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Still EXU-SF20 User Manual

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

Table of Contents

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Still EXU-SF20 Specifications

General IconGeneral
BrandStill
ModelEXU-SF20
CategoryTrucks
LanguageEnglish

Summary

Foreword

Your industrial truck

General information about the truck and its operating instructions.

EC declaration of conformity in accordance with Machinery Directive

Declaration of conformity with EU directives for the industrial truck.

Information about documentation

Details on the scope of documentation and how to use it.

Date of edition and latest update of this manual

Information on the publication date and manufacturer's right to make changes.

Copyright and trademark rights

Restrictions on reproduction and dissemination of the manual.

Explanation of symbols used

Definitions and meanings of various symbols used in the manual.

Explanation of the cross-references

Guidance on how to interpret cross-references within the manual.

Defining directions

Explanation of directional terms used for truck operation and illustration.

Illustrations

Information on the use of schematic representations in the manual.

Environmental considerations

Information regarding packaging and disposal of components and batteries.

Introduction

Technical description

Detailed description of the EXU-SF electric pallet truck's features and components.

Use of the Truck

Information on the intended use and proper operation of the truck.

Unintended use

Warnings and prohibitions regarding unauthorized or improper use of the truck.

Place of use

Guidelines for suitable operating environments and conditions for the truck.

Residual risks

Discussion of inherent risks and potential dangers when operating the truck.

Stability

Factors affecting truck stability and risks associated with instability.

Special risks associated with using the truck and attachments

Specific risks when using the truck with additional attachments.

Overview of hazards and countermeasures

Table detailing hazards, measures, and notes for safe operation.

Hazards to employees

Safety regulations and responsibilities for protecting employees during operation.

Safety

Definition of terms used for responsible persons

Definitions of roles such as Operating company, Specialist, Expert, and Driver.

Basic principles for safe operation

General principles for safe operation, insurance, and modifications.

Safety tests

Procedures for regular safety inspections and electrical insulation tests.

Safety regulations for handling consumables

Safety rules for handling oils and other permissible consumables.

Permissible consumables

Details on permissible consumables for the truck.

Oils

Safety information and handling of oils.

Hydraulic fluid

Safety warnings and handling instructions for hydraulic fluid.

Battery acid

Safety warnings and handling instructions for battery acid.

Disposal of consumables

Guidelines for proper disposal of used oils, battery acid, and other materials.

Emissions

Information on noise emissions and vibrations from the truck.

Traction battery emissions

Information on explosive gases generated during battery charging.

Safety devices

Location and description of main safety devices on the truck.

Location of safety devices

Diagram showing the location of key safety devices on the truck.

Ride-on mode (case 1)

Configuration and speed for ride-on mode case 1.

Ride-on mode (case 2)

Configuration and speed for ride-on mode case 2.

Pedestrian mode

Operating configurations and speed limits for pedestrian mode.

Damage, defects and misuse of safety devices

Procedures for reporting damage and warnings about deactivating safety features.

Battery connection cables

Caution regarding the use of non-original battery connection cables.

Overview

Overview

Diagram and list of main components and parts of the truck.

Control and display elements

Description of the truck's controls and display indicators.

Tiller controls

Detailed description of the controls located on the tiller head.

Combi tiller

Instructions for unfolding and folding the combi tiller.

Pedestrian position with tiller folded

Configuration and speed for pedestrian mode with tiller folded.

Pedestrian position with tiller unfolded

Configuration and speed for pedestrian mode with tiller unfolded.

Ride-on position

Configuration and speed for ride-on mode.

Combined indicator

Description of the combined indicator and its readouts.

On/Off switch

Explanation of driving modes and ignition key operation.

Digicode option (LFM Go)

Details on using the digicode for truck operation and programming.

Emergency stop handle

Procedure for operating the emergency stop handle.

Side protection

Description of side protection arms and their positions.

Platform

Description of platform positions and moving/adjusting the platform.

Markings

Illustration and list of various labels and marking positions on the truck.

Marking positions

Diagram showing the locations of all markings on the truck.

Chassis frame labelling

Location of the truck's serial number on the chassis frame.

Labels

Visual guide to various labels affixed to the truck and their meanings.

Data plate

Information on the truck's data plate, including model, serial number, and specifications.

Accessibility

Information on accessing internal parts and components of the truck.

Application

Intended use of the trucks

Defines the machine's designed purpose for transporting palletized loads.

Checks and actions prior to commissioning

Daily checks and essential actions to perform before operating the truck.

Daily checks and actions prior to use

Essential daily checks before using the truck.

List of checks to be carried out prior to use

Comprehensive checklist for pre-operation inspection.

Connecting the battery (wall-mounted battery charger)

Procedure for connecting the battery using a wall-mounted charger.

Commissioning

Steps for starting up the truck after initial setup or maintenance.

Start-up

Initial steps to start and operate the truck.

Check the information on the combined indicator

How to interpret information displayed on the truck's combined indicator.

Checking the anti-crush safety device

Procedure for testing the anti-crush safety function.

Checking the brake

Procedure for checking the efficiency of the truck's parking and service brakes.

Checking the emergency stop

Procedure for testing the emergency stop handle function.

Checking the horn

Procedure for testing the operation of the warning horn.

Driving

General safety instructions and considerations for driving the truck.

Driving safety instructions

Key safety rules and guidelines for operating the truck.

Behaviour when driving

Proper conduct and awareness required while driving the truck.

Visibility when driving

Ensuring clear visibility and awareness of surroundings while driving.

Before driving

Safety measures and warnings related to people in the danger area.

Dimensions of the traffic routes and manoeuvring areas

Technical dimensions and aisle width requirements for safe operation.

Traffic route conditions

Requirements for traffic route surfaces and clearances.

Rules regarding the traffic routes and the manoeuvring areas

Guidelines for using authorised traffic routes and storing loads.

Hazards

Signalling of hazards on traffic routes.

Behaviour in emergencies

Procedure for shutting down power in an emergency using the stop handle.

Driving position

Description of pedestrian and ride-on mode driving positions.

Traction control throttles

Operation of travel throttles, anti-crush feature, and warning horn.

Guiding

Information on turning radius and its dependency on fork arms and battery.

Braking

Instructions for gentle, moderate, and parking brake operation.

Standby

Information on the standby function for energy saving.

Lifting

Instructions for operating the fork lifting and lowering functions.

Handling loads

Safety rules and procedures for picking up and handling loads.

Load handling safety rules

Essential safety rules for handling loads with the truck.

Picking up a load

Step-by-step guide for safely picking up loads with the forks.

Transporting a load

Guidelines for safely transporting loads, including on slopes.

Setting a load down on the ground

Procedure for safely lowering loads onto the ground.

Transporting pallets or other containers

Rules for transporting multiple pallets or containers.

Driving on upward and downward slopes

Specific instructions for driving on slopes.

Transporting the truck in the lift

Safety procedures for transporting the truck using a lift.

Driving on loading bridges

Precautions for crossing loading bridges.

Cold store usage (optional)

Information on special equipment and operating ranges for cold store use.

Error display

Information on displaying and interpreting error codes.

Handling the truck in specific situations

Procedures for towing and moving the truck.

Towing and moving

Instructions for safely towing and moving the truck.

Towing without a battery

Procedure for manually releasing the brake for towing without a battery.

Transporting the truck

Instructions for safely transporting the truck by road, rail, or ramp.

Handling the battery

Information on battery types, preparation, and fire prevention measures.

Types of battery

Information on different battery types compatible with the truck.

Preparation

Steps and personnel qualifications required for battery preparation.

Fire prevention measures

Safety measures to prevent fires when handling batteries.

Safe parking

Guidelines for safely parking the truck during battery servicing.

Opening/closing the battery compartment

Step-by-step instructions for opening and closing the battery compartment.

Charging curve selector

Guide to selecting the correct charging curve for different battery types.

Other charging characteristics

Information on maintenance charges and partial recharging.

Protection during charging

Details on mains micro-break, time, and temperature protection during charging.

Putting out of commission and storage

Procedures for replacing batteries and parking the truck for storage.

Replacing the battery

Methods for safely replacing the truck's battery.

Parking the truck.

Instructions for properly parking the truck.

Temporary putting out of commission

Instructions for temporary storage of the truck.

Permanent putting out of commission (destruction)

Procedure for scrapping the truck and disposing of its components.

Measures when storing the stacker for a longer period of time

Corrosion protection measures and pre-operation checks for long-term storage.

Taking back into service after storage

Inspection and service procedures for returning a stored truck to operation.

Maintenance

General maintenance information

General guidelines for servicing the truck according to the service plan.

General

Overview of maintenance requirements and service plan adherence.

Service plan

Information on maintenance scheduling based on operating hours.

Quality and quantity of lubricants and other ingredients

Guidelines for lubricants and other materials used in maintenance.

Staff training and qualifications for maintenance and repairs

Requirements for personnel performing maintenance and repairs.

Ordering spare parts and consumables

Information on ordering genuine spare parts and recommended consumables.

Cleaning

Instructions for cleaning the truck, including outside and electrical installations.

Cleaning the truck

Procedures for washing the exterior of the truck.

Cleaning the electrical installations

Instructions for cleaning the truck's electrical components.

Maintenance as Required

Procedures for servicing wheels, rollers, and checking cable connections.

Servicing the wheels and rollers

Checking tyre tread and wear on wheels and rollers.

Tightening the drive wheel fixing screws

Procedure for checking and tightening drive wheel fixing screws.

Checking the condition of cables, terminals and battery connector

Inspection of cables, terminals, and battery connector for damage.

Cleaning the battery and its compartment

Procedure for cleaning the battery and its compartment, including sulphate removal.

Fuses

Location and identification of fuses on the fuse holder.

Servicing the on-board charger

Safety warnings and checks for the on-board charger.

Servicing the brake

Procedures for checking parking and service brake operation and adjustment.

Checking the platform air spring pressure

Procedure for checking and adjusting the platform air spring pressure.

Maintenance every 500 hours

Tasks to be performed during 500-hour maintenance intervals.

Other tasks

General maintenance tasks for 500-hour intervals.

Maintaining the hydraulic system

Procedure for checking oil level and sealing of the hydraulic system.

Maintaining the electric motors

Checking electrical connections and replacing motor brushes.

Maintaining the electrical system

Checking cable and fuse connection mountings for the electrical system.

Servicing the brake

Procedures for checking brake air gap and braking power.

Checking the forks

Procedure for checking the condition of the forks and their sealing.

Checking the platform air spring pressure

Procedure for checking the platform air spring pressure.

Maintenance every 1000 hours

Tasks to be performed during 1000-hour maintenance intervals.

Work that must also be carried out

Additional work required for 1000-hour maintenance.

Servicing the on-board charger

Checks for the security of mechanical and electrical parts of the charger.

Maintenance every 2000 hours

Tasks to be performed during 2000-hour maintenance intervals.

Work that must also be carried out

Additional work required for 2000-hour maintenance.

Maintaining the hydraulic system

Procedure for draining hydraulic oil and replacing the suction filter.

Servicing the battery according to the manufacturer’s instructions

Instructions for servicing the battery as per manufacturer's guidelines.

Electrical insulation test

Procedure for testing the truck's electrical insulation resistance.

Measuring battery insulation resistance

Method for measuring battery insulation resistance.

Measuring the insulation resistance of the electrical system

Procedure for measuring the electrical system's insulation resistance.

Periodic inspections

Requirements for statutory accident prevention checks and specialist inspections.

Maintenance every 5000 hours

Tasks to be performed during 5000-hour maintenance intervals.

Work that must also be carried out

Additional work required for 5000-hour maintenance.

Maintaining the reducer

Procedure for draining and filling the reducer with oil.

Technical data

Dimensions

Diagram showing the physical dimensions of the electric pallet truck.

Technical data (VDI)

Detailed specifications for the truck, including characteristics, weights, wheels, and dimensions.

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