Still Trolley Mover User manual

STILL portal frame
Routenzug-
Original instructions
0510
89708011526 EN -

Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.still.de
Rules for the operating com-
pany of industrial trucks
In addition to these operating instructions, a
code of practice containing additional informa-
tion for the operating companies of industrial
trucks is also available.
This guide provides information for handling
industrial trucks:
●
Information on how to select suitable indus-
trial trucks for a particular area of applica-
tion
●
Prerequisites for the safe operation of in-
dustrial trucks
●
Information on the use of industrial trucks
●
Information on transport, initial commission-
ing and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address
https://m.still.de/vdma
in a web browser or by scanning the QR code.


Preface
I89708011526 EN -

1 Foreword
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Issue date and topicality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Explanation of signal terms used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disposing of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2 Introduction
Using the STILL portal frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Competent person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Basic principles for safe operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Warning regarding non-genuine parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Modifications and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Damage and defects to safety systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disposing of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
3Overviews
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table of contents
III89708011526 EN -

Labelling points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Position of the identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Service plan before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembling the tugger train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Pre-shift checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Uncoupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Working with the STILL portal frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
4Disposal
Disposing of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Transport
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Repairs
Inspection and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service plan: monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service plan: every three months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Service plan: every six months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Service plan - Annual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Cleaning the trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Checking the condition of cables and electrical connections . . . . . . . . . . . . . . . . . . . . . 48
Possible sources of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Possible sources of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7 Technical data
Technical data for STILL portal frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table of contents
IV 89708011526 EN -

1
Foreword

General
Issue date and topicality
The issue date of these operating instructions
can be found on the title page.
STILL makes continuous efforts to enhance
and improve its trucks. These instructions are
therefore subject to change, and any claims
based on the information and/or illustrations
contained in these operating instructions can-
not be asserted.
If you require technical support for the Trolley-
Mover, please contact the authorised service
centre.
Have a good trip, your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg, Germany
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third parties
—including as excerpts—except with the ex-
press written approval of the manufacturer.
CE labelling
The manufacturer uses CE labelling to indi-
cate that the STILL portal frame complies with
the standards and regulations valid at the time
the STILL portal frame was placed on the mar-
ket. Compliance is confirmed by the issue of
an EC declaration of conformity. The CE label-
ling is attached to the nameplate (identification
plate).
An unauthorised structural change or addition
to the STILL portal frame can compromise
safety, thus invalidating the EC declaration of
conformity.
The EC declaration of conformity must be
carefully stored and made available for pre-
sentation to the relevant authorities at any
time.
CE-Symbol

Foreword
1
General
2 89708011526 EN -

Information about the documentation
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third parties
—including as excerpts—except with the ex-
press written approval of the manufacturer.
Explanation of signal terms used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered to
in order to prevent the risk of injuries.
CAUTION
Indicates procedures that must be strictly adhered to
in order to prevent material damage and/or destruc-
tion.
NOTE
For technical requirements that require special
attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Terms and definitions
STILL portal frame
The STILL portal frame is a device for picking
up loads. It is designed for picking up trolleys.
The trolleys are raised by an integral lifting de-
vice. The trolleys must be lifted to ensure safe
transportation with low levels of noise.
Foreword
1
Information about the documentation
389708011526 EN -

Trolley
A trolley is a roller platform that can be used to
transport a wide range of loads such as pal-
lets, crates, etc.
Trolleys of various dimensions can be used,
adapted to the respective load.
Foreword
1
Information about the documentation
4 89708011526 EN -

Environmental considerations
Packaging
When the TrolleyMover is delivered, certain
parts are packaged to provide protection dur-
ing transport. This packaging must be com-
pletely removed prior to initial commissioning.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the TrolleyMover.
Disposing of units
It may be necessary to exchange units as part
of maintenance work. This may result in the
need to dispose of replaced units.
A STILL portal frame is composed of different
materials. In accordance with regional or na-
tional regulations, each of these materials
must undergo
●
Disposal
●
Treatment
●
Recycling
ENVIRONMENT NOTE
We recommend working with a waste man-
agement company when disposing of hazard-
ous materials.
Foreword
1
Environmental considerations
589708011526 EN -

Foreword
1
Environmental considerations
6 89708011526 EN -

2
Introduction

Using the STILL portal frame
Intended use
The trailers are used to move and lift the loads
specified on the nameplate.
The following must also be taken into account:
●
The operating instructions for the tow trac-
tor
●
Other specific national regulations.
Changes to components may be made only
with the approval of the manufacturer.
Roadways
Roadways must be sufficiently firm, level and
free from objects. Drainage channels, level
crossings and similar obstacles must be ev-
ened out and, if necessary, ramps must be
provided so that trucks can drive over these
obstacles with as few bumps as possible.
Trailers may only be used on roadways that
do not have excessively sharp bends, exces-
sively steep gradients or excessively narrow
or low entrances. Gradients must not exceed
the values given in the operating instructions
and must have a surface with sufficient grip.
The top and bottom of the gradient must fea-
ture smooth and gradual transitions to prevent
the load from scraping the ground and the un-
dercarriage from being damaged.
The permitted area load and point load of the
roadways must not be exceeded. There must
be a sufficient distance between the highest
points of the tugger train or the load and the
fixed elements of the surrounding area. Haz-
ardous areas on roadways must be secured or
indicated by the customary road traffic signs
and, if applicable, by additional warning signs.
Damage and defects
Damage or other faults on the trailers must be
reported to the supervisor immediately. Trail-
ers that are not safe to operate must not be
used until they have been properly repaired.
Introduction
2
Using the STILL portal frame
8 89708011526 EN -

Improper use
DANGER
High risk of property damage, injury and death.
Avoid improper use.
DANGER
Risk of explosion in at-risk areas and areas where
there is a risk of fire!
The trailers are not equipped for use in areas where
there is a risk of fire or explosion.
–Do not drive into areas where there is a risk of fire
or explosion!
WARNING
Serious injuries
It is not permitted to transport people on the trailers
or trolleys.
The trailers are not permitted for use on public
roads and are not equipped for road use.
The following list serves by way of example
and does not claim to be exhaustive.
In addition, it is not permitted:
●
To stack/unstack on slopes
●
To step onto the trough
●
To exceed the maximum load capacity
●
To distribute the load in such a manner that
more than 70% of the load is carried on any
one trailer
●
To travel at a speed greater than 15 km/h
●
To use the machine where the application
condition have not been adapted, e.g. in
areas with excessively low floor load ca-
pacity, insufficient overhead clearance etc.
The operating company or driver, and not the
manufacturer, is liable if the trailers are used
in a manner that is not permitted.
Introduction
2
Using the STILL portal frame
989708011526 EN -

Residual risk
Residual risk
Residual dangers, residual risks
Despite careful working and compliance with
standards and regulations, the possibility of
other risks occurring when using the Trolley-
Mover cannot be entirely excluded.
The TrolleyMover and all other system compo-
nents comply with current safety require-
ments. Nevertheless, even when the Trolley-
Mover is used for its proper purpose and all
the instructions specified here are followed,
some residual risk cannot be excluded.
A residual risk cannot be excluded even be-
yond the narrow limits of the danger area that
the TrolleyMover itself represents. Persons in
the area around the TrolleyMover must exer-
cise a heightened degree of awareness so
that they can react immediately in the event of
any malfunction, incident or breakdown etc.
WARNING
All personnel working in the vicinity of the Trolley-
Mover must be instructed regarding the dangers that
arise through use of the TrolleyMover.
In addition, attention must be drawn to the safety
regulations in these operating instructions.
Risks can include:
●
Escape of consumables due to leakages,
rupture of lines and containers etc.
●
Risk of accident when driving over difficult
ground such as gradients, very smooth or
uneven surfaces, or with poor visibility etc.
●
Falling or tripping when loading or unload-
ing the Trolleys into or out of the frame us-
ing the TrolleyMover
●
Human error — disregarding safety regula-
tions.
●
Risk caused by unrepaired damage.
●
Risk caused by insufficient maintenance or
testing.
●
Risk caused by using the wrong consuma-
bles.
●
Risk caused by exceeding testing intervals
Introduction
2
Residual risk
10 89708011526 EN -

The manufacturer is not held responsible for
accidents involving a TrolleyMover caused by
the operating company's intentional or negli-
gent failure to comply with these regulations.
Danger to employees
According to the German workplace safety or-
dinance (BetrSichVO) and labour protection
law (ArbSchG), the operating company must
determine and assess hazards during opera-
tion, and establish the occupational health and
safety measures required for employees. The
operating company must therefore draw up
the appropriate company directive (Section 6
ArbSchG) for the operation and make it availa-
ble to the driver. These operating instructions
for the STILL portal frame do not constitute a
company directive. A responsible person must
be appointed.
The construction and equipment of the STILL
portal frame correspond to the Machinery Di-
rective 2006/42/EC and are therefore marked
with the CE labelling. However, the operating
company must select the type and equipment
of the portal frame such that they comply with
the local provisions for deployment.
The result must be documented (Section 6
ArbSchG). When deployment of the portal
frame involves similar hazard situations, the
results may be summarised. This summary is
designed to help to meet the requirements of
these regulations. The summary specifies the
primary hazards that, in the event of non-com-
pliance, are the most frequent cause of acci-
dents. If other major hazards are present as a
result of the specific operating conditions,
these hazards must also be taken into consid-
eration.
The conditions of use for the STILL portal
frame are broadly similar in many plants,
meaning that the hazards can be summarised
in one overview. Information provided on this
subject by the relevant employers' liability in-
surance association or national authorities
must be observed.
Introduction
2
Residual risk
1189708011526 EN -

Stability
Stability is guaranteed if the trailer is used ac-
cording to its intended purpose.
The following actions may jeopardise stability:
●
Cornering at excessive speeds
●
Loading and unloading on ascending and
descending gradients
●
Driving with loads where the centre of gravi-
ty of the load is usually higher than 400 mm
●
Turning on and driving diagonally across
descents or ascents
●
Driving on descents or ascents with the
load on the downhill side
●
Driving with loads that protrude beyond the
outer edges of the trailer
●
Driving with a swinging load
●
Driving over ramp edges or steps
Introduction
2
Residual risk
12 89708011526 EN -

Safety
Operating company
The operating company is the natural or legal
person who uses the STILL portal frame or on
whose authority the STILL portal frame is
used.
The operating company must ensure that the
STILL portal frame is used only for its proper
purpose and in compliance with the safety
regulations set out in these operating instruc-
tions.
The operating company must ensure that all
users understand the safety information in
these operating instructions.
The operating company is responsible for the
scheduling and correct performance of regular
safety checks.
It is recommended that these checks comply
with national performance specifications.
Competent person
A competent person is defined as a service
engineer or a person who fulfils the following
requirements:
●
A completed vocational qualification that
demonstrably proves their professional ex-
pertise This proof is to consist of a vocation-
al qualification or a similar document
●
Professional experience indicating that the
competent person has gained practical ex-
perience of industrial trucks over a proven
period during their career. During this time,
this person has become familiar with a wide
range of symptoms that require checks to
be carried out, such as based on the results
of a hazard assessment or a daily inspec-
tion.
●
Recent professional involvement in the field
of the industrial truck test in question and
an appropriate further qualification are es-
sential. The competent person must have
experience of carrying out the test in ques-
tion or of carrying out similar tests. More-
over, this person must be aware of the lat-
est technological developments regarding
the industrial truck being checked and the
risks being assessed.
Introduction
2
Safety
1389708011526 EN -

Basic principles for safe operation
Warning regarding non-genuine
parts
The original parts and accessories are de-
signed specifically for the STILL portal frame.
Please note that parts and accessories not
supplied by the manufacturer have also not
been tested or approved by the manufacturer.
CAUTION
Installation and/or use of non-genuine parts may
therefore adversely affect the design features of the
STILL portal frame and thus impair active and/or
passive driving safety.
Before installing non-genuine parts, we recommend
that approval is obtained from the manufacturer. The
manufacturer accepts no liability for any damage
caused by the use of non-genuine parts and non-ap-
proved accessories.
Modifications and retrofitting
Changes to the STILL portal frame that will
adversely affect stability, load capacity and
safety systems, among other things, must not
be made without the manufacturer's approval.
The STILL portal frame may only be converted
with the written approval of the manufacturer.
Approval from the relevant authority must be
obtained where applicable.
Damage and defects to safety sys-
tems
The operator must report any damage or other
defects to the STILL portal frame to the super-
visory personnel immediately.
A STILL portal frame that is not functional or
safe to drive must not be used until it has
been properly repaired.
Introduction
2
Basic principles for safe operation
14 89708011526 EN -