Still EXU-S 22 Original Instructions Manual Download Page 104

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Maintenance

Maintenance as required

0148_003-045

– Disconnect the battery connector (3).
– Remove the bonnet(2) to gain access to the

fuse carrier.

0249_00

-046

The following fuses are located on the fuse

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)

3 A

50018043464 EN - 10/2017

Summary of Contents for EXU-S 22

Page 1: ...Original instructions Electric pallet truck EXU S 22 EXU S 24 0177 0178 50018043464 EN 10 2017 ...

Page 2: ......

Page 3: ...ies 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 a...

Page 4: ......

Page 5: ...ied 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 Material...

Page 6: ...tion 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 use...

Page 7: ...2 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 Addin...

Page 8: ...ge 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...

Page 9: ...1 Introduction ...

Page 10: ...industrial vehicles and on the labels and adhesive supplied to the forklift The forklift may not be put to any use other that than indicated in this manual The forklift must be used by appropriately trained operators only For the necessary operator training contact the authorised sales network Persons working near the forklift must also be instructed in the risks associated with use of the forklif...

Page 11: ...d with this symbol may cause damage to the forklift and in some cases result in warranty invalidity ENVIRONMENT NOTE Failure to observe the instructions highlighted with this symbol may cause environmental damage NOTE This symbol is used to provide additional information 50018043464 EN 10 2017 3 ...

Page 12: ...sure that the truck has all of the options requested and that it has been delivered with the following documentation Original instructions Rules for the compliant use industrial vehicles EC Declaration of Compliance Warranty book If the forklift has been delivered with a traction battery and or battery charger ensure that such products conform to the order and that the relative user and maintenanc...

Page 13: ... 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 50018043464 EN 10 2017 5 ...

Page 14: ...LL 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 ...

Page 15: ...load centre approximately on the forklift s median longitudinal plane DANGER The forklift must not be used for other purposes Any other use renders the user solely responsible for injury damage to persons and or objects and voids the warranty The following scenarios are examples of incorrect use of the forklift truck Transport on uneven irregular or non compact surfaces loads that exceed the weigh...

Page 16: ...ry and must be accompanied by a speciﬁc EC Declaration of Compliance which replaces that of the standard forklift and by the relevant User and maintenance manual Contact the authorised sales network for more information Modiﬁcations to Forklift No modiﬁcations may be made to the forklift otherwise the EC certiﬁcate and the warranty will become invalid with the exception of assembly of the options ...

Page 17: ...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 ...

Page 18: ... 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 ...

Page 19: ...2 Safety ...

Page 20: ...ies Never raise the load using just one fork Place the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork carriage The load must be placed on the fork arms so that the centre of gravity falls lengthwise on the mid point between the fork arms Do not drive with loads off centre laterally with respect to the forklift s median axis Lac...

Page 21: ...272 3 Safety Regulations Relative to Forklift Use The operator must familiarize himself with the forklift to be able to better describe any defects and assist maintenance personnel The operator trained and authorized to use the forklift must be familiar with the controls and performances of the forklift Any defect squeaking leaks etc must be promptly reported because if neglected it could cause mo...

Page 22: ...anti pollution laws ENVIRONMENT NOTE The incorrect or unlawful use of brake ﬂuid is harmful to people s health and the environ ment Oils Do not allow to come into contact with the skin Do not inhale oil vapors Wear appropriate means of individual protection during forklift maintenance operations gloves goggles etc to prevent the oil from coming into contact with your skin ENVIRONMENT NOTE The used...

Page 23: ...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 vi...

Page 24: ...d 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 in...

Page 25: ... 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 accordance with Harmonised European Standard EN 12053 and declared according to EN ISO 4871 with weighted time percentages of the Transport Lifting and Idling modes CAUTION The value expressed above can be used to com pare forklift trucks of the same category This can not be...

Page 26: ...indicate any danger as in this case CAUTION The value expressed above can be used to com pare forklift trucks of the same category It cannot be used to determine the operator s daily expo 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 daily exposure must be calculated using data from the place o...

Page 27: ...lete check of the technical condition of the truck must be performed with regard to accident safety In addition the truck must be thoroughly 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 inspections have been carried out The inspection date is indicated by an adhe sive label...

Page 28: ...2 Safety Safety tests 20 50018043464 EN 10 2017 ...

Page 29: ...3 Overview ...

Page 30: ...lopes 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 im...

Page 31: ...duces 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 ...

Page 32: ...ays 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 coc...

Page 33: ... 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 e...

Page 34: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 0148_003 001 23 1 Forks 2 Battery compartment 3 Battery cover 4 Battery lock 5 Battery connector 6 Cockpit 7 Lift cylinder 8 Pump motor 9 Backrest 10 Hydraulic oil tank 11 Brake 12 Drive motor 13 Platform interlock zone 14 Stabiliser 15 Traction wheel 16 Gearbox 17 Stabiliser 18 Steering motor 19 Steering controller 20 Fuse mount 26 50018043...

Page 35: ...ng the position are relative to the driver s seat The load is at the front 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 sequenc...

Page 36: ...play elements View of the control elements 123 456 789 PRG PRG 1 2 3 4 5 6 7 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 ...

Page 37: ... Lift button 3 Horn button 4 Tortoise button 5 PRG scrolling button 6 Numbers 123 button 7 Display 8 I ON button 9 Numbers 456 button 10 PRG input enter button 11 Numbers 789 button 12 Hare button 13 Horn button 14 Lift button 15 Lower button 16 Handle 17 Travel control 18 Emergency brake switch 19 Travel control 20 Handle 50018043464 EN 10 2017 29 ...

Page 38: ...truck to be braked 0148_003 004 1 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 30 50018043464 EN 10 2017 ...

Page 39: ... hooking label 3 Operating and maintenance manual label 4 Annual testing label Germany only 5 Nominal value designation plate 6 Cold store label on cold store version only 7 Danger of crushing feet label 8 Hook symbol Description of labels 1 The label indicates the danger and risk of crushing hands area 50018043464 EN 10 2017 31 ...

Page 40: ...tes 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 w...

Page 41: ...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 Data plate NOTE Please indicate the serial number for all technical enquiries 50018043464 EN 10 2017 33 ...

Page 42: ...t rear 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 ...

Page 43: ...anager 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 ...

Page 44: ...3 Overview Options 36 50018043464 EN 10 2017 ...

Page 45: ...4 Application ...

Page 46: ...ny 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 d...

Page 47: ...ea 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 ...

Page 48: ... 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 OM0747 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 ...

Page 49: ...th chocks 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 ...

Page 50: ...t 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 ...

Page 51: ...e damage e g deformation cracks heavy wear hairline cracks to forks 1 and other lifting devices Inspect the wheels and load wheels 2 for strings ﬁbres and any other objects that could hinder their free rotation 0148_003 009 4 The latch 4 must be closed 50018043464 EN 10 2017 43 ...

Page 52: ... 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...

Page 53: ...ial 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 har...

Page 54: ... pallet truck is equipped with a digital control and is taken into operation by entering a driver code The driver code consists of four ﬁgures and is assigned by the pool manager It is used for normal use and operation of the truck by the driver and operator 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 d...

Page 55: ...code The digits are entered in the same way as on a mobile phone Press keys 1 2 or 3 several times until the desired digit is shown for digits 1 2 3 press key 123 1 4 5 6 press key 456 2 7 8 9 press key 789 3 After entering a digit the display moves to the next position The display shows a ﬂashing line 9 the illustration shows an example NOTE If the digit entered is wrong it is possible to cancel ...

Page 56: ...arry out the activation procedure again NOTE 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 50 123 456 789 PRG PRG 1044_505 001 1 2 3 4 5 6 7 Starting with FleetManager op tional Push the I key...

Page 57: ...ed 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 handling battery electrolyte Press the PRG scrolling button 4 to display the available battery charge 3 NOTE After the battery is connected the correct state of charge appears only after about 1 min...

Page 58: ...ton 4 to display the time remaining until the next scheduled servicing The time is shown in hours 6 and with the symbol of a spanner 5 Have the maintenance carried out according to service hours speciﬁed in the maintenance schedule NOTE The display of the time to the next servicing can be set by your Service Please contact your Service in this regard The display can show subsequent informa tion Ch...

Page 59: ... 456 789 PRG PRG 1047_003 008 2 Operating the horn Press the horn button 2 on the cockpit Check of brake and presence area 123 456 789 PRG PRG 0148_003 012 1 1 Start the truck slowly with the throttle 1 50018043464 EN 10 2017 51 ...

Page 60: ... Drive the truck slowly using the traction control 4 Press the emergency brake button 5 The truck will be braked and remains stationary The StoP signal appears on the display 6 NOTE Press the button I ON 7 to resume work After StoP disappears from the display the truck is operational again CAUTION Only use this brake system in the event of an emergency 52 50018043464 EN 10 2017 ...

Page 61: ...uck 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 Th...

Page 62: ...diately 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 implement...

Page 63: ...r 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 r...

Page 64: ... or if necessary by additional warning signs Emergency stop procedure In an emergency all truck functions can be cut off 0148_003 016 1 To do so depress the emergency isolator button 1 The truck comes to a stop CAUTION 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 56 50018043464 EN 10 2017 ...

Page 65: ...hrottle 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 Reversing Depress the lower 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 Reversing direction Allow the...

Page 66: ...h the left and the right hand Always operate the travel control slowly to avoid jerky starting braking or reverslng Steering 0148_003 017 1 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 Brakes WARNING The surface ﬁnish inﬂuences the driving and bra king behaviour of th...

Page 67: ...rottle 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 SToP appears in the display 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 50...

Page 68: ...ox 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 123 456 789 PRG PRG 0249_003 013 2 1 Press the lift button 2 The forks are raised Their movement can be stopped at any time by releasing the button 60 50018043464 EN 10 2017 ...

Page 69: ...Application 4 Lifting Lowering the forks 0148_003 020 Press the lower button 1 The forks are lowered Their movement can be stopped at any time by releasing the button 50018043464 EN 10 2017 61 ...

Page 70: ...tands in the truck s area of operation DANGER Risk of injury and crushing for the operator and for any pedestrians Risk of damage to the truck and the goods During movement of the truck and the loads espe cially in reverse gear be careful not to hit any obst acles You must maintain an adequate safety di stance from obstacles e g other pallets protru ding objects shelving pedestrians other trucks i...

Page 71: ...m 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 ...

Page 72: ...etres from the ground and read the Transporting loads section 0148_003 022 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...

Page 73: ...king the truck away Check that the truck s path is free of any objects people and obstacles of any type Look behind you and back away very slowly to fully extract the forks from the load DANGER Risk of injury and crushing for the operator Risk of damage to the truck and the goods During the entire load placement operation be careful not to hit any obstacles You must maintain an adequate safety dis...

Page 74: ...across inclines Speed must be reduced when driving down on an incline 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 0148_003 023 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 ...

Page 75: ...nd 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 50018043464 EN 10 2017 67 ...

Page 76: ...uck on a lift Using the truck on lifts is only allowed if the lift has sufﬁcient load capacity check the maximum weight of the truck including the traction battery and only with appropriate authorisation Slowly drive the truck onto the lift load ﬁrst Secure the truck in the lift so that no part comes into contact with the walls of the lift A minimum distance of 100 mm from the walls of the lift mu...

Page 77: ...ules 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 t...

Page 78: ...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 t...

Page 79: ...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...

Page 80: ...master code NOTE The truck is turned off the battery is connec ted 123 456 789 PRG PRG 1044_505 009 1 2 3 4 5 6 Press the I ON button 5 Enter a valid 4 digit master code with the buttons 123 1 456 2 and 789 3 7 1044_505 010 Scroll with the PRG scrolling button 6 until Pin 7 appears in the display 10 1044_505 011 Conﬁrm with the PRG enter button 4 until Add 10 appears in the display 72 50018043464 ...

Page 81: ... add a sixth master code Err will appear in the display 9 1044_505 013 Conﬁrm with the PRG enter button 4 until the new master code 9 blinks an example is shown 10 1044_505 011 Then release the button Add 10 will appear again in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge appears in the display The new master code is entered Deleting a m...

Page 82: ...ay 10 1044_505 015 Conﬁrm with the PRG enter button 4 until dEL 10 appears in the display 8 1044_505 012 Conﬁrm with the PRG enter button 4 A ﬂashing line cursor 8 will appear in the 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 No...

Page 83: ...in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge 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 123 456 789 PRG PRG 1044_505 009 1 2 3 4 5 6 Press the I ON button 5 Enter the valid 4 digit master code with the buttons 123 1 456 2 and 789 3 50018043464 EN 10 20...

Page 84: ...h 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 9 1044_505 013 Conﬁrm with the PRG enter button 4 until the new driver s code 9 blinks an example is shown 10 1044_505 011 Then release the button Add 10 will appear again in the display 11 1044_505 014 Press the PRG scr...

Page 85: ...roll with the PRG scrolling button 6 until USEr 7 appears in the display 10 1044_505 015 Conﬁrm with the PRG enter button 4 until dEL 10 appears in the display 8 1044_505 012 Conﬁrm with the PRG enter button 4 A ﬂashing line cursor 8 will appear in the 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 driv...

Page 86: ...de 9 to be deleted blinks an example is shown 10 1044_505 015 Then release the button dEL 10 will appear again in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge appears in the display The driver s code is deleted 78 50018043464 EN 10 2017 ...

Page 87: ...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 ope...

Page 88: ... to 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 Handling the truck in speciﬁc situations Towing and moving The truck ...

Page 89: ...ading weight 0148_003 026 3 For hoisting with a crane always attach the slings to the points identiﬁed with the hook 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 Towing procedure Towing the truck is...

Page 90: ...ery 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 batteri...

Page 91: ...ompartment 0148_003 028 2 1 Turn the lock 1 90 and lift the battery cover 2 Closing the battery compartment 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 Battery charging with external battery charger CAUTION Deep discharges damage the battery The battery must be charged...

Page 92: ... 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 ...

Page 93: ... covered with a rubber mat DANGER Danger to life No one should be under a raised load Unlock the battery 3 4 0148_003 057 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 traction in order to avoid the boot being damaged The hooks must be placed so that they cannot fall on the battery c...

Page 94: ...s 0148_003 031 1 2 Open the battery cover 1 Remove the side cover 2 0148_003 032 4 3 Place a suitable trolley 4 next to the battery 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 p...

Page 95: ...truck with chocks 0148_003 033 1 Lower the forks 1 on the ground WARNING Before leaving the truck lower the load fully 0148_003 034 2 Depress the emergency isolator button 2 NOTE 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 50018043464 EN 10 201...

Page 96: ...ssary 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 electr...

Page 97: ...he 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...

Page 98: ...4 Application Storage 90 50018043464 EN 10 2017 ...

Page 99: ...5 Maintenance ...

Page 100: ...l speciﬁcati ons NOTE Contact the authorised service network for a maintenance contract appropriate to your forklift CAUTION Maintenance intervals are deﬁned for standard use In the following cases it is necessary to reduce the interval between the various scheduled maintenance operations in the event of use in dusty or salty environments extremely high or low ambient temperatures high levels of a...

Page 101: ...arnesses 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 pini...

Page 102: ...peated 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 ...

Page 103: ...efully as possible after every work cycle It is preferable to use cold compressed air and detergents Use water dampened rags to clean the parts of the body CAUTION Do not clean the truck with direct jets of water DO NOT use solvents and petrols that could damage parts of the truck Fuses CAUTION Before performing any work on the electrical in stallation remove any power from the system by disconnec...

Page 104: ...the battery connector 3 Remove the bonnet 2 to gain access to the fuse carrier 4 3 2 0249_003 046 1 5 The following fuses are located on the fuse 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 3 A 96 50018043464 EN 10 2017 ...

Page 105: ...tenance 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 ...

Page 106: ...riod of Inactivity DANGER Perform the following operations before using the forklift Clean forklift truck thoroughly Check the battery charge level and re assemble it in the forklift making sure to spread Vaseline on the terminals Lubricate all of the parts provided with lubricating nipples and the chains Carry out the ﬂuid level checks Perform all of the functional maneuvers of the forklift and o...

Page 107: ...6 Technical data ...

Page 108: ...6 Technical data Dimensions Dimensions 100 50018043464 EN 10 2017 ...

Page 109: ... capacity Q kg 2200 Nominal load centre of gravity c mm 600 1 Load distance x mm 1023 2 Centre to centre distance y mm 1617 2 Weights EXU S 22 EXU S 22 Tare weight including battery kg 1120 Pressure on the axles with load drive side load side kg 1820 1500 Loads on the axles without load drive side load side kg 210 910 Wheels and tyres EXU S 22 EXU S 22 Tyres Polyurethane Wheel size drive side mm 2...

Page 110: ...4 mm 1030 Height of forks when lowered h13 mm 85 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 under mast m2 mm 30 Aisle width for pallet 800 x 1200 lengthwise b12 x l6 Ast mm 2821 5 2890 5 Aisle width for pallet 1000 x...

Page 111: ...S 22 EXU S 22 Travel motor rating S2 60min kW 3 0 Lifting motor rating S3 15 kW 2 2 Battery in accordance with DIN 43 531 35 36 A B C no no Battery voltage nominal capacity K5 V Ah 24 465 Battery weight 5 kg 405 Energy consumption according to VDI cycle kWh h 1 05 Other EXU S 22 EXU S 22 Speed control AC controller Average noise level measured at the driver s ear dB A 65 1 For forks with l 1190 mm...

Page 112: ...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 ...

Page 113: ... load centre of gravity c mm 600 1 Load distance x mm 1005 2 Centre to centre distance y mm 1599 2 Weights EXU S 24 EXU S 24 Tare weight including battery kg 1150 Pressure on the axles with load drive side load side kg 2233 1317 Loads on the axles without load drive side load side kg 232 918 Wheels and tyres EXU S 24 EXU S 24 Tyres Polyurethane Wheel size drive side mm 250 x 100 Wheel size load si...

Page 114: ...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 under mast m2 mm 24 4 Aisle width for pallet 800 x 1200 lengthwise b12 x l6 Ast mm 2814 5 2883 5 Aisle width for pallet 1000 x 1200 lengthwise b12 x l6 Ast mm 2781 5 6 2851 5 6 Bending radius Wa mm 2107 5 2177 5 Performance data EXU S 24 EXU S 24 Driving sp...

Page 115: ...tage nominal capacity K5 V Ah 24 465 Battery weight 5 kg 5 405 Energy consumption according to VDI cycle kWh h 1 07 Other EXU S 24 EXU S 24 Speed control AC controller Average noise level measured at the driver s ear dB A 65 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 a...

Page 116: ...038 2108 2123 2193 1190 1023 2238 2308 2323 2393 1600 1433 2648 2718 2733 2803 2390 c 2390 d not available EXU S 24 Turning radius Wa and load distance x with forks lowered a Battery compartment 70 3PzS Battery compartment 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 2...

Page 117: ...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 ...

Page 118: ...litres Oil for pivot wheels only if the STILL DRIVEspeed version is present AP31 hydraulic oil Generic lubricant Tutela MP 02 Cold storage version Quantity Traction transmission gear oil FUCHS Renolin PG 220 1 1 litres Lifting hydraulics oil EQUIVIS XV32 2 5 litres Oil for pivot wheels only if the STILL DRIVEspeed version is present AP31 hydraulic oil Generic lubricant Tutela EP2 110 50018043464 E...

Page 119: ...ademark rights 4 D Danger area 39 Danger zone 54 Date of edition of this manual 4 Dead man s zone 30 Declaration of conformity 6 Deﬁnition of directions 27 Deleting a driver s code 77 Deleting a master code 73 Digicode control 71 Dimensions 100 Dimensions of roads and working aisles 55 Disposal Battery 9 Components 9 Driver s code 71 Driving Safety instructions 38 Driving on loading bridges 67 Dri...

Page 120: ...ks 15 S Safe parking of the truck 87 Safety Inspection 19 Safety regulations when handing loads 62 Sample graphics 27 Service code 72 Soft braking 59 Stability 16 Steering 58 T Technical description 22 Towing procedure 81 Transport 40 Transporting a load 64 Turning on the truck 46 Tyres 109 U Update of this manual 4 V View of the control elements 28 Visibility when driving 53 Visual checks 42 W Wh...

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Page 122: ...STILL GmbH 50018043464 EN 10 2017 ...

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