Still EXG-10 User manual

Original instructions
Counterweight pallet stacker
EXG-10
EXG-12
EXG-16
1217 1218 1219
1170 801 15 09 EN - 07/2012

Table of contents
g
1 Introduction
Electric pallet stacker .................................................. 2
Your industrial truck ................................................... 3
General ............................................................ 3
ECdeclarationofconformity ............................................. 4
Information about documentation ......................................... 5
Documentationscope ................................................. 5
Copyrightandpropertyrights ............................................ 5
Explanation of symbols used ............................................ 5
Explanation of the cross-references ....................................... 6
Date of issue and update of this manual . . . ................................. 6
Definitionofdirections ................................................. 6
Use of the truck ...................................................... 7
Intended use of the trucks ............................................... 7
Unauthorised use ..................................................... 8
Placeofuse ......................................................... 8
Residual risks ....................................................... 9
Residual dangers, residualrisks .......................................... 9
Specialrisksassociatedwithusingthetruckandattachments .................... 9
Overviewofhazardsandcountermeasures ................................. 10
Danger to employees . . ............................................... 12
Environmental considerations .......................................... 13
Packaging ......................................................... 13
Disposing of componentsandbatteries .................................... 13
2Safety
Definition of responsible persons ........................................ 16
Operatingcompany .................................................. 16
Specialist .......................................................... 16
Drivers ........................................................... 16
Basic principles for safe operation ....................................... 18
Insurance cover on company premises .................................... 18
Modificationsandrefitting .............................................. 18
Warning regarding non-original parts ..................................... 18
Damage, faults ..................................................... 19
Medicaldevices ..................................................... 19
Safety tests ........................................................ 20
Regular safety inspectionofthetruck ..................................... 20
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Table of contents
g
Safety regulations for handling consumables ............................... 21
Permissibleconsumables ............................................. 21
Oils .............................................................. 21
Hydraulicfluid ...................................................... 22
Batteryacid ........................................................ 22
Disposalofconsumables .............................................. 23
Safety devices ...................................................... 24
Damage, defects and misuse of safety devices . . . ........................... 24
3Overviews
Overview .......................................................... 26
Controls and display .................................................. 27
Tiller and dashboard ................................................. 27
Multifunction indicator ................................................ 28
Markings .......................................................... 31
Markingpositions .................................................... 31
Identification label ................................................... 32
4Use
Intended use of the trucks .............................................. 34
Checks and actions prior to commissioning ................................. 35
List of checks prior tostart-up ........................................... 35
Commissioning ..................................................... 36
Multifunctiondisplaysettings ........................................... 36
Checking the anti-crushsafetydevice ..................................... 42
Checkingthehorn ................................................... 43
Driving ............................................................ 44
Driving safety instructions .............................................. 44
Driving ............................................................ 45
Braking ........................................................... 48
Lifting ............................................................ 49
Useofthemast ..................................................... 49
Capacity .......................................................... 52
Handling loads ...................................................... 5
4
Loadhandlingsafetyrules ............................................. 54
Working with loads ................................................... 55
Driving on upward and downward slopes .................................. 60
Transportingthetruckinthelift .......................................... 60
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Table of contents
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Driving on loading bridges ............................................. 60
Transportingpalletsorothercontainers ................................... 61
Cold store (option) ................................................... 62
Cold store usage (optional) ............................................. 62
Handling the truck in specific situations .................................... 64
Truck towing procedure ............................................... 64
Slinging,lifting,towingandremovalofthemast .............................. 66
Handling the battery .................................................. 68
Battery charging with an externalcharger .................................. 68
Verticaloutputbattery ................................................ 70
Side access battery; selection of battery compartment opening side ............... 72
Side access battery; unlocking/lockingthebattery ............................ 73
Putting Out of Commission and Storage ................................... 74
Parkingthetruck. .................................................... 74
Long-term truck storage ............................................... 74
Recommissioningafterstorage ......................................... 75
5 Maintenance
General maintenance information ........................................ 78
General ........................................................... 78
Servicing and maintenance personnel training and qualification . ................. 78
Battery maintenance staff .............................................. 79
Maintenance operations that do not require special training ..................... 79
1000 hour service plan . ............................................... 80
2000 hour service plan . ............................................... 82
Technical data for inspection and maintenance .............................. 84
Recommended lubricants ............................................. 85
Maintenance safety instructions ......................................... 86
Servicing and maintenance measures .................................... 86
Working on the electrical equipment ...................................... 86
Safetydevices ...................................................... 86
Preparation for maintenance ........................................... 87
Accesstothetechnicalcompartment ..................................... 87
Typesofliftingmasts ................................................. 89
Cleaning .......................................................... 92
Cleaningthetruck ................................................... 92
Maintenance as required .............................................. 94
Cleaning the batteryanditscompartment .................................. 94
Transmission ....................................................... 95
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Checkingthebatterychargingstatus ..................................... 96
Opening the battery cover . . . .......................................... 97
Maintenance every 1000 hours .......................................... 9
8
Checkingtheconditionandtightnessofwheels .............................. 98
Adjustingthebrakeairgap ............................................. 99
Batterymaintenance .................................................100
Electromagnetic brake, checking the brake assistance circuit for leaks . ............102
Lubricating the load wheel axles and mast tilt bearings ........................103
Cleaning the electrical plate and checking the connections .....................104
Electrical equipment, checking the control modules and their connections ..........105
Electrical equipment, testing and cleaning the fan . ...........................105
Cleaning the cooling fins ...............................................10
6
Specificmastmaintenance .............................................107
Hydraulicsystems ...................................................110
Transmission .......................................................113
Maintenance every 2000 hours ..........................................114
Hydraulicsystems ...................................................114
Transmission .......................................................116
6 Technical data
Technical Data Sheet EXG 10-12-16 .....................................118
Loads per axle ......................................................121
Mast table .........................................................123
Annex
7Diagrams
Hydraulic installation .................................................134
Proportional control / Without Initial Lift ....................................134
Hydraulic diagram(withmasttilt) ........................................136
Electrical installation .................................................138
Circuitdiagrampartslist ...............................................138
Power EXG10, EXG12,EXG16 .........................................141
ControlsEXG10,EXG12,EXG16 ....................................... . 143
MasttiltoptionEXG10,EXG12,EXG16 ...................................145
IV 1170 801 15 09 [EN]

1
Introduction

1Introduction
Electric pallet stacker
Electric pallet stacker
Electric counterweight pallet stacker types
EXG 10, EXG 12 and EXG 16 are designed for
stacking.
Theycanalsobeusedtotransportpalletsofa
maximum weight 1000 kg (EXG 10), 1200 kg
(EXG 12) and 1600 kg (EXG 16) inside stores,
warehouses and factories.
EXG capacity
EXG 10: maximum of 1000 kg on the fork arms
EXG 12: maximum of 1200 kg on the fork arms
EXG 16: maximum of 1600 kg on the fork arms
Configuration
EXG trucks are configured to pedestrian
version as follows:
–unladen: 6 km/h in forward travel and 5
km/h in reverse travel
–laden: 6 km/h in forward travel and 5 km/h
in the direction of the forks
These safe, robust, comfortable and ex-
tremely stable trucks offer excellent perfor-
mance due to their construction which in-
cludes:
– a fixed central chassis with the mechanical,
electrical and hydraulic units required to
operate the truck,
– a fixed fork carriage at the rear of the
battery.
Drive system
The drive is provided by a 3 kW asynchronous
traction motor.
The drive wheel is driven by a transmission
gear with a first stage reduction and a spur and
pinion final drive.
The power is supplied by a 3PzS, 4PzS and
5PzS capacity lead-acid battery.
There are several battery types available:
– Vertical access
– Side access
The power supply to the traction motor is
controlled by an electronic control module
which provides complete control of the speed,
acceleration and braking.
Steering
The electric steering offers driving precision
and reduced effort during manoeuvres.
Steering is controlled by a tiller designed for
pedestrian driving.
The drive unit is mounted on a turntable;
steering lock is provided by an electric geared
motor which positions the turntable.
The steering motor is controlled by an elec-
tronic module that receives information from
the tiller and the wheel angle position.
Lifting system
The pallet stackers are fitted with pump unit
having a 3 kW motor and a single pump.
Braking
EXG models are fitted with two types of
brakes:
–an electromagnetic safety brake that also
acts as a parking brake.
The parking brake is applied automatically in
the following situations:
• tiller released
• truck stationary with drive direction switch
in neutral
• power off.
The safety brake is applied automatically in
the event of a fault in the traction or steering
control systems.
–an electric counter-current brake which is
applied automatically when the accelerator
is released and when the direction of travel
is reversed.
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Introduction 1
Your industrial truck
Driver’s compartment
Pedestrian model:
• the speed is limited to 6 km/h
• the tiller has all the control units and pro-
vides the steering for the truck.
All models are also equipped with:
• an emergency off switch on the control
board.
• a multifunction display which shows the
date, operating hours and battery charge
level.
Options
Various options are available on EXG trucks:
•Cold Store option
• gradual carriage stop
• digicode
• load backrest
• computer pack
• battery holder.
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.
The driving permit must be obtained from the
appropriate office.
The trucks have been fitted with state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
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1Introduction
Your industrial truck
EC declaration of conformity
Declaration
STILL GmbH
Berzeliusstrasse 10
22113 Hamburg
GERMANY
We declare that the machine
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 S.A.S.
The manufacturer declares that the truck
complies with the requirements of the EC
directives valid at the time of marketing. This is
confirmed by the EC declaration of conformity
and by the EC labelling on the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
relevant authorities.
41
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Introduction 1
Information about documentation
Information about documentation
Documentation scope
• Operating instructions document
• Operating instructions for attachment parts
(special equipment)
• Spare parts catalogue
• 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. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year of
manufacture located on the designation plate
(see "Marking chapter") in the field provided:
Production no. ...........................................
Year of manufacture
...................................................
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructions must be stored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the oper-
ator must immediately request a replacement
from the manufacturer.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see "Definition of
responsible persons" chapter) must ensure
that all operators have received, read and
understood these instructions.
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.
Copyright and propertyrights
This manual - and any excerpts thereof - may
not be reproduced, translated or transmitted
in any form to third parties without the express
written permission of the manufacturer.
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid life-threatening danger or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid damage to and/or destruction of equipment.
NOTE
For technical requirements that require
special attention.
1170 801 15 09 [EN] 5

1Introduction
Information about documentation
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to another section: "Expla-
nation of cross references" chapter
• Cross reference to another chapter: "Defi-
nition of responsible persons" chapter
Date of issue and update of this manual
The publication date of these operating
instructions is printed on the cover.
STILL makes continuous efforts to develop
and improve its industrial trucks. For this
reason, the manufacturer reserves the right to
make changes and no claim will be accepted
concerning the information provided in this
instruction manual.
If you require technical assistance with your
truck, please contact your nearest STILL
service centre.
We hope you enjoy your driving
STILL GmbH
Berzeliusstr. 4
22113 Hamburg
Germany
.
Definition of directions
Names used in the text: forward travel (1),
reverse travel (3), to the right (2) and to the
left (4) refer to component installation position
with respect to the driver’s compartment.
The load is positioned at the back.
61
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Introduction 1
Use of the truck
Use of the truck
Intended use of the trucks
CAUTION
This machine was designed for the transport and
storage on racks (pallet stackers only) of loads
packed on pallets or in industrial containers de-
signed for this purpose.
The dimensions and capacity of the pallet or contai-
ner must be adapted to the load being transported
and must ensure stability.
The table of characteristics and performance atta-
ched to this user manual gives you the information
you need to check that the equipment is suitable for
the work being carried out.
Any specific usage must be authorised by the
site manager; an analysis of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
1170 801 15 09 [EN] 7

1Introduction
Use of the truck
Unauthorised use
Any danger caused as a result of unauthorised
use becomes the responsibility of the operator
or driver and not that of the manufacturer.
Use for purposes other than those described
in these operating instructions is prohibited.
Transporting people is prohibited.
The forklift truck should not be used in areas
where there is a risk of fire, explosion or
corrosion, or in areas that are particularly
dusty.
Stacking or unstacking is not permissible on
inclined surfaces or ramps.
Place of use
Thetruckcanbeusedoutdo
ors and in build-
ings. The truck must not be used outdoors in
bad weather. Operation on public roads is per-
mitted only if the special equipment specified
in the Road Traffic Licensing Regulations is
installed.
The regulations applicable in different coun-
tries for driving on public roads must be ob-
served.
The sites on which the truck is used must com-
ply with the applicable regulations (condition
of the ground, lighting etc.).
The ground must have sufficient load capacity
(concrete, asphalt).
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;
an approval may be necessary for this envi-
ronment (see chapter entitled "Description").
The operator (see chapter entitled "Definition
of responsible persons") must ensure that
appropriate fire protection is available in
the vicinity of the truck during operation.
Depending on the application,additional fire
protection must be provided on the industrial
truck. If in doubt, please contact the relevant
authorities.
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Introduction 1
Residual risks
Residual risks
Residual dangers, residual risks
Despite all operational precautions and
compliance with standards and rules, the
possibility of additional risks when using the
truck cannot be entirely excluded.
The truck and all its components comply with
the regulations relating to current applicable
safety rules.
Persons in the vicinity of the truck must be
particularly cautious and react immediately
in the event of any malfunction, incident,
breakdown etc.
WARNING
Personnel in contact with the truck must be infor-
med of the risks related to using the truck.
These operating instructions draw your attention to
the safety rules.
The risks are:
• Escape of consumables due to leaks,
ruptured lines and tanks etc.
• Risk of accident when driving over difficult
ground such as slopes, soft or irregular
surfaces or in poor visibility etc.
• Falling, tripping etc. when moving on the
industrial truck, especially in the wet, with
leaking consumables or icy surfaces.
• Loss of stability due to the load being
unstable or the load slipping etc.
• Risk of fire and explosion due to batteries
and electrical voltages.
• Human error - Disregarding safety regula-
tions.
It is important to adjust the speed of the truck
depending on the load and ground conditions.
The stability of the truck has been tested to the
latest standards. These standards only take
account of the static and dynamic tilting forces
that can arise during operation that complies
with the specifications and operating rules.
Risks caused by misuse or incorrect operation
that jeopardise the stability cannot be ruled
out in extreme situations.
Special risks associated with using the truck and attachments
The manufacturer’s approval is required as
soon as:
• The truck is used differently from its normal
use
• The driver is not sure if he can use the truck
correctly and without risk of accident
1170 801 15 09 [EN] 9

1Introduction
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 Check note
√ actioned
- not applicable
Notes
Truck equipment does
not comply with local
regulations
Test O If in doubt, consult
competent factory
inspectorate or
employers’ liability
insurance association
Lack of skills and
qualification of driver
Driver training (sit-on
and stand-on)
O BGG 925
VDI 3313 driver permit
Usage by unautho-
rised persons
Access with key only
for authorised persons
O
Truck not in a safe
condition
Recurrent testing and
rectification of defects
OBetrSichVO
(Workplace Safety
Ordinance)
Risk of falling when
using working
platforms
Compliance with
national regulations
(different national
laws)
OBetrSichVO
(Workplace
Safety Ordinance)
and employer’s
liability insurance
associations
Impaired visibility due
to load
Resource planning OBetrSichVO
(Workplace Safety
Ordinance)
Assessment of diesel
exhaust gases
O TRGS 554 and
BetrSichVO
(Workplace Safety
Ordinance)
Contamination of
respiratory air
Assessment of LPG
exhaust gases
OMAK(Maximum
Workplace
Concentrations) list
and BetrSichVO
(Workplace Safety
Ordinance)
10 1170 801 15 09 [EN]

Introduction 1
Residual risks
Hazard Measure Check note
√ actioned
- not applicable
Notes
Issuing of operating
instructions
O BetrSichVO
(Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
Written notice of
instruction to driver
O BetrSichVO
(Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
Impermissible usage
(improper usage)
Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
O
When fuelling
a) Diesel Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
O
b) LPG Observe BGV D34,
operating instructions
and VDMA rules
O
When charging the
traction battery
Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
OVDE 0510: In
particular
- Ensure ventilation
- Insulation value
within permissible
range
When using battery
chargers
Observe BetrSichVO
(Workplace Safety
Ordinance), BGR
104 and operating
instructions
O BetrSichVO
(Workplace Safety
Ordinance) and BGR
104
When parking LPG
trucks
Observe BetrSichVO
(Workplace Safety
Ordinance), BGR
104 and operating
instructions
O BetrSichVO
(Workplace Safety
Ordinance) and BGR
104
1170 801 15 09 [EN] 11

1Introduction
Residual risks
Hazard Measure Check note
√ actioned
- not applicable
Notes
With driverless transport systems
Roadway quality
inadequate
Clean/clear driveways O BetrSichVO
(Workplace Safety
Ordinance)
Load carrier
incorrect/slipped
Reattach load to pallet OBetrSichVO
(Workplace Safety
Ordinance)
Drive behaviour
unpredictable
Employee training OBetrSichVO
(Workplace Safety
Ordinance)
Driveways blocked Mark driveways
Keep driveways clear
OBetrSichVO
(Workplace Safety
Ordinance)
Driveways intersect Announce right-of-
way rule
OBetrSichVO
(Workplace Safety
Ordinance)
No person detection
during depositing and
retrieval
Employee training OBetrSichVO
(Workplace Safety
Ordinance)
.
Danger to employees
The operating company must identify and
evaluate the dangers involved in using the
truck. It must also establish which occupa-
tional health and safety measures are required
to protect employees. Appropriate operating
instructions must be drafted and provided for
the driver accordingly. A person responsible
for health and safety must be appointed.
Construction and equipment of the truck corre-
spond to the Machinery Directive 2006/42/EC
and they are therefore identified with the CE
symbol. As a result, these factors are not
included in the hazard assessment; nor are
the attachments, which have their own CE
labelling. The operating company must, how-
ever, select the type and equipment of the
truck so as to comply with the local provisions
for deployment.
The results must be published. In the case
of truck deployment involving similar hazard
situations it is permitted to summarise the
results. This overview (see chapter entitled
"Overview of hazards and countermeasures")
is intended to facilitate compliance with the
conditions of these regulations. The overview
indicates the main causes of accidents in
the event of non-compliance. If other major
operational hazards are involved, they must
also be taken into consideration.
The working conditions for the trucks are
largely similar for many sites. The dangers
canthereforebesummarisedinasingle
overview. It is recommended that the infor-
mation provided by the relevant employers’
liability insurance association be observed in
this respect.
12 1170 801 15 09 [EN]

Introduction 1
Environmental considerations
Environmental considerations
Packaging
When the truck is delivered, some parts are
packaged to provide better 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.
Disposing of components and batteries
The truck is made up of different materials.
When components or batteries need to be
changed, they must be:
• disposed of,
•processed
• recycled in accordance with the applicable
regional and national regulations
NOTE
The documentation provided by the battery
manufacturer must be consulted when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company when disposing of compo-
nents and batteries.
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1Introduction
Environmental considerations
14 1170 801 15 09 [EN]