Still GX-X User manual

Original instructions
GX-X, GX-Q
Turret truck
2201
5220 804 2501 EN - 12/2012

Table of contents
g
1 Foreword
General ............................................................ 2
EC declaration of conformity in accordance with Machinery Directive ............... 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 advice ................................................ 10
General safety information ............................................. 11
Non-ionising radiation ................................................ 12
Vibrations ......................................................... 12
Special safety advices for engaging loads .................................. 13
Safe handling of operating media ........................................ 14
Risk assessment .................................................... 15
Residual dangers .................................................... 16
Inspections ........................................................ 16
Application area ..................................................... 1
6
Original parts ....................................................... 17
Directives and guidelines .............................................. 17
Driver permit ....................................................... 17
Personal protective equipment .......................................... 18
3Overview
View of the truck ..................................................... 20
Display and Operating panel ........................................... 21
Displays .......................................................... 23
Purpose of use ...................................................... 27
5220 804 2501 [EN] I

Table of contents
g
Functions ......................................................... 28
4 Operation
Commissioning ..................................................... 32
Commissioning ..................................................... 32
Transporting and loading .............................................. 32
Installingthebattery .................................................. 34
Batterylock ........................................................ 37
Batterydischargeindicator ............................................. 39
Daily commissioning ................................................. 40
Checklist before startingwork ........................................... 40
Control devices ..................................................... 42
Enteringandleaving ................................................. 42
Seatswitch ........................................................ 42
Settingthedisplaybrightness ........................................... 45
Switchingthedisplay ................................................. 46
Driving ............................................................ 46
Initialdrivingexercises ................................................ 46
Pedal operation ..................................................... 49
Joystickfunctions .................................................... 50
Mechanical guidance MZF . . . .......................................... 51
Load pick-up ....................................................... 52
Loadpickup ....................................................... 52
Adjustableforks ..................................................... 53
Parkingandleavingthetruck ........................................... 54
Emergency operation................................................. 54
Emergency operation ................................................. 54
Retrievingthetruck .................................................. 56
Parking and Decommissioning the truck ................................... 57
Decommissioning ................................................... 57
II 5220 804 2501 [EN]

Table of contents
g
5 Maintenance
Fuses ............................................................ 60
Servicing - General .................................................. 61
Maintenance plan ................................................... 62
Lubricants ......................................................... 67
Lubrication plan ..................................................... 67
Battery check ....................................................... 68
6 Technical Data
Technical data ...................................................... 72
7 Optional Equipment
Inductive guidance IZF................................................ 75
Acoustic warning signal ............................................... 75
Working platforms ................................................... 76
Trucks for use in coldstorage ........................................... 76
Clipboard .......................................................... 77
Working spotlights ................................................... 78
Electronic access control .............................................. 78
Two-pedal design ................................................... 80
Intermediate lift restriction ............................................. 80
Hydraulic fork arm positioner* ........................................... 80
Attachments ....................................................... 81
Electrical seat adjustment ............................................. 83
Telescopic table ..................................................... 84
Height preselection system ............................................ 86
5220 804 2501 [EN] 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
220 804 2501 [EN]

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
.
5220 804 2501 [EN] 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
220 804 2501 [EN]

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
5220 804 2501 [EN] 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 box includes, among other items, an
adhesive label that shows how to disable the
magnetic brake mechanically. 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
220 804 2501 [EN]

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:
5220 804 2501 [EN] 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
220 804 2501 [EN]

2
Safety

2Safety
General safety advice
General safety advice
• All personnel must be kept clear of the
working area (danger zone) of the truck.
Should anyone enter the working area,
all truck movements must be brought to
an immediate standstill and the person
instructed to vacate the area.
• The truck may only be operatedfromthe
operator’s cab.
• When travelling without load, lower fork to
the floor level.
• When travelling with load, the load has to be
lifted several centimeters (max. 500 mm)
above the floor.
• 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 thisishighly
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 marked travelling paths are provided,
then, for safety reasons the truck may only
be moved within those marks.
• It is not permitted for anyonetostand
beneath a raised load or cab.
• The operator is obliged to adjust the driving
speed to the relevant situation. Particularly
when driving around corners, the overall
height and the high centre of gravity must
be taken into consideration.
• 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 5220 804 2501 [EN]

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.
• By removing and taking the switch key when
leaving the truck, the driver can secure the
truck against unauthorised use.
• 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 gassing area of the
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!
5220 804 2501 [EN] 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
<0,8m/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 5220 804 2501 [EN]

Safety 2
Special safety advices for engaging loads
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.
Special safety advices for
engaging loads
Discuss this with your contractor.
Recognising danger is half the battle!
• 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.
5220 804 2501 [EN] 13

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..
• Take care to dispose of oil-containing
wastes correctly.
• Dispose of used oil correctly.
Personal protective gear
•Avoidallsk
in contact. Pay particular at-
tentiontop
revent 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.
14 5220 804 2501 [EN]