Still EK-X10 User manual

Original instructions
High-level order picker
EK-X10
2101
5212 804 3001 EN - 02/2017

Table of contents
g
1 Foreword
General ............................................................ 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Safety instructions .................................................... 4
Standard design 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 ............................................. 10
Non-ionising radiation ................................................ 11
Vibrations ......................................................... 11
Special safety advices for engaging loads .................................. 13
Safe handling of operating media ........................................ 14
Risk assessment .................................................... 16
Regular testing ..................................................... 16
Residual risks ...................................................... 16
Residual risks when using order pickers ................................... 17
Application area ..................................................... 17
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
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3Overview
Safety equipment .................................................... 26
Truck description .................................................... 27
View of the truck with a low lift mast ....................................... 28
Viewofthetruckwithahighliftmast ...................................... 29
Labelling on standard trucks ............................................ 30
Labelling on special equipment .......................................... 32
Operator´s console .................................................. 33
Standard display unit ................................................. 34
Displays .......................................................... 35
LCD display unit with a keypad .......................................... 36
Displays, information ................................................. 3
7
View into the control compartment ....................................... 39
4 Operation
General commissioning ............................................... 42
Commissioning ..................................................... 42
Transporting and loading .............................................. 42
Drivebattery ....................................................... 45
Replacing the battery ................................................. 47
Daily commissioning ................................................. 49
Checklistbeforestartingwork ........................................... 49
Access to the driver's compartment ...................................... 51
Accesstothedriver'scompartment ....................................... 51
Operating devices ................................................... 52
Brakesystem ....................................................... 52
Steeringsystem ..................................................... 53
Switchingonthecontrolsystem ......................................... 55
Driving ............................................................ 56
Types of guidance ................................................... 56
Driving without automatic guidance ....................................... 58
Drivingwithguidance ................................................. 61
Pickingupaload .................................................... 64
Picking up and setting down loads ....................................... 64
Load capacity diagram ................................................ 65
Support screws ..................................................... 66
Load pick-up without automatic guidance .................................. 66
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Loadpick-upwithautomaticguidance ..................................... 68
Parking, decommissioning ............................................. 69
Parkingandleavingthetruck ........................................... 6
9
Decommissioning ................................................... 69
Emergency operation ................................................. 70
Emergency operation . . ............................................... 70
Emergency lowering valve ............................................. 73
Emergency abseil system .............................................. 75
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Table of contents
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5 Maintenance
Securing the load support .............................................. 80
Removing the hood .................................................. 80
Fuses in general .................................................... 80
Fuses ............................................................ 81
General information about maintenance and servicing ......................... 82
Service plan ........................................................ 84
Lubricants ......................................................... 89
Battery maintenance ................................................. 90
6 Technical data
Technical data ...................................................... 92
Driving speeds ...................................................... 93
7 Special equipment
Inductive guidance (IZF) ............................................... 96
Personal protection system (MPSE) ...................................... 98
Pedestrian operation ................................................. 99
Two-person cab .....................................................101
Electronic access control ..............................................102
Working platforms ...................................................103
Trucks for use in cold storage ...........................................103
Load-side operating panel .............................................104
Battery on roller tracks ................................................106
Acoustic warning signal ...............................................108
Leaning cushion ....................................................108
Tilt barrier .........................................................109
IV 5212 804 3001 EN - 02/2017

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
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Foreword 1
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
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
.
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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 design and optional equipment
These instructions describe the intended use
and the prescribed maintenance and servicing
for industrial trucks in the standard design and
for the optional equipment available at the time
of going to press.
Special versions and special equipment
(UPA)
For industrial trucks in a customer-specific
special version or with special equipment,
additional order-related documentation is
created and supplied if required.
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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
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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 delivery from the factory.
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 are required to disable the
magnetic brake.
Depending on the type, additional lubricating
nipples may be included for maintenance.
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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. However, these instruc-
tions use only the masculine form of address,
hereinafter "operator", to simplify the text.
The dimensions of the operator's compart-
ment on our industrial trucks are designed in
accordance with standard DIN EN ISO 3411
and are accordingly constructed for both fe-
male and male operators. This standard also
stipulates ranges within which the operator's
body weight and dimensions should lie. If
these industrial trucks are operated by per-
sons (male or female) who do not meet these
criteria, the following effects must be consid-
ered:
• 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.
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1Foreword
Operator, form of address
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2
Safety

2Safety
General safety information
General safety information
• People must not encroach into the working
area (danger area) of the industrial truck
If a person does enter the danger area, all
movements of the industrial truck must be
stopped immediately and the person must
be directed away from the area
• The industrial truck must be operated
exclusively from the driver's compartment
• If industrial trucks are equipped for pedes-
trian mode or with external operating pan-
els, the industrial trucks may be operated
using these features For further safety infor-
mation for this purpose, refer to the relevant
additional descriptions
• When driving without a load, lower the fork
to floor height
• 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 doing this is highly danger-
ous
• Aside from the driver, there must be no other
person present on the industrial truck This
is unless the industrial truck has additional
equipment to enable operation with two
persons
• If there are marked roadways, the industrial
truck must be moved only within these
markings for safety reasons
• It is never permitted for anyone to stand be-
neath a raised load or driver's compartment.
• 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 industrial truck.
Thedrivermusttakeacco
unt of this in his
driving and braking style.
General safety information
• Essentially, all safety information located
on the industrial 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 industrial truck is
approaching.
• If the driver has restricted vision, e.g. due to
a bulky load, a guide must ensure that the
route is clear.
• When driving through doorways and under
ceiling joists, take the height of the industrial
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 industrial truck
but also uncontrolled movements and are
therefore prohibited.
• The driver can secure the industrial truck
against unauthorised use by removing and
taking the switch key or by clearing the
access information on the electronic access
control system when leaving the industrial
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 protection goggles.
The operator and operating company are
responsible for ensuring this.
• The openings in the area of the battery
where gas may be released must not be
covered or sealed. To prevent the formation
of potentially explosive gas mixtures, an
unrestricted air supply is required.
• Under no circumstances should openings
be made in the battery's gassing area,
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Safety 2
Non-ionising radiation
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!
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
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2Safety
Vibrations
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
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.
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Safety 2
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.
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2Safety
Safe handling of operating media
Safe handling of operating
media
The following operating media are used in this
truck:
• Gear oill
• Hydraulic oil
• Battery acid
The handling of these materials is governed
by comprehensive safety regulations. The
most important points include:
For gear and hydraulic oil
DANGER
Danger to life or danger of injury from hydraulic fluid
escaping under pressure.
If hydraulic fluid escapes under pressure, for ex-
ample from a damaged pipe or through leaks in
a component, it can easily penetrate the skin. By
poisoning the surrounding tissue this can lead to
the loss of the affected body part or even to death.
Even if such injuries do not feel particularly painful
or serious, a doctor must be consulted immediately.
The cause of the injury must be described exactly
and the treatment started promptly.
ENVIRONMENT NOTE
• Oils pose a threat to the water supply, and
must accordingly always be transported
and collected in regulation containers.
• Do not spill oil. Bind any spillages using
suitable materials..
• Takecaretodisposeof oil-containing
wastes correctly.
• Dispose of used oil correctly.
Personal protective gear
• Avoid all skin contact. Pay particular at-
tention to prevent contact with oil emerging
under pressure (hose breakage, leaks).
• Do not breathe in oil mist.
• If it is not possible to avoid contact with oils,
personal protective gear such as protective
gloves, protective goggles etc. must be
worn.
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