Original instructions

Electric pallet truck

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

0153 0154 0155 0157 0180

0181 0182

1152 807 80 01 EN - 05/2015

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1 Introduction
Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Information about documentation . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 4
Documentation scope . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 4
Copyright and property rights . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 4
Explanation of symbols used . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 4
Explanation of the cross-references . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 5
Date of issue and update of this manual ... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 5
Defining directions . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . ..... ... 5
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disposing of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 8
Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 8
Unauthorised use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 9
Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... 9
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 10
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 10
Special risks associated with using the truck and attachments . . ............... .. 10
Overview of hazards and countermeasures . . . . . . . . . . . . . . . . ............... .. 12
Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 14

2 Safety
Definition of the responsible persons ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 16
Operating company . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 16
Specialist . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 16
Drivers . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 16
Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 18
Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 18
Modifications and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 18
Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 18
Damage, faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 19
Medical devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 19
Special lithium-ion safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Electrical insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 23
Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 23
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 23
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 24
Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 24
Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 25
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Damage, faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3 Overviews
Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Controls and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 29
Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 29
Battery charge indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 30
Digicode option (LFM Go) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 32
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Marking positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FleetManager option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lithium-ion specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lithium-ion marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 Use
Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checks and actions prior to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
List of checks prior to start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Charging a Gel or Lead battery (wall-mounted charger) . . . . . . . . . . . . . . . . . . . . . . . . 42
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 43
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 43
Checking the anti-crush safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 44
Checking the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 45
Checking the emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 45
Checking the horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 46
Operating the FleetManager™ option . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . 47
Description of the FleetManager option . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . 47
Commissioning a truck equipped with the FleetManager™ option .. . . . . . . . . . . . . . . 48
FleetManager™ option: Colour code for the LEDs . . . . . . . . . . ... . . . . . . . . . . . . . . 49

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Disconnecting a truck equipped with the FleetManager™ option . . . . . . . . . . . . . . . . . 51

Lithium-ion specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Vertical access lithium-ion batteries: connecting/disconnecting the battery connector
............................................................. . . 53
Commissioning a truck equipped with a vertical access lithium-ion battery . . . . . . . . . . 54
Side access lithium-ion batteries: connecting/disconnecting the battery connector
............................................................. . . 55
Commissioning a truck equipped with a side access lithium-ion battery . . . . . . . . . . . . 55
Display on a truck equipped with a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . 57
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 58
Driving safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 58
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 59
Using the folding platform (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 60
OptiSpeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 61
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 62
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 62
Standby (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 62
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Lift control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Handling loads . . . . . . . . . . . . . . . . . . . ... ............... ............... .. 64
Load handling safety rules . . . . . . . . . . ... ............... ............... .. 64
Before picking up a load . . . . . . . . . . . . ... ............... ............... .. 65
Transporting pallets or other containers ... ............... ............... .. 67
Driving on upward and downward slopes .. ............... ............... .. 68
Transporting the truck in the lift . . . . . . . ... ............... ............... .. 68
Driving on loading bridges . . . . . . . . . . ... ............... ............... .. 68
Cold store usage (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Handling the truck in specific situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Truck towing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Slinging, lifting and setting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Gel or lead batteries: Handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 74
Battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 74
Opening/closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 75
Charging the battery using an external charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 76
On-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 77
Using the charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 79
Gel or Lead batteries: Adjusting the on-board charger . . . . . . . . . . . . . . . . . . . . . . . .. 81
Changing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 82
Gel and lead side access batteries: changing the battery using a trolley . . . . . . . . . . .. 83

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Side access battery: changing the battery using a moveable support . . . . . . . . . . . . . . 85

Lithium-ion specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 87
Charging lithium-ion batteries using an external charger . . . . . . . . . . . ............ 87
Replacing the vertical access lithium-ion battery . . . . . . . . . . . . . . . . . ............ 91
Side access lithium-ion battery: changing the battery . . . . . . . . . . . . . ............ 93
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Putting out of Commission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Park the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Gel or lead batteries: Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Storage of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Permanent Putting Out of Commission (Destruction) . . . . . . . . . . . . . . . . . . . . . . . . . 97
Lithium-ion specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Transporting a truck equipped with a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . 98
Lithium-ion batteries: Long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5 Maintenance
General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 102
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 102
Servicing and maintenance personnel training and qualification . . . . . . ............ 103
Battery maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 103
Maintenance operations that do not require special training . . . . . . . . . ............ 103
Ordering spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . ............ 103
List of inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 104
Technical inspection and maintenance characteristics . . . . . . . . . . . . . ............ 105
Maintenance safety instructions . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 106
Servicing and maintenance measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 106
Working on the electrical equipment . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 106
Safety devices . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 106
Preparatory tasks for maintenance . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 107
Slinging and jacking the truck . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 107
Access to the technical compartment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 108
Accessing the reducer and the brake .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 110
Maintenance plan for the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Servicing wheels and rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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Regular maintenance of the transmission gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Folding platform maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Gel or lead batteries: Maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Clean the battery and its compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Checking the condition of cables, terminals and battery connector . . . . . . . . . . . . . . . . 118
Lithium-ion specific: Maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cleaning the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Lithium-ion battery: harnesses and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Service plan 1000 h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 121
Work that must also be carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 121
1000-hour maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 121
Checking the brake air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 123
Adjusting the height of the stabilisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 124
Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .. 125
Checking the wear on collars and hinge pins . . . . . . . . . . . . . . . . . . . . . . . ....... .. 126
Gel or lead batteries: Maintenance every 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . 127
Checking the on-board charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Maintenance every 3000 hours . . . .... . . . . . . . . . . . . . . . . . . . . . . . . ......... .. 130
Work that must also be carried out .... . . . . . . . . . . . . . . . . . . . . . . . . ......... .. 130
3000-hour maintenance schedule . .... . . . . . . . . . . . . . . . . . . . . . . . . ......... .. 130
Hydraulic circuit, draining the circuit ... . . . . . . . . . . . . . . . . . . . . . . . . ......... .. 131
Servicing the reducer . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . ......... .. 132

6 Technical Data
Datasheet EXU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Datasheet EXU 20S - EXU 22S (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Noise emission values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Vibration characteristic values for bodily vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1152 807 80 01 [EN] V

 1

Introduction
1 Introduction
Your industrial truck

Your industrial truck

General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
The trucks have been fitted with state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.

2 1152 807 80 01 [EN]

Introduction 1
Your industrial truck

EC declaration of conformity

Declaration

STILL GmbH
Berzeliusstrasse 10
22113 Hamburg

GERMANY

We declare that the machine

Industrial truck according to these operating instructions

Model according to these operating instructions

conforms to the latest version of the Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL S.A.S.

The manufacturer declares that the truck

complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the EC labelling on the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
relevant authorities.

1152 807 80 01 [EN] 3

1 Introduction
Information about documentation
Information about documentation
Documentation scope
• Operating instructions document
• Operating instructions for attachment parts
(special equipment)
• Spare parts catalogue
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of the truck in all possible
variants at the time of printing. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year of
manufacture located on the designation plate
(see "Marking chapter") in the field provided:
Production no. ...........................................
Year of manufacture
...................................................
Copyright and property rights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid life-threatening danger or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
4 1152 807 80 01 [EN]
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructions must be stored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the oper-
ator must immediately request a replacement
from the manufacturer.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see "Definition of
responsible persons" chapter) must ensure
that all operators have received, read and
understood these instructions.
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
CAUTION
Compulsory procedure that must be followed to
avoid damage to and/or destruction of equipment.
NOTE
For technical requirements that require
special attention.
Introduction 1
Information about documentation

ENVIRONMENT NOTE
To prevent environmental damage.

Explanation of the cross-references

Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to another section: "Expla-
nation of cross references" chapter
• Cross reference to another chapter: "Defi-
nition of responsible persons" chapter

Date of issue and update of this manual

The publication date of these operating We hope you enjoy your driving
instructions is printed on the cover.
STILL makes continuous efforts to develop
and improve its industrial trucks. For this STILL GmbH
reason, the manufacturer reserves the right to
Berzeliusstr. 4
make changes and no claim will be accepted
concerning the information provided in this 22113 Hamburg
instruction manual.
Germany
If you require technical assistance with your
truck, please contact your nearest STILL
service centre.
.

Defining directions
Names used in the text: forward travel (1),
reverse travel (3), to the right (2) and to the
left (4) refer to component installation position
with respect to the driver’s compartment.
The load is positioned at the back.

1152 807 80 01 [EN] 5

1 Introduction
Environmental considerations

Environmental considerations
Packaging
When the truck is delivered, some parts are
ENVIRONMENT NOTE
packaged to provide better protection during
transport. This packaging must be removed The packaging material must be disposed of
completely prior to initial start-up. properly after delivery of the truck.

Disposing of components and batteries

The truck is made up of different materials.
When components or batteries need to be
changed, they must be:
• disposed of,
• processed
• recycled in accordance with the applicable
regional and national regulations
NOTE
The documentation provided by the battery
manufacturer must be consulted when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company when disposing of compo-
nents and batteries.

6 1152 807 80 01 [EN]

Introduction 1
Description

Description
The electric pallet trucks EXU 16, EXU 18, Batteries
EXU 20 and EXU 22 are designed to handle
Power is supplied by either:
pallets or containers.
– A lead battery
Their small volume, their ease of driving and
their performance make them very appropri- – A gel battery
ate for loading and unloading operations.
– Or a lithium-ion battery (the truck therefore
The range of these trucks covers capacities of has specific characteristics).
1600, 1800, 2000 and 2200 kg.
The types of battery removal that are available
are as follows:
Drive
• Vertical access (Types BS, 2Pzs, 3Pzs)
Drive is provided by a 1.2 kW asynchronous • Side access on rollers (Types 2PzS and
traction motor. 3PzS). This system allows the battery to be
The motor unit is driven by the truck controller, changed quickly.
which incorporates the transistor speed
controller. Braking system
This controller offers excellent performance • counter-current, upon accelerator release
and enables optimum control of speed, • counter-current, by switching the direction
acceleration and counter-current braking. of travel
The power supply to the traction motor is • counter-current, controlled by rear safety
controlled by an electronic controller with inverter switch
microprocessor, which provides complete • electromagnetic safety, controlled by the
control of speed, acceleration and braking. emergency stop handle
• electromagnetic safety, controlled by the
Steering upper or lower position of the tiller
A long, robust, ergonomic tiller allows the • electromagnetic parking, applied when
operator to direct the drive/steering wheel supply is cut.
effortlessly.
Stabilisers
The various controls: forward travel, reverse
travel, lifting and lowering of the load arms, The 5-point chassis has 2 suspended stabilis-
and the horn are grouped together at the end ers which compensate for ground irregulari-
of the tiller. ties.
For safety reasons a gas spring automatically
returns the tiller to the upper position when it is Lifting system
released.
Capacity:
The speed of the truck is limited to 6 km/h
• EXU 16: 1600 kg
in both directions of travel (key in the Hare
position). • EXU 18: 1800 kg
• EXU 20: 2000 kg
The speed of the truck is limited to 4 km/h in
• EXU 22: 2200 kg
both directions of travel (key in the Tortoise
position). • EXU 20 S* : 2000 kg
• EXU 22 S* : 2200 kg
* S : Folding platform.

1152 807 80 01 [EN] 7

1 Introduction
Use of truck

The cylinder activates the lift shaft, which • a battery disconnection handle (emergency
transmits the movement to the push rods. stop) located in the driver’s compartment
These activate the wheel clevises, resulting in • an hour meter/discharge indicator.
the load arms lifting. • an ignition key with 3 positions (stop/Tor-
toise/Hare)
All the joint pins are treated for anti-wear and
• a tiller with the following controls: for-
anti-corrosion properties. The joint rings are
ward/reverse travel, accelerator, lifting/low-
self-lubricating.
ering of the load arms, horn and safety
Pump motor power: inverter
• EXU 16 and EXU 18: 1 kW • OptiSpeed (EXU16, EXU18, EXU20,
EXU22) : : variable speed according to
• EXU 20: 1.2 kW
tiller position.
• EXU 22: 1.4 kW
• EXU 16-18-20 CS* : 1.2 kW As OPTIONS:
• EXU 22 CS*: 1.4 kW • backrest
* CS : Cold store (option) • digicode (LFM Go)
• cold-store version
Driver’s compartment • Fleet Manager
• on-board charger
The standard equipment in the driver’s com-
• accessory holder
partment comprises:
• an office compartment for storing rolls of
film and adhesive, gloves, pens etc.
• a clip for attaching documents together

Use of truck
Intended use of the trucks

CAUTION
This machine was designed for the transport and
storage on racks (pallet stackers only) of loads
packed on pallets or in industrial containers de-
signed for this purpose.
The dimensions and capacity of the pallet or contai-
ner must be adapted to the load being transported
and must ensure stability.
The table of characteristics and performance atta-
ched to this user manual gives you the information
you need to check that the equipment is suitable for
the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.

8 1152 807 80 01 [EN]

Introduction
Unauthorised use
Any danger caused as a result of unauthorised
use becomes the responsibility of the operator
or driver and not that of the manufacturer.
Use for purposes other than those described
in these operating instructions is prohibited.
Transporting people is prohibited.
Place of use
The truck can be used outdoors and in build-
ings. The truck must not be used outdoors in
bad weather. Operation on public roads is per-
mitted only if the special equipment specified
in the Road Traffic Licensing Regulations is
installed.
The regulations applicable in different coun-
tries for driving on public roads must be ob-
served.
The sites on which the truck is used must com-
ply with the applicable regulations (condition
of the ground, lighting etc.).
The ground must have sufficient load capacity
(concrete, asphalt).
1152 807 80 01 [EN]
1
Use of truck
The forklift truck should not be used in areas
where there is a risk of fire, explosion or
corrosion, or in areas that are particularly
dusty.
Stacking or unstacking is not permissible on
inclined surfaces or ramps.
The truck is suitable for indoor and outdoor use
(temperatures ranging from -20°C to +40°C).
If your truck is to be used in a refrigerated stor-
age area, it must be configured accordingly;
an approval may be necessary for this envi-
ronment (see chapter entitled "Description").
The operator (see chapter entitled "Definition
of responsible persons") must ensure that
appropriate fire protection is available in
the vicinity of the truck during operation.
Depending on the application,additional fire
protection must be provided on the industrial
truck. If in doubt, please contact the relevant
authorities.
9
1 Introduction
Residual risks

Residual risks
Residual dangers, residual risks
Despite all operational precautions and
compliance with standards and rules, the
possibility of additional risks when using the
truck cannot be entirely excluded.
The truck and all its components comply with
the regulations relating to current applicable
safety rules.
Persons in the vicinity of the truck must be
particularly cautious and react immediately
in the event of any malfunction, incident,
breakdown etc.
WARNING
Personnel in contact with the truck must be infor-
med of the risks related to using the truck.
These operating instructions draw your attention to
the safety rules.
The risks are:
• Escape of consumables due to leaks,
ruptured lines and tanks etc.
• Risk of accident when driving over difficult
ground such as slopes, soft or irregular
surfaces or in poor visibility etc.
• Falling, tripping etc. when moving on the
industrial truck, especially in the wet, with
leaking consumables or icy surfaces.
• Loss of stability due to the load being
unstable or the load slipping etc.
• Risk of fire and explosion due to batteries
and electrical voltages.
• Human error - Disregarding safety regula-
tions.
It is important to adjust the speed of the truck
depending on the load and ground conditions.
The stability of the truck has been tested to the
latest standards. These standards only take
account of the static and dynamic tilting forces
that can arise during operation that complies
with the specifications and operating rules.
Risks caused by misuse or incorrect operation
that jeopardise the stability cannot be ruled
out in extreme situations.

Special risks associated with using the truck and attachments

The manufacturer’s approval is required as
soon as:
• The truck is used differently from its normal
use
• The driver is not sure if he can use the truck
correctly and without risk of accident

10 1152 807 80 01 [EN]

Introduction 1
Residual risks

1152 807 80 01 [EN] 11

1 Introduction
Residual risks

Overview of hazards and counter-

measures

NOTE
This table is intended to help evaluate the
hazards in your facility and applies to all drive
types. It does not claim to be complete.

NOTE
Observe the national regulations for your
country!
Hazard Measure Check note Notes
√ actioned
- not applicable
Truck equipment does Test O If in doubt, consult
not comply with local competent factory
regulations inspectorate or
employers’ liability
insurance association
Lack of skills and Driver training (sit-on O BGG 925
qualification of driver and stand-on) VDI 3313 driver permit
Usage by unautho- Access with key only O
rised persons for authorised persons
Truck not in a safe Recurrent testing and O BetrSichVO
condition rectification of defects (Workplace Safety
Ordinance)
Risk of falling when Compliance with O BetrSichVO
using working national regulations (Workplace
platforms (different national Safety Ordinance)
laws) and employer’s
liability insurance
associations
Impaired visibility due Resource planning O BetrSichVO
to load (Workplace Safety
Ordinance)
Contamination of Assessment of diesel O TRGS 554 and
respiratory air exhaust gases BetrSichVO
(Workplace Safety
Ordinance)
Assessment of LPG O MAK (Maximum
exhaust gases Workplace
Concentrations) list
and BetrSichVO
(Workplace Safety
Ordinance)

12 1152 807 80 01 [EN]

Introduction 1
Residual risks

Hazard Measure Check note Notes

√ actioned
- not applicable
Impermissible usage Issuing of operating O BetrSichVO
(improper usage) instructions (Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
Written notice of O BetrSichVO
instruction to driver (Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
Observe BetrSichVO O
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
When fuelling
a) Diesel Observe BetrSichVO O
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
b) LPG Observe BGV D34, O
operating instructions
and VDMA rules
When charging the Observe BetrSichVO O VDE 0510: In
traction battery (Workplace Safety particular
Ordinance), operating - Ensure ventilation
instructions and - Insulation value
VDMA (German within permissible
Engineering range
Federation) rules
When using battery Observe BetrSichVO O BetrSichVO
chargers (Workplace Safety (Workplace Safety
Ordinance), BGR Ordinance) and BGR
104 and operating 104
instructions
When parking LPG Observe BetrSichVO O BetrSichVO
trucks (Workplace Safety (Workplace Safety
Ordinance), BGR Ordinance) and BGR
104 and operating 104
instructions

1152 807 80 01 [EN] 13

1 Introduction
Residual risks

Hazard Measure Check note Notes

√ actioned
- not applicable
With driverless transport systems
Roadway quality Clean/clear driveways O BetrSichVO
inadequate (Workplace Safety
Ordinance)
Load carrier Reattach load to pallet O BetrSichVO
incorrect/slipped (Workplace Safety
Ordinance)
Drive behaviour Employee training O BetrSichVO
unpredictable (Workplace Safety
Ordinance)
Driveways blocked Mark driveways O BetrSichVO
Keep driveways clear (Workplace Safety
Ordinance)
Driveways intersect Announce right-of- O BetrSichVO
way rule (Workplace Safety
Ordinance)
No person detection Employee training O BetrSichVO
during depositing and (Workplace Safety
retrieval Ordinance)
.

Danger to employees
The operating company must identify and
evaluate the dangers involved in using the
truck. It must also establish which occupa-
tional health and safety measures are required
to protect employees. Appropriate operating
instructions must be drafted and provided for
the driver accordingly. A person responsible
for health and safety must be appointed.
Construction and equipment of the truck corre-
spond to the Machinery Directive 2006/42/EC
and they are therefore identified with the CE
symbol. As a result, these factors are not
included in the hazard assessment; nor are
the attachments, which have their own CE
labelling. The operating company must, how-
ever, select the type and equipment of the
truck so as to comply with the local provisions
for deployment.
The results must be published. In the case
of truck deployment involving similar hazard
situations it is permitted to summarise the
results. This overview (see chapter entitled
"Overview of hazards and countermeasures")
is intended to facilitate compliance with the
conditions of these regulations. The overview
indicates the main causes of accidents in
the event of non-compliance. If other major
operational hazards are involved, they must
also be taken into consideration.
The working conditions for the trucks are
largely similar for many sites. The dangers
can therefore be summarised in a single
overview. It is recommended that the infor-
mation provided by the relevant employers’
liability insurance association be observed in
this respect.

14 1152 807 80 01 [EN]

 2

Safety
2 Safety
Definition of the responsible persons
Definition of the responsible persons
Operating company
The operating company is the natural or legal
person or group who operates the truck or on
whose authority the truck is used.
The operating company must ensure that the
truck is only used for its intended purpose and
in compliance with the safety guidelines set
out in these operating instructions.
Specialist
A specialist is deemed to be:
• A person whose experience and technical
training has allowed him to develop relevant
knowledge of industrial trucks
• A person who is also familiar with national
health and safety regulations and gener-
ally recognised technical directives and
Drivers
This truck may only be driven by suitable
persons who are at least 18 years of age, have
been trained in driving, have demonstrated
their skills in driving and handling loads, and
have been specifically designated to drive the
truck. Specific knowledge of the truck is also
necessary.
Driver rights,duties and rules of be-
haviour
The driver must be duly informed of his rights
and 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 appropriate
for the conditions, the task and the load to
be lifted. The driver must also wear safety
footwear to be able to drive and brake in com-
plete safety.
16 1152 807 80 01 [EN]
The operating company must ensure that
all users read and understand the safety
information in these instructions.
The operating company is responsible for the
scheduling and correct performance of regular
safety checks.
It is recommended that these checks comply
with national performance specifications.
conventions (standards, VDE regulations,
technical regulations of other European
Union member states or countries that are
signatories to the treaty that established the
European Economic Area). This expertise
allows him to assess the condition of indus-
trial trucks in terms of health and safety
The driver must be familiar with the operating
instructions and have access to them at all
times.
The driver must:
• Have read and understood the operating
instructions
• Have familiarised himself with safe opera-
tion of the truck
• Be physically and mentally able to drive the
truck safely
DANGER
The use of drugs, alcohol or medications that affect
reactions impair the ability to drive the truck.
Individuals under the influence of the above-men-
tioned substances are not permitted to perform
work of any kind on or with the truck.
Safety 2
Definition of the responsible persons

Prohibition of use by unauthorised

persons
The driver is responsible for the truck during
working hours. He must not allow unautho-
rised persons to operate the truck.
When leaving the truck, the driver must secure
it against unauthorised use.

1152 807 80 01 [EN] 17

2 Safety
Basic principles for safe operation

Basic principles for safe operation

Insurance cover on company
premises
The company premises are very often re-
stricted public traffic areas.

NOTE
It is advisable to review the operational liability
insurance so that insurance covers the truck
with respect to third parties in the event of
damage caused in restricted public traffic
areas.

Modifications and refitting

If your truck is to be used in specific conditions
(e.g. refrigerated warehouse or flameproof
protection), it must be specially equipped and
approved for this purpose, if applicable.
If your truck is used for work that is not spec-
ified in the guidelines or in these instructions,
and it must be modified or refitted for this pur-
pose, it is important to remember that any
structural modification could affect truck han-
dling while driving as well as the stability of the
truck, and could lead to accidents. You should
therefore contact the manufacturer before car-
rying out any modification. Permission from
the manufacturer is required for any modifica-
tion that may affect the truck’s stability.
Any constructional modification or transfor-
mation of your truck is forbidden without prior
written permission from the manufacturer.
Authorisation from the relevant authority may
also be required.
SPECIAL CASE: if the manufacturer of the
truck is no longer in business and its activity is
unlikely to be taken over by a successor
In this specific case, you may plan a modifica-
tion or alteration to your truck provided that:
• The modification or alteration is designed,
tested and implemented by one or more
engineers who are experts in the field of
industrial trucks and their safety
• A record is kept of the design, the different
tests and the implementation of the modifi-
cation or alteration
• Appropriate changes are approved and
made to the capacity plate, decals, labels
and operating instructions
• a permanent and clearly visible label is
attached to the truck indicating the nature of
the modification or alteration as well as the
date of the modification or alteration, and
the name and address of the company that
carried out the work.

Warning regarding non-original parts

Original parts, attachments and accessories attachment parts and accessories supplied
are specially designed for this truck. We by other companies have not been tested or
draw your attention to the fact that parts, approved by STILL.

18 1152 807 80 01 [EN]

Safety 2
Basic principles for safe operation

CAUTION
The installation or use of such products may have a
negative impact on the design of the truck and thus
impair active or passive driving safety.
We recommend that you obtain approval from the
manufacturer and, if applicable, from the relevant
regulatory authorities before installing such parts.
The manufacturer accepts no liability for any da-
mage caused by the use of non-original parts and
non-original accessories.

Damage, faults
Any damage or faults observed on the truck or
the accessories must be reported immediately
to the responsible personnel. The truck and
accessories must never be used before they
are correctly reconditioned as they cannot be
guaranteed to be safe for operating or driving.
The safety mechanisms and switches must
never be removed or disabled. The predefined
setpoint values must not be modified.
Work on the electric installation (e.g. connect-
ing a radio, additional lights or other acces-
sories) is permitted only with the approval of
the manufacturer.

Medical devices
The operation of medical devices, for example
pacemakers or hearing aids, can be impaired.
Check with your doctor or manufacturer if the
medical devices are sufficiently protected
against electromagnetic interference.

1152 807 80 01 [EN] 19

2 Safety
Special lithium-ion safety rules
Special lithium-ion safety rules
If you have a truck equipped with a lithium-
ion battery, special safety rules should be
followed. A lithium-ion label will be displayed
in the truck.
It is necessary to respect the following guide-
lines:
– Please take note of the information on the
lithium-ion supplement supplied with these
operating instructions.
– Only persons who have been trained to
work with lithium-ion technology are per-
mitted to work on the batteries (for example
After-Sales Service Centre technicians).
– Do not place lithium-ion batteries on or near
flames or hot heat sources (> 70°C). This
may cause the batteries to overheat or burst
into flames. This type of use also impairs the
performance of the batteries and reduces
their service life.
– Improper use may cause overheating or
serious injury. Respect the following safety
rules:
• Never short circuit the battery terminals
• Do not reverse the battery polarity
• Do not open the battery
• Do not submit the battery to excessive
mechanical constraints
• Do not expose the battery unit to humidity or
water (> 95%)
• Install the batteries in a Level 2 pollution
zone in accordance with standard EN
60664-1
– Batteries must be installed in a room that
can be easily ventilated in the event of
incorrect use.
20 1152 807 80 01 [EN]
– The forklift operator must drive the truck
carefully to avoid any risk of piercing or
damaging the lithium-ion batteries.
DANGER
Risk of injury
In the event of an accident (shock, fall, collision),
the battery may be damaged, pierced or deformed.
Set up a safety perimeter of five metres around the
battery. Contact the emergency services and tell
them that there is a lithium-ion battery fire. Contact
the after-sales service department.
– Store strapped batteries on pallets. Do
not store them too high to reduce any risk
of falling. Do not store on the ground to
reduce the risk of humidity and impacts. We
recommend that batteries are stored at a
height between 60 and 120 cm.
– In the event of an unusual smell, change of
shape or any other anomaly during oper-
ation, disconnect the battery immediately
(using either the emergency stop socket or
the charger socket). Contact the after-sales
service department. If necessary, also con-
tact the emergency services and tell them
that there is a lithium-ion battery fire.
DANGER
There is a risk of fire.
Have class D fire extinguishers or inert gas, carbon
dioxide, powder or foam fire extinguishers near the
zone in which the lithium-ion batteries are used.
DANGER
Electrical danger
Do not open the battery. Electrical risk.
Only the After-Sales Service Centre technicians
can open the battery.
Safety 2
Safety tests

Safety tests
Regular safety inspection of the truck
Safety inspection based on time and
extraordinary incidents
The operating company (see chapter entitled
"Definition of responsible persons") must
ensure that the truck is checked by a specialist STILL GmbH Hamburg
at least once a year or after noteworthy Regelmäßige Prüfung
incidents. (FEM 4.004)
As part of this inspection: nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
• A full check of the technical condition of the 95/63/EG, 99/92/EG, 2001/45/EG
truck in terms of accident safety must be Nächste Prüfung
performed
• The truck must be thoroughly checked to
detect any damage that may have been
caused by improper use

56344391019
• A test log must be created.
The results of the inspection must be retained
until at least a further two inspections have
been carried out.
The inspection date is indicated by an adhe-
sive label on the truck. Die Prüfplakette ersetzt nicht das Prüfprotokoll

– Arrange for the service centre to perform Mitglied der:

Fédération
periodic safety inspections on the truck. Européene
de la Manutention
– Observe the guidelines for tests carried out
on the truck in accordance with FEM 4.004.
0000_003-001_V3

The operator is responsible for ensuring that

any defects are remedied immediately.
– Contact your service centre.

NOTE
Observe the regulations in force in your
country.

1152 807 80 01 [EN] 21

2 Safety
Safety tests
Electrical insulation testing
The truck’s electrical insulation must have
sufficient insulation resistance. Insulation
resistance must be tested in accordance with
EN 1175–1 and ISO 20898 at least once a
year.
NOTE
The truck’s electrical system and drive batte-
ries must be checked separately.
Measuring battery insulation resistance
NOTE
• Test voltage > battery nominal voltage
• The test voltage must not exceed 100 V or
triple the value of the nominal voltage
– Measure insulation resistance using a
suitable meter.
The insulation resistance is sufficient when it
has a resistance of at least 50 Ohms multiplied
by the nominal voltage of the truck circuit,
22
between the parts under voltage and the truck
chassis.
Contact the After-Sales Service.
Measuring the insulation resistance of
the electrical system
NOTE
• Test voltage > battery nominal voltage
• The test voltage must not exceed 100 V or
triple the value of the nominal voltage
– Check that there is no voltage before testing
the circuit.
– Measure insulation resistance using a
suitable meter.
The insulation resistance is sufficient when
it has a resistance of at least 1000 Ohms
multiplied by the nominal voltage of the truck
circuit, between the parts under voltage and
the truck chassis.
Contact the After-Sales Service.
1152 807 80 01 [EN]
Safety 2
Safety regulations for handling consumables

Safety regulations for handling consumables

Permissible consumables

WARNING Refer to the maintenance data table for

the permissible substances necessary for
Consumables can be dangerous.
operation.
It is necessary to follow the safety regulations when
handling these substances.

Oils

DANGER WARNING
Oils are flammable! There is a risk of slipping on spilled oil, particularly
– Follow the statutory regulations when combined with water!

– Do not allow oils to come into – Collect spilled oil immediately using an oil-
contact with hot motor parts. binding agent and dispose of it in accordance
with regulations.
– No smoking, fires or flames!

ENVIRONMENT NOTE
DANGER Oils are water pollutants!
Oils are toxic!
Always store oil in containers that comply with
– Avoid contact and consumption the applicable regulations.
– In case of inhalation of steam
or fumes, breathe fresh air Avoid spilling oils.
immediately.
Collect spilt oil immediately using an oil
– After contact with the eyes, rinse
thoroughly with water (for at least
binding agent and dispose of it in accordance
10 minutes) and then consult an with regulations.
eye specialist.
Dispose of old oils according to the applicable
– If swallowed, do not induce regulations.
vomiting. Seek immediate medical
attention.

WARNING
Prolonged intensive contact with the
skin can result in loss of skin oils and
cause irritation.
– Avoid contact and consumption.
– Wear protective gloves!
– After any contact, wash the skin
with soap and water and then apply
a skin care product.
– Immediately change soaked
clothing and shoes.

1152 807 80 01 [EN] 23

2 Safety
Safety regulations for handling consumables

Hydraulic fluid

WARNING ENVIRONMENT NOTE

During operation of the forklift truck,
hydraulic fluids are pressurised and Hydraulic fluid is a water-polluting substance!
are hazardous to your health.
Always store hydraulic fluid in containers
– Do not spill these fluids! complying with the regulations.
– Follow the statutory regulations
Avoid spilling.
– Do not allow the fluids to come into
contact with hot motor parts. Spilt hydraulic fluid should be removed with
– Do not allow to come into contact oil-binding agents at once and disposed of
with the skin. according to the regulations.
– Avoid inhaling the spray
Dispose of old hydraulic fluid according to
– Penetration of pressurised
fluids into the skin is particularly regulations.
dangerous if these fluids escape
at high pressure due to leaks in
the hydraulic system. In case of
such injury, seek medical advice
immediately.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).

Battery acid

WARNING WARNING
Battery acid contains dissolved Battery acid contains dissolved
sulphuric acid. This is toxic. sulphuric acid. This is corrosive.
– Avoid contact and consumption. – When working with battery acid,
– In case of injury, seek medical always wear protective clothing
advice immediately. and eye protection.
– Do not allow any acid to get onto
the clothing or skin or into the
eyes; if this does happen, rinse
immediately with plenty of clean
water.
– In case of injury, seek medical
advice immediately.
– Immediately rinse away spilt
battery acid with plenty of water.
– Follow the statutory regulations

ENVIRONMENT NOTE

24 1152 807 80 01 [EN]

Safety 2
Safety devices

– Dispose of used battery acid in line with the

applicable regulations.

Disposal of consumables
ENVIRONMENT NOTE
Materials that have to be disposed of following
maintenance, repair and cleaning must be
systematically collected and disposed of in
accordance with regulations. Observe the
national regulations for your country. Work
may only be carried out in areas designated
for this purpose. Take care to minimise, as far
as possible, any impact on the environment.
• Any spillage of fluids such as hydraulic oil,
brake fluid or gear lubricant oil must be
immediately soaked up with an oil-binding
agent.
• The regulations for disposal of used oil are
applicable.
• Any spillage of battery acid must be neu-
tralised immediately.

Safety devices
Damage, faults
Any damage or faults observed on the truck or Work on the electric installation (e.g. connect-
the accessories must be reported immediately ing a radio, additional lights or other acces-
to the responsible personnel. The truck and sories) is permitted only with the approval of
accessories must never be used before they the manufacturer.
are correctly reconditioned as they cannot be
guaranteed to be safe for operating or driving.
The safety mechanisms and switches must
never be removed or disabled. The predefined
setpoint values must not be modified.

1152 807 80 01 [EN] 25

2 Safety
Safety devices

26 1152 807 80 01 [EN]

 3

Overviews
3 Overviews
Overviews

Overviews

1 Battery plug handle (emergency stop) 9 Traction motor

2 Battery cover 10 Pump unit
3 Switch key 11 Electromagnetic brake
4 Traction control module 12 Lift cylinder
5 Fork arms 13 Digicode (LFM Go)*
6 Load wheels 14 Tiller
7 Stabiliser wheels 15 Platform*
8 Drive wheel

*Option

28 1152 807 80 01 [EN]

Overviews 3
Controls and display

Controls and display

Tiller

1 Handle 4 Horn
2 Lowering 5 Throttle
3 Raising 6 Anti-collision device

1152 807 80 01 [EN] 29

3 Overviews
Controls and display

Battery charge indicator

COMMENTS / SCREEN
DESCRIPTION EXPLANATION
MESSAGES
91% - 100%: 10 bars
1% - 10%: 1 bar
Full charge: 100% 0%: 1 flashing bar (lift
Battery charge level
1 Low charge: 10% Dis- function not permitted).
represented by 10 bars
charged : 0% NB: To protect the battery,
0% corresponds to max.
80% discharge.
1)Flashing: less than 50
hours truck operation until
2 Service alarm (red) the next service
2)Constant: service date
overdue
Switched on: default or
3 Red indicator light
alarm

30 1152 807 80 01 [EN]

Overviews
DESCRIPTION
4 Green indicator light
5 Breakdown code
6 Fault or brake wear (air gap)
7 Hourmeter
8 STOP alarm (red)
9 T° alarm (red)
.
1152 807 80 01 [EN]
3
Controls and display
COMMENTS / SCREEN
EXPLANATION
MESSAGES
Switched off: truck switched
off
Switched on: truck switched
on
These codes help the After
Sales Service to decide on
E3 294
the appropriate response
from the service engineer
Do not operate the truck
- The meter runs from when
the truck is switched on and
a control is used.
- When counting, the dot
Indicates the number of next to the tenths of an hour
operating hours of the flashes.
machine -The hourmeter displays
hours and tenths of an hour.
- When the power supply is
disconnected, the hours are
stored in the memory.
Misc. problems Do not operate the truck
-> Truck is stopped
Constant: control module
In general, wait a few
overheating
minutes and then continue.
31
3 Overviews
Controls and display

Digicode option (LFM Go)

1 Switch ON (operating mode) 4 Key fault or incorrect code

2 Switch OFF and awaiting code 5 Time delay of automatic switch-off
3 Programming mode active

Operation Key in LED status Notes

USE
red off continuous
* 0 0 0 0 0 # or * 1 green (1)(correct PIN) 0 0 0 0 0 or 1 2 3
ON 2 3 4 5 # (by default) 4 5 PIN code by default
red flashing green
off (4)(incorrect PIN)
red off green
OFF # (3 seconds) Truck power off
flashing (2)

PROGRAMMING (truck switch OFF only (2))

ADMINISTRA- Once the diodes have
TOR CODE ES- * 0 0 0 0 0 0 0 gone out, the electronic
continuous red
SENTIAL FOR 0 # (by default) key automatically
continuous green (3)
ALL DIGICODE reverts to "operating
SETTINGS mode"
New operator * 0 * 4 5 6 7 8 #
red off green flashing Example of new
code (2) (code accepted) operator code: 45678
Allocating * 2 * 5 4 3 2 1 #
red off green flashing *2*: operator reference
operator codes (2) (code accepted) 10 options from 0 to 9
Deleting operator * 2 * #
red off green flashing *2*: operator reference
codes (2) (deletion accepted) (between 0 and 9)
Modifying * * 9 * 1 2 3 4 red off green flashing
administrator 5 6 7 8 # (2) (code accepted)
codes
To reactivate the default
Restoring
administrator code
the initial
(00000000), please
administrator
contact your agent or
code
nearest dealer.

32 1152 807 80 01 [EN]

Overviews 3
Controls and display

PROGRAMMING (truck switch OFF only (2))

Power switches off
Activating the red flashing green automatically after
automatic * * 2 * 1 # flashing (5) (5 s before 10 mins (600 s by
switch-off switch-off) default) if the truck is
not being used.
Example: automatically
Setting the
switches off after 1 min.
time delay of * * 3 * 6 0 #
red off green flashing
(60s) when not used.
the automatic (2) (value accepted)
Minimum setting = 10 s
switch-off
/ maximum = 3000 s
Deactivating red off green
the automatic * * 2 * 0 # flashing (2) (command
switch-off accepted)
.

1152 807 80 01 [EN] 33

3 Overviews
Markings

Markings
Marking positions

1 Manufacturer’s symbol 9 Cold storage area label

2 EXU 16 model label 10 ELECTRICAL HAZARD label (option)
3 EXU 18 model label 11 DANGER INSTRUCTIONS label (option):
4 EXU 20 model label see chapter 4 "Adjusting the on-board
5 EXU 22 model labe charger"
6 Identification label 12 Label PIEK (option) on the outside of the
7 Slinging label truck
8 Warranty label (for Germany only) on the
inside of the truck

34 1152 807 80 01 [EN]

Overviews 3
Markings

Identification label

NOTE
Indicate the serial number for all technical
enquiries.

1 Model
2 Manufacturer
3 Serial number
4 Year of manufacture
5 Unladen weight (without battery) in kg
6 Battery maximum weight
7 Battery minimum weight
8 Additional weight (ballast) in kg
9 Nominal motor power (kW)
10 Battery voltage V
11 Rated capacity in kg
12 EC conformity symbol

1152 807 80 01 [EN] 35

3 Overviews
FleetManager option

FleetManager option
The FleetManager option allows you to control
access to the truck. The option is a fleet
management system.
You can access the system:
• Either by using a keypad
• Or by using a reading device for a transpon-
der or an RFID card
The fleet manager sets the access details via
the web interface. This affects the transpon-
der cards or PIN codes for the corresponding
trucks. It is possible to change the amount
of time for which the access authorisation is
valid.

36 1152 807 80 01 [EN]

Overviews 3
Lithium-ion specific

Lithium-ion specific
Lithium-ion marking

1 Standard label for a truck equipped with a

lithium-ion battery

1152 807 80 01 [EN] 37

3 Overviews
Lithium-ion specific

38 1152 807 80 01 [EN]

 4

Use
4 Use
Intended use of the trucks

Intended use of the trucks

CAUTION
This machine was designed for the transport and
storage on racks (pallet stackers only) of loads
packed on pallets or in industrial containers de-
signed for this purpose.
The dimensions and capacity of the pallet or contai-
ner must be adapted to the load being transported
and must ensure stability.
The table of characteristics and performance atta-
ched to this user manual gives you the information
you need to check that the equipment is suitable for
the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.

40 1152 807 80 01 [EN]

Use 4
Checks and actions prior to use

Checks and actions prior to use

List of checks prior to start-up

WARNING – Attachments (special equipment) must be

properly secured and function according to
Damage or other defects on the forklift truck or
attachments (special equipment) can result in their operating instructions.
accidents.
– Damaged or missing stickers must be
If damage or other defects are noticed on the truck replaced in compliance with the marking
or attachments (special equipment) during the
following inspections, do not use the truck until position table.
it has been properly repaired. Do not remove or – The roller guide rails must be coated in a
disable the safety systems and switches. Do not
change the pre-set values. visible layer of grease.
– The wheels must show no signs of defects
or heavy wear. The mounting must be
WARNING
correct.
Risk of falling!
– Check that there are no foreign objects that
When working on high-level parts of the truck, do
not use truck components for access or to stand on. could hinder the operation of the wheels
and rollers.
– Use suitable access equipment.
– The warning devices (horn etc.) must work.
Ensure that the truck is in good working
– The battery cover must be closed.
condition prior to start-up.
– Check that the covers are correctly posi-
To do this, carry out the following checks:
tioned.
– Fork arms or other load-carrying equipment
– The operator must be qualified to drive the
should not show any signs of noticeable
truck. The operator must be able to reach
damage (for example: bending, cracks,
the controls and operate them (especially
significant wear).
the anti-crush device). Do not obstruct
– Check that there are no signs of leaking access to the controls.
consumables under the truck.
Please inform your supervisor if you notice
– Do not restrict the field of vision. Ensure the any defects.
visible area specified by the manufacturer
is observed.

1152 807 80 01 [EN] 41

4 Use
Checks and actions prior to use

Charging a Gel or Lead battery

(wall-mounted charger)
– Open the cover.
– Leave it open.
– Remove the battery disconnection handle
(1) from the truck plug (2).
– Connect the wall-mounted charger.

42 1152 807 80 01 [EN]

Use 4
Setup

Setup
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 the
desired position or enter the 5-figure code
then validate using the # key on the digicode
keyboard (default code = 00000).

NOTE
With the digicode option, when the key is
turned to the 0 position the truck is in tortoise
mode. The truck will still function if the key is
removed.

Selecting the driving mode

NOTE
The ignition key may be turned to two different
positions to choose the driving mode.
"Tortoise" position (2) : gentle acceleration
and deceleration; max. speed: 4 km/h
"Hare" position (3) : strong acceleration and
deceleration; max. speed: 6 km/h
– Check the battery charge with the combined
indicator (4) and change or charge the
battery if necessary.
– Turn the ignition key (1) to the "hare"
position (3) for normal driving mode.

NOTE
Perform a visual check on the truck before
starting.

1152 807 80 01 [EN] 43

4 Use
Setup

Checking the anti-crush safety

device
Anti-crush safety function
The truck moves in reverse when the anti-
crush button (2) is pressed.
If the truck is being operated in narrow areas
(such as in a lift for example), the operator may
get stuck against the wall if care is not taken.
Without an anti-crush safety device, the tiller
could injure the operator.
The truck automatically shifts into reverse
when the anti-crush device on the tiller head
comes into contact with the driver’s body.
When the operator moves away from the
anti-crush device, the vehicle stops even if
forward travel is selected again.
Normal operation may be resumed after
releasing the drive direction switches.

Checking the anti-crush safety device

WARNING
Ensure that the test zone is free of people and
objects, both in front of and behind the truck.

– Operate the drive direction selector (1) or

(3) in forward travel.
The truck moves forward.
– Activate the anti-crush safety device (2).

WARNING
The truck stops and shifts into fast reverse.

– Release the anti-crush safety device.

The truck stops.

44 1152 807 80 01 [EN]

Use 4
Setup

Checking the brake

CAUTION
Perform this check on a flat surface.

– While driving, tilt the tiller in areas (1) et (3),

to test brake response.
In these two areas, the truck is braked and the
drive unit is no longer powered. Releasing the
tiller in the drive area (2) sends the tiller into
the (3) area and cuts traction.

Checking the emergency stop

– Pull the emergency stop handle (4) up-
wards.
– The power supply to the machine is cut off.
– The electrical controls and motors are
disabled.
– The electromagnetic brake is applied.
– Reconnect the emergency stop handle (4)
to restore the circuits.

1152 807 80 01 [EN] 45

4 Use
Setup

Checking the horn

– Press the horn button (5) located on the
upper part of the tiller.
– The horn sounds.

46 1152 807 80 01 [EN]

Use 4
Operating the FleetManager™ option

Operating the FleetManager™ option

Description of the FleetManager option
The Fleet Manager fleet management system Shock sensor
allows access control and transmission of
This sensor allows you to record the shocks
truck data.
received by the truck.
The web interface allows data to be parame-
If the truck receives a shock, it is possible to
terised. The fleet manager parameterises the
configure a speed reduction.
truck based on his chosen options.
The fleet manager is the only person who is
Software is also available.
able to change certain parameters.
Additional options:
• Shock sensor NOTE
• Tools for wireless data management: Replace the sensor if it is faulty.
▶ GSM(2) GPRS(1)module with antenna
The options available on the truck are: GSM GPRS module
• Access control The module consists of a GSM modem and an
• Access control and shock sensor antenna.
• Access control and GPRS module The module allows you to:
• Access control, shock sensor and GPRS • Access truck information remotely
module
• Use geolocation
(1)
GPRS: General Packet Radio Service
The data is stored on a server.
(2)
GSM: Global System for Mobile Communi-
Data is transmitted by Bluetooth (default) or by
cation
GSM module (optional).

1152 807 80 01 [EN] 47

4 Use
Operating the FleetManager™ option

Commissioning a truck equipped

with the FleetManager™ option
Commissioning a truck equipped with a
keypad or an electronic key
– Turn the switch key to start the truck.
– Enter the PIN code on the keypad. The PIN
code consists of five to eight digits.
By default, no PIN code is given as a factory
setting.
If the PIN code is correct, the LED (1) is not
lit. The LED (2) flashes slowly at two-second
intervals (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 can
specify that the operator must enter a prelimi-
nary code when logging in. The operator can
then assess the state of the truck.

Commissioning a truck equipped with an

RFID reading device
– Turn the switch key to start the truck.
– Place the RFID transponder card or the
RFID transponder (4) in front of the reading
device (3).
If the card is correct, the LED (1) is not lit. The
LED (2) flashes slowly at two-second intervals
(green colour).
Two acoustic signals sound.
The truck is now ready for use.

48 1152 807 80 01 [EN]

Use 4
Operating the FleetManager™ option

FleetManager™ option: Colour code

for the LEDs
The LEDs can have different statuses and
different colours. Below is the list of the most
common messages and their meanings.

Malfunction Cause Solution

LED status
Signal transmitter
LED 1 LED 2
Reading device
variant: no
valid access Generate a
authorisation valid access
Keypad variant: authorisation
no valid access using the
authorisation interface
Lit continuously A long acoustic for the PIN code
Off signal sounds
Red colour entered

Keypad variant:
PIN code entered
Re-enter the
incorrect or not
PIN code
confirmed using
the Enter key

The operator
has been
granted access Use the interface
authorisation. to enter a new
Lit continuously Flashes once A long acoustic
But the period period of validity
Red colour Green colour signal sounds
of validity has
expired.
The date of the Update the date
truck is incorrect of the truck
Flashes quickly Lit continuously Memory is 80% Clear the
Yellow colour Green colour full memory
There are several
possible causes:
- Reading device
or keypad not
A long acoustic accessible Contact the
Flashes quickly Flashes quickly
signal sounds - GPRS module After-Sales
Red colour Red colour
upon activation not accessible Service Centre
- Built-in
rechargeable
battery flat
- Memory full

1152 807 80 01 [EN] 49

4 Use
Operating the FleetManager™ option

Malfunction Cause Solution

LED status
Signal transmitter
LED 1 LED 2
Flashes quickly Lit continuously A shock has
Reset the shock
Red colour Green colour occurred
The truck is
The truck is
switched on but
connected via
is not moving.
a Bluetooth link.
Wait for all of
The operating
Flashes quickly the relevant
Off data is being
Blue colour data to be read.
read. The
As soon as the
reading process
LEDs change to
can take up to
a different status,
five minutes.
resume work.
.

50 1152 807 80 01 [EN]

Use 4
Operating the FleetManager™ option

Disconnecting a truck equipped with

the FleetManager™ option

NOTE
Operators must not log off intentionally while
driving.
WARNING
Access to the truck must be disabled.
Unauthorised users are not allowed to use the truck.

Disconnecting a truck equipped with a

keypad or electronic key
– Park the truck in a safe place.
– Press the button (3) to log off. Keep the
button pressed in.
No LEDs light up. A long acoustic signal
sounds.
The LED (1) lights up for a second (red colour).
The LED (2) is not lit. A long acoustic signal
sounds.
The LED (1) is no longer lit. The LED (2)
flashes slowly at two-second intervals (green
colour). No acoustic signal sounds.
The truck is disabled.
– Turn the switch key to the off position to
switch the truck off completely.

1152 807 80 01 [EN] 51

4 Use
Operating the FleetManager™ option

Disconnecting a truck equipped with an

RFID reading device
– Park the truck in a safe place.
– Briefly place the RFID card or the RFID
transponder (4) in front of the reading device
(3).
The LED (1) lights up for a second (red colour).
The LED (2) is not lit. A long acoustic signal
sounds.
The LED (1) is no longer lit. The LED (2)
flashes slowly at two-second intervals (green
colour). No acoustic signal sounds.
The truck is disabled.
– Turn the switch key to the off position to
switch the truck off completely.

52 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Lithium-ion specific
Vertical access lithium-ion batteries:
connecting/disconnecting the
battery connector

WARNING
Electrical risk
Regularly check the condition of the contacts of the
connectors.
Each ½ connector has a polarising pin. Ensure
the polarising pin is present and in good condition.
They prevent the risk of reverse polarity.

Disconnecting the battery connector

– Secure the truck.
– Turn off the ignition and remove the key.
There are two different ways to disconnect the
battery. It is up to the operator to choose which
one to use.
– Pull the emergency stop handle (1) upwards
to disconnect it. The emergency stop
handle (1) is located at the front of the truck.
– Alternatively, open the cover of the battery
compartment. Next, disconnect the battery
connector (2).
It is not necessary to turn off the lithium-ion
battery once the battery has been discon-
nected.

Connecting the battery connector

Check if the operator has disconnected the
battery connector (2) or the emergency stop
handle (1).
– Press the emergency stop handle (1) into
the fixed socket on the truck.
– Alternatively, reconnect the battery connec-
tor (2).

1152 807 80 01 [EN] 53

4 Use
Lithium-ion specific

Commissioning a truck equipped

with a vertical access lithium-ion
battery

NOTE
Do not connect any additional electrical
devices on the truck. Contact the After-Sales
Service if you want to add additional devices.
To commission a truck equipped with a vertical
access lithium-ion battery, proceed as follows:
– Open the cover of the battery compartment

– Connect the truck battery connector (2)

– Turn on the battery To this end, check that
the green indicator light (1) is on
If the green indicator light is on, the battery is
functioning.
If the green indicator light is off, the battery
is not turned on. Press the button for one
second. Wait until the button lights up. The
indicator light will then turn bright green.
– Close the battery compartment cover.
– Turn the truck off by turning the key or by
typing in the PIN on the digicode.
The truck is ready for operation.

Switching off the truck

– Turn the key or press and hold the # button
on the digicode.

NOTE
It is not necessary to turn off the battery. If the
truck is not used for a certain period of time,
the battery is automatically turned off. This
period of time is normally 24 hours. It can be
configured. Contact the After-Sales Service to
configure this. If you want to turn it off, simply
press on the button for one second. Wait for
the button to turn off.

54 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Side access lithium-ion batteries:

connecting/disconnecting the
battery connector

WARNING
Electrical risk.
Regularly check the condition of the contacts of the
connectors.
Each ½ connector has a polarising pin. Ensure the
polarising pins are present and in good condition.
They prevent any risk of reverse polarity.

Disconnecting the battery connector

– Immobilise the machine.
– Switch off the ignition and remove the key.
– Pull the emergency stop handle (2) upwards
to disconnect it. The emergency stop
handle (2) is located at the front of the truck.
It is not necessary to switch off the lithium-ion
battery once the battery connector has been
disconnected.

Connecting the battery connector

– Press the emergency stop handle (2) into
the fixed socket on the truck.

Commissioning a truck equipped

with a side access lithium-ion battery

NOTE
Do not connect any additional electrical
devices to the truck. Contact the After-Sales
Service if you want to add additional devices.
To commission a truck equipped with a side
access lithium-ion battery, proceed as follows:
– Connect the truck battery connector (2).

1152 807 80 01 [EN] 55

4 Use
Lithium-ion specific

– Open the cover of the battery compartment.

– Switch on the battery. To this end, check
that the green indicator light (1) is on.
If the green indicator light is on, the battery is
functioning.
If the green indicator light is off, the battery
is not switched on. Press the button for one
second. Wait until the button lights up. The
indicator light will then turn bright green.
– Close the battery compartment cover.
– Switch on the truck by turning the key or by
entering the PIN on the electronic key.
The truck is ready for operation.

Switching off the truck

– Turn the key or press and hold the # button
on the electronic key.

NOTE
It is not necessary to switch off the battery. If
the truck is not used for a certain period of time,
the battery is automatically switched off. This
period of time is normally 24 hours. It can be
configured. Contact the After-Sales Service to
configure this. To switch off the battery, simply
press on the button for one second. Wait for
the button to turn off.

56 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Display on a truck equipped with a

lithium-ion battery
An EXU truck equipped with a lithium-ion
battery has a specific display (1).
It is recognisable by its white screen.
The other functions are identical to the stan-
dard display. They are described in chapter 3:
Display.

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4 Use
Driving

Driving
Driving safety instructions
Behaviour when driving
The operator must obey the same rules within
the plant as he would on the road . He must
drive at a speed appropriate for the driving
conditions . For example, an operator should
drive slowly around corners, when entering
and passing through narrow passageways,
when driving through swing doors, at blind
spots, or on uneven surfaces . The operator
must always maintain a safe braking distance
from vehicles and persons in front of him and
must always have the truck under control.
He should avoid sudden stops, making
fast U-turns, overtaking other vehicles in
potentially dangerous areas or areas with
poor visibility.
Driving the truck while seated is prohibited.
All EXU 16/18/20/22 models are designed to
be operated in pedestrian mode, therefore :
• Never sit on the truck to drive it.
• The truck must not be used as a stepladder.
• The truck was not designed to transport
people and must not be used for this
purpose.
• The operator must always stay within the
truck clearance.
• Stay in the safety area (working area
defined by the manufacturer).
Use of a telephone or radio in the truck is
permitted , but avoid using these devices
when driving as they may distract you.
Take a test drive on an open surface .

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Use 4
Driving

Driving
– Turn the ignition key to the Tortoise po-
sition (slow acceleration and deceleration)
or the Hare position (faster acceleration
and deceleration).
– Lower the tiller in (2) zone.

NOTE
The truck is in the drive position in the (2)
position. In the lower (1) or upper (3) the brake
is applied and the traction motor is switched
off.

NOTE
Always operate the travel throttle slowly, as
the truck reacts immediately. Abrupt starts or
braking or reversal of direction of travel must
be avoided at all costs.

Forward travel
– Press with your thumb on the lower part of
the throttle.
– The speed increases with the movement of
the throttle; speed is limited to 4 or 6 km/h
depending on the position of the key.
– When the control throttle is released, the
truck brakes electrically.

Reverse travel
– Press with your thumb on the upper part of
the throttle.
– The speed increases with the movement of
the throttle; speed is limited to 4 or 6 km/h
depending on the position of the key.
– When the control throttle is released, the
truck 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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4 Use
Driving

Using the folding platform (option)

1
There are two positions for the folding platform
2
(1): A
• Position A: platform raised 3
• Position B: platform lowered
In pedestrian mode, the platform is raised. B
The maximum authorised speed is 6 km/h. 2276

In ride-on mode, the platform is lowered. The

maximum authorised speed is 6 km/h.

Driving in ride-on mode

To use the truck in ride-on mode, proceed as
follows:
– Lower the platform (1) in the direction
indicated by the arrow (3)
Once the job is complete, it is necessary to
raise the platform.
– Raise the platform (1) in the direction
indicated by the arrow (2)

Driving in pedestrian mode

The platform (1) is raised. The operator walks
alongside the truck.

DANGER
Risk of injury.
Ensure that the platform is raised correctly before
walking alongside the truck.
Ensure that the platform is correctly in the vertical
position.

DANGER
Risk of injury.
In pedestrian mode, stay sufficiently far away from
the truck. The truck must not be able to strike the
operator’s feet.
Wear safety shoes.

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Use 4
Driving

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 is
switched off.
In zone (3) the truck can be used at full speed.
The traction speed is proportional to the
throttle activation.
In zone (2) the maximum authorised speed
varies according to the angle of the tiller.

A Braking range
B Unlimited driving range
C Driving range speed limiter
D Maximum speed charasteristic

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4 Use
Driving

Braking

WARNING
The quality of the floor surface affects the braking
distance of the truck.
To be taken into consideration when driving.

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

Moderate braking
– Switch throttle (2) or (3) in the opposite
direction of travel.

Parking brake
– Release the drive direction switch (2) or (3).
The truck is braked with the electromagnetic
brake when its speed approaches 0 km/h or
when the tiller returns to the vertical position.

Standby (optional)
The truck can be put in energy-saving mode to
prolong the service life of the battery when it is
not in use.
After a certain period of inactivity, the truck
switches off. To restart the truck, you must
switch it off and then switch it on again, using
the key.
This time period can be configured between 0
and 10 minutes. This function is disabled by
default.

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Lifting

Timeout can be adjusted. Please call the

After-Sales Service Centre.

Lifting
Lift control elements
Raising the fork arms
– Activate the control switch (1)

Lowering the fork arms

– Activate the control switch (2)

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4 Use
Handling loads

Handling loads
Load handling safety rules

WARNING
Closely follow the following instructions before
picking up loads. Never touch or stand on moving
parts of the truck (e.g. lifting device, pushing
devices, work installations or devices for picking
up loads).

WARNING
Take care not to trap hands or feet when operating
the truck.

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Use 4
Handling loads

Before picking up a load

DANGER
Safety footwear must be worn.

CAUTION
Transporting people is strictly prohibited.

CAUTION
Be careful not to touch adjacent loads or loads
positioned at the side or in front of the load being
handled.
The loads are to be stacked so that they are aligned
with a small space between each of them and so
that they do not catch each other.

Ensure that the load weight does not exceed

the truck’s capacity.
– Refer to the nominal capacity specified on
the truck’s capacity rating plate.
– You must also make sure that the load is
stable, well-balanced and centred between
the load arms in order to avoid dropping any
part of the load.
– Check that the width of the load is compati-
ble with the width of the load arms.

Picking up a load
– Approach the load carefully.
– Lower the load arms so that they can easily
be inserted into the pallet.
– Insert the load arms under the load.
– If the load is shorter than the load arms,
position it so that the end of the load over-
hangs the end of the load arms by a few
centimetres, in order to avoid hooking the
load in front.
– Raise the load a few centimetres.
– Withdraw the load slowly and in a straight
line.

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4 Use
Handling loads

Transporting a load
– Always drive forwards for optimum visibility.
– When carrying a load on a slope, always
climb and descend with the load uphill.
Never travel across the slope or make a
U-turn.
– Reverse travel must only be used for
depositing a load. Since visibility in this
direction is restricted, you should only travel
at very low speed.
– To facilitate movement over obstacles,
increase the ground clearance.

Setting a load down on the ground

– Carefully move the truck to the desired area.
– Carefully move the load into the deposit
area.
– Lower the load until the load arms are free.
– Withdraw the truck in a straight line.
– Raise the load arms again several centime-
tres.
CAUTION
Be careful to keep clear of other loads at the side of
or behind the truck.

DANGER
Personnel must not stand under or near the truck
when the load is in the raised position.

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Handling loads

Transporting pallets or other contain-

ers
As a general rule, loading units must be trans-
ported one by one (e.g. pallets). Transporting
several loading units at a time is only autho-
rised:
• when the safety preconditions are fulfilled.
• by order of the monitoring agent.
The forklift operator must ensure that the
loading unit is properly packaged. He must
only move loading units that have been
carefully prepared and that meet the safety
requirements.
0252_003-103

0252_003-104

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4 Use
Handling loads

Driving on upward and downward

slopes
Slopes should always be approached with the
load facing towards the top of the slope. Only
slopes marked as clear traffic routes compat-
ible with the truck’s technical specifications
can be safely used.

DANGER
The operator must ensure that the ground is clean
and has a non-slip surface.
Never travel across slopes or make a U-turn on a
slope!
Do not park the truck on a slope.
Reduce speed when going down slopes.

Please observe the maximum gradients

defined as suitable for laden and unladen
transport.

Transporting the truck in the lift

The truck must only be taken in lifts with an A minimum safety distance of 100 mm from
adequate loading capacity that are designed the walls of the lift must always be observed.
for this purpose, and for which authorisation
Anyone transported with the truck must only
has been received from the operator. Inside
enter the lift after the truck has been correctly
the lift, the truck must be immobilised so that
immobilised and they must exit the lift first.
no part is in contact with the wall of the lift cage.

Driving on loading bridges

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

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Use 4
Cold store usage (optional)

Cold store usage (optional)

Designation
Your truck is fitted with special equipment
for use in cold stores. It can be used for two
operating ranges and carries a cold store
label.
The cold store equipment for the truck consists
of using specialised oils (for the hydraulic
installation and the gears) suitable for cold
stores.

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

Operating range 2: alternating use indoors

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

Use

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

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

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4 Use
Cold store usage (optional)

– Drive the truck for approximately 5 minutes

and operate the brakes several times to
ensure the truck operates safely.
– Operate all the lifting functions several
times. This warming up phase is required to
allow the oil to reach operating temperature.

Use

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

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

Parking
– Always park the truck outside the cold store.

CAUTION
The batteries must not remain discharged or un-
used in the cold store overnight.

– Charge the battery outside the cold store

and use a spare battery.

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Use 4
Handling the truck in specific situations

Handling the truck in specific situations

Truck towing procedure
It is not possible to tow the truck with no
electrical function. The electromagnetic brake
remains in the closed position.
Truck towing is authorised with a rigid connec-
tion (tow bar) if the truck to be towed can no
longer be braked. Check that the towing vehi-
cle is sufficiently powerful to pull and brake the
truck 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.
CAUTION
This procedure must be carried out by authorised
personnel.

– Unload the fork arms, then disconnect the

battery.
– Remove the engine cover.
– Two M5 X 35 screws (1) are required.
– Screw the screws (1) to the brake (2) in the
holes (3). The brake is then unlocked.

CAUTION
The truck must only be towed at low speeds.

1
0252_003-109

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4 Use
Handling the truck in specific situations

– After towing, chock the truck to prevent it

from moving.
2
– To re-establish brake operation, unscrew
and remove the two screws (1).
– Refit the covers.
WARNING
It is essential that the covers are correctly refitted
before the machine is used.

0252_003-110

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Use 4
Handling the truck in specific situations

Slinging, lifting and setting the truck

Loading with a hoist
CAUTION
Use a hoist and hooks of sufficient capacity. Refer
to the load weight shown on the truck’s data plate.

– Attach a sling or a hook to the 2 points

indicated (3).

CAUTION
It is strictly prohibited to sling the truck by the tiller or
other points not designed for this.

CAUTION
Wedge battens between the chassis and slings to
prevent damage.

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

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4 Use
Gel or lead batteries: Handling the battery

Gel or lead batteries: Handling the battery

Battery type
The pallet stacker can be equipped with
different types of batteries. Observe the
information on the nattery type plate. Also
refer to ⇒ Chapter "Technical Data", P. 133 for
this purpose.

WARNING
The weight and dimensions of the battery affect
truck stability.
Do not change the weight conditions when chan-
ging the battery. Do not remove nor change the
position of additional weights.

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

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Use 4
Gel or lead batteries: Handling the battery

Opening/closing the battery cover

Opening
– Park the truck.
– Lower the load arms.
– Turn the key switch off.
– Lift the cover (1).

Closing
CAUTION
Keep fingers away from moving parts to avoid any
risk of them being trapped.

– Close the cover (1).

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4 Use
Gel or lead batteries: Handling the battery

Charging the battery using an

external charger

CAUTION
The battery may be damaged if discharged beyond
a given limit.
– Immediately charge the battery.

– Safely park the truck

– Before charging, check the condition of the
battery cable and the charging cable and
replace these cables if necessary.
– Disconnect the battery connector (4).
– Connect the battery plug to the charge
station connector.
WARNING
Only disconnect the battery connector from the
battery charger when both the battery charger and
truck are switched off.

NOTE
Follow the instructions provided by the battery
and battery charger manufacturers (equali-
sing charge)
WARNING
Risk of damage, short circuit or explosion.
Do not place metal objects or tools on the battery.
No smoking!

WARNING
The electrolyte (diluted sulphuric acid) is toxic and
very caustic.
Follow the safety regulations when handling battery
acid.

WARNING
Explosive gases are generated during battery
charging.
– Ensure the work area is well-ventilated.

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Use 4
Gel or lead batteries: Handling the battery

On-board charger
Precautions for installation and use
The on-board charger means you no longer
have to use a charging room. In fact, this
charger can be connected to any 2P+T 230 V
16 A socket. However, before charging this
way, the user must ensure that the location
selected for charging satisfies all the required
safety 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
connected and protected.
• Before charging, check the condition of
the connections and cables (retighten, as
required).
• Charging must be carried out in an area
where there is no condensation or pollution
as well as sufficient ventilation.
• The charger must not be exposed to oil,
grease and other similar substances.
• Charging must be carried out with the truck
stopped.
• The increase in the temperature of the unit
in relation to the ambient temperature is
10°C maximum. That of the expelled air
is 25°C maximum. Wait 10 minutes after
stopping the charger before touching the
unit.
• Since the charger is cooled by forced
ventilation, do not block the air inlets
and outlets. There must be sufficient air
circulation to the outside.

Electrical characteristics of the charger

Mains voltage 190 V < U < 260 V Maximum output
35 A +/-2%
current
50 / 60 Hz +/-1%
Nominal battery
(automatic 24V
voltage
Network frequency adaptation)
No inrush current to Tolerance on the
1%
the mains connection voltage of bearing U
Maximum output
.

1040 W +/-3%
power

Battery characteristics
Gel or open lead-acid
Battery type
battery
Number of
12 2 V components
components
140 Ah minimum to
375 Ah maximum
Capacity (adaptation of the
charging curve by a
selector)
.

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4 Use
Gel or lead batteries: Handling the battery
General conditions for use
Storage temperature -45° C to +80° C
Operating
-15° C to +40° C
temperature
Relative humidity 90%
Weight 2 kg
Volume 1.4 litres
.
Electrical safety
• Protection against inversion of battery po-
larity: the charger is protected by an output
relay. After reconnecting the battery in the
right direction, the charger restarts charging
without requiring human intervention.
• Mains protection: by a 250 V 10 A 5x20
timed fuse. The mains fuse is fitted directly
to the electronic card. The user is not
authorised to replace this fuse. If this fuse is
faulty, the charger must be returned to the
service centre.
Relay
A 2x1.5 mm2 lead is used to connect the safety
relay. The relay has a maximum cut-off power
of 16 A.
• Contact A: blue wire
• Contact B: brown wire
• When the charger is neither connected
to the mains nor the battery, the "contact
A" and "contact B" outputs are electrically
insulated from one another.
• When the charger is connected to the
battery only, the "contact A" and "contact
B" outputs are electrically connected.
• When the charger is connected to the mains
and the battery, the "contact A" and "contact
B" outputs are electrically insulated from
one another.
• When the charger is connected to the mains
only, the "contact A" and "contact B" outputs
are electrically insulated from one another.
(see wiring diagram)
78 1152 807 80 01 [EN]
Other charging characteristics
Maintenance charges
If the charger stays connected to the mains,
it restarts a charging cycle every 48 hours
after the end of the previous charge in order to
compensate for self-discharge.
Partial recharging
The charger adapts automatically to the
battery discharge situation and therefore
allows any type of partial charging to be carried
out ("opportunity charging").
The overcharging calculation takes into
account partial recharging. The mixture is
always sufficient, without needless water
consumption, which prevents premature
wear of the batteries (often due to overlong
charging periods) and reduces the need for
maintenance.
Protection during charging
Mains micro-break protection
If the mains power is cut off, all the charging
parameters in progress are stored in the
memory for 13 minutes. As soon as the mains
power returns, charging resumes from the
point (I, U) at which it was cut off, with the
number of Ah already injected stored in the
memory.
If the cut-off period is longer than 13 minutes
(the truck could have been used), a complete
charging cycle is initialised.
Time protection
If during phases I1 + P + U > 16H, the charger
becomes faulty. This can happen when a
battery has a short-circuited component.
Simply reset the mains to cancel the fault.
Temperature safety
Since the charger is cooled by ventilation, the
air inlets and outlets must never be blocked.
The fan runs when the mains power is con-
nected. It stops when charging is complete or
when the mains power is disconnected.
Use 4
Gel or lead batteries: Handling the battery

The charger supplies reduced power if the

ambient temperature exceeds the usage
temperature range, in order to protect itself
(the charging period will be extended in this
case).
The charger stops if the micro-controller
detects a temperature measurement fault.

Using the charger

Before charging, it is necessary to ensure that Phase Green LED Red LED
the location selected for charging satisfies all
Mains socket
of the safety requirements.
discon- Off Off
nected
NOTE Charging
Flashing Off
The charger is compatible with wet lead and phases
gel batteries with a maximum capacity of Stopped /
400 Ah. Equalisation / Continuously
Off
Maintenance lit
The charger is designed: phase
– To be incorporated in the truck Charging
Continuously
process too Off
– To stay permanently connected to the lit
long
battery
Charger
– To operate in all positions polarity
– To stay connected to the mains during reversed
periods when the truck is not being used (+bat and
to ensure the availability of the machine -bat charger
cables
CAUTION reversed, Continuously Continuously
with the lit lit
Do not disconnect the battery connector during
charging (green indicator light flashes). battery
remaining
The truck cannot be operated during charging.
normally
connected
The on-board charger is intended for recharg-
to the truck
ing the battery.
assembly)
– Switch off the truck. Battery
Do not pull the emergency stop handle. This polarity Off Off
operation cuts off the circuits and stops the reversed
battery from charging. Selector
in neutral Flashing Flashing
– Open the cover of the battery compartment position
to ensure good ventilation.
– Avoid interrupting the charging procedure
– Connect the cord to the mains socket.
until it is complete (to optimise battery
– Connect the charger plug to a mains wall service life).
socket.

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4 Use
Gel or lead batteries: Handling the battery

CAUTION CAUTION
It is strictly prohibited to use an on-board charger Risk of damage to the mains cable due to frequent
other than the one recommended. operator handling. Risk of electric shock and/or
burns!
The mains cable must be checked regularly as
CAUTION part of periodic statutory checks and maintenance
operations.
Risk of damage to the mains cable resulting in
electric shock and/or burns!
Park the truck sufficiently close to the mains wall
socket to ensure that the mains cable on the
on-board charger is not taut when connected and
charging.

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Gel or lead batteries: Handling the battery

Gel or Lead batteries: Adjusting the

on-board charger
• When the truck is delivered with its battery,
the charger settings are adjusted in the
factory.
• The adjustment depends on the selected
battery.

Charging curve selector

The curve is selected using the selector
located 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 diodes
flash simultaneously to indicate that no curve
has been selected.
The four thick lines indicate the four charging
curves:
• open lead-acid battery with a capacity
below 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
CAUTION

If the battery is changed during the service

life of the truck, it is essential to ensure that
the charger settings correspond to the new
battery type. Any modification to the settings
must be carried out by a qualified technician.

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4 Use
Gel or lead batteries: Handling the battery

Changing the battery

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

– Attach the lifting device (1) correctly to

the battery (2) (see the lifting device user
manual), then remove it from the truck.
– The lifting device must exercise vertical
traction in order to avoid the boot being
damaged. The hooks must be placed so
that they cannot fall on the battery cells
when the lifting device is slackened.

CAUTION
Use small hooks for slinging the battery.

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Use 4
Gel or lead batteries: Handling the battery

Gel and lead side access batteries:

changing the battery using a trolley
Positioning the truck
– On level ground, move the pallet truck close
to the trolley (2).
– Align the battery compartment with the
empty space on the trolley (1).
– Using the load arm lifting/lowering controls,
adjust the height of the battery compartment
to that of the edge of the trolley (3).
– Switch off the ignition and pull the emer-
gency stop handle.

CHANGING THE BATTERY

REMOVE THE DISCHARGED BATTERY:
– Open the battery case cover.
– Fit the battery connector on the cells.
– Push the lever towards the battery(A) then
lift 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 truck
using an extension lead.

NOTE
Use a fairly long extension lead to allow the
truck to move.
– Connect the battery connector and then
switch on the ignition.
– Move the truck forwards or backwards to
align the battery compartment with the
charged battery (3).
– Switch off the ignition and pull the emer-
gency stop handle.
– Disconnect and remove the extension lead.

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4 Use
Gel or lead batteries: Handling the battery

– Turn the retaining lock of the charged

battery.
INSTALL THE CHARGED BATTERY:
– Fully insert the charged battery in its com-
partment.
– Fold the stop down.
– Lift the lever slightly and then unlock the
notch.
– 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
prevent them from being damaged when a battery
is removed from or inserted into its compartment.

CAUTION
During operations to fit the battery, keep your
fingers away from moving parts to avoid any risk
of them being trapped. We recommend the use of
gloves.

CAUTION
Before using this machine, ensure that the battery
is correctly installed and that its cover is correctly
locked.

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Gel or lead batteries: Handling the battery

Side access battery: changing the

battery using a moveable support

CAUTION
During operations to fit the battery, keep your
fingers away from moving parts to avoid any risk
of them being trapped. We recommend the use of
gloves.

Positioning the truck

– On level ground, move the pallet truck close
to the moveable support
– Switch off the ignition and pull the emer-
gency stop handle.

CHANGING THE BATTERY

REMOVE THE DISCHARGED BATTERY:
– Open the battery case cover.
– Fit the battery connector on the cells.
– Push the lever towards the battery(A) then
lift the notch (B).
– Lift the lever (C)to release the battery
– Lift the stop
– Pull the discharged battery onto the move-
able support.
– Lock the discharged battery on the move-
able support using the hook.
– Release the moveable support by lifting up
the 2 wheel locks with your foot and take the
discharged battery to the charging station.
INSTALL THE CHARGED BATTERY:
– Fully insert the charged battery in its com-
partment.
– Fold the stop down.
– Lift the lever slightly and then unlock the
notch.
– Fold the lever down to lock the battery.
– Connect the recharged battery.
– Close the battery cover.

1152 807 80 01 [EN] 85

4 Use
Gel or lead batteries: Handling the battery

CAUTION
Before using the machine, ensure that the battery
is correctly installed and that its cover is correctly
locked.

86 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Lithium-ion specific
Charging lithium-ion batteries using
an external charger
Read the information in the documentation
provided with the charger.
It provides information on:
• the various charger screens
• possible error messages
• precautions for use.

CAUTION
Risk of damage to the battery
It is essential to use the charger supplied with the
battery for charging lithium-ion batteries.

DANGER
Electrical danger
Do not touch the lithium-ion battery when it is
charging and do not wear rings or jewellery. Do
not place metal objects on or near the battery. Do
not light a naked flame in the vicinity of the charging
zone or near charging batteries.

WARNING
To avoid any sparks, always connect the battery
connector before switching the battery charger on
and disconnect it after switching the charger off.

It is important to charge the lithium-ion battery

fully at least once a week.
The LED located on the display flashes red.
You must therefore recharge the battery to
100%.

Charging the vertical access lithium-ion

battery using an external charger
To recharge the lithium-ion battery, proceed
as follows:
– Park the truck close to the charging station.

1152 807 80 01 [EN] 87

4 Use
Lithium-ion specific

– Secure the truck. Lower the fork arms.

– Switch off the ignition (2).

– Open the battery compartment cover.

– Unplug the battery connector (1).
– Plug the socket of the charging station into
the connector (1) located on the battery.
– Switch the charger on as directed in the
specific instructions for the charger. A
screen appears displaying the words
Battery connected. Charging the battery
is automatically managed by the on-board
electronics of the battery.
– When charging is complete and the charger
has stopped, unplug the charger.

NOTE
It is possible to stop charging before the end of
the complete cycle. The operator can resume
work more quickly. It is advisable to recharge
the battery after each use if possible. The
battery charge percentage is indicated on the
display screen. The charging time is indicated
on the screen of the charger.
– Reconnect the battery connector (1) on the
truck.
– Then close the battery compartment cover.
– Switch on the ignition (2) and check the
charging status of the truck on the display
(3).
– The truck is now ready for use.

88 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Charging the side access lithium-ion

battery using an external charger
To recharge the lithium-ion battery, proceed
as follows:
– Park the truck close to the charging station.
– Secure the truck. Lower the fork arms.
– Switch off the ignition (2) (key or electronic
key).
– Pull the emergency stop handle to discon-
nect the battery connector (1).

– Plug the socket of the charging station into

the connector (3) located in the technical
compartment.
– Switch the charger on as directed in the
specific instructions for the charger. A
screen appears displaying the words
Battery connected. Charging the battery
is automatically managed by the on-board
electronics of the battery.
– When charging is complete and the charger
has stopped, unplug the charger.

NOTE
It is possible to stop charging before the end of
the complete cycle. The operator can resume
work more quickly. It is advisable to recharge
the battery after each use if possible. The
battery charge percentage is indicated on the
display screen. The charging time is indicated
on the screen of the charger.
– Reconnect the emergency stop connector
(1) to the truck.

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4 Use
Lithium-ion specific

– Switch on the ignition (2) (key or electronic

key) and check the charging status of the
truck on the display.
– The truck is now ready for use.

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Use 4
Lithium-ion specific

Replacing the vertical access

lithium-ion battery
When handling batteries, make sure that the
capacity of the equipment used (hoist, slings,
hooks) is sufficient for the weight of the battery.
When installing a replacement battery, it is
imperative to use the same model of lithium-
ion battery.
Refer to the rating plate of the truck for the
minimum and maximum acceptable weights.

DANGER
Electrical danger
The components of the lithium-ion battery should
be handled with great care.

CAUTION
The battery is a heavy and fragile component that
must be handled with care. Wearing gloves is
recommended.

CAUTION
Risk of being trapped
During operations to lock and insert the battery,
keep your fingers away from moving parts to avoid
any risk of them being trapped.

Changing the battery using a hoist

– Bring truck to a controlled stop.
– Lower the forks.
– Turn off the ignition and remove the key.
– Pull the emergency stop handle (4) and
remove it.
– Open the battery hood.
– Turn off the battery (5) (see chapter 4
Commissioning a truck equipped with a
lithium-ion battery).
– Unplug the battery connector (2).

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4 Use
Lithium-ion specific

– Remove the screw (1) that holds the fas-

tener on the side of the battery compart-
ment.

– Attach the slinging hooks (3) to the battery

case.

NOTE
Using secured hooks is recommended.
– Lift the battery slowly.
– Replace the battery.
– Position the new battery carefully in the
chassis.
– Guide it to the end of travel.
– Remove the sling hooks.
– Refit the fastener (1) on the side of the
battery compartment. Tighten the screw to
torque. The torque is 17 Nm for an electrical
tool.
– Reconnect the battery connector (2).
– Close the battery hood.
– Reconnect the emergency stop handle (4).
– Restart the truck.

NOTE
There is a ballast plate at the bottom of the
battery container. It is essential to leave
this in place and not to move it. This plate
is necessary and ensures the stability of the
truck.

92 1152 807 80 01 [EN]

Use 4
Lithium-ion specific

Side access lithium-ion battery:

changing the battery
It is not possible to change the side access
lithium-ion battery.
If the side access lithium-ion battery is faulty,
please contact the After-Sales Service.
Only After-Sales Service technicians are
authorised to change the lithium-ion battery.
The mounting (1) of the lithium-ion battery
must be checked regularly.
The tightening torque is 20 Nm.

WARNING
If the mounting is loose, the battery can be dislod-
ged from its compartment.
Carefully check the tightening torque.

1152 807 80 01 [EN] 93

4 Use
Error codes

Error codes
The combined indicator may display an error
code. When an error code is displayed, please
call the After-Sales Service Centre.

NOTE
Four error codes may be displayed. For
example:
• E1: 239 0.0 h
• E2: 212
• E3: 426
• E4: 320
Make a note of these error codes before
switching off the truck. These error codes 0252_003-065-V2

are stored, but are not necessarily displayed

on the combined indicator.

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Use 4
Putting out of Commission

Putting out of Commission

Park the truck

WARNING – Remove the ignition key or press the

digicode # key for 2 seconds.
Do not park the truck on a slope or, if this is really
necessary, make sure it is secured with chocks. – Press emergency stop button.
Never leave the truck with the load in the raised
position.
Restarting work
Park the truck – Push emergency stop button.
– Lower the forks arms. – Put the key back in the ignition or enter the
5-digit code on the electronic key (default
code: 12345).

1152 807 80 01 [EN] 95

4 Use
Gel or lead batteries: Storage

Gel or lead batteries: Storage

Storage of truck
Precautions should be taken if the truck must
not be used for a reasonably long period. The
operations depend on the length of time it is
unused.
Long-term truck storage
The following work must be carried out on
the truck to prevent corrosion if it needs to be
stored for a long period of time. If the truck is to
be stored for more than two months, it must be
positioned in a clean and dry area. The area
must be well-ventilated with no risk of freezing.
The following operations must be performed:
– Clean the truck thoroughly.
– Check the hydraulic oil level and refill if
necessary.
– Lower the forks onto a suitable support (e.g.
a pallet) until the chains are slack.
– Coat any unpainted metal parts with a thin
layer of oil or grease.
– Grease all hinges and joints.
– Check battery condition and electrolyte
density. Maintain the battery in accordance
with the manufacturer’s requirements.
(Follow the instructions).
– Spray contacts with an aerosol product
designed for contacts.
– Raise and chock the truck: the wheels must
not touch the ground in order to prevent
irreversible deformation of the tyres.
– Cover the truck with a cotton cover to protect
it from dust.
CAUTION
We recommend that you do not use a plastic sheet
as this encourages condensation to form.
Consult the service department for further
measures to take if the truck must be stored
for a longer period of time.
Recommissioning after storage
If the truck has been stored for more than
six months, it must be checked carefully
before being recommissioned. This check
is similar to the workplace accident prevention
inspection. It is therefore necessary to check
all points and systems that are important for
truck safety.
Carry out the following operations:
– Clean the truck thoroughly.
– Grease all hinges and joints.
– Check the condition and density of elec-
trolyte, and, if necessary, recharge the
battery.
– Check that there are no traces of conden-
sation water in the hydraulic oil. Drain if
necessary.
– Carry out the same maintenance work as
for the first time it was commissioned.
– Commission the truck.
– In particular, check the following during
start-up:
• traction, control and steering.
• brakes (service brake and parking brake).
• lifting device.

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Use 4
Gel or lead batteries: Storage

Permanent Putting Out of Commis-

sion (Destruction)
When scrapping the truck, it is necessary to:
– Remove the various parts of the truck
(covers, battery, chains, motors etc.)
– Sort out the components depending on their
type: pipes, rubber components, lubricants,
aluminium, iron etc.
– Before scrapping the truck, notify the
competent authorities of your country in
writing.
– After receiving the authorisation from the
competent authorities, remove any compo-
nents according to national standards.

NOTE
The client is solely responsible for any irreg-
ularities he has committed during or after the
scrapping of the truck’s components and the
removal of components.

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4 Use
Lithium-ion specific

Lithium-ion specific
Transporting a truck equipped with a
lithium-ion battery
A lithium-ion battery is a special product.
Special precautions should be taken when:
• transporting a truck equipped with a lithium-
ion battery
• transporting only the lithium battery.
A special label must be affixed for transport.
This logo depends on the battery transport
conditions (transported separately or in the
truck).
Refer to the specifications and rules in force in
your country before transporting the truck and
the lithium-ion battery.

98 1152 807 80 01 [EN]

Use
Lithium-ion batteries: Long-term storage
DANGER
Electrical danger
We recommend that batteries are stored at a height
between 60 and 120 cm.
Remain extremely vigilant when manoeuvring to
avoid piercing the batteries.
Special precautions should be taken when
storing lithium-ion batteries.
– Store the battery in a dry place at a tem-
perature between 0 and 40° to preserve its
service life. This area must not be hermeti-
cally sealed to allow air renewal.
– Indicate the storage area. Access should be
strictly limited to personnel who are aware
of the risks and safety instructions.
– It is strongly advisable to recharge the
battery fully before storing it.
– Batteries can be stored for a maximum
period of 12 months if they are fully charged
(100%).
– Regularly check the charge level of the
battery. Check the level at least every 3
months. Maintain the charge level above
30%. Recharge the battery if necessary.
– Completely recharge the battery every 3
months to avoid impairing the performance
of the battery.
– Recharging could take up to 24 hours.
CAUTION
A battery that has reached an excessively low level
cannot be recharged.
Contact your After-Sales Service immediately.
Precautions should be taken if the truck must
not be used for a reasonably long period. The
operations depend on the length of time it is
unused.
1152 807 80 01 [EN]
4
Lithium-ion specific
Storage of trucks for a period of less than
two months
If the truck is not used for a period of up to
two months, it is necessary to perform certain
operations:
– Clean the truck carefully.
– Check the hydraulic oil level and refill if
necessary.
– Coat any unpainted metal parts with a thin
layer of oil or grease.
– Grease all hinges and joints.
– Spray contacts with a suitable aerosol
product.
– Place the truck on chocks to avoid the tyres
becoming flat.
– Cover the truck with a cotton cover to protect
it from dust. Avoid using a plastic sheet.
Long-term truck storage
The following work must be carried out on
the truck to prevent corrosion if it needs to be
stored for a long period of time. If the truck is to
be stored for more than two months, it must be
positioned in a clean and dry area. The area
must be well-ventilated with no risk of freezing.
The following operations must be performed:
– Clean the truck carefully.
– Check the hydraulic oil level and refill if
necessary.
– Coat any unpainted metal parts with a thin
layer of oil or grease.
– Grease all hinges and joints.
– Recharge the lithium-ion battery every
3 months. Please observe the above
instructions.
– Spray contacts with an aerosol product
designed for contacts.
99
4 Use
Lithium-ion specific
– Raise and chock the truck: the wheels must
not touch the ground in order to prevent
irreversible deformation of the tyres.
– Cover the truck with a cotton cover to protect
it from dust.
CAUTION
We recommend that you do not use a plastic sheet
as this encourages condensation to form.
Consult the After-Sales Service for further
measures to take if the truck must be stored
for a longer period of time.
Recommissioning after storage
If the truck has been stored for more than
six months, it must be checked carefully
before being recommissioned. This check
is similar to the workplace accident prevention
inspection. It is therefore necessary to check
100 1152 807 80 01 [EN]
all points and devices that are important for
truck safety.
Carry out the following operations:
– Clean the truck carefully.
– Grease all hinges and joints.
– Check the battery charge status and
recharge the battery if necessary.
– Check that there are no traces of conden-
sation water in the hydraulic oil. Drain if
necessary.
– Carry out the same maintenance work as
for the first time it was commissioned.
– Commission the truck.
– In particular, check the following during
start-up:
• traction, control and steering
• brakes (service brake and parking brake).
 5

Maintenance
5 Maintenance
General maintenance information

General maintenance information

General
The following instructions contain all the
information required for servicing your truck.
Carry out the various maintenance work in
compliance with the maintenance plan. This
will ensure that your truck is reliable and in
good working order and that the warranty
remains valid.

Service plan
Maintenance work must be carried out ac-
cording to the hour meter. Please consult the
truck’s maintenance plan.
The service plan is followed by advice to
facilitate work.
Maintenance intervals must be reduced if the
truck is used under harsh conditions (extreme
heat or extreme cold, large quantities of dust). 0.0 h

Grade and quantity of lubricants and

other consumables
Only lubricants and other consumables
specified in these operating instructions are 0252_003-065-V2

authorised for use during maintenance work.

Lubricants and other consumables required
for truck maintenance are listed in the mainte-
nance specifications table.
Never mix different qualities of grease or oil.
If it is absolutely necessary to change brands,
make sure to flush thoroughly beforehand.
Before changing any filters or working on
the hydraulic system, thoroughly clean the
surface and the areas around the part.
All containers used to pour oil must be clean.

102 1152 807 80 01 [EN]

Maintenance 5
General maintenance information

Servicing and maintenance personnel training and qualification

Truck maintenance must only be carried out The person responsible for carrying out the
by qualified and authorised personnel. inspection must have sufficient knowledge
and experience to be able to assess the
The annual inspection for prevention of
condition of the truck and the efficiency of
accidents at work must be carried out by a
the protective installations in accordance
person qualified to do so. The person carrying
with the technical regulations and principles
out this inspection must provide their expertise
established for checking industrial trucks.
and opinion without being influenced by
economic factors or company internal issues.
Safety is the only critical deciding factor.

Battery maintenance staff

Batteries must only be recharged, maintained
and changed by specially trained personnel.
Personnel must follow the manufacturer’s
instructions of the battery, the battery charger
and the truck.
It is essential to follow the battery maintenance
instructions and the battery charger operating
instructions.

Maintenance operations that do not require special training

Simple maintenance operations such as A specific qualification is not necessary.
checking the hydraulic fluid level or checking
Refer to the maintenance section of this
the battery electrolyte level can be carried out
manual for further information.
by persons with no special training.

Ordering spare parts and consumables

Spare parts are provided by our spare parts
service department. You will find the infor-
mation required to place an order in the spare
parts and fitting catalogue.
Only use spare parts recommended by the
manufacturer.
Unauthorised spare parts may increase the
risk of accidents due to faults relating to
quality or incorrect choices. Anyone who uses
non-compliant spare parts must assume full
responsibility in the event of an accident.

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5 Maintenance
General maintenance information

List of inspections
Maintenance and lubrication
1. Every day
2. Carry out maintenance according to the
hour meter (bold typeface)
After 4000 hours of service, for example, it will
be necessary, to carry out the maintenance
and lubrication work for every "1000 hours".
After 6000 hours of service, for example, it will
be necessary to carry out the maintenance
and lubrication work for every "1000 and
3000 hours".
After 9000 hours of service, continue as
above, therefore instead of 1000 hours:
10,000 hours of service.

Truck:
Type No:

1000 2000 3000 4000 5000

1000 1000 1000 1000 1000
3000
6000 7000 8000 9000 10000
1000 1000 1000 1000 1000
3000 3000
.

104 1152 807 80 01 [EN]

Maintenance 5
General maintenance information

Technical inspection and maintenance characteristics

Assembly Item/Lubricant Capacities/Setting values

Hydraulic oil 1,25 l
Filter element Efficency : 300 µm
EXU16 maximum pressure 219 bar
Main hydraulic system
EXU18 maximum pressure 219 bar
EXU20 maximum pressure 186 bar
EXU22 maximum pressure 201 bar
Reducer Reducer oil 0.9 litre maximum
Drive wheel Wheel nuts Tightening torque: 80 Nm

Stabiliser wheels Wheel pin bolt Tightening torque: 35 Nm

Load wheels Locking screw Tightening torque: 50 Nm
Traction and pump motor Fuses Power 125A, Quantity: 1
Control cable harness Fuses Control 7.5A, Quantity: 1
Traction motor Maintenance free 1.2 kW (AC)
EXU16, EXU18 : 1,0 kW
EXU16,18,20CF*, EXU20 : 1,2
Pump motor Maintenance free
kW
EXU22, EXU22CF* : 1,4 kW
Battery Distilled water As required
Joints Lithium grease As required

*CF: Cold store

1152 807 80 01 [EN] 105

5 Maintenance
Maintenance safety instructions

Maintenance safety instructions

Servicing and maintenance measures
To avoid accidents during servicing and – Ensure that there is no risk of the truck
maintenance operations, take all necessary moving or starting up unexpectedly. For
safety measures. For example: this reason, remove the battery connector.

Working on the electrical equipment

Operations on the truck’s electrical system
must only be carried out when there is no
voltage supply.
Operating checks, testing and adjustment
work on parts supplied with voltage must only
be 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 removed
before carrying out any operations on electric
components.
Remove the electric equipment (which com-
prises electric components such as the trac-
tion controller) before carrying out any welding
operations. This precaution prevents this
electric equipment from being damaged.
Operations on the electric system require the
consent of the manufacturer.

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

106 1152 807 80 01 [EN]

Maintenance 5
Preparatory tasks for maintenance

Preparatory tasks for maintenance

Slinging and jacking the truck
To lift the truck, its sub-assemblies or ad-
ditional equipment, lifting devices must be
hooked only to the appropriate lifting points.
When jacking, take appropriate measures (us-
ing chocks or wooden blocks) to prevent the
truck from slipping or tipping over.

Jacking
The truck must be jacked and chocked in order
to perform certain maintenance operations.
Always make sure:
• To use a jack with an adequate lifting
capacity,
• Make sure that the truck is parked on level
ground and is secured against rolling and
tipping.

WARNING
Disconnect the battery plug before lifting the truck!

Lifting by the chassis

– Position the truck so that the fork arms touch
the wall.
– Lift up the truck until the wheels are no
longer in contact with the ground.
– Raise the truck with chocks.

1152 807 80 01 [EN] 107

5 Maintenance
Preparatory tasks for maintenance

Access to the technical compartment

– Fully raise the pallet truck’s load arms to
facilitate these operations.

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

Opening the lower cover

– Unscrew the 2 screws (1) that hold the cover
in place.
– Unclip the cover at both ends
– Raise and pull back the lower cover.

Opening the front cover

After removing the lower cover:
– Unscrew the 4 screws (2) that hold the cover
in place.

Accessing the pump unit

After removing the front cover:

108 1152 807 80 01 [EN]

Maintenance 5
Preparatory tasks for maintenance

– Remove the plastic cover by unscrewing

the 2 screws (3) to provide easy access to
the pump unit.

– Then remove the mounting bracket (4)

1152 807 80 01 [EN] 109

5 Maintenance
Preparatory tasks for maintenance

Accessing the reducer and the brake

To access the reducer and the brake:
– Turn the tiller to the right or left-hand stop.
– Unscrew the 2 screws (3)

– Unscrew the 2 screws (2) located either

side of the two 1/2 covers.
– Remove the two 1/2 covers.

110 1152 807 80 01 [EN]

Maintenance 5
Maintenance plan for the lithium-ion battery

Maintenance plan for the

lithium-ion battery
The lithium ion battery does not require special
maintenance. However, it is necessary to
perform some maintenance operations, in
addition to the usual maintenance plan for the
truck.

As required

Clean the battery.

Check the battery connections and sockets.
Fully charge the battery at least once a week.
Check the tightness of the battery terminal. Retighten to the correct torque if necessary. The
torque is 23 Nm.
(For the vertical access battery only) Check the tightness of the battery mounting plate screw on
the battery compartment. Retighten to the correct torque if necessary. The torque is 17 Nm.
(For the side access battery only) Check the tightness of the battery mounting plate screw on the
battery compartment. Retighten to the correct torque if necessary. The torque is 20 Nm.

Maintenance operations every three months

Battery
Fully recharge the battery if it is in the storage area in or out of the truck

Maintenance operations every 1000 hours, but at least every 12 months

Battery
Visually check the battery
.

1152 807 80 01 [EN] 111

5 Maintenance
Cleaning

Cleaning
Clean the truck
Washing instructions
– Always park the truck as specified.
– Disconnect the battery connector (4).

CAUTION
– Disconnect the battery connector when washing
the truck.

Washing the exterior of the truck

WARNING
Do not use inflammable fluids for cleaning. Ob-
serve the above safety precautions for preventing
sparks through shorts (disconnecting the battery
connector). When the truck is being cleaned, care-
fully cover all vulnerable components, particularly
electric components. Observe the manufacturer’s
instructions for handling the cleaners.

– Clean the truck exterior with water and

cleaning agents soluble in water (sponge,
rags).
– Clean especially the oil filler openings and
the surrounding area.
– Grease the required assemblies (mast,
controls and joints).

Cleaning the electrical system

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

NOTE
Use only dry cleaning agents as cleaning
agents. Do not remove covers, etc.
– Clean electrical components with a non-
metallic brush and and blow dry with a weak
jet of air.

112 1152 807 80 01 [EN]

Maintenance 5
Cleaning

After washing the truck.

– Dry the truck thoroughly (eg with com-
pressed air).
– Take the truck back into operation accord-
ing to instructions.
If moisture has penetrated the motors despite
the precautionary measures, dry them first
with compressed air; if not, there is the risk of
short circuits! The truck must ONLY then be
turned on and taken into operation to prevent
any damage due to corrosion.

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5 Maintenance
Maintenance as required

Maintenance as required
Servicing wheels and rollers
Check the tyres and the wear on the
wheels and rollers
The tyre tread on the drive wheel (1), the
stabilising wheel (2) and the rollers (3) must
not be damaged.

Dimensions
Drive wheel 230 x 75 mm
Stabiliser wheels 125 x 40 mm
Single rollers 85 x 100 mm
Dual rollers 85 x 80 mm

– Replace damaged or worn wheels with new

wheels, and damaged or worn rollers with
new ones.
CAUTION
A wrongly adjusted stabilising wheel can lead to
stability problems.
This adjustment must be carried out by our service
department.

114 1152 807 80 01 [EN]

Maintenance 5
Maintenance as required

Checking the fuses

– Control fuses are accessed by removing
the front hood.
The 125 A fuse (1) protects the traction and
lifting power circuit.
The 7,5 A fuse (2) protects the control circuit.
We recommend that this operation be carried
out by our After-Sales Service Centre.

1152 807 80 01 [EN] 115

5 Maintenance
Maintenance as required

Regular maintenance of the trans-

mission gear
To increase the service life of the transmission
gear, 2 grease nipples (1) have been added to
its turntable.
It is therefore possible to regularly lubricate
the transmission gear.

NOTE
Use the lubricants recommended by the
manufacturer.

Folding platform maintenance

The folding platform must be checked regu-
larly. The following operations must be carried
out at least every three months or every 500
hours.
– Check that the folding platform operates
correctly
– Clean and lubricate the articulated parts of
the platform

116 1152 807 80 01 [EN]

Maintenance 5
Gel or lead batteries: Maintenance as required

Gel or lead batteries: Maintenance as required

Clean the battery and its compart-
ment

WARNING
This task must be carried out by a person wearing
acid-resistant protective gloves and industrial
goggles. Follow the safety regulations described in
previous chapters.

ENVIRONMENT NOTE
Do not pour acid-bearing wash water down the
drain. For more information, see the battery
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 damp
cloth.
– If sulphate build-up is heavy, you will need
to take out the battery, jet wash it and clean
the frame.

Lead battery
– Check that there are no electrolytes at the
bottom of the compartment by connecting
the rubber suction bulb supplied with the
battery to the plastic pump tube.
– Pump off any electrolyte that may have
spilled between the cells.
– Clean the top of the cells with a damp cloth.

CAUTION
In case of heavy sulphate build-up or excessive
electrolyte spillage, please contact the After-Sales
Service Centre.

1152 807 80 01 [EN] 117

5 Maintenance
Gel or lead batteries: Maintenance as required

Checking the condition of cables,

terminals and battery connector
– Check that the cable insulation is undam-
aged and that there are no signs of over-
heating at the connections.
– Check that the "+" and "-" output terminals
are not sulfated (presence of white salt).
– Check the condition of the power outlet
contacts and the presence of the keying pin.
– Check the condition of the locking tab on the
battery connector.

CAUTION
The points mentioned above can cause serious
incidents. In the event of a fault, please contact the
After-Sales Service.

118 1152 807 80 01 [EN]

Maintenance 5
Lithium-ion specific: Maintenance as required

Lithium-ion specific: Maintenance as required

Cleaning the lithium-ion battery

DANGER
Electrical danger
Do not open the battery.

Lithium-ion batteries do not require any

specific maintenance. However, it is advisable
to clean it regularly depending on its use.

CAUTION
Always switch off the battery before working on an
electrical component.

– Immobilise the truck.

– Lower the forks.
– Turn off the ignition and remove the key.
– Pull the emergency stop handle.
– Open the battery compartment cover.
– Switch off the battery using the button (1).
– Blow compressed air into the battery to
remove dust and impurities.

WARNING
It is advisable to wear industrial goggles and a
mask.

– Check the condition of the terminals.

DANGER
Electrical danger
Do not wear jewellery or metal objects.

– Switch on the battery.

– Close the battery compartment cover.
– Restart the truck.

1152 807 80 01 [EN] 119

5 Maintenance
Lithium-ion specific: Maintenance as required

Lithium-ion battery: harnesses and

cables

DANGER
Risk of short circuit
Do not use cables or harnesses other than those
provided with the lithium-ion battery that was sold
to you.

Using the cables provided with the vertical

access lithium-ion battery with a side access
lithium-ion battery is strictly forbidden.
Using the cables provided with the side access
battery with a vertical access battery is also
strictly forbidden.
A short circuit may occur and damage the
cable harness and the connector.

120 1152 807 80 01 [EN]

Maintenance 5
Service plan 1000 h

Service plan 1000 h

Work that must also be carried out
– Carry out maintenance work as necessary.
Refer to the chapter entitled Maintenance
as required.

1000-hour maintenance schedule

Maintenance operations every 1000 hours

Depending upon use, environmental conditions and driving style, the following procedures must
be performed every 1000 hours.

Preparatory tasks

Clean the truck (if necessary)

Check the error codes (using the diagnostic tool)
Traction motor
Check that the cables and bundling are in good condition
Transmission
Check for any possible oil leaks from the transmission gear
Lubricate the ring gear
Steering/Wheels/Braking
Check the wear on the tyre tread of the wheels
Check the brake air gap
Check that the nuts are tight
Electrical equipment
Clean and blow out the electrical plate
Check the mounting of the electrical connections
Check and adjust the battery electrolyte level
Check the condition and mounting of the battery cables
Hydraulic system
Check the system oil level

Check the system for leaks

1152 807 80 01 [EN] 121

5 Maintenance
Service plan 1000 h

Maintenance operations every 1000 hours

Load lift system

Check the level of wear on the rings and clevis pins
Oil or generously grease the rings and clevis pins

Final tasks
Check the general condition of the forks and the chassis
.

122 1152 807 80 01 [EN]

Maintenance 5
Service plan 1000 h

Checking the brake air gap

IMPORTANT
The mechanical braking torque is factory set.
– The brake must be checked in the braked
position, i.e. with the power supply cut.
– Check the air gap on the brake using a set
of wheel chocks.
– The value of the original air gap is 0.2 mm.
After partial wear of the disc, the maximum
air gap is 0.5 mm. Above this value, there is
a risk of not being able to release the brake
fully and a risk of overheating.
– If the air gap is close to the limit value of
0.5 mm, it must be adjusted.
– Loosen the three fixing screws (3).
– Adjust the three banjo bolts (4) to set the air
gap to its original value of 0.20 mm.
– Retighten the three mounting screws (3).
– Check the air gap at 3 points at 120°
intervals.
– Make sure that the air gap is equal right
around the brake.

NOTE
We recommend that this operation be carried
out by our After-Sales Service Centre.

1152 807 80 01 [EN] 123

5 Maintenance
Service plan 1000 h

Adjusting the height of the stabilisers

NOTE
Adjusting the clevis (1) with new drive wheel
and 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 the
height of the stabilisers:
– Loosen the lock nut (2) (36 spanner) by
holding the ball bearing (3) by its flat surface
(36 spanner)
– Tighten the clevis (1) using a 14 mm Allen
key to lower the wheel or loosen the clevis
(1) using a 14 mm Allen key to lift the wheel
– After adjustment, lock the clevis (1) with the
lock nut (2) tightened to a torque of 35 Nm

NOTE
To screw, unscrew or lock the clevis (1) always
hold the ball bearing (3) by its flat surface (36
spanner) during the procedure.

124 1152 807 80 01 [EN]

Maintenance 5
Service plan 1000 h

Oil level check

– Lower the load arms completely.
– Switch off the ignition and pull the emer-
gency stop handle.
– Pull back the cover of the technical com-
partment (see description in ″Access to the
technical compartment″).
– The oil level must be in the centre between
the minimum and maximum marks on the
tank 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).

1152 807 80 01 [EN] 125

5 Maintenance
Service plan 1000 h

Checking the wear on collars and

hinge pins
It is important to check the condition of the col-
lars and hinge pins on the following elements
of the lifting system :
• (1) Load arm shaft / support roller clevis
• (2) Push rod shaft / support roller clevis
• (3) Mobile chassis shaft / lift shaft
• (4) Fixed chassis / lift shaft
• (5) Cylinder / fixed chassis
• (6) Lift shaft / push rods

NOTE
If significant wear is found, replace the worn
collars and pins before the other components
are damaged.

126 1152 807 80 01 [EN]

Maintenance 5
Gel or lead batteries: Maintenance every 1000 hours

Gel or lead batteries: Maintenance every 1000 hours

Checking the on-board charger
– Connect the cord to the 220 V mains.
– Check that the green indicator light on the
display is flashing and that the red one is off
(charging in progress).
– Check that the truck is immobilised (traction
and lifting not permitted) as long as it is
connected to the 220 V supply.
– Disconnect the mains cord.

1152 807 80 01 [EN] 127

5 Maintenance
Gel or lead batteries: Maintenance every 1000 hours

Battery maintenance
The operations described below relate to
lead batteries with liquid electrolyte. For
batteries with gel electrolyte, which are said
to be "maintenance-free", please refer to the
manufacturer’s instructions.
WARNING
Avoid contact with the acid. Do not create a short-
circuit. Refer to the recommendations in the daily
checks section. The electrolyte contains sulphuric
acid, which is a hazardous product. Wear gloves
and goggles when working on the battery. In case
of contact with eyes or skin, rinse immediately with
clean water, then seek medical advice if necessary.
Charging the battery releases hydrogen, which can
create an explosive mixture. Do not create sparks,
do not smoke and keep naked flames away from
a battery which is being charged or has recently
been charged. To prevent the accumulation of
hydrogen, keep the battery cover open during
charging. Charge the battery in a well-ventilated
room. Do not place metal objects on the battery:
there is a risk of creating a short-circuit.

CAUTION
Before commencing work, unplug the battery
connector by pulling the emergency stop handle.

Electrical equipment, testing electrolyte

level and topping up with water
– This check and any topping up required
should be carried out every week, after
charging an open lead battery only.
– Turn off the key switch, open the cover and
disconnect the battery connector.
– Check the level, which should be up to the
base of the plug, slightly above the splash
guard.
– Add demineralised water to top up cells with
a low water level.
– Then refit the plugs.

CAUTION
Only top up with demineralised water. Never top
up before charging (risk of overflow). Do not overfill
the cells.

128 1152 807 80 01 [EN]

Maintenance 5
Gel or lead batteries: Maintenance every 1000 hours

NOTE
For more information, refer to the instructions
supplied with the battery.

Electrical equipment: checking the

electrolyte density
Measuring the density gives an accurate
indication of the charging status of each cell in
an open lead battery only. This measurement
can be taken before or after charging:
• Minimum density of an 80% discharged
battery: 1.14
• High density, battery 100% charged: 1.29
to 1.32 (depending on make)
– We recommend a reading every 1 or 2
weeks.
– Note down the values read in your battery
monitoring logbook.
– Lift the cover over each cell plug as de-
scribed above.
– Carefully record the specific gravity of each
cell with the hydrometer.
– Close the various stoppers after measure-
ment.

NOTE
If the density in the cells differs or it is very low
in certain cells, contact our service engineers.
Allowing the battery charge to fall below the
threshold of 1.14 is very detrimental to its
service life.

1152 807 80 01 [EN] 129

5 Maintenance
Maintenance every 3000 hours

Maintenance every 3000 hours

Work that must also be carried out
– Carry out the required maintenance work.
Refer to the Maintenance as required
chapter.
– Carry out all 1000-hour maintenance work.
Refer to the Maintenance every 1000 hours
chapter.

3000-hour maintenance schedule

Additional maintenance operations every 3000 hours

Depending upon use, environmental conditions and driving style, the following procedures must
be performed every 3000 hours.

Transmission
Drain the transmission gear oil
Hydraulic system
Drain the hydraulic system
.

130 1152 807 80 01 [EN]

Maintenance 5
Maintenance every 3000 hours

Hydraulic circuit, draining the circuit

Draining the circuit
– Lower the load arms to the ground to
eliminate pressure in the hydraulic circuit.
– Switch off the ignition and unplug the battery
connector.
– Disconnect the power supply to the solenoid
valve (3).
– Disconnect the cylinder supply hose (1).
– Remove the 2 screws (2) that hold the upper
support (angle bracket) in place.
– Lift out the hydraulic unit.
– Remove the unit’s upper support and the
filler 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 compartment
with 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
specifications (see lubrication table).

1152 807 80 01 [EN] 131

5 Maintenance
Maintenance every 3000 hours

Servicing the reducer

Draining the oil

NOTE
This operation must be carried out by the
service centre.

132 1152 807 80 01 [EN]

 6

Technical Data
6 Technical Data
Datasheet EXU

Datasheet EXU

134 1152 807 80 01 [EN]

Technical Data 6
Datasheet EXU

DESIGNATION
1.1 Manufacturer STILL GmbH
1.2 Model type EXU16 EXU18 EXU20 EXU22
Method of propulsion: battery, diesel, petrol,
1.3 Battery
LPG, mains power
Driving: manual, pedestrian, standing, seated,
1.4 Pedestrian
order picking
1.5 Rated capacity Q (kg) 1600 1800 2000 2200
1.6 Centre of gravity c (mm) 600
Distance from
load wheel axle 1150
1.8 X (mm) 963 / 883
to load mating lowered/raised
face (±5 mm)
Wheelbase 1150 1304 / 1449 /
1.9 Y (mm) 1381 / 1301
(±5 mm) lowered/raised 1228 1370

WEIGHT EXU16 EXU18 EXU20 EXU22

Battery
BS 430 / /
2 Pzs 495 /
82 Ah lithium-ion
352 / /
Weight in battery
2.1 working order kg 164 Ah lithium-ion
(±10%) 373 / /
battery
205 Ah lithium-ion
392 /
battery
410 Ah lithium-ion
433 /
battery
Load per laden
axle, 680 / 746 / 789 /
2.2 kg 2 PzS - 1150 /
drive side/load 1350 1542 1699
side (±10%)
Load per unladen
axle, 2 PzS rollers / drive
2.3 drive side/load kg 384/104 /
wheels
side (±10%)

WHEELS EXU16 EXU18 EXU20 EXU22

3.1 Tyres: polyurethane, rubber C+P/P C+P/P C+P/P C+P/P
Drive wheel
dimensions
3.2 Øxl (mm) 230 x 75
(width at the
ground)
Wheel sizes, load
3.3 Øxl (mm) Ø85 x 105 (bogies = 85 x 100)
side

1152 807 80 01 [EN] 135

6 Technical Data
Datasheet EXU
Additional wheels Øxl
3.4 Stabilisers 125 x 40
(dimensions) (mm)
Number of wheels at drive side/load side (x =
3.5 1x+ 2 / 2 (4 in bogies)
drive wheel)
Drive side track
3.6 mm 482
width (± 5 mm)
Load side track Mobile chassis
3.7 width (± 5 mm) mm 355 / 395 / 515
52/56/68

DIMENSIONS EXU16 EXU18 EXU20 EXU22

Lift
4.4 unladen/laden h3 (mm) 130
(± 5 mm)
Height of tiller in
4.9 driving position, h14 (mm) 740 / 1250
min/max.
Height at the
ends of the fork in
4.15 the lower position h13 (mm) 85
(max)
Total length (± 5 L1 1660 / 1660 /
4.19 BS / 2 PzS - / 1730 - / 1820
mm) (mm) 1730 1730
Length to load
L2
4.20 mating face BS / 2 PzS 510 / 580 - / 580 - / 670
(mm)
(±5 mm)
4.21 Total width b1 (mm) 720
Dimensions of
4.22 s/e/l (mm) 165 - 55 - 1150
forks
Outside fork
4.25 b5 (mm) 520 - 560 - 680
spread
Ground
clearance
4.32 at centre of m2 (mm) 36 / 166
wheelbase,
min/max
Battery EXU16 EXU18 EXU20 EXU22
Aisle width with
a 1000 x 1200 BS 1947 / 1962 / /
4.33 pallet crosswise Ast (mm)
(lowered/raised 2 Pzs 1997 / 2017 /
forks) 2060 /
3 Pzs / / /
2055
Aisle width with BS 1997 / 2012 / /
an 800 x 1200
4.34 pallet lengthwise Ast (mm) 2 Pzs 2047 / 2067 /
(lowered/raised 2110 /
forks) 3 Pzs / / /
2105

136 1152 807 80 01 [EN]

Technical Data 6
Datasheet EXU

Turning radius BS 1560 / 1495 / /

(mini) Wa
4.35 2 Pzs 1610 / 1550 /
(lowered/raised (mm)
forks) 1670 /
3 Pzs / / /
1585

PERFORMANCE DATA EXU16 EXU18 EXU20 EXU22

Transfer speed when
5.1 km/h 6/6
laden/unladen (5%)
Lifting speed when 0.03 /
5.2 m/s 0.04 / 0.06
laden/unladen (10%) 0.04
Lowering speed when
5.3 laden/unladen (10%) m/s 0.071 / 0.065 0.07/0.06
Maximum gradient when
5.8 % 14 / 24 13 / 24 11 / 24 10 / 24
laden/unladen, 5 minutes
Acceleration time when
5.9 laden/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 EXU22

Traction motor, hourly AC
6.1 kW 1.2
output motor
DC
6.2 Lift motor at 15% utilisation kW 1 1 1.2 1.4
motor
Battery type in accordance
with
6.3 DIN 46 536 B BS/2 Pzs BS/2 Pzs 2 Pzs 3 Pzs
DIN 46 531 / 35 /36 A, B, C,
no
24/160
BS / /
24/220
2 Pzs / 24 / 375 /
82 Ah
lithium-
23/82 / /
ion
battery
164 Ah
Battery voltage and lithium-
6.4 capacity (discharge in 5 V/Ah 23/164 / /
ion
h) battery
205 Ah
lithium-
/ 23/205 /
ion
battery
410 Ah
lithium-
/ 23/410 /
ion
battery

1152 807 80 01 [EN] 137

6 Technical Data
Datasheet EXU

BS 141 / /
2 Pzs 213 /
82 Ah
lithium-
63 / /
ion
battery
164 Ah
lithium-
kg 84 / /
6.5 Battery weight (±10%) ion
battery
205 Ah
lithium-
110 /
ion
battery
410 Ah
lithium-
151 /
ion
battery
Energy consumption
6.6 according to standardised kWh / h 0.38
VDI cycle

OTHER EXU16 EXU18 EXU20 EXU22

8.1 Speed control AC controller LAC
.

138 1152 807 80 01 [EN]

Technical Data 6
Datasheet EXU

1152 807 80 01 [EN] 139

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

Datasheet EXU 20S - EXU 22S (option)

140 1152 807 80 01 [EN]

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

DESIGNATION
1.1 Manufacturer STILL GmbH
1.2 Model type EXU 20S EXU 22S
Method of propulsion: battery, diesel, petrol, LPG, mains
1.3 Battery
power
1.4 Driving: manual, pedestrian, standing, seated, order picking Pedestrian
1.5 Rated capacity Q (kg) 2000 2200
1.6 Centre of gravity c (mm) 600
Distance from load
1.8 wheel axle to load x (mm) 1150 lowered/raised 962/895.5
mating face (±5 mm)
1.9 Wheelbase (±5 mm) y (mm) 1150 lowered/raised 1379/1312.5 1454/1387.5

WEIGHT Battery EXU 20S EXU 22S

BS /
Weight in working 2 Pzs 540 /
2.1 kg
order (±10%)
3 Pzs / 585
Load per laden axle, 2 Pzs 876/1664 /
2.2 drive side/load side kg
(±10%) 3 Pzs / 934/1851
Load per unladen axle, 2 Pzs 435/105 /
2.3 drive side/load side kg
(±10%) 3 Pzs / 460/125

WHEELS EXU 20S EXU 22S

3.1 Tyres: polyurethane, rubber C+P/P
Drive wheel
3.2 dimensions (width at Øxl (mm) 230 x 75 POLYURETHANE
the ground)
Ø85 x 105 (bogies =
3.3 Wheel sizes, load side Øxl (mm)
85 x 100)
Additional wheels
3.4 Øxl (mm) Stabilisers 125 x 40
(dimensions)
3.5 Number of wheels at drive side/load side (x = drive wheel) 1x+ 2 / 2 (4 in bogies)
Drive side track width
3.6 (± 5 mm) mm 482
Load side track width
3.7 mm Mobile chassis 52/56/68 355/395/515
(± 5 mm)

1152 807 80 01 [EN] 141

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

DIMENSIONS EXU 20S EXU 22S

Lift unladen/laden (±
4.4 h3 (mm) 125
5 mm)
Height of tiller in driving
4.9 h14 (mm) 740/1250
position, min/max.
Height at the ends of
4.15 the fork in the lower h13 (mm) 85
position (max)
4.19 Total length (± 5 mm) L1 (mm) Pedestrian/ride-on 1896/2286 1980/2360
Length to load mating
4.20 L2 (mm) Pedestrian/ride-on 745/1135 830/1210
face (±5 mm)
4.21 Total width b1 (mm) 720
4.22 Dimensions of forks s/e/l (mm) 165/55/1150
4.25 Outside fork spread b5 (mm) 520/560/680
Ground clearance at
4.32 centre of wheelbase, m2 (mm) 34/159
min/max
Lowered forks

Aisle width with a 1000 Pedestrian/ride-on 1975/2344 2058/2427

4.33 Ast (mm)
x 1200 pallet crosswise Raised forks
Pedestrian/ride-on 1908/2277 1996/2365
Lowered forks
Aisle width with an Pedestrian/ride-on 2175/2544 2265/2431
4.34 800 x 1200 pallet Ast (mm)
lengthwise Raised forks
Pedestrian/ride-on 2108/2477 2195/2564
Lowered forks
Pedestrian/ride-on 1737/2106 1824/2193
4.35 Turning radius (mini) Wa (mm)
Raised forks
Pedestrian/ride-on 1670/2039 1757/2126

PERFORMANCE DATA EXU 20S EXU 22S

Transfer speed when
5.1 km/h 6/6
laden/unladen (5%)
Lifting speed when 2 Pzs 0.04/0.06 /
5.2 m/s
laden/unladen (10%) 3 Pzs / 0.03/0.04

Lowering speed when 2 Pzs 0.07/0.06 /

5.3 laden/unladen (10%) m/s
3 Pzs / 0.07/0.06

142 1152 807 80 01 [EN]

Technical Data 6
Datasheet EXU 20S - EXU 22S (option)
Maximum gradient when
5.8 % 11/24 10/24
laden/unladen, 5 minutes
Acceleration time when
5.9 s 8.04/6.5
laden/unladen (d = 10 m)
5.10 Service brake Electromagnetic

DRIVE EXU 20S EXU 22S

6.1 Traction motor, hourly output kW AC motor 1.2

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

Battery type in accordance with
6.3 DIN 46 536 B 2 Pzs 3 Pzs
DIN 46 531 / 35 /36 A, B, C, no
BS / /
Battery voltage and capacity
6.4 V/Ah 2 Pzs 24/250 /
(discharge in 5 h)
3 Pzs / 24/375

BS / /
6.5 Battery weight (10%) kg 2 Pzs 219 /
3 Pzs / 287
Energy consumption according to
6.6 kWh / h 0.38 0.38
standardised VDI cycle

OTHER EXU 20S EXU 22S

8.1 Speed control AC controller LAC
.

1152 807 80 01 [EN] 143

6 Technical Data
Noise emission values

Noise emission values

Calculated in the test cycle in accordance
with EN 12053 from the weighted values for
the TRACTION, LIFT and IDLING operating
states.
Acoustic pressure level on the driver’s
compartment
EXU 16, EXU 18,
LPAZ = 70 dB (A)
EXU 20, EXU 22
in the LIFT
LPa = 73 dB (A)
operating state
in the "Idling"
LPb = 0 dB (A)
operating status
in the DRIVE 73,5 dB
LPc =
operating state (A)
Insecurity KPA ± 2,5 dB (A)

NOTE
Lower or higher noise values may occur when
using industrial trucks, due e.g. to the method
of operation, environmental factors and other
sources of noise.

144 1152 807 80 01 [EN]

Technical Data 6
Vibration characteristic values for bodily vibrations

Vibration characteristic values

for bodily vibrations
The values were determined according to EN
13059 using trucks with standard equipment
according to the data sheet (driving over test
course with humps).
Specified vibration characteristic according
to EN 13059
Measured
vibration aW.ZS = 0,80 m/s2
characteristic
Insecurity K = 0,3 m/s2

Specified vibration characteristic for hand-

arm vibrations
Vibration characteristic < 2,5 m/s2

NOTE
The vibration characteristic for bodily vibrati-
ons cannot be used to determine the actual
load level of vibrations during operation. This
depends on the operating conditions (state
of pathway, method of operation etc.) and
should therefore be determined on site, where
appropriate. It is mandatory to specify the
hand-arm vibrations even where the values do
not indicate any hazard, as in this case.

1152 807 80 01 [EN] 145

6 Technical Data
Vibration characteristic values for bodily vibrations

146 1152 807 80 01 [EN]

Index
g

A Clean the truck . . . . . . . . . . . . . . . . . . . 112

Cleaning the electrical system . . . . . . . 112
Access to the technical compartment . . 108
Consumables . . . . . . . . . . . . . . . . . . . . 23
Accessing the reducer and the brake . . 110
Battery acid safety instructions . . . . . 24
Adjusting the height of the stabilisers
Disposal . . . . . . . . . . . . . . . . . . . . . . 25
Stabilisers . . . . . . . . . . . . . . . . . . . . 124
Oil Safety Information . . . . . . . . . . . . 23
Adjusting the on-board charger . . . . . . . . 81
Safety information for handling
After washing the truck . . . . . . . . . . . . . 113
hydraulic fluid . . . . . . . . . . . . . . . . 24
Anti-crush safety device
Copyright and property rights . . . . ...... 4
Checking . . . . . . . . . . . . . . . . . . . . . 44
Cross references . . . . . . . . . . . . . ...... 5
Description of the function . . . . . . . . . 44
Attachments D
Special risks . . . . . . . . . . . . . . . . . . . 10
Damage, faults . . . . . . . . . . . . . . . . 19, 25
B Danger to employees . . . . . . . . . . . . . . . 14
Datasheet EXU . . . . . . . . . . . . . . . . . . 134
Battery
Datasheet EXU 20S - EXU 22S
Charging a Gel or Lead battery (option) . . . . . . . . . . . . . . . . . . . 140
(wall-mounted charger) . . . . . . . . 42
Destruction . . . . . . . . . . . . . . . . . . . . . . 97
Cleaning the battery . . . . . . . . . . . . 117
Digicode option (LFM Go) . . . . . . . . . . . . 32
Disposal . . . . . . . . . . . . . . . . . . . . . .. 6
Directions
Battery acid . . . . . . . . . . . . . . . . . . . . . . 24
Defining directions . . . . . . . . . ...... 5
Battery charge indicator . . . . . . . . . . . . . 30
Disposal
Battery electrolyte density . . . . . . . . . . 129
Battery . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery maintenance . . . . . . . . . . . . . . 128
Components . . . . . . . . . . . . . . . . . . . . 6
Battery type . . . . . . . . . . . . . . . . . . . . . . 74
Documentation scope . . . . . . . . . . . . . . . 4
Brake
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Checking the brake . . . . . . . . . . . . . . 45
Driver rights,duties and rules of
Braking . . . . . . . . . . . . . . . . . . . . . . . . . 62 behaviour . . . . . . . . . . . . . . . . . . 16
Braking system . . . . . . . . . . . . . . ...... 7 Driver’s compartment . . . . . . . . . . . . . . . . 8
C Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Changing the battery . . . . . . . . . . . . . . . 82 Driving on loading bridges . . . . . . . . . . . 68
Changing the battery using a hoist . . . . . 91 Driving on upward and downward
Charger slopes . . . . . . . . . . . . . . . . . . . . . 68
Using the charger . . . . . . . . . . . . . . . 79 Driving safety instructions . . . . . . . . . . . . 58
Check the tyres and the wear on the
wheels and rollers . . . . . . . . . . . 114 E
Checking the brake air gap . . . . . . . . . . 123 EC declaration of conformity . . . . . ...... 3
Checking the cables, terminals and Electrical insulation testing . . . . . . . . . . . 22
battery connector . . . . . . . . . . . . 118
Electrolyte level and battery water
Checking the emergency stop . . . . . . . . 45 top-up . . . . . . . . . . . . . . . . . . . . 128
Checking the horn . . . . . . . . . . . . . . . . . 46 Error codes . . . . . . . . . . . . . . . . . . . . . . 94
Checks prior to start-up . . . . . . . . . . . . . 41

1152 807 80 01 [EN] 147

 Index
g

F L
FleetManager™ Lead battery . . . . . . . . . . . . . . . . . . . . 117
Colour code for the LEDs . . . . . . . . . . 49 Lift control elements . . . . . . . . . . . . . . . . 63
Commissioning a truck equipped Lifting system . . . . . . . . . . . . . . . . . . . . . . 7
with a keypad or an electronic key . 48 Checking the wear on collars and
Commissioning a truck equipped hinge pins . . . . . . . . . . . . . . . . . 126
with an RFID reading device . . . . . 48 List of inspections . . . . . . . . . . . . . . . . 104
Description . . . . . . . . . . . . . . . . . . . . 47 Lithium-ion batteries
Disconnecting a truck equipped Lithium-ion batteries: Long-term
with a keypad or electronic key . . . 51 storage . . . . . . . . . . . . . . . . . . . . 99
Disconnecting a truck equipped Special lithium-ion safety rules . . . . . . 20
with an RFID reading device . . . . . 52
Lithium-ion battery
Disconnecting the truck . . . . . . . . . . . 51
Changing the side access
Start-up . . . . . . . . . . . . . . . . . . . . . . 48 lithium-ion battery . . . . . . . . . . . . . 93
FleetManager™ option . . . . . . . . . . . . . . 36 Charging lithium-ion batteries using
Folding platform an external charger . . . . . . . . . . . 87
Driving in pedestrian mode . . . . . . . . 60 Charging using an external
Driving in ride-on mode . . . . . . . . . . . 60 charger . . . . . . . . . . . . . . . . . 87, 89
Maintenance . . . . . . . . . . . . . . . . . . 116 Cleaning the lithium-ion battery . . . . 119
Use . . . . . . . . . . . . . . . . . . . . . . . . . 60 Display . . . . . . . . . . . . . . . . . . . . . . . 57
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 115 Harnesses and cables . . . . . . . . . . . 120
Maintenance plan for the lithium-ion
G battery . . . . . . . . . . . . . . . . . . . . 111
Gel and lead side access batteries: Marking . . . . . . . . . . . . . . . . . . . . . . 37
changing the battery using a Transporting a truck equipped with
trolley . . . . . . . . . . . . . . . . . . . . . 83 a lithium-ion battery . . . . . . . . . . . 98
Gel battery . . . . . . . . . . . . . . . . . . . . . . 117 Load handling safety rules . . . . . . . . . . . 64
General . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lowering the fork arms . . . . . . . . . . . . . . 63

H M
Hazards and countermeasures . . . . . . . . 12 Maintenance schedule
Hoisting the truck 1000 hours . . . . . . . . . . . . . . . . . . . 121
Lifting by the chassis . . . . . . . . . . . . 107 3000 hours . . . . . . . . . . . . . . . . . . . 130
Hydraulic circuit, draining the circuit . . . 131 Manual issue date . . . . . . . . . . . . . . . . .. 5
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 24 Markings . . . . . . . . . . . . . . . . . . . . . . . . 34
Measuring battery insulation resistance . 22
I Measuring the insulation resistance of
Identification label . . . . . . . . . . . . . . . . . 35 the electrical system . . . . . . . . . . . 22
Insurance cover on company premises . . 18 Medical devices . . . . . . . . . . . . . . . . . . . 19
Modifications and refitting . . . . . . . . . . . . 18
J
Jacking . . . . . . . . . . . . . . . . . . . . . . . . 107

148 1152 807 80 01 [EN]

Index
g

N Side access lithium-ion battery

Commissioning a truck equipped
Noise
with a lithium-ion battery . . . . . . . . 55
Noise emission values . . . . . . . . . . . 144
Slinging and jacking the truck . . . . . . . . 107
O Special risks . . . . . . . . . . . . . . . . . . . . . 10
Specialist . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil level check . . . . . . . . . . . . . . . . . . . 125
Stabilisers . . . . . . . . . . . . . . . . . . . . . . .. 7
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . 43
On-board charger
Steering . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Checking the charger . . . . . . . . . . . 127
Symbols used . . . . . . . . . . . . . . . . . . . .. 4
Opening/closing the battery cover . . . . . . 75
Operating company . . . . . . . . . . . . . . . . 16 T
OptiSpeed . . . . . . . . . . . . . . . . . . . . . . . 61
Technical inspection and maintenance
Ordering spare parts and consumables . 103 characteristics . . . . . . . . . . . . . . 105
Overviews . . . . . . . . . . . . . . . . . . . . . . . 28 Transporting the truck in the lift . . . . . . . . 68
P U
Packaging . . . . . . . . . . . . . . . . . . . . . . . . 6 Unauthorised use . . . . . . . . . . . . . . . . . . . 9
Parking brake . . . . . . . . . . . . . . . . . . . . 62 Update of this manual . . . . . . . . . . . . . . . . 5
Permanent Putting Out of Commission . . 97
Place of use . . . . . . . . . . . . . . . . . . . . . . . 9 V
Prohibition of use by unauthorised Vertical access lithium-ion batteries
persons . . . . . . . . . . . . . . . . . . . . 17
Connecting/disconnecting the
battery connector . . . . . . . . . . . . . 53
R
Vertical access lithium-ion battery
Raising the fork arms . . . . . . . . . . . . . . . 63 Commissioning a truck equipped
Regular maintenance of the transmis- with a lithium-ion battery . . . . . . . . 54
sion gear . . . . . . . . . . . . . . . . . . 116 Replacing the lithium-ion battery . . . . 91
Residual dangers, residual risks . . . . . . . 10 Vibration characteristic values for
bodily vibrations . . . . . . . . . . . . . 145
S
Safety devices . . . . . . . . . . . . . . . . . . . 106 W
Safety Inspection . . . . . . . . . . . . . . . . . . 21 Warning regarding non-original parts . . . 18
Selecting the driving mode . . . . . . . . . . . 43 Washing instructions . . . . . . . . . . . . . . 112
Servicing and maintenance measures . 106 Washing the exterior of the truck . . . . . . 112
Servicing wheels and rollers . . . . . . . . . 114 Work that must also be carried
Side access battery: changing the out . . . . . . . . . . . . . . . . . . . 121, 130
battery using a moveable support . 85 Working on the electrical equipment . . . 106
Side access lithium-ion batteries
Connecting/disconnecting the
battery connector . . . . . . . . . . . . . 55

1152 807 80 01 [EN] 149

STILL GmbH
Berzeliusstrasse 10
D-22113 Hamburg

Ident no. 1152 807 80 01 EN