Original instructions Electric pallet truck

Electric pallet truck

EXU-16EXU-18EXU-20EXU-22

Original instructions

0153 0154 0155 0157 2351 23532355 2357

1152 807 80 01 EN - 02/2021 - 17

Address of manufacturer andcontact details

STILL GmbHBerzeliusstraße 1022113 Hamburg, GermanyTel. +49 (0) 40 7339-0Fax: +49 (0) 40 7339-1622Email: [email protected]: http://www.still.de

Preface

I1152 807 80 01 EN - 02/2021 - 17

1 Introduction Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Copyright and property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Rules for the operating company of industrial trucks. . . . . . . . . . . . . . . . . . . . . . . . . . 5

Eco-design requirements for electric motors and variable speed drives . . . . . . . . . . . 6

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Permissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Description of use and climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Unauthorised use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Explanation of symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Disposing of components and batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Disposal of consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Noise emission values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Vibration characteristic values for bodily vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Definition of responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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III1152 807 80 01 EN - 02/2021 - 17

3 Overviews Truck overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control and display components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Tiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Battery charge indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Digicode option (LFM Go) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Location of markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4 Use Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

List of checks prior to start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Checks and actions prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Charging a Gel or Lead battery (wall-mounted charger) . . . . . . . . . . . . . . . . . . . . . . . . . 35Checking the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Checking the emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Checking the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Checking the anti-crush safety device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Truck operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Driving safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Defining directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Driving on upward and downward slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44OptiSpeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Creep Speed function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Standby (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operating the FleetManager™ option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Description of the FleetManager option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Commissioning a truck equipped with the FleetManager™ option . . . . . . . . . . . . . . . . 49FleetManager™ option: Colour code for the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Disconnecting a truck equipped with the FleetManager™ option . . . . . . . . . . . . . . . . . 52

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IV 1152 807 80 01 EN - 02/2021 - 17

Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Load handling safety rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Grabbing a loading unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Transporting pallets or other containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Lift control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Load handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Using the folding platform (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Cold store usage (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Parking the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Handling the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Order picking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Opening/closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Charging the battery using an external charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65On-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Using the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Gel or Lead batteries: Adjusting the on-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . 69Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Gel and lead side access batteries: changing the battery using a trolley . . . . . . . . . . . . 71Side access battery: changing the battery using a moveable support . . . . . . . . . . . . . . 73

Handling the truck in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Truck towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Handling the truck in specific situations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Slinging the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Transporting the truck in the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5 Maintenance General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Servicing and maintenance personnel training and qualification. . . . . . . . . . . . . . . . . . . 83Battery maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Maintenance operations that do not require special training . . . . . . . . . . . . . . . . . . . . . . 83Ordering spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Maintenance safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Servicing and maintenance measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Technical inspection and maintenance characteristics . . . . . . . . . . . . . . . . . . . . . . . . 85

Access to the technical compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Accessing the reducer and the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1000-hour/annual maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Clean the battery and its compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93General information on battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Folding platform maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Steering and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Servicing wheels and rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Adjusting the height of the stabilisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Maintaining the reinforced stabilisers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Regular maintenance of the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Checking the condition of cables, terminals and battery connector . . . . . . . . . . . . . . . . 99Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Hydraulic circuit, draining the circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Storage and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Storage of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Permanent Putting Out of Commission (Destruction) . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6 Technical specifications Datasheet EXU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Datasheet EXU 20S - EXU 22S (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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VI 1152 807 80 01 EN - 02/2021 - 17

1

Introduction

Your industrial truckGeneralThe truck described in these operating instruc-tions corresponds to the applicable standardsand safety regulations.

If the truck is to be operated on public roads, itmust conform to the existing national regula-tions for the country in which it is being used.The driving permit must be obtained from theappropriate office.

The truck has been fitted with state-of-the-arttechnology. Following these operating instruc-tions will allow the truck to be handled safely.By complying with the specifications in theseoperating instructions, the functionality and theapproved features of the truck will be retained.

Get to know the technology, understand it anduse it safely - these operating instructions pro-vide the necessary information and help toavoid accidents and to keep the truck readyfor operation beyond the warranty period.

Therefore:

– Before commissioning the truck, read theoperating instructions and follow the instruc-tions.

– Always follow all of the safety informationcontained in the operating instructions andon the truck.

Introduction1Your industrial truck

2 1152 807 80 01 EN - 02/2021 - 17

CE labelling The manufacturer uses CE labelling to indi-cate that the truck complies with the standardsand regulations valid at the time of marketing.The supplied EC declaration of conformityconfirms this. The CE labelling is attached tothe nameplate.

An independent structural change or an addi-tion to the tow tractor can compromise safety,thereby invalidating the EC declaration of con-formity.

The EC declaration of conformity must becarefully stored and made available to the re-sponsible authorities.

Copyright and property rightsThis manual - and any excerpts thereof - maynot be reproduced, translated or transmitted inany form to third parties without the expresswritten permission of the manufacturer.

CE-Symbol

Introduction 1Your industrial truck

31152 807 80 01 EN - 02/2021 - 17

EC declaration of conformity

Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg

GERMANY

We declare that the machine Industrial truck according to these operating instructionsModel according to these operating instructions conforms to the latest version of the Machinery Directive 2006/42/EC. Person authorised to compile the technical documents: See EC compliance declaration STILL S.A.S.

The manufacturer declares that the truck com-plies with the requirements of the EC direc-tives valid at the time of marketing. This isconfirmed by the EC declaration of conformityand by the EC labelling on the nameplate.

An independent structural change or additionto the truck can compromise safety, thus inva-lidating the EC declaration of conformity.

The EC declaration of conformity must becarefully stored and made available to the rel-evant authorities.

Introduction1EC declaration of conformity

4 1152 807 80 01 EN - 02/2021 - 17

Identification label

NOTE

Indicate the serial number for all technical en-quiries.

Rules for the operating com-pany of industrial trucksIn addition to these operating instructions, acode of practice containing additional informa-tion for the operating companies of industrialtrucks is also available.

This guide provides information for handlingindustrial trucks:● Information on how to select suitable indus-

trial trucks for a particular area of applica-tion

● Prerequisites for the safe operation of in-dustrial trucks

● Information on the use of industrial trucks● Information on transport, initial commission-

ing and storage of industrial trucks

ModelManufacturerSerial numberYear of manufactureUnladen weight (without battery) in kgMaximum battery weightMinimum battery weight (for a lithium-ionbattery, the weight of the ballast container isincluded)Additional weight (ballast weight) in kgNominal motor power (kW)Battery voltage in VNominal capacity in kgEC conformity symbol

1234567

89101112

Introduction 1Identification label

51152 807 80 01 EN - 02/2021 - 17

Internet address and QR codeThe information can be accessed at any timeby pasting the address https://m.still.de/vdmain a web browser or by scanning the QR code.

Eco-design requirements forelectric motors and variablespeed drivesAll motors in this industrial truck are exemptfrom Regulation (EU) 2019/1781 becausethese motors do not meet the description giv-en in Article 2 "Scope", Item (1) (a) and be-cause of the provisions in Article 2 (2) (h) "Mo-tors in cordless or battery-operated equip-ment" and Article 2 (2) (o) "Motors designedspecifically for the traction of electric vehicles".

All variable speed drives in this industrial truckare exempt from Regulation (EU) 2019/1781because these variable speed drives do notmeet the description given in Article 2"Scope", Item (1) (b).

Introduction1Eco-design requirements for electric motors and variable speed drives

6 1152 807 80 01 EN - 02/2021 - 17

Spare parts list The spare parts list can be downloaded by en-tering the address https://sparepartlist.still.euinto a web browser or by scanning the QRcode displayed to the side.

When the web page is open, please type inthe following password: Spareparts24!

On the next screen, please enter your emailaddress and truck serial number to receive thelink by email. Then download the spare partslist.

2511

Introduction 1Spare parts list

71152 807 80 01 EN - 02/2021 - 17

Permissible use The truck described in these operating instruc-tions is suitable for lifting and transportingloads.

The truck should only be used for the purpo-ses for which it was designed, as described inthese instructions.

If the truck needs to be used for purposes oth-er than those specified in these instructions,you should first:● Obtain permission from the manufacturer● Obtain permission from the competent au-

thorities, if applicable

The purpose of obtaining these permissions inadvance is to limit danger as far as possible.

Description of use and climatic conditionsNormal use– Indoor and outdoor use.

– Ambient temperature in tropical and Nordicregions ranging from -10°C to 45°C

– Start capability from -10°C to 45°C.

– Maximum start time of 20 seconds

– Use at up to 2000 metres above sea level.

Special use (partly with special meas-ures) for trucks equipped with Gel orLead batteries– Use, for example, in the event of abrasive

dust (such as AL203), lint, acid, leach, saltand incombustible substances.

– Ambient temperature in tropical regions upto 55 °C.

– Start capability at -25°C.

– Use at up to 3,500 metres above sea level.

Introduction1Permissible use

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Unauthorised useAny danger caused as a result of unauthor-ised use becomes the responsibility of the op-erator or driver and not that of the manufactur-er.

Use for purposes other than those describedin these operating instructions is prohibited.

Transporting people is prohibited.

The forklift truck should not be used in areaswhere there is a risk of fire, explosion or corro-sion, or in areas that are particularly dusty.

Stacking or unstacking is not permissible oninclined surfaces or ramps.

Explanation of symbols used DANGER

Compulsory procedure that must be followed toavoid life-threatening danger or physical harm.

WARNINGCompulsory procedure that must followed to avoidinjury.

CAUTIONCompulsory procedure that must be followed toavoid damage to and/or destruction of equipment.

NOTE

For technical requirements that require specialattention.

ENVIRONMENT NOTE

To prevent environmental damage.

Disposing of components and batteriesThe truck is made up of different materials.

If components or batteries must be replacedand scrapped, they must be:● disposed of● treated or● recycled in accordance with regional and

national regulations

NOTE

The documentation provided by the batterymanufacturer must be observed when dispos-ing of batteries.

ENVIRONMENT NOTE

We recommend working with a waste man-agement company when disposing of compo-nents and batteries.

Introduction 1Unauthorised use

91152 807 80 01 EN - 02/2021 - 17

Introduction1Disposing of components and batteries

10 1152 807 80 01 EN - 02/2021 - 17

2

Safety

Safety regulationsThese operating instructions, which come withthe truck, must be communicated to all thoseconcerned and in particular to personnel re-sponsible for maintenance and driving. Theemployer must make sure that the forklift op-erator has properly understood all the safetyinformation.

Please observe the directives and safety regu-lations attached, in particular:● Information concerning the use of materials

handling trucks● Regulations concerning traffic lanes and

working areas● Appropriate behaviour, rights and responsi-

bilities of the driver● Use in particular areas● Information about the weight and dimen-

sions of pallets or any other container● Information concerning starting, driving and

braking● Information concerning maintenance and

repair

● Regular checks and technical inspections● Recycling of lubricants, oils and batteries● Residual risks.

Care is recommended both for the user andthe person in charge (employer) with regard toadhering to all safety rules concerning the useof material-handling trucks.

When instructing forklift operators, we recom-mend the following points are emphasized:● The features of the truck● The special accessories● The specific features of the working envi-

ronment.

Train the user in how to drive the truck, until itis under proper control.

Then, and only then, proceed to transferringpallets.

Forklift truck stability is guaranteed when theunit is used correctly.

Safety2Safety regulations

12 1152 807 80 01 EN - 02/2021 - 17

Safety regulations for handling consumablesPermissible consumables

WARNINGConsumables can be dangerous.It is necessary to follow the safety regulations whenhandling these substances.

Refer to the maintenance data table for thepermissible substances necessary for opera-tion.

Oils DANGER

Oils are flammable!– Follow the statutory regulations– Do not allow oils to come into contact

with hot motor parts.– No smoking, fires or flames!

DANGER

Oils are toxic!– Avoid contact and consumption– In case of inhalation of steam or

fumes, breathe fresh air immediately.– After contact with the eyes, rinse thor-

oughly with water (for at least 10 mi-nutes) and then consult an eye spe-cialist.

– If swallowed, do not induce vomiting.Seek immediate medical attention.

WARNING

Prolonged intensive contact with the skincan result in loss of skin oils and causeirritation.– Avoid contact and consumption.– Wear protective gloves!– After any contact, wash the skin with

soap and water and then apply a skincare product.

– Immediately change soaked clothingand shoes.

WARNINGThere is a risk of slipping on spilled oil, particularlywhen combined with water!– Collect spilled oil immediately using an oil-binding

agent and dispose of it in accordance with regula-tions.

ENVIRONMENT NOTE

Oils are water pollutants!

Always store oil in containers that comply withthe applicable regulations.

Avoid spilling oils.

Collect spilt oil immediately using an oil bind-ing agent and dispose of it in accordance withregulations.

Dispose of old oils according to the applicableregulations.

Safety 2Safety regulations for handling consumables

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Hydraulic fluid

WARNING

During operation of the forklift truck, hy-draulic fluids are pressurised and arehazardous to your health.– Do not spill these fluids!– Follow the statutory regulations– Do not allow the fluids to come into

contact with hot motor parts.– Do not allow to come into contact with

the skin.– Avoid inhaling the spray– Penetration of pressurised fluids into

the skin is particularly dangerous ifthese fluids escape at high pressuredue to leaks in the hydraulic system.In case of such injury, seek medicaladvice immediately.

– To avoid injury, use appropriate per-sonal protective equipment (e.g. pro-tective gloves, industrial goggles, skinprotection and skin care products).

ENVIRONMENT NOTE

Hydraulic fluid is a water-polluting substance!

Always store hydraulic fluid in containers com-plying with the regulations.

Avoid spilling.

Spilt hydraulic fluid should be removed withoil-binding agents at once and disposed of ac-cording to the regulations.

Dispose of old hydraulic fluid according to reg-ulations.

Battery acid

WARNING

Battery acid contains dissolved sulphuricacid. This is toxic.– Avoid contact and consumption.– In case of injury, seek medical advice

immediately.

WARNING

Battery acid contains dissolved sulphuricacid. This is corrosive.– When working with battery acid, al-

ways wear protective clothing andeye protection.

– Do not allow any acid to get onto theclothing or skin or into the eyes; if thisdoes happen, rinse immediately withplenty of clean water.

– In case of injury, seek medical adviceimmediately.

– Immediately rinse away spilt batteryacid with plenty of water.

– Follow the statutory regulations

ENVIRONMENT NOTE

– Dispose of used battery acid in line with theapplicable regulations.

Safety2Safety regulations for handling consumables

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Disposal of consumables

ENVIRONMENT NOTE

Materials that have to be disposed of followingmaintenance, repair and cleaning must besystematically collected and disposed of in ac-cordance with regulations. Observe the na-tional regulations for your country. Work mayonly be carried out in areas designated for thispurpose. Take care to minimise, as far as pos-sible, any impact on the environment.

● Any spillage of fluids such as hydraulic oil,brake fluid or gear lubricant oil must be im-mediately soaked up with an oil-bindingagent.

● The regulations for disposal of used oil areapplicable.

● Any spillage of battery acid must be neutral-ised immediately.

Safety 2Safety regulations for handling consumables

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EmissionsNoise emission valuesCalculated in the test cycle in accordance withEN 12053 from the weighted values for theTRACTION, LIFT and IDLING operatingstates.

Acoustic pressure level on the driver's com-partmentEXU 16, EXU 18,EXU 20, EXU 22 LPAZ = 70 dB (A)

in the LIFT operat-ing state LPa = 73 dB (A)

in the "Idling" oper-ating status LPb = 0 dB (A)

Acoustic pressure level on the driver's com-partmentin the DRIVE oper-ating state LPc = 73,5 dB

(A)Insecurity KPA ± 2,5 dB (A)

NOTE

Lower or higher noise values may occur whenusing industrial trucks, due e.g. to the methodof operation, environmental factors and othersources of noise.

Vibration characteristic values for bodily vibrationsThe values were determined according to EN13059 using trucks with standard equipmentaccording to the data sheet (driving over testcourse with humps).

Specified vibration characteristic accordingto EN 13059Measured vibra-tion characteris-tic

aW.ZS = 0,80 m/s2

Insecurity K = 0,3 m/s2

Specified vibration characteristic for hand-arm vibrationsVibration characteristic < 2,5 m/s2

NOTE

The vibration characteristic for bodily vibra-tions cannot be used to determine the actualload level of vibrations during operation. Thisdepends on the operating conditions (state ofpathway, method of operation etc.) and shouldtherefore be determined on site, where appro-priate. It is mandatory to specify the hand-armvibrations even where the values do not indi-cate any hazard, as in this case.

Safety2Emissions

16 1152 807 80 01 EN - 02/2021 - 17

Residual dangers, residual risksDespite all operational precautions and com-pliance with standards and rules, the possibili-ty of additional risks when using the truck can-not be entirely excluded.

The truck and all its components comply withthe regulations relating to current applicablesafety rules.

Persons in the vicinity of the truck must beparticularly cautious and react immediately inthe event of any malfunction, incident, break-down etc.

WARNINGPersonnel in contact with the truck must be informedof the risks related to using the truck.These operating instructions draw your attention tothe safety rules.

The risks are:● Escape of consumables due to leaks, rup-

tured lines and tanks etc.● Risk of accident when driving over difficult

ground such as slopes, soft or irregular sur-faces or in poor visibility etc.

● Falling, tripping etc. when moving on the in-dustrial truck, especially in the wet, withleaking consumables or icy surfaces.

● Loss of stability due to the load being unsta-ble or the load slipping etc.

● Risk of fire and explosion due to batteriesand electrical voltages.

● Human error - Disregarding safety regula-tions.

It is important to adjust the speed of the truckdepending on the load and ground conditions.

The stability of the truck has been tested tothe latest standards. These standards onlytake account of the static and dynamic tiltingforces that can arise during operation thatcomplies with the specifications and operatingrules. Risks caused by misuse or incorrect op-eration that jeopardise the stability cannot beruled out in extreme situations.

StabilityStability is only guaranteed if the industrialtruck is used according to the indicated rec-ommendations.

It is not guaranteed in the event of:

– cornering at high speeds

– moving with a load that is protruding to theside (e.g. sideshift)

– turning and driving diagonally on descentsor ascents

– driving on descents or ascents with the loadon the downhill side

– loads that are too wide or too heavy

– driving with an unstable load

– ramp edges or steps.

Safety 2Residual dangers, residual risks

171152 807 80 01 EN - 02/2021 - 17

Definition of responsible personsOperating companyThe operating company is the natural or legalperson or group who operates the truck or onwhose authority the truck is used.

The operating company must ensure that thetruck is only used for its intended purpose andin compliance with the safety guidelines setout in these operating instructions.

The operating company must ensure that allusers read and understand the safety informa-tion in these instructions.

The operating company is responsible for thescheduling and correct performance of regularsafety checks.

It is recommended that these checks complywith national performance specifications.

SpecialistA specialist is deemed to be:● A person whose experience and technical

training has allowed him to develop relevantknowledge of industrial trucks

● A person who is also familiar with nationalhealth and safety regulations and generallyrecognised technical directives and conven-

tions (standards, VDE regulations, technicalregulations of other European Union mem-ber states or countries that are signatoriesto the treaty that established the EuropeanEconomic Area). This expertise allows himto assess the condition of industrial trucksin terms of health and safety

DriversThis truck may only be driven by suitable per-sons who are at least 18 years of age, havebeen trained in driving, have demonstratedtheir skills in driving and handling loads, andhave been specifically designated to drive thetruck. Specific knowledge of the truck is alsonecessary.

Driver rights,duties and rules of behav-iourThe driver must be duly informed of his rightsand duties.

The driver must be granted the required rights.

The driver must wear protective equipment(protection suit, safety helmet, industrial gog-gles and protective gloves) that is appropriatefor the conditions, the task and the load to belifted. The driver must also wear safety foot-wear to be able to drive and brake in completesafety.

The driver must be familiar with the operatinginstructions and have access to them at alltimes.

The driver must:● Have read and understood the operating in-

structions● Have familiarised himself with safe opera-

tion of the truck● Be physically and mentally able to drive the

truck safely

DANGERThe use of drugs, alcohol or medications that affectreactions impair the ability to drive the truck.Individuals under the influence of the above-men-tioned substances are not permitted to perform workof any kind on or with the truck.

Safety2Definition of responsible persons

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Prohibition of use by unauthorised per-sonsThe driver is responsible for the truck duringworking hours. He must not allow unauthor-ised persons to operate the truck.

When leaving the truck, the driver must secureit against unauthorised use.

Safety 2Definition of responsible persons

191152 807 80 01 EN - 02/2021 - 17

Safety testsRegular safety inspection of thetruckSafety inspection based on time and ex-traordinary incidentsThe operating company (see chapter entitled"Definition of responsible persons") must en-sure that the truck is checked by a specialistat least once a year or after noteworthy inci-dents.

As part of this inspection:● A full check of the technical condition of the

truck in terms of accident safety must beperformed

● The truck must be thoroughly checked todetect any damage that may have beencaused by improper use

● A test log must be created.

The results of the inspection must be retaineduntil at least a further two inspections havebeen carried out.

The inspection date is indicated by an adhe-sive label on the truck.

– Arrange for the service centre to performperiodic safety inspections on the truck.

– Observe the guidelines for tests carried outon the truck in accordance with FEM 4.004.

The operator is responsible for ensuring thatany defects are remedied immediately.

– Contact your service centre.

NOTE

Observe the regulations in force in your coun-try.

Regelmäßige Prüfung(FEM 4.004)

nach nationalen Vorschriftenbasierend auf den EG-Richtlinien:95/63/EG, 99/92/EG, 2001/45/EG

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung

5634

4391

019

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

0000_003-001_V3

Safety2Safety tests

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3

Overviews

Truck overviewOverviews

Battery plug handle (emergency stop)Battery coverSwitch keyTraction control moduleFork armsLoad wheelsStabiliser wheelsDrive wheel

12345678

Traction motorPump unitElectromagnetic brakeLift cylinderDigicode (LFM Go)*TillerPlatform*

9101112131415

*Option

Overviews3Truck overview

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Control and display componentsTiller

HandleLoweringRaising

123

HornThrottleAnti-collision device

456

Overviews 3Control and display components

231152 807 80 01 EN - 02/2021 - 17

Battery charge indicator

DESCRIPTION EXPLANATION COMMENTS / SCREENMESSAGES

1 Battery charge level repre-sented by 10 bars

Full charge: 100%Low charge: 10% Dis-charged : 0%

91% - 100%: 10 bars1% - 10%: 1 bar0%: 1 flashing bar (lift func-tion not permitted).NB: To protect the battery,0% corresponds to max.80% discharge.

2 Service alarm (red)

1)Flashing: less than 50hours truck operation untilthe next service2)Constant: service dateoverdue

3 Red indicator light Switched on: default oralarm

Overviews3Control and display components

24 1152 807 80 01 EN - 02/2021 - 17

DESCRIPTION EXPLANATION COMMENTS / SCREENMESSAGES

4 Green indicator light

Switched off: truck switchedoffSwitched on: truck switchedon

5 Breakdown code E3 294

These codes help the AfterSales Service to decide onthe appropriate responsefrom the service engineer

6 Fault or brake wear (air gap) Do not operate the truck

7 Hourmeter Indicates the number of op-erating hours of the machine

- The meter runs from whenthe truck is switched on anda control is used.- When counting, the dotnext to the tenths of an hourflashes.-The hourmeter displayshours and tenths of an hour.- When the power supply isdisconnected, the hours arestored in the memory.

8 STOP alarm (red) Misc. problems Do not operate the truck

9 T° alarm (red) Constant: control moduleoverheating

-> Truck is stoppedIn general, wait a few mi-nutes and then continue.


251152 807 80 01 EN - 02/2021 - 17

Digicode option (LFM Go)

Switch ON (operating mode)Switch OFF and awaiting codeProgramming mode active

123

Key fault or incorrect codeTime delay of automatic switch-off

45

Operation Key in LED status NotesUSE

ON* 0 0 0 0 0 # or

* 1 2 3 4 5 # (by de-fault)

○ red off ● continuousgreen (1)(correct PIN)● red flashing ○ greenoff (4)(incorrect PIN)

0 0 0 0 0 or 1 2 3 4 5PIN code by default

OFF # (3 seconds) ○ red off ● green flash-ing (2) Truck power off

PROGRAMMING (truck switch OFF only (2)) ADMINISTRA-

TOR CODE ES-SENTIAL FORALL DIGICODE

SETTINGS

* 0 0 0 0 0 0 0 0# (by default)

● continuous red ● con-tinuous green (3)

Once the diodes havegone out, the electronic

key automatically revertsto "operating mode"

New operatorcode * 0 * 4 5 6 7 8 # ○ red off ● green flash-

ing (2) (code accepted)Example of new opera-

tor code: 45678Allocating opera-

tor codes* 2 * 5 4 3 2 1 # ○ red off ● green flash-

ing (2) (code accepted)*2*: operator reference10 options from 0 to 9

Deleting operatorcodes * 2 * #

○ red off ● green flash-ing (2) (deletion accep-

ted)

*2*: operator reference(between 0 and 9)

Modifying admin-istrator codes

* * 9 * 1 2 3 4 56 7 8 #

○ red off ● green flash-ing (2) (code accepted)

Restoring the ini-tial administrator

code

To reactivate the defaultadministrator code

(00000000), please con-tact your agent or near-

est dealer.

Overviews3Control and display components

26 1152 807 80 01 EN - 02/2021 - 17

PROGRAMMING (truck switch OFF only (2))

Activating the au-tomatic switch-off * * 2 * 1 #

● red flashing ● greenflashing (5) (5 s before

switch-off)

Power switches off auto-matically after 10 mins(600 s by default) if thetruck is not being used.

Setting the timedelay of the auto-matic switch-off

* * 3 * 6 0 # ○ red off ● green flash-ing (2) (value accepted)

Example: automaticallyswitches off after 1 min.

(60s) when not used.Minimum setting = 10 s /

maximum = 3000 sDeactivating the

automatic switch-off

* * 2 * 0 #○ red off ● green flash-ing (2) (command ac-

cepted)


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MarkingsLocation of markings

Brand labelEXU16 model labelEXU18 model labelEXU20 model labelEXU22 model labelIdentification labelSlinging label

1234567

Warranty label (for Germany only) on the in-side of the tillerCold store labelELECTRICAL DANGER labelDANGER INSTRUCTIONS labelPIEK label on the outside of the tiller

8

9101112

Overviews3Markings

28 1152 807 80 01 EN - 02/2021 - 17

Serial number

NOTE

Indicate the serial number for all technical en-quiries.

The serial number contains the following infor-mation:

1 Production location

2 Type

3 Year of production

4 Count number

7090_921-004

xx xxxx x xxxxx

1

2

3

4

Overviews 3Markings

291152 807 80 01 EN - 02/2021 - 17

Overviews3Markings

30 1152 807 80 01 EN - 02/2021 - 17

4

Use

DescriptionThe electric pallet trucks EXU 16, EXU 18,EXU 20 and EXU 22 are designed to handlepallets or containers.

Their small volume, their ease of driving andtheir performance make them very appropriatefor loading and unloading operations.

The range of these trucks covers capacities of1600, 1800, 2000 and 2200 kg.

DriveDrive is provided by a 1.2 kW asynchronoustraction motor.

The motor unit is driven by the truck controller,which incorporates the transistor speed con-troller.

This controller offers excellent performanceand enables optimum control of speed, accel-eration and counter-current braking.

The power supply to the traction motor is con-trolled by an electronic controller with micro-processor, which provides complete control ofspeed, acceleration and braking.

SteeringA long, robust, ergonomic tiller allows the op-erator to direct the drive/steering wheel effort-lessly.

The various controls: forward travel, reversetravel, lifting and lowering of the load arms,and the horn are grouped together at the endof the tiller.

For safety reasons a gas spring automaticallyreturns the tiller to the upper position when itis released.

The speed of the truck is limited to 6 km/h inboth directions of travel (key in the Hare posi-tion).

The speed of the truck is limited to 4 km/h inboth directions of travel (key in the Tortoiseposition).

BatteriesPower is supplied by either:

– A lead battery

– A gel battery

– Or a lithium-ion battery (the truck thereforehas specific characteristics).

The types of battery removal that are availableare as follows:● Vertical access (Types BS, 2Pzs, 3Pzs)● Side access on rollers (Types 2PzS and

3PzS). This system allows the battery to bechanged quickly.

Braking system

● counter-current, upon accelerator release● counter-current, by switching the direction

of travel● counter-current, controlled by rear safety in-

verter switch● electromagnetic safety, controlled by the

emergency stop handle● electromagnetic safety, controlled by the

upper or lower position of the tiller● electromagnetic parking, applied when sup-

ply is cut.

StabilisersThe 5-point chassis has 2 suspended stabilis-ers which compensate for ground irregulari-ties.

Lifting systemCapacity:● EXU 16: 1600 kg● EXU 18: 1800 kg● EXU 20: 2000 kg● EXU 22: 2200 kg● EXU 20 S* : 2000 kg● EXU 22 S* : 2200 kg

* S : Folding platform.

Use4Description

32 1152 807 80 01 EN - 02/2021 - 17

The cylinder activates the lift shaft, whichtransmits the movement to the push rods.

These activate the wheel clevises, resulting inthe load arms lifting.

All the joint pins are treated for anti-wear andanti-corrosion properties. The joint rings areself-lubricating.

Pump motor power:● EXU 16 and EXU 18: 1 kW● EXU 20: 1.2 kW● EXU 22: 1.4 kW● EXU 16-18-20 CS* : 1.2 kW● EXU 22 CS*: 1.4 kW

* CS : Cold store (option)

Driver's compartment

The standard equipment in the driver's com-partment comprises:● an office compartment for storing rolls of

film and adhesive, gloves, pens etc.● a clip for attaching documents together

● a battery disconnection handle (emergencystop) located in the driver's compartment

● an hour meter/discharge indicator.● an ignition key with 3 positions (stop/

Tortoise/Hare)● a tiller with the following controls: forward/

reverse travel, accelerator, lifting/loweringof the load arms, horn and safety inverter

● OptiSpeed (EXU16, EXU18, EXU20,EXU22) : : variable speed according to tillerposition.

As OPTIONS:● backrest● digicode (LFM Go)● cold-store version● Fleet Manager● reinforced stabilisers● on-board charger● accessory holder

Use 4Description

331152 807 80 01 EN - 02/2021 - 17

List of checks prior to start-up WARNING

Damage or other defects on the truck or attachments(special equipment) can result in accidents.If damage or other faults are noticed on the truck orattachments (special equipment) during the followinginspections, do not use the truck until it has beenproperly repaired. Do not remove or disable the safe-ty systems and switches. Do not change the pre-setvalues.

Before start-up, ensure that the truck operatescorrectly.

To do this, perform the following checks:

– The load arms must not show any signs ofnoticeable damage (for example: bending,cracks, significant wear).

– Check that there are no signs of leakingconsumables under the truck.

– Do not restrict the field of vision. Ensure thevisible area specified by the manufacturer isobserved.

– Attachment parts (special equipment) mustbe properly secured and function accordingto their operating instructions.

– Damaged or missing stickers must be re-placed in compliance with the marking posi-tion table.

– The roller channels must be coated in avisible layer of grease.

– The wheels must show no signs of defectsor heavy wear. They must be mounted cor-rectly.

– Check that there are no foreign objects thatcould hinder the operation of the wheelsand rollers.

– The warning devices (horn etc.) must work.

– The battery hood must be closed.

– Check that the hoods are correctly posi-tioned.

– The operator must be qualified to drive thetruck. The operator must be able to reachthe controls and operate them (especiallythe anti-crush device). Do not obstruct ac-cess to the controls.

Please inform your supervisor if you noticeany defects.

Use4List of checks prior to start-up

34 1152 807 80 01 EN - 02/2021 - 17

Checks and actions prior to commissioningCharging a Gel or Lead battery(wall-mounted charger)– Open the cover.

– Leave it open.

– Remove the battery disconnection handle(1) from the truck plug (2).

– Connect the wall-mounted charger.

Checking the brake

NOTE

Perform this check on a flat surface.

– Drive the machine forward

– Tilt the tiller in areas (1) and (3)

In these two areas, the machine is braked andthe drive unit is no longer powered.

Releasing the tiller in the drive area (2) sendsthe tiller into the area (3) and cuts traction.

Use 4Checks and actions prior to commissioning

351152 807 80 01 EN - 02/2021 - 17

Checking the emergency stop– Pull the emergency stop handle (4) up-

wards.

– The power supply to the machine is cut off.

– The electrical controls and motors are disa-bled.

– The electromagnetic brake is applied.

– Reconnect the emergency stop handle (4)to restore the circuits.

Checking the horn– Press the horn button (5) located on the up-

per part of the tiller.

– The horn sounds.

Use4Checks and actions prior to commissioning

36 1152 807 80 01 EN - 02/2021 - 17

Checking the anti-crush safety de-viceAnti-crush safety functionThe machine moves in the opposite directionwhen the anti-crush button (2) is pressed.

If the truck is being operated in narrow areas(such as in a lift for example), the operatormay get stuck against the wall if care is nottaken. Without an anti-crush safety device, thetiller could injure the operator.

The truck immediately moves off in the oppo-site direction when the anti-crush device onthe tiller head comes into contact with the driv-er's body. When the operator moves awayfrom the anti-crush safety device, the machinestops even if a drive direction is selectedagain.

Normal operation may be resumed after re-leasing the drive switches.

Checking the anti-crush safety device

WARNINGEnsure that the test zone is free of people and ob-jects, both in front of and behind the truck.

– Move the drive switch (1) or (3) to move thetruck towards you.

– Operate the anti-crush safety device (2).

The truck stops and accelerates in the oppo-site drive direction.

– Release the anti-crush safety button.

The truck stops.

Use 4Checks and actions prior to commissioning

371152 807 80 01 EN - 02/2021 - 17

Truck operating instructions The trucks are designed for indoor and out-door use in non-hazardous atmospheres. Thetemperature should be between -10°C and+45°C and the relative humidity of the air lessthan 95%.

NOTE

A cold store option is available for lower tem-peratures.

The places where the truck is used must com-ply with the applicable regulations (conditionof the ground, lighting etc.).

The trucks must be used on dry, clean andflat ground.

Before using the truck, it is essential to checkthe working environment. This check can takethe form of visual inspection.

The work area must be clear. The truck's pathmust be free of obstacles and people.

The forklift operator must be alert to anythingthat might prevent manoeuvres being carriedout safely. The following may create a poten-tial danger:● A person near the truck● The forklift operator must not use an MP3

player or any other electrical equipment thatcould impair awareness of his/her surround-ings

● There must be no signs of oil or grease onthe floor

The forklift operator must take care whentransporting a load. The load dimensions caninterfere with manoeuvres and restrict the fieldof vision. The speed of the truck must also bereduced as the truck could tip over whenbreaking or cornering.

The loads must be consistent, with a maxi-mum recommended height of 2 m.

For uses other than those shown above,please consult the After-Sales Service Centre.

It is important to use pallets that are in goodcondition.

Speed must be reduced when moving overobstacles to prevent the truck from becomingunbalanced and vibrations in the forklift opera-tor's arms.

The trucks can drive across ramps and shal-low inclines. With an initial lift, they can crosslarger obstacles.

WARNINGRisk of loss of stability– Always adapt your driving to the ground condi-

tions (uneven surfaces etc.), particularly hazard-ous working areas and the load.

NOTE

● To prevent the bottom of the load lift systemfrom scraping the ground, always move theload arms to the raised position before set-ting off

● Always switch off the ignition before leavingthe truck

WARNINGRisk of injuryAlways keep your hands on the controls. Never putyour hands near moving parts and assemblies with-out first lowering the load arms to the ground anddisconnecting the battery.

For effective protection, safety shoes must be worn.

WARNINGDriving safety guidelines:– The driver must drive slowly around corners and

when entering narrow passageways.– The driver must always maintain a safe braking

distance from vehicles or people in front of him.– The driver must avoid stopping suddenly, making

U-turns too quickly and overtaking in dangerousareas with poor visibility.

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CAUTIONRisk of injury

Before using a side access truck, check that the bat-tery is correctly locked.

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Driving safety guidelinesBehaviour when drivingOperators must obey the same rules withinthe plant as on the road. They must drive atspeeds appropriate for the driving conditions.

Therefore, they must drive slowly:● When cornering● Through narrow passageways● Through swing doors● In low-visibility areas● When the roadway is uneven

Operators must always maintain a safe brak-ing distance from vehicles or people in front ofthem. They must always maintain control ofthe truck. They must avoid sudden stops,making fast U-turns, overtaking other vehiclesin potentially hazardous or low-visibility areas.

Driving the truck while sitting on top of it isprohibited.

These trucks are designed to be used as apallet truck. Therefore:

● Never sit on the truck to drive it● The truck must not be used as a stepladder● This truck is not designed to transport peo-

ple● The operator must always stay within the

truck clearance● Stay in the safety area (working area de-

fined by the manufacturer)● Ensure the stability of the truck and do not

exceed its maximum capacity

Use of a telephone or radio with the truck ispermitted.

However, do not use these devices when driv-ing as they may distract you.

Take a test drive on an open surface.

NOTE

Drivers must wear safety shoes that fit proper-ly to be able to drive and brake in completesafety.

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DrivingDefining directionsNames used in the text: forward travel (1), re-verse travel (3), to the right (2) and to the left(4) refer to component installation positionwith respect to the driver's compartment.

The load is positioned at the back.

Start-up– Connect the battery plug , if necessary

– Keep the tiller in the vertical position.

– Put the throttle in neutral (centre position).

– Insert the ignition key (1) and turn it to thedesired position or enter the 5-figure codethen validate using the # key on the digi-code keyboard (default code = 00000).

NOTE

With the digicode option, when the key isturned to the 0 position the truck is in tortoisemode. The truck will still function if the key isremoved.

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Selecting the driving mode

NOTE

The ignition key may be turned to two differentpositions to choose the driving mode.

"Tortoise" position (2) : gentle accelerationand deceleration; max. speed: 4 km/h

"Hare" position (3) : strong acceleration anddeceleration; max. speed: 6 km/h

– Check the battery charge with the combinedindicator (4) and change or charge the bat-tery if necessary.

– Turn the ignition key (1) to the "hare" posi-tion (3) for normal driving mode.

NOTE

Perform a visual check on the truck beforestarting.

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Driving– Turn the ignition key to the Tortoise po-

sition (slow acceleration and deceleration)or the Hare position (faster accelerationand deceleration).

– Lower the tiller in (2) zone.

NOTE

The truck is in the drive position in the (2) po-sition. In the lower (1) or upper (3) the brake isapplied and the traction motor is switched off.

NOTE

Always operate the travel throttle slowly, asthe truck reacts immediately. Abrupt starts orbraking or reversal of direction of travel mustbe avoided at all costs.

Forward travel– Press with your thumb on the lower part of

the throttle.

– The speed increases with the movement ofthe throttle; speed is limited to 4 or 6 km/hdepending on the position of the key.

– When the control throttle is released, thetruck brakes electrically.

Reverse travel– Press with your thumb on the upper part of

the throttle.

– The speed increases with the movement ofthe throttle; speed is limited to 4 or 6 km/hdepending on the position of the key.

– When the control throttle is released, thetruck brakes electrically.

Reversing the direction of travel– Release the throttle.

– Operate it progressively in the opposite di-rection until the required speed is reached.

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Driving on upward and downwardslopesSlopes should always be approached with theload facing towards the top of the slope. Onlyslopes marked as clear traffic routes compati-ble with the truck's technical specifications canbe safely used.

DANGERThe operator must ensure that the ground is cleanand has a non-slip surface.Never travel across slopes or make a U-turn on aslope!

Do not park the truck on a slope.

Reduce speed when going down slopes.

Please observe the maximum gradients de-fined as suitable for laden and unladen trans-port.

OptiSpeed– Lower the tiller.

NOTE

The truck is only in a driving position in areas(2) & (3). In the lower (4) or upper (1) zone,the brake is applied and the traction motor isswitched off.

In zone (3) the truck can be used at full speed.The traction speed is proportional to the throt-tle activation.

In zone (2) the maximum authorised speedvaries according to the angle of the tiller.

Braking rangeUnlimited driving rangeDriving range speed limiterMaximum speed charasteristic

ABCD

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Braking

WARNINGThe quality of the floor surface affects the brakingdistance of the truck.To be taken into consideration when driving.

Gentle braking– During operation, release throttle (2) or (3).

Moderate braking– Switch throttle (2) or (3) in the opposite di-

rection of travel.

Parking brake– Release the drive direction switch (2) or (3).

The truck is braked with the electromagneticbrake when its speed approaches 0 km/h orwhen the tiller returns to the vertical position.

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Creep Speed functionThis function makes it possible to manoeuvrethe truck in confined spaces.

The tiller remains in the vertical position.

– Press the Creep Speed button (1) (tortoiseicon) on the tiller. Hold the button down.

– Gently move the drive switch forwards orbackwards depending on the manoeuvre tobe performed.

NOTE

The traction speed can be set between 0.5and 1.5 km/h. Contact the After-Sales Serviceto change this.

The Creep Speed function cancels automati-cally when the tiller is in the drive position.

CAUTIONDanger of forklift operator being trapped by the truck.Gently move the drive switch to adjust the truckspeed. This prevents it moving too quickly towardsthe operator.

NOTE

If the operator releases the Creep Speed but-ton and/or the drive switch, the vertical posi-tion of the tiller applies the emergency brakeagain.

Standby (optional)The truck can be put in energy-saving mode toprolong the service life of the battery when it isnot in use.

After a certain period of inactivity, the truckswitches off. To restart the truck, you mustswitch it off and then switch it on again, usingthe key.

This time period can be configured between 0and 10 minutes. This function is disabled bydefault.

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Timeout can be adjusted. Please call the Af-ter-Sales Service Centre.

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Operating the FleetManager™ optionDescription of the FleetManager optionThe FleetManager option allows you to controlaccess to the truck. The option is a fleet man-agement system.

You can access the system:● Either by using a keypad● Or by using a reading device for a trans-

ponder or an RFID card

The fleet manager sets the access details viathe web interface. This affects the transpondercards or PIN codes for the correspondingtrucks. It is possible to change the amount oftime for which the access authorisation is val-id.

Software is also available.

Additional options:● Shock sensor● Tools for wireless data management:

▶ GSM(2)GPRS(1) module with antenna

The options available on the truck are:● Access control● Access control and shock sensor● Access control and GPRS module● Access control, shock sensor and GPRS

module(1) GPRS: General Packet Radio Service

(2) GSM: Global System for Mobile Communi-cation

Shock sensorThis sensor allows you to record the shocksreceived by the truck.

If the truck receives a shock, it is possible toconfigure a speed reduction.

The fleet manager is the only person who isable to change certain parameters.

NOTE

Replace the sensor if it is faulty.

GSMGPRS moduleThe module consists of a GSM modem and anantenna.

The module allows you to:● Access truck information remotely● Use geolocation

The data is stored on a server.

Data is transmitted by Bluetooth (default) or byGSM module (optional).

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Commissioning a truck equippedwith the FleetManager™ option Commissioning a truck equipped with akeypad or an electronic key – Turn the switch key to start the truck.

– Enter the PIN code on the keypad. The PINcode consists of five to eight digits.

By default, no PIN code is given as a factorysetting.

If the PIN code is correct, the LED (1) is not lit.The LED (2) flashes slowly at two-second in-tervals (green colour).

No acoustic signal sounds.

– Press the Enter key (3) to confirm.

The truck is now ready for use.

NOTE

In the configuration, the fleet manager canspecify that the operator must enter a prelimi-nary code when logging in. The operator canthen assess the state of the truck.

Commissioning a truck equipped withan RFID reading device – Turn the switch key to start the truck.

– Place the RFID transponder card or theRFID transponder (4) in front of the readingdevice (3).

If the card is correct, the LED (1) is not lit. TheLED (2) flashes slowly at two-second intervals(green colour).

Two acoustic signals sound.

The truck is now ready for use.

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FleetManager™ option: Colour code for the LEDs The LEDs can have different statuses and dif-ferent colours. Below is the list of the mostcommon messages and their meanings.

Malfunction Cause SolutionLED status

Signal transmitter LED 1 LED 2

Lit continuouslyRed colour Off A long acoustic

signal sounds

Reading devicevariant: no valid

access authorisa-tion Generate a valid

access authorisa-tion using the in-

terfaceKeypad variant:no valid accessauthorisation forthe PIN code en-

tered

Keypad variant:PIN code entered

incorrect or notconfirmed using

the Enter key

Re-enter the PINcode

Lit continuouslyRed colour

Flashes onceGreen colour

A long acousticsignal sounds

The operator hasbeen granted ac-cess authorisa-

tion. But the peri-od of validity has

expired.

Use the interfaceto enter a new pe-

riod of validity

The date of thetruck is incorrect

Update the dateof the truck

Flashes quicklyYellow colour

Lit continuouslyGreen colour Memory is 80%

full Clear the memory

Flashes quicklyRed colour


A long acousticsignal sounds

upon activation

There are severalpossible causes:- Reading deviceor keypad not ac-

cessible- GPRS modulenot accessible

- Built-in re-chargeable bat-

tery flat- Memory full

Contact the After-Sales Service

Centre


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Malfunction Cause SolutionLED status

Signal transmitter LED 1 LED 2


Lit continuouslyGreen colour A shock has oc-

curred Reset the shock

Flashes quicklyBlue colour Off

The truck is con-nected via a Blue-tooth link. The op-erating data is be-

ing read. Thereading process

can take up to fiveminutes.

The truck isswitched on but isnot moving. Waitfor all of the rele-vant data to be

read. As soon asthe LEDs changeto a different sta-tus, resume work.


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Disconnecting a truck equipped withthe FleetManager™ option

NOTE

Operators must not log off intentionally whiledriving.

WARNINGAccess to the truck must be disabled.Unauthorised users are not allowed to use the truck.

Disconnecting a truck equipped with akeypad or electronic key – Park the truck in a safe place.

– Press the button (3) to log off. Keep the but-ton pressed in.

No LEDs light up. A long acoustic signalsounds.

The LED (1) lights up for a second (red col-our). The LED (2) is not lit. A long acousticsignal sounds.

The LED (1) is no longer lit. The LED (2) flash-es slowly at two-second intervals (green col-our). No acoustic signal sounds.

The truck is disabled.

– Turn the switch key to the off position toswitch the truck off completely.


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Disconnecting a truck equipped with anRFID reading device – Park the truck in a safe place.

– Briefly place the RFID card or the RFIDtransponder (4) in front of the reading de-vice (3).

The LED (1) lights up for a second (red col-our). The LED (2) is not lit. A long acousticsignal sounds.

The LED (1) is no longer lit. The LED (2) flash-es slowly at two-second intervals (green col-our). No acoustic signal sounds.

The truck is disabled.

– Turn the switch key to the off position toswitch the truck off completely.


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Transporting loadsLoad handling safety rules

WARNING

Closely follow the following instructions before pick-ing up loads. Never touch or stand on moving partsof the truck (e.g. lifting device, pushing devices, workinstallations or devices for picking up loads).

WARNINGTake care not to trap hands or feet when operatingthe truck.

Grabbing a loading unitWatch out for the following elements:● the load must be well-balanced and centred

correctly between the fork arms● the fork arms must be sufficiently slid un-

derneath the load to guarantee stability.

The load must not protrude too far over thefork arms, nor should the fork arms protrudetoo far out from the load.

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Transporting pallets or other con-tainersAs a general rule, loading units must be trans-ported one by one (e.g. pallets). Transportingseveral loading units at a time is only author-ised:● when the safety preconditions are fulfilled.● by order of the monitoring agent.

The forklift operator must ensure that the load-ing unit is properly packaged. He must onlymove loading units that have been carefullyprepared and that meet the safety require-ments.

0252_003-103

0252_003-104

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Lift control elements

Raising the fork arms– Activate the control switch (1)

Lowering the fork arms– Activate the control switch (2)

Load handling

CAUTIONRisk of injurySafety shoes must be worn.

Transporting people is strictly prohibited.

CAUTIONRisk of fallingBe careful not to touch adjacent loads or loads posi-tioned at the side or in front of the load being han-dled.

The loads are to be stacked so that they are alignedwith a small space between each of them and so thatthey do not catch each other.

Before picking up a loadEnsure that its weight does not exceed thetruck's capacity.

– Refer to the nominal capacity specified onthe truck's identification label.

– You must also make sure that the load isstable, well-balanced and centred betweenthe load arms in order to avoid droppingany part of the load.


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– Check that the width of the load is compati-ble with the width of the load arms.

Picking up a load– Approach the load carefully.

– Lower the load arms so that they can easilybe inserted into the pallet.

– Insert the load arms under the load.

– If the load is shorter than the load arms, po-sition it so that the end of the load over-hangs the end of the load arms by a fewcentimetres, in order to avoid hooking theload in front.

– Raise the load a few centimetres from itssupport.

– Withdraw the load slowly and in a straightline.

Transporting a load

Observe the following recommendations:● Drive forwards for optimum visibility● Travel up or down slopes with the load up-

hill Do not travel across the slope or make aU-turn

● Reverse travel is used for setting down theload Adjust your speed.

● Do not drive with an unstable load● Raise the forks slightly in order to pass ob-

stacles● Be careful of low passageways, low door-

ways, scaffolding, pipes etc.● Check that the width of the load is not

greater than the width of the aisle

Setting a load down on the ground– Carefully move the truck to the desired

area.

– Carefully move the load into the unloadingarea.

– Lower the load until the load arms are free.

– Withdraw the truck in a straight line.

– Raise the load arms again several centime-tres.

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CAUTIONRisk of fallingBe careful to keep clear of other loads at the side ofor behind the truck.

Before leaving the truck

NOTE

Always stop the truck on level ground awayfrom traffic routes.

– Ensure the load arms are in the lower posi-tion.

– Switch off the ignition, then remove the keyor press # on the electronic key for 3 sec-onds.

– In the event of a prolonged standstill, pullon the emergency stop handle.


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Using the folding platform(option)There are two positions for the folding platform(1):● Position A: platform raised● Position B: platform lowered

In pedestrian mode, the platform is raised.The maximum authorised speed is 6 km/h.

In ride-on mode, the platform is lowered. Themaximum authorised speed is 6 km/h.

Driving in ride-on mode To use the truck in ride-on mode, proceed asfollows:

– Lower the platform (1) in the direction indi-cated by the arrow (3)

Once the job is complete, it is necessary toraise the platform.

– Raise the platform (1) in the direction indi-cated by the arrow (2)

Driving in pedestrian mode The platform (1) is raised. The operator walksalongside the truck.

DANGERRisk of injury.Ensure that the platform is raised correctly beforewalking alongside the truck.

Ensure that the platform is correctly in the verticalposition.

DANGERRisk of injury.In pedestrian mode, stay sufficiently far away fromthe truck. The truck must not be able to strike the op-erator's feet.

Wear safety shoes.

2276

1

2

3

A

B

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Cold store usage (option)DesignationYour truck is fitted with special equipment foruse in cold stores. It can be used for two oper-ating ranges and carries a cold store label.

The cold store equipment for the truck con-sists of using specialised oils (for the hydraulicinstallation and the gears) suitable for coldstores.

Proper usageOperating range 1: permanent use in areaswith temperatures of –5 °C and for short peri-ods of time down to –10 °C. Parking outsidethe cold store.

Operating range 2: alternating use indoorsand outdoors in compliance with the rules be-low, temperature range from –32 °C to +40 °C.Parking outside the cold store. This use re-quires hydraulic oil for cold stores as given onthe list of maintenance characteristics.

Use

GeneralThe change in temperature between the coldindoors and the heat outside causes conden-sation. This water can freeze when the truckgoes back into the cold store and jam themoving parts of the truck. This is why thelength of time the truck remains in the differenttemperature areas given below for the two op-erating ranges must be strictly adhered to.

The temperature of the traction batteries mustnever fall to the temperature of the cold store,otherwise they will stop working.

Prior to start-up

CAUTIONThe truck must be dry and at operating temperaturebefore being used in the cold store.

1044_920-001

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– Drive the truck for approximately 5 minutesand operate the brakes several times to en-sure the truck operates safely.

– Operate all the lifting functions severaltimes. This warming up phase is required toallow the oil to reach operating temperature.

Use

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

Operating range 2Alternating use indoors with temperaturesdown to –32 °C and outside with temperaturesup to +25 °C for short periods of time even upto +40 °C. The truck must not leave the coldarea for more than 10 minutes, because thislength of time is not long enough for the for-mation of condensation. If the truck stays out-side for longer than 10 minutes, it must remainoutside for long enough to allow the conden-sation to run away. This generally takes atleast 30 minutes.

DANGERIf the condensation freezes in the cold store, themoving parts that have become jammed must notbe freed by hand.

Parking– Always park the truck outside the cold

store.

CAUTION

The batteries must not remain discharged or unusedin the cold store overnight.

– Charge the battery outside the cold storeand use a spare battery.

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Parking the truck WARNING

Risk of injuryNever leave the truck with the load in the raised posi-tion.

Do not stop the truck on a slope. If this is absolutelynecessary, make sure it is safely secured usingchocks.

Stopping the truck – Immobilise the truck.

– Lower the load arms.

– Switch off the ignition (key or electronickey).

– Pull the emergency stop handle.

Restarting work – Switch on the ignition again (key or elec-

tronic key).

– Press in the emergency stop handle.

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Handling the batteryBattery typeTrucks can be fitted with different types of bat-tery. Comply with the information indicated onyour battery's type plate, as well as with itsfeatures.

WARNINGThe weight and size of the battery influence the sta-bility of the truck.The new battery must weigh the same as the oldone. Do not remove extra weight or change its posi-tion.

CAUTIONBe careful not to damage any wiring when replacingthe battery.

Order pickingMaintenance personnelThe battery must be replaced by speciallytrained personnel. Personnel must follow themanufacturer's instructions for the battery, thecharger and the truck.

It is also necessary to follow the battery main-tenance instructions.

Fire protection measures

WARNING

Do not smoke or create a flame whenhandling batteries. There must be nocombustible material or tools that pro-duce sparks within a minimum radius of2 m around the truck and the batterycharger.

The work area must be well ventilated.Fire extinguishers must be provided andlocated near the work area.

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Parking the truck securelyWhen the battery is being worked on, the truckmust be parked safely. The truck can only berestarted when the covers and connectorshave been put back in the operating position.

Opening/closing the battery cover Opening– Park the truck.

– Lower the load arms.

– Turn the key switch off.

– Lift the cover (1).

Closing

CAUTION

Keep fingers away from moving parts to avoid anyrisk of them being trapped.

– Close the cover (1).

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Charging the battery using an exter-nal charger

CAUTIONThe battery may be damaged if discharged beyond agiven limit.– Immediately charge the battery.

– Safely park the truck

– Before charging, check the condition of thebattery cable and the charging cable andreplace these cables if necessary.

– Disconnect the battery connector (4).

– Connect the battery plug to the charge sta-tion connector.

WARNING

Only disconnect the battery connector from the bat-tery charger when both the battery charger and truckare switched off.

NOTE

Follow the instructions provided by the batteryand battery charger manufacturers (equalisingcharge)

WARNINGRisk of damage, short circuit or explosion.Do not place metal objects or tools on the battery. Nosmoking!

WARNINGThe electrolyte (diluted sulphuric acid) is toxic andvery caustic.Follow the safety regulations when handling batteryacid.

WARNINGExplosive gases are generated during battery charg-ing.– Ensure the work area is well-ventilated.


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On-board chargerPrecautions for installation and useThe on-board charger means you no longerhave to use a charging room. In fact, thischarger can be connected to any 2P+T 230 V16 A socket. However, before charging thisway, the user must ensure that the locationselected for charging satisfies all the requiredsafety guarantees:● The electrical installation must comply with

standard NF C 15 100.● The electric wall socket must be a 2 pole +

earth 16 A 230 V type that is correctly con-nected and protected.

● Before charging, check the condition of theconnections and cables (retighten, as re-quired).

● Charging must be carried out in an areawhere there is no condensation or pollutionas well as sufficient ventilation.

● The charger must not be exposed to oil,grease and other similar substances.

● Charging must be carried out with the truckstopped.

● The increase in the temperature of the unitin relation to the ambient temperature is10°C maximum. That of the expelled air is25°C maximum. Wait 10 minutes after stop-ping the charger before touching the unit.

● Since the charger is cooled by forced venti-lation, do not block the air inlets and outlets.There must be sufficient air circulation tothe outside.

Electrical characteristics of the charger

Mains voltage 190 V < U < 260 V

Network frequency

50 / 60 Hz +/-1% (au-tomatic adaptation)No inrush current tothe mains connection

Maximum outputpower 1040 W +/-3%

Maximum output cur-rent 35 A +/-2%

Nominal battery volt-age 24V

Tolerance on the volt-age of bearing U 1%

Battery characteristics

Battery type Gel or open lead-acidbattery

Number of compo-nents 12 2 V components

Capacity

140 Ah minimum to375 Ah maximum(adaptation of thecharging curve by aselector)

General conditions for use

Storage temperature -45° C to +80° COperating tempera-ture -15° C to +40° C

Relative humidity 90%Weight 2 kgVolume 1.4 litres

Electrical safety● Protection against inversion of battery po-

larity: the charger is protected by an outputrelay. After reconnecting the battery in theright direction, the charger restarts chargingwithout requiring human intervention.

● Mains protection: by a 250 V 10 A 5x20timed fuse. The mains fuse is fitted directlyto the electronic card. The user is not au-thorised to replace this fuse. If this fuse isfaulty, the charger must be returned to theservice centre.

RelayA 2x1.5 mm2 lead is used to connect the safe-ty relay. The relay has a maximum cut-offpower of 16 A.● Contact A: blue wire● Contact B: brown wire


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● When the charger is neither connected tothe mains nor the battery, the "contact A"and "contact B" outputs are electrically insu-lated from one another.

● When the charger is connected to the bat-tery only, the "contact A" and "contact B"outputs are electrically connected.

● When the charger is connected to themains and the battery, the "contact A" and"contact B" outputs are electrically insulatedfrom one another.

● When the charger is connected to themains only, the "contact A" and "contact B"outputs are electrically insulated from oneanother.

(see wiring diagram)

Other charging characteristicsMaintenance charges

If the charger stays connected to the mains, itrestarts a charging cycle every 48 hours afterthe end of the previous charge in order tocompensate for self-discharge.

Partial recharging

The charger adapts automatically to the bat-tery discharge situation and therefore allowsany type of partial charging to be carried out("opportunity charging").

The overcharging calculation takes into ac-count partial recharging. The mixture is alwayssufficient, without needless water consump-tion, which prevents premature wear of thebatteries (often due to overlong charging peri-ods) and reduces the need for maintenance.

Protection during chargingMains micro-break protection

If the mains power is cut off, all the chargingparameters in progress are stored in the mem-ory for 13 minutes. As soon as the mains pow-er returns, charging resumes from the point (I,U) at which it was cut off, with the number ofAh already injected stored in the memory.

If the cut-off period is longer than 13 minutes(the truck could have been used), a completecharging cycle is initialised.

Time protection

If during phases I1 + P + U > 16H, the chargerbecomes faulty. This can happen when a bat-tery has a short-circuited component. Simplyreset the mains to cancel the fault.

Temperature safety

Since the charger is cooled by ventilation, theair inlets and outlets must never be blocked.

The fan runs when the mains power is con-nected. It stops when charging is complete orwhen the mains power is disconnected.

The charger supplies reduced power if theambient temperature exceeds the usage tem-perature range, in order to protect itself (thecharging period will be extended in this case).

The charger stops if the micro-controller de-tects a temperature measurement fault.

Using the chargerBefore charging, it is necessary to ensure thatthe location selected for charging satisfies allof the safety requirements.

NOTE

The charger is compatible with wet lead andgel batteries with a maximum capacity of400 Ah.

The charger is designed:

– To be incorporated in the truck

– To stay permanently connected to the bat-tery

– To operate in all positions

– To stay connected to the mains during peri-ods when the truck is not being used to en-sure the availability of the machine


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CAUTION

Do not disconnect the battery connector duringcharging (green indicator light flashes).

The truck cannot be operated during charging.

The on-board charger is intended for recharg-ing the battery.

– Switch off the truck.

Do not pull the emergency stop handle. Thisoperation cuts off the circuits and stops thebattery from charging.

– Open the cover of the battery compartmentto ensure good ventilation.

– Connect the cord to the mains socket.

– Connect the charger plug to a mains wallsocket.

Phase Green LED Red LEDMains socketdisconnected Off Off

Chargingphases Flashing Off

Stopped /Equalisation /Maintenancephase

Continuouslylit Off

Chargingprocess toolong

Off Continuouslylit

Charger po-larity reversed(+bat and -batcharger ca-bles reversed,with the bat-tery remain-ing normallyconnected tothe truck as-sembly)

Continuouslylit

Continuouslylit

Phase Green LED Red LEDBattery polari-ty reversed Off Off

Selector inneutral posi-tion

Flashing Flashing

– Avoid interrupting the charging procedureuntil it is complete (to optimise battery serv-ice life).

CAUTIONIt is strictly prohibited to use an on-board chargerother than the one recommended.

CAUTIONRisk of damage to the mains cable resulting in elec-tric shock and/or burns!Park the truck sufficiently close to the mains wallsocket to ensure that the mains cable on the on-board charger is not taut when connected and charg-ing.

CAUTIONRisk of damage to the mains cable due to frequentoperator handling. Risk of electric shock and/orburns!The mains cable must be checked regularly as partof periodic statutory checks and maintenance opera-tions.


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Gel or Lead batteries: Adjusting theon-board charger ● When the truck is delivered with its battery,

the charger settings are adjusted in the fac-tory.

● The adjustment depends on the selectedbattery.

Charging curve selectorThe curve is selected using the selector loca-ted on the front face of the charger.

The curve selector is protected by a cap.

The four thin lines indicate neutral positions.The charger does not flow and the two diodesflash simultaneously to indicate that no curvehas been selected.

The four thick lines indicate the four chargingcurves:● open lead-acid battery with a capacity be-

low 210 Ah● open lead-acid battery with a capacity

greater than 210 Ah● gel battery with a capacity below 210 Ah● gel battery with a capacity greater than

210 Ah

If the battery is changed during the service lifeof the truck, it is essential to ensure that thecharger settings correspond to the new batterytype. Any modification to the settings must becarried out by a qualified technician.

Changing the batteryMaintain a safe distance for battery removal toavoid damaging the truck.


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– Open the battery compartment (1).

– Unplug the battery connector (2).

In order to avoid short-circuits, it is recommen-ded that batteries with polar terminals or un-protected connections be covered with a rub-ber mat.

– Unlock the battery.

– Attach the lifting device (1) correctly to thebattery (2) (see the lifting device user man-ual), then remove it from the truck.

– The lifting device must exercise verticaltraction in order to avoid the boot beingdamaged. The hooks must be placed sothat they cannot fall on the battery cellswhen the lifting device is slackened.

CAUTION

Use small hooks for slinging the battery.


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Gel and lead side access batteries:changing the battery using a trolleyPositioning the truck– On level ground, move the pallet truck

close to the trolley (2).

– Align the battery compartment with theempty space on the trolley (1).

– Using the load arm lifting/lowering controls,adjust the height of the battery compart-ment to that of the edge of the trolley (3).

– Switch off the ignition and pull the emergen-cy stop handle.

CHANGING THE BATTERYREMOVE THE DISCHARGED BATTERY:

– Open the battery case cover.

– Fit the battery connector on the cells.

– Push the lever towards the battery(A) thenlift the notch (B).

– Lift the lever(C) to release the battery

– Raise the opposite stop of the lever.

– Pull the discharged battery onto the trolley(2).

– Turn the lock on the trolley to the "closed"position to lock the battery on the trolley (2).

– Connect the charged battery (3) to the truckusing an extension lead.

NOTE

Use a fairly long extension lead to allow thetruck to move.

– Connect the battery connector and thenswitch on the ignition.

– Move the truck forwards or backwards toalign the battery compartment with thecharged battery (3).


– Disconnect and remove the extension lead.


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– Turn the retaining lock of the charged bat-tery.

INSTALL THE CHARGED BATTERY:

– Fully insert the charged battery in its com-partment.

– Fold the stop down.

– Lift the lever slightly and then unlock thenotch.

– Fold the lever down to lock the battery.

– Connect the recharged battery.

– Close the battery cover.

CAUTION

Place the cables correctly above the battery to pre-vent them from being damaged when a battery is re-moved from or inserted into its compartment.

CAUTION

During operations to fit the battery, keep your fingersaway from moving parts to avoid any risk of them be-ing trapped. We recommend the use of gloves.

CAUTION

Before using this machine, ensure that the battery iscorrectly installed and that its cover is correctlylocked.


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Side access battery: changing thebattery using a moveable support

CAUTION

During operations to fit the battery, keep your fingersaway from moving parts to avoid any risk of them be-ing trapped. We recommend the use of gloves.

Positioning the truck– On level ground, move the pallet truck close

to the moveable support


CHANGING THE BATTERYREMOVE THE DISCHARGED BATTERY:

– Open the battery case cover.

– Fit the battery connector on the cells.

– Push the lever towards the battery(A) thenlift the notch (B).

– Lift the lever (C)to release the battery

– Lift the stop

– Pull the discharged battery onto the movea-ble support.

– Lock the discharged battery on the movea-ble support using the hook.

– Release the moveable support by lifting upthe 2 wheel locks with your foot and takethe discharged battery to the charging sta-tion.

INSTALL THE CHARGED BATTERY:

– Fully insert the charged battery in its com-partment.

– Fold the stop down.

– Lift the lever slightly and then unlock thenotch.

– Fold the lever down to lock the battery.

– Connect the recharged battery.

– Close the battery cover.


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CAUTION

Before using the machine, ensure that the battery iscorrectly installed and that its cover is correctlylocked.


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Handling the truck in an emergencyTruck towing procedureIt is not possible to tow the truck with no elec-trical function. The electromagnetic brake re-mains in the closed position.

Truck towing is authorised with a rigid connec-tion (tow bar) if the truck to be towed can nolonger be braked. Check that the towing vehi-cle is sufficiently powerful to pull and brake thetruck being towed.

Moving with no battery

NOTE

In the event of an electrical fault or no battery,it is possible to unlock the brake manually.

CAUTIONThis procedure must be carried out by authorisedpersonnel.

– Unload the fork arms, then disconnect thebattery.

– Remove the engine cover.

– Two M5 X 35 screws (1) are required.

– Screw the screws (1) to the brake (2) in theholes (3). The brake is then unlocked.

CAUTIONThe truck must only be towed at low speeds.

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1

Use 4Handling the truck in an emergency

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– After towing, chock the truck to prevent itfrom moving.

– To re-establish brake operation, unscrewand remove the two screws (1).

– Refit the covers.

WARNINGIt is essential that the covers are correctly refitted be-fore the machine is used.

0252_003-110

3

2

Use4Handling the truck in an emergency

76 1152 807 80 01 EN - 02/2021 - 17

Handling the truck in specific situationsSlinging the truck

CAUTIONRisk of injuryUse a hoist and hooks of sufficient capacity. Refer tothe load weight shown on the truck's data plate.

– Attach a sling or a hook to the 2 points indi-cated (3).

CAUTIONRisk of damage to the truckIt is strictly prohibited to sling the truck by the tiller orother points not designed for this.

Wedge battens between the chassis and slings toprevent damage.

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

Lifting the truckTo lift the truck, its sub-assemblies or addition-al equipment, lifting devices must be hookedonly to the appropriate lifting points. Whenjacking, take appropriate measures (usingchocks or wooden blocks) to prevent the truckfrom slipping or tipping over.

Use 4Handling the truck in specific situations

771152 807 80 01 EN - 02/2021 - 17

JackingThe truck must be jacked and chocked in or-der to perform certain maintenance opera-tions. Always make sure:● To use a jack with an adequate lifting ca-

pacity,● Make sure that the truck is parked on level

ground and is secured against rolling andtipping.

WARNINGElectrical hazardsDisconnect the battery connector before lifting thetruck.

Lifting by the chassis– Position the truck so that the fork arms

touch the wall.

– Lift up the truck until the wheels are no lon-ger in contact with the ground.

– Raise the truck with chocks.

Transporting the truck

CAUTIONAlways switch off the ignition and disconnect the bat-tery.Never tie down or sling the truck by the control unitor other points not designed for this.

CAUTIONRisk of damage to the truck.Use a hoist and woven NON METALLIC slings withan adequate lifting capacity. Refer to the load weightshown on the truck's capacity plate.

The lifting operations must be performed by qualifiedpersonnel.

Trucks are generally transported by road or byrail.

Use4Handling the truck in specific situations

78 1152 807 80 01 EN - 02/2021 - 17

The truck must be suitably protected from theeffects of the weather during transport andstorage.

To load or unload the truck, use an inclinedplane or a mobile ramp.

If the truck is out of service or if the batteryhas been removed, sling the truck. See Chap-ter 4 Slinging the truck.

DANGERDanger of death.Do not stand within the hoist's operating radius orbelow the lifted truck.

Transporting the machineIf the truck has to be transported, please en-sure that it is properly chocked and protectedagainst bad weather.

WARNINGRisk of truck losing stabilityExercise great care when moving a truck that has nobattery and is equipped with reinforced stabilisers.

Transporting the truck in the liftThe truck must only be taken in lifts with anadequate loading capacity that are designedfor this purpose, and for which authorisationhas been received from the operator. Insidethe lift, the truck must be immobilised so thatno part is in contact with the wall of the liftcage.

A minimum safety distance of 100 mm fromthe walls of the lift must always be observed.

Anyone transported with the truck must onlyenter the lift after the truck has been correctlyimmobilised and they must exit the lift first.

Driving on loading bridgesBefore crossing a loading bridge, the operatormust make sure it is properly attached and se-cured and its load capacity is sufficient. Crossthe loading bridge slowly and carefully. Thedriver must be sure that the vehicle to be en-tered is secured sufficiently against movement

and that it can support the load of the forklifttruck.

The lorry driver and lift truck operator must co-ordinate the departure time of the lorry.

Use 4Handling the truck in specific situations

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Use4Handling the truck in specific situations

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5

Maintenance

General maintenance informationGeneralThe following instructions contain all the infor-mation required for servicing your truck. Carryout the various maintenance work in compli-ance with the maintenance plan. This will en-sure that your truck is reliable and in goodworking order and that the warranty remainsvalid.

Service planMaintenance work must be carried out accord-ing to the hour meter. Please consult thetruck's maintenance plan.

The service plan is followed by advice to facili-tate work.

Maintenance intervals must be reduced if thetruck is used under harsh conditions (extremeheat or extreme cold, large quantities of dust).

Grade and quantity of lubricants andother consumablesOnly lubricants and other consumables speci-fied in these operating instructions are author-ised for use during maintenance work.

Lubricants and other consumables requiredfor truck maintenance are listed in the mainte-nance specifications table.

Never mix different qualities of grease or oil. Ifit is absolutely necessary to change brands,make sure to flush thoroughly beforehand.

Before changing any filters or working on thehydraulic system, thoroughly clean the surfaceand the areas around the part.

All containers used to pour oil must be clean.

0.0 h

0252_003-065-V2

Maintenance5General maintenance information

82 1152 807 80 01 EN - 02/2021 - 17

Servicing and maintenance personnel training and qualificationTruck maintenance must only be carried outby qualified and authorised personnel.

The annual inspection for prevention of acci-dents at work must be carried out by a personqualified to do so. The person carrying out thisinspection must provide their expertise andopinion without being influenced by economicfactors or company internal issues. Safety isthe only critical deciding factor.

The person responsible for carrying out the in-spection must have sufficient knowledge andexperience to be able to assess the conditionof the truck and the efficiency of the protectiveinstallations in accordance with the technicalregulations and principles established forchecking industrial trucks.

Battery maintenance staffBatteries must only be recharged, maintainedand changed by specially trained personnel.Personnel must follow the manufacturer's in-structions of the battery, the battery chargerand the truck.

It is essential to follow the battery mainte-nance instructions and the battery charger op-erating instructions.

Maintenance operations that do not require special trainingSimple maintenance operations such aschecking the hydraulic fluid level or checkingthe battery electrolyte level can be carried outby persons with no special training.

A specific qualification is not necessary.

Refer to the maintenance section of this man-ual for further information.

Ordering spare parts and consumablesSpare parts are provided by our spare partsservice department. You will find the informa-tion required to place an order in the spareparts and fitting catalogue.

Only use spare parts recommended by themanufacturer.

Unauthorised spare parts may increase therisk of accidents due to faults relating to quali-ty or incorrect choices. Anyone who uses non-compliant spare parts must assume full re-sponsibility in the event of an accident.

Maintenance 5General maintenance information

831152 807 80 01 EN - 02/2021 - 17

Maintenance safety guidelinesServicing and maintenance measures To avoid accidents during servicing and main-tenance operations, take all necessary safetymeasures. For example:

– Ensure that there is no risk of the truckmoving or starting up unexpectedly. For thisreason, remove the battery connector.

Working on the electrical equipment Operations on the truck's electrical systemmust only be carried out when there is no volt-age supply.

Operating checks, testing and adjustmentwork on parts supplied with voltage must onlybe carried out by personnel:● who have received detailed instructions● who have been authorised to perform this

work● who have taken the necessary precaution-

ary measures.

Rings, metal bracelets etc., must be removedbefore carrying out any operations on electriccomponents.

Remove the electric equipment (which compri-ses electric components such as the tractioncontroller) before carrying out any welding op-erations. This precaution prevents this electricequipment from being damaged.

Operations on the electric system require theconsent of the manufacturer.

Safety devices After any repair or maintenance work, it isnecessary:● to refit all safety devices● to check these for correct operation.

Maintenance5Maintenance safety guidelines

84 1152 807 80 01 EN - 02/2021 - 17

Technical inspection and maintenance characteristicsAssembly Item/Lubricant Capacities/Setting values

Main hydraulic system Hydraulic oil 1,25 lReducer Reducer oil 0.9 litre maximumTraction and pump motor Fuses Power 125A, Quantity: 1Control cable harness Fuses Control 7.5A, Quantity: 1Traction motor Maintenance free 1.2 kW (AC)

Pump motor Maintenance free

EXU16, EXU18 : 1,0 kWEXU16,18,20CF*, EXU20 : 1,2kWEXU22, EXU22CF* : 1,4 kW

Battery Distilled water As requiredJoints Lithium grease As required

*CF: Cold store

Maintenance 5Technical inspection and maintenance characteristics

851152 807 80 01 EN - 02/2021 - 17

Access to the technical com-partment– Fully raise the pallet truck's load arms to fa-

cilitate these operations.

CAUTION

Before removing anything from the truck– Turn the key switch off.– Pull the battery connector handle (emergency

stop handle).

Opening the lower cover– Unscrew the 2 screws (1) that hold the cov-

er in place.

– Unclip the cover at both ends

– Raise and pull back the lower cover.

Maintenance5Access to the technical compartment

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Opening the front coverAfter removing the lower cover:

– Unscrew the 4 screws (2) that hold the cov-er in place.

Accessing the pump unitAfter removing the front cover:

– Remove the plastic cover by unscrewingthe 2 screws (3) to provide easy access tothe pump unit.

Maintenance 5Access to the technical compartment

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– Then remove the mounting bracket (4)

Maintenance5Access to the technical compartment

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Accessing the reducer andthe brakeTo access the reducer and the brake:

– Turn the tiller to the right or left-hand stop.

– Unscrew the 2 screws (3)

– Unscrew the 2 screws (2) located eitherside of the two 1/2 covers.

– Remove the two 1/2 covers.

Maintenance 5Accessing the reducer and the brake

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1000-hour/annual maintenance plan

Maintenance operations every 1000 hours

Depending on the application, environmental conditions and driving style, the following proce-dures should be carried out every 1000, 2000, 4000, 7000 and 8000 hours

Preparatory tasks

Clean the truck (if necessary)Check the error codes (using the diagnostic tool)Traction motorCheck that the cables and bundling are in good conditionTransmissionCheck for any possible oil leaks from the transmission gearLubricate the ring gearSteering/Wheels/BrakingCheck the wear on the tyre tread of the wheelsCheck the brake air gapCheck that the nuts are tightElectrical equipmentClean and blow out the electrical plateCheck the mounting of the electrical connectionsCheck and adjust the battery electrolyte levelCheck the condition and mounting of the battery cablesHydraulic systemCheck the system oil level

Check the system for leaks

Load lift systemCheck the level of wear on the rings and clevis pins

Oil or generously grease the rings and clevis pins

Final tasksCheck the general condition of the forks and the chassis

Maintenance51000-hour/annual maintenance plan

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3000-hour maintenance schedule

Additional maintenance operations every 3000 hours

Depending upon use, environmental conditions and driving style, the following procedures mustbe performed every 3000, 6000 and 9000 hours

InformationCarry out all 1000-hour maintenance workTransmissionDrain the transmission gear oilHydraulic systemDrain the hydraulic system

Maintenance 53000-hour maintenance schedule

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Chassis, bodywork and fittingsClean the truckWashing instructions– Always park the truck as specified.

– Disconnect the battery connector (4).

CAUTION

– Disconnect the battery connector when washingthe truck.

Washing the exterior of the truck

WARNING

Do not use inflammable fluids for cleaning. Observethe above safety precautions for preventing sparksthrough shorts (disconnecting the battery connector).When the truck is being cleaned, carefully cover allvulnerable components, particularly electric compo-nents. Observe the manufacturer’s instructions forhandling the cleaners.

– Clean the truck exterior with water andcleaning agents soluble in water (sponge,rags).

– Clean especially the oil filler openings andthe surrounding area.

– Grease the required assemblies (mast, con-trols and joints).

Cleaning the electrical system

WARNING

Do not aim the steam cleaning device directly onelectric motors and other electric components,brakes and bearings.

NOTE

Use only dry cleaning agents as cleaningagents. Do not remove covers, etc.

– Clean electrical components with a non-metallic brush and and blow dry with aweak jet of air.

Maintenance5Chassis, bodywork and fittings

92 1152 807 80 01 EN - 02/2021 - 17

After washing the truck.– Dry the truck thoroughly (eg with com-

pressed air).

– Take the truck back into operation accord-ing to instructions.

If moisture has penetrated the motors despitethe precautionary measures, dry them firstwith compressed air; if not, there is the risk ofshort circuits! The truck must ONLY then beturned on and taken into operation to preventany damage due to corrosion.

Clean the battery and its compart-ment

WARNINGRisk of injuryThis task must be carried out by a person wearingacid-resistant protective gloves and industrial gog-gles. Follow the safety regulations described in previ-ous chapters.

ENVIRONMENT NOTE

Do not pour acid-bearing wash water downthe drain. For more information, see the bat-tery instructions.

Gel battery– Check for traces of sulphate in the compart-

ment and frame.

– If there is only minimal sulphate build-up,just wipe the top of the cells with a dampcloth.

– If sulphate build-up is heavy, you will needto take out the battery, jet wash it and cleanthe frame.

Lead battery– Check that there are no electrolytes at the

bottom of the compartment by connectingthe rubber suction bulb supplied with thebattery to the plastic pump tube.

Maintenance 5Chassis, bodywork and fittings

931152 807 80 01 EN - 02/2021 - 17

– Pump off any electrolyte that may have spil-led between the cells.

– Clean the top of the cells with a damp cloth.

CAUTION

In case of heavy sulphate build-up or excessive elec-trolyte spillage, please contact the After-Sales Serv-ice Centre.

General information on battery maintenance DANGER

Risk of injuryBefore carrying out any operations on the electric in-stallation, turn the truck power supply off. Disconnectthe battery connector.

Precautions to be taken during batterymaintenance The plugs on the battery cells must always bedry and clean.

Neutralise any spilt battery acid immediately.

The battery terminals and lugs must be clean,lightly covered with grease for terminals andsecurely tightened.

Charging the batteryDuring the charging process, the surface ofthe battery cells must be clear to ensure suffi-cient ventilation.

Do not place metal objects on the battery.

The battery cover must remain open duringcharging. See the chapter entitled Batterycharging using an external charger.

Battery typeLead or gel batteries are used. It is advisableto choose a compatible charger.

Before charging, ensure that the charger issuitable for the type of battery.

CAUTIONGel batteries are subject to specific charging, mainte-nance and treatment instructions. A non-compatiblecharger may result in a battery failure.Observe the manufacturer's recommendations.

NOTE

● The discharge indicators used to check thebattery must also be suitable for the type ofbattery.

● Contact the relevant After-Sales ServiceCentre.

Charging the battery – Park the truck in an area without condensa-

tion or pollution and with sufficient ventila-tion.

– Stop the truck.

– Pull the emergency stop handle.

– Open the battery hood.

– Do not disconnect the battery plug.

CAUTIONDo not expose the charger to water, rain, oils, greaseor any similar substances.The charger becomes hot during the operation.

Maintenance5Chassis, bodywork and fittings

94 1152 807 80 01 EN - 02/2021 - 17

CAUTIONDo not obstruct the ventilation. Allow the charger tocool down for 10 minutes after charging is completebefore touching it. Do not use the charger out of thetruck.

Folding platform maintenance The folding platform must be checked regular-ly. The following operations must be carriedout at least every three months or every 500hours.

– Check that the folding platform operatescorrectly

– Clean and lubricate the articulated parts ofthe platform

Maintenance 5Chassis, bodywork and fittings

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Steering and wheelsServicing wheels and rollersCheck the tyres and the wear on thewheels and rollersThe tyre tread on the drive wheel (1), the sta-bilising wheel (2) and the rollers (3) must notbe damaged.

DimensionsDrive wheel 230 x 75 mmStabiliser wheels 125 x 40 mmSingle rollers 85 x 100 mmDual rollers 85 x 80 mm

– Replace damaged or worn wheels with newwheels, and damaged or worn rollers withnew ones.

CAUTIONA wrongly adjusted stabilising wheel can lead to sta-bility problems.This adjustment must be carried out by our servicedepartment.

Adjusting the height of the stabilis-ers

NOTE

Adjusting the clevis (1) with new drive wheeland stabiliser wheels R = 22 mm.

PLEASE NOTE:● Lower the stabilisers to stabilise the truck.● Lift the stabilisers if the truck often encoun-

ters obstacles and if grip must be improved.

Follow the instructions below to adjust theheight of the stabilisers:

– Loosen the lock nut (2) (36 spanner) byholding the ball bearing (3) by its flat sur-face (36 spanner)

Maintenance5Steering and wheels

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– Tighten the clevis (1) using a 14 mm Allenkey to lower the wheel or loosen the clevis(1) using a 14 mm Allen key to lift the wheel

– After adjustment, lock the clevis (1) with thelock nut (2) tightened to a torque of 35 Nm

NOTE

To screw, unscrew or lock the clevis (1) al-ways hold the ball bearing (3) by its flat sur-face (36 spanner) during the procedure.

Maintaining the reinforced stabilis-ers (option)Trucks may be equipped with two damper sta-bilisers (1). They ensure the dynamic stabilityof the truck.

Stabilisers do not require any specific mainte-nance or adjustment work. Wheel wear (drivewheel and stabiliser wheel) is automaticallycompensated.

However, it is necessary to check the condi-tion of the stabilisers:● No significant damage to the superstructure

(2)● The damper cylinder pins must not be twis-

ted● No oil leakage must be present on the

damper cylinder. This cylinder must be in-side the spiral spring

● No damage to the rollers (3). The wheelsmust rotate freely

● No locking at the level of the upper bearing(4)

● Ensure that the wheel nuts are correctlytightened

WARNINGRisk of loss of dynamic stabilityThe dynamic behaviour of the device must be moni-tored, particularly when turning. The behaviour of thetruck must be the same when cornering, whetherturning to the left or right. If there is a difference inbehaviour, please contact the After-Sales ServiceCentre. Only the technician can replace the two sta-bilisers if deemed necessary.

Maintenance 5Steering and wheels

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Regular maintenance of the trans-mission gear To increase the service life of the transmissiongear, 2 grease nipples (1) have been added toits turntable.

It is therefore possible to regularly lubricatethe transmission gear.

NOTE

Use the lubricants recommended by the man-ufacturer.

Maintenance5Steering and wheels

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Electrical equipmentChecking the fuses– Control fuses are accessed by removing the

front hood.

The 125 A fuse (1) protects the traction andlifting power circuit.

The 7,5 A fuse (2) protects the control circuit.

We recommend that this operation be carriedout by our After-Sales Service Centre.

Checking the condition of cables,terminals and battery connector– Check that the cable insulation is undam-

aged and that there are no signs of over-heating at the connections.

– Check that the "+" and "-" output terminalsare not sulfated (presence of white salt).

– Check the condition of the power outlet con-tacts and the presence of the keying pin.

– Check the condition of the locking tab onthe battery connector.

CAUTION

The points mentioned above can cause serious inci-dents. In the event of a fault, please contact the Af-ter-Sales Service.

Maintenance 5Electrical equipment

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Battery maintenanceThe operations described below relate to leadbatteries with liquid electrolyte. For batterieswith gel electrolyte, which are said to be"maintenance-free", please refer to the manu-facturer's instructions.

WARNING

Avoid contact with the acid. Do not create a short-cir-cuit. Refer to the recommendations in the dailychecks section. The electrolyte contains sulphuricacid, which is a hazardous product. Wear gloves andgoggles when working on the battery. In case of con-tact with eyes or skin, rinse immediately with cleanwater, then seek medical advice if necessary. Charg-ing the battery releases hydrogen, which can createan explosive mixture. Do not create sparks, do notsmoke and keep naked flames away from a batterywhich is being charged or has recently been charg-ed. To prevent the accumulation of hydrogen, keepthe battery cover open during charging. Charge thebattery in a well-ventilated room. Do not place metalobjects on the battery: there is a risk of creating ashort-circuit.

CAUTION

Before commencing work, unplug the battery con-nector by pulling the emergency stop handle.

Electrical equipment, testing electrolytelevel and topping up with water– This check and any topping up required

should be carried out every week, aftercharging an open lead battery only.

– Turn off the key switch, open the cover anddisconnect the battery connector.

– Check the level, which should be up to thebase of the plug, slightly above the splashguard.

– Add demineralised water to top up cells witha low water level.

– Then refit the plugs.

Maintenance5Electrical equipment

100 1152 807 80 01 EN - 02/2021 - 17

CAUTION

Only top up with demineralised water. Never top upbefore charging (risk of overflow). Do not overfill thecells.

NOTE

For more information, refer to the instructionssupplied with the battery.

Electrical equipment: checking the elec-trolyte densityMeasuring the density gives an accurate indi-cation of the charging status of each cell in anopen lead battery only. This measurement canbe taken before or after charging:● Minimum density of an 80% discharged bat-

tery: 1.14● High density, battery 100% charged: 1.29 to

1.32 (depending on make)

– We recommend a reading every 1 or 2weeks.

– Note down the values read in your batterymonitoring logbook.

– Lift the cover over each cell plug as descri-bed above.

– Carefully record the specific gravity of eachcell with the hydrometer.

– Close the various stoppers after measure-ment.

NOTE

If the density in the cells differs or it is very lowin certain cells, contact our service engineers.Allowing the battery charge to fall below thethreshold of 1.14 is very detrimental to itsservice life.

Maintenance 5Electrical equipment

1011152 807 80 01 EN - 02/2021 - 17

Hydraulic systemsOil level check

– Lower the load arms completely.


– Pull back the cover of the technical com-partment (see description in ″Access to thetechnical compartment″).

– The oil level must be in the centre betweenthe minimum and maximum marks on thetank for correct use of the truck functions.

– Top up if necessary.

– Replace and tighten the plug afterwards.

CAUTION

Only use hydraulic oil that complies with the specifi-cations (see lubrication table).

Maintenance5Hydraulic systems

102 1152 807 80 01 EN - 02/2021 - 17

Hydraulic circuit, draining the circuitDraining the circuit– Lower the load arms to the ground to elimi-

nate pressure in the hydraulic circuit.

– Switch off the ignition and unplug the bat-tery connector.

– Disconnect the power supply to the sole-noid valve (3).

– Disconnect the cylinder supply hose (1).

– Remove the 2 screws (2) that hold the up-per support (angle bracket) in place.

– Lift out the hydraulic unit.

– Remove the unit's upper support and thefiller tube/breather.

– Unscrew the tank's mounting clip.

– Remove the tank.

– Drain the oil.

Filling up– Fit new seals on the tank and couplings.

– Refit the unit in the technical compartmentwith its tube and upper support.

– Connect the pipes and the power supply.

– Unscrew the filler plug.

– Fill up the tank through the filler hole.

– Tighten the plug.

– Operate the lifting system several times.

CAUTION

Always use hydraulic oil in accordance with the spec-ifications (see lubrication table).

Maintenance 5Hydraulic systems

1031152 807 80 01 EN - 02/2021 - 17

Storage and decommissioningStorage of truckPrecautions should be taken if the truck mustnot be used for a reasonably long period. Theoperations depend on the length of time it isunused.

Long-term truck storageThe following work must be carried out on thetruck to prevent corrosion if it needs to be stor-ed for a long period of time. If the truck is to bestored for more than two months, it must bepositioned in a clean and dry area. The areamust be well-ventilated with no risk of freez-ing.

The following operations must be performed:

– Clean the truck thoroughly.

– Check the hydraulic oil level and refill if nec-essary.

– Lower the forks onto a suitable support (e.g.a pallet) until the chains are slack.

– Coat any unpainted metal parts with a thinlayer of oil or grease.

– Grease all hinges and joints.

– Check battery condition and electrolyte den-sity. Maintain the battery in accordance withthe manufacturer's requirements. (Followthe instructions).

– Spray contacts with an aerosol product de-signed for contacts.

– Raise and chock the truck: the wheels mustnot touch the ground in order to prevent ir-reversible deformation of the tyres.

– Cover the truck with a cotton cover to pro-tect it from dust.

CAUTIONWe recommend that you do not use a plastic sheetas this encourages condensation to form.

Consult the service department for furthermeasures to take if the truck must be storedfor a longer period of time.

Recommissioning after storageIf the truck has been stored for more than sixmonths, it must be checked carefully beforebeing recommissioned. This check is similar tothe workplace accident prevention inspection.It is therefore necessary to check all pointsand systems that are important for truck safe-ty.

Carry out the following operations:

– Clean the truck thoroughly.

– Grease all hinges and joints.

– Check the condition and density of electro-lyte, and, if necessary, recharge the battery.

– Check that there are no traces of condensa-tion water in the hydraulic oil. Drain if nec-essary.

– Carry out the same maintenance work asfor the first time it was commissioned.

– Commission the truck.

– In particular, check the following duringstart-up:

● traction, control and steering.● brakes (service brake and parking brake).● lifting device.

Maintenance5Storage and decommissioning

104 1152 807 80 01 EN - 02/2021 - 17

Permanent Putting Out of Commis-sion (Destruction) When scrapping the truck, it is necessary to:

– Remove the various parts of the truck (cov-ers, battery, chains, motors etc.)

– Sort out the components depending on theirtype: pipes, rubber components, lubricants,aluminium, iron etc.

– Before scrapping the truck, notify the com-petent authorities of your country in writing.

– After receiving the authorisation from thecompetent authorities, remove any compo-nents according to national standards.

NOTE

The client is solely responsible for any irregu-larities he has committed during or after thescrapping of the truck's components and theremoval of components.

Maintenance 5Storage and decommissioning

1051152 807 80 01 EN - 02/2021 - 17

Maintenance5Storage and decommissioning

106 1152 807 80 01 EN - 02/2021 - 17

6

Technical specifications

Datasheet EXU

Technical specifications6Datasheet EXU

108 1152 807 80 01 EN - 02/2021 - 17

DESIGNATION1.1 Manufacturer STILL GmbH1.2 Model type EXU16 EXU18 EXU20 EXU22

1.3 Method of propulsion: battery, diesel, petrol,LPG, mains power Battery

1.4 Driving: manual, pedestrian, standing, seated,order picking Pedestrian

1.5 Rated capacity Q (kg) 1600 1800 2000 22001.6 Centre of gravity c (mm) 600

1.8

Distance fromload wheel axleto load matingface (±5 mm)

X (mm)

1150 lowered/raised 963 / 883

1.9 Wheelbase(±5 mm)

Y (mm)

1150 lowered/raised

1304 /1228 1381 / 1301 1449 /

1370

WEIGHT EXU16 EXU18 EXU20 EXU22 Battery

2.1 Weight in work-ing order (±10%) kg

BS 430 / /2 Pzs 495 /

82 Ah lithium-ionbattery 352 / /

164 Ah lithium-ionbattery 373 / /

205 Ah lithium-ionbattery 392 /

410 Ah lithium-ionbattery 433 /

2.2

Load per ladenaxle,drive side/loadside (±10%)

kg 2 PzS - 1150 680 /1350

746 /1542

789 /1699 /

2.3

Load per unladenaxle,drive side/loadside (±10%)

kg 2 PzS rollers / drivewheels 384/104 /

WHEELS EXU16 EXU18 EXU20 EXU223.1 Tyres: polyurethane, rubber C+P/P C+P/P C+P/P C+P/P

3.2

Drive wheel di-mensions (widthat the ground)

Øxl (mm) 230 x 75

3.3

Wheel sizes, loadside Øxl (mm) Ø85 x 105 (bogies = 85 x 100)

Technical specifications 6Datasheet EXU

1091152 807 80 01 EN - 02/2021 - 17

3.4

Additional wheels(dimensions)

Øxl(mm) Stabilisers 125 x 40

3.5

Number of wheels at drive side/load side (x =drive wheel) 1x+ 2 / 2 (4 in bogies)

3.6

Drive side trackwidth (± 5 mm) mm 482

3.7

Load side trackwidth (± 5 mm) mm Mobile chassis

52/56/68 355 / 395 / 515

DIMENSIONS EXU16 EXU18 EXU20 EXU22

4.4 Lift unladen/laden(± 5 mm) h3 (mm) 130

4.9Height of tiller indriving position,min/max.

h14 (mm) 740 / 1250

4.15

Height at theends of the forkin the lower posi-tion (max)

h13 (mm) 85

4.19 Total length (± 5mm)

L1(mm) BS / 2 PzS 1660 /

17301660 /1730 - / 1730 - / 1820

4.20Length to loadmating face(±5 mm)

L2(mm) BS / 2 PzS 510 / 580 - / 580 - / 670

4.21 Total width b1 (mm) 720

4.22 Dimensions offorks s/e/l (mm) 165 - 55 - 1150

4.25 Outside forkspread b5 (mm) 520 - 560 - 680

4.32

Ground clear-ance at centre ofwheelbase,min/max

m2 (mm) 36 / 166

4.33

Aisle width with a1000 x 1200 pal-let crosswise(lowered/raisedforks)

Ast (mm)

Battery EXU16 EXU18 EXU20 EXU22BS 1947 / 1962 / /

2 Pzs 1997 / 2017 /

3 Pzs / / / 2060 /2055

4.34

Aisle width withan 800 x 1200pallet lengthwise(lowered/raisedforks)

Ast (mm)

BS 1997 / 2012 / /2 Pzs 2047 / 2067 /

3 Pzs / / / 2110 /2105

4.35 Turning radius(mini)

Wa(mm) BS 1560 / 1495 / /


110 1152 807 80 01 EN - 02/2021 - 17

(lowered/raisedforks)

2 Pzs 1610 / 1550 /

3 Pzs / / / 1670 /1585

PERFORMANCE DATA EXU16 EXU18 EXU20 EXU22

5.1 Transfer speed when la-den/unladen (5%) km/h 6 / 6

5.2 Lifting speed when laden/unladen (10%) m/s 0.04 / 0.06 0.03 /

0.04

5.3 Lowering speed when la-den/unladen (10%) m/s 0.071 / 0.065 0.07/0.06

5.8 Maximum gradient whenladen/unladen, 5 minutes % 14 / 24 13 / 24 11 / 24 10 / 24

5.9 Acceleration time when la-den/unladen (d = 10 m) s 7.58 / 6.5 7.65 / 6.5 8.04 / 6.5 8.04 / 6.5

5.10 Service brake Electromagnetic

DRIVE EXU16 EXU18 EXU20 EXU226.1

Traction motor, hourly out-put kW AC mo-

tor 1.2

6.2 Lift motor at 15% utilisation kW DC mo-

tor 1 1 1.2 1.4

6.3

Battery type in accordancewith DIN 46 531 / 35 /36 A, B, C,no

DIN 46 536 B BS/2 Pzs BS/2 Pzs 2 Pzs 3 Pzs

6.4

Battery voltage and capaci-ty (discharge in 5 h) V/Ah

BS 24/16024/220 / /

2 Pzs / 24 / 375 /82 Ah

lithium-ion bat-

tery

23/82 / /

164 Ahlithium-ion bat-

tery

23/164 / /


tery

/ 23/205 /


tery

/ 23/410 /


1111152 807 80 01 EN - 02/2021 - 17

6.5 Battery weight (±10%) kg

BS 141 / /2 Pzs 213 /82 Ah

lithium-ion bat-

tery

63 / /


tery

84 / /


tery

110 /


tery

151 /

6.6

Energy consumption ac-cording to standardised VDIcycle

kWh / h 0.38

OTHER EXU16 EXU18 EXU20 EXU228.1 Speed control AC controller LAC


112 1152 807 80 01 EN - 02/2021 - 17


1131152 807 80 01 EN - 02/2021 - 17

Datasheet EXU 20S - EXU 22S (option)

Technical specifications6Datasheet EXU 20S - EXU 22S (option)

114 1152 807 80 01 EN - 02/2021 - 17

DESIGNATION1.1 Manufacturer STILL GmbH1.2 Model type EXU 20S EXU 22S

1.3 Method of propulsion: battery, diesel, petrol, LPG, mains pow-er Battery

1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian1.5 Rated capacity Q (kg) 2000 22001.6 Centre of gravity c (mm) 600

1.8Distance from loadwheel axle to load mat-ing face (±5 mm)

x (mm) 1150 lowered/raised 962/895.5

1.9 Wheelbase (±5 mm) y (mm) 1150 lowered/raised 1379/1312.5 1454/1387.5

WEIGHT Battery EXU 20S EXU 22S

2.1 Weight in working or-der (±10%) kg

BS /

2 Pzs 540 /

3 Pzs / 585

2.2Load per laden axle,drive side/load side(±10%)

kg2 Pzs 876/1664 /

3 Pzs / 934/1851

2.3Load per unladen axle,drive side/load side(±10%)

kg2 Pzs 435/105 /

3 Pzs / 460/125

WHEELS EXU 20S EXU 22S3.1 Tyres: polyurethane, rubber C+P/P

3.2Drive wheel dimen-sions (width at theground)

Øxl (mm) 230 x 75 POLYURETHANE

3.3 Wheel sizes, load side Øxl (mm) Ø85 x 105 (bogies = 85 x100)

3.4 Additional wheels (di-mensions) Øxl (mm) Stabilisers 125 x 40

3.5 Number of wheels at drive side/load side (x = drive wheel) 1x+ 2 / 2 (4 in bogies)

3.6 Drive side track width(± 5 mm) mm 482

3.7 Load side track width(± 5 mm) mm Mobile chassis 52/56/68 355/395/515

DIMENSIONS EXU 20S EXU 22S

4.4 Lift unladen/laden (±5 mm) h3 (mm) 125

Technical specifications 6Datasheet EXU 20S - EXU 22S (option)

1151152 807 80 01 EN - 02/2021 - 17

4.9 Height of tiller in driv-ing position, min/max. h14 (mm) 740/1250

4.15Height at the ends ofthe fork in the lowerposition (max)

h13 (mm) 85

4.19 Total length (± 5 mm) L1 (mm) Pedestrian/ride-on 1896/2286 1980/2360

4.20 Length to load matingface (±5 mm) L2 (mm) Pedestrian/ride-on 745/1135 830/1210

4.21 Total width b1 (mm) 7204.22 Dimensions of forks s/e/l (mm) 165/55/11504.25 Outside fork spread b5 (mm) 520/560/680

4.32Ground clearance atcentre of wheelbase,min/max

m2 (mm) 34/159

4.33Aisle width with a 1000x 1200 pallet cross-wise

Ast (mm)

Lowered forks Pedestrian/ride-on 1975/2344 2058/2427

Raised forks Pedestrian/ride-on 1908/2277 1996/2365

4.34Aisle width with an 800x 1200 pallet length-wise

Ast (mm)

Lowered forks Pedestrian/ride-on 2175/2544 2265/2431

Raised forks Pedestrian/ride-on 2108/2477 2195/2564

4.35 Turning radius (mini) Wa (mm)

Lowered forksPedestrian/ride-on 1737/2106 1824/2193

Raised forksPedestrian/ride-on 1670/2039 1757/2126

PERFORMANCE DATA EXU 20S EXU 22S

5.1 Transfer speed when la-den/unladen (5%) km/h 6/6

5.2 Lifting speed when laden/unladen (10%) m/s

2 Pzs 0.04/0.06 /3 Pzs / 0.03/0.04

5.3 Lowering speed when la-den/unladen (10%) m/s

2 Pzs 0.07/0.06 /3 Pzs / 0.07/0.06

5.8 Maximum gradient whenladen/unladen, 5 minutes % 11/24 10/24

5.9 Acceleration time when la-den/unladen (d = 10 m) s 8.04/6.5

5.10 Service brake Electromagnetic

DRIVE EXU 20S EXU 22S6.1 Traction motor, hourly output kW AC motor 1.2


116 1152 807 80 01 EN - 02/2021 - 17

6.2 Lift motor at 15% utilisation kW DC motor 1.2 1.4

6.3 Battery type in accordance with DIN 46 531 / 35 /36 A, B, C, no DIN 46 536 B 2 Pzs 3 Pzs

6.4 Battery voltage and capacity (dis-charge in 5 h) V/Ah

BS / /2 Pzs 24/250 /

3 Pzs / 24/375

6.5 Battery weight (10%) kgBS / /

2 Pzs 219 /3 Pzs / 287

6.6 Energy consumption according tostandardised VDI cycle kWh / h 0.38 0.38

OTHER EXU 20S EXU 22S8.1 Speed control AC controller LAC

Technical specifications 6Datasheet EXU 20S - EXU 22S (option)

1171152 807 80 01 EN - 02/2021 - 17


118 1152 807 80 01 EN - 02/2021 - 17

AAccessing the reducer and the brake. . . . 89Access to the technical compartment. . . . 86Address of manufacturer. . . . . . . . . . . . . . . IAdjusting the height of the stabilisers

Stabilisers. . . . . . . . . . . . . . . . . . . . . . . 96Adjusting the on-board charger . . . . . . . . 69After washing the truck. . . . . . . . . . . . . . . 93Anti-crush safety device

Checking. . . . . . . . . . . . . . . . . . . . . . . . 37Description of the function. . . . . . . . . . 37

BBattery

Charging a Gel or Lead battery (wall-mounted charger). . . . . . . . . . . . . . . . 35

Cleaning the battery. . . . . . . . . . . . . . . 93Type. . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Battery acid. . . . . . . . . . . . . . . . . . . . . . . . 14Battery charge indicator. . . . . . . . . . . . . . . 24Battery electrolyte density. . . . . . . . . . . . 101Battery maintenance. . . . . . . . . . . . . . . . 100Brake

Checking the brake. . . . . . . . . . . . . . . . 35Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Braking system. . . . . . . . . . . . . . . . . . . . . 32

CCE labelling. . . . . . . . . . . . . . . . . . . . . . . . . 3Changing the battery. . . . . . . . . . . . . . . . . 69Charger

Using the charger. . . . . . . . . . . . . . . . . 67Charging the battery. . . . . . . . . . . . . . . . . 94Checking the anti-crush safety device. . . . 37Checking the cables, terminals and battery

connector. . . . . . . . . . . . . . . . . . . . . . . . 99Checking the emergency stop. . . . . . . . . . 36Checking the horn. . . . . . . . . . . . . . . . . . . 36Checks prior to start-up. . . . . . . . . . . . . . . 34Check the tyres and the wear on the

wheels and rollers. . . . . . . . . . . . . . . . . . 96Cleaning the electrical system. . . . . . . . . . 92Clean the truck. . . . . . . . . . . . . . . . . . . . . . 92Climatic conditions. . . . . . . . . . . . . . . . . . . . 8Consumables. . . . . . . . . . . . . . . . . . . . . . . 13

Battery acid safety instructions. . . . . . . 14Disposal. . . . . . . . . . . . . . . . . . . . . . . . 15

Oil Safety Information. . . . . . . . . . . . . . 13Safety information for handling hydraul-

ic fluid. . . . . . . . . . . . . . . . . . . . . . . . . 14Contact details. . . . . . . . . . . . . . . . . . . . . . . ICopyright and property rights. . . . . . . . . . . 3

DDatasheet EXU. . . . . . . . . . . . . . . . . . . . 108Datasheet EXU 20S - EXU 22S (option). 114Description of use. . . . . . . . . . . . . . . . . . . . 8Destruction. . . . . . . . . . . . . . . . . . . . . . . . 105Digicode option (LFM Go). . . . . . . . . . . . . 26Directions

Defining directions. . . . . . . . . . . . . . . . 41Display components. . . . . . . . . . . . . . . . . 23Disposing of components and batteries. . . . 9Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Driver rights,duties and rules of behaviour. 18Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Driver's compartment. . . . . . . . . . . . . . . . . 33Driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Driving on loading bridges. . . . . . . . . . . . . 79Driving on upward and downward slopes. 44Driving safety guidelines. . . . . . . . . . . . . . 40

EEC declaration of conformity. . . . . . . . . . . . 4Electrolyte level and battery water top-up. 100

FFleetManager™

Colour code for the LEDs. . . . . . . . . . . 50Commissioning a truck equipped with a

keypad or an electronic key. . . . . . . . 49Commissioning a truck equipped with

an RFID reading device. . . . . . . . . . . 49Description. . . . . . . . . . . . . . . . . . . . . . 48Disconnecting a truck equipped with a

keypad or electronic key. . . . . . . . . . 52Disconnecting a truck equipped with an

RFID reading device. . . . . . . . . . . . . 53Disconnecting the truck. . . . . . . . . . . . 52Start-up. . . . . . . . . . . . . . . . . . . . . . . . . 49

Folding platformDriving in pedestrian mode. . . . . . . . . . 59Driving in ride-on mode. . . . . . . . . . . . 59

Index

1191152 807 80 01 EN - 02/2021 - 17

Maintenance. . . . . . . . . . . . . . . . . . . . . 95Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

GGel and lead side access batteries: chang-

ing the battery using a trolley. . . . . . . . . 71Gel battery. . . . . . . . . . . . . . . . . . . . . . . . . 93General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General information on battery mainte-

nance. . . . . . . . . . . . . . . . . . . . . . . . . . . 94General maintenance information

General. . . . . . . . . . . . . . . . . . . . . . . . . 82

HHandling the truck in specific situations. . . 77Hydraulic circuit, draining the circuit. . . . 103Hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . 14

IIdentification label. . . . . . . . . . . . . . . . . . . . 5

JJacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

LLead battery. . . . . . . . . . . . . . . . . . . . . . . . 93Lift control elements. . . . . . . . . . . . . . . . . . 56Lifting system. . . . . . . . . . . . . . . . . . . . . . . 32Lifting the truck. . . . . . . . . . . . . . . . . . 77, 78Load handling. . . . . . . . . . . . . . . . . . . . . . 56Load handling safety rules. . . . . . . . . . . . . 54Lowering the fork arms. . . . . . . . . . . . . . . 56

MMaintaining the reinforced stabilisers (op-

tion). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Maintenance plan

1000-hour/annual maintenance plan . . 90Maintenance schedule

3000 hours. . . . . . . . . . . . . . . . . . . . . . 91Markings. . . . . . . . . . . . . . . . . . . . . . . . . . 28

NNoise

Noise emission values. . . . . . . . . . . . . 16

OOil level check. . . . . . . . . . . . . . . . . . . . . 102

Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Opening/closing the battery cover. . . . . . . 64Operating company. . . . . . . . . . . . . . . . . . 18Operating devices. . . . . . . . . . . . . . . . . . . 23OptiSpeed. . . . . . . . . . . . . . . . . . . . . . . . . 44Ordering spare parts and consumables. . . 83Order picking. . . . . . . . . . . . . . . . . . . . . . . 63Overviews. . . . . . . . . . . . . . . . . . . . . . . 0, 22

PParking brake. . . . . . . . . . . . . . . . . . . . . . . 45Permanent Putting Out of Commission. . 105Permissible use. . . . . . . . . . . . . . . . . . . . . . 8Precautions to be taken during battery

maintenance. . . . . . . . . . . . . . . . . . . . . . 94Prohibition of use by unauthorised persons. 19

RRaising the fork arms. . . . . . . . . . . . . . . . . 56Regular maintenance of the transmission

gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Residual dangers, residual risks. . . . . . . . 17Restarting work. . . . . . . . . . . . . . . . . . . . . 62

SSafety devices. . . . . . . . . . . . . . . . . . . . . . 84Safety Inspection. . . . . . . . . . . . . . . . . . . . 20Selecting the driving mode. . . . . . . . . . . . 42Serial number. . . . . . . . . . . . . . . . . . . . . . 29Servicing and maintenance measures. . . . 84Servicing wheels and rollers. . . . . . . . . . . 96Side access battery: changing the battery

using a moveable support. . . . . . . . . . . . 73Slinging the truck. . . . . . . . . . . . . . . . . . . . 77Spare parts list. . . . . . . . . . . . . . . . . . . . . . . 7Specialist. . . . . . . . . . . . . . . . . . . . . . . . . . 18Stabilisers. . . . . . . . . . . . . . . . . . . . . . . . . 32Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . 17Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . 41Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . 32Stopping the truck. . . . . . . . . . . . . . . . . . . 62Symbols used. . . . . . . . . . . . . . . . . . . . . . . 9

TTechnical inspection and maintenance

characteristics. . . . . . . . . . . . . . . . . . . . . 85Transporting the machine. . . . . . . . . . . . . 79Transporting the truck. . . . . . . . . . . . . . . . 78

Index

120 1152 807 80 01 EN - 02/2021 - 17

Transporting the truck in the lift. . . . . . . . . 79Truck operating instructions. . . . . . . . . . . . 38

UUnauthorised use. . . . . . . . . . . . . . . . . . . . . 9

VVibration characteristic values for bodily vi-

brations. . . . . . . . . . . . . . . . . . . . . . . . . . 16

WWashing instructions. . . . . . . . . . . . . . . . . 92Washing the exterior of the truck. . . . . . . . 92Working on the electrical equipment. . . . . 84

Index

1211152 807 80 01 EN - 02/2021 - 17

STILL GmbH

1152 807 80 01 EN - 02/2021 - 17

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Original instructions Electric pallet truck

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