Still EXU-SF20 User manual

Original instructions
Electric pallet truck
EXU-SF20
0179
50018043429 EN - 00-10/2013

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Date of edition and latest update of this manual ............................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of symbols used ............................................ 7
Explanation of the cross-references ....................................... 7
Definingdirections .................................................... 8
Illustrations ......................................................... 8
Environmental considerations ........................................... 9
Packaging .......................................................... 9
Disposal of components andbatteries ...................................... 9
2 Introduction
Technical description ................................................. 12
Use of the Truck ..................................................... 14
Intended use of the trucks .............................................. 14
Proper usage ....................................................... 14
Unintended use ..................................................... 15
Placeofuse ........................................................ 15
Residual risks ...................................................... 17
Residual dangers, residual risks ......................................... 17
Special risks associatedwithusingthetruckandattachments ................... 18
Overviewofhazardsandcountermeasures ................................. 20
Hazardstoemployees ................................................ 22
3Safety
Definition of terms used for responsible persons ............................. 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Expert ............................................................ 27
Driver ............................................................ 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
Warning regarding non-original parts ..................................... 29
Modificationsandrefitting .............................................. 29
50018043429 [EN] I

Table of contents
g
Medicalequipment .................................................. 30
Safety tests ........................................................ 31
Regular safety inspection of thetruck ..................................... 31
Electricalinsulationtest ............................................... 31
Safety regulations for handling consumables ............................... 33
Permissibleconsumables ............................................. 33
Oils .............................................................. 33
Hydraulicfluid ...................................................... 34
Batteryacid ........................................................ 35
Disposalofconsumables .............................................. 36
Emissions ......................................................... 37
Safety devices ...................................................... 39
Locationofsafetydevices ............................................. 39
Damage, defects and misuse of safety devices . . . ........................... 41
Battery connection cables ............................................. 41
4Overview
Overview .......................................................... 44
Control and display elements ........................................... 46
Tillercontrols ....................................................... 46
Combitiller ........................................................ 48
Combinedindicator .................................................. 52
On/Offswitch ....................................................... 53
Digicodeoption(LFMGo) .............................................. 54
Emergency stop handle ............................................... 56
Side protection ...................................................... 57
Description ........................................................ 57
Platform .......................................................... 59
Description ........................................................ 59
Markings .......................................................... 61
Markingpositions .................................................... 61
Chassis frame labelling ............................................... 62
Labels ............................................................ 63
Dataplate ......................................................... 65
Accessibility ........................................................ 66
Internalaccessibility .................................................. 66
II 50018043429 [EN]

Table of contents
g
5Application
Intended use of the trucks .............................................. 68
Checks and actions prior to commissioning ................................. 69
Dailychecksandactionspriortouse ...................................... 69
Connecting the battery (wall-mounted battery charger) ........................ 71
Commissioning ..................................................... 72
Start-up ........................................................... 72
Checktheinformationonthecombinedindicator ............................. 73
Checking the anti-crush safetydevice ..................................... 73
Checkingthebrake .................................................. 75
Checking the emergency stop .......................................... 76
Checkingthehorn ................................................... 76
Driving ............................................................ 77
Drivingsafetyinstructions .............................................. 77
Visibility when driving ................................................. 77
Beforedriving ...................................................... 79
Behaviour in emergencies ............................................. 82
Drivingposition ..................................................... 83
Driving ............................................................ 85
Guiding ........................................................... 87
Braking ........................................................... 88
Parkingbrake ...................................................... 88
Standby ........................................................... 88
Lifting ............................................................ 89
Lifting ............................................................ 89
Handling loads ...................................................... 90
Load handling safety rules ............................................. 90
Handling a load ..................................................... 90
Transportingpalletsorothercontainers ................................... 93
Driving on upward and downwardslopes .................................. 94
Transportingthetruckinthelift .......................................... 94
Driving on loading bridges ............................................. 94
Cold store usage (optional) ............................................. 95
Designation ........................................................ 95
Error display ....................................................... 97
Error codes ........................................................ 97
Battery electrolyte level indicator LED (optional) ............................. 97
Handling the truck in specific situations .................................... 98
Towing and moving .................................................. 98
50018043429 [EN] III

Table of contents
g
Transportingthetruck ................................................100
Handling the battery ..................................................101
Typesofbattery .....................................................101
Preparation ........................................................101
Opening/closing the battery compartment ..................................103
Charging the battery using anexternalcharger ..............................106
On-boardcharger ...................................................107
Replacingthebattery .................................................113
Puttingoutofcommissiona
nd storage ....................................113
Parkingthetruck. ....................................................113
Temporaryputtingoutofcommission .....................................114
Permanent putting out of commission(destruction) ...........................115
Measureswhenstoringthestackerforalongerperiodoftime ...................116
Takingbackintoserviceafterstorage .....................................117
6 Maintenance
General maintenance information ........................................120
General . . .........................................................120
Staff training and qualifications for maintenance and repairs ....................120
Battery maintenance personnel .........................................121
Servicesnotrequiringspecialqualifications ................................121
Orderingsparepartsandconsumables ....................................122
Listofinspections ...................................................12
4
Servicingandinspectionintervals ........................................125
Maintenancespecificationstable ........................................127
Maintenance safety guidelines ..........................................128
Safety measures for maintenance and repair ...............................128
Workontheelectricalequipment ........................................128
Safetydevices ......................................................128
Settings ...........................................................128
Preparatory procedures for maintenance ..................................129
Slinging and jackingthetruck ...........................................129
Accesstothetechnicalcompartment .....................................130
Cleaning ..........................................................131
Cleaning the truck ...................................................131
Maintenance as Required .............................................133
Servicingthewheelsandrollers .........................................133
Checking the conditionofcables,terminalsandbatteryconnector ................133
Cleaning the battery and its compartment ..................................135
IV 50018043429 [EN]

Table of contents
g
Fuses ........................................................... . 136
Servicing the on-board charger ..........................................136
Servicingthebrake ..................................................137
Checkingtheplatformairspringpressure ..................................137
Maintenance every 500 hours ...........................................139
Othertasks ...................................................... . . 139
Maintainingthehydraulicsystem ........................................140
Maintainingtheelectricmotors ..........................................141
Maintaining the electrical system ........................................143
Servicingthebrake ..................................................144
Checkingtheforks ...................................................145
Checking the platform air springpressure ..................................145
Maintenance every 1000 hours ..........................................147
Workthatmustalsobecarriedout .......................................147
Servicing the on-board charger ..........................................147
Maintenance every 2000 hours ..........................................149
Workthatmustalsobecarriedout .......................................149
Maintaining the hydraulicsystem ........................................150
Servicingthebatteryaccordingtothemanufacturer’sinstructions ................151
Electricalinsulationtest ...............................................151
Periodicinspections ..................................................1
53
Maintenance every 5000 hours ..........................................155
Workthatmustalsobecarriedout .......................................155
Maintaining the reducer ...............................................156
7 Technical data
Dimensions ........................................................158
Technical data (VDI) .................................................159
50018043429 [EN] V

1
Foreword

1Foreword
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.
Thetruckshavebeenfittedw
ith 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.
25
0018043429 [EN]

Foreword 1
Your industrial truck
EC declaration of conformity in accordance with Machinery Directive
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
.
50018043429 [EN] 3

1Foreword
Information about documentation
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• 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 production located on the nameplate
⇒ Chapter "Data plate", P.4-65inthefield
provided:
Production no. ...........................................
Year of production
...................................................
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.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 26) must ensure that all operators
have received, read and understood these
instructions.
45
0018043429 [EN]

Foreword 1
Information about documentation
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.
50018043429 [EN] 5

1Foreword
Information about documentation
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.
65
0018043429 [EN]

Foreword 1
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require
special attention.
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 a section: ⇒ Chap-
ter "Explanation of the cross-refer-
ences",P.1-7
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 26
50018043429 [EN] 7

1Foreword
Information about documentation
Defining directions
Names used in the text: forward travel (1),
reverse travel (3), to the right (2) and to the
left (4) refer to the installation position of
the components in relation to the driver’s
compartment, with the load positioned at the
front.
CAUTION
Steering direction: one clockwise rotation of the
steering mechanism will turn the truck towards the
left when it is travelling forwards.
Illustrations
At many points in this documentation the
(mostly sequential) operation of certain func-
tions or operating procedures is explained. To
illustrate these operations, schematic repre-
sentations of an truck are used.
NOTE
These schematic representations do not
represent the design state of the documented
truck. They only serve to illustrate operating
procedures.
85
0018043429 [EN]

Foreword 1
Environmental considerations
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.
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.
50018043429 [EN] 9

1Foreword
Environmental considerations
10 50018043429 [EN]

2
Introduction

2Introduction
Technical description
Technical description
The EXU-SF electric pedestrian and ride-on
pallet trucks are designed to handle pallets
with a maximum weight of 2000 kg inside
trucks, warehouses and plants.
Drive
These pallettrucksarefittedwitha2.3kW
traction motor driving the drive wheel via a
reducer:
• Asynchronous travel motor, 2.3 kW
• Starting and accelerating without jerking
• Regenerative braking
• A speed of 7.5 km/h under load and 9
km/h unladen when all safety functions are
active (see ⇒ Chapter "Location of safety
devices", P. 3-39).
Raising
Nominal load: 2000 kg
Pump assembly power output: 2.2 kW
(S3=15%)
Driving
A new fixed (standard production) or tele-
scopic (optional) tiller, that is both strong
and ergonomic enabling the operator to ef-
fortlessly direct the drive wheel and steering
wheel.
The tiller is used to activate the following
controls: steering, front and rear traction
throttles, warning horn, proportional lifting
and lowering buttons and rear safety button.
For safety reasons, the tiller, under thrust from
a gas cylinder, automatically goes back to the
upper position when it is released.
Braking system
The electromagnetic brake fitted to EXU-SF
pallet trucks is noted for its short handling
times, low inertia and torque transmission with
no angle clearance.
Braking:
12 50018043429 [EN]