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 2351 2353
2355 2357
1152 807 80 01 EN - 02/2021 - 17

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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 2351 2353 2355 2357 1152 807 80 01 EN - 02/2021 - 17...
  • 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 - 02/2021 - 17...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... General .
  • Page 6 Table of contents Overviews Truck overview............Overviews .
  • Page 7 Table of contents Transporting loads ........... . Load handling safety rules.
  • Page 8 Table of contents Maintenance safety guidelines ......... . 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 Industrial truck according to these operating instructions Model according to these operating instructions 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 en- quiries. 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: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Eco-design requirements for electric motors and variable speed drives 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. Eco-design requirements for electric motors and variable...

  • Page 15: Spare Parts List

    Spare parts list  The spare parts list can be downloaded by en- tering the address https://sparepartlist.still.eu into a web browser or by scanning the QR code displayed to the side. When the web page is open, please type in...

  • Page 16: Permissible Use

    Introduction Permissible use Permissible use The truck described in these operating instruc- The purpose of obtaining these permissions in tions is suitable for lifting and transporting advance is to limit danger as far as possible. loads. The truck should only be used for the purpo- ses for which it was designed, as described in these instructions.

  • Page 17: Unauthorised Use

    Introduction Unauthorised use Unauthorised use Any danger caused as a result of unauthor- Transporting people is prohibited. ised use becomes the responsibility of the op- The forklift truck should not be used in areas erator or driver and not that of the manufactur- where there is a risk of fire, explosion or corro- sion, or in areas that are particularly dusty.
  • Page 18 Introduction Disposing of components and batteries 1152 807 80 01 EN - 02/2021 - 17...

  • Page 19: Safety

    Safety...

  • Page 20: Safety Regulations

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

  • Page 21: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. 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 ENVIRONMENT NOTE During operation of the forklift truck, hy- draulic fluids are pressurised and are Hydraulic fluid is a water-polluting substance! hazardous to your health. Always store hydraulic fluid in containers com- –...

  • Page 23: Disposal Of Consumables

    Safety Safety regulations for handling consumables Disposal of consumables Any spillage of fluids such as hydraulic oil, ● ENVIRONMENT NOTE brake fluid or gear lubricant oil must be im- mediately soaked up with an oil-binding Materials that have to be disposed of following agent.

  • Page 24: Emissions

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

  • Page 25: Residual Dangers, Residual Risks

    Safety Residual dangers, residual risks Residual dangers, residual risks Falling, tripping etc. when moving on the in- Despite all operational precautions and com- ● dustrial truck, especially in the wet, with pliance with standards and rules, the possibili- leaking consumables or icy surfaces. ty of additional risks when using the truck can- Loss of stability due to the load being unsta- not be entirely excluded.

  • Page 26: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal The operating company is responsible for the person or group who operates the truck or on scheduling and correct performance of regular whose authority the truck is used.
  • Page 27 Safety Definition of responsible persons Prohibition of use by unauthorised per- When leaving the truck, the driver must secure it against unauthorised use. sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. 1152 807 80 01 EN - 02/2021 - 17...

  • Page 28: Safety Tests

    Safety inspection based on time and ex-  traordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must en- STILL GmbH Hamburg sure that the truck is checked by a specialist at least once a year or after noteworthy inci- Regelmäßige Prüfung dents.
  • Page 29 Overviews...

  • Page 30: Overviews

    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 - 02/2021 - 17...

  • 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 - 02/2021 - 17...

  • 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 func- Battery charge level repre- Low charge: 10% Dis- tion not permitted).
  • 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 # green (1)(correct PIN) 0 0 0 0 0...
  • Page 35 Overviews Control and display components PROGRAMMING (truck switch OFF only (2)) Power switches off auto- ● red flashing ● green Activating the au- matically after 10 mins flashing (5) (5 s before * * 2 * 1 # tomatic switch-off (600 s by default) if the switch-off) truck is not being used.

  • Page 36: Markings

    Overviews Markings Markings Location of markings Brand label Warranty label (for Germany only) on the in- EXU16 model label side of the tiller EXU18 model label Cold store label EXU20 model label ELECTRICAL DANGER label EXU22 model label DANGER INSTRUCTIONS label Identification label PIEK label on the outside of the tiller Slinging label...

  • Page 37: Serial Number

    Overviews Markings Serial number  xx xxxx x xxxxx NOTE Indicate the serial number for all technical en- quiries. The serial number contains the following infor- mation: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 1152 807 80 01 EN - 02/2021 - 17...
  • Page 38 Overviews Markings 1152 807 80 01 EN - 02/2021 - 17...

  • 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 appropriate –...
  • Page 41 Description a battery disconnection handle (emergency The cylinder activates the lift shaft, which ● stop) located in the driver's compartment transmits the movement to the push rods. an hour meter/discharge indicator. ● These activate the wheel clevises, resulting in an ignition key with 3 positions (stop/ ●...

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

    List of checks prior to start-up List of checks prior to start-up – Damaged or missing stickers must be re- WARNING placed in compliance with the marking posi- Damage or other defects on the truck or attachments tion table. (special equipment) can result in accidents. –...

  • 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 disa- bled. – The electromagnetic brake is applied. –...

  • Page 45: Checking The Anti-Crush Safety Device

    Checks and actions prior to commissioning Checking the anti-crush safety de- vice 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 out- Speed must be reduced when moving over door use in non-hazardous atmospheres. The obstacles to prevent the truck from becoming temperature should be between -10°C and unbalanced and vibrations in the forklift opera- +45°C and the relative humidity of the air less tor's arms.
  • Page 47 Truck operating instructions Before using a side access truck, check that the bat- CAUTION tery is correctly locked. Risk of injury 1152 807 80 01 EN - 02/2021 - 17...

  • Page 48: 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 peo- ●...

  • Page 49: 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 - 02/2021 - 17...
  • Page 50 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 51: 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) po- sition.

  • Page 52: 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 compati- ble 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 53: 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 di- rection of travel.

  • Page 54: 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. –...
  • Page 55 Driving Timeout can be adjusted. Please call the Af- ter-Sales Service Centre. 1152 807 80 01 EN - 02/2021 - 17...

  • Page 56: 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 man- cation agement system. Shock sensor You can access the system: Either by using a keypad This sensor allows you to record the shocks...

  • Page 57: 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 58: 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 dif- ferent 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...
  • Page 59 Operating the FleetManager™ option Malfunction Cause Solution LED status Signal transmitter LED 1 LED 2 Flashes quickly Lit continuously A shock has oc- Reset the shock Red colour Green colour curred The truck is The truck is con- switched on but is nected via a Blue- not moving.

  • Page 60: 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 ...
  • Page 61 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 de- vice (3). The LED (1) lights up for a second (red col- our).

  • Page 62: Transporting Loads

    Transporting loads Transporting loads Load handling safety rules  WARNING Closely follow the following instructions before pick- ing 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 63: Transporting Pallets Or Other Containers

    Transporting loads Transporting pallets or other con-  tainers 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 author- ised: when the safety preconditions are fulfilled. ●...

  • Page 64: 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) Load handling CAUTION Risk of injury Safety shoes must be worn. Transporting people is strictly prohibited. CAUTION Risk of falling Be careful not to touch adjacent loads or loads posi-...
  • Page 65 Transporting loads – Check that the width of the load is compati- ble with the width of the load arms. Picking up a load  – Approach the load carefully. – Lower the load arms so that they can easily be inserted into the pallet.
  • Page 66 Transporting loads CAUTION Risk of falling Be careful to keep clear of other loads at the side of or behind the truck. Before leaving the truck NOTE Always stop the truck on level ground away from traffic routes. – Ensure the load arms are in the lower posi- tion.

  • Page 67: 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 68: 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 oper- ating ranges and carries a cold store label. The cold store equipment for the truck con- sists of using specialised oils (for the hydraulic installation and the gears) suitable for cold stores.
  • Page 69 Cold store usage (option) – Drive the truck for approximately 5 minutes and operate the brakes several times to en- sure 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.

  • Page 70: Parking The Truck

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

  • Page 71: Handling The Battery

    Handling the battery Handling the battery Battery type Trucks can be fitted with different types of bat- tery. 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 sta- bility of the truck.

  • Page 72: Opening/Closing The Battery Cover

    Handling the battery Parking the truck securely When the battery is being worked on, the truck must be parked safely. The truck can only be restarted when the covers and connectors have been put back in the operating position. Opening/closing the battery cover Opening –...

  • Page 73: Charging The Battery Using An External Charger

    Handling the battery Charging the battery using an exter- nal 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 74: On-Board Charger

    Handling the battery On-board charger Precautions for installation and use Nominal battery volt- The on-board charger means you no longer Tolerance on the volt- have to use a charging room. In fact, this age of bearing U charger can be connected to any 2P+T 230 V 16 A socket.

  • Page 75: Using The Charger

    Handling the battery When the charger is neither connected to Protection during charging ● the mains nor the battery, the "contact A" Mains micro-break protection and "contact B" outputs are electrically insu- lated from one another. If the mains power is cut off, all the charging When the charger is connected to the bat- ●...
  • Page 76 Handling the battery Phase Green LED Red LED CAUTION Battery polari- Do not disconnect the battery connector during ty reversed charging (green indicator light flashes). Selector in The truck cannot be operated during charging. neutral posi- Flashing Flashing tion The on-board charger is intended for recharg- ing the battery.

  • Page 77: Gel Or Lead Batteries: Adjusting The On-Board Charger

    Handling the battery Gel or Lead batteries: Adjusting the on-board charger When the truck is delivered with its battery, ● the charger settings are adjusted in the fac- tory. The adjustment depends on the selected ● battery. Charging curve selector ...
  • Page 78 Handling the battery – Open the battery compartment (1).  – Unplug the battery connector (2). In order to avoid short-circuits, it is recommen- ded that batteries with polar terminals or un- protected connections be covered with a rub- ber mat. –...

  • Page 79: 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 80 Handling the battery – Turn the retaining lock of the charged bat- tery. 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 81: 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 be- ing trapped. We recommend the use of gloves. Positioning the truck –...
  • Page 82 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 - 02/2021 - 17...

  • Page 83: 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 elec- trical function. The electromagnetic brake re- mains 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 84 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 be- fore the machine is used.

  • Page 85: 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 indi- ...

  • Page 86: Transporting The Truck

    Handling the truck in specific situations Jacking The truck must be jacked and chocked in or- der to perform certain maintenance opera- tions. Always make sure: To use a jack with an adequate lifting ca- ● pacity, Make sure that the truck is parked on level ●...

  • Page 87: 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 To load or unload the truck, use an inclined below the lifted truck.
  • Page 88 Handling the truck in specific situations 1152 807 80 01 EN - 02/2021 - 17...

  • Page 89: Maintenance

    Maintenance...

  • Page 90: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the infor- mation required for servicing your truck. Carry out the various maintenance work in compli- ance with the maintenance plan. This will en- sure that your truck is reliable and in good working order and that the warranty remains valid.

  • Page 91: 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 in- by qualified and authorised personnel. spection must have sufficient knowledge and experience to be able to assess the condition The annual inspection for prevention of acci- of the truck and the efficiency of the protective dents at work must be carried out by a person...

  • Page 92: Maintenance Safety Guidelines

    Maintenance Maintenance safety guidelines Maintenance safety guidelines Servicing and maintenance measures To avoid accidents during servicing and main- – Ensure that there is no risk of the truck tenance operations, take all necessary safety moving or starting up unexpectedly. For this measures.

  • Page 93: Technical Inspection And Maintenance Characteristics

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

  • Page 94: Access To The Technical Compartment

    Maintenance Access to the technical compartment Access to the technical com- partment – Fully raise the pallet truck's load arms to fa- cilitate these operations. CAUTION Before removing anything from the truck – Turn the key switch off. – Pull the battery connector handle (emergency stop handle).
  • Page 95 Maintenance Access to the technical compartment Opening the front cover  After removing the lower cover: – Unscrew the 4 screws (2) that hold the cov- er in place. Accessing the pump unit After removing the front cover: – Remove the plastic cover by unscrewing ...
  • Page 96 Maintenance Access to the technical compartment – Then remove the mounting bracket (4)  1152 807 80 01 EN - 02/2021 - 17...

  • Page 97: 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 ...

  • Page 98: 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 99: 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 100: 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 101: 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 102: General Information On Battery Maintenance

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

  • Page 103: 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 regular- ly.

  • Page 104: 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 sta- bilising wheel (2) and the rollers (3) must not be damaged.

  • Page 105: Maintaining The Reinforced Stabilisers (Option)

    Maintenance Steering and wheels – Tighten the clevis (1) using a 14 mm Allen key to lower the wheel or loosen the clevis (1) using a 14 mm Allen key to lift the wheel – 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) al-...

  • Page 106: 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 man- ufacturer.

  • Page 107: 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 108: 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 manu- facturer's instructions. WARNING Avoid contact with the acid. Do not create a short-cir- cuit.
  • Page 109 Maintenance Electrical equipment CAUTION Only top up with demineralised water. Never top up before charging (risk of overflow). Do not overfill the cells. NOTE For more information, refer to the instructions supplied with the battery. Electrical equipment: checking the elec- ...

  • Page 110: Hydraulic Systems

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

  • Page 111: Hydraulic Circuit, Draining The Circuit

    Maintenance Hydraulic systems Hydraulic circuit, draining the circuit Draining the circuit  – Lower the load arms to the ground to elimi- nate pressure in the hydraulic circuit. – Switch off the ignition and unplug the bat- tery connector. – Disconnect the power supply to the sole- noid valve (3).

  • Page 112: 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 113: 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 (cov- ers, battery, chains, motors etc.) – Sort out the components depending on their type: pipes, rubber components, lubricants, aluminium, iron etc.
  • Page 114 Maintenance Storage and decommissioning 1152 807 80 01 EN - 02/2021 - 17...

  • Page 115: Technical Specifications

    Technical specifications...

  • Page 116: Datasheet Exu

    Technical specifications Datasheet EXU Datasheet EXU 1152 807 80 01 EN - 02/2021 - 17...
  • Page 117 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 118 Technical specifications Datasheet EXU Additional wheels Øxl Stabilisers 125 x 40 (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 119 Technical specifications Datasheet EXU 2 Pzs 1610 / 1550 (lowered/raised 1670 / forks) 3 Pzs 1585 PERFORMANCE DATA EXU16 EXU18 EXU20 EXU22 Transfer speed when la- km/h 6 / 6 den/unladen (5%) Lifting speed when laden/ 0.03 / 0.04 / 0.06 unladen (10%) 0.04 Lowering speed when la-...
  • Page 120 Technical specifications Datasheet EXU 2 Pzs 82 Ah lithium- ion bat- tery 164 Ah lithium- ion bat- Battery weight (±10%) tery 205 Ah lithium- ion bat- tery 410 Ah lithium- ion bat- tery Energy consumption ac- cording to standardised VDI kWh / h 0.38 cycle...
  • Page 121 Technical specifications Datasheet EXU 1152 807 80 01 EN - 02/2021 - 17...

  • Page 122: 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 - 02/2021 - 17...
  • Page 123 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 pow- Battery 1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian 1.5 Rated capacity...
  • Page 124 Technical specifications Datasheet EXU 20S - EXU 22S (option) Height of tiller in driv- h14 (mm) 740/1250 ing position, min/max. Height at the ends of 4.15 the fork in the lower h13 (mm) position (max) 4.19 Total length (± 5 mm) L1 (mm) Pedestrian/ride-on 1896/2286...
  • Page 125 Technical specifications Datasheet EXU 20S - EXU 22S (option) 6.2 Lift motor at 15% utilisation DC motor Battery type in accordance with DIN 46 536 B 2 Pzs 3 Pzs DIN 46 531 / 35 /36 A, B, C, no Battery voltage and capacity (dis- 2 Pzs 24/250...
  • Page 126 Technical specifications Datasheet EXU 20S - EXU 22S (option) 1152 807 80 01 EN - 02/2021 - 17...
  • Page 127 Index Oil Safety Information....13 Safety information for handling hydraul- Accessing the reducer and the brake..ic fluid......14 Access to the technical compartment.
  • Page 128 Index Maintenance..... 95 Oils....... 13 Use.
  • Page 129 Index Transporting the truck in the lift..79 Truck operating instructions... . 38 Washing instructions....Washing the exterior of the truck.
  • Page 132 STILL GmbH 1152 807 80 01 EN - 02/2021 - 17...

This manual is also suitable for:

Exu-18Exu-20Exu-22

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