Still SU-20 Original Instructions Manual
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Still SU-20 Original Instructions Manual

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Original instructions
SU-20
1610
45418043404 EN - 09/2014

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  • Page 1 Original instructions SU-20 1610 45418043404 EN - 09/2014...

  • Page 3: Table Of Contents

    Table of contents Introduction Forklift data ............General information .
  • Page 4 Table of contents Electromagnetic radiation ..........17 Non-ionised radiation .
  • Page 5 Table of contents Breaking-In ............41 Checks and Inspections .
  • Page 6 Table of contents Checks and Inspections After a Long Period of Inactivity ..... . . 68 Permanent Putting Out of Commission (Demolition) ......68 Supply Table .

  • Page 7: Introduction

    Introduction...

  • Page 8: Forklift Data

    Introduction 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 •...
  • Page 9 Introduction How to Consult the Manual CAUTION NOTE Failure to observe the instructions highlighted with This symbol is used to provide additional this symbol may cause damage to the forklift and, information. in some cases, result in warranty invalidity. ENVIRONMENT NOTE Failure to observe the instructions highlighted with this symbol may cause environmental damage.

  • Page 10: Date Of Edition And Latest Update Of This Manual

    Introduction 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.
  • Page 11 Introduction Delivery of the forklift and documentation 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.

  • Page 12: Ec Declaration Of Conformity In Accordance With Machinery Directive

    Introduction 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 according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 13: Technical Service And Spare Parts

    Introduction Technical service and spare parts Technical service and spare parts For scheduled maintenance and any repairs to the technical characteristics of the forklift over the forklift, contact only the authorised service time. network. Only original spare parts provided by the man- The authorised service network has personnel ufacturer may be used for forklift maintenance trained by the manufacturer, original spare...

  • Page 14: Working Conditions

    Introduction Working conditions • transporting and/or lifting people; • turning and/or moving sideways on slopes (upwards or downwards); • pushing or pulling loads; • colliding with stationary and/or mobile • moving upwards or downwards on a slope structures; with the load facing downwards; •...

  • Page 15: Applied Equipment

    Introduction Applied equipment Applied equipment To use equipment that has not been applied, • add a label with the new residual capacity is please contact the authorised sales network, • provide documentation on the equipment in order to: (user and maintenance manual and EC •...

  • Page 16: Packaging

    Introduction 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. 45418043404 [EN]...

  • Page 17: Safety

    Safety...

  • Page 18: Safety Regulations

    Safety Safety regulations Safety regulations General Precautions regulations integrate those in the manual NOTE "Rules for approved use of industrial vehicles". Some safety regulations to be followed when using the forklift are listed below. These General Safety Rules • Only allow qualified, trained and authorized the safety distances established by the personnel to use the forklift.

  • Page 19: Battery Connection Cables

    Safety Safety regulations CAUTION DO NOT pass over cracks or damaged parts of the floor with the forklift. Dirt and any objects in the work path must be removed immediately. Battery connection cables CAUTION Using sockets with NON-ORIGINAL battery con- nection cables can be dangerous (see purchase references in the parts catalogue) Requirements for the traction-battery...

  • Page 20: Safety Regulations Relative To Operating Materials

    Safety Safety regulations Safety Regulations Relative to Operating Materials Rules for handling and disposing of Oils operating materials • Do not allow to come into contact with the skin. ENVIRONMENT NOTE • Do not inhale oil vapors. Improper use and disposal of operating and •...

  • Page 21: Residual Risks

    Safety Residual risks and disposal of the life-expired battery must NOTE be carried out as required by law. We advise you to contact the authorised service network For greater information, consult the specific that is equipped for eco-friendly disposal in battery manual that comes with the battery.
  • Page 22 Safety Residual risks • Fire and explosion risks due to batteries and electrical voltages. • Human error resulting from failure to observe the safety guidelines. • Unrepaired damage or defective and worn components. • Insufficient maintenance and testing • Use of incorrect consumables •...

  • Page 23: Electromagnetic Radiation

    Safety Electromagnetic radiation Electromagnetic radiation The limit values for electromagnetic emissions and for immunity relative to the forklift are those provided by the EN 12895 standard. Non-ionised radiation 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...

  • Page 24: Location Of Labels

    Safety Location of labels Location of labels Fuchs MR 310 2155 Danger of cutting hands Warning sign: moving parts Cold store version oil top-up point (optional) Battery change label Danger of cuts to the feet Step plate adjustment label Truck lifting points Reverse steering label Cold-storage room version (optional) This symbol, where present, indicates that...

  • Page 25: Description Of Labels

    Safety Description of labels Description of labels (1)This symbol indicates the danger of cutting using the truck and prior to carrying out any hands. maintenance work. (2) This label, where present, indicates that (7)This label indicates to press the operator the truck is set up for the “cold-store”...

  • Page 26: Safety Devices

    Safety Safety devices Safety devices 2118 The operator must be aware of the presence • Battery lock pads with cover closed (6). of the following safety devices: • Reverse gear warning buzzer (optional) (7). • EMERGENCY stop button (1). NOTE •...

  • Page 27: Safety Tests

    Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents STILL GmbH Hamburg The operating company must ensure that the truck is checked at least once a year, or Regelmäßige Prüfung following noteworthy incidents.
  • Page 28 Safety Safety tests 45418043404 [EN]...

  • Page 29: Knowledge Of The Truck

    Knowledge of the Truck...

  • Page 30: General Truck View

    Knowledge of the Truck General Truck View General Truck View 2130 Platform Control panel (optional) Driver’s seat Drive wheel Start/stop key Twin pivoting wheel Emergency switch Forks Horn button Load castors Fork arm lifting push button Motor compartment cover Fork arm lowering push-button Battery cover Drive control throttle Arm rest cushion...

  • Page 31: Definition Of Direction Of Travel

    Knowledge of the Truck Definition of direction of travel Definition of direction of travel 2119 The direction of travel for standard models is defined as follows: A = Direction of travel away from the forks (forward) B = Direction of travel fork side (reverse) "A"...

  • Page 32: Instrumentation And Controls

    Knowledge of the Truck Instrumentation and Controls Instrumentation and Controls Start/stop key Key 1 has two positions: 0 =No circuit powered (key removal posi- tion); I =Circuit powered. In position I the display (2) lights up. NOTE All of the controls described on the following pages work with the key in position "I"...

  • Page 33: Battery Charging Status Indicator

    Knowledge of the Truck Instrumentation and Controls Battery charging status indicator Display (1) After starting the truck, the operating hours will appear for a few seconds on the display. Then the available remaining battery capacity in % appears on the display. If an alarm goes off while the truck is in use, the relevant code appears on the display alternating with the percentage of charge left on the battery.

  • Page 34: Drive Control Throttle

    Knowledge of the Truck Instrumentation and Controls Drive control throttle When the throttle (1) is turned in direction (B) the forklift starts moving in the direction of the forks; when it is turned in direction (A), it starts moving in the opposite direction to the forks. The release of the throttle causes braking (electric release braking) and subsequently the stopping of the forklift.

  • Page 35: Fork Arm Raising/Lowering Push-Buttons

    Knowledge of the Truck Instrumentation and Controls Fork arm raising/lowering push- buttons • Press the push-button(1) to raise the fork arms. Release the push-button to stop fork movement. • Press the push-button(2) to lower the fork arms. Release the push-button to stop fork movement.

  • Page 36: Steering Wheel

    Knowledge of the Truck Instrumentation and Controls Steering wheel The rotation of the steering wheel (1) turns the forklift. A complete turn requires about four revolu- tions of the steering wheel. OM1322 Operator presence pedal Engaging the operator present pedal (1) activates the machine’s functions.

  • Page 37: Step Plate Adjustment Button

    Knowledge of the Truck Instrumentation and Controls Step plate adjustment button Lift the step plate Press button (1). The step plate lifts automati- cally. Release the button as soon as you reach the right height. Lower the step plate Press the button (1) and put your own weight on the step plate.

  • Page 38: Battery Cover Release Lever

    Knowledge of the Truck Instrumentation and Controls Battery cover release lever • This lever (1) is used to open the battery cover. • To open the cover, push the lever (1) in the direction (A). NOTE For further information, refer to the "Internal accessibility"...

  • Page 39: List Of Available Options

    Knowledge of the Truck List of available options List of available options 2153 • Tandem load rollers (1). • Control panel (2) • Equipment for cold climates (3). Refer to Chapter 4 for additional information on the use of this version of the truck. •...
  • Page 40 Knowledge of the Truck List of available options CAUTION Contact the technical service network authorised by the manufacturer for information on the assembly of the options. 45418043404 [EN]...

  • Page 41: Internal Accessibility

    Knowledge of the Truck Internal accessibility Internal accessibility DANGER It is prohibited to use the truck with the covers open. In order to use the truck, the covers for access to the inner parts must be closed and secured properly. DANGER Before accessing the inner parts of the truck, carefully follow the instructions given in Chapter...
  • Page 42 Knowledge of the Truck Internal accessibility – To access the motor/fuse compartment, unscrew the two screws (5) and then open the cover (6). Turn the plate over (7) to access the electronic components and the fuses. 2139 45418043404 [EN]...

  • Page 43: Truck Identification

    Knowledge of the Truck Truck Identification Truck Identification Location of Data Plates Tipo-Type-Modèle-Tip / Matricola-Serial no-No de série-Serien-Nr / Anno-year-année-Baujahr Portata nominale Massa a vuoto Rated capacity Unladen mass Capacité nominale Masse à vide Nenn-Tragfähigkeit Leergewicht Tensione batteria Battery voltage Tension batterie batteriespannung Potenza trazione...

  • Page 44: Forklift Identification Plate

    Knowledge of the Truck Truck Identification Forklift Identification Plate – The identification plate indicates the following data: • A = Type of forklift • B = Serial number • C = Year of manufacture Tipo-Type-Mod le-Tip / Matricola-Serial no-No de s rie-Serien-Nr / Anno-year-ann e-Baujahr •...

  • Page 45: Use And Operation

    Use and Operation...

  • Page 46: Truck Transport And Lifting

    Use and Operation Truck Transport and Lifting Truck Transport and Lifting Transporting the truck The forklift is normally transported by road and rail. If the forklift’s dimensions exceed the max. clearance size allowed, it is trans- ported disassembled. The sales network is in charge of the disassembly and reassembly operations.

  • Page 47: Loading And Unloading The Truck

    Use and Operation Breaking-In Loading and unloading the truck Use a lifting crane to load and unload the truck or use an inclined plane or a movable platform with a slope and structural strength compatible with the truck’s performance and weight (see "Technical Data"...

  • Page 48: Checks And Inspections

    Use and Operation Checks and Inspections Checks and Inspections Daily checks before use The following checks must be performed on a • Make sure that the start/stop key works daily basis in order to keep your truck in good correctly; condition and to operate safely.

  • Page 49: Use Of The Truck

    Use and Operation Use of the Truck Use of the Truck Operator restrictions The vehicles are designed, in accordance with DIN EN ISO 3411, for male and female personnel with a height ranging between 1510 mm and 1880 mm. In compliance with this regulation, the operator’s body weight is limited to 98 kg.

  • Page 50: Climbing On And Off

    Use and Operation Use of the Truck Climbing on and off The diagram shows the three support points that the operator must use to get on and off the truck. 2157 Start-up After having performed the daily checks, carry • Check that the emergency stop button is not out the following operations to start the forklift: pressed.

  • Page 51: Truck Operation

    Use and Operation Use of the Truck Truck operation • Press the operator present pedal with your left foot (4). NOTE By releasing the operator present pedal while the truck is moving, the truck brakes and slows down until it stops. •...

  • Page 52: Steering The Forklift Truck

    Use and Operation Use of the Truck Steering the forklift truck OM1341 Use the steering wheel to steer during forklift • Turning the steering wheel clockwise (H) in operation. forward gear (A) the forklift turns to the right (E). • Turning the steering wheel anti-clockwise •...

  • Page 53: Truck Reverse Steering (Optional)

    Use and Operation Use of the Truck Truck reverse steering (optional) 2166 Use the steering wheel to steer during truck • Turning the steering wheel clockwise (H) in operation. forward travel (A) causes the truck to turn to the left (E). •...

  • Page 54: Reverse Drive

    Use and Operation Use of the Truck Reverse drive Reverse of direction without load on forks Reverse of direction with load on forks • To reverse direction when travelling without • To reverse direction with a load on the fork a load on the fork arms, turn the traction arms, release the traction control throttle control throttle in the opposite direction of...

  • Page 55: Using The Truck On Inclines, Loading Bridges And Lifts

    Use and Operation Use of the Truck Using the truck on inclines, loading bridges and lifts. Driving on inclines Using the truck on a lift When driving the truck up or down inclines, Using the truck on lifts is only allowed if the you must not exceed the values for inclines lift has sufficient load capacity (check the indicated in the chapter "Technical data".

  • Page 56: Leaving The Truck

    Use and Operation Use of the Truck Leaving the truck Follow the operations listed below in the order given when leaving the forklift: • Lower the forks to the ground. • Release the operator present pedal; releas- ing the operator present pedal will activate the parking brake.

  • Page 57: Forklift Use In Cold-Storage Rooms

    Use and Operation Load Placement Forklift Use in Cold-Storage Rooms. A truck specifically equipped for cold-storage CAUTION rooms must be used when working at temper- If the truck has been working in environments at atures below +5°C. temperatures below -5°C and it is taken outside the cold-storage room, let it stand either for a sufficien- Forklifts equipped for working in cold climates tly long time to allow evaporation of any condensa-...

  • Page 58: Deposit The Load

    Use and Operation Load Placement • Approach the load with caution and as carefully as possible. • Slowly insert the forks at the centre of the load to be lifted. • Lift the load off the floor. Deposit the load. •...

  • Page 59: Forklift Towing

    Use and Operation Forklift Towing Forklift Towing The forklift may not be towed in the case of breakdown. The forklift must be lifted with due caution, as described on the preceding pages. 45418043404 [EN]...

  • Page 60: Battery Recharging

    Use and Operation Battery Recharging Battery Recharging CAUTION • Turn on the external battery charger. • Connect plug the battery charger in to begin The battery is recharged with the forklift off. charging. • After the battery charging operation is DANGER completed, turn off the battery charger.

  • Page 61: Maintenance

    Maintenance...

  • Page 62: General Information

    Maintenance General Information General Information To keep your forklift in good condition, carry DANGER out the servicing indicated regularly, within the Scheduled maintenance and repairs must be times indicated and using the consumption done by the service network authorised by the materials provided for that purpose, as speci- manufacturer in order to maintain the machine fied on the following pages.

  • Page 63: Scheduled Maintenance

    Maintenance Scheduled Maintenance Scheduled Maintenance Synoptic Table of Maintenance Operations Operations Intervals in hours Further checks 1000 2000 3000 Make sure that the platform adjustment works correctly and locks properly Make sure that the seat height adjustment works correctly and locks properly Check the fuses Battery check...

  • Page 64: Lubrication Diagram

    Maintenance Scheduled Maintenance Change hydraulic system oil Check and lubricate the fork carriage and slide guides Grease the reducer fifth wheel Replacement of the lift motor brushes ENVIRONMENT NOTE During maintenance operations, follow the instructions provided in the section "Safety regulations relative to operating materials"...
  • Page 65 Maintenance Scheduled Maintenance • (1) Lubricate the steering unit’s gears with multi-purpose grease every 1000 hours or every 6 months. • (2) Lubricate the steering turntable of the transmission gear with universal grease every 2000 hours or every 12 months. •...

  • Page 66: Maintenance As Required

    Maintenance Maintenance as required Maintenance as required Cleaning the Forklift Cleaning depends on the type of use and the Use water-dampened rags to clean the parts workplace. Should the truck come into contact of the body. with highly aggressive elements such as salt CAUTION water, fertilizers, chemical products, cement, etc., it should be cleaned as carefully as...

  • Page 67: Changing The Battery

    Maintenance Maintenance as required Changing the battery 2135 WARNING The hydraulic controls (1, 5, 11) described below work by pressing the operator presence pedal at the same time (U). The operator presence pedal (U) must be pressed with the left foot when the operator is on board the truck.
  • Page 68 DANGER The truck can still be manoeuvred, even with the battery raised. However, before driving the truck, make sure that the battery lifting device is lowered, the battery compartment cover is closed and the battery is properly secured by the locking devices (14).
  • Page 69 – Place the manufacturer-approved battery side removal roller unit next to the truck (8); position it so that it is still and stable; adjust the height of the roller unit so that it is level with the underside of the battery at the battery compartment.
  • Page 70 Maintenance Maintenance as required – Push the battery (9) from the outside towards the inside, sliding it along the rollers on the truck chassis. – Check that the battery (9) is aligned with the side of the truck and does not protrude beyond it.

  • Page 71: Stand With Lateral Battery Extraction Roller Unit (Optional)

    Maintenance Maintenance as required Stand with lateral battery extraction roller unit (optional) OM1343 The stand is used as follows: CAUTION 1) Position the stand with battery extraction Adjust the height of the supports so that the surface of the roller unit is perfectly horizontal. roller unit at the battery outlet.

  • Page 72: Fuse Replacement

    Maintenance Maintenance as required Fuse replacement 2144 • Turn off the truck and perform the prelimi- CAUTION nary maintenance operations. Before replacing the fuse, eliminate the cause that led to its blowing. The blown fuse must only be DANGER replaced with a fuse of the same amperage. Do not tamper with the truck’s electrical system.
  • Page 73 Maintenance Maintenance as required • Loosen the screws, replace fuses (2) and • (2) Traction fuse 1F1 = 125A (3) and retighten the screws. • (3) Pump fuse 2F1 = 200A • (4) Fuse 3F1 = 30A Service fuses • (5) Fuse 1F3 = 10A •...

  • Page 74: Decommissioning

    Maintenance Decommissioning Decommissioning General Information The operations to be performed for "Tem- porary decommissioning" and "Permanent decommissioning" are listed in this chapter. Temporary Putting Out of Commission The following operations must be performed • Perform the lubrication operations indicated when the forklift is not going to be used for a in the maintenance chapter.

  • Page 75: Supply Table

    Maintenance Supply Table Supply Table Standard Cold-store version version Drive reduction Tutela Matrix Tutela Matrix unit oil Quantity (l) Oil for hydraulic Idraulicar Tutela GI/M lifting AP31 equipment Quantity (l) Generic Tutela Tutela MP 02 lubricant JOTA1 45418043404 [EN]...

  • Page 76: Resolution Of Operating Defects

    Maintenance Resolution of Operating Defects Resolution of Operating Defects The operating defects which can occur during truck use are indicated in this section, with relative causes and solutions. If the defects should persist even after having carried out all of the checks indicated, contact the manufacturer’s authorised service network.
  • Page 77 Technical data...

  • Page 78: Technical Data

    Technical data Technical data Technical data a / 2 a / 2 2152 Fork 1000 1150 1200 1400 1600 2390 length Centre 1200 of gravity Distance x 1020 1220 1420 1840 Wheel- 1473 1623 1673 1873 2073 2493 base Total 1820 1970 2020...
  • Page 79 Technical data Technical data Characteristics Power unit type Electric Drive type Stand-on Load capacity / Load Q (t) Load centres of gravity (mm) Load distance from load wheel 969/904 (mm) axle with forks lowered/raised Distance between axles with forks 1623/1558 (mm) lowered/raised Weights...
  • Page 80 Technical data Technical data s/e/l 52 / 170 / 1150 4.22 Fork dimensions (mm) 4.25 External fork arm gauge 520 - (670) (mm) Clear span at mid wheelbase with 4.32 (mm) load Working aisle with pallet 1000 x 2026 4.33 (mm) 1200 fork insertion 1200 Working aisle with pallet 800 x...

  • Page 81: Battery Dimensions And Weights

    Technical data Battery dimensions and weights Control type Electronic Operating noise in driver’s ear dB(A) < 70 (1) The values in the table, unless indicated otherwise, are for forks with length l = 1150 x 520 mm (2) Standard rubber traction wheel, Vulkollan optional (ø...

  • Page 82: Vibrations

    Technical data Vibrations of the Translation, Lifting and Idling modes. It NOTE can only be used as a comparison value for various forklifts. Noise values that are lower or higher than those indicated above can occur during actual forklift use, for example, following different operating modes, different environmental conditions, additional noise sources.
  • Page 83 Index Battery Packaging ..... . . 10 Disposal ..... . Residual dangers .
  • Page 86 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 45418043404 EN...

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