulic oil, ENVIRONMENT NOTE brake fluid or gear lubricant oil must be Materials that have to be disposed of following immediately soaked up with an oil-binding maintenance, repair and cleaning must be agent.

• Page 40: Emc — Electromagnetic Compatibility

  Safety EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key An EMC test thus firstly measures the electro- quality feature of the truck. magnetic interference emitted by the truck and secondly checks it for sufficient resistance to EMC involves electromagnetic interference with reference •…

• Page 41: General Views

  General views…

• Page 42: Description Of The Pallet Truck

  General views Description of the pallet truck Description of the pallet truck Overview of the main components Tiller Traction motor cover Battery discharge indicator Hydraulic cylinder Emergency switch Drive wheel Main cover Castors Fork Safety (belly) button Load roller Butterfly-switch (MT15) / Joystick (MT15s) Battery charging cable 1133 801 16 01 EN — 11/2018…

• Page 43: Description Of The Safety Devices And Warning Labels

  General views Description of the pallet truck Description of the safety devices and warning labels The truck has an emergency switch (3) which stops all lifting-, lowering-, driving- functions and engages the fail safe electromagnetic brake when it is pushed. By turning the pushed button 90°…

• Page 44: Identification Plate

  General views Description of the pallet truck Identification plate Type Own mass (self weight) in kg without battery Serial number Manufacturer Year of manufacture Refer to technical data listed in this operating Unladen mass in kg instructions for more detailed information Max.

• Page 45: Operation

  Operation…

• Page 46: Cleaning The Forklift

  Check and actions prior to use Commissioning, transporting, decommissioning Commissioning Commissioning data Type ECU 15C Commissioning weight [kg] app. 230 kg Dimensions [mm] 1750x700x900 After receiving our new pallet truck or for re-commissioning you have to do following before (firstly) operating the truck:…

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  Operation Check and actions prior to use • Check if are all parts included and not damaged. • Eventually installation of the multifunction tiller. • Eventually installation and charging the batteries. • Do the work according to the daily inspec- tions as well as functional checks.
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  Operation Check and actions prior to use For final decommissioning: – Hand the truck to a designated recycling company. ENVIRONMENT NOTE Oil, batteries and electric components must be recycled due to legal regulations. 1133 801 16 01 EN — 11/2018…

• Page 49: List Of Checks Prior To Start-Up

  Operation Check and actions prior to use List of checks prior to start-up WARNING – Attachments (special equipment) must be properly secured and function according to Damage or other defects on the forklift truck or their operating instructions. attachments (special equipment) can result in accidents.

• Page 50: Battery Charging

  Operation Check and actions prior to use Battery charging NOTE • The battery must be charged when the goods arrive, otherwise the battery will be damaged. • The battery must be charged at least one time per month. • Only qualified personnel are allowed to service or charge the batteries.

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  Operation Check and actions prior to use Battery indicator The discharge status is indicated by ten red LED segments. • Only when the battery is properly charged, the most right LED lit. As the battery’s state-of-charge decreases, successive LEDs light up, only one on at a time. •…

• Page 52: Setup

  Operation Setup Orange Charging Fully charged Green NOTE When charging is finished, disconnect the connector from the socket and place it in the designated pocket. Setup Checking the safety (belly) button Safety (belly) button’s function The truck is equipped with a safety (belly) button(12) which switches the driving direction away from the operator, if the truck travels towards the operator and the tiller is activated…

• Page 53: Checking The Brake And Emergency Switch

  Operation Setup Checking the brake and emergency switch Operating position Neutral position CAUTION Perform these checks on a flat surface. – Turn the drive direction switch to the desired direction forward or backward. – If move the drive direction switch back to the neutral position(B), the controller should decelerates the truck until the truck stops.

• Page 54: Checking The Horn

  Operation Setup – If the truck stopped, the parking brake will be engaged. Checking the emergency switch – Press the emergency switch(3). – The power supply to the truck is cut off. – The electrical controls and motors are disabled. –…

• Page 55: Operation

  Operation Operation Operation Operating instructions NOTE Before operating this truck, please follow the warnings and safety instructions. NOTE Driving (travelling and lifting ) on a substan- tially firm, smooth and prepared surfaces. NOTE Driving with the horizontal load centre of gravity approximately on the longitudinal centre plane of the truck.

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  Operation Operation – Press the horn button (14) to activate the audible warning signal. Parking CAUTION Don’t park the truck on inclined surfaces. NOTE The truck is equipped with an electromagnetic fail safe stopping and parking brake. Always lower the forks fully when parking.. –…
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  Operation Operation – Move the joystick(7) to the right(A) direction for lifting. – Move the joystick(7) to the left(B) direction for lowering. Travelling CAUTION Travel on inclines only with the load facing uphill. Don’t travel on inclines more than specified with the technical data.
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  Operation Operation – Move the tiller to the operating zone. – For MT15, turn the drive direction switch(13) to the desired driving direction forward or backwards. 1133 801 16 01 EN — 11/2018…
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  Operation Operation – For MT15s, pull the joystick(2) towards B with your thumb for travelling in B direction. – For MT15s, push the joystick(2) towards A with your thumb for travelling in A direction. Operating zone of the tiller Control the travelling speed carefully until you reached the desired speed.
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  Operation Operation up to the upper neutral position (‘B’). The truck brakes until it stops. • The safety (belly) button (12) prevents the operator from being crushed. If this button is activated, the truck decelerates and or starts travelling into the backwards direction (‘Bw.’) for a short distance and stops.

• Page 61: Maintenance

  Maintenance…

• Page 62: General Maintenance Information

  Maintenance General maintenance information General maintenance information General The following instructions contain all the The forklift must undergo functional testing information required for servicing your truck. and a trial run after each inspection. Carry out the various maintenance work in compliance with the maintenance plan.

• Page 63: Servicing And Maintenance Personnel Training And Qualification

  Maintenance Maintenance safety instructions • Check the vertical creep of the truck. • Check the lifting and lowering functions by operating the buttons. • Check the smooth movement of the wheels. • Check if all bolts and nuts are tightened •…

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  Maintenance Maintenance safety instructions Hydraulic Check the hydraulic cylinder, piston for damage noise • • • and leakage. Check the hydraulic connections and hose for damage • an leakage. Check the hydraulic oil level, refill if necessary. • Replace the hydraulic oil after every 1500 working •…

• Page 65: Technical Inspection And Maintenance Characteristics

  Maintenance Maintenance safety instructions 26 Check the main power cable for damages. • 27 Check the start-up protection during charging. • Function • 28 Check the horn function. 29 Check the air gap of the electromagnetic brake. • 30 Test the emergency braking. •…

• Page 66: Preparatory Tasks For Maintenance

  Maintenance Preparatory tasks for maintenance Preparatory tasks for maintenance Lubricating points Grease nipple Steering bearings Shaft Joints Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease.No.2、3、4, do not need to adding grease if these components are not main- tained or replaced.

• Page 67: Check And Refill Hydraulic Oil

  Maintenance Preparatory tasks for maintenance Check and refill hydraulic oil The required hydraulic fluid- type is • H-LP 46, DIN 51524 • Viscosity is 41.4 — 47 cSt • The amount is about 0.7L to 1.0L ENVIRONMENT NOTE Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company.

• Page 68: Checking Electrical Fuses

  Maintenance Preparatory tasks for maintenance Checking electrical fuses Fuse Rate FU 01 FU 02 – Remove the main cover. – Replace the fuses if necessary. 1133 801 16 01 EN — 11/2018…

• Page 69: Trouble Shooting

  Maintenance Trouble shooting Trouble shooting If the truck has malfunctions: TROUBLE CAUSE REPAIR Lift only the max. capacity, mentioned Load weight too high on the ID-plate Battery discharged Charge the battery Check and eventually replace the Lifting fuse faulty Load can’t be lifted lifting fuse Check and eventually refill hydraulic Hydraulic oil level too low…

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  Maintenance Trouble shooting 1133 801 16 01 EN — 11/2018…

• Page 71: Technical Data

  Technical data…

• Page 72: Main Technical Data

  Technical data Main technical data Main technical data Main technical data for standard version DESCRIPTION Manufacturer Still Model type ECU 15C Method of propulsion: battery, diesel, petrol, LPG, Battery mains power 1133 801 16 01 EN — 11/2018…

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  Distance from centre of load wheels to front forks Wheelbase: Forks up/down y (mm) 1293 WEIGHT ECU 15C Weight in running order (±10%) Load per laden axle, traction end/load end (±10%) 520 / 1180 Load per unladen axle, traction end/load end (±10%)
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  Technical data Main technical data for standard version DIMENSIONS ECU 15C 4.34 Aisle width with a 800 x 1200 pallet lengthwise Ast (mm) 1880 4.35 Turning radius Wa (mm) 1540 PERFORMANCE DATA ECU 15C Transfer speed, laden/unladen km / h 4.2 / 4.6…
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  Index Description of the safety devices and warning labels ….35 Address of manufacturer … . . I Disposal Attachments Battery .
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  Index Servicing and maintenance personnel training and qualification ..55 Oils ……29 Signals .
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  STILL GmbH 1133 801 16 01 EN – 11/2018…

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  Original instructions Electric pallet truck EXD-S 0282 50028043344 EN — 01/2018…
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  • Information on transport, initial commis- sioning and storage of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 50028043344 EN — 01/2018…

• Page 5: Table Of Contents

  Table of contents Introduction Forklift data …………2 General information .

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  Table of contents Overviews Technical description ……….22 Sample graphics .
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  Table of contents Driving …………48 Driving safety guidelines .
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  Table of contents Handling the battery ……….82 Battery type .
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  Table of contents Technical data Dimensions …………108 VDI data sheet for standard EXD-S 20 .

• Page 11: Introduction

  Introduction…

• Page 12: Forklift Data

  Introduction Forklift data Forklift data We recommend that you record the principal forklift data in the following table so that they are available if required by the sales network or authorised service centre. Type Serial number Date of delivery General information •…

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  Introduction How to Consult the Manual CAUTION ENVIRONMENT NOTE Failure to observe the instructions highlighted with Failure to observe the instructions highlighted this symbol may cause damage to the forklift and, with this symbol may cause environmental in some cases, result in warranty invalidity. damage.

• Page 14: Date Of Edition And Latest Update Of This Manual

  Introduction Date of edition and latest update of this manual Date of edition and latest update of this manual The publication date of these operating instructions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks, and therefore reserves the right to implement changes and to accept no claims concerning the information provided in this manual.

• Page 15: Ce Labelling

  Introduction CE labelling CE labelling The manufacturer uses CE labelling to indi- cate that the truck complies with the standards and regulations valid at the time of marketing. This is confirmed by the issued EC declaration of conformity. The CE labelling is attached to the nameplate.

• Page 16: Ec Declaration Of Conformity In Accordance With Machinery Directive

  Introduction EC declaration of conformity in accordance with Machinery Directive EC declaration of conformity in accordance with Machinery Di- rective Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

• Page 17: Technical Service And Spare Parts

  Introduction Technical service and spare parts Technical service and spare parts For scheduled maintenance and any repairs to the technical characteristics of the forklift over the forklift, contact only the authorised service time. network. Only original spare parts provided by the man- The authorised service network has personnel ufacturer may be used for forklift maintenance trained by the manufacturer, original spare…

• Page 18: Modifications To Forklift

  Introduction Modifications to Forklift Do not use beyond the limits of the climatic use precautions are necessary. Contact the conditions indicated below: authorised sales network for more informa- tion. • Maximum ambient temperature: +40°C • Minimum ambient temperature: +5°C DANGER •…

• Page 19: Environmental Considerations

  Introduction Environmental considerations Environmental considerations Disposal of components and batteries The truck is composed of different materials. If components or batteries need to be replaced and disposed of, they must be: • disposed of, • treated or • recycled in accordance with regional and national regulations.

• Page 20: Packaging

  Introduction Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during transport. This packaging must be removed completely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck. 50028043344 EN — 01/2018…

• Page 21: Safety

  Safety…

• Page 22: Safety Guidelines

  Safety Safety guidelines Safety guidelines General Precautions regulations integrate those in the manual NOTE «Rules for approved use of industrial vehicles». Some safety regulations to be followed when using the forklift are listed below. These General Safety Rules • Only allow qualified, trained and authorized •…

• Page 23: Battery Connection Cables

  Safety Safety guidelines CAUTION Passing over cracks or damaged parts of the floor with the truck is prohibited. Dirt and any objects in the work path must be removed immediately. Battery connection cables CAUTION Using sockets with NON-ORIGINAL battery con- nection cables can be dangerous (see purchase references in the parts catalogue) Requirements for the traction-battery…

• Page 24: Safety Regulations Relative To Operating Materials

  Safety Safety guidelines Safety Regulations Relative to Operating Materials Rules for handling and disposing of Oils operating materials • Do not allow to come into contact with the skin. ENVIRONMENT NOTE • Do not inhale oil vapors. Improper use and disposal of operating and •…

• Page 25: Residual Risk

  Safety Residual risk and disposal of the life-expired battery must NOTE be carried out as required by law. We advise For greater information, consult the specific you to contact the authorised service network battery manual that comes with the battery. that is equipped for eco-friendly disposal in accordance with current regulations.

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  Safety Residual risk • Human error resulting from failure to observe the safety guidelines. • Unrepaired damage or defective and worn components. • Insufficient maintenance and testing • Use of incorrect consumables • Maintenance intervals exceeded The manufacturer shall not be held responsi- ble for accidents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or…

• Page 27: Electromagnetic Radiation

  Safety Electromagnetic radiation Electromagnetic radiation The limit values for electromagnetic emissions and for immunity relative to the forklift are those provided by the EN 12895 standard. Non-ionised radiation If the forklift is equipped at the factory or later with devices that emit non-ionising radiation (such as radio transmitters, RFID players, data terminals, scanners, etc), the compatibility of such devices must be verified…

• Page 28: Vibrations

  Safety Vibrations Vibrations Vibrations to which the hands and arms CAUTION are exposed The value expressed above can be used to com- pare forklift trucks of the same category. It cannot The following value is valid for all truck models: be used to determine the operator’s daily expo- •…

• Page 29: Safety Tests

  Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents STILL GmbH Hamburg The operating company must ensure that the truck is checked at least once a year, or Regelmäßige Prüfung following noteworthy incidents.

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  Safety Safety tests 50028043344 EN — 01/2018…

• Page 31: Overviews

  Overviews…

• Page 32: Technical Description

  1 tonne on ground proportional to the load on the forks. each level, for optimal loading/unloading of • For lateral stability, two exclusive STILL lorries and transfer of loads. twin wheels have been specially designed…

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  Overviews Technical description Cockpit • Both EXD-S platform types always provide great comfort with their innovative, unique, • The new «cockpit» console contains all the fully sprung platform floors. functions for access, operation and control • The truck incorporates various storage on the EXD-S.

• Page 34: Sample Graphics

  Mast and initial lift tive 98/37 and carry the «CE» symbol. • The new mast design provides excellent • STILL is certified to ISO 9001. visibility when loading. • Optispeed allows speed reduction with • Full view of the load.

• Page 35: Overviews

  Overviews Overviews Overviews 0249_003-002 Lift cylinder main lift Drive motor Mast Steering motor Emergency stop switch Steer control Cockpit Brake Lift cylinder, basic lift Fuse mount Pump motor Battery Hydraulic oil tank Load wheel Stabiliser Forks Gearbox Travel control Traction wheel Protective screen 50028043344 EN — 01/2018…

• Page 36: Control And Display Elements

  Overviews Control and display elements Control and display elements View of the control elements 0249_003-003 Battery cover Battery compartment lock Cockpit Document holder Emergency isolator button 50028043344 EN — 01/2018…

• Page 37: Cockpit

  Overviews Control and display elements Cockpit 6 7 8 0249_003-062 Lower button Numbers button Lift button button Hare Horn button Horn button button Main lift up button Tortoise PRG ↑ (scrolling) button Main lift down button Numbers button Handle Display Travel control (ON) button Emergency brake switch…

• Page 38: Markings

  Overviews Markings Markings Location of plates and labels DANGER DANGER DANGER DANGER DANGER DANGER DANGER DANGER 0249_003-004 Brand label Label «Danger of getting pinched for hands» Label «Fill hydraulic oil here» Label «Danger of getting pinched for feet» Brand label and truck designation Manufacturer’s plate Label «Lifting slings here»…

• Page 39: Chassis Frame Labelling

  Overviews Markings Notice labels The warning labels and warning notices must always be obeyed. Chassis frame labelling The truck’s serial number is marked on the chassis frame (1). 2265 50028043344 EN — 01/2018…

• Page 40: Data Plate

  Overviews Options and variants Data plate NOTE Please indicate the serial number for all technical enquiries. 2327 Model Rated capacity in kg Manufacturer Serial no. Unladen weight (without battery) in kg Year of manufacture EC conformity symbol QR code Battery voltage V Nominal power rating in kW Minimum battery weight Maximum battery weight…

• Page 41: Overview Of Accessories

  Overviews Options and variants • Document holder • Preparation for data input terminal • Customer’s logo • Rollover bar (various types) • FleetManager • Tray 71 • Battery electrolyte level indicator LED Overview of accessories • Master code (factory setting «1 2 3 4») •…

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  Overviews Options and variants 50028043344 EN — 01/2018…

• Page 43: Application

  Application…

• Page 44: Authorised And Safe Use

  Application Authorised and safe use Authorised and safe use Intended use of the trucks CAUTION This machine is intended for the transport of loads packed on pallets or in industrial containers de- signed for this purpose, as well as for placing pallets into and removing pallets from stock.

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  Application Authorised and safe use • The truck has not been designed to trans- port anyone other than the operator and must not be used for this purpose. • The operator must always stay within the truck clearance. • Stay in the safety area (working area defined by the manufacturer).

• Page 46: Definition Of Directions

  Application Definition of directions There must be sufficient distance between the highest part of the truck or the load and the surrounding fixed installations. The height depends on the lift height and the dimensions of the load. Refer to the technical characteristics.

• Page 47: Truck Transport And Lifting

  Application Truck transport and lifting Truck transport and lifting Transporting the truck The forklift is normally transported by road and rail. If the forklift’s dimensions exceed the max. clearance size allowed, it is trans- ported disassembled. The sales network is in charge of the disassembly and reassembly operations.

• Page 48: Checks And Actions Prior To Commissioning

  Application Checks and actions prior to commissioning Checks and actions prior to commissioning Visual inspections WARNING Damages or any other defects on the truck or the attachment (option) can lead to accidents. If damages or any other defects on the truck or on attachment (option) are detected during the following checks, do not use the truck until it is properly repaired.

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  Application Checks and actions prior to commissioning – The latch (7) must be closed. – The battery cover (6) must be closed. 0249_003-006 – The cover (3) must be fitted. – The protective screen (2) must be fitted and undamaged. –…

• Page 50: Connecting The Battery Plug (Charging Station)

  Application Checks and actions prior to commissioning Connecting the battery plug (charg- ing station) – Disconnect the battery socket (1) from the charging station and insert into the plug on the truck. 0249_003-080 – The latch (2) must be closed. –…

• Page 51: Commissioning

  Application Commissioning Commissioning Turning on the truck NOTE The pallet truck is equipped with a digital control and is taken into operation by entering a driver code. The driver code consists of four figures and is assigned by the pool manager. It is used for normal use and operation of the truck by the driver and operator.

• Page 52: Entering The User Code

  Application Commissioning Entering the user code – Press the key (on) (6). The display (4) shows the message (8). This Code message switches off after approximately one second. You can then enter the 4-digit user code. The digits are entered in the same way as on a mobile phone.

• Page 53: Starting With Fleetmanager (Optional)

  Application Commissioning – The digit will be deleted and the flashing line (9) will reappear. It is now possible to enter digits again. – After the fourth digit has been entered, confirm this code by pressing (5). PRG ↲ The name of the truck manufacturer is displayed.

• Page 54: Hour Meter

  Battery discharge indicator – Press the key (browse) (4) to view PRG ↑ the battery charge (3) that is still available. NOTE The correct battery charge status is only indicated approx. 1 minute after connection. The charge status is indicated in % and updates in increments of 5%.

• Page 55: Display Of Time To Next Servicing

  Application Commissioning Display of time to next servicing – Press the (scrolling) button (4) to PRG ↑ display the time remaining until the next scheduled servicing. The time is shown in hours (6) and with the symbol of a spanner (5).

• Page 56: Check Of Brake And Presence Area

  Application Commissioning Check of brake and presence area – Start the truck slowly with the throttle (1). 0249_003-065 – Step off the presence area (2) while leaving the throttle actuated. 0249_003-066 50028043344 EN — 01/2018…

• Page 57: Checking The Emergency Brake Button

  Application Commissioning Checking the emergency brake button – Drive the truck slowly using the traction control (4). – Press the emergency brake button (5). The truck will be braked and remains stationary. – The signal appears on the display StoP (6).

• Page 58: Driving

  Application Driving Driving Driving safety guidelines Behaviour when driving In the plant, the driver must drive the truck according to regulations for driving on public roads. The speed of the truck must be appro- priate for local conditions. For example, speed must be reduced when cornering, in narrow passages, when driving through swing doors, in areas with reduced visibility and/or on un-…

• Page 59: Before Driving

  Application Driving Before driving Persons in the danger area Before and during operation of the truck, the driver must ensure that no person is standing in the danger area of the truck. A warning signal must be given in the event of danger to persons.

• Page 60
  Application Driving Dimensions of roads and working aisles The dimensions specified in the description section apply under established conditions and should ensure safe manoeuvring. Check in each case whether a wider aisle is required when, for example, the load dimensions deviate.

• Page 61: Emergency Stop Procedure

  Application Driving railway crossings and the like must be level and, if necessary, provided with ramps so that they can be crossed without jolts, if possible. There must be sufficient clearance between the highest parts of the truck or load and fixed parts of the surroundings.

• Page 62: Driving, Ride-On Standing Mode

  Application Driving Driving, ride-on standing mode – Stand upright, with feet placed in the presence zone (1) of the platform. NOTE The truck must be switched on. WARNING The platform floor must be kept free of any object that could activate the operator presence mat by its weight.

• Page 63: Selecting The Driving Mode

  Application Driving Selecting the driving mode NOTE The pallet truck has 2 selectable driving modes. – For normal travel, push the button (3). Hare – To drive with gentle accelerations, push the button (2). Tortoise NOTE The travel control (4) and (5) can be operated with both the left and the right hand.

• Page 64
  Application Driving Soft braking NOTE The truck is braked electrically. – Release throttle (3) or (4) when driving. 0249_003-067 – Leave the presence area (5). Average braking – Operate the butterfly valve (3) or (4) in the opposite direction. Emergency braking CAUTION This type of braking may only be used in an emer- gency.

• Page 65: Speed Limitation

  Application Driving The truck is braked by the electromagnetic brake. Speed limitation When the forks are lifted for more than 250 mm, the max. travel speed is reduced as follows: Forward travel 6 km/h Reverse travel 7 km/h > 250 mm 0249_003-011 50028043344 EN — 01/2018…

• Page 66: Using The Truck On Inclines, Loading Bridges And Lifts

  Application Driving Using the truck on inclines, loading bridges and lifts. Driving on inclines Using the truck on a lift When driving the truck up or down inclines, Using the truck on lifts is only allowed if the you must not exceed the values for inclines lift has sufficient load capacity (check the indicated in the chapter «Technical data».

• Page 67: Lifting

  Application Lifting Lifting Lifting devices The truck has 2 lifting devices: Initial lift (h5) The initial lift raises the wheel legs to 130 mm maximum. Main lift (h3) The main lift raises the forks to 1580 mm maximum. Types of masts Telescopic When the lift button is pushed, the inner mast 0249_003-012…

• Page 68: Lifting Device Controls

  Application Lifting Lifting device controls WARNING Risk of injury! The safety regulations must be fol- lowed closely, see Link error: Target with XID = «Sicherheitsvorschriften_im_Um- gang_mit_Lasten» not found! Do not put your hands into moving truck parts (e.g. mast, sideshift, implements, load lifting device etc).

• Page 69
  Application Lifting Raising the initial lift – Press the initial lift button (2) to raise the wheel legs 130 mm. 0249_003-015 Lowering the initial lift – Press the initial lift button (1) to fully lower the wheel legs. 0249_003-016 50028043344 EN — 01/2018…

• Page 70: Load Placement

  Application Load placement Load placement Safety regulations when handing loads DANGER DANGER Wear protective footwear. Risk of injury and crushing for the operator and for any pedestrians! Risk of damage to the truck and the goods CAUTION During movement of the truck and the loads, espe- cially in reverse gear, be careful not to hit any obst- Transporting passengers is strictly prohibited.

• Page 71: Checks To Be Carried Out Before Lifting A Load

  Application Load placement Checks to be carried out before lifting a load WARNING Never exceed the capacity of the truck. This ca- pacity is based on the centre of gravity and the lift height of the load. Comply strictly with the load diagram! It is not permitted to increase the capacity by adding extra weight to the truck.

• Page 72: Load Removal

  Application Load placement Load removal DANGER NOTE Before picking up the load, make sure that its di- Further information on the general rules of mensions and weight fall within the truck specifi- truck use and taking up and depositing loads cations, as indicated in the «TECHNICAL DATA»…

• Page 73
  Application Load placement Picking up one load – Lift the load (1) with the main lift, initial lift Fig 1 (2). Observe the data on the capacity plate (Fig. 1). 0249_003-017 – Before driving, lower the load (1) and the initial lift (2) (Fig.
• Page 74
  Application Load placement – Before driving, lower the upper load (1) as Fig 4 near as possible to the lower load (3) (Fig. 0249_003-020 Never lift or transport persons on the forks. Keeps your hands off moving parts of the truck (eg mast) DANGER CAUTION…
• Page 75
  Application Load placement Do not step under the elevated forks! CAUTION Risk of injury! 0249_003-021 50028043344 EN — 01/2018…

• Page 76: Transporting Loads

  Application Load placement Transporting loads As a general rule, loads must be transported one by one (e.g. pallets). Transporting several loads at once is only authorised: • If the safety requirements are met • On the orders of the supervisor in charge The operator must ensure that the load is properly packaged.

• Page 77: Driving Up And Down On An Incline

  Application Load placement Driving up and down on an incline When driving up and down on an incline, the load must always be carried uphill. It is only permitted to drive on inclines which are identified as suitable for traffic and which can be safely negotiated according to the technical data of the truck.

• Page 78: Entering Lifts

  Application Load placement DANGER DANGER Risk of injury and crushing for the operator! Risk of Never leave the forklift with the forks raised whether damage to the truck and the goods loaded or not. During the entire load placement operation, be careful not to hit any obstacles.

• Page 79: Cold Store Use

  Application Cold store use Cold store use Designation Your truck is fitted with special equipment for use in cold stores. It can be used for two operating ranges and carries a cold store label. The cold store equipment for the truck consists of using specialised oils (for the hydraulic installation and the gears) suitable for cold stores.

• Page 80
  Application Cold store use – Drive the truck for approximately 5 minutes and operate the brakes several times to ensure the truck operates safely. – Operate all the lifting functions several times. This warming up phase is required to allow the oil to reach operating temperature. Operating range 1 Permanent use in areas with temperatures of–5 °C and for short periods of time down to…

• Page 81: Digicode

  Application Digicode Digicode Digicode control Access to the electronic control is granted with three different codes: • Driver’s code • master code • service code Driver’s code The driver’s code consists of four digits and must be created by the Pool Manager. It is used for the regular utilisation and opera- tion of the truck by the driver and operator.

• Page 82: Adding The Master Code

  Application Digicode Service code The service code is only intended for the after-sales service. It allows the diagnosis of the truck for inspections and the access to the driver’s and master code. Adding the master code NOTE The truck is turned off, the battery is connec- ted.

• Page 83: Deleting A Master Code

  Application Digicode – Confirm with the (enter) button (4). PRG ↲ 1044_505-012 A flashing line cursor (8) will appear in the display. – Enter the desired new 4-digit master code with the buttons (1), (2) or (3) as described above. NOTE The controller can store a maximum of five master codes.

• Page 84
  Application Digicode – Press the (ON) button (5). – Enter the valid 4-digit master code with the buttons (1), (2) and (3). 1044_505-009 – Scroll with the (scrolling) button (6) PRG ↑ 1044_505-010 until (7) appears in the display. – Confirm with the (enter) button (4) PRG ↲…

• Page 85: Adding A Driver’s Code

  Application Digicode – Confirm with the (enter) button (4) PRG ↲ 1044_505-013 until the master code (9) to be deleted blinks (an example is shown). – Then release the button. (10) will 1044_505-015 appear again in the display. – Press the (scrolling) button (6) until PRG ↑…

• Page 86
  Application Digicode – Scroll with the (scrolling) button (6) PRG ↑ 1044_505-016 until (7) appears in the display. USEr – Confirm with the (enter) button (4) PRG ↲ 1044_505-011 until (10) appears in the display. – Confirm with the (enter) button (4). PRG ↲…

• Page 87: Deleting A Driver’s Code

  Application Digicode Deleting a driver’s code NOTE The truck is turned off, the battery is connec- ted. – Press the (ON) button (5). – Enter the valid 4-digit master code with the buttons (1), (2) and (3). 1044_505-009 – Scroll with the (scrolling) button (6) PRG ↑…
• Page 88
  Application Digicode – Confirm with the (enter) button (4) PRG ↲ 1044_505-013 until the driver’s code (9) to be deleted blinks (an example is shown). – Then release the button. (10) will 1044_505-015 appear again in the display. – Press the (scrolling) button (6) until PRG ↑…

• Page 89: Error Codes

  Application Error codes Error codes Error code 11 12 If an error code such as (15) appears, E380 shut the truck off by pressing button (10) and repeat the start-up ⇒ Chapter «Commission- ing», P. 41. If the error code persists, call your Service.

• Page 90: Battery Electrolyte Level Indicator Led (Optional)

  Application Battery electrolyte level indicator LED (optional) Error code Description Action Right button operated at power-up. Release the right button (12). Horn Horn E380 Release the right button Lowering Right button operated at power-up. Lowering E381 (13). Right button operated at power-up. Release the right button (14).

• Page 91: Handling The Truck In Specific Situations

  Application Handling the truck in specific situations Handling the truck in specific situations Hoisting the truck CAUTION Only use a lifting gear and crane with a sufficient load capacity. See the vehicle identification plate for the loading weight. – For hoisting with a crane, always attach the slings to the points identified with the hook symbol.

• Page 92: Handling The Battery

  Application Handling the battery Handling the battery Battery type The pallet stacker can be equipped with different types of batteries. Observe the information on the nattery type plate. Also refer to ⇒ Chapter «VDI data sheet for standard EXD-S 20», P. 6-109 for this purpose. WARNING The weight and dimensions of the battery affect truck stability.

• Page 93: Opening/Closing The Battery Compartment

  Application Handling the battery Safe parking Park the truck securely before carrying out work on the battery. The truck can only be operated when the battery cover is closed and the battery outlet is inserted. If the truck is enabled for side removal of the battery, the truck can only be operated once the battery is fixed in place properly using the battery locking system.

• Page 94
  Application Handling the battery – Disconnect the battery connector (3). WARNING Switch the truck and charger off before disconnec- ting the male and female connectors. – Connect the battery connector to the charger connector. NOTE Observe the information in the operating instructions for your battery and battery charger (equalising charge).

• Page 95: Removing The Battery

  Application Handling the battery Removing the battery – Turn the lock (1) 90° and lift the battery cover (2). 0249_003-069 – Disconnect the battery connector (3). – Lift the battery latch (4) to release the battery. 0249_003-070 50028043344 EN — 01/2018…

• Page 96: Installing The Battery

  Application Handling the battery – Put the battery trolley (6) opposite the battery. – Stand opposite the battery trolley and push the battery (5) onto the trolley. CAUTION Risk of injury through squeezing. Don’t put the hands into the frame or between the battery and the battery trolley.

• Page 97: Removing The Battery Cover

  Application Handling the battery – Close the battery latch (4). – Connect the battery connector (3). 0249_003-070 – Now the battery cover can be reinstalled. 0249_003-072 Removing the battery cover – Park the pallet truck. 50028043344 EN — 01/2018…

• Page 98
  Application Handling the battery – Push in the emergency isolator switch (2). – To open the battery compartment, turn the latch (1) 90 degrees. 0249_003-074 – Lift the battery cover (3) a few centimetres. 0249_003-075 50028043344 EN — 01/2018…

• Page 99: Installing The Battery Cover

  Application Handling the battery – Remove the battery cover (3) by lifting. 0249_003-076 Installing the battery cover – Install the battery cover (1). 0249_003-077 50028043344 EN — 01/2018…

• Page 100
  Application Handling the battery – Close the battery cover (1). 0249_003-078 – To close the battery compartment, turn the latch (3) 90 degrees. – Release the emergency isolator switch (2). 0249_003-079 50028043344 EN — 01/2018…

• Page 101: Decommissioning

  Application Decommissioning Decommissioning Safe parking of the truck – Park the truck in a dry, clean and well- ventilated area. WARNING Do not park the truck on gradients. In exceptional cases, secure the truck with chocks. – Lower the forks (1) on the ground. WARNING –…

• Page 102: Storage

  Application Storage Storage Measures when storing the stacker for a longer period of time If the stacker is to be held in storage for a longer longer period of time, carry out the following corrosion protection measures. If the stacker is to be stored for over two months, park it in a clean and dry storage area, which is also well ventilated and frost-free.

• Page 103: Taking Back Into Service After Storage

  Application Storage If the truck is to be taken out of service for an even longer period, contact your after-sales service. Taking back into service after storage If the pallet stacker has been out of service for over six months, it must be inspected carefully before it is taken back into service.

• Page 104
  Application Storage 50028043344 EN — 01/2018…

• Page 105: Maintenance

  Maintenance…

• Page 106: General Information

  Maintenance General Information General Information To keep your forklift in good condition, carry NOTE out the servicing indicated regularly, within the Contact the authorised service network for times indicated and using the consumption a maintenance contract appropriate to your materials provided for that purpose, as speci- forklift.

• Page 107: Scheduled Maintenance

  Maintenance Scheduled maintenance Scheduled maintenance Summary table of maintenance operations EXD-S Operations Completed Intervals in hours 1000 2000 5000 Checks and tests prior to commissioning ● Check the hydraulic system oil level ● Test the insulation between the chassis ● and the electric motors Test the insulation between the chassis ●…

• Page 108
  Maintenance Scheduled maintenance etc.) or at least every 12 months (whichever comes first). 2000 = To be repeated every 2000 hours. For example at 2000, 4000, 6000, 8000, 10,000 etc.) 5000 = To be repeated every 5000 hours. For example at 5000, 10,000, 15,000, 20,000 etc.) ▲…

• Page 109: Maintenance As Required

  Maintenance Maintenance as required Maintenance as required Cleaning the Forklift Cleaning depends on the type of use and the Use water-dampened rags to clean the parts workplace. Should the truck come into contact of the body. with highly aggressive elements such as salt CAUTION water, fertilizers, chemical products, cement, etc., it should be cleaned as carefully as…

• Page 110: Fuses

  Maintenance Maintenance as required Fuses CAUTION Before performing any work on the electrical in- stallation, remove any power from the system by disconnecting the battery connector. – Open the battery cover (1). 0249_003-044 – Disconnect the battery connector (3). – Remove the bonnet (2) to gain access to the fuse carrier.

• Page 111: Battery Replacement With Side Removal

  – Place the manufacturer-approved battery side-removal roller unit next to the truck; position it so that it is still and stable; adjust the height of the roller unit so that it is level with the underside of the battery at the…

• Page 112
  Maintenance Maintenance as required – Pull the battery outwards, sliding it along the rollers on the truck frame and positioning it on the previously prepared external roller unit. – Hook the battery at the two points (8) with a sling or chain. –…
• Page 113
  Maintenance Maintenance as required NOTE After having positioned the battery holddown, check that there is little or no clearance in the battery compartment. 50028043344 EN — 01/2018…

• Page 114: Decommissioning

  Maintenance Decommissioning Decommissioning General Information The operations to be performed for «Tem- porary decommissioning» and «Permanent decommissioning» are listed in this chapter. 50028043344 EN — 01/2018…

• Page 115: Forklift Towing

  Maintenance Decommissioning Forklift Towing The forklift may not be towed in the case of breakdown. The forklift must be lifted with due caution, as described on the preceding pages. Temporary Putting Out of Commission The following operations must be performed •…
• Page 116
  Maintenance Decommissioning 50028043344 EN — 01/2018…

• Page 117: Technical Data

  Technical data…

• Page 118: Dimensions

  Technical data Dimensions Dimensions 0249_003-081 50028043344 EN — 01/2018…

• Page 119: Vdi Data Sheet For Standard Exd-S 20

  Technical data VDI data sheet for standard EXD-S 20 VDI data sheet for standard EXD-S 20 Designation EXD-S 20 EXD-S 20 Access from Access from Driver’s platform rear the side Power source: Electric, Battery Battery diesel, petrol, LP gas, mains power Operator type: Hand, Ride-on…

• Page 120
  Technical data VDI data sheet for standard EXD-S 20 Basic dimensions EXD-S 20 EXD-S 20 Height with mast lowered h1 (mm) 1355 1355 Height of mast, retracted h1′ (mm) 1410 1410 with free lift Lifting h3 (mm) 1580 1580 Overall height with mast h4 (mm) 2070 2070…

• Page 121: Mast Types Exd-S

  Technical data Mast types EXD-S Motors EXD-S 20 EXD-S 20 Steering motor, rating S2 = 60 min Lift motor, rating S3 = 15% 2.2 kW S3, 5 2.2 kW S3, 5 Battery to DIN 43531/35/36 IEC 254-2: B IEC 254-2: B A, B, C, no Rated battery voltage C5 V/Ah…

• Page 122: Battery Specifications (To Din 43531 B)

  Technical data Battery specifications (to DIN 43531 B) Battery specifications (to DIN 43531 B) CAUTION Only use batteries in accordance with DIN. The battery tray must be closed at the bottom. Do not change the location of added weights. Max. tray size in mm Weight in kg Battery type Capacity in Ah…

• Page 123: Supply Table Exd Exd-Sf Exd-S

  Technical data Supply table EXD EXD-SF EXD-S Supply table EXD EXD-SF EXD-S Standard version Traction transmission gear FUCHS Renolin PG 220 Lifting hydraulics Olio idraulico HLF 32 Generic lubricant Tutela MP 02 Chain grease Kluber / Structovis EHD Cold storage version Traction transmission gear FUCHS Renolin PG 220…

• Page 124
  Technical data Supply table EXD EXD-SF EXD-S 50028043344 EN — 01/2018…
• Page 125
  Index Dimensions of roads and working aisles . 50 Disposal Adding a driver’s code ….75 Battery ……9 Adding the master code .
• Page 126
  Index Safety Inspection ….19 Safety regulations when handing loads . . 60 Mast types EXD-S ….111 Sample graphics .
• Page 128
  STILL GmbH 50028043344 EN – 01/2018…

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5. EXV 12

Manuals and User Guides for Still EXV 12. We have 2 Still EXV 12 manuals available for free PDF download: Original Instructions Manual

1. Manuals
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5. EXV 12i

Manuals and User Guides for Still EXV 12i. We have 2 Still EXV 12i manuals available for free PDF download: Original Instructions Manual