Still EK-X User manual

Original instructions
High level order picker
EK-X
2131 2133
5213 804 2501 EN - 01/2016

Table of contents
g
1 Foreword
General ............................................................ 2
EC declaration of conformity ............................................. 3
Safety instructions .................................................... 4
Standard version and optional equipment ................................... 4
Truck identification, Factory nameplate ..................................... 5
Product support documentation .......................................... 6
Accessories accompanying the product .................................... 6
Safe-keeping and passing on............................................ 7
Copyright and proprietary rights .......................................... 7
Operator, form of address ............................................... 7
2Safety
General safety information ............................................. 10
General safety information ............................................. 11
Non-ionising radiation ................................................ 12
Vibrations ......................................................... 12
Special safety advices for engaging loads .................................. 14
Safe handling of operating media ........................................ 15
Risk assessment .................................................... 16
Regular testing ..................................................... 17
Residual dangers .................................................... 17
Residual hazards with commissioner trucks ................................ 18
Application area ..................................................... 19
Intended use ....................................................... 20
Narrow aisle vehicles ................................................. 21
Original parts ....................................................... 21
Directives and guidelines .............................................. 22
Driver’s licence..................................................... 22
Alterations to industrial trucks ........................................... 22
Personal protective equipment .......................................... 23
5213 804 2501 EN - 01/2016 I

Table of contents
g
3Overview
View of the truck ..................................................... 26
Labelling on standard trucks ............................................ 2
7
Labelling on special equipment .......................................... 29
Truck description .................................................... 30
Operator´s console .................................................. 31
Display unit ........................................................ 32
Indicators and information ............................................. 34
View into the control compartment ....................................... 35
Safety equipment .................................................... 36
4 Operation
General commissioning ............................................... 40
Commissioning ..................................................... 40
Transporting and loading .............................................. 41
Support screws ..................................................... 44
Drivebattery ....................................................... 45
Commissioningthebattery ............................................. 46
Replacingthebattery ................................................. 47
Batterylock ........................................................ 49
Daily commissioning ................................................. 50
Checklistbeforestartingwork ........................................... 50
Access to the driver’s compartment ...................................... 52
Accesstothedriver’scompartment ...................................... 52
Operating devices ................................................... 53
Brakesystem ....................................................... 53
Steeringsystem ..................................................... 54
Switchingonthecontrolsystem ......................................... 56
Driving ............................................................ 57
Types of guidance ................................................... 57
Driving without guidance .............................................. 58
Driving with automatic guidance ......................................... 62
Load pick-up ....................................................... 65
Picking up and setting down loads ....................................... 65
Diagram of permissible loads . .......................................... 66
Load pick-up without guidance .......................................... 67
Load pick-up with automatic guidance ..................................... 68
II 5213 804 2501 EN - 01/2016

Table of contents
g
Parking, decommissioning ............................................. 69
Parkingandleavingthetruck ........................................... 69
Decommissioning ................................................... 70
Emergency operation ................................................. 71
Emergency operation . . ............................................... 71
Emergency lowering valve ............................................. 74
Emergency abseil system .............................................. 76
5 Maintenance
Securing the load support .............................................. 82
Removing the hood .................................................. 82
Fuses ............................................................ 82
General maintenance information ........................................ 83
Maintenance schedule ................................................ 8
5
Battery check ....................................................... 89
Lubricants ......................................................... 90
Lubrication schedule................................................. 92
6 Technical data
Technical data ...................................................... 94
7 Special equipment
Inductive guidance (IZF) ............................................... 96
Personal protection system (MPSE) ...................................... 98
Two-person cab ..................................................... 99
Working platforms ...................................................101
Trucks for use in cold storage ...........................................101
Load-side operating panel .............................................102
Battery on roller tracks ................................................105
Acoustic warning signal ...............................................106
Tilt barrier .........................................................106
Leaning cushion ....................................................107
Height-adjustable operating panel .......................................107
End of aisle automatic braking ..........................................108
5213 804 2501 EN - 01/2016 III

1
Foreword

1Foreword
General
General
Our industrial trucks comply with applicable
European regulations. Any other applicable
country-specific regulations or operating
conditions for the use of industrial trucks must
also be observed.
The aim of this manual is to inform you about
how to safely handle your industrial truck
and how to keep it operational. It is therefore
essential that operators, operating personnel
and maintenance personnel familiarise
themselves with, understand and adhere to
the contents of this manual. The operability,
performance and service life of the vehicle are
dependent on:
•Properuse
• A daily inspection by the operator and
• Regular, appropriate maintenance work
25
213 804 2501 EN - 01/2016

Foreword 1
EC declaration of conformity
EC declaration of conformity
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
5213 804 2501 EN - 01/2016 3

1Foreword
Safety instructions
Safety instructions
Explanations of the terms used in this manual:
DANGER
There is the risk of fatality to the operator.
The procedures indicated should be complied with
in full in order to avoid this danger.
WARNING
There is a hazard that could cause major damage
to property or to the health of the operator.
The procedures indicated should be complied with
in full in order to avoid this danger.
CAUTION
There is a risk of damage to property.
The procedures indicated should be complied with
in full in order to avoid this danger.
NOTE
Special attention is drawn to procedures and
technical requirements that must particularly
be observed.
Standard version and optional
equipment
These instructions describe the specified use
and the prescribed maintenance work for
industrial trucks in the standard version and
the supplementary equipment on offer at the
time of printing.
Special versions and special equipment
(UPA)
For industrial trucks in special versions or
equipped with special equipment, a additional
order related documentation will be created
and published if advised.
45
213 804 2501 EN - 01/2016

Foreword 1
Truck identification, Factory nameplate
Truck identification, Factory
nameplate
The nameplate is fitted in the area of the
driving seat and contains the following details:
Factory nameplate
1 CE symbol. The CE symbol confirms that
the EU machine guidelines and all the
relevant guidelines, which are valid for this
product, have been met.
2Trucktype
3 Truck serial number. This serial number
must be given in the event of any queries.
4 Year of manufacture
5 Nominal loading capacity
6 Unladen weight
7 Battery voltage
8 Maximum battery weight
9 Minimum battery weight
10 Rated drive power
11 Ballast weight
12 Name of manufacturer
5213 804 2501 EN - 01/2016 5

1Foreword
Product support documentation
Product support documenta-
tion
This includes:
• Spare parts list
• Operating and maintenance manual
• VDMA (German Engineering Federation)
information booklet on proper usage
• Any additional documentation for the
driver’s seat
• Any additional documentation for an attach-
ment
• Any additional documentation for the
battery
• Any additional order-related documentation
Accessories accompanying
the product
Each truck is supplied with a box of acces-
sories upon deliveryfromthefactory.
The contents differ depending on the truck
type and the order.
This includes, among other items, an adhesive
label that shows how to disable the magnetic
brake on the traction motor using mechanical
means. This adhesive label can be affixed in
a suitable position in the control compartment
near the magnetic brake.
This box also contains the documentation
to accompany the product, and the screws
and wrench that arerequiredtodisablethe
magnetic brake.
Depending on the type, additional lubricating
nipples may be included for maintenance.
65
213 804 2501 EN - 01/2016

Foreword 1
Safe-keeping and passing on
Safe-keeping and passing on
• These operating and maintenance instruc-
tions must be kept safely so that the opera-
tor always has access to them.
• Documents can be ordered retrospectively.
Please give the ID or the order number.
• If the truck is sold on, the complete docu-
mentation should be passed onalongwith
the truck.
Copyright and proprietary
rights
This manual - and any excerpts thereof - may
not be reproduced, translated or tansmitted in
any form to third parties without the express
written permission of the manufacturer.
Operator, form of address
Our products are suitable for use by male
or female operators. If applicable in your
language, however, these instructions use
only the masculine form of address to simplify
the text"."
The dimensions of the operator’s compart-
ment on our trucks are designed in accor-
dance with standard DIN EN ISO 3411 and
are accordingly constructed for both female
and male operators. This standard also stipu-
lates ranges within which the operator’s body
weight and dimensions should lie. If these
trucks are operated by persons (male or fe-
male) who do not meet these criteria, the fol-
lowing effects must be considered:
5213 804 2501 EN - 01/2016 7

1Foreword
Operator, form of address
• The ergonomic conditions may be less
favourable. For example, it may not be
possible to reach pedals such as the
accelerator and brake pedals, the overhead
guards might be too low or the adjustment
ranges for the steering wheel and seat may
no longer be sufficient.
• The load-bearing capacity of the industrial
truck may be negatively affected.
Please consult your authorised dealer wher-
ever help is required.
85
213 804 2501 EN - 01/2016

2
Safety

2Safety
General safety information
General safety information
• People must stay away from the working
area (danger area) of the truck. If a person
does enter the danger area, all movements
of the truck must be stopped immediately
and the person must be directed away from
the area.
• The truck may only be operated from the
operator’s cab.
• When travelling without load, lower fork to
the floor level.
• When driving with a load, the load must be
lifted a few centimetres off the ground (clear
of the ground, max. 500 mm).
• The driver must keep all body parts within
the contours of the driver’s compartment.
The driver must refrain from sticking his
head out to gain a better view and from
reaching into the area of the moving lift
mast, because even doing this is highly
dangerous.
• Aside from the driver, there must be no other
person present on the truck, unless the
truck has additional equipment to enable
operation with two persons.
• If there are marked roadways, the truck is
to be moved only within these markings for
safety reasons.
• It is never permitted for anyone to stand
beneath a raised load or driver’s compart-
ment.
• Basically, it is the driver’s duty to adapt his
driving speed to the local conditions and
the respective situation. When cornering
in particular, attention must be paid to the
overall height and the centre of gravity,
which will be high as a result.
• The condition of the floor surface influences
the braking distance of the truck. The driver
must take account of this in his driving and
braking style.
10 5213 804 2501 EN - 01/2016

Safety 2
General safety information
General safety information
• Essentially, all safety information located
on the truck must be observed.
• Missing or illegible safety information is to
be changed.
• When cornering and driving past parts of
buildings that restrict visibility, use the horn
to warn others that the truck is approaching.
• If the driver’s view is obstructed, e.g. due to
a bulky load, a guide must patrol the route
to ensure safety.
• When driving through doorways and under
ceiling joists, take the height of the truck into
consideration.
• Multiple operations or other types of oper-
ations not described here, especially the
blocking or disabling of operating devices,
can cause damage to the truck but also
uncontrolled movements and is therefore
prohibited.
• The driver can secure the truck against
unauthorised use by removing and taking
the switch key or by deleting the access
information on the electronic access control
system when leaving the truck.
• If required by the area of application and
work situation, the operator must use
suitable personal protective equipment
such as protective shoes, safety helmet,
protective gloves or industrial goggles.
The operator and operating company are
responsible for ensuring this.
• The openings in the gassingareaofthe
battery must not be covered or fully closed.
The unrestricted air supply is required
to prevent the formation of potentially
explosive gas mixtures.
• Under no circumstances should openings
be made in the battery’s gassing area,
which could allow the gas created during
charging to enter the area of the driver’s
compartment.
Operating safety is more important than
working speed!
5213 804 2501 EN - 01/2016 11

2Safety
Non-ionising radiation
Non-ionising radiation
WARNING
Risk of injury
Persons with active or non-active medically implan-
ted devices must take it upon themselves to ensure
that they are not exposed to dangerous electroma-
gnetic radiation. The table below indicates the limit
values for the maximum electric field strength of the
electromagnetic radiation emitted by this truck.
It is the responsibility of the truck operating com-
pany to explain these dangers to the employees in
detail.
Maximum limit values for the electromagnetic
emitted interference in accordance with EN
12895 at a distance of 10m.
Frequency [MHz] Electric field strength
[dBµV/m]
30 to 75 34
75 to 400 34 to 45 with
increasing frequency
400 to 1000 45
.
Vibrations
The vibrations of the machine must be deter-
mined on an identical machine in accordance
with the standard EN 13059" Vibration mea-
surements on industrial trucks".
Weighted effective
value of the
acceleration the
body (feet or seat
surface) is subjected
to
<1,2m/s
2
Uncertainty K 0,3 m/s2
Tests have indicated that the amplitude of the
hand and arm vibrations on the steering wheel
or the operating devices in the truck is less
than 2.5 m/s2. There are therefore no mea-
surement guidelines for these measurements.
The personal vibration load on the driver
over a working day shall be determined in
12 5213 804 2501 EN - 01/2016

Safety 2
Vibrations
accordance with the Directive 2002/44/EC by
the operating company at the actual place
of use, in order to consider all additional
influences, such as driving route, intensity
of use etc.
5213 804 2501 EN - 01/2016 13

2Safety
Special safety advices for engaging loads
Special safety advices for
engaging loads
Discuss this with your contractor.
Recognising danger is half the battle!
• Loads consisting of loose packaged items
must not be higher than the upper edge of
the cab parapet.
• Loads may only be transported in appropri-
ate containers or safe packaging.
• The load must not change its gravity center
position or even fall down when acceler-
ating/ braking or when travelling in curves
(centrifugal force).
• If loads cannot be transported with the
necessary safety, then the safety has to
be brought about by using appropriate
containers or fastenings.
• Before engaging any load, ensure that it
does not exceed the loading capacity of
the truck (diagram of permissible loads) or
the maximum permissible dimensions as
specified by the data sheet.
• Loads which are to be transported and
placed in storage must be securely pack-
aged to ensure that the centre of gravity of
the load does not shift during transport, and
that no parts are able to drop out. Remem-
ber to pay sufficient attention to the safety of
your workmates.
• If very high loads have to be transported
which block the view of the travel path, the
relevant safety measures must be taken.
• The load suspension device must never be
used to raise hanging or suspended loads.
14 5213 804 2501 EN - 01/2016