Still EXU-16 Original Instructions Manual
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Still EXU-16 Original Instructions Manual

Electric pallet truck
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Original instructions
Electric pallet truck
EXU-16
EXU-18
EXU-20
EXU-22
0153 0154 0155 0157 1180
1182 1184 1186
1152 807 80 01 EN - 09/2019

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Summary of Contents for Still EXU-16

  • Page 1 Original instructions Electric pallet truck EXU-16 EXU-18 EXU-20 EXU-22 0153 0154 0155 0157 1180 1182 1184 1186 1152 807 80 01 EN - 09/2019...
  • Page 3 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 1152 807 80 01 EN - 09/2019...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... 2 General .
  • Page 6 Table of contents Overviews Truck overview ........... . . 22 Overviews .
  • Page 7 Table of contents Transporting loads ........... 53 Load handling safety rules .
  • Page 8 Table of contents Maintenance safety guidelines ......... . 82 Servicing and maintenance measures .

  • 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. The supplied EC declaration of conformity confirms this. The CE labelling is attached to the nameplate.

  • Page 12: Ec Declaration Of Conformity

    Introduction EC declaration of conformity 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: Identification Label

    Introduction Identification label Identification label NOTE Indicate the serial number for all technical enquiries. 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 container is included) Additional weight (ballast weight) in kg Nominal motor power (kW)
  • Page 14 Rules for the operating company of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 1152 807 80 01 EN - 09/2019...
  • Page 15 Introduction Rules for the operating company of industrial trucks 1152 807 80 01 EN - 09/2019...

  • Page 16: Permissible Use

    Introduction Permissible use Permissible use The truck described in these operating in- If the truck needs to be used for purposes other structions is suitable for lifting and transporting than those specified in these instructions, you loads. should first: • Obtain permission from the manufacturer The truck should only be used for the purposes •...

  • Page 17: Unauthorised Use

    Introduction Unauthorised use 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. corrosion, or in areas that are particularly dusty.
  • Page 18 Introduction Disposing of components and batteries 1152 807 80 01 EN - 09/2019...

  • Page 19: Safety

    Safety...

  • Page 20: Safety Regulations

    Safety Safety regulations Safety regulations These operating instructions, which come • Regular checks and technical inspections with the truck, must be communicated to all • Recycling of lubricants, oils and batteries those concerned and in particular to personnel • Residual risks. responsible for maintenance and driving.

  • Page 21: 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 22: 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 23: Disposal Of Consumables

    Safety Safety regulations for handling consumables – 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...

  • Page 24: Emissions

    Safety Emissions Emissions Noise emission values Acoustic pressure level on the driver's Calculated in the test cycle in accordance compartment with EN 12053 from the weighted values for the TRACTION, LIFT and IDLING operating in the DRIVE = 73,5 dB (A) states.

  • Page 25: Residual Dangers, Residual Risks

    Safety Residual dangers, 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.

  • Page 26: Specialist

    Safety Definition of responsible persons The operating company must ensure that The operating company is responsible for the all users read and understand the safety scheduling and correct performance of regular information in these instructions. safety checks. It is recommended that these checks comply with national performance specifications.

  • Page 27: 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 28 Safety Safety tests 1152 807 80 01 EN - 09/2019...

  • Page 29: Overviews

    Overviews...

  • Page 30: Truck Overview

    Overviews Truck overview Truck overview Overviews Battery plug handle (emergency stop) Traction motor Battery cover Pump unit Switch key Electromagnetic brake Traction control module Lift cylinder Fork arms Digicode (LFM Go)* Load wheels Tiller Stabiliser wheels Platform* Drive wheel *Option 1152 807 80 01 EN - 09/2019...

  • Page 31: Control And Display Components

    Overviews Control and display components Control and display components Tiller Handle Horn Lowering Throttle Raising Anti-collision device 1152 807 80 01 EN - 09/2019...

  • Page 32: Battery Charge Indicator

    Overviews Control and display components Battery charge indicator COMMENTS / SCREEN DESCRIPTION EXPLANATION MESSAGES 91% - 100%: 10 bars 1% - 10%: 1 bar Full charge: 100% 0%: 1 flashing bar (lift Battery charge level Low charge: 10% Dis- function not permitted). represented by 10 bars charged : 0% NB: To protect the battery,...
  • Page 33 Overviews Control and display components COMMENTS / SCREEN DESCRIPTION EXPLANATION MESSAGES Switched off: truck switched Green indicator light Switched on: truck switched These codes help the After Sales Service to decide on Breakdown code E3 294 the appropriate response from the service engineer Fault or brake wear (air gap) Do not operate the truck - The meter runs from when...

  • Page 34: Digicode Option (Lfm Go)

    Overviews Control and display components Digicode option (LFM Go) Switch ON (operating mode) Key fault or incorrect code Switch OFF and awaiting code Time delay of automatic switch-off Programming mode active Operation Key in LED status Notes ○ red off ● continuous * 0 0 0 0 0 # 0 0 0 0 0 1 2 3 4...
  • Page 35 Overviews Control and display components PROGRAMMING (truck switch OFF only (2)) Power switches off ● red flashing ● green automatically after Activating the flashing (5) (5 s before 10 mins (600 s by * * 2 * 1 # automatic switch-off) default) if the truck is switch-off...

  • Page 36: Markings

    Overviews Markings Markings Marking positions Manufacturer's symbol Cold storage area label EXU 16 model label ELECTRICAL HAZARD label (option) EXU 18 model label DANGER INSTRUCTIONS label (option): EXU 20 model label see chapter 4 "Adjusting the on-board EXU 22 model labe charger"...

  • Page 37: Serial Number

    Overviews Markings Serial number xx xxxx x xxxxx NOTE Indicate the serial number for all technical enquiries. The serial number contains the following information: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 1152 807 80 01 EN - 09/2019...
  • Page 38 Overviews Markings 1152 807 80 01 EN - 09/2019...

  • Page 40: Description

    Description Description Batteries The electric pallet trucks EXU 16, EXU 18, EXU 20 and EXU 22 are designed to handle Power is supplied by either: pallets or containers. – A lead battery Their small volume, their ease of driving and their performance make them very appropri- –...
  • Page 41 Description The cylinder activates the lift shaft, which • a battery disconnection handle (emergency transmits the movement to the push rods. stop) located in the driver's compartment • an hour meter/discharge indicator. These activate the wheel clevises, resulting in • an ignition key with 3 positions (stop/Tor- the load arms lifting.

  • Page 42: List Of Checks Prior To Start-Up

    List of checks prior to start-up List of checks prior to start-up WARNING – Damaged or missing stickers must be replaced in compliance with the marking Damage or other defects on the truck or attach- position table. ments (special equipment) can result in accidents. If damage or other faults are noticed on the truck –...

  • Page 43: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Charging a Gel or Lead battery (wall-mounted charger) – Open the cover. – Leave it open. – Remove the battery disconnection handle (1) from the truck plug (2). –...

  • Page 44: Checking The Emergency Stop

    Checks and actions prior to commissioning Checking the emergency stop – Pull the emergency stop handle (4) up- wards. – The power supply to the machine is cut off. – The electrical controls and motors are disabled. – The electromagnetic brake is applied. –...

  • Page 45: Checking The Anti-Crush Safety Device

    Checks and actions prior to commissioning Checking the anti-crush safety device Anti-crush safety function The machine moves in the opposite direction when the anti-crush button (2) is pressed. If the truck is being operated in narrow areas (such as in a lift for example), the operator may get stuck against the wall if care is not taken.

  • Page 46: Truck Operating Instructions

    Truck operating instructions Truck operating instructions The trucks are designed for indoor and Speed must be reduced when moving over outdoor use in non-hazardous atmospheres. obstacles to prevent the truck from becoming The temperature should be between -10°C unbalanced and vibrations in the forklift and +45°C and the relative humidity of the air operator's arms.

  • Page 47: Driving Safety Guidelines

    Driving safety guidelines Driving safety guidelines Behaviour when driving • Never sit on the truck to drive it • The truck must not be used as a stepladder Operators must obey the same rules within • This truck is not designed to transport the plant as on the road.

  • Page 48: Driving

    (default code = 00000). NOTE With the digicode option, when the key is turned to the 0 position the truck is in tortoise mode. The truck will still function if the key is removed. 1152 807 80 01 EN - 09/2019...
  • Page 49 Driving Selecting the driving mode NOTE The ignition key may be turned to two different positions to choose the driving mode. "Tortoise" position (2) : gentle acceleration and deceleration; max. speed: 4 km/h "Hare" position (3) : strong acceleration and deceleration;...

  • Page 50: Driving

    Driving Driving – Turn the ignition key to the Tortoise sition (slow acceleration and deceleration) or the position (faster acceleration Hare and deceleration). – Lower the tiller in (2) zone. NOTE The truck is in the drive position in the (2) position.

  • Page 51: Driving On Upward And Downward Slopes

    Driving Driving on upward and downward slopes Slopes should always be approached with the load facing towards the top of the slope. Only slopes marked as clear traffic routes compat- ible with the truck's technical specifications can be safely used. DANGER The operator must ensure that the ground is clean and has a non-slip surface.

  • Page 52: Braking

    Driving Braking WARNING The quality of the floor surface affects the braking distance of the truck. To be taken into consideration when driving. Gentle braking – During operation, release throttle (2) or (3). Moderate braking – Switch throttle (2) or (3) in the opposite direction of travel.

  • Page 53: Creep Speed Function

    Driving Creep Speed function This function makes it possible to manoeuvre the truck in confined spaces. The tiller remains in the vertical position. – Press the Creep Speed button (1) (tortoise icon) on the tiller. Hold the button down. – Gently move the drive switch forwards or backwards depending on the manoeuvre to be performed.
  • Page 54 Driving Timeout can be adjusted. Please call the After-Sales Service Centre. 1152 807 80 01 EN - 09/2019...

  • Page 55: Operating The Fleetmanager™ Option

    Operating the FleetManager™ option Operating the FleetManager™ option Description of the FleetManager option The FleetManager option allows you to control GSM: Global System for Mobile Communi- access to the truck. The option is a fleet cation management system. Shock sensor You can access the system: •...

  • Page 56: Commissioning A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Commissioning a truck equipped with the FleetManager™ option Commissioning a truck equipped with a keypad or an electronic key – Turn the switch key to start the truck. – Enter the PIN code on the keypad. The PIN code consists of five to eight digits.

  • Page 57: Fleetmanager™ Option: Colour Code For The Leds

    Operating the FleetManager™ option FleetManager™ option: Colour code for the LEDs The LEDs can have different statuses and different colours. Below is the list of the most common messages and their meanings. Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Reading device variant: no...
  • Page 58 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has Reset the shock Red colour Green colour occurred The truck is The truck is switched on but connected via a is not moving.

  • Page 59: Disconnecting A Truck Equipped With The Fleetmanager™ Option

    Operating the FleetManager™ option Disconnecting a truck equipped with the FleetManager™ option NOTE Operators must not log off intentionally while driving. WARNING Access to the truck must be disabled. Unauthorised users are not allowed to use the truck. Disconnecting a truck equipped with a keypad or electronic key –...
  • Page 60 Operating the FleetManager™ option Disconnecting a truck equipped with an RFID reading device – Park the truck in a safe place. – Briefly place the RFID card or the RFID transponder (4) in front of the reading device (3). The LED (1) lights up for a second (red colour). The LED (2) is not lit.

  • Page 61: Transporting Loads

    Transporting loads Transporting loads Load handling safety rules WARNING Closely follow the following instructions before picking up loads. Never touch or stand on moving parts of the truck (e.g. lifting device, pushing devices, work installations or devices for picking up loads). WARNING Take care not to trap hands or feet when operating the truck.

  • Page 62: Transporting Pallets Or Other Containers

    Transporting loads Transporting pallets or other contain- As a general rule, loading units must be trans- ported one by one (e.g. pallets). Transporting several loading units at a time is only autho- rised: • when the safety preconditions are fulfilled. •...

  • Page 63: Lift Control Elements

    Transporting loads Lift control elements Raising the fork arms – Activate the control switch (1) Lowering the fork arms – Activate the control switch (2) Before picking up a load DANGER Safety footwear must be worn. CAUTION Transporting people is strictly prohibited. CAUTION Be careful not to touch adjacent loads or loads positioned at the side or in front of the load being...
  • Page 64 Transporting loads Picking up a load – Approach the load carefully. – Lower the load arms so that they can easily be inserted into the pallet. – Insert the load arms under the load. – If the load is shorter than the load arms, position it so that the end of the load over- hangs the end of the load arms by a few centimetres, in order to avoid hooking the...
  • Page 65 Transporting loads DANGER Personnel must not stand under or near the truck when the load is in the raised position. 1152 807 80 01 EN - 09/2019...

  • Page 66: Using The Folding Platform (Option)

    Using the folding platform (option) Using the folding platform (option) There are two positions for the folding platform (1): • Position A: platform raised • Position B: platform lowered In pedestrian mode, the platform is raised. 2276 The maximum authorised speed is 6 km/h. In ride-on mode, the platform is lowered.

  • Page 67: Cold Store Usage (Option)

    Cold store usage (option) Cold store usage (option) 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 68 Cold store usage (option) – 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 69: Parking The Truck

    Parking the truck Parking the truck WARNING – Lower the load arms. Risk of injury – Switch off the ignition (key or electronic key). Never leave the truck with the load in the raised position. – Pull the emergency stop handle. Do not stop the truck on a slope.

  • Page 70: Handling The Battery

    Handling the battery Handling the battery Battery type Trucks can be fitted with different types of battery. Comply with the information indicated on your battery's type plate, as well as with its features. WARNING The weight and size of the battery influence the stability of the truck.

  • Page 71: Opening/Closing The Battery Cover

    Handling the battery restarted when the covers and connectors have been put back in the operating position. Opening/closing the battery cover Opening – Park the truck. – Lower the load arms. – Turn the key switch off. – Lift the cover (1). Closing CAUTION Keep fingers away from moving parts to avoid any...

  • Page 72: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an external charger CAUTION The battery may be damaged if discharged beyond a given limit. – Immediately charge the battery. – Safely park the truck – Before charging, check the condition of the battery cable and the charging cable and replace these cables if necessary.

  • Page 73: On-Board Charger

    Handling the battery On-board charger Precautions for installation and use • Charging must be carried out in an area where there is no condensation or pollution The on-board charger means you no longer as well as sufficient ventilation. have to use a charging room. In fact, this •...
  • Page 74 Handling the battery Weight 2 kg after the end of the previous charge in order to compensate for self-discharge. Volume 1.4 litres Partial recharging The charger adapts automatically to the Electrical safety battery discharge situation and therefore allows any type of partial charging to be carried •...

  • Page 75: Using The Charger

    Handling the battery The charger stops if the micro-controller detects a temperature measurement fault. Using the charger Before charging, it is necessary to ensure that Phase Green LED Red LED the location selected for charging satisfies all Mains socket of the safety requirements. disconnected Charging Flashing...

  • Page 76: Gel Or Lead Batteries: Adjusting The On-Board Charger

    Handling the battery CAUTION CAUTION Risk of damage to the mains cable resulting in Risk of damage to the mains cable due to frequent electric shock and/or burns! operator handling. Risk of electric shock and/or burns! Park the truck sufficiently close to the mains wall socket to ensure that the mains cable on the The mains cable must be checked regularly as on-board charger is not taut when connected and...

  • Page 77: Changing The Battery

    Handling the battery Changing the battery Maintain a safe distance for battery removal to avoid damaging the truck. – Open the battery compartment (1). – Unplug the battery connector (2). In order to avoid short-circuits, it is recom- mended that batteries with polar terminals or unprotected connections be covered with a rubber mat.

  • Page 78: Gel And Lead Side Access Batteries: Changing The Battery Using A Trolley

    Handling the battery Gel and lead side access batteries: changing the battery using a trolley Positioning the truck – On level ground, move the pallet truck close to the trolley (2). – Align the battery compartment with the empty space on the trolley (1). –...
  • Page 79 Handling the battery – Turn the retaining lock of the charged battery. INSTALL THE CHARGED BATTERY: – Fully insert the charged battery in its com- partment. – Fold the stop down. – Lift the lever slightly and then unlock the notch.

  • Page 80: Side Access Battery: Changing The Battery Using A Moveable Support

    Handling the battery Side access battery: changing the battery using a moveable support CAUTION During operations to fit the battery, keep your fingers away from moving parts to avoid any risk of them being trapped. We recommend the use of gloves.
  • Page 81 Handling the battery CAUTION Before using the machine, ensure that the battery is correctly installed and that its cover is correctly locked. 1152 807 80 01 EN - 09/2019...

  • Page 82: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Truck towing procedure It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. Truck towing is authorised with a rigid connec- tion (tow bar) if the truck to be towed can no longer be braked.
  • Page 83 Handling the truck in an emergency – After towing, chock the truck to prevent it from moving. – To re-establish brake operation, unscrew and remove the two screws (1). – Refit the covers. WARNING It is essential that the covers are correctly refitted before the machine is used.

  • Page 84: Handling The Truck In Specific Situations

    Handling the truck in specific situations Handling the truck in specific situations Slinging the truck CAUTION Risk of injury Use a hoist and hooks of sufficient capacity. Refer to the load weight shown on the truck's data plate. – Attach a sling or a hook to the 2 points indicated (3).

  • Page 85: Transporting The Truck

    Handling the truck in specific situations Jacking The truck must be jacked and chocked in order to perform certain maintenance operations. Always make sure: • To use a jack with an adequate lifting capacity, • Make sure that the truck is parked on level ground and is secured against rolling and tipping.

  • Page 86: Transporting The Machine

    Handling the truck in specific situations The truck must be suitably protected from the DANGER effects of the weather during transport and Danger of death. storage. Do not stand within the hoist's operating radius or below the lifted truck. To load or unload the truck, use an inclined plane or a mobile ramp.

  • Page 87: Maintenance

    Maintenance...

  • Page 88: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the information required for servicing your truck. Carry out the various maintenance work in compliance with the maintenance plan. This will ensure that your truck is reliable and in good working order and that the warranty remains valid.

  • Page 89: Servicing And Maintenance Personnel Training And Qualification

    Maintenance General maintenance information Servicing and maintenance personnel training and qualification Truck maintenance must only be carried out The person responsible for carrying out the by qualified and authorised personnel. inspection must have sufficient knowledge and experience to be able to assess the The annual inspection for prevention of condition of the truck and the efficiency of accidents at work must be carried out by a...

  • Page 90: Maintenance Safety Guidelines

    Maintenance Maintenance safety guidelines Maintenance safety guidelines Servicing and maintenance measures To avoid accidents during servicing and – Ensure that there is no risk of the truck maintenance operations, take all necessary moving or starting up unexpectedly. For safety measures. For example: this reason, remove the battery connector.

  • Page 91: Technical Inspection And Maintenance Characteristics

    Maintenance Technical inspection and maintenance characteristics Technical inspection and maintenance characteristics Assembly Capacities/Setting values Item/Lubricant Main hydraulic system Hydraulic oil 1,25 l Reducer Reducer oil 0.9 litre maximum Traction and pump motor Power 125A, Quantity: 1 Fuses Control 7.5A, Quantity: 1 Control cable harness Fuses 1.2 kW (AC)

  • Page 92: Access To The Technical Compartment

    Maintenance Access to the technical compartment Access to the technical compartment – Fully raise the pallet truck's load arms to facilitate these operations. CAUTION Before removing anything from the truck – Turn the key switch off. – Pull the battery connector handle (emergency stop handle).
  • Page 93 Maintenance Access to the technical compartment – Remove the plastic cover by unscrewing the 2 screws (3) to provide easy access to the pump unit. – Then remove the mounting bracket (4) 1152 807 80 01 EN - 09/2019...

  • Page 94: Accessing The Reducer And The Brake

    Maintenance Accessing the reducer and the brake Accessing the reducer and the brake To access the reducer and the brake: – Turn the tiller to the right or left-hand stop. – Unscrew the 2 screws (3) – Unscrew the 2 screws (2) located either side of the two 1/2 covers.

  • Page 95: 1000-Hour/Annual Maintenance Plan

    Maintenance 1000-hour/annual maintenance plan 1000-hour/annual maintenance plan Maintenance operations every 1000 hours Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out every 1000, 2000, 4000, 7000 and 8000 hours Preparatory tasks Clean the truck (if necessary) Check the error codes (using the diagnostic tool) Traction motor Check that the cables and bundling are in good condition...

  • Page 96: 3000-Hour Maintenance Schedule

    Maintenance 3000-hour maintenance schedule 3000-hour maintenance schedule Additional maintenance operations every 3000 hours Depending upon use, environmental conditions and driving style, the following procedures must be performed every 3000, 6000 and 9000 hours Information Carry out all 1000-hour maintenance work Transmission Drain the transmission gear oil Hydraulic system...

  • Page 97: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Clean the truck Washing instructions – Always park the truck as specified. – Disconnect the battery connector (4). CAUTION – Disconnect the battery connector when washing the truck. Washing the exterior of the truck WARNING Do not use inflammable fluids for cleaning.

  • Page 98: Clean The Battery And Its Compartment

    Maintenance Chassis, bodywork and fittings After washing the truck. – Dry the truck thoroughly (eg with com- pressed air). – Take the truck back into operation accord- ing to instructions. If moisture has penetrated the motors despite the precautionary measures, dry them first with compressed air;...

  • Page 99: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings – Pump off any electrolyte that may have spilled between the cells. – Clean the top of the cells with a damp cloth. CAUTION In case of heavy sulphate build-up or excessive electrolyte spillage, please contact the After-Sales Service Centre.

  • Page 100: Folding Platform Maintenance

    Maintenance Chassis, bodywork and fittings CAUTION Do not obstruct the ventilation. Allow the charger to cool down for 10 minutes after charging is complete before touching it. Do not use the charger out of the truck. Folding platform maintenance The folding platform must be checked regu- larly.

  • Page 101: Steering And Wheels

    Maintenance Steering and wheels Steering and wheels Servicing wheels and rollers Check the tyres and the wear on the wheels and rollers The tyre tread on the drive wheel (1), the stabilising wheel (2) and the rollers (3) must not be damaged. Dimensions Drive wheel 230 x 75 mm...

  • Page 102: Maintaining The Reinforced Stabilisers (Option)

    Maintenance Steering and wheels – After adjustment, lock the clevis (1) with the lock nut (2) tightened to a torque of 35 Nm NOTE To screw, unscrew or lock the clevis (1) always hold the ball bearing (3) by its flat surface (36 spanner) during the procedure.

  • Page 103: Regular Maintenance Of The Transmission Gear

    Maintenance Steering and wheels Regular maintenance of the trans- mission gear To increase the service life of the transmission gear, 2 grease nipples (1) have been added to its turntable. It is therefore possible to regularly lubricate the transmission gear. NOTE Use the lubricants recommended by the manufacturer.

  • Page 104: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Checking the fuses – Control fuses are accessed by removing the front hood. The 125 A fuse (1) protects the traction and lifting power circuit. The 7,5 A fuse (2) protects the control circuit. We recommend that this operation be carried out by our After-Sales Service Centre.

  • Page 105: Battery Maintenance

    Maintenance Electrical equipment Battery maintenance The operations described below relate to lead batteries with liquid electrolyte. For batteries with gel electrolyte, which are said to be "maintenance-free", please refer to the manufacturer's instructions. WARNING Avoid contact with the acid. Do not create a short- circuit.
  • Page 106 Maintenance Electrical equipment NOTE For more information, refer to the instructions supplied with the battery. Electrical equipment: checking the electrolyte density Measuring the density gives an accurate indication of the charging status of each cell in an open lead battery only. This measurement can be taken before or after charging: •...

  • Page 107: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Oil level check – Lower the load arms completely. – Switch off the ignition and pull the emer- gency stop handle. – Pull back the cover of the technical com- partment (see description in ″Access to the technical compartment″).

  • Page 108: Hydraulic Circuit, Draining The Circuit

    Maintenance Hydraulic systems Hydraulic circuit, draining the circuit Draining the circuit – Lower the load arms to the ground to eliminate pressure in the hydraulic circuit. – Switch off the ignition and unplug the battery connector. – Disconnect the power supply to the solenoid valve (3).

  • Page 109: Storage And Decommissioning

    Maintenance Storage and decommissioning Storage and decommissioning Storage of truck Precautions should be taken if the truck must CAUTION not be used for a reasonably long period. The We recommend that you do not use a plastic sheet operations depend on the length of time it is as this encourages condensation to form.

  • Page 110: Permanent Putting Out Of Commission (Destruction)

    Maintenance Storage and decommissioning Permanent Putting Out of Commis- sion (Destruction) When scrapping the truck, it is necessary to: – Remove the various parts of the truck (covers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.

  • Page 111: Technical Specifications

    Technical specifications...

  • Page 112: Datasheet Exu

    Technical specifications Datasheet EXU Datasheet EXU 1152 807 80 01 EN - 09/2019...
  • Page 113 Technical specifications Datasheet EXU DESIGNATION 1.1 Manufacturer STILL GmbH 1.2 Model type EXU16 EXU18 EXU20 EXU22 Method of propulsion: battery, diesel, petrol, Battery LPG, mains power Driving: manual, pedestrian, standing, seated, Pedestrian order picking 1.5 Rated capacity Q (kg) 1600...
  • Page 114 Technical specifications Datasheet EXU Additional wheels Øxl 125 x 40 Stabilisers (dimensions) (mm) Number of wheels at drive side/load side (x = 1x+ 2 / 2 (4 in bogies) drive wheel) Drive side track width (± 5 mm) Load side track Mobile chassis 355 / 395 / 515 width (±...
  • Page 115 Technical specifications Datasheet EXU PERFORMANCE DATA EXU16 EXU18 EXU20 EXU22 Transfer speed when km/h 6 / 6 laden/unladen (5%) Lifting speed when 0.04 / 0.06 0.03 / 0.04 laden/unladen (10%) Lowering speed when 0.071 / 0.065 0.07/0.06 laden/unladen (10%) Maximum gradient when 14 / 24 13 / 24 11 / 24...
  • Page 116 Technical specifications Datasheet EXU 2 Pzs 82 Ah lithium- battery 164 Ah lithium- 6.5 Battery weight (±10%) battery 205 Ah lithium- battery 410 Ah lithium- battery Energy consumption according to standardised kWh / h 0.38 VDI cycle OTHER EXU16 EXU18 EXU20 EXU22 8.1 Speed control...
  • Page 117 Technical specifications Datasheet EXU 1152 807 80 01 EN - 09/2019...

  • Page 118: Datasheet Exu 20S - Exu 22S (Option)

    Technical specifications Datasheet EXU 20S - EXU 22S (option) Datasheet EXU 20S - EXU 22S (option) 1152 807 80 01 EN - 09/2019...
  • Page 119 Technical specifications Datasheet EXU 20S - EXU 22S (option) DESIGNATION 1.1 Manufacturer STILL GmbH 1.2 Model type EXU 20S EXU 22S Method of propulsion: battery, diesel, petrol, LPG, mains Battery power 1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian 1.5 Rated capacity...
  • Page 120 Technical specifications Datasheet EXU 20S - EXU 22S (option) Height of tiller in driving h14 (mm) 740/1250 position, min/max. Height at the ends of the fork in the lower position h13 (mm) 4.15 (max) 4.19 Total length (± 5 mm) L1 (mm) Pedestrian/ride-on 1896/2286...
  • Page 121 Technical specifications Datasheet EXU 20S - EXU 22S (option) Acceleration time when 8.04/6.5 laden/unladen (d = 10 m) Electromagnetic 5.10 Service brake DRIVE EXU 20S EXU 22S 6.1 Traction motor, hourly output AC motor 6.2 Lift motor at 15% utilisation DC motor Battery type in accordance with DIN 46 536 B...
  • Page 122 Technical specifications Datasheet EXU 20S - EXU 22S (option) 1152 807 80 01 EN - 09/2019...
  • Page 123 Index Checking the horn ....36 Checks prior to start-up ... . . 34 Access to the technical compartment .
  • Page 124 Index Lifting system ..... 32 Lifting the truck ....76 – 77 FleetManager™...
  • Page 125 Index Safety devices ....82 Technical inspection and maintenance characteristics ....83 Safety Inspection .
  • Page 128 STILL GmbH 1152 807 80 01 EN – 09/2019...

This manual is also suitable for:

Exu-20Exu-22Exu-18

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