Still EXU-S 22 User manual

Original instructions
Electric pallet truck
EXU-S 22
EXU-S 24
0177 0178
50018043464 EN - 10/2017

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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Table of contents
g
1 Introduction
Forklift data ......................................................... 2
General information ................................................... 2
How to Consult the Manual .............................................. 2
Date of edition and latest update of this manual ............................... 4
Copyright and trademark rights ........................................... 4
Delivery of the forklift and documentation ................................... 4
CE labelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Technical service and spare parts ......................................... 7
Type of use ......................................................... 7
Working conditions ................................................... 7
Modifications to Forklift ................................................. 8
Applied equipment .................................................... 8
User obligations ...................................................... 8
Environmental considerations ........................................... 9
Disposal of components and batteries ...................................... 9
Packaging ......................................................... 10
2Safety
Safety guidelines .................................................... 12
GeneralPrecautions ................................................. 12
General Safety Rules ................................................. 12
Flooringrequirements ................................................ 12
Batteryconnectioncables ............................................. 13
Requirements for the traction-batterychargingarea .......................... 13
SafetyRegulationsRelativetoForkliftUse ................................. 13
SafetyRegulationsRelativetoOperatingMaterials ........................... 14
Residual risks ...................................................... 15
Residual dangers, residual risks ......................................... 15
Electromagnetic radiation .............................................. 17
Non-ionised radiation ................................................. 1
7
Noise ............................................................. 17
Vibrations ......................................................... 18
Safety tests ........................................................ 19
Regular safety inspection of the truck ..................................... 19
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Table of contents
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3Overview
Technical description ................................................. 22
Overviews ......................................................... 26
Definition of directions ................................................ 27
Sample graphics .................................................... 27
Control and display elements ........................................... 28
Viewofthecontrolelements ............................................ 28
Cockpit ........................................................... 29
Deadman'szone .................................................... 30
Markings .......................................................... 31
Locationofdesignationplatesandlabels .................................. 31
Chassis frame labelling ............................................... 32
Dataplate ......................................................... 33
Options ........................................................... 34
Models ........................................................... 34
Options ........................................................... 34
Accessories ........................................................ 35
4 Application
Authorised and safe use ............................................... 38
Intended use of the trucks .............................................. 38
Safetyinstructionsrelatingtouseofthetruck ............................... 38
Truck transport and lifting .............................................. 40
Transportingthetruck ................................................ 40
Transport .......................................................... 40
Climatic Conditions forTransportandStorage ............................... 41
Breaking-In ........................................................ 41
Checks and actions prior to use ......................................... 42
Visualchecks ...................................................... 42
Connecting the battery plug (charging station) ............................... 46
Start-up ........................................................... 46
Turningonthetruck .................................................. 4
6
Enteringtheusercode ................................................ 47
Starting with FleetManager (optional) ..................................... 48
Hourmeter ........................................................ 49
Batterycharge ...................................................... 49
Displayoftimetonextservicing ......................................... 50
Operatingthehorn ................................................... 51
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Checkofbrakeandpresencearea ....................................... 51
Checking the emergency brake button .................................... 52
Driving ............................................................ 53
Drivingsafetyrules ................................................... 53
Visibilitywhendriving ................................................. 53
Beforedriving ...................................................... 54
Dimensions of roads and working aisles . . . ................................ 55
Emergency stop procedure ............................................ 56
Drivinginridermode ................................................. 57
Selectingthedrivingmode ............................................. 58
Steering ........................................................... 58
Brakes ............................................................ 58
Automaticshutdown .................................................. 60
Lifting ............................................................ 60
Operatingthemainlift ................................................ 60
Load placement ..................................................... 62
Safety regulations when handing loads .................................... 62
Beforepickingupaload ............................................... 6
3
Takingupload ...................................................... 64
Transportingaload .................................................. 64
Depositing a load on the ground ......................................... 65
Drivingupanddownonanincline ........................................ 66
Enteringlifts ........................................................ 66
Driving on loading bridges ............................................. 67
Usingthetruckoninclines,loadingbridgesandlifts. .......................... 68
Towingtrailers ...................................................... 68
Cold store usage (optional) ............................................. 69
Designation ........................................................ 69
Digicode .......................................................... 71
Digicodecontrol ..................................................... 71
Addingthemastercode ............................................... 72
Deletingamastercode ................................................ 73
Addingadriver'scode ................................................ 75
Deletingadriver'scode ............................................... 77
Error codes ........................................................ 79
Errorcode ......................................................... 79
Battery electrolyte level indicator LED (optional) ............................. 80
Handling the truck in specific situations .................................... 80
Towingandmoving .................................................. 80
Hoistingthetruck .................................................... 81
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Table of contents
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Towing procedure ................................................... 81
Handling the battery .................................................. 82
Batterytype ........................................................ 82
Preparation ........................................................ 82
Opening/closing the battery compartment .................................. 83
Battery charging with externalbatterycharger ............................... 83
Changing the battery ................................................. 84
Changing the battery with crane ......................................... 85
Changing the battery with lateralremovaltrolley ............................. 86
Decommissioning ................................................... 87
Safeparkingofthetruck ............................................... 87
Storage ........................................................... 88
Measureswhenstoringthestackerforalongerperiodoftime ................... 88
Takingbackintoserviceafterstorage ..................................... 89
5 Maintenance
General Information .................................................. 92
Operations Preliminary to Maintenance ................................... 92
Scheduled maintenance .............................................. 93
Summary table of maintenance operations EXU-S ........................... 93
Maintenance as required .............................................. 95
Cleaning the Forklift .................................................. 95
Fuses ............................................................ 95
Decommissioning ................................................... 97
General Information .................................................. 97
ForkliftTowing ...................................................... 98
TemporaryPuttingOutofCommission .................................... 98
Checks and Inspections After a Long Period of Inactivity ....................... 98
Permanent Putting OutofCommission(Demolition) .......................... 98
6 Technical data
Dimensions ........................................................100
VDI data sheet for standard EXU-S 22 ....................................101
VDI data sheet for standard EXU-S 24 ....................................105
Turning radius and load distance EXU-S ...................................108
Wheels and tyres ....................................................109
Supply table EXU-S EXU-SF ...........................................110
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1
Introduction

1Introduction
Forklift data
Forklift data
We recommend that you record the principal
forklift data in the following table so that they
are available if required by the sales network
or authorised service centre.
Type
Serial number
Date of delivery
.
General information
• This manual contains "Original Instructions"
provided by the manufacturer.
• The "operator" is defined as the person
driving the forklift.
• The "user" is the physical or legal person
who has the forklift truck used by the
operators.
• For correct use of the forklift and in order
to avoid accidents, the operator is obliged
to read, understand and apply the contents
of this manual, the "Rules for the use of
industrial vehicles" and the labels and
plates applied to the forklift.
• This manual and the attached "Rules for
the use of industrial vehicles" must be kept
carefully and must always be on the forklift
for fast consultation.
• The manufacturer assumes no responsibil-
ity for any accidents to persons or damage
to things due to the failure to observe the
instructions in this manual, in the "Rules for
the use of industrial vehicles" and on the
labels and adhesive supplied to the forklift.
• The forklift may not be put to any use other
that than indicated in this manual.
• The forklift must be used by appropriately
trained operators only. For the necessary
operator training, contact the authorised
sales network.
• Persons working near the forklift must also
be instructed in the risks associated with
use of the forklift.
• In the interests of clear information, some
illustrations in this manual show the forklift
without the safety equipment (guards,
panels, etc.). The forklift may not be used
without safety equipment.
How to Consult the Manual
There is a table of contents at the beginning
of the manual for ease of use. The manual is
divided into chapters with specific topics. The
name and title of the chapter are given at the
top of each page The following is found at the
bottom of each page: the type of manual, the
identifying code, the language and the manual
version.
Some general information is provided in this
manual. Please only consider the information
relevant for your specific forklift.
The following symbols have been used to
highlight some parts of this manual.
DANGER
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.
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Introduction 1
HowtoConsulttheManual
CAUTION
Failure to observe the instructions highlighted with
this symbol may cause damage to the forklift and,
in some cases, result in warranty invalidity.
ENVIRONMENT NOTE
Failure to observe the instructions highlighted
with this symbol may cause environmental
damage.
NOTE
This symbol is used to provide additional
information.
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1Introduction
Date of edition and latest update of this manual
Date of edition and latest
update of this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark
rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Delivery of the forklift and documentation
Ensure that the truck has all of the options
requested and that it has been delivered with
the following documentation:
• Original instructions
• Rules for the compliant use industrial
vehicles;
•ECDeclaratio
n of Compliance;
• Warranty book.
If the forklift has been delivered with a traction
battery and/or battery charger, ensure that
such products conform to the order and that
the relative user and maintenance manual are
included, as well as the EC declaration for the
battery charger.
If applied equipment, other equipment or
devices are present, ensure that they conform
to the order and that the relative use and
maintenance manual and of the relative EC
declaration (if provided by regulations in
effect) are included.
All of the above documentation must be kept
for the entire operative life of the forklift. In the
event that the documentation is lost or dam-
aged, contact the authorised sales network for
copies of the original documentation.
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Introduction 1
CE labelling
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
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1Introduction
EC declaration of conformity in accordance with Machinery Directive
EC declaration of conformity in accordance with Machinery Di-
rective
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
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Introduction 1
Technical service and spare parts
Technical service and spare parts
For scheduled maintenance and any repairs to
the forklift, contact only the authorised service
network.
The authorised service network has personnel
trained by the manufacturer, original spare
parts and the tools necessary to carry out
maintenance and repairs.
Servicing by the authorised service network
and the use of original spare parts maintain
the technical characteristics of the forklift over
time.
Only original spare parts provided by the man-
ufacturer may be used for forklift maintenance
and repairs. The use of non-original spare
parts invalidates the warranty and renders the
user responsible for any accidents due to the
inappropriateness of the non-original parts.
Type of use
"Normal use conditions"oftheforkliftare
understood as:
• lifting and/or transport of loads using forks
with weight and load centre within the
values provided (see Chapter 6 - Technical
Data).
• transport and/or lifting on smooth, flat and
compact surfaces;
• transport and/or lifting of stable loads
uniformly distributedontheforks;
• transport and/or lifting with the load centre
approximately on the forklift's median
longitudinal plane.
DANGER
The forklift must not be used for other purposes.
Any other use renders the user solely responsible
for injury/damage to persons and/or objects and
voids the warranty.
The following scenarios are examples of
incorrect use of the forklift truck:
• Transport on uneven (irregular or non-
compact) surfaces
• loads that exceed the weight and/or load
centre limits;
• transporting non-stable loads;
• transporting loads not equally distributed on
the forks;
• transporting swinging loads;
• transporting loads whose load centre is
considerably displaced with respect to the
forklift's longitudinal median plane;
• transporting loads of dimensions such as to
block the view of the operator when driving;
• transporting loads piled so high that they
could fall onto the operator;
• travelling with a load over 300 mm off the
ground;
• transporting and/or lifting people;
• pushing or pulling loads;
• moving upwards or downwards on a slope
with the load facing downwards;
• turning at high speed;
• turning and/or moving sideways on slopes
(upwards or downwards);
• colliding with stationary and/or mobile
structures;
DANGER
Improper use of the forklift could cause it and/or at
the load to overturn.
Working conditions
The forklift has been designed and built for
internal transport.
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1Introduction
Modifications to Forklift
Do not use beyond the limits of the climatic
conditions indicated below:
• Maximum ambient temperature: +40°C
• Minimum ambient temperature: +5°C
• Altitude up to 2000 m
• Relative humidity between 30% and 95%
(without condensation).
CAUTION
Do not use the forklift in dusty areas.
Using the forklift in environments with high concen-
trations of salty air or water could interfere with its
proper operation and cause corrosion of metallic
parts.
If the forklift must be used in conditions that
exceed the limits indicated or, in any case,
under extreme conditions (extreme weather,
cold-storage rooms, presence of strong mag-
netic fields etc), appropriate equipment and/or
use precautions are necessary. Contact the
authorised sales network for more informa-
tion.
DANGER
The forklift may not be used in environments in
which there is a risk of explosion. It may not be
used to handle explosive loads.
For forklifts that must operate in environments
in which there is a risk of explosion or must
handle explosive loads, appropriate equip-
ment is necessary and must be accompanied
by a specific EC Declaration of Compliance
which replaces that of the standard forklift,
and by the relevant User and maintenance
manual.
Contact the authorised sales network for more
information.
Modifications to Forklift
No modifications may be made to the forklift,
otherwise the EC certificate and the warranty
will become invalid, with the exception of:
• assembly of the options provided by the
manufacturer
• assembly of applied equipment
for which it is necessary to refer exclusively to
the authorised sales network
DANGER
If the forklift is equipped at the factory or later with
devices that emit non-ionising radiation (such as
radio transmitters, RFID players, data terminals,
scanners, etc), the compatibility of such devices
must be verified with the presence of operators
using medical devices (such as heart pacemakers).
Applied equipment
To use equipment that has not been applied,
please contact the authorised sales network,
in order to:
• verify feasibility
• install the equipment
• add a label with the new residual capacity is
• provide documentation on the equipment
(user and maintenance manual and EC
certificate).
User obligations
Users must comply with applicable local legis-
lation governing forklift use and maintenance.
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Introduction 1
Environmental considerations
Environmental considerations
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
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1Introduction
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
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2
Safety

2Safety
Safety guidelines
Safety guidelines
General Precautions
NOTE
Some safety regulations to be followed when
using the forklift are listed below. These
regulations integrate those in the manual
"Rules for approved use of industrial vehicles".
General Safety Rules
• Only allow qualified, trained and authorized
personnel to use the forklift.
• Do not install equipment on the forklift un-
less supplied or indicated by the manufac-
turer.
• Maintain the forklift in full working efficiency
in order to limit any type of risk to the
minimum.
• Do not use the truck with bonnets or doors
open or with guards removed.
• The data plates found on the forklift must
be kept in good condition and replaced if
damaged.
• Carefully read and follow all of the safety
indications found on the forklift.
• Make sure that the forklift has sufficient
overhead clearance.
• Do not park the forklift in front of fire-fighting
devices or fire escapes or anywhere that it
blocks traffic.
• If the forklift shows signs of failure or
breakage and there is reason to consider
it unsafe, stop, park it, and notify the
maintenance manager.
• Maintain appropriate distances from high
voltage overhead cables. Comply with
the safety distances established by the
competent authorities.
• Never raise the load using just one fork.
• Place the load on the fork carriage or in such
a way that the centre of gravity of the load is
as close as possible to the fork carriage.
• The load must be placed on the fork arms
so that the centre of gravity falls lengthwise
on the mid point between the fork arms.
• Do not drive with loads off-centre laterally
with respect to the forklift's median axis.
Lack of compliance with this regulation can
compromise forklift stability.
• Make sure that the surface on which the
load rests is able to support its weight.
• Always use safety clothing compliant with
current regulations and any personal pro-
tective equipment that may be applicable.
• Do not travel on loose or hilly ground or on
steps.
• Do not drive with loads raised more than
300 mm from ground level.
• Do not turn or stack on slopes.
• Reduce speed on slopes.
• Do not overload the forklift beyond the
capacity limits indicated on the capacity
plates.
• Individuals under the influence of drugs and
alcohol are not permitted to use the truck.
• The operator may not use an MP3 player
or any electrical device that may distract
their attention from the surrounding work
environment.
Flooring requirements
The work floor must be even and free of holes
or dips, which can be difficult to get around.
Any steps must be equipped with ramps to
prevent impacts with the wheels, which affect
the entire structure of the truck.
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