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

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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]

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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

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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]

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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]