Still EXU-SF20 Original Instructions Manual

Electric pallet truck

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Original instructions

Electric pallet truck

EXU-SF20

0179

50018043429 EN - 00-10/2013

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Page 1 Original instructions Electric pallet truck EXU-SF20 0179 50018043429 EN - 00-10/2013...
Page 3: Table Of Contents
Table of contents Foreword Your industrial truck ........... 2 General .
Page 4 Table of contents Medical equipment ..........30 Safety tests .
Page 5 Table of contents Application Intended use of the trucks ..........68 Checks and actions prior to commissioning .
Page 6 Table of contents Transporting the truck ..........100 Handling the battery .
Page 7 Table of contents Fuses ............136 Servicing the on-board charger .
Page 9: Foreword
Foreword...
Page 10: Your Industrial Truck
Foreword 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.
Page 11: Ec Declaration Of Conformity In Accordance With Machinery Directive
Foreword 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 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 12: Information About Documentation
Foreword 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.
Page 13 Foreword 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]...
Page 14: Date Of Edition And Latest Update Of This Manual
Foreword 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.
Page 15: Explanation Of Symbols Used
Foreword 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.
Page 16: Defining Directions
Foreword 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.
Page 17: Environmental Considerations
Foreword 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.
Page 18 Foreword Environmental considerations 50018043429 [EN]...
Page 19: Introduction
Introduction...
Page 20: Technical Description
Introduction Technical description Technical description Driving The EXU-SF electric pedestrian and ride-on pallet trucks are designed to handle pallets A new ﬁxed (standard production) or tele- with a maximum weight of 2000 kg inside scopic (optional) tiller, that is both strong trucks, warehouses and plants.
Page 21 Introduction Technical description • Counter-current, upon accelerator release • Exterior fork width = 520 mm • Counter-current by switching the direction • Exterior fork width = 670 mm of travel • Housing for 360 Ah TROG 113 battery • Counter-current, controlled by the rear •...
Page 22: Use Of The Truck
Introduction Use of the Truck Use of the Truck Intended use of the trucks CAUTION This machine is designed for the transport of loads packed on pallets or in industrial containers de- signed for this purpose, as well as for entering and removing pallets to and from stock (if necessary on a truck).
Page 23: Unintended Use
Introduction Use of the Truck Unintended use Any danger due to unauthorised use becomes the responsibility of the operator or driver and not of the manufacturer (also see ⇒ Chap- ter "Deﬁnition of terms used for responsible persons", P. 26). Use for purposes other than those described in these operating instructions is prohibited.
Page 24 Introduction Use of the Truck 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 and, if necessary, approved for that environ- ment (see ⇒...
Page 25: Residual Risks
Introduction Residual risks Residual risks Residual dangers, residual risks Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the truck cannot be entirely excluded. The truck and all other system components comply with current safety requirements. Nevertheless, even when the truck is used for its proper purpose and all instructions are followed, some residual risk cannot be...
Page 26: Special Risks Associated With Using The Truck And Attachments
Introduction Residual risks The manufacturer is not held responsible for accidents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or carelessly. Stability The stability of the truck has been tested to the latest technological standards and is guaranteed if the truck is used properly and according to its intended purpose.
Page 27 Introduction Residual risks 50018043429 [EN]...
Page 28: Overview Of Hazards And Countermeasures
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...
Page 29 Introduction Residual risks Hazard Measure Check note Notes √ actioned - not applicable Impermissible usage Issuing of operating BetrSichVO (improper usage) instructions (Workplace Safety Ordinance) and ArbSchG (Health and Safety at Work Act) Written notice of BetrSichVO instruction to driver (Workplace Safety Ordinance) and ArbSchG (Health and...
Page 30: Hazards To Employees
Introduction Residual risks Hazard Measure Check note Notes √ actioned - not applicable With driverless transport systems Roadway quality Clean/clear driveways BetrSichVO inadequate (Workplace Safety Ordinance) Load carrier Reattach load to pallet BetrSichVO incorrect/slipped (Workplace Safety Ordinance) Drive behaviour Employee training BetrSichVO unpredictable (Workplace Safety...
Page 31 Introduction Residual risks The results must be documented (§ 6 Arb- SchG). In the case of truck deployment involv- ing similar hazard situations it is permitted to summarise the results. This overview (see ⇒ Chapter "Overview of hazards and coun- termeasures", P.
Page 32 Introduction Residual risks 50018043429 [EN]...
Page 33: Safety
Safety...
Page 34: Definition Of Terms Used For Responsible Persons
Safety Deﬁnition of terms used for responsible persons Deﬁnition of terms used for 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 proper purpose and in compliance with the safety regulations set out...
Page 35: Expert
Safety Deﬁnition of terms used for responsible persons truck to be tested and the risk being as- sessed. Expert An expert is considered to be someone whose technical training and experience have en- abled them to develop appropriate knowledge of industrial trucks and who is sufﬁciently fa- miliar with the applicable national health and safety regulations, directives and generally recognised technical conventions (standards,...
Page 36 Safety Deﬁnition of terms used for responsible persons and safety gloves) suited to the operating con- ditions, the job and the load to be lifted. The driver must wear safety footwear for driving and braking in complete safety. The drive must be familiar with the operating instructions, which must remain accessible at all times.
Page 37: Basic Principles For Safe Operation
STILL. CAUTION Installation and/or use of such products may there- fore have a negative impact on the design features of the truck and thus impair active and/or passive driving safety.
Page 38: Medical Equipment
Safety Basic principles for safe operation You should therefore contact the manufac- turer before carrying out any modiﬁcation. No modiﬁcation that may affect stability is permit- ted without the manufacturer’s authorisation. Any constructional modiﬁcation or transfor- mation of your truck is forbidden without prior written permission from the manufacturer.
Page 39: 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 by a specialist at least once a Regelmäßige Prüfung year or after particular incidents.
Page 40 Safety Safety tests Measuring battery insulation resistance NOTE Nominal battery voltage < test voltage < 500V. – Measure insulation resistance using a suitable meter. The insulation resistance is sufﬁcient when it has a nominal value of at least 1000 Ohms/V against the chassis.
Page 41: Safety Regulations For Handling Consumables
Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relating to consumables may result in a risk of injury, death or damage to the environment. – Observe the safety regulations when handling such materials.
Page 42: Hydraulic Fluid
Safety Safety regulations for handling consumables WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin! – Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin with soap and water, and then apply a skin care product.
Page 43: Battery Acid
Safety Safety regulations for handling consumables WARNING These ﬂuids are pressurised during operation of the truck and are hazardous to your health. – Do not allow the ﬂuids to come into contact with the skin. – Avoid inhaling spray. – Penetration of pressurised ﬂuids into the skin is particularly dangerous if these ﬂuids escape at high pressure due to leaks in...
Page 44: Disposal Of Consumables
Safety Safety regulations for handling consumables WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, always wear a protection suit and eye protection. – When working with battery acid, never wear a watch or any jewellery.
Page 45: Emissions
Safety Safety regulations for handling consumables Emissions Noise emissions The values are determined using the methods set out in European Standard EN 12053 (measurement of noise emissions from industrial trucks, based on Standards ISO 11201 and EN ISO 3744 and in compliance with standard EN ISO 4871).
Page 46 Safety Safety regulations for handling consumables Weighted effective value of the stress on the body by 1.02 m/s acceleration (feet or seat): Uncertainty K ±0.33 m/s Trials have shown that the amount of hand- arm vibration when using the steering wheel and controls is less than 2.5 m/s for industrial trucks.
Page 47: Safety Devices
Safety Safety devices Safety devices Location of safety devices Main safety devices on the truck Emergency stop handle Driver’s side protection Tiller position sensor Cowling secured with screws Anti-crush safety feature Driver on the platform presence sensor Ride-on mode (case 1) Ride-on mode (case 2) •...
Page 48 Safety Safety devices Pedestrian mode DANGER • the two protection arms are in a closed Safety features must not be deactivated. position, • the platform is in a closed position (upper DANGER position), Do not sit on the side protection bars. •...
Page 49: Damage, Defects And Misuse Of Safety Devices
Safety Battery connection cables Damage, defects and misuse of safety devices The driver must report any damage or other defects to the truck or attachment immediately to the supervisory personnel. Trucks and attachments that are not functional or safe may not be used until they have been properly repaired.
Page 50 Safety Battery connection cables 50018043429 [EN]...
Page 51 Overview...
Page 52: Overview
Overview Overview Overview Tiller Brake Pump motor Traction motor Folding side protection arms Drive wheel Lifting cylinder Folding platform Hydraulic oil tank Reducer 50018043429 [EN]...
Page 53 Overview Overview Shock absorbers Rollers Stabiliser roller Battery Power steering motor Traction controller Steering controller Battery hood Fork Fuse holder 50018043429 [EN]...
Page 54: Control And Display Elements
Overview Control and display elements Control and display elements Tiller controls Handle Signal horn Traction control throttle Traction control throttle Forks lowering Anti-crush safety feature Fork lifting WARNING Risk of injury The safety regulations must be strictly adhered to. Access to the controls is needed at all times. Do not obstruct or hinder access to the controls.
Page 55 Overview Control and display elements WARNING Always hold onto the handles of the tiller head when driving. 50018043429 [EN]...
Page 56: Combi Tiller
Overview Control and display elements Combi tiller Unfolding the combi tiller – Pull on the lock to unlock the tiller. – Pull on the tiller handle to unfold it. 50018043429 [EN]...
Page 57 Overview Control and display elements – The tiller is unfolded. Folding the combi tiller – Push on the tiller handles to fold it. 50018043429 [EN]...
Page 58 Overview Control and display elements Pedestrian position with tiller folded In this conﬁguration: • the protective arms are folded • the platform is folded • the tiller is folded • the speed is 4 km/h Pedestrian position with tiller unfolded In this conﬁguration: •...
Page 59 Overview Control and display elements Ride-on position In this conﬁguration: • the protective arms are open • the platform is open • the tiller is folded • the speed is 9 km/h CAUTION In the ride-on position, the combi tiller should not be unfolded.
Page 60: Combined Indicator
Overview Control and display elements Combined indicator 0252_003-007-V2 Discharge indicator Red indicator light Green indicator light Operating hours display 50018043429 [EN]...
Page 61: On/Off Switch
Overview Control and display elements On/Off switch The switch has two driving modes. • "Tortoise" position: gentle acceleration and deceleration; low speed • "Hare" position: fast acceleration and deceleration – To set the truck in motion, turn the ignition key (1) to the desired position. –...
Page 62: Digicode Option (Lfm Go)
Overview Control and display elements Digicode option (LFM Go) Switch ON (operating mode) Key fault or incorrect code Switch OFF and awaiting code Time delay of automatic switch-off Programming mode active Operation Key in LED status Notes red off continuous * 0 0 0 0 0 # 0 0 0 0 0 1 2 3...
Page 63 Overview Control and display elements PROGRAMMING (truck switch OFF only (2)) Power switches off red ﬂashing green automatically after Activating the ﬂashing (5) (5 s before 10 mins (600 s by * * 2 * 1 # automatic switch-off) default) if the truck is switch-off not being used.
Page 64: Emergency Stop Handle
Overview Control and display elements Emergency stop handle – Pressing the emergency stop handle (1) will lock all the functions on the truck. – To restore the operating conditions, elim- inate the causes of the emergency, then release the tiller in the rest position and un- lock the emergency stop handle by lifting it.
Page 65: Side Protection
Overview Side protection Side protection Description The arms are designed to provide the driver with side protection when the truck is being operated in ride-on mode. There are two positions: – Position "A" = arms closed: position used when the driver is a pedestrian with the platform raised or lowered (in this case, the speed is limited to 6 km/h).
Page 66 Overview Side protection DANGER Do not sit on the side protection bars. DANGER Do not climb on the side protection bars. 50018043429 [EN]...
Page 67: Platform
Overview Platform Platform Description There are three platform positions: If the platform is raised and the arms are open, the traction is locked. Position "A" = platform raised: this position is used in pedestrian mode and with the arms Moving the platform closed.
Page 68 Overview Platform DANGER Risk of ejection from the platform. Correctly position yourself on the platform between the two side protection bars. Travel round corners at low speed. 50018043429 [EN]...
Page 69: Markings
Overview Markings Markings Marking positions "STILL" label "Max. pressure" label "Decal information" label (version without "Platform pressure diagram" label digicode) Company plate (afﬁxed to the far left of the "EXU-SF" logo battery connector in the case) "Slinging" label UVV support (Germany only) Gel battery label, if applicable (afﬁxed next...
Page 70: Chassis Frame Labelling
Overview Markings Chassis frame labelling The truck’s serial number is marked on the chassis frame (1). 2265 50018043429 [EN]...
Page 71: Labels
Overview Markings Labels Operating instructions Do not lift a load with the initial lift in the upper Slinging - See the operating instructions position UVV support (Germany only) Do not step under a raised load UVV plate (Germany only) Do not climb Company plate Do not stand on the forks Load capacity plate (example)
Page 72 Overview Markings On-board charger label Automatic mode selection indicator (EXU-H Mains connector (on-board charger) autolift only) "Plugs" label Manual or automatic mode selection Hydraulic ﬁller (EXU-H autolift only) Maximum pressure (example) Automatic lifting/lowering mode selection Platform pressure diagram (example) Arrows Operating mode indication label Cold store "Cockpit"...
Page 73: Data Plate
Overview Markings Data plate NOTE Please indicate the serial no. for all technical enquiries. Model Manufacturer Serial no. Year of manufacture Unladen weight (without battery) in kg Maximum battery weight Minimum battery weight Additional weight (ballast) in kg Nominal power rating in kW Battery voltage V Rated capacity in kg EC conformity symbol...
Page 74: Accessibility
Overview Accessibility Accessibility Internal accessibility – To access the internal parts of the truck (electronic, electrical and mechanical parts), follow the instructions provided in chapter ⇒ Chapter "Access to the technical compartment", P. 6-130. – To access the battery (1) and sockets (2), unlock and lift the cover (3).
Page 75: Application
Application...
Page 76: Intended Use Of The Trucks
Application Intended use of the trucks Intended use of the trucks CAUTION This machine is designed for the transport of loads packed on pallets or in industrial containers de- signed for this purpose, as well as for entering and removing pallets to and from stock (if necessary on a truck).
Page 77: Checks And Actions Prior To Commissioning
Application Checks and actions prior to commissioning Checks and actions prior to commissioning Daily checks and actions prior to use CAUTION • Check that the anti-crush safety device is operating correctly (see ⇒ Chapter "Check- Do not use the truck if it (or its accessories) is ing the anti-crush safety device", P.
Page 78 Application Checks and actions prior to commissioning propriate training that is updated whenever necessary. • Driving a ride-on motor-driven truck is subject to having obtained a driving permit. 50018043429 [EN]...
Page 79: Connecting The Battery (Wall-Mounted Battery Charger)
Application Checks and actions prior to commissioning Connecting the battery (wall- mounted battery charger) – Open the battery cover. – Remove the battery plug (1) from the wall-mounted charger socket and connect it to the (2) truck socket. 50018043429 [EN]...
Page 80: Commissioning
Application Commissioning Commissioning Start-up NOTE Perform a visual inspection of the truck before starting (see ⇒ Chapter "Daily checks and actions prior to use", P. 5-69). – Connect the battery connector (1). – Pull the emergency stop handle (2). – Place the tiller in the vertical position. –...
Page 81: Check The Information On The Combined Indicator
Application Commissioning Check the information on the combined indicator The instrument can display several of the truck’s functions: Discharge indicator The discharge indicator (3) operates after the battery plug has been connected. Monitoring the discharge process protects the battery from deep discharge. When the battery is fully charged, the 10 status bars are lighted.
Page 82 Application Commissioning Checking the anti-crush safety device WARNING Ensure that the test area is free of people and objects, both in front of and behind the truck. – Operate the throttle (1) or (3) for forward travel. The truck moves forward. –...
Page 83: Checking The Brake
Application Commissioning Checking the brake CAUTION Perform this check on a ﬂat surface. – While driving, test the efﬁciency of the brake by tilting the tiller in areas (A) and (C). In these two areas, the truck is stopped and the drive unit is no longer powered.
Page 84: Checking The Emergency Stop
Application Commissioning Checking the emergency stop – Drive slowly forwards. – Press the emergency stop handle (1): the truck stops. – Pull the emergency stop handle (1): the truck is functional. Checking the horn – Operate the horn switch (1). The horn sounds.
Page 85: Driving
Application 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...
Page 86 Application Driving transporting goods that obstruct visibility, the truck must be driven with the load trailing. If this is not possible, a guide must walk ahead of the truck. In this case, the truck may only be driven at walking pace and with the utmost caution.
Page 87: Before Driving
Application Driving Before driving People in the danger area Before starting the truck and while you are working, ensure that no one is in the danger area. If people are in danger, warn them well in advance. Stop working with the truck immediately if the people do not leave the danger area despite the warnings.
Page 88 Application Driving Dimensions of the trafﬁc routes and manoeuvring areas The dimensions given below and the aisle width requirements apply to set conditions to guarantee manoeuvring safety. In some cases it may be necessary to check if the width of the aisles is sufﬁcient; for example if the dimensions of the load differ from those given.
Page 89 Application Driving Trafﬁc route conditions The trafﬁc route surfaces must be sufﬁciently ﬂat, clean and clear of fallen objects. Drainage channels, railway crossings and other similar items must be level and, if necessary, ﬁtted with ramps so that the truck can cross without jerking.
Page 90: Behaviour In Emergencies
Application Driving Behaviour in emergencies In an emergency, the power supply to all functions on the truck can be shut down. – Press the emergency stop handle (1). The truck stops. – To restart the truck, release the emergency stop handle (1) by pulling on it. CAUTION This safety device must only be used in an emer- gency.
Page 91: Driving Position
Application Driving Driving position There are two driving positions for the EXU- • Pedestrian mode driving position • Ride-on mode driving position Pedestrian mode driving position The driver controls the truck as a pedestrian, using the controls located on the tiller head. CAUTION The truck may only be operated in pedestrian mode if the protective arms are in the closed position.
Page 92 Application Driving WARNING When the side protection bars are in the upper position: there is a risk of pinching your ﬁngers between the underside of the tiller head and the top of the protection arms. Always hold onto the handles of the tiller head when driving.
Page 93: Driving
Application Driving Driving – Turn the ignition key to the required posi- tion: position (gentle accelera- Tortoise tion and deceleration; low speed) or Hare position (fast acceleration and decelera- tion). – Hold one of the tiller handles (1). – Lower the tiller. NOTE The machine is only in the driving position in zone (B).
Page 94 Application Driving The traction controls are only operational when the tiller is in the operating position The lifting controls are operational even when the tiller is in the upper position. Traction control throttles – When the lower part of the throttle (2) or (6) is pressed, the truck will move towards the driver (reverse travel);...
Page 95: Guiding
Application Driving Guiding The turning radius (Wa) depends on the length of the fork arms and the battery (see ⇒ Chapter "Technical data (VDI)", P. 7-159). Turning radius value (Wa) (in mm) Type EXU-SF 1752 / 2171 50018043429 [EN]...
Page 96: Braking
Application 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) to the opposite direction of travel.
Page 97: Lifting
Application Lifting This time period can be conﬁgured between 0 and 10 minutes. This function is disabled by default. Timeout can be adjusted. Please call the service department. Lifting Lifting WARNING Risk of injury The safety regulations must be strictly adhered to. It is strictly forbidden to touch or stand on moving parts (e.g.
Page 98: Handling Loads
Application Handling loads Handling loads Load handling safety rules WARNING DANGER Closely observe 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).
Page 99 Application Handling loads CAUTION Be careful not to touch adjacent loads or loads positioned at the sides or in front of the load being handled. Loads must be arranged so that they are aligned with a narrow space between them to prevent them from catching.
Page 100 Application 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.
Page 101: Transporting Pallets Or Other Containers
Application Handling loads Transporting pallets or other contain- As a general rule loading units must be trans- ported one by one (e.g. pallets). Transporting several loading units at once is only authorised • the safetypreconditions are fulﬁlled. • by order of the supervisor, The operator must ensure that the loading unit is properly packed.
Page 102: Driving On Upward And Downward Slopes
Application 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. The operator must ensure that the ground is clean and has a non-slip surface.
Page 103: Cold Store Usage (Optional)
Application 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.
Page 104 Application 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.
Page 105: Error Display
Application Error display Error display Error codes The combined indicator may display an error code. When an error code is displayed, please call our service department. NOTE Four error codes may be displayed. For example: • E1: 239 • E2: 212 •...
Page 106: Handling The Truck In Specific Situations
Application Handling the truck in speciﬁc situations Handling the truck in speciﬁc situations Towing and moving The truck cannot be towed if there is no electical power as the electric brake is applied. If the brake of the towed truck is no longer functioning, the truck may only be towed with a ﬁxed connection (tow bar).
Page 107 Application Handling the truck in speciﬁc situations – After towing the truck, secure it with squared timbers to prevent it from rolling. – Unscrew and remove the two screws (1) to restore the braking function. – Remove the covers. WARNING Before the truck is taken into service, all covers must be mounted as speciﬁed.
Page 108: Transporting The Truck
Application Handling the truck in speciﬁc situations Transporting the truck CAUTION Always switch off the ignition and disconnect the battery. Never tie down or sling the truck by the tiller or other points not designed for this. CAUTION Use a hoist and woven NON METALLIC slings with an adequate lifting capacity.
Page 109: Handling The Battery
Application Handling the battery Handling the battery Types of battery Trucks can be ﬁtted with different types of battery. Comply with the information on your battery’s type plate, as well as the speciﬁcations deﬁned in ⇒ Chapter "Technical data (VDI)", P. 7-159. WARNING The weight and size of the battery inﬂuence the stability of the truck.
Page 110 Application Handling the battery only be operated after the battery cover is closed and the battery connector plugged in. 50018043429 [EN]...
Page 111: Opening/Closing The Battery Compartment
Application Handling the battery Opening/closing the battery com- partment Opening – Park the truck. – Turn the lock button (1) clockwise. – Lift the battery cover (2) using the handle (3). 50018043429 [EN]...
Page 112 Application Handling the battery – Pull the battery connector handle (4). Closing WARNING Risk of crushing. Be sure not to leave anything between the battery cover and the edge of the chassis when closing the cover. – Connect the battery connector (4). 50018043429 [EN]...
Page 113 Application Handling the battery – Close the battery cover (2). – Turn the lock button (1) anti-clockwise. 50018043429 [EN]...
Page 114: Charging The Battery Using An External Charger
Application 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. – Park the truck safely. – Open the battery compartment. – Before charging, check the condition of the battery cable and the charger cable.
Page 115: On-Board Charger
Application Handling the battery On-board charger CAUTION It is strictly prohibited to use an on-board charger other than the one recommended. Precautions for installation and use The Charis HF 2+ on-board 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...
Page 116 Application Handling the battery • To be incorporated inside an industrial truck. The charger must never be used alone (out of the truck). • To stay connected permanently to the battery. • To operate in all positions. • To stay connected to the mains during periods when the truck is not being used to ensure the availability of the machine (see section on "Other charging details").
Page 117 Application Handling the battery Nominal battery voltage Tolerance on the voltage of bearing U Battery characteristics Battery type Gel or open lead-acid traction battery Number of components 12 x 2 V components 140 Ah minimum to 375 Ah maximum (adapta- Capacity tion of the charging curve by a selector) General conditions for use...
Page 118 Application Handling the battery Continuously lit Equalisation Continuously lit Maintenance phase Continuously lit Charging too long Continuously lit Charger polarity reversed (+bat and -bat charger cables reversed, with the battery Continuously lit Continuously lit remaining normally connected to the truck assembly) Battery polarity reversed Selector in neutral position Flashing...
Page 119 Application Handling the 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. CAUTION Risk of damaging the battery prematurely! It is essential to select the correct type of battery on the selector.
Page 120 Application Handling the battery Protection during charging Mains micro-break protection If the mains power is cut off, all the existing charging parameters 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.
Page 121: Replacing The Battery
Application Putting out of commission and storage Replacing the battery There are two options: • from above using a lifting device, • from the side using a battery trolley (option). To prevent short-circuits, it is recommended that batteries with polar terminals or unpro- tected connections be covered with a rubber mat.
Page 122: Temporary Putting Out Of Commission
Application Putting out of commission and storage Temporary putting out of commis- sion If the truck will not be used for extended periods, it is necessary to: • Clean the truck as indicated in the chapter ⇒ Chapter "Cleaning the truck", P. 6-131, •...
Page 123: Permanent Putting Out Of Commission (Destruction)
Application Putting out of commission and storage Permanent putting out of commis- sion (destruction) When a decision is taken to scrap the truck, it is necessary to: • Remove the various parts of the truck (covers, battery, chains, motors etc.), •...
Page 124: Measures When Storing The Stacker For A Longer Period Of Time
Application Putting out of commission and storage Measures when storing the stacker for a longer period of time If the stacker is to be held in storage for a longer longer period of time, carry out the following corrosion protection measures. If the stacker is to be stored for over two months, park it in a clean and dry storage area, which is also well ventilated and frost-free.
Page 125: Taking Back Into Service After Storage
Application Putting out of commission and storage Taking back into service after storage If the pallet stacker has been out of service for over six months, it must be inspected carefully before it is taken back into service. The inspection, similarly to the safety inspection, should also include safety-related points on the truck.
Page 126 Application Putting out of commission and storage 50018043429 [EN]...
Page 127: Maintenance
Maintenance...
Page 128: General Maintenance Information
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 tasks in compliance with the service plan. This will ensure your truck is reliable and in good working order and that the warranty remains valid.
Page 129: Battery Maintenance Personnel
Maintenance General maintenance information inspection must be performed by an expert. The expert must provide his opinion and safety assessment irrespective of the internal and ﬁnancial circumstances of the company. Only the safety aspect is decisive. He must have adequate knowledge and experience to assess the state of the vehicle and the effectiveness of the protective devices in accordance with the rules of technology and...
Page 130: Ordering Spare Parts And Consumables
Maintenance General maintenance information Ordering spare parts and consum- ables 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.
Page 131 Maintenance General maintenance information 50018043429 [EN]...
Page 132: List Of Inspections
Maintenance General maintenance information List of inspections Maintenance and lubrication 1. daily 2. carry out maintenance according to the hour meter (bold typeface) E.g. after 3000 hours of service all the "500 and 1000 hour" maintenance and lubrication work should be carried out. After 9000 hours of service, continue as above, therefore instead of 500 hours: 9500 hours of service.
Page 133: Servicing And Inspection Intervals
Maintenance General maintenance information Servicing and inspection intervals Carry out the work according to the intervals listed below. Figure Intervals Work to be done Cleaning the truck Servicing the wheels and rollers As required Servicing the battery Servicing the brake Checking the platform air spring pressure Servicing the hydraulic system Servicing the steering motor...
Page 134 Maintenance General maintenance information Figure Intervals Work to be done Servicing the hydraulic system Servicing the electrical system annually/2000 hours Checking the insulation Accident prevention technical inspection 5 years/5000 hours Servicing the reducer 50018043429 [EN]...
Page 135: Maintenance Specifications Table
Maintenance General maintenance information Maintenance speciﬁcations table Lubricants and Abbre- Sub-assembly Speciﬁcation Dimension consumables viation Battery Fluid level Distilled water as required Insulation 1000 ohm min. in resistance relation to the chassis Lubricants Lithium-based NLGI Multi S2 grease, TOTAL as required Joints and seals MIL-L-2105, gearbox oil...
Page 136: Maintenance Safety Guidelines
Maintenance Maintenance safety guidelines Maintenance safety guidelines Safety measures for maintenance and repair To prevent accidents during maintenance and repair, perform all necessary safety measures such as: – Ensure that the truck is secured against in- advertent movement or accidental starting (disconnect the battery connector).
Page 137: Preparatory Procedures For Maintenance
Maintenance Preparatory procedures for maintenance Preparatory procedures for maintenance Slinging and jacking the truck Slinging To lift the truck, the truck sub-assemblies or additional equipment, lifting devices must only be hooked onto the appropriate lifting points. When lifting with a jack, take appropriate measures (use chocks or wooden blocks) to prevent the truck from slipping or tipping over.
Page 138: Access To The Technical Compartment
Maintenance Preparatory procedures for maintenance Access to the technical compartment – Disconnect the battery socket. – Open out the side protections (1) and lower the platform (2). – Remove the two screws (3). – Put the side protections back in the upper position and reclose them in an interme- diate position to assist with removing the cover.
Page 139: Cleaning
Maintenance Cleaning Cleaning Cleaning the truck Cleaning instructions – Always park the truck following the instruc- tions provided. – Push the emergency stop. – Disconnect the battery connector. CAUTION The battery must always be disconnected during cleaning procedures. Washing the outside of the truck WARNING –...
Page 140 Maintenance Cleaning Cleaning the electrical installations WARNING Do not expose electrical equipment (especially motors) to direct jets. NOTE Only use dry cleaning products. Do not remove the protective covers. – Clean the electrical installations with a non-metal brush and dry with lightly compressed air.
Page 141: Maintenance As Required
Maintenance Maintenance as Required Maintenance as Required Servicing the wheels and rollers Checking tyres and wear on wheels and rollers The tyre tread on the drive wheel, stabilising wheels and rollers should show no signs of deterioration. Dimensions Drive wheel Ø230 x 75 mm Stabilising wheel Ø140 x 54 mm...
Page 142 Maintenance Maintenance as Required CAUTION The above defects can lead to serious incidents; in the event of a fault, please contact our service engineers. 50018043429 [EN]...
Page 143: Cleaning The Battery And Its Compartment
Maintenance Maintenance as Required Cleaning the battery and its compart- ment WARNING This delicate operation must be carried out wearing acid-resistant gloves and clothing and protective glasses. Follow the safety precautions described in previous chapters. ENVIRONMENT NOTE Do not pour acid-bearing wash water down the drain.
Page 144: Fuses
Maintenance Maintenance as Required Fuses CAUTION Before carrying out any operations on the electrical system, turn the truck power supply off by discon- necting the battery connector. – Open the battery cover. – Disconnect the battery connector. – Remove the cover to gain access to the fuse holder.
Page 145: Servicing The Brake
Maintenance Maintenance as Required Servicing the brake Checking the operation of the parking brake – Drive forwards. – Check the efﬁciency of the brake by tilting the tiller upwards (C) and downwards (A). WARNING If the brake is not working properly, attempt to adjust it.
Page 146 Maintenance Maintenance as Required – This adjustment is made by connecting a pneumatic air line to the connection socket located under the platform. Refer to the chart located on the hood, behind the platform (see ⇒ Chapter "Marking posi- tions", P. 4-61). 50018043429 [EN]...
Page 147: Maintenance Every 500 Hours
Maintenance Maintenance every 500 hours Maintenance every 500 hours Other tasks – Perform all maintenance work; see the "Maintenance" chapter. 50018043429 [EN]...
Page 148: Maintaining The Hydraulic System
Maintenance Maintenance every 500 hours Maintaining the hydraulic system Checking the oil level and sealing of the hydraulic system – Remove the front cover. – Check the hose and its connections for leaks (traces of oil). – Lower the forks. –...
Page 149: Maintaining The Electric Motors
Maintenance Maintenance every 500 hours Maintaining the electric motors Checking the electrical connections Traction controller Fuse holder Pump motor Steering controller Power steering motor Traction motor – Check the mounting, condition and insula- tion of the control unit cables, and the fuses on the traction motor, power-assisted steer- ing motor and pump motor.
Page 150 Maintenance Maintenance every 500 hours Minimum length x = 11 mm (pump motor) Minimum length (power-assisted x = 11 mm steering motor) – Change all the brushes when a brush reaches this measurement. NOTE Before reassembling, check that there are no traces of burning on the manifold.
Page 151: Maintaining The Electrical System
Maintenance Maintenance every 500 hours Maintaining the electrical system Checking the cable and fuse connection mountings WARNING Stop the truck and disconnect the battery before carrying out the following checks. – Remove the front cover. – Check the condition of fuses (1), (2), (3) and (4).
Page 152: Servicing The Brake
Maintenance Maintenance every 500 hours Servicing the brake Checking the air gap – Release the brake. – Measure the air gap (1) with an adjustment shim at three different points separated by 120°. Air gap of 0.15 to 0.4 mm Minimum thickness 0.6 mm for the rotor...
Page 153: Checking The Forks
Maintenance Maintenance every 500 hours Checking the forks Checking the condition of the forks – Check that the fork arms show no signs of distortion, splits, heavy wear or cracks. CAUTION The fork carriage must be changed by our service department if it is damaged.
Page 154 Maintenance Maintenance every 500 hours 50018043429 [EN]...
Page 155: Maintenance Every 1000 Hours
Maintenance Maintenance every 1000 hours Maintenance every 1000 hours Work that must also be carried out – Carry out maintenance work as neces- sary, see ⇒ Chapter "Maintenance as Re- quired", P. 133. – Carry out 500-hour maintenance, see ⇒ Chapter "Maintenance every 500 hours", P.
Page 156 Maintenance Maintenance every 1000 hours 50018043429 [EN]...
Page 157: Maintenance Every 2000 Hours
Maintenance Maintenance every 2000 hours Maintenance every 2000 hours Work that must also be carried out – Carry out maintenance work as neces- sary, see ⇒ Chapter "Maintenance as Re- quired", P. 133. – Carry out 500-hour maintenance, see ⇒ Chapter "Maintenance every 500 hours", P.
Page 158: Maintaining The Hydraulic System
Maintenance Maintenance every 2000 hours Maintaining the hydraulic system Draining the hydraulic oil and replacing the hydraulic oil suction ﬁlter (every 2000 hours or at least every year) WARNING Hydraulic oil can damage your health. Follow the safety rules for the use of hydraulic oil. –...
Page 159: Servicing The Battery According To The Manufacturer's Instructions
Maintenance Maintenance every 2000 hours – Remove the suction ﬁlter (5) from the pump motor and replace it. – Fit a new sealing ring (4) . – Re-attach the hydraulic oil tank to the pump motor and reﬁt them. – Fill the tank with new hydraulic oil in accor- dance with the maintenance speciﬁcations table.
Page 160 Maintenance Maintenance every 2000 hours The insulation resistance is sufﬁcient when it has a nominal value of at least 1000 Ohms/V against the chassis. Ask our service department. Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage < test voltage < 500V. –...
Page 161: Periodic Inspections
Statutory accident prevention checks as scheduled or following a speciﬁc event (in Germany: UVV; Please observe national instructions and regulations) (at least once a STILL GmbH Hamburg year). Regelmäßige Prüfung The lifting truck must be checked by a spe- (FEM 4.004) cialised technician.
Page 162 Maintenance Maintenance every 2000 hours 50018043429 [EN]...
Page 163: Maintenance Every 5000 Hours
Maintenance Maintenance every 5000 hours Maintenance every 5000 hours Work that must also be carried out – Carry out maintenance work as neces- sary, see ⇒ Chapter "Maintenance as Re- quired", P. 133. – Carry out 500-hour maintenance, see ⇒ Chapter "Maintenance every 500 hours", P.
Page 164: Maintaining The Reducer
Maintenance Maintenance every 5000 hours Maintaining the reducer Draining the oil CAUTION Drain the oil when hot. Follow the safety regulations regarding the use of oil. – Stop and chock the truck, and then take off the cover. – Remove the drive unit and take out the motor.
Page 165: Technical Data
Technical data...
Page 166: Dimensions
Technical data Dimensions Dimensions 50018043429 [EN]...
Page 167: Technical Data (Vdi)
Technical data Technical data (VDI) Technical data (VDI) CHARACTERISTICS Model type EXU-SF 20 Drive: electric, diesel, petrol, LPG. Electric Driving mode: manual, pedes- trian, ride-on standing, ride-on ride-on/pedestrian seated, order picking Nominal capacity / load Q (kg) 2000 Nominal load centre of gravity c (mm) x (mm) Load distance...
Page 168 Technical data Technical data (VDI) DIMENSIONS b1 (mm) 4.21 Total width s/e/l (mm) 4.22 Dimensions of forks 55 / 172 / 1190 4.25 Outside fork spread b5 (mm) Ground clearance, laden, under m1 (mm) 4.32 mast Aisle width for pallet 800 x 1200 Ast (mm) 2129 / 2542 2210 / 2618...
Page 169 Index Copyright and trademark rights ..6 Cross references ....7 Anti-crush safety feature Check .
Page 170 Index Modiﬁcations and reﬁtting ... . 29 Forks 500-hour maintenance ..145 Oils ......33 Fuses .
Page 171 Index Stability ......18 Standby ......88 Unintended use .
Page 174 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 50018043429 EN...

Still EXU-SF20 Original Instructions Manual

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