Still EXU-H-18 Original Instructions Manual
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Still EXU-H-18 Original Instructions Manual

Electric pallet truck
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Original instructions
Electric pallet truck
EXU-H-18
EXU-H-20
0161 0162 1183 1185
1152 801 15 17 EN - 09/2019

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  • Page 1 Original instructions Electric pallet truck EXU-H-18 EXU-H-20 0161 0162 1183 1185 1152 801 15 17 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 801 15 17 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 Overview .
  • Page 7 Table of contents Grabbing a loading unit ..........53 Transporting pallets or other containers .
  • Page 8 Table of contents Maintenance safety guidelines ......... . 86 Servicing and maintenance measures .
  • Page 9 Table of contents Technical specifications EXU-H datasheet ........... . 116 Technical datasheet EXU-H 20S (option) .

  • Page 11: Introduction

    Introduction...

  • Page 12: 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 13: 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 14: 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 15: 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 16 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 801 15 17 EN - 09/2019...
  • Page 17 Introduction Rules for the operating company of industrial trucks 1152 801 15 17 EN - 09/2019...

  • Page 18: 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 19: 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 20 Introduction Disposing of components and batteries 1152 801 15 17 EN - 09/2019...

  • Page 21: Safety

    Safety...

  • Page 22: 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 23: 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 24: 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 25: 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 26: Emissions

    Safety Emissions Emissions Noise emission values Calculated during the test cycle performed in NOTE accordance with standard EN12053. Lower or higher noise values may occur when Acoustic pressure level in the driver's com- using industrial trucks, e.g. due to the mode partment of operation, environmental factors and other 59 dB...

  • Page 27: 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 28: 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 29: 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 30 Safety Safety tests 1152 801 15 17 EN - 09/2019...

  • Page 31: Overviews

    Overviews...

  • Page 32: Truck Overview

    Overviews Truck overview Truck overview Overview Backrest* Drive wheel Tiller Traction motor Battery connector handle (emergency stop) Pump unit Battery cover Electromagnetic brake Ignition key Horn Traction controller Lift cylinder Fork arms Digicode* Load wheels Load arms Stabiliser wheels Platform* *Option 1152 801 15 17 EN - 09/2019...

  • Page 33: Control And Display Components

    Overviews Control and display components Control and display components Tiller Handle Travel throttle valve Load arm lifting Anti-crush safety feature Proportional lowering of fork arms Travel throttle valve Proportional lifting of fork arms Lowering the load arms Horn 1152 801 15 17 EN - 09/2019...

  • Page 34: 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 35 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 36: 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 37 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 38: Markings

    Overviews Markings Markings Marking positions Manufacturer's label Warranty label (for Germany only) on the EXU H 18 model label inside of the tiller EXU H 20 model label Cold storage area label Identification label (see next page) Capacity label Slinging label Label PIEK (option) on the outside of the ELECTRICAL HAZARD label (option) tiller...

  • Page 39: 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 801 15 17 EN - 09/2019...
  • Page 40 Overviews Markings 1152 801 15 17 EN - 09/2019...

  • Page 42: Description

    Description Description The pallet trucks EXU-H18 and EXU-H20 are Two types of battery removal are available made up of a high lift (fork arm) and a low lift • Vertical removal (2Pzs BS) on EXU-H18 (load arm). and (2Pzs DIN) on EXU-H20 •...
  • Page 43 Description • electromagnetic safety device, controlled • a 3-position ignition key (stop/tortoise/hare) by the upper or lower position of the tiller • a tiller with the following controls: for- • electromagnetic parking, applied when ward/reverse travel, accelerator, lifting/low- supply is cut. ering of the fork arms (proportional control), lifting/lowering of the load arms, horn and safety reverser...

  • Page 44: 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 45: 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 46: 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 47: 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 48: 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 49: Driving

    Driving Driving 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 50: Defining Directions

    (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 801 15 17 EN - 09/2019...
  • Page 51 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 52: 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 53: 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 54: 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 55: 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 56 Driving Timeout can be adjusted. Please call the After-Sales Service Centre. 1152 801 15 17 EN - 09/2019...

  • Page 57: 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 58: 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 59: 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 60 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 61: 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 62 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 63: 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 64: 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 65: Lifting

    Transporting loads Lifting WARNING Risk of injury The safety regulations must be strictly adhered to. It is strictly forbidden to touch or stand on moving parts (e.g. lifting device, pushing devices, work installations, load lifting devices). The pallet truck has two lift systems: 1-Main lift (forks) The maximum load is 800 kg at a distance of 600 mm from the centre of the load.

  • Page 66: Main Lift-Base Lift

    Transporting loads Main lift-Base lift Main Lift Fork arms lifting – Press the proportional control button (2). Fork arms lowering – Press the proportional control button (1). NOTE A groove (3) is present on each side of the button. This helps you to feel the button and to identify it even if there is not much light.
  • Page 67 Transporting loads CAUTION Be careful not to touch adjacent loads or loads positioned at the side or in front of the load being handled. The loads are to be stacked so that they are aligned with a small space between each of them and so that they do not catch each other.
  • Page 68 Transporting loads Transporting a load – Always drive forwards for optimum visibility. – When carrying a load on a slope, always climb and descend with the load uphill. Never travel across the slope or make a U-turn. – Reverse travel must only be used for depositing a load.

  • Page 69: Using Autolift (Option)

    Transporting loads Using Autolift (option) NOTE Training on how to use this option is required before use. WARNING Risk of accident! Ensure that there is nobody in the work area. Description of the Autolift option The Autolift option enables automatic lifting and automatic lowering of the forks.
  • Page 70 Transporting loads The enclosure for the Autolift option The enclosure for the Autolift option consists • An emergency off switch (1) • An activation button (2) • A selector switch for stopping/automatic lifting/automatic lowering (3) Loading and unloading DANGER In case of danger, press the emergency off switch (1).
  • Page 71 Transporting loads – Press the activation button (2) The pallet lifts automatically as the packets are unloaded. The upper level of the load is aligned at 800 mm from the ground. Two gauges are used for the levelling. 1152 801 15 17 EN - 09/2019...

  • Page 72: 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 73: 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 74 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 75: Stopping The Truck

    Stopping the truck Stopping the truck WARNING – Switch off the ignition then remove the key or press the button on the digicode for Do not stop the truck on a slope, or if this is absolu- 2 seconds. tely necessary, make sure it is safely secured using chocks.

  • Page 76: 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 77: 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 78: 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 79: 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 80 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 81: 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 82: 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 83: 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 84: 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 85 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 86: 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 87 Handling the battery CAUTION Before using the machine, ensure that the battery is correctly installed and that its cover is correctly locked. 1152 801 15 17 EN - 09/2019...

  • Page 88: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Towing the truck It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. You may tow the truck with a rigid connection (tow bar) if the truck to be towed can no longer be braked.
  • Page 89 Handling the truck in an emergency – Close the hood of the technical compart- ment. 1152 801 15 17 EN - 09/2019...

  • Page 90: 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 91: 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 92: 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 93: Maintenance

    Maintenance...

  • Page 94: 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 95: 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 96: 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 97: Technical Specifications For Inspection And Maintenance

    Maintenance Technical specifications for inspection and maintenance Technical specifications for inspection and maintenance Capacities/Setting values Unit Item/Lubricant Maximum level 0.97 l Main hydraulic system Hydraulic oil Minimum level 0.92 l Reducer Reducer oil 0.9 litre maximum Traction and pump motor Power 125 A, Quantity: 1 Fuses Control 7.5 A, Quantity: 1...

  • Page 98: 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 99 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 801 15 17 EN - 09/2019...

  • Page 100: 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 101: Maintenance Plan As Required

    Maintenance Maintenance plan as required Maintenance plan as required Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out as required Preparation Cleaning the truck Chassis and equipment Checking the brake operation Checking the condition of the roller frame Wheels Checking the wheels for wear Electrical equipment...

  • Page 102: 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 Preparation 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 103 Maintenance 1000-hour/annual maintenance plan Maintenance operations every 1000 hours Oil or generously grease the rings and clevis pins Final tasks Check the general condition of the forks and the chassis 1152 801 15 17 EN - 09/2019...

  • Page 104: 3000-Hour Maintenance Plan

    Maintenance 3000-hour maintenance plan 3000-hour maintenance plan 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 105: 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 106: 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 107: 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 108: 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 109: 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 110: 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 111: 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 112: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Servicing the electrical system Checking the cable and fuse connection mountings WARNING Stop the truck and disconnect the battery before carrying out the following checks. – Remove the front hood. – Check the condition of the fuses (1). –...

  • Page 113: 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 114 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 115: Checking The Condition Of Cables, Terminals And Battery Connector

    Maintenance Electrical equipment Checking the condition of cables, terminals and battery connector – Check that the cable insulation is undam- aged and that there are no signs of over- heating at the connections. – Check that the "+" and "-" output terminals are not sulfated (presence of white salt).

  • Page 116: Cleaning The Sensors For The Autolift Option

    Maintenance Electrical equipment – Check that the truck is immobilised (traction and lifting not permitted) as long as the cord is connected to the 220 V supply. – Disconnect the mains cord. NOTE In the event of a fault, do not work on the charger.

  • Page 117: 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 118: 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 119: Lift Mast

    Maintenance Lift mast Lift mast Specific mast maintenance Check the condition of the mast and the chain mountings – Thoroughly clean the mast guide rails (1) and the chain (2). – Inspect surfaces for wear and check rota- tion of rollers. –...
  • Page 120 Maintenance Lift mast Adjust the length of the mast chain NOTE Depending on the use of the truck, the chains are liable to stretch and as a result they have to be adjusted regularly. – Lower the mast completely. – Unscrew the locknut (5). –...
  • Page 121 Maintenance Lift mast NOTE Use of high pressure liquid cleaning devices is not advisable. Lubricate the mast – Coat the guidance surfaces, the return pulleys and the chain with a special aerosol chain lubricant. NOTE For equipment that is used in the food industry, use a dry lubricant instead of an aerosol.

  • Page 122: Commissioning And Storage

    Maintenance Commissioning and storage Commissioning and storage 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 123: Permanent Putting Out Of Commission (Destruction)

    Maintenance Commissioning and storage 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 124 Maintenance Commissioning and storage 1152 801 15 17 EN - 09/2019...
  • Page 125 Technical specifications...
  • Page 126 Technical specifications EXU-H datasheet EXU-H datasheet 1152 801 15 17 EN - 09/2019...
  • Page 127 Technical specifications EXU-H datasheet DESIGNATION 1.1 Manufacturer STILL GmbH 1.2 Model type EXU–H 18 EXU-H 20 1.3 Method of propulsion: battery, diesel, petrol, LPG, mains power Battery 1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian Fork arms/load arms nominal...
  • Page 128 Technical specifications EXU-H datasheet DIMENSIONS EXU–H 18 EXU-H 20 Lowered mast height (height of tiller - h1 (mm) 1370 highest point of the truck) (max) 4.3 Free lift (max) h2 [mm] 4.4 Lift (± 5 mm) (max) h3 (mm) 4.6 Initial lift (± 5 mm) h5 (mm) Height of tiller in driving position h14(mm)
  • Page 129 Technical specifications EXU-H datasheet Maximum gradient when laden/un- 12/24 10/24 laden, 5 minutes Acceleration time when laden/un- 8.45/7.1 8.8/7.1 laden (d = 10 m) Electromagnetic 5.10 Service brake DRIVE EXU–H 18 EXU-H 20 6.1 Traction motor, hourly output AC motor 6.2 Lift motor at 15% utilisation DC motor DIN 43 535 A...
  • Page 130 Technical specifications Technical datasheet EXU-H 20S (option) Technical datasheet EXU-H 20S (option) 1152 801 15 17 EN - 09/2019...
  • Page 131 Technical specifications Technical datasheet EXU-H 20S (option) DESIGNATION 1.1 Manufacturer STILL GmbH 1.2 Model type EXU-H 20S 1.3 Method of propulsion: battery, diesel, petrol, LPG, mains power Battery 1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian Fork/load arm nominal...
  • Page 132 Technical specifications Technical datasheet EXU-H 20S (option) Height at the ends of the fork in the lower h13 (mm) 4.15 position (max) 4.19 Total length (± 5 mm) L1 (mm) 2367 4.20 Length to load mating face (±5 mm) L2 (mm) Pedestrian/ride-on 787/1177 4.21 Total width (±...
  • Page 133 Technical specifications Technical datasheet EXU-H 20S (option) Battery voltage and capacity (discharge in 5 V/Ah 2 Pzs 24/190 6.5 Battery weight (10%) 2 Pzs Energy consumption according to standard- kWh / h 0.38 ised VDI cycle OTHER EXU-H 20S 8.1 Speed control AC controller 8.4 Noise level at operator's ears (±...
  • Page 134 Technical specifications Technical datasheet EXU-H 20S (option) 1152 801 15 17 EN - 09/2019...
  • Page 135 Index Checking the cables, terminals and battery connector ... . 105 Access to the technical compartment . . . 88 Checking the electrical connections . . . 105 Accessing the reducer and the brake . . . 90 Checking the emergency stop .
  • Page 136 Index Lifting ......55 Base lift ..... . . 56 FleetManager™...
  • Page 137 Index Precautions to be taken during battery Start-up ......40 maintenance ....97 Steering .
  • Page 140 STILL GmbH 1152 801 15 17 EN – 09/2019...

This manual is also suitable for:

Exu-h-20

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