Original instructions

Electric pallet truck

EXU-S 22
EXU-S 24

0177 0178

50018043464 EN - 10/2017
Preface
g

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

Rules for the operating

company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for the safe operation of
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks

Internet address and QR code

The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.

50018043464 EN - 10/2017 I
Table of contents
g

1 Introduction
Forklift data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
How to Consult the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Date of edition and latest update of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Delivery of the forklift and documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 6
Technical service and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Type of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Working conditions ................................................... 7
Modifications to Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Applied equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
User obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Safety
Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
Flooring requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
Battery connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 13
Requirements for the traction-battery charging area . . . . . . . . . ............... .. 13
Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . ............... .. 13
Safety Regulations Relative to Operating Materials . . . . . . . . . . ............... .. 14
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electromagnetic radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Non-ionised radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

50018043464 EN - 10/2017 III

 Table of contents
g

3 Overview
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sample graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 28
View of the control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 28
Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 29
Dead man's zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 30
Markings . . . . . . . . . . . . . . . . . . . . . . . ........ ............... ............ 31
Location of designation plates and labels ....... ............... ............ 31
Chassis frame labelling . . . . . . . . . . . . ........ ............... ............ 32
Data plate . . . . . . . . . . . . . . . . . . . . . . ........ ............... ............ 33
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 34
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 34
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 34
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 35

4 Application
Authorised and safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Safety instructions relating to use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Truck transport and lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 40
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 40
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 40
Climatic Conditions for Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . ...... 41
Breaking-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Checks and actions prior to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the battery plug (charging station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 46
Turning on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 46
Entering the user code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 47
Starting with FleetManager (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 48
Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 49
Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 49
Display of time to next servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 50
Operating the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 51

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Check of brake and presence area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Checking the emergency brake button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 53
Driving safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 53
Visibility when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 53
Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 54
Dimensions of roads and working aisles . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 55
Emergency stop procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 56
Driving in rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 57
Selecting the driving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 58
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 58
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 58
Automatic shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .. 60
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Operating the main lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Load placement . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 62
Safety regulations when handing loads . . . . . . . . . .......... ............... .. 62
Before picking up a load . . . . . . . . . . . . . . . . . . . . .......... ............... .. 63
Taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 64
Transporting a load . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 64
Depositing a load on the ground . . . . . . . . . . . . . . .......... ............... .. 65
Driving up and down on an incline . . . . . . . . . . . . . .......... ............... .. 66
Entering lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 66
Driving on loading bridges . . . . . . . . . . . . . . . . . . .......... ............... .. 67
Using the truck on inclines, loading bridges and lifts. ......... ............... .. 68
Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... ............... .. 68
Cold store usage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Digicode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 71
Digicode control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 71
Adding the master code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 72
Deleting a master code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 73
Adding a driver's code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 75
Deleting a driver's code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .. 77
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Battery electrolyte level indicator LED (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Handling the truck in specific situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Towing and moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hoisting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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g

Towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Handling the battery . . . . . . . . . . . . . . . . . . . . . .. ............... ............ 82
Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ............... ............ 82
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ............... ............ 82
Opening/closing the battery compartment . . . . . .. ............... ............ 83
Battery charging with external battery charger . . .. ............... ............ 83
Changing the battery . . . . . . . . . . . . . . . . . . . . .. ............... ............ 84
Changing the battery with crane . . . . . . . . . . . . .. ............... ............ 85
Changing the battery with lateral removal trolley .. ............... ............ 86
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safe parking of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Measures when storing the stacker for a longer period of time . . . . . . . . . . . . . . . . . . . 88
Taking back into service after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5 Maintenance
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Operations Preliminary to Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Summary table of maintenance operations EXU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Cleaning the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 97
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 97
Forklift Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 98
Temporary Putting Out of Commission . . . . . . . . . . . . . . . . . . . . . . . . ............ 98
Checks and Inspections After a Long Period of Inactivity . . . . . . . . . . . ............ 98
Permanent Putting Out of Commission (Demolition) . . . . . . . . . . . . . . ............ 98

6 Technical data
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
VDI data sheet for standard EXU-S 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
VDI data sheet for standard EXU-S 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Turning radius and load distance EXU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Supply table EXU-S EXU-SF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

VI 50018043464 EN - 10/2017
 1

Introduction
1 Introduction
Forklift data

Forklift data
We recommend that you record the principal
forklift data in the following table so that they
are available if required by the sales network
or authorised service centre.

Type
Serial number
Date of delivery
.

General information
• This manual contains "Original Instructions" to things due to the failure to observe the
provided by the manufacturer. instructions in this manual, in the "Rules for
• The "operator" is defined as the person the use of industrial vehicles" and on the
driving the forklift. labels and adhesive supplied to the forklift.
• The "user" is the physical or legal person • The forklift may not be put to any use other
who has the forklift truck used by the that than indicated in this manual.
operators. • The forklift must be used by appropriately
• For correct use of the forklift and in order trained operators only. For the necessary
to avoid accidents, the operator is obliged operator training, contact the authorised
to read, understand and apply the contents sales network.
of this manual, the "Rules for the use of • Persons working near the forklift must also
industrial vehicles" and the labels and be instructed in the risks associated with
plates applied to the forklift. use of the forklift.
• This manual and the attached "Rules for • In the interests of clear information, some
the use of industrial vehicles" must be kept illustrations in this manual show the forklift
carefully and must always be on the forklift without the safety equipment (guards,
for fast consultation. panels, etc.). The forklift may not be used
• The manufacturer assumes no responsibil- without safety equipment.
ity for any accidents to persons or damage

How to Consult the Manual

There is a table of contents at the beginning Some general information is provided in this
of the manual for ease of use. The manual is manual. Please only consider the information
divided into chapters with specific topics. The relevant for your specific forklift.
name and title of the chapter are given at the
The following symbols have been used to
top of each page The following is found at the
highlight some parts of this manual.
bottom of each page: the type of manual, the
identifying code, the language and the manual DANGER
version.
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.

2 50018043464 EN - 10/2017
Introduction 1
How to Consult the Manual

CAUTION ENVIRONMENT NOTE

Failure to observe the instructions highlighted with Failure to observe the instructions highlighted
this symbol may cause damage to the forklift and,
in some cases, result in warranty invalidity. with this symbol may cause environmental
damage.

NOTE
This symbol is used to provide additional
information.

50018043464 EN - 10/2017 3
1 Introduction
Date of edition and latest update of this manual

Date of edition and latest

update of this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.

Copyright and trademark

rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.

Delivery of the forklift and documentation

Ensure that the truck has all of the options included, as well as the EC declaration for the
requested and that it has been delivered with battery charger.
the following documentation:
If applied equipment, other equipment or
• Original instructions devices are present, ensure that they conform
• Rules for the compliant use industrial to the order and that the relative use and
vehicles; maintenance manual and of the relative EC
• EC Declaration of Compliance; declaration (if provided by regulations in
• Warranty book. effect) are included.

If the forklift has been delivered with a traction All of the above documentation must be kept
battery and/or battery charger, ensure that for the entire operative life of the forklift. In the
such products conform to the order and that event that the documentation is lost or dam-
the relative user and maintenance manual are aged, contact the authorised sales network for
copies of the original documentation.

4 50018043464 EN - 10/2017
Introduction 1
CE labelling

CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.

CE-Symbol

50018043464 EN - 10/2017 5
1 Introduction
EC declaration of conformity in accordance with Machinery Directive

EC declaration of conformity in accordance with Machinery Di-

rective

Declaration

STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany

We declare that the

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.

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL GmbH

6 50018043464 EN - 10/2017
Introduction 1
Technical service and spare parts

Technical service and spare parts

For scheduled maintenance and any repairs to the technical characteristics of the forklift over
the forklift, contact only the authorised service time.
network.
Only original spare parts provided by the man-
The authorised service network has personnel ufacturer may be used for forklift maintenance
trained by the manufacturer, original spare and repairs. The use of non-original spare
parts and the tools necessary to carry out parts invalidates the warranty and renders the
maintenance and repairs. user responsible for any accidents due to the
inappropriateness of the non-original parts.
Servicing by the authorised service network
and the use of original spare parts maintain

Type of use
"Normal use conditions" of the forklift are • transporting loads not equally distributed on
understood as: the forks;
• lifting and/or transport of loads using forks • transporting swinging loads;
with weight and load centre within the • transporting loads whose load centre is
values provided (see Chapter 6 - Technical considerably displaced with respect to the
Data). forklift's longitudinal median plane;
• transport and/or lifting on smooth, flat and • transporting loads of dimensions such as to
compact surfaces; block the view of the operator when driving;
• transport and/or lifting of stable loads • transporting loads piled so high that they
uniformly distributed on the forks; could fall onto the operator;
• transport and/or lifting with the load centre • travelling with a load over 300 mm off the
approximately on the forklift's median ground;
longitudinal plane.
• transporting and/or lifting people;
DANGER • pushing or pulling loads;
The forklift must not be used for other purposes. • moving upwards or downwards on a slope
Any other use renders the user solely responsible with the load facing downwards;
for injury/damage to persons and/or objects and • turning at high speed;
voids the warranty.
• turning and/or moving sideways on slopes
(upwards or downwards);
The following scenarios are examples of
incorrect use of the forklift truck: • colliding with stationary and/or mobile
structures;
• Transport on uneven (irregular or non-
compact) surfaces DANGER
• loads that exceed the weight and/or load Improper use of the forklift could cause it and/or at
centre limits; the load to overturn.
• transporting non-stable loads;

Working conditions
The forklift has been designed and built for
internal transport.

50018043464 EN - 10/2017 7
1 Introduction
Modifications to Forklift

Do not use beyond the limits of the climatic use precautions are necessary. Contact the
conditions indicated below: authorised sales network for more informa-
• Maximum ambient temperature: +40°C tion.
• Minimum ambient temperature: +5°C DANGER
• Altitude up to 2000 m The forklift may not be used in environments in
• Relative humidity between 30% and 95% which there is a risk of explosion. It may not be
(without condensation). used to handle explosive loads.

CAUTION For forklifts that must operate in environments

Do not use the forklift in dusty areas. in which there is a risk of explosion or must
Using the forklift in environments with high concen- handle explosive loads, appropriate equip-
trations of salty air or water could interfere with its ment is necessary and must be accompanied
proper operation and cause corrosion of metallic by a specific EC Declaration of Compliance
parts.
which replaces that of the standard forklift,
and by the relevant User and maintenance
If the forklift must be used in conditions that manual.
exceed the limits indicated or, in any case,
under extreme conditions (extreme weather, Contact the authorised sales network for more
cold-storage rooms, presence of strong mag- information.
netic fields etc), appropriate equipment and/or

Modifications to Forklift
No modifications may be made to the forklift, DANGER
otherwise the EC certificate and the warranty If the forklift is equipped at the factory or later with
will become invalid, with the exception of: devices that emit non-ionising radiation (such as
• assembly of the options provided by the radio transmitters, RFID players, data terminals,
manufacturer scanners, etc), the compatibility of such devices
must be verified with the presence of operators
• assembly of applied equipment using medical devices (such as heart pacemakers).
for which it is necessary to refer exclusively to
the authorised sales network

Applied equipment
To use equipment that has not been applied, • add a label with the new residual capacity is
please contact the authorised sales network, • provide documentation on the equipment
in order to: (user and maintenance manual and EC
• verify feasibility certificate).
• install the equipment

User obligations
Users must comply with applicable local legis-
lation governing forklift use and maintenance.

8 50018043464 EN - 10/2017
Introduction 1
Environmental considerations

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

NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.

ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.

50018043464 EN - 10/2017 9
1 Introduction
Environmental considerations

Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.

ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.

10 50018043464 EN - 10/2017
 2

Safety
2 Safety
Safety guidelines

Safety guidelines
General Precautions
NOTE regulations integrate those in the manual
"Rules for approved use of industrial vehicles".
Some safety regulations to be followed when
using the forklift are listed below. These

General Safety Rules

• Only allow qualified, trained and authorized • Place the load on the fork carriage or in such
personnel to use the forklift. a way that the centre of gravity of the load is
• Do not install equipment on the forklift un- as close as possible to the fork carriage.
less supplied or indicated by the manufac- • The load must be placed on the fork arms
turer. so that the centre of gravity falls lengthwise
• Maintain the forklift in full working efficiency on the mid point between the fork arms.
in order to limit any type of risk to the • Do not drive with loads off-centre laterally
minimum. with respect to the forklift's median axis.
• Do not use the truck with bonnets or doors Lack of compliance with this regulation can
open or with guards removed. compromise forklift stability.
• The data plates found on the forklift must • Make sure that the surface on which the
be kept in good condition and replaced if load rests is able to support its weight.
damaged. • Always use safety clothing compliant with
• Carefully read and follow all of the safety current regulations and any personal pro-
indications found on the forklift. tective equipment that may be applicable.
• Make sure that the forklift has sufficient • Do not travel on loose or hilly ground or on
overhead clearance. steps.
• Do not park the forklift in front of fire-fighting • Do not drive with loads raised more than
devices or fire escapes or anywhere that it 300 mm from ground level.
blocks traffic. • Do not turn or stack on slopes.
• If the forklift shows signs of failure or • Reduce speed on slopes.
breakage and there is reason to consider • Do not overload the forklift beyond the
it unsafe, stop, park it, and notify the capacity limits indicated on the capacity
maintenance manager. plates.
• Maintain appropriate distances from high • Individuals under the influence of drugs and
voltage overhead cables. Comply with alcohol are not permitted to use the truck.
the safety distances established by the • The operator may not use an MP3 player
competent authorities. or any electrical device that may distract
• Never raise the load using just one fork. their attention from the surrounding work
environment.

Flooring requirements
The work floor must be even and free of holes prevent impacts with the wheels, which affect
or dips, which can be difficult to get around. the entire structure of the truck.
Any steps must be equipped with ramps to

12 50018043464 EN - 10/2017
Safety 2
Safety guidelines

CAUTION
Passing over cracks or damaged parts of the floor
with the truck is prohibited. Dirt and any objects in
the work path must be removed immediately.

Battery connection cables

CAUTION
Using sockets with NON-ORIGINAL battery con-
nection cables can be dangerous (see purchase
references in the parts catalogue)

Requirements for the traction-battery

charging area
When the traction battery is being charged, the
area must be sufficiently ventilated in order to
download or eliminate the gases produced
(EN 50272-3).

Safety Regulations Relative to Forklift Use

• The operator must familiarize himself with ENVIRONMENT NOTE
the forklift to be able to better describe any
defects and assist maintenance personnel. Report any oil and/or battery fluid leaks: they
The operator, trained and authorized to use are dangerous and highly polluting.
the forklift, must be familiar with the controls
CAUTION
and performances of the forklift.
If you notice a burning smell, stop the forklift and
• Any defect (squeaking, leaks, etc.) must be
turn off the engine, then disconnect the battery.
promptly reported because, if neglected, it
could cause more serious failures/defects.
• Carry out the inspections indicated in the
chapter on "Daily Inspections".

50018043464 EN - 10/2017 13
2 Safety
Safety guidelines

Safety Regulations Relative to Operating Materials

Rules for handling and disposing of Oils
operating materials • Do not allow to come into contact with the
skin.
ENVIRONMENT NOTE • Do not inhale oil vapors.
Improper use and disposal of operating and • Wear appropriate means of individual
cleaning materials can cause serious damage protection during forklift maintenance
to the environment. operations (gloves, goggles, etc.) to
prevent the oil from coming into contact
Always use and handle the operating materi-
with your skin.
als in a suitable manner and follow the manu-
facturer's instructions for the product's use.
ENVIRONMENT NOTE
Keep the operating materials only in contain-
ers intended for this purpose and in a location The used oils and relative filters contain sub-
that satisfies the requirements. stances that are hazardous to the environment
and must be disposed of according to current
The operating materials may be flammable, so regulations. We advise you to contact the au-
avoid contact with hot objects or open flames. thorised service network.
When topping up the operating materials, only DANGER
clean containers should be used.
The penetration in the skin of hydraulic oil that has
Follow the manufacturer's safety and disposal leaked under pressure from the forklift's hydraulic
instructions regarding the operating and system is dangerous. If this type of lesion should
cleaning materials. occur, contact a doctor immediately.

Do not disperse oils or other operating liquids!

Any spilt liquid must be immediately collected DANGER
and neutralised with a binding material (such Small high pressure jets of oil can penetrate the
as an oil binder) and then disposed of in skin. Look for any leaks using a piece of cardboard.
accordance with current regulations.
Always comply with anti-pollution regulations!
Before carrying out work that involves lubrica- Battery Acid
tion, filter replacement or hydraulic equipment • Do not inhale the vapor: it is poisonous.
interventions, the area in question must be
• Use adequate means of individual protec-
thoroughly cleaned.
tion to prevent contact with the skin.
The replaced parts must always be disposed • Battery acid is corrosive: if it should come
of in accordance with the anti-pollution laws. into contact with your skin, rinse abundantly
with water.
ENVIRONMENT NOTE • Explosive gas mixtures can form when
The incorrect or unlawful use of brake fluid is charging the battery; therefore, the rooms
harmful to people's health and the environ- in which the battery is charged must be in
ment. compliance with the specific regulations on
the subject (e.g. EN 50272-3 etc.).
• DO NOT smoke or use open flames and
lights within a 2 m radius from the charged
battery and in the battery charging area.

14 50018043464 EN - 10/2017
Safety 2
Residual risks

NOTE and disposal of the life-expired battery must

be carried out as required by law. We advise
For greater information, consult the specific you to contact the authorised service network
battery manual that comes with the battery. that is equipped for eco-friendly disposal in
accordance with current regulations.
ENVIRONMENT NOTE
The batteries contain substances that are ha-
zardous to the environment. The replacement

Residual risks
Residual dangers, residual risks
Despite careful use and compliance with
standards and regulations, the possibility
of other risks occurring when using the truck
cannot be entirely excluded.
The truck and all other system components
comply with current safety requirements.
Nevertheless, even when the truck is used
for its proper purpose and all instructions
are followed, some residual risks cannot be
excluded.
Even outside the defined danger areas of
the truck, residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck must
be instructed regarding the risks that arise through
use of the truck.
In addition, we draw your attention to the Safety
Guidelines in these operating instructions.

Risks can include:

• Escape of consumables due to leakages,
rupture of lines and containers etc.
• Risk of accidents when driving on ramps or
in conditions of poor visibility, etc.
• Falling, tripping etc. when moving the truck,
especially in wet or icy conditions or when
consumables are leaking.
• Fire and explosion risks due to batteries and
electrical voltages.

50018043464 EN - 10/2017 15
2 Safety
Residual risks

• Human error resulting from failure to

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

Stability
The stability of the truck has been tested
in accordance with up-to-date technical
regulations and is guaranteed if the truck is
used correctly and in line with the intended
purpose. These standards only take into
account the static and dynamic tipping forces
that can arise during use in accordance
with the operating standards and intended
purpose. In extreme cases there is a risk of
exceeding the moment of tilt due to improper
use or incorrect operation, which will affect
stability.
Risks can include:
• loss of stability due to unstable or sliding
loads etc.;
• turns at excessive speeds;
• moving with the load raised;
• moving with a load that is projecting to the
side (e.g. side shift);
• turning and driving diagonally across
slopes;
• driving on slopes with the load pointing
downhill;
• oversized loads;
• swinging loads;
• steps or ramp edges.

16 50018043464 EN - 10/2017
Safety 2
Electromagnetic radiation

Electromagnetic radiation
The limit values for electromagnetic emissions
and for immunity relative to the forklift are
those provided by the EN 12895 standard.

Non-ionised radiation
If the forklift is equipped at the factory or
later with devices that emit non-ionising
radiation (such as radio transmitters, RFID
players, data terminals, scanners, etc), the
compatibility of such devices must be verified
with the presence of operators using medical
devices (such as heart pacemakers).

Noise
Sound pressure level in driver's seat LpAZ < 70 dB (A)
Uncertainty factor KpA=4 dB (A)

The value is determined in a test cycle in CAUTION

accordance with Harmonised European The value expressed above can be used to com-
Standard EN 12053 and declared according to pare forklift trucks of the same category. This can-
EN ISO 4871 with weighted time percentages not be used to determine the noise level in workpla-
of the Transport, Lifting and Idling modes. ces (daily personal noise exposure). Noise values
that are lower or higher than those indicated above
can occur during actual truck use, for example
following different operating modes, different envi-
ronmental conditions and additional noise sources.

50018043464 EN - 10/2017 17
2 Safety
Vibrations

Vibrations
Vibrations to which the hands and arms CAUTION
are exposed The value expressed above can be used to com-
pare forklift trucks of the same category. It cannot
The following value is valid for all truck models: be used to determine the operator's daily expo-
• āw< 2.5 m/s2 sure to vibrations during real operation of the truck;
these vibrations depend on the conditions of use
(floor conditions, method of use etc.) and therefore
NOTE daily exposure must be calculated using data from
the place of use.
It is mandatory to specify the hand-arm
vibrations, even where the values do not
indicate any danger, as in this case.

18 50018043464 EN - 10/2017
Safety 2
Safety tests

Safety tests
Regular safety inspection of the truck
Safety inspection based on time and
extraordinary incidents
The operating company must ensure that STILL GmbH Hamburg
the truck is checked at least once a year, or
Regelmäßige Prüfung
following noteworthy incidents. (FEM 4.004)
As part of this inspection, a complete check nach nationalen Vorschriften
of the technical condition of the truck must be basierend auf den EG-Richtlinien:
95/63/EG, 99/92/EG, 2001/45/EG
performed with regard to accident safety.
In addition, the truck must be thoroughly Nächste Prüfung
checked for damage that could potentially
have been caused by improper use. A test
log must be created. The results from the
inspection must be retained until a further two

56344391019
inspections have been carried out.
The inspection date is indicated by an adhe-
sive label on the truck.
– Arrange for the service centre to perform
periodic safety inspections on the truck.
– Observe guidelines for checks carried out Die Prüfplakette ersetzt nicht das Prüfprotokoll

on the truck in accordance with FEM 4.004. Mitglied der:

Fédération
The operator is responsible for ensuring any Européene
de la Manutention
defects are remedied without delay.
0000_003-001_V3

– Contact your service centre.

NOTE
Observe the national regulations for your
country!

50018043464 EN - 10/2017 19
2 Safety
Safety tests

20 50018043464 EN - 10/2017
 3

Overview
3 Overview
Technical description

Technical description

This robust stand-on electric pallet truck is

ideal for loading and unloading lorries, and
its high driving speed also makes it easy to
transport over longer distances.

Chassis
• The EXU-S was designed for loading and
unloading lorries and has excellent handling
on slopes and in the confined spaces of
lorries.
• The even chassis moves smoothly and
never catches on protruding edges of
ramps, whilst the platform's tapered sides
protect the operator from colliding with side
walls, even when working on the end two
pallet rows.
• The platform is an integral part of the
chassis and it has an enclosed, high-
resistance structure providing extreme
reliability, even on violent impacts on the
dock.
• To optimise traction and braking, the
centre-mounted drive unit is sprung and

22 50018043464 EN - 10/2017
Overview 3
Technical description

features variable wheel pressure on the

ground proportional to the load on the forks.
• For lateral stability, two exclusive STILL
twin-wheels have been specially designed
for the EXU-S for extreme reliability in the
most arduous applications.

Steering
• Fully electric steering "with automatic return
to neutral".
• In the centre angle range, any unintentional
steering movements are damped by means
of an electronic filter, guaranteeing precise
steering.
• Automatic speed reduction during cornering
combined with the stabilising wheels gives
high lateral stability and reduces centrifugal
force effects on the operator and the load.

Cockpit
• The new console "cockpit" contains all the
functions for access, operation and control
on the EXU-S.
• Due to the ergonomic layout of the controls,
all functions can be operated with either
hand.
• The following functions are integrated into
the cockpit:
• Steering and speed control
• Raising/lowering of forks
• Hour meter connected to functions
• Battery discharge indicator with fork lift
cut-out
• Operator profiles with two performance
modes
• Performance mode selection by electronic
key
• Service centre diagnosis for maintenance
(by means of service codes)
• In addition, the cockpit provides a secure
support for the operator whilst driving, so
that he does not get tired or have to keep
turning backwards and forwards.

50018043464 EN - 10/2017 23
3 Overview
Technical description

Driver rides standing on "sprung"

platform
• Depending on the application, the EXU-S
is available with two platform types that
are ergonomically suited to the operator’s
needs. These needs are very different
from one type of job to another, so we have
designed two different platforms.
• For typical loading/unloading applications
where pallet transfer or long runs require the
driver to spend a long time standing on the
truck, the platform with side access will offer
the greatest comfort and safety for driving in
both directions.
• If the driver has to step in and out frequently
for any peripheral work, (scanning products,
manual handling etc.), then the platform
with rear access is best suited.
• Either EXU-S platform type always provides
great comfort due to an innovative, unique,
fully sprung platform floor.
• The truck incorporates various storage
facilities and a holder for rolls of stretch
wrap integrated within the hood.
• A clipboard is available as standard.

Driving
• The asynchronous traction technology is
powerful and economical. Travel power is
3.0 kW.
• The latest generation of asynchronous
controller combined with the cockpit offers
the possibility of selecting two drive modes
by touching one of the two performance
mode buttons:
• In "ECO" mode (Tortoise button), the
controller supplies the travel motor with low
current and it accelerates gradually. This
results in 15 % more battery economy, but
the same productivity as other machines of
this type.
• In "BOOST" mode (Hare button), the
controller drives the travel motor to provide
very high torque and acceleration, even
when fully loaded. While economy remains
unchanged, productivity increases by
around 25 %.

24 50018043464 EN - 10/2017
Overview 3
Technical description

• With each mode, the drive characteristics

can be adjusted (speed, acceleration,
braking) to precisely match the application
or driver preference.
• Thanks to the controller's speed control
system, the EXU-S will start smoothly
and accelerate to maximum travel speed,
regardless of the load on the forks.
• The service brake is activated by releasing
the butterfly valves or by reversing the
direction of travel.
• To avoid any unintentional movements
whilst on a ramp, the (electromagnetic)
parking brake is activated once the butterfly
valves are in neutral position or the operator
leaves the platform.

Hydraulic system
• A pump unit comprising a compact, 2.2-kW
pump motor with built-in oil tank, solenoid
valve and safety valve controlling electrical
end-of-travel lift cut-out.
• This hydraulic system offers very short
lift times, even with a full load, thereby
providing high productivity for loading and
unloading lorries with the EXU-S.

Brake circuit
• There are two independent brake circuits.
• Progressive service brake with energy
recovery activated by releasing or reversing
the butterfly valves.
• Emergency brake with electromagnetic disc
activated by a button in the cockpit.
• Driving is only possible when the operator
is on the platform, which acts as a contact
switch.

Battery
• The battery is easily accessible which
makes it easier to recharge or carry out
maintenance work (for example, "filling the
water up"). The batteries can be replaced

50018043464 EN - 10/2017 25
3 Overview
Overviews

vertically with a sling, or from the side using

rollers, if used for 2 or 3 work shifts.
• Two different battery compartments allow
batteries with 450 Ah or 600 Ah capacities
to be used.

Overviews
5 6
4 23
3 7

2 8

10

11

12
22
21

20

19 13

18
17 16 15 14 0148_003-001

1 Forks 11 Brake
2 Battery compartment 12 Drive motor
3 Battery cover 13 Platform (interlock zone)
4 Battery lock 14 Stabiliser
5 Battery connector 15 Traction wheel
6 Cockpit 16 Gearbox
7 Lift cylinder 17 Stabiliser
8 Pump motor 18 Steering motor
9 Backrest 19 Steering controller
10 Hydraulic oil tank 20 Fuse mount

26 50018043464 EN - 10/2017
Overview 3
Definition of directions

21 Drive controller
22 Load wheel
23 Mounting bracket for accessories (option)

Definition of directions
3
The references forwards (1), backwards
(3), right (2) and left (4) when describing the
position are relative to the driver's seat. The
load is at the front.

2 4

1 0249_003-001

Sample graphics
This documentation explains the (usually
sequential) sequence of certain functions or
operations. Schematic diagrams of a truck are
used to illustrate these sequences.

NOTE
These schematic diagrams are not represen-
tative of the constructed state of the docu-
mented truck. They serve only to illustrate the
sequences.

50018043464 EN - 10/2017 27
3 Overview
Control and display elements

Control and display elements

View of the control elements
1 2 3

5
123 456 789

PRG
PRG

7 6 0148_003-002

1 Battery cover
2 Battery compartment lock
3 Cockpit
4 Document holder
5 Diagnostic connector
6 Glove compartment
7 Emergency isolator button

28 50018043464 EN - 10/2017
Overview 3
Control and display elements

Cockpit

4 5 6 7 8 9 10 11
3 12
13
2 14

1 123 456 789

15
PRG
PRG

20 16

19 18 17 0148_003-003

1 Lower button 11 Numbers 789 button

2 Lift button 12 Hare button
3 Horn button 13 Horn button
4 Tortoise button 14 Lift button
5 PRG ↑ (scrolling) button 15 Lower button
6 Numbers 123 button 16 Handle
7 Display 17 Travel control
8 I (ON) button 18 Emergency brake switch
9 Numbers 456 button 19 Travel control
10 PRG ↲ input (enter) button 20 Handle

50018043464 EN - 10/2017 29
3 Overview
Control and display elements

Dead man's zone

CAUTION
The pallet truck has a foot interlock zone which can
cause the truck to be braked.

Method of operation
The driver must stand with one foot on the foot
interlock zone (1) of the driver’s platform. The
feet must stay in the area of this platform.
The pallet truck is braked as soon as the foot
interlock is no longer activated (the driver
leaves the platform).

1 0148_003-004

30 50018043464 EN - 10/2017
Overview 3
Markings

Markings
Location of designation plates and labels

1 2 3

4
8

6
7 *

2329

1 "Danger of crushing hands" label 5 Nominal value designation plate

2 "No hooking" label 6 "Cold store" label (on cold store version only)
3 "Operating and maintenance manual" label 7 "Danger of crushing feet" label
4 Annual testing label (Germany only) 8 "Hook" symbol

Description of labels
(1) The label indicates the danger and risk of
crushing hands area.

50018043464 EN - 10/2017 31
3 Overview
Markings

(2) This label indicates that you must not lift

the truck by hooking onto the cockpit
(3) This label indicates that you should consult
the operating and maintenance manual before
using the truck and before carrying out any
maintenance work.
(4) This label is only present on trucks sold in
Germany. The label indicates the date of the
truck's periodic safety inspection.
(5) This designation plate gives the identifica-
tion data for the truck
(6) This symbol, where present, indicates
that the truck is set up for use in cold-storage
(option).
(7) The label indicates the danger and risk of
crushing feet area.
(8) This label indicates where to attach the
truck's lifting hook.

Warning plates
Always observe the indications on the warning
plates.

Chassis frame labelling

The truck's serial number is marked on the
chassis frame (1).

2265

32 50018043464 EN - 10/2017
Overview 3
Markings

Data plate
NOTE 1 2 3 4 5 6
Please indicate the serial number for all
technical enquiries.

7 8
9 10 11 12 13
2327

1 Model
2 Rated capacity in kg
3 Manufacturer
4 Serial no.
5 Unladen weight (without battery) in kg
6 Year of manufacture
7 EC conformity symbol
8 QR code
9 Battery voltage V
10 Nominal power rating in kW
11 Minimum battery weight
12 Maximum battery weight
13 Additional weight (ballast) in kg

50018043464 EN - 10/2017 33
3 Overview
Options

Options
Models
1 Platform, access on left side
1

0148_003-006

2 Platform, access at rear

2

0148_003-007

Options
• Single load wheels
• Continuous operation hour meter (with own
battery in the tiller head)
• Battery charge indicator (for gel battery)
• Battery charge indicator (for gel battery)
with service interval indicator
• Battery charge indicator (for lead battery)
with service interval indicator

34 50018043464 EN - 10/2017
Overview 3
Options

• Cold store version

• Document holder
• Preparation for data input terminal
• FleetManager
• Tray 71
• Various fork gauges and fork lengths
• Various load rack sizes
• Various types of tyre for the drive wheel
• Slow speed with forks lowered
• Battery electrolyte level indicator LED

Accessories
• Master code (factory setting "1 2 3 4")
• Key for battery compartment (2 items)

50018043464 EN - 10/2017 35
3 Overview
Options

36 50018043464 EN - 10/2017
 4

Application
4 Application
Authorised and safe use

Authorised and safe use

Intended use of the trucks

CAUTION
This machine is intended for the transport of loads
packed on pallets or in industrial containers de-
signed for this purpose, as well as for placing pallets
into and removing pallets from stock.
The dimensions and capacity of the pallets or
containers must be adapted to the load being
transported to ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of the
information you need to check that the equipment
is suitable for the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.

Safety instructions relating to use of

the truck
Behaviour when driving
The operator must obey the same rules within
the plant as on the road. The operator must
drive at a speed appropriate for the driving
conditions. For example, the operator should
drive slowly around corners, when entering
and travelling through narrow passageways,
when driving through swing doors, at blind
spots, or on uneven surfaces. The operator
must always maintain a safe braking distance
from vehicles and persons in front of him and
must always have the truck under control. The
operator must avoid sudden stops, making
fast U-turns and overtaking other vehicles in
potentially dangerous areas or areas with poor
visibility.
WARNING
Driving the truck while sitting down is prohibited.

Please remember the following:

• Drive the truck as described in the "Operator
positions" section.
• The truck must not be used as a stepladder.

38 50018043464 EN - 10/2017
Application 4
Authorised and safe use

• The truck has not been designed to trans-

port anyone other than the operator and
must not be used for this purpose.
• The operator must always stay within the
truck clearance.
• Stay in the safety area (working area
defined by the manufacturer).

NOTE
Using a telephone or radio in the truck is
permitted, but avoid using these devices when
driving as they may distract you.

People in the danger area

Before starting the truck and while you are
working, ensure that no one is in the danger
area. If people are in danger, warn them
well in advance. Stop working with the truck
immediately if the people do not leave the
danger area despite the warnings.
DANGER
Risk of injury! There is a risk of physical injury inside
the danger area. Danger of death from falling loads!
Do not stand on the forks!
Standing or walking under the forks is strictly
forbidden, even when they are not loaded!

Danger area
The danger area is the area in which people
are in danger from the forklift truck move-
ments, from its work equipment and from its
load lifting devices (e.g. accessories) or from
the load. The danger area also includes ar-
eas in which a load could fall or in which work
equipment could lower or fall.

Traffic route conditions

The surface of traffic routes must be suf-
ficiently level, clean and clear of objects.
Drainage channels, railway crossings and
other similar obstacles must be levelled and, if
necessary, fitted with ramps so that the truck
can cross without jolting.

50018043464 EN - 10/2017 39
4 Application
Truck transport and lifting

There must be sufficient distance between

the highest part of the truck or the load and
the surrounding fixed installations. The
height depends on the lift height and the
dimensions of the load. Refer to the technical
characteristics.

Regulations regarding the traffic routes

and the manoeuvring areas
Only traffic routes authorised by the operator
or his agent may be used. Traffic routes
must be free of obstacles. Loads may only
be unloaded and stored in places designed
for this purpose. The operator or his agent
must ensure that no unauthorised person
approaches the working area.

Hazards
Hazards on the traffic routes must be signalled
by standard road signs or possibly by addi-
tional warning notices.

Truck transport and lifting

Transporting the truck
The forklift is normally transported by road
and rail. If the forklift's dimensions exceed
the max. clearance size allowed, it is trans-
ported disassembled. The sales network is
in charge of the disassembly and reassembly
operations. The forklift must be secured to the
transport means during transport using appro-
OM0747
priate restraint systems. Block the wheels with
wedges to prevent even the slightest move-
ment.

Transport
– Shut down the truck with the key switch.
– Disconnect the battery connector.

40 50018043464 EN - 10/2017
Application 4
Breaking-In

Chocking the truck

– Secure the truck against rolling and sliding 0148_003-027

with chocks (1).

1
Lashing down the truck
– Attach the lashing ropes (2) at the frame.

Climatic Conditions for Transport and Storage

The forklift must be protected from atmo-
spheric agents during transport and storage.

Breaking-In
This type of forklift does not require special
breaking-in operations.

50018043464 EN - 10/2017 41
4 Application
Checks and actions prior to use

Checks and actions prior to use

Visual checks

WARNING
Damage or other faults on the truck or attachments
(special equipment) can result in accidents.
If damage or other faults are noticed on the truck
or attachments (special equipment) during the
following checks, do not use the truck until it has
been properly repaired. Do not remove or disable
the safety systems and switches. Do not change
the pre-set values.

CAUTION
Only use the truck if all of the covers are fitted
correctly and the covers and doors are closed
correctly.

CAUTION
Perform checks on a flat surface. Make sure that
there are no people or objects in the test area in
front of and/or behind the truck.

CAUTION
Drive very slowly during the operational tests.

Ensure that the vehicle is in good working

condition prior to start-up. These checks
supplement and do not replace the scheduled
maintenance operations.

42 50018043464 EN - 10/2017
Application 4
Checks and actions prior to use

– No visible damage (e.g. deformation,

cracks, heavy wear, hairline cracks) to forks
5 3
(1) and other lifting devices.
1
– Inspect the wheels and load wheels (2) for
strings, fibres and any other objects that
could hinder their free rotation.

0148_003-008

– The latch (4) must be closed.

4

0148_003-009

50018043464 EN - 10/2017 43
4 Application
Checks and actions prior to use

– The battery cover (5) must be closed.

– The cover (3) must be fitted.
• Check that the warning and safety labels 5 3
are complete and intact; see ⇒ Chap-
ter "Location of designation plates and la-
bels", P. 3-31.
• Replace any damaged or missing labels
according to the overview of the location of
plates and labels
• Attachments (optional) must be properly
secured and operated in accordance with
their user manual
• Inspect hydraulic pipes and hoses for visible
damage and leakage. Replace damaged
hoses 0148_003-010

• Check that there are NO oil leakages in the

area under the truck
• Visually check the uncovered sections of
hydraulic hoses and pipes to ensure that
they are in good condition and to detect any
oil leakages
• Check that there are no objects (wires of
various types, nails, screws, pieces of tape
etc.) impeding the operation of the wheels
and rollers. The wheels and the load rollers
must roll freely
• The wheels must not show any sign of
damage or heavy wear. They must be
correctly mounted
• Check that the battery hood is fully and
properly closed
• Check that all of the hoods and protective
guards are present and check that they are
correctly mounted
• There must be no objects on the truck that
may limit visibility
• Check that NO stickers are missing or
damaged. Replace damaged or missing
stickers in compliance with the marking
position table
• Visually check that the forks or other
load-carrying equipment show NO obvious
damage (e.g. bends, cracks, significant
wear)
• Check that the battery male connector and
female connector are fully intact and in good

44 50018043464 EN - 10/2017
Application 4
Checks and actions prior to use

condition. Check that they are working

correctly
• Check that the start/stop key works cor-
rectly
• Check that the horn works correctly
• Check that the buttons and the control
throttles on the tiller are working correctly
• One at a time, push the buttons and then
release them. Check that the buttons return
automatically to their initial positions. The
buttons must not remain activated or stuck
• Turn the drive control throttle and then re-
lease it. Check that the throttle automat-
ically returns to the initial position when it
is released. The throttle must not remain
activated or locked
• Test that the truck brakes and stops when
the throttle is released during travel
• Check that the emergency stop button is
operating correctly. Carry out the test when
travelling towards the forks
• Check that the brake is operating correctly
• Test that the electromagnetic brake works
effectively
• Check that the battery harness is in good
condition
• Check and test the battery electrolyte level
and density as indicated in the battery
instructions
• The operator must be qualified to drive the
truck. The operator must be able to reach
the controls and operate them (especially
the anti-crush protective device). Do not
obstruct access to the controls

50018043464 EN - 10/2017 45
4 Application
Start-up

Connecting the battery plug (charg-

ing station)
– Disconnect the battery socket (1) from the
charging station and insert into the plug on 1 2
3
the truck.
– The latch (2) must be closed.
– Close the battery cover (3).

0148_003-011

Start-up
Turning on the truck
NOTE
The pallet truck is equipped with a digital
control and is taken into operation by entering
a driver code. The driver code consists of four 123 456 789

figures and is assigned by the pool manager.

It is used for normal use and operation of
PRG
PRG

the truck by the driver and operator. The

knowledge of the code is like a key and should
not be misused. Do not tell third persons your
driver code except if expressly ordered to do
so.
– It is possible to send other codes; see chap-
ter: ⇒ Chapter "Digicode control", P. 4-71.
1047_003-007

46 50018043464 EN - 10/2017
Application 4
Start-up

Entering the user code 1 2 3 4

– Press the I key (on) (6). The display
(4) shows the message Code (8). This
message switches off after approximately
one second. You can then enter the 4-digit
user code. The digits are entered in the
same way as on a mobile phone.
– Press keys (1), (2) or (3) several times until 123 456 789
the desired digit is shown;
for digits:
• 1-2-3, press key 123 (1), PRG
• 4-5-6, press key 456 (2), PRG
• 7-8-9, press key 789 (3). 5
7 6
After entering a digit, the display moves to the
1044_505-001

next position. The display shows a flashing

line (9) (the illustration shows an example).

NOTE 8
If the digit entered is wrong, it is possible to
cancel it by depressing the PRG ↑ key (scroll)
(7).

1044_505-002

50018043464 EN - 10/2017 47
4 Application
Start-up

– The digit will be deleted and the flashing line

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

NOTE
%
If an error code is displayed, e.g. E380(10),
stop the truck by pressing the key (6) and carry
out the activation procedure again.

NOTE 10 1044_505-017

It is possible to show the following displays by

repeatedly depressing the PRG ↑ key (scroll)
(7).
• Hour meter ⇒ Chapter "Hour meter", P. 4-49
• Battery charging ⇒ Chapter "Battery
charge", P. 4-49
• Servicing interval management ⇒ Chap-
ter "Display of time to next servic-
ing", P. 4-50

Starting with FleetManager (op- 1 2 3 4

tional)
– Push the I key (START) (6). Do not pay
attention to the Code alert that appears in
the display
– Start the truck directly via the FleetManager
keyboard or reading device, depending on
the version. 123 456 789

PRG
PRG
5
7 6 1044_505-001

48 50018043464 EN - 10/2017
Application 4
Start-up

Hour meter
1
The operating hours (1) appear approx.
4 to 5 seconds after starting the truck, accom-
panied by the hourglass symbol (2). The total
hours are indicated from when the truck is first
commissioned. The hour meter totals during
travel. Perform maintenance work according
to the operating hours in accordance with the
maintenance schedule.

NOTE 2 1044_505-004

The meter goes to 9999.

Battery charge
3
WARNING
Do not place any metallic objects or tools on the
battery. No naked lights, no smoking permitted!
The battery could be damaged, shorted or an
explosion could occur. %

WARNING
The electrolyte (diluted sulphuric acid) is poisonous
and caustic! Follow the safety precautions for 1044_505-005

handling battery electrolyte.

– Press the PRG ↑ (scrolling) button (4) to

display the available battery charge (3).
123 456 789
NOTE
After the battery is connected, the correct state
of charge appears only after about 1 minute. PRG
PRG
The charge is shown in per cent and changes
in steps of 5 %.
4 1044_505-006

NOTE
The factory setting of the battery charge
indicator is for a lead battery. The indicator
can also be set to a gel battery. Please contact
your Service.
• If a residual charge of 20% is reached, the
battery must be charged soon.
• The driving speed is reduced.

50018043464 EN - 10/2017 49
4 Application
Start-up

CAUTION
Deep discharging damages the battery.
The battery must immediately be charged as deep
discharging begins.

Display of time to next servicing

– Press the PRG ↑ (scrolling) button (4) to
display the time remaining until the next
scheduled servicing. The time is shown in
123 456 789
hours (6) and with the symbol of a spanner
(5). Have the maintenance carried out
according to service hours specified in the
PRG
maintenance schedule.
PRG
NOTE
The display of the time to the next servicing
4 1044_505-006

can be set by your Service. Please contact

your Service in this regard.
5 6
– The display can show subsequent informa-
tion ⇒ Chapter "Error code", P. 4-79.

1044_505-018

50 50018043464 EN - 10/2017
Application 4
Start-up

Operating the horn

2
– Press the horn button (2) on the cockpit.

123 456 789

PRG
PRG

1047_003-008

Check of brake and presence area

– Start the truck slowly with the throttle (1). 0148_003-012

123 456 789

PRG
PRG

1 1

50018043464 EN - 10/2017 51
4 Application
Start-up

– Step off the presence area (2) while leaving

the throttle actuated.

2 0148_003-013

Checking the emergency brake 6 7

button
– Drive the truck slowly using the traction
control (4).
– Press the emergency brake button (5). The
truck will be braked and remains stationary.
123 456 789

PRG

– The StoP signal appears on the display

PRG

(6).

NOTE
Press the button I "ON" "7" to resume work.
After StoP disappears from the display, the 4
truck is operational again. 5 1047_003-009

CAUTION
Only use this brake system in the event of an
emergency!

52 50018043464 EN - 10/2017
Application 4
Driving

Driving
Driving safety rules
Behaviour when driving
The driver must drive the truck within the
plant according to regulations for driving on
public roads. The speed of the truck must be
appropriate for local conditions. For example,
speed must be reduced when cornering, in
narrow passages, when driving through swing
doors, in areas with reduced visibility and/or on
uneven ground. A safe distance must always
be maintained from people and any vehicles in
front. Sudden braking, fast turns, overtaking
in hazardous areas or areas with poor visibility
must be avoided.
Do not sit on the truck when driving.
EXU-S 22/24 trucks are designed for opera-
tion in ride-on mode, therefore:
• Do not operate the truck when sitting.
• Never use the truck as a climbing aid.
• Never use the truck to transport persons.
• Do not lean out. Always stay within the truck
profile.
The use of a mobile phone or radiophone
when operating the vehicle is permitted.
However, do not use these devices while
driving, as this will reduce your concentration.
First practice driving in a clear area or on a free
roadway.

Visibility when driving

The driver must look in the direction of travel
and have a clear view of the route travelled
on. He must always ensure that the way
is clear, particularly when reversing. When
transporting goods that obstruct visibility, the
truck must be driven with the load trailing.
If this is not possible, a guide must walk
ahead of the truck. In this case, the truck may
only be driven at walking pace and with the
utmost caution. The truck must be stopped
immediately when eye contact with the guide
is lost.

50018043464 EN - 10/2017 53
4 Application
Driving

Before driving
Persons in the danger area
Before and during operation of the truck, the
driver must ensure that no person is standing
in the danger area of the truck. A warning
signal must be given in the event of danger to
persons. If these persons refuse to leave the
danger area despite the warning, the driver
must stop working with the truck immediately.

WARNING
Risk of injury!! Within of the danger
zone there is a risk of being injured.
Do not step on the forks.

DANGER
Risk of death through falling loads!
It is expressly forbidden to stand under
the raised forks or to walk by beneath
them, even if there is no load on the
forks.

Danger zone
The danger zone is the area in which persons
are endangered through the movement of the
truck, its implements, load-lifting devices (eg
attachments) or the carried load. This also
includes the area within the range of falling
loads or a descending implement.

54 50018043464 EN - 10/2017
Application 4
Driving

Dimensions of roads and working

aisles

100
The dimensions specified in the description
section apply under established conditions X

and should ensure safe manoeuvring. Check

in each case whether a wider aisle is required

Ast 3
when, for example, the load dimensions
deviate.
The required aisle widths (Ast) depend on
the dimensions of the load and are calculated
according to the following formula: Ast = Wa -
X + length of pallet + 200 mm.

Wa
Observe your local and national regulations.
Please see ⇒ Chapter "VDI data sheet for

100
0148_003-014

standard EXU-S 22", P. 6-101.

The truck may only be used on roadways
without any tight curves, excessive slopes or
passages that are too narrow or too low.
The following inclines or slopes may be driven
on with the truck:
The slopes must not exceed the above
gradients and should have a rough surface.
Smooth passages at the top and lower end
should prevent the load from touching the
ground or damage to the truck.

Condition of roadways
Roadways must be solid enough, free of
debris and fallen objects. Drainage ducts,
tracks and the like must be level and, if
necessary, provided with ramps so that they
can be crossed without jolts, if possible.
0148_003-015

There must be sufficient clearance between

the highest parts of the truck or the load and
the surrounding fixtures. The height depends
on the lift height and the load dimension.
Check the datasheet for the truck.

Rules for roadways and working area

Only roadways made available by the operator
or his representative may be driven on. The
roadways must be free of obstacles. The
load may only be stacked and stored in the
appropriate places. The operator and his

50018043464 EN - 10/2017 55
4 Application
Driving

representative must ensure that unauthorized

persons keep away from the working area.

Hazard areas
Hazardous areas on roadways must be
marked with the usual traffic signs or, if
necessary, by additional warning signs.

Emergency stop procedure

In an emergency, all truck functions can be cut
off.
– To do so, depress the emergency isolator
button (1). The truck comes to a stop.
CAUTION 1
This safety feature may only be used in an emer-
gency.

NOTE
After pulling up the emergency isolator button
re-enter the driver's code to resume work.

0148_003-016

56 50018043464 EN - 10/2017
Application 4
Driving

Driving in rider mode

– Step on the platform with both feet and step
on the presence area (1).

NOTE
The pallet truck is turned on.
WARNING
There should be no objects lying on the floor of the
driver’s platform, whose weight could activate the
dead man’s switch under the mat.

1 0148_003-004

Driving forward
– Depress the top part of the throttle (2) or (3)
with the thumb.
– Truck speed is increased by depressing the
travel control further.
– When the travel control is released, the
truck is braked electrically. 123 456 789

PRG
PRG

Reversing
– Depress the lower part of the throttle (2) or
(3) with the thumb.
– Truck speed is increased by depressing the
travel control further.
3 2
– When the travel control is released, the
truck is braked electrically. 1044_501-003

Reversing direction
– Allow the travel control to return to its neutral
position.
– Operate the travel control progressively
in the opposite direction of travel until the
desired speed is reached.

50018043464 EN - 10/2017 57
4 Application
Driving

Selecting the driving mode 2 3

NOTE
The pallet truck has 2 selectable driving
modes.
– For normal travel, push the Hare button (3). 123 456 789

– To drive with gentle accelerations, push the

PRG
PRG

Tortoise button (2).

NOTE
The travel control (4) and (5) can be operated
with both the left and the right hand. Always
operate the travel control slowly to avoid jerky 5 4
starting, braking or reverslng. 1044_503-001

Steering
The truck is steered by turning the cockpit in
range (1).
The turning radius (Wa) depends on the fork
length and the battery. (See ⇒ Chapter "VDI
data sheet for standard EXU-S 22", P. 6-101)

0148_003-017

Brakes

WARNING
The surface finish influences the driving and bra-
king behaviour of the truck.
Therefore take this into account when driving and
braking (eg: wet floor).

58 50018043464 EN - 10/2017
Application 4
Driving

Soft braking

NOTE
The truck is braked electrically.
– Release throttle (3) or (4) when driving.
1

123 456 789

PRG
PRG

4 3
2 0148_003-018

– Leave the presence area (5).

Average braking
– Operate the throttle (3) or (4) in the opposite
direction.

Emergency braking
CAUTION
This type of braking may only be used in an emer-
gency.

– Press the emergency brake button (2). The

pallet truck stops.
5
– SToP appears in the display. 0148_003-019

NOTE
Press the button I "ON" (1) to resume work.
After StoP disappears from the display, the
truck is operational again.
The truck is operational again.

Parking brake
– Release traction control (3) or (4).

50018043464 EN - 10/2017 59
4 Application
Lifting

The truck is braked by the electromagnetic

brake.

Automatic shutdown
NOTE
If you leave the truck with the control turned
on, it will be shut off automatically after approx.
15 minutes. The truck can only be operated
again after the driver code is entered. The
delay time is adjustable. Please contact your
Service Engineer in this regard.

Lifting
Operating the main lift
Elevating the forks
– Press the lift button (2). The forks are
raised. Their movement can be stopped 2
at any time by releasing the button.

123 456 789

PRG
PRG

1 0249_003-013

60 50018043464 EN - 10/2017
Application 4
Lifting

Lowering the forks

– Press the lower button (1). The forks are
lowered. Their movement can be stopped
at any time by releasing the button.

0148_003-020

50018043464 EN - 10/2017 61
4 Application
Load placement

Load placement
Safety regulations when handing loads

DANGER DANGER
Wear protective footwear. Risk of injury and crushing for the operator and for
any pedestrians! Risk of damage to the truck and
the goods
CAUTION During movement of the truck and the loads, espe-
cially in reverse gear, be careful not to hit any obst-
Transporting passengers is strictly prohibited. acles. You must maintain an adequate safety di-
stance from obstacles (e.g. other pallets, protru-
ding objects, shelving, pedestrians, other trucks in
DANGER transit etc.).

Before picking up the load, make sure that its di-

mensions and weight fall within the truck specifi- DANGER
cations, as indicated in the "TECHNICAL DATA"
chapter. Risk of injury and crushing for the operator!
The operator must always remain inside the enve-
lope of the truck.
DANGER
The loads must be arranged so that they cannot
slip or overturn and fall to the ground. In order to NOTE
guarantee load stability, make sure that the load is
balanced and centred on the forks. Further information on the general rules of
truck use and picking up and depositing loads
is provided in the "Safety Regulations for
CAUTION Industrial Forklift Use" manual attached to
Make sure that nobody stands in the truck's area of this manual.
operation.

62 50018043464 EN - 10/2017
Application 4
Load placement

Before picking up a load

Load capacity
Do not exceed the load capacity of the truck.
See ⇒ Chapter "VDI data sheet for standard
EXU-S 22", P. 6-101.
WARNING
Never exceed the stated maximum load capacities!
Otherwise truck stability will not be ensured.
The load capacity plate must be observed. Do
not mount additional weights to increase the load
capacity. Do not exceed the stated maximum load
capacities! Otherwise truck stability will not be
ensured.

WARNING
When small parts are transported, a protective
guard must be attached to prevent goods from
falling onto the driver.

50018043464 EN - 10/2017 63
4 Application
Load placement

Taking up load
– Approach the load with caution and with as inserted far enough in that the load is resting
much precision as possible. against the fork carriage. The load centre of
gravity must be centred between the forks.
– Lower the fork arms so that they can easily
be inserted into the pallet. DANGER
– Slowly insert the forks at the centre of the Pay attention to the part of the forks protruding from
load to be lifted. the load to be lifted.
Do not strike the wall, the shelving or other loads
CAUTION and/or objects behind the load to be picked up.
Insert the fork without bumping into either the
shelving or the load. – Lift the load a few centimetres from the
ground and read the "Transporting loads"
– Insert the forks as far as possible below section.
the load. If possible, the forks should be

Transporting a load
As a general rule, loads must be transported
one by one (e.g. pallets). Transporting several
loads at once is only authorised:
• If the safety requirements are met.
• On the orders of the supervisor in charge.
The operator must ensure that the load is
properly packaged. The operator can only
move loads that have been properly packaged
and are safe and secure.
WARNING
The load must be at a height that does not obstruct
the driver's view of the front, otherwise drive with
the load trailing. If this is not possible, work with a 0148_003-022

guide walking beside the truck. In this case, drive

the truck only at walking speed and with the utmost
caution. Stop the truck immediately if you lose
contact with the guide.

DANGER
Lower or raise the load until there is sufficient
ground clearance.
Do not allow the load, the pallets or the container to
trail along the floor.

64 50018043464 EN - 10/2017
Application 4
Load placement

DANGER
When travelling and transporting the load, be aware
of the side clearance of the load, particularly when
cornering.
Avoid hitting shelving and objects in your path.

DANGER
Danger of load tipping over
Avoid sudden starts and stops.
Approach corners slowly and carefully.

Depositing a load on the ground

• Approach the load deposit area. DANGER
• Lower the fork arms until the load is de- Risk of injury and crushing for the operator! Risk of
posited in the required area, then free the damage to the truck and the goods
forks from any contact with the pallet or con- During the entire load placement operation, be
tainer. careful not to hit any obstacles. You must maintain
an adequate safety distance from obstacles (e.g.
• Look behind you before backing the truck other pallets, protruding objects, shelving etc.).
away
• Check that the truck's path is free of any
objects, people and obstacles of any type DANGER
• Look behind you and back away very slowly Never leave the forklift with the forks raised whether
to fully extract the forks from the load. loaded or not.

NOTE
Further information on the general rules of
forklift use is provided in the Rules for the Use
of Industrial Vehicles Manual enclosed with
this manual.

50018043464 EN - 10/2017 65
4 Application
Load placement

Driving up and down on an incline

When driving up and down on an incline, the
load must always be carried uphill.
It is only permitted to drive on inclines which
are identified as suitable for traffic and which
can be safely negotiated according to the
technical data of the truck. The driver must
satisfy himself that the ground is clean and
provides enough grip. It is not allowed to turn
on, park on or travel across inclines. Speed
must be reduced when driving down on an
incline.

0148_003-021

Entering lifts
With this truck, the driver may only enter lifts
having a sufficient load capacity and for which
the operator of the lift has given permission to
enter.
In the lift, the truck must be secured so that no
parts touch the shaft walls.
The clearance to the shaft wall must at least
100 mm.
The maximum weight of the truck (dead weight
without driver, the max. load.

EXU-22 3320 kg

EXU-24 3520 kg

Persons travelling with the lift at the same time

may enter the lift only after the truck is standing
securely and they must leave the lift first.
0148_003-023

66 50018043464 EN - 10/2017
Application 4
Load placement

Driving on loading bridges

Before crossing a loading bridge, the operator
must make sure it is properly attached and
secured and its load capacity is sufficient.
Cross the loading bridge slowly and carefully.
The driver must be sure that the vehicle to
be entered is secured sufficiently against
movement and that it can support the load of
the forklift truck.
The lorry driver and lift truck operator must
coordinate the departure time of the lorry.

0148_003-024

50018043464 EN - 10/2017 67
4 Application
Load placement

Using the truck on inclines, loading bridges and lifts.

Driving on inclines Using the truck on a lift
When driving the truck up or down inclines, Using the truck on lifts is only allowed if the
you must not exceed the values for inclines lift has sufficient load capacity (check the
indicated in the chapter "Technical data". maximum weight of the truck including the
traction battery) and only with appropriate
The operator must check that the ground is
authorisation.
clear with a good grip.
Slowly drive the truck onto the lift load-first.
WARNING
Secure the truck in the lift so that no part
When driving up or down inclines, the speed of
travel must be reduced. comes into contact with the walls of the lift.
A minimum distance of 100 mm from the walls
of the lift must always be observed.
DANGER
WARNING
Risk of tipping!
The truck must be correctly immobilised so that it
When driving up or down inclines, do not turn, cannot move inadvertently.
reverse and/or travel diagonally.

CAUTION
WARNING
Personnel accompanying the truck onto the lift may
When driving on an incline with a load, you must only enter the lift once the truck is secure and must
keep the load facing upwards. exit the lift first after transit.

DANGER
Risk of accident Using the truck on loading bridges
Keep the truck at a safe distance from the edges of DANGER
ramps, tailboards etc.
Risk of accident
Before driving on to a loading bridge, the operator
CAUTION must check that it has been properly fitted and
secured and has sufficient load capacity.
In certain cases, it is permitted to drive with the
forks pointing towards the top of the incline even if You must drive onto the loading bridge slowly and
the truck is not loaded. carefully.
In these cases, drive with the utmost care and avoid The operator must check that the vehicle to be
turning until all the wheels are on a flat surface. loaded or unloaded is sufficiently secure so that it
will not move and that it is suitable to support the
strain of the truck.
DANGER The lorry driver and the forklift truck operator must
agree on the time of departure of the lorry.
Risk of accident
Do not park on an incline: if, in the event of an
emergency, you have to do so, apply the parking
brake and block the wheels with chocks.

Towing trailers
The forklift is not qualified to tow trailers.

68 50018043464 EN - 10/2017
Application 4
Cold store usage (optional)

Cold store usage (optional)

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.

Proper usage
Operating range 1: permanent use in areas
with temperatures of –5 °C and for short
periods of time down to –10 °C. Parking
outside the cold store.
1044_920-001

Operating range 2: alternating use indoors

and outdoors in compliance with the rules
below, temperature range from –32 °C to +40
°C. Parking outside the cold store. This use
requires hydraulic oil for cold stores as given
on the list of maintenance characteristics.

Use

General
The change in temperature between the
cold indoors and the heat outside causes
condensation. This water can freeze when
the truck goes back into the cold store and jam
the moving parts of the truck. This is why the
length of time the truck remains in the different
temperature areas given below for the two
operating ranges must be strictly adhered to.
The temperature of the traction batteries must
never fall to the temperature of the cold store,
otherwise they will stop working.

Prior to start-up
CAUTION
The truck must be dry and at operating temperature
before being used in the cold store.

50018043464 EN - 10/2017 69
4 Application
Cold store usage (optional)

– 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.

Use

Operating range 1
Permanent use in areas with temperatures
of–5 °C and for short periods of time down to
–10 °C.

Operating range 2
Alternating use indoors with temperatures
down to –32 °C and outside with temperatures
up to +25 °C for short periods of time even
up to +40 °C. The truck must not leave the
cold area for more than 10 minutes, because
this length of time is not long enough for the
formation of condensation. If the truck stays
outside for longer than 10 minutes, it must
remain outside for long enough to allow the
condensation to run away. This generally
takes at least 30 minutes.
DANGER
If the condensation freezes in the cold store, the
moving parts that have become jammed must not
be freed by hand.

Parking
– Always park the truck outside the cold store.
CAUTION
The batteries must not remain discharged or un-
used in the cold store overnight.

– Charge the battery outside the cold store

and use a spare battery.

70 50018043464 EN - 10/2017
Application 4
Digicode

Digicode
Digicode control
Access to the electronic control is granted with
three different codes:
• Driver's code
• master code
123 456 789

• service code
PRG
PRG

Driver's code
The driver's code consists of four digits and
must be created by the Pool Manager.
It is used for the regular utilisation and opera-
tion of the truck by the driver and operator.
The knowledge of the code should be re- 1047_003-007

garded as a key and must not be misused.

The driver's code must not be given to other
persons without express order.
The control can store a maximum of 200
driver's codes. A driver's code can be added
⇒ Chapter "Adding a driver's code", P. 4-75
or deleted ⇒ Chapter "Deleting a driver's
code", P. 4-77 with the master code.

Master code
The master code consists of four digits and is
reserved for the Pool Manager.
The factory setting of this code is "1234". The
pool manager is advised to replace this code
with a new master code ⇒ Chapter "Deleting
a master code", P. 4-73 or ⇒ Chapter "Adding
the master code", P. 4-72.
Like the driver's code, it is used for the regular
operation and use of the truck, but it also
allows the addition or deletion of a driver's
code. This control can store a maximum of
five master codes.

NOTE
If master codes or driver's codes are forgotten
or get lost, please contact the Service Engin-
eer, for he alone can make the stored codes
visible.

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4 Application
Digicode

Service code
The service code is only intended for the
after-sales service. It allows the diagnosis
of the truck for inspections and the access to
the driver's and master code.

Adding the master code

NOTE
The truck is turned off, the battery is connec-
ted.
– Press the I (ON) button (5).
1 2 3
– Enter a valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).

123 456 789

PRG
PRG
4
6 5 1044_505-009

– Scroll with the PRG ↑ (scrolling) button (6) 1044_505-010

until Pin (7) appears in the display. 7

– Confirm with the PRG ↲ (enter) button (4) 1044_505-011

until Add (10) appears in the display. 10

72 50018043464 EN - 10/2017
Application 4
Digicode

– Confirm with the PRG ↲ (enter) button (4). 1044_505-012

A flashing line cursor (8) will appear in the 8

display.
– Enter the desired new 4-digit master code
with the buttons (1), (2) or (3) as described
above.

NOTE
The controller can store a maximum of five
master codes. If one attempts to add a sixth
master code, Err will appear in the display.
– Confirm with the PRG ↲ (enter) button (4) 1044_505-013

until the new master code (9) blinks (an 9

example is shown).

– Then release the button. Add (10) will 1044_505-011

appear again in the display. 10

– Press the PRG ↑ (scrolling) button (6) until 1044_505-014

a normal readout (11) (eg battery charge) 11

appears in the display. The new master
code is entered. %

Deleting a master code

NOTE
The truck is turned off, the battery is connec-
ted.

50018043464 EN - 10/2017 73
4 Application
Digicode

– Press the I (ON) button (5).

1 2 3
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).

123 456 789

PRG
PRG
4
6 5 1044_505-009

– Scroll with the PRG ↑ (scrolling) button (6) 1044_505-010

until Pin (7) appears in the display. 7

– Confirm with the PRG ↲ (enter) button (4) 1044_505-015

until dEL (10) appears in the display. 10

– Confirm with the PRG ↲ (enter) button (4). 1044_505-012

A flashing line cursor (8) will appear in the 8

display.
– Enter the 4-digit master code to be deleted
with the buttons (1), (2) or (3) as described
above.

NOTE
If one attempts to delete an erroneous master
code, Errwill appear in the display. If only
one master code remains, None will appear in
the display.

74 50018043464 EN - 10/2017
Application 4
Digicode

– Confirm with the PRG ↲ (enter) button (4) 1044_505-013

until the master code (9) to be deleted blinks 9

(an example is shown).

– Then release the button. dEL (10) will 1044_505-015

appear again in the display. 10

– Press the PRG ↑ (scrolling) button (6) until 1044_505-014

a normal readout (11) (eg battery charge) 11

appears in the display. The master code is
deleted. %

Adding a driver's code

NOTE
The truck is turned off, the battery is connec-
ted.
– Press the I (ON) button (5).
1 2 3
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).

123 456 789

PRG
PRG
4
6 5 1044_505-009

50018043464 EN - 10/2017 75
4 Application
Digicode

– Scroll with the PRG ↑ (scrolling) button (6) 1044_505-016

until USEr (7) appears in the display. 7

– Confirm with the PRG ↲ (enter) button (4) 1044_505-011

until Add (10) appears in the display. 10

– Confirm with the PRG ↲ (enter) button (4). 1044_505-012

A flashing line cursor (8) will appear in the 8

display.
– Enter the new 4-digit driver's code with the
buttons (1), (2) or (3) as described above.

NOTE

The controller can store a maximum of 200

driver's codes. If one attempts to add a 201st
driver's code, Err will appear in the display.
– Confirm with the PRG ↲ (enter) button (4) 1044_505-013

until the new driver's code (9) blinks (an 9

example is shown).

– Then release the button. Add (10) will 1044_505-011

appear again in the display. 10

– Press the PRG ↑ (scrolling) button (6) until 1044_505-014

a normal readout (11) (eg battery charge) 11

appears in the display. The new driver's
code is entered. %

76 50018043464 EN - 10/2017
Application 4
Digicode

Deleting a driver's code

NOTE
The truck is turned off, the battery is connec-
ted.
– Press the I (ON) button (5).
1 2 3
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).

123 456 789

PRG
PRG
4
6 5 1044_505-009

– Scroll with the PRG ↑ (scrolling) button (6) 1044_505-016

until USEr (7) appears in the display. 7

– Confirm with the PRG ↲ (enter) button (4) 1044_505-015

until dEL (10) appears in the display. 10

– Confirm with the PRG ↲ (enter) button (4). 1044_505-012

A flashing line cursor (8) will appear in the 8

display.
– Enter the 4-digit driver's code to be deleted
with the buttons (2), (3) or (3) as described
above.

NOTE
If one attempts to delete an erroneous driver's
code, Err will appear in the display.

50018043464 EN - 10/2017 77
4 Application
Digicode

– Confirm with the PRG ↲ (enter) button (4) 1044_505-013

until the driver's code (9) to be deleted blinks 9

(an example is shown).

– Then release the button. dEL (10) will 1044_505-015

appear again in the display. 10

– Press the PRG ↑ (scrolling) button (6) until 1044_505-014

a normal readout (11) (eg battery charge) 11

appears in the display. The driver's code is
deleted. %

78 50018043464 EN - 10/2017
Application 4
Error codes

Error codes
Error code 4 5 6 7 8 11 12
If an error code such as E380 (15) appears, 2 14
shut the truck off by pressing button (10) and
repeat the start-up ⇒ Chapter "Start-up", P. 46.
If the error code persists, call your Service. 3 13
123 456 789

PRG
PRG

10 9 1044_505-024

15

1044_505-019

Error code Description Action

E350 Travel control operated at power-up. Release the travel control (1).
E370 Left Lift button operated at power-up. Release the left Lift button (2).
E371 Left Lowering button operated at power-up. Release the left Lowering button (3).
E372 Left Horn button operated at power-up. Release the left Horn button (4).
E373 Tortoise button operated at power-up. Release the Tortoise button (5).
E374 Button 1-2-3 operated at power-up. Release the button 1-2-3 (6).
E375 Button 4-5-6 operated at power-up. Release the button 4-5-6 (7).
E376 Button 7-8-9 operated at power-up. Release the button 7-8-9 (8).
E377 PROG button operated at power-up. Release the button PROG (9).
E378 ON button operated at power-up. Release the ON button (10).
E379 Hare button operated at power-up. Release the Hare button (11).

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4 Application
Battery electrolyte level indicator LED (optional)

Error code Description Action

E380 Right Horn button operated at power-up. Release the right Horn button (12).
Release the right Lowering button
E381 Right Lowering button operated at power-up.
(13).
E382 Right Lift button operated at power-up. Release the right Lift button (14).
.

Battery electrolyte level 1

indicator LED (optional)
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the battery plug.
The LED indicates whether it is necessary to
2
top up the distilled water in the battery.
Operation:
• If the LED (1) or (2) is green, there is a
sufficient level of electrolyte in the battery.
The battery must not be topped up with
distilled water.
• If the LED (1) or (2) is red, there is an
insufficient level of electrolyte in the battery.
The battery must be topped up with distilled
water.

2256

Handling the truck in specific situations

Towing and moving
The truck cannot be towed if there is no
electical power as the electric brake is applied.
If the brake of the towed truck is no longer
functioning, the truck may only be towed with
a fixed connection (tow bar). For towing you
need a pulling vehicle with sufficient tractive
and braking force for the truck being towed.

80 50018043464 EN - 10/2017
Application 4
Handling the truck in specific situations

Towing without a battery

NOTE
In case of an electric failure or if no battery is
installed, the brake can be released manually.
CAUTION
This service must be carried out by your after-sales
service.

Hoisting the truck

CAUTION
Only use a lifting gear and crane with a sufficient
load capacity. See the vehicle identification plate
for the loading weight.

– For hoisting with a crane, always attach the

slings to the points identified with the hook 3
symbol.
CAUTION
It is strictly forbidden to attach the lifting slings to
the cockpit or to other points not intended for this
purpose.

CAUTION
– Insert pieces of wood to prevent damage.

DANGER
Danger to life!
Do not step or stand under a suspended load. 0148_003-026

Towing procedure
Towing the truck is only possible if there is still
a power supply, otherwise the electric brake is
still applied.

NOTE
The brake can be released. Please contact
your after-sales service.

50018043464 EN - 10/2017 81
4 Application
Handling the battery

Handling the battery

Battery type
The pallet stacker can be equipped with
different types of batteries. Observe the
information on the nattery type plate. Also
refer to ⇒ Chapter "Technical data", P. 99 for
this purpose.
WARNING
The weight and dimensions of the battery affect
truck stability.
Do not change the weight conditions when chan-
ging the battery. Do not remove nor change the
position of additional weights.

Damage to cables
CAUTION
Take care not to damage the battery leads when
removing and installing the battery.

Preparation
Maintenance personnel
The battery may only be changed by spe-
cially trained personnel, in accordance with
the manufacturer's instructions for the battery,
the battery charger and the truck. The main-
tenance instructions for the battery must be
observed.

Fire prevention measures

WARNING
Do not smoke or use a naked flame
when handling batteries. In the
area designated for parking the
truck to recharge the battery or
battery charger, there should be no
flammable materials or substances
that can cause sparks within a radius
of at least 2 metres. The charging
area must be well ventilated. Keep a
fire extinguisher at hand.

82 50018043464 EN - 10/2017
Application 4
Handling the battery

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

Opening/closing the battery com-

partment
Opening the battery compartment
– Turn the lock (1) 90° and lift the battery
cover (2). 1
Closing the battery compartment
2
WARNING
Danger of crushing.
When closing the battery door, there should be
nothing between battery door and edge of the
frame.

– Lower the battery compartment and turn the

lock 90°.

0148_003-028

Battery charging with external

battery charger

CAUTION
Deep discharges damage the battery.
– The battery must be charged at once.

– Park the truck safely, refer to ⇒ Chap-

ter "Safe parking of the truck", P. 4-87.
– Open the battery compartment.
– Before charging, inspect the battery leads
and charging cables for damage and
replace them, if required.

50018043464 EN - 10/2017 83
4 Application
Handling the battery

– Disconnect the battery connector (3).

3
WARNING
Switch the truck and charger off before disconnec-
ting the male and female connectors.

– Connect the battery connector to the

charger connector.

NOTE
Observe the information in the operating
instructions for your battery and battery
charger (equalising charge).
WARNING
Risk of damage, shorting and explosion. 0148_003-029

Do not place any metallic objects or tools on the

battery. No naked lights, no smoking permitted.

WARNING
The electrolyte (diluted sulphuric acid) is poisonous
and caustic!
Observe the safety precautions for handling battery
acid.

WARNING
Explosive gases are released during charging.
– Ensure that the room ventilation is adequate.

Changing the battery

There are two possibilities of replacing the
battery:
– Vertically with a lifting tackle (all trucks).
– from the side using a battery trolley (optional
- only for EXU 18 and 20 with side door).
In order to avoid short-circuits, it is recom-
mended that batteries with polar terminals or
unprotected connections be covered with a
rubber mat.

84 50018043464 EN - 10/2017
Application 4
Handling the battery

DANGER
Danger to life!
No-one should be under a raised load.

Changing the battery with crane

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

DANGER
Danger to life!
No-one should be under a raised load.

– Unlock the battery.

0148_003-030

– Attach the lifting device (3) correctly to

the battery (4) (see the lifting device user
manual), then remove it from the truck.
– The lifting device must exercise vertical 3
traction in order to avoid the boot being
damaged. The hooks must be placed so
that they cannot fall on the battery cells
when the lifting device is slackened.
– Installation and connection of the charged
battery is the reverse of removal. Make sure
lateral cover (2) is properly put in place. 4

0148_003-057

50018043464 EN - 10/2017 85
4 Application
Handling the battery

Changing the battery with lateral

removal trolley

CAUTION
When removing or installing the battery keep your
hands away from chassis and battery! There is an
increased risk of squeezing your hands!

– Open the battery cover (1).

– Remove the side cover (2).
1

0148_003-031

– Place a suitable trolley (4) next to the

battery.
3
– Position yourself to the side opposite to the
side cover and push the battery (3) onto the
removal trolley (4).
– To install the new battery position your-
self opposite to the side cover and pull the
battery towards you into the battery com-
partment.
– Put the side cover (2) in place.

4
0148_003-032

86 50018043464 EN - 10/2017
Application 4
Decommissioning

Decommissioning
Safe parking of the truck
– Park the truck in a dry, clean and well-
ventilated area.
WARNING
Do not park the truck on gradients. In exceptional
cases, secure the truck with chocks.

– Lower the forks (1) on the ground.

WARNING
1
– Before leaving the truck, lower the load fully.

0148_003-033

– Depress the emergency isolator button (2).

NOTE 2
If you leave the truck without disconnecting
the battery connector, the control is shut off
automatically after approx. 15 minutes.
The truck can only be operated again after
re-entering the driver code.

0148_003-034

50018043464 EN - 10/2017 87
4 Application
Storage

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

Measures before taking out of operation

– Clean the stacker thoroughly.
– Raise the forks several times as far as
possible.
– Check the hydraulic oil level, adding oil if
necessary.
– Lower the forks on to an appropriate sup-
port, for example a pallet, until the lift chains
are relaxed.
– Coat all blank, moving parts with a thin film
of oil or grease.
– Oil all moving parts and joints.
– Check the condition and electrolyte density
of the battery, service the battery accord-
ing to the instructions of the manufacturer.
(Follow the battery manufacturer’s instruc-
tions.)
– Spray all naked electric contacts with a
suitable contact spray.
CAUTION
– Block up the truck so that the wheels are clear
of the ground. This will prevent a permanent
deformation of the tyres.

– Cover the pallet stacker with a cotton

blanket and protect it against dust.
CAUTION
We do not recommend using a plastic foil as this
enhances the formation of condensate.

88 50018043464 EN - 10/2017
Application 4
Storage

If the truck is to be taken out of service for an

even longer period, contact your after-sales
service.

Taking back into service after

storage
If the pallet stacker has been out of service for
over six months, it must be inspected carefully
before it is taken back into service. The
inspection, similarly to the safety inspection,
should also include safety-related points on
the truck.
– Clean the stacker thoroughly.
– Oil all moving parts and joints.
– Check the condition and acid density of the
battery, charging it if required.
– Check the hydraulic oil for condensate and
renew the oil, if necessary.
– Perform the services as before initial
operation.
– Take the pallet stacker into operation.
– During the next commissioning, check in
particular:
• Traction drive, control, steering
• Brake (service brake, parking brake)
• Lifting device

50018043464 EN - 10/2017 89
4 Application
Storage

90 50018043464 EN - 10/2017
 5

Maintenance
5 Maintenance
General Information

General Information
To keep your forklift in good condition, carry NOTE
out the servicing indicated regularly, within the
times indicated and using the consumption Contact the authorised service network for
materials provided for that purpose, as speci- a maintenance contract appropriate to your
fied on the following pages. Please make sure forklift.
that you keep a record of work done; this is the
CAUTION
only way for the guarantee to remain valid.
Maintenance intervals are defined for standard
Maintenance is divided into: use. In the following cases, it is necessary to
• Regular Service (scheduled by the user) reduce the interval between the various scheduled
maintenance operations: in the event of use in
• Planned maintenance (to be performed dusty or salty environments, extremely high or low
by the service network authorised by the ambient temperatures, high levels of air humidity,
manufacturer) particularly intense and heavy-duty uses, and
specific national regulations for trucks or individual
DANGER components.

Planned maintenance and repairs must be perfor-

med by the service network authorised by the ma-
nufacturer in order to keep the machine in perfect
condition and compliant with technical specificati-
ons.

Operations Preliminary to Maintenance

Do the following before performing mainte- DANGER
nance operations: Before performing any intervention on the electric
• Place the truck on a flat surface and make system, disconnect the battery outlet from the
relative plug.
sure that it cannot move accidentally.
• Lower the forks fully.
• Switch off the vehicle.
• Press the emergency stop button.

92 50018043464 EN - 10/2017
Maintenance 5
Scheduled maintenance

Scheduled maintenance
Summary table of maintenance operations EXU-S

Operations Intervals in hours Completed

(a) (b) (c) v
1000 2000 5000
Checks and tests prior to commissioning
Check the oil level in the hydraulic system
and the transmission gear
Test the insulation between the chassis
and the electric motors
Test the insulation between the chassis
and the electronic control
Check the condition of the battery and
check that it is correctly mounted
Check the condition of the electrical
system (wiring harnesses and fuses) and
that it is correctly mounted
Check for wear on the lift motor brushes
and replace if necessary
Check the truck braking
Check and adjust the electromagnetic
brake
Check that the forks are in good condition

Check the condition of the piping

Check for oil leakages from cylinders and

hydraulic connectors
Tyre wear check
Check the correct mounting of the electri-
cal steering pinion gear
Check wheel tightness
Change the hydraulic oil and filter

Service the transmission gear

1000 (a) = To be repeated every 1000 hours

(for example at 1000, 2000, 3000, 4000, 5000
etc.) or at least every 12 months (whichever
comes first).
2000 (b) = To be repeated every 2000 hours.
For example at 2000, 4000, 6000, 8000,
10,000 etc.)

50018043464 EN - 10/2017 93
5 Maintenance
Scheduled maintenance

5000 (c) = To be repeated every 5000 hours.

For example at 5000, 10,000, 15,000, 20,000
etc.)

ENVIRONMENT NOTE
During maintenance operations, follow the
instructions provided in the section "Safety
regulations relative to operating materials" in
"Chapter 2".

94 50018043464 EN - 10/2017
Maintenance 5
Maintenance as required

Maintenance as required
Cleaning the Forklift
Cleaning depends on the type of use and the Use water-dampened rags to clean the parts
workplace. Should the truck come into contact of the body.
with highly aggressive elements such as salt
water, fertilizers, chemical products, cement, CAUTION
etc., it should be cleaned as carefully as Do not clean the truck with direct jets of water; DO
possible after every work cycle. It is preferable NOT use solvents and petrols that could damage
to use cold compressed air and detergents. parts of the truck.

Fuses

CAUTION
Before performing any work on the electrical in-
stallation, remove any power from the system by
disconnecting the battery connector.

– Open the battery cover (1).

1 2

0148_003-044

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5 Maintenance
Maintenance as required

– Disconnect the battery connector (3).

3
– Remove the bonnet(2) to gain access to the
fuse carrier.

0148_003-045

The following fuses are located on the fuse

1
carrier:

1 Main fuse 400 A

2 Fuse F3 7.5 A
3 Fuse F4 7.5 A
4 Fuse F5 20 A
5 Fuse F8 (Option) 3A
.

4 3 2 0249_003-046

96 50018043464 EN - 10/2017
Maintenance 5
Decommissioning

Decommissioning
General Information
The operations to be performed for "Tem-
porary decommissioning" and "Permanent
decommissioning" are listed in this chapter.

50018043464 EN - 10/2017 97
5 Maintenance
Decommissioning

Forklift Towing
The forklift may not be towed in the case of
breakdown.
The forklift must be lifted with due caution, as
described on the preceding pages.

Temporary Putting Out of Commission

The following operations must be performed • Perform the lubrication operations indicated
when the forklift is not going to be used for a in the maintenance chapter.
long time: • Remove the battery and put it in a room
• Clean the forklift as indicated in the "Mainte- where there is no danger of freezing.
nance" chapter and put it in a dust-free and Charge the battery at least once a month.
dry room. - • Raise the forklift so that the wheels do not
• Lower the forks. touch the ground; otherwise, the wheels will
become flat at the point of contact with the
• Lightly grease all of the unpainted parts with
floor.
oil or grease.
• Cover the forklift with a NON-plastic sheet.

Checks and Inspections After a Long Period of Inactivity

DANGER • Carry out the fluid level checks.

Perform the following operations before using the • Perform all of the functional maneuvers of
forklift: the forklift and of its safety devices both
loaded and unloaded.
• Clean forklift truck thoroughly.
DANGER
• Check the battery charge level and re-
Follow the instructions provided in the maintenance
assemble it in the forklift, making sure to
chapter for the operations indicated previously.
spread Vaseline on the terminals.
• Lubricate all of the parts provided with
lubricating nipples and the chains.

Permanent Putting Out of Commission (Demolition)

The forklift must be demolished in compliance components and rubber components must
with local legislation. Contact the authorised be disposed of in compliance with specific
service network or authorised companies to local legislation for each type of material.
scrap the forklift according to local legislation.
DANGER
ENVIRONMENT NOTE Disassembly of the forklift for scrapping is extre-
mely hazardous.
In particular, batteries, fluids (oils, fuels,
lubricants, etc, electrical and electronic

98 50018043464 EN - 10/2017
 6

Technical data
6 Technical data
Dimensions

Dimensions

100 50018043464 EN - 10/2017

Technical data 6
VDI data sheet for standard EXU-S 22

VDI data sheet for standard

EXU-S 22
Characteristics

EXU-S 22 EXU-S 22
Rear access Side access
Type of platform

Electric
Drive: electric, diesel,
petrol, LPG.

Driving mode: manual, Standing

pedestrian, ride-on
standing, ride-on seated,
order picking
Rated/load capacity Q (kg) 2200
Nominal load centre of (1)
c (mm) 600
gravity
x (mm) (2)
Load distance 1023
y (mm) (2)
Centre-to-centre distance 1617
.

Weights
EXU-S 22 EXU-S 22
Tare weight including battery kg 1120
Pressure on the axles, with
drive side/load side kg 1820/1500
load
Loads on the axles, without
drive side/load side kg 210/910
load
.

Wheels and tyres

EXU-S 22 EXU-S 22
Tyres Polyurethane

Wheel size drive side mm ∅250 x 100

Wheel size load side mm ∅85 x 80
Pivoting wheels drive side mm ∅140 x 54

50018043464 EN - 10/2017 101

6 Technical data
VDI data sheet for standard EXU-S 22

EXU-S 22 EXU-S 22
4/1x + 2
Number of wheels (x =
drive side/load side
drive)

Track drive side b10 (mm) 348/388/498

Track load side b11 (mm) 470
.

Dimensions
EXU-S 22 EXU-S 22
Lift h3 (mm) 130
Step plate height h7 (mm) 225
Height of cockpit in
min/max h14 (mm) 1030
operating position
Height of forks when
h13 (mm) 85
lowered

Overall length unladen l1 [mm] 2415 (3) 2487 (3)

Length of the drive unit l2 [mm] 1225 (3) 1297 (3)

Overall width b1 (mm) 720

Dimensions of forks s/e/l (mm) 55 (78 max)/172/1190
Fork arm external spread b5 (mm) 520/560/670

Ground clearance, loaded,

m2 (mm) 30
under mast

Ast (mm) 2821 (5) 2890 (5)

Aisle width for pallet 800 x
1200 lengthwise (b12 x l6)

Ast (mm) 2791 (5) (6) 2861 (5) (6)

Aisle width for pallet 1000 x
1200 lengthwise (b12 x l6)

Bending radius Wa (mm) 2125 (5) 2195 (5)

.

102 50018043464 EN - 10/2017

Technical data 6
VDI data sheet for standard EXU-S 22

Performance data
EXU-S 22 EXU-S 22
Driving speed with/without load km/h 10/12
Lifting speed with/without load m/s 0.043/0.062
Lowering speed with/without load m/s 0.068/0.065
Surmountable gradient with/without load % 10%/15%
Acceleration time (over 10
laden/unladen s 6.2/4.6
metres)
Service brake electromagnetic
.

Electric motors
EXU-S 22 EXU-S 22
Travel motor, rating S2 = kW
3.0
60min
Lifting motor, rating S3 = 2.2
kW
15%

Battery in accordance with

DIN 43 531/35/36 A, B, C, no
no

Battery voltage/nominal
V/Ah 24/465
capacity K5
Battery weight (+/- 5%) kg 405
Energy consumption
kWh/h 1.05
according to VDI cycle
.

Other
EXU-S 22 EXU-S 22
Speed control AC-controller
Average noise level
measured at the driver's dB (A) < 65
ear
(1) For forks with l = 1190 mm
(2) With forks lowered. For the value with forks
raised, deduct 113 mm
(3) With compartment 71: +85 mm
(4) Dimensions relating to fork length marked
with an asterisk

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6 Technical data
VDI data sheet for standard EXU-S 22

(5) With forks raised

(6) Values calculated with Wa and fork length l
= 990 mm
Edition dated 22/10/2015

104 50018043464 EN - 10/2017

Technical data 6
VDI data sheet for standard EXU-S 24

VDI data sheet for standard

EXU-S 24
Characteristics

EXU-S 24 EXU-S 24
Type of platform Rear access Side access
Drive: electric, diesel, Electric
petrol, LPG
Driving mode: manual, Standing
pedestrian, ride-on
standing, ride-on seated,
order picking
Rated/load capacity Q (kg) 2400
Nominal load centre of (1)
c (mm) 600
gravity
x (mm) (2)
Load distance 1005
y (mm) (2)
Centre-to-centre distance 1599
.

Weights

EXU-S 24 EXU-S 24
Tare weight including battery kg 1150

Pressure on the axles, with

drive side/load side kg 2233/1317
load

Loads on the axles, without

drive side/load side kg 232/918
load
.

Wheels and tyres

EXU-S 24 EXU-S 24
Tyres Polyurethane

Wheel size drive side mm ∅250 x 100

Wheel size load side mm ∅85 x 80
Pivoting wheels drive side mm ∅140 x 54
4/1x + 2
Number of wheels (x =
drive side/load side
drive)

50018043464 EN - 10/2017 105

6 Technical data
VDI data sheet for standard EXU-S 24

EXU-S 24 EXU-S 24
Track drive side b10 (mm) 348/388/498
Track load side b11 (mm) 470
.

Dimensions
EXU-S 24 EXU-S 24

Lift h3 (mm) 130

Height of cockpit in
min/max h14 (mm) 1030
operating position
Step plate height min/max h7 (mm) 225
Height of forks when
h13 (mm) 85
lowered
(3)
Overall length unladen l1 [mm] 2415 2487 (3)
Length of the drive unit l2 [mm] 1225 (3) 1297 (3)

Overall width b1 (mm) 720

Dimensions of forks s/e/l (mm) 61 (78 max)/172 (4)/1190
Fork arm external spread b5 (mm) 520/560/670
Ground clearance, loaded, (4)
m2 (mm) 24
under mast
Ast (mm) 2814 (5) 2883 (5)
Aisle width for pallet 800 x
1200 lengthwise (b12 x l6)

Ast (mm) 2781 (5) (6) 2851 (5) (6)

Aisle width for pallet 1000 x
1200 lengthwise (b12 x l6)

Bending radius Wa (mm) 2107 (5) 2177 (5)

.

Performance data
EXU-S 24 EXU-S 24
Driving speed with/without load km/h 9/12
Lifting speed with/without load m/s 0.043/0.062

Lowering speed with/without load m/s 0.068/0.065

Surmountable gradient with/without load % 9.3%/15%

106 50018043464 EN - 10/2017

Technical data 6
VDI data sheet for standard EXU-S 24

EXU-S 24 EXU-S 24
Acceleration time (over 10
laden/unladen s 6.3/4.8
metres)
Service brake electromagnetic
.

Electric motors

EXU-S 24 EXU-S 24
Travel motor, rating S2 = kW
3.0
60min
Lifting motor, rating S3 = 2.2
kW
15%
Battery in accordance with
DIN 43 531/35/36 A, B, C, no
no
Battery voltage/nominal
V/Ah 24/465
capacity K5
Battery weight (+/- 5%) kg (+/- 5%) 405
Energy consumption
kWh/h 1.07
according to VDI cycle
.

Other
EXU-S 24 EXU-S 24
Speed control AC-controller
Average noise level
measured at the driver's dB (A) < 65
ear
(1) For forks with l = 1190 mm
(2) With forks lowered. For the value with forks
raised, deduct 113 mm
(3) With compartment 71: +85 mm
(4) Dimensions relating to fork length marked
with an asterisk
(5) With forks raised
(6) Values calculated with Wa and fork length l
= 990 mm
Edition dated 22/10/2015

50018043464 EN - 10/2017 107

6 Technical data
Turning radius and load distance EXU-S

Turning radius and load

distance EXU-S
EXU-S 22
Turning radius (Wa) and load distance (x) with forks lowered (a)
Battery compartment Battery compartment
70 (3PzS) 71 (4PzS)
345 - 465 Ah 560 - 620 Ah

Forks Load Rear Side Rear Side

length distance access access access access

l x Wa Wa Wa Wa
mm mm mm mm mm mm
990 823 2038 2108 2123 2193
1190 1023 2238 2308 2323 2393
1600 1433 2648 2718 2733 2803
2390 c
not available
2390 d
.

EXU-S 24
Turning radius (Wa) and load distance (x) with forks lowered (a)
Battery compartment Battery compartment
70 (3PzS) 71 (4PzS)
345 - 465 Ah 560 - 620 Ah

Fork Load Rear Side Rear Side

length distance access access access access
l x Wa Wa Wa Wa
mm mm mm mm mm mm
990 805 2020 2090 2105 2175
1190 1005 2220 2290 2305 2375
1450 b 1135 2350 2420 - -
1600 1415 2630 2700 2715 2785
2390 c 2205 3420 3490 3505 3575
2390 d 1847 3062 3132 3147 3217
.

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Technical data 6
Wheels and tyres

Legend:
a = for value with forks raised deduct 113 mm
b = available only when b5 = 560 mm
c = useful for transporting three Euro pallets
on the short side
d = useful for transporting two Euro pallets on
the long side

Wheels and tyres

Approved types of wheels
Only the wheel types listed in the parts cata-
logue may be used.

50018043464 EN - 10/2017 109

6 Technical data
Supply table EXU-S EXU-SF

Supply table EXU-S EXU-SF

Standard version Quantity

Traction transmission
FUCHS Renolin PG 220 1.1 litres
gear oil
Lifting hydraulics oil Olio idraulico HLF 32 2.5 litres
Oil for pivot wheels
(only if the "STILL
AP31 hydraulic oil -
DRIVEspeed" version
is present)
Generic lubricant Tutela MP 02 -

Cold storage version Quantity

Traction transmission
FUCHS Renolin PG 220 1.1 litres
gear oil
Lifting hydraulics oil EQUIVIS XV32 2.5 litres
Oil for pivot wheels
(only if the "STILL
AP31 hydraulic oil -
DRIVEspeed" version
is present)
Generic lubricant Tutela EP2 -
.

110 50018043464 EN - 10/2017

Index
g

A Deleting a master code . . . . . . . . . . . . . . 73

Digicode control . . . . . . . . . . . . . . . . . . . 71
Accessories . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . 100
Adding a driver's code . . . . . . . . . . . . . . 75
Dimensions of roads and working aisles . 55
Adding the master code . . . . . . . . . . . . . 72
Disposal
Address of manufacturer . . . . . . . . . . . . . I
Battery . . . . . . . . . . . . . . . . . . . . . . . . 9
Automatic shutdown . . . . . . . . . . . . . . . . 60
Components . . . . . . . . . . . . . . . . . . . . 9
Average braking . . . . . . . . . . . . . . . . . . . 59
Driver's code . . . . . . . . . . . . . . . . . . . . . 71
B Driving
Battery Safety instructions . . . . . . . . . . . . . . . 38
Disposal . . . . . . . . . . . . . . . . . . . .... 9 Driving on loading bridges . . . . . . . . . . . 67
Battery charge . . . . . . . . . . . . . . . . . . . . 49 Driving safety rules . . . . . . . . . . . . . . . . . 53
Battery charging with external battery Driving up and down on an incline . . . . . . 66
charger . . . . . . . . . . . . . . . . . . . . 83
E
Battery compartment
Opening/closing . . . . . . . . . . . . . . . . 83 EC declaration of conformity in
Battery type . . . . . . . . . . . . . . . . . . . . . . 82 accordance with Machinery
Directive . . . . . . . . . . . . . . . . . . . . 6
Before operation . . . . . . . . . . . . . . . . . . 42
Emergency braking . . . . . . . . . . . . . . . . 59
Before picking up a load . . . . . . . . . . . . . 63
Emergency stop procedure . . . . . . . . . . 56
C Entering lifts . . . . . . . . . . . . . . . . . . . . . . 66
Entering the user code . . . . . . . . . . . . . . 47
CE labelling . . . . . . . . . . . . . . . . . . . . . . . 5
Error code . . . . . . . . . . . . . . . . . . . . . . . 79
Changing the battery . . . . . . . . . . . . . . . 84
Changing the battery with crane . . . . . . . 85 F
Changing the battery with lateral
Fork length . . . . . . . . . . . . . . . . . . . . . 108
removal trolley . . . . . . . . . . . . . . . 86
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Check of brake and presence area . . . . . 51
Checking the emergency brake button . . 52 H
Chocking the truck . . . . . . . . . . . . . . . . . 41
Hazard areas . . . . . . . . . . . . . . . . . . . . . 56
Closing the battery compartment . . . . . . 83
Hour meter . . . . . . . . . . . . . . . . . . . . . . 49
Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . 29
Contact details . . . . . . . . . . . . . . . . . . . . . I I
Copyright and trademark rights . . . . . . . . . 4
Intended use of the trucks . . . . . . . . . . . . 38
D
L
Danger area . . . . . . . . . . . . . . . . . . . . . 39
Lashing down the truck . . . . . . . . . . . . . . 41
Danger zone . . . . . . . . . . . . . . . . . . . . . 54
Location of designation plates and
Date of edition of this manual . . . . . . . . . . 4
labels . . . . . . . . . . . . . . . . . . . . . . 31
Dead man's zone . . . . . . . . . . . . . . . . . . 30
Declaration of conformity . . . . . . . . . . . . . 6 M
Definition of directions . . . . . . . . . . . . . . 27
Master code . . . . . . . . . . . . . . . . . . . . . . 71
Deleting a driver's code . . . . . . . . . . . . . 77

50018043464 EN - 10/2017 111

 Index
g

Models . . . . . . . . . . . . . . . . . . . . . . . . . 34 Service code . . . . . . . . . . . . . . . . . . . . . 72

Soft braking . . . . . . . . . . . . . . . . . . . . . . 59
O Stability . . . . . . . . . . . . . . . . . . . . . . . . . 16
Opening the battery compartment . . . . . . 83 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 58
Operating the horn . . . . . . . . . . . . . . . . . 51
Operating the main lift . . . . . . . . . . . . . . 60 T
Options . . . . . . . . . . . . . . . . . . . . . . . . . 34 Technical description . . . . . . . . . . . . . . . 22
Overviews . . . . . . . . . . . . . . . . . . . . . . . 26 Towing procedure . . . . . . . . . . . . . . . . . 81
Transport . . . . . . . . . . . . . . . . . . . . . . . . 40
P Transporting a load . . . . . . . . . . . . . . . . 64
Packaging . . . . . . . . . . . . . . . . . . . . . . . 10 Turning on the truck . . . . . . . . . . . . . . . . 46
Parking brake . . . . . . . . . . . . . . . . . . . . 59 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Pre-operation checks . . . . . . . . . . . . . . . 42
Preparation . . . . . . . . . . . . . . . . . . . . . . 82
U
Update of this manual . . . . . . . . . . . . . . . . 4
R
Residual dangers . . . . . . . . . . . . . . . . . . 15 V
Residual risks . . . . . . . . . . . . . . . . . . . . 15 View of the control elements . . . . . . . . . . 28
Visibility when driving . . . . . . . . . . . . . . . 53
S Visual checks . . . . . . . . . . . . . . . . . . . . . 42
Safe parking of the truck . . . . . . . . . . . . . 87
Safety Inspection . . . . . . . . . . . . . . . . . . 19
W
Safety regulations when handing loads . . 62 Wheels . . . . . . . . . . . . . . . . . . . . . . . . 109
Sample graphics . . . . . . . . . . . . . . . . . . 27

112 50018043464 EN - 10/2017

STILL GmbH

50018043464 EN – 10/2017