Still EK-X Original Instructions Manual Download Page 108

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Special equipment

Load-side operating panel

Second operating panel

A truck can be equipped with a second

operating panel on the load side (1) as special

equipment. This second operating panel is

functionally identical to the standard operating

panel on the lift mast side, except for the

key switch and the display. It is therefore

possible for the truck to be operated either

via the operating panel on the lift mast side

or the operating panel on the load side. It is

guaranteed that only one operating panel can

be activated at a time. The truck is switched on

via the common key switch on the operating

panel at the lift mast side (2). This operating

panel is always automatically active when the

truck is switched on.

NOTE

For switching on, follow the notes in the

operating instructions in the chapter entitled

"Switching on the controller".

Changing the active operating panel

CAUTION

During the operating panel switchover, the steering,

in addition to all other functions, can be switched to

the other operating panel. As a result, the switcho-

ver can cause a major change in the steering angle.
Move the steering to the straight ahead position

before each operating panel switchover.

If the active operating panel now needs to

be changed, the truck must be brought to a

standstill, the foot switch released and the

X button (3) in the operating panel that has

been passive until now must be pressed. The

functions are thus shifted on to this operating

panel. The other operating panel is therefore

passive and no more truck functions can be

triggered.

NOTE

The emergency stop switches in both opera-

ting panels are active at all times.

102

5213 804 2501 EN - 01/2016

Summary of Contents for EK-X

Page 1: ...Original instructions High level order picker EK X 2131 2133 5213 804 2501 EN 01 2016 ...

Page 2: ......

Page 3: ...f address 7 2 Safety General safety information 10 General safety information 11 Non ionising radiation 12 Vibrations 12 Special safety advices for engaging loads 14 Safe handling of operating media 15 Risk assessment 16 Regular testing 17 Residual dangers 17 Residual hazards with commissioner trucks 18 Application area 19 Intended use 20 Narrow aisle vehicles 21 Original parts 21 Directives and g...

Page 4: ... 45 Commissioning the battery 46 Replacing the battery 47 Battery lock 49 Daily commissioning 50 Checklist before starting work 50 Access to the driver s compartment 52 Access to the driver s compartment 52 Operating devices 53 Brake system 53 Steering system 54 Switching on the control system 56 Driving 57 Types of guidance 57 Driving without guidance 58 Driving with automatic guidance 62 Load pi...

Page 5: ...ion 83 Maintenance schedule 85 Battery check 89 Lubricants 90 Lubrication schedule 92 6 Technical data Technical data 94 7 Special equipment Inductive guidance IZF 96 Personal protection system MPSE 98 Two person cab 99 Working platforms 101 Trucks for use in cold storage 101 Load side operating panel 102 Battery on roller tracks 105 Acoustic warning signal 106 Tilt barrier 106 Leaning cushion 107...

Page 6: ......

Page 7: ...1 Foreword ...

Page 8: ... 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 Proper use A daily inspection by the operator and Regular appro...

Page 9: ... Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH 5213 804 2501 EN 01 2016 3 ...

Page 10: ...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 equipme...

Page 11: ... that the EU machine guidelines and all the relevant guidelines which are valid for this product have been met 2 Truck type 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 manufactu...

Page 12: ...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 ...

Page 13: ...hout 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 c...

Page 14: ...ls 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 8 5213 804 2501 EN 01 2016 ...

Page 15: ...2 Safety ...

Page 16: ...and from reaching into the area of the moving lift mast because even doing this is highly dangerous Aside from the driver there must be no other person present on the truck unless the truck has additional equipment to enable operation with two persons If there are marked roadways the truck is to be moved only within these markings for safety reasons It is never permitted for anyone to stand beneat...

Page 17: ... is therefore prohibited The driver can secure the truck against unauthorised use by removing and taking the switch key or by deleting the access information on the electronic access control system when leaving the truck If required by the area of application and work situation the operator must use suitable personal protective equipment such as protective shoes safety helmet protective gloves or ...

Page 18: ...h 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 sub...

Page 19: ...tions accordance with the Directive 2002 44 EC by the operating company at the actual place of use in order to consider all additional inﬂuences such as driving route intensity of use etc 5213 804 2501 EN 01 2016 13 ...

Page 20: ...s 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 shif...

Page 21: ...ven 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 material...

Page 22: ...e immediately using plenty of clear water and consult a doctor Comply with the additional operating instructions supplied by the battery and the battery charger manufacturer Risk assessment According to the relevant CE Directives the operator of a business enterprise is required to compile an Operating instruction document based on a risk assessment The aim of the analysis is to establish those ha...

Page 23: ... inspection has to be created Please check whether regular safety inspec tions of the truck by an authorized expert are a legal requirement in the country this truck will be used You are responsible for doing so as operating company of the truck Residual dangers Despite adherence to all valid safety regula tions relating to the design and construction of our trucks and irrespective of correct oper...

Page 24: ...ly when cornering Description of the situations Depending on their design or the way in which the commissioner trucks described here are used there may be a risk of severe injury to the operator from static building or racking parts The risk exists in trucks Without barriers and a cab rail Without rail guidance With feed in rollers on one or both sides With a one sided guide In versions speciﬁed t...

Page 25: ...g to VDI2695 category 1 with ﬂat and even ﬂoor without signiﬁcant slopes below 3 normal work load 50 capacity utilization full load and half shift or half load and full shift and ambient temperatures according to EN 1175 1 WARNING Restrictions in the applicational area The trucks described here must notbe used in areas at risk from ﬁre in areas at risk from explosions iin areas with atmospheres co...

Page 26: ...ed by taking measures on site such as using approach rails for the load wheel arms It is the responsibility of the operating company to identify and eliminate any danger areas and or to prohibit any reasonably foreseeable misuse by issuing operating instructions The industrial truck is also suitable for raising lowering and transporting unit loads Use for other purposes is prohibited NOTE There ar...

Page 27: ... may only be operated in narrow aisles in accordance with the intended use if suitable precautions have been taken e g mobile or stationary protective equip ment to EN 2006 42 EG and EN ISO 13849 which prevent the possibility of collisions oc curring between persons and vehicles or which prevent persons and other vehicles also being present at that time In Europe it is the owner s responsibility t...

Page 28: ...er s licence serves as proof that com prehensive training has been completed As the operating company you are responsible for ensuring that this requirement is fulﬁlled We recommend that you contact your branch or specialist representative They will be able to offer you the relevant training and tests required to obtain your driver s licence Alterations to industrial trucks Operating companies may...

Page 29: ...tion or conversion alteration or conversion date and name and address of the organisation entrusted with this task Personal protective equipment For operation of our products no personal protective equipment is required under normal application conditions However it is possible that the use of personal protective equipment is required at the place of use due to the on site circumstances or local o...

Page 30: ...2 Safety Personal protective equipment 24 5213 804 2501 EN 01 2016 ...

Page 31: ...3 Overview ...

Page 32: ... guard 4 Mirror module 5 Abseil system 6 Operating panel 7 Barrier 8 Auxiliary lift 9 Load fork 10 Lift cylinder 11 Lift mast bracing 12 Battery compartment cover 13 Control compartment cover 14 Battery 15 Battery lock 16 Guide rollers 17 Load wheel Option 26 5213 804 2501 EN 01 2016 ...

Page 33: ...Driver s compartment only approved for use by a single person c It is not permitted for people to sit or stand on the load on the load support underneath a raised load or to be carried as passengers 4 Risk of crushing hands 5 Storage space for abseil system 6 Risk of crushing feet 7 Foot switch 8 Storage space for product documentation 5213 804 2501 EN 01 2016 27 ...

Page 34: ...A number of information signs are ﬁtted on every truck depending on the series to draw attention to hazards technical data or requirements These signs must always be present in full and must always be legible NOTE The section entitled Labelling for special equipment provides details of further infor mation signs that may also be required based on the order 28 5213 804 2501 EN 01 2016 ...

Page 35: ...operated if a safety barrier closed on three sides is not present 5 Lubricants suitable for cold store applica tions must be used see lubricants for cold store trucks 6 Industrial truck with cold store equipment 7 This industrial truck must only be operated by operators with the appropriate training 8 Switch in switched off position 9 Switch in automatic mode position The pictograms shown here rep...

Page 36: ...h a height that the load is clear of the ground during transportation In very narrow aisles the order pickers are guided either mechanically or inductively see section entitled Special equipment If the aisles are wide enough the trucks can be driven freely with the load lowered All movements driving lifting lowering cab lift lifting lowering auxiliary lift are inﬁnitely adjustable Operating errors...

Page 37: ... surface for two hand operation 7 Special function preselection button 8 Override button e g to release the brake following automatic braking or to bridge intermediate lift cut out 9 Preselector button additional lift 10 Display ﬁeld for truck operating status 11 Steering wheel and sensor surface for two hand operation 12 Operating rocker switch for cab lift or addi tional lift lower Option 5213 8...

Page 38: ...f the number 5 or switch to operating hours display in hrs 6 Entry of the number 6 or switch to function 2 7 Entry of the number 7 or switch to drive programme 3 8 Entry of the number 8 or switch to lift height indicator in mm 9 Entry of the number 9 or switch to function 3 10 LCD display see chapter LCD displays 11 Brightness sensor 12 Selection and deselection button for IZF special function 13 ...

Page 39: ...nd operation required on steering wheel 9 Second hand operation required on hand hold 10 Automatic mechanism for inductive guid ance 11 Actuation required using foot switch 12 Operating status of inductive guidance 13 Indicators for operating hours speed lift height load weight Switch using the keypad 14 PIN code entry required using keypad 15 Indicators for error messages and informa tion Option ...

Page 40: ... discharged battery voltage too low or battery faulty Insert the correct charged battery or call battery customer service Info2 Emergency off switch pressed Unlock the emergency off switch Info3 Truck control unit has triggered the drive stop Can be unlocked or bridged as an option in order to continue driving at creep speed Info9 Steering knob more than 2 from the straight ahead position within m...

Page 41: ...n current fuse for driving and pump 5 Truck control unit 6 Horn 7 Electromagnetic brake 8 Steering motor 9 Traction motor 10 Steering gears and gearbox 11 Collision protection 12 Hydraulic oil tank 13 Hydraulic oil ﬁlter 14 Hydraulic oil ﬁlling opening 15 Emergency lowering valve 16 Pump motor 17 Battery connector 18 Direction indicator 5213 804 2501 EN 01 2016 35 ...

Page 42: ...shed Only touch the grip areas to open and close the barrier If the lift height of the cab ﬂoor is up to 1 2 m driven freely or guided the cab barriers may be left open when the truck is being driven If the truck is to be driven at lift heights greater than 1 2 m the barriers must be closed Horn The horn is an acoustic warning unit that the driver can use at blind spots to signal that the truck is...

Page 43: ...he driver s overhead guard of the vehicle de scribed here is not suitable for protection against particularly small objects paper rolls or packaged wood If this type of object has to be transported the driver s overhead guard must be modiﬁed ac cordingly 5213 804 2501 EN 01 2016 37 ...

Page 44: ...3 Overview Safety equipment 38 5213 804 2501 EN 01 2016 ...

Page 45: ...4 Operation ...

Page 46: ...tions have to be checked The connections which must be disassembled for shipping should be reassembled carefully All nuts and bolts must be tightened to the appropriate torque After the oil levels on the hydraulic tank and gear box have been checked commissioning can begin This commissioning should be done professionally be our service personnel Be fore starting work work through the Checklist bef...

Page 47: ...uitable hoists and har nesses must be available Hooking on NOTE We always recommend the use of textile straps so as to protect the paintwork of your truck Shims may be required to protect the harnesses from sharp edges The lifting points for the chassis are located on the right and left in the area of the load wheels as well as in the chassis area next to the drive unit The lifting points are indi...

Page 48: ...g on the lift mast To hook on the lift mast belts can be wound around the uppermost bridge pieces Har nesses suitable for this purpose must be used shackle or lifting device If necessary the individual lift mast parts can be lashed to each other during this process to prevent them from separating unintentionally and thus shift ing the centre of gravity NOTE Take care to ensure that neither the cab...

Page 49: ... mechanically A notice regarding transportation is ﬁtted in the driver s compartment Prior to commissioning release the load wheel brake transportation safety device In order to do this use a suitable hexagon socket wrench to release two screws in each of the load wheel arms Release the screws far enough to allow the brake function to operate correctly CAUTION When commissioning check that the bra...

Page 50: ...the chassis of the truck are used to improve stability The support screws may only be adjusted by authorised service personnel If problems arise when the truck is operated on uneven surfaces the stability must be recalculated by the manufacturer It will then be possible to increase the setting dimensions for the support screws if necessary The truck will then be equipped with a new load capacity d...

Page 51: ...means of a ﬁrmly mounted ballast and compensate for the different format using shims If your truck has been ﬁtted with an additional weight to compensate for a lighter battery this weight must not be removed Ensure compliance with the information given on the rating plate Battery dimensions The battery must ﬁll the chamber with only a few millimetres clearance This prevents the battery from slippi...

Page 52: ...sing the battery correctly exe cuted commissioning is imperative If the bat tery was procured separately from the truck pay particular attention to checking the rated voltage the required minimum weight and the mounted battery plug This is particularly im portant if the batteries have been loaded and delivered dry due to long transportation dis tances e g from overseas Always precisely observe the...

Page 53: ...gainst the lift mast A special hinge system guides the cover For maintenance work the cover can be removed completely Battery compartment door Side battery compartment doors can be built in as an option To open the doors turn both latches 90 After reinserting the battery compartment doors lock both latches again securely Option 5213 804 2501 EN 01 2016 47 ...

Page 54: ...ttery change frame Alternatively the battery rests on roller chan nels and can be installed and removed from the side using a battery change frame Pre assembled plates with clamping screws secure the battery against rolling out to the side Pre assembled plate removed 2 Pre assembled plate inserted and clamp ing screws tightened 3 Ensure that the clamping screws are tightened symmetri cally on both...

Page 55: ...or message appears on the display Battery lock for narrow chassis In trucks with a narrow chassis the battery is secured with a lock located above the battery To lock the battery securely push both levers downwards NOTE Before starting work check whether the locking plates are pressed against the battery without any play If this is not the case the authorised service centre can adjust the locking ...

Page 56: ...and with all covers in place Function check of the braking systems Check the function of th foot switch braking function Check the reversing brake The braking and subsequent acceleration must be smooth and without jerking Check the braking function after actuating the emergency STOP switch and Check system function on End of aisle braking Automatic braking with release creep speed switchover and c...

Page 57: ...he load chain must not demonstrate any damage Other checks Check the overhead guard for deformation damage and cracks at the welded seams Carry out a visual check of the overhead guard cover Carry out a visual check of the load back rest Check the wheels for foreign bodies Drive wheel and load wheels must be checked for their condition Check the barrier and the emergency OFF switch When the barrie...

Page 58: ...crushed WARNING Risk of falling When climbing in and out it is important to note the difference in height between the ﬂoor of the driver s compartment and the ground NOTE The barriers are monitored by electrical means The industrial truck is only ready for operation when the barriers have been correctly closed The barriers comprise an upper section stomach bar a centre section knee bar and a lower...

Page 59: ...errupted and the information 15 will appear in the display If the braking process is initiated by releasing the foot switch the generator brake is applied ﬁrst Towards the end of the braking process the spring loaded brake also comes into action The foot switch serves equally as the service brake and the parking brake WARNING Risk of accident The ﬂoor of the cab must be kept free of objects Otherw...

Page 60: ...ion in the opposite direction In this case brake linings are not used This form of braking can be metered precisely through the deﬂection the drive lever If the lever is released at the same time as the drive direction is reversed the truck remains stationary Emergency off switch Pressing the emergency off switch 3 ac tivates mechanical braking and brakes the truck to a standstill in the shortest ...

Page 61: ...y 130 to each side The steering thereby moves a maximum of around 95 to each side Steering wheel In trucks with a steering wheel the steering also moves a maximum of around 90 to each side You can use parameters to set whether 2 3 or 4 revolutions of the steering wheel are required The steering wheel has no end stops 5213 804 2501 EN 01 2016 55 ...

Page 62: ...driver s cab is up to a height of 1 2 m the cab barriers may be left open when the truck is being driven If the truck is driven at a lift height of greater than 1 2 m the barriers must be closed DANGER Danger of accidents Never mount or jump onto the truck while it is moving Never step or jump down from a moving truck Release the emergency stop switch 3 by turning Activate the key switch 4 Provide...

Page 63: ...ate a sensor or a function As a general rule the truck switches over to using the guidance system automatically More detailed information can be found in the relevant dedicated chapter Inductive guidance IZF The industrial trucks can be guided inductively when travelling within aisles To achieve this a wire is embedded into the ﬂoor this wire is live with current The magnetic ﬁeld generated by thi...

Page 64: ...on a clear level surface in the warehouse If you carry out the exercises described in the following you will soon become familiar with the truck These exercises are essential in order to maximize on the high performance potential provided by this truck Foot switch Pressing the foot switch 1 releases the brake and the traction controller receives the release signal for travel Releasing the foot swi...

Page 65: ...ke for regular tasks For lift heights where the ﬂoor of the driver s cab is up to a height of 1 2 m the cab barriers may be left open when the truck is being driven Handhold sensor A sensor is integrated into the handhold next to the operating lever which detects contact with the driver s hand In order to obtain a drive enable status the foot switch must be actuated and contact must be made with t...

Page 66: ...sle to another Conversely the steering wheel 4 has no stops To achieve the maximum steering angle of approx 90 on each side it is necessary to make approx 3 turns from the straight ahead position to the left or right Trucks with this equipment are mainly intended for use in warehouses without guidance due to the sensitive steering 60 5213 804 2501 EN 01 2016 ...

Page 67: ...eration 4 Driving Emergency stop switch Pressing the emergency stop switch 5 activates mechanical braking and brakes the truck to a standstill in the shortest distance possible 5213 804 2501 EN 01 2016 61 ...

Page 68: ...ail switches 1 are operated Through detection of the rail guide by means of a rail switch 1 steering control is auto matically switched over to the new guidance system For this the driver s left hand must make contact with the steering knob steering wheel When the controller recognizes the hand contact it enables further functions If you only wish to travel the two hand control switch must be acti...

Page 69: ...operating rocker switch select the direction of movement and speed NOTE In order to inﬂuence the damping control and other transitions it is necessary to ﬁrst select the required movement using the relevant preselection Additional lift and then to deﬂect the control lever or the operatingrocker switch Additional lift lift lower operation using the load side buttons Press the preselector button Pre...

Page 70: ...can be moved to the target aisle If the truck is turned back by 90 at the right place then it is positioned ready to enter in front of the new rack aisle This driving technique for changing rack aisles transferring is illustrated in the adjacent sketch Diagonal travel Diagonal travel is the name given to combi nation of the functions drive and lift cab drive and lower cab Diagonal travel is also a...

Page 71: ...uches the back of the fork CAUTION During this process the load may be moved or even knocked over Make sure not to jolt the fork Setting down loads Carefully approach the place at which the load will be set down Position the load as accurately as possible Lower the load carefully until it rests se curely on the supporting surface Lower the fork until there is sufﬁcient free space between the load ...

Page 72: ...e appliance Of course this applies also to the weight accruing as a result of the goods in the consignment Example Example for a truck with a low single mast Cabin ﬂoor lifting heiht max 4550mm Auxiliary lift lifting height plus 800mm The distance of load centre from heel of fork 400 mm max load 800 kg 500 mm max load 500 kg 600 mm max load 300 kg Increasing liting height and increasing dis tance ...

Page 73: ...r it and therefore also cannot warn of overloading The operator must ensure that the load capacity of the order picker is not exceeded during picking work DANGER Risk of tipping to the side Under no circumstances must the truck be driven round corners with a load raised further than just clear of the ground At greater heights only positio ning movements at creep speed are permitted The steering mu...

Page 74: ...ily for the collection or distribution of goods in containers or on pallets The depositing and removal of loads are not possible in narrow aisles During transport the additional lift must be lowered on principle DANGER Danger of tilting forward As a result of the order picking process transpor ted loads are collected and so increasing weight accumulated on the load carrier As this is a manu ally p...

Page 75: ...ating rocker switch for 1 or 2 press button 3 1 Preselection additional lift 2 Lift 3 Lower 4 Not assigned Additional lift load side operation This truck can optionally be equipped with load side operation for the additional lift Parking decommissioning Parking and leaving the truck NOTE 5213 804 2501 EN 01 2016 69 ...

Page 76: ...f a racking aisle or in a loading bay If there are parking spaces the truck must be parked there The fork is to be lowered to the ﬂoor as far as possible and if there is one the tilt attachment must tilt towards the ﬂoor to reduce the risk of stumbling Decommissioning ENVIRONMENT NOTE If the truck described here has to be decom missioned pay attention to ensure that all components are disposed of ...

Page 77: ...the two screw plugs on the cover anti clockwise and remove them Hold the cover at the ventilation openings lift it off and then place to one side The lowering valve is located in the control compartment and can be accessed once the control compartment cover has been opened Rotate the wing screw 1 on the valve block anti clockwise The lowering procedure begins Do not adjust any screws other than th...

Page 78: ...ws M4X25 and the corresponding nuts M4 and washers M4 into the provided bores in the brake block Releasing the load wheel brake A power supply is required to release the load wheel brake If there is no power supply available e g during emergency operation of the industrial truck the load wheel brakes must be released mechanically In order to do this use a suitable hexagon socket wrench to release ...

Page 79: ... placed underneath the drive wheel or underneath the chassis As the drive wheel does not come into contact with the ground when using this towing method the brakes can also no longer operate Therefore please observe the safety information in the section entitled Brake emergency ventilation When hooking on the truck in order for it to be towed with the drive unit leading a sling or rope that is of ...

Page 80: ...ing procedure is complete rotate the valve clockwise to close it again Emergency lowering of the driver s cab Leaving the driver s cab in an emergency situation If a technical defect causes the truck to shut down when the driver s cab is raised or if an operator in the raised cab becomes incapable e g falls unconscious of operating the truck the driver s cab can be lowered by a second person on th...

Page 81: ...ng valve has of the lift mast is obstructed a third person with full view of the lift mast must be involved Clearly this third person must be able to communicate readily with the operator of the lowering valve and the truck operator If a movement like the one described cannot be detected immediately or if one of the chains has slackened a mechanical jam at the lift mast is suspected The emergency ...

Page 82: ...r than 3000 mm above the ground NOTE Two versions are available As standard a system is supplied that includes a safety harness designed for people up to a height of approximately 2 m For larger operators a variant is available as an option that includes a safety harness that can be adjusted up to size XXL The storage location for the emergency abseil system is marked with an adhesive label 1 76 5...

Page 83: ...ling The carabiner which is also included in the scope of delivery is hooked into this bore The rope is then guided through this carabiner Carabiners must always be closed Abseiling exercises are only permitted under the supervision of an expert In Germany the abseiling procedure must be practised at least once a year We recommend these practice exercises for other countries even if they have not ...

Page 84: ...ourable position the rope can be redirected with an additional carabiner in most versions of the overhead guard This additional carabiner is attached to the safety harness chest eyelet area To redirect the rope the carabiner is detached from its original position and reattached in a bore provided in a strut on the overhead guard 2 Testing A technical expert must check the abseil system at least on...

Page 85: ...pension points approved by the manufac turer are used Different operators If an industrial truck is used by multiple persons e g in multi shift use it may be indicated that several preset abseil systems must be kept on hand This is particularly sensible if the different operators are of widely varying heights and or weights and the safety harness would therefore have to be adjusted to a signiﬁcant...

Page 86: ...4 Operation Emergency operation 80 5213 804 2501 EN 01 2016 ...

Page 87: ...5 Maintenance ...

Page 88: ... the control compartment the hood must be removed Remove the two plastic screws Turn anti clockwise to open Lift the hood upwards out of the latch and place on one side The hood is very light and can consequently be removed without using any special aids The hood is mounted in reverse sequence Place the hood carefully into its guide and latch mechanism and hand tighten the plastic screws Fuses 1 P...

Page 89: ...ential that you carry out thorough mainte nance in a correct manner at the prescribed intervals The maintenance work is described in the maintenance schedule and must be car ried out by trained specialist personnel We recommend that you use our original spare parts which can be found in the spare parts list The installation of other parts will invali date the warranty Our dedicated service team wi...

Page 90: ...5 Maintenance General maintenance information Only regular servicing will enable you to make full use of the warranty 84 5213 804 2501 EN 01 2016 ...

Page 91: ...rive wheel and check for wear Check that the drive wheel wheel screws and cushion tyre are securely attached Check the traction motor bearing for operat ing noise replace the bearing if necessary Steering Check the function of the steering system Check the maximum steering angle It must be possible to steer 90 to each side Check the level of play and the status of the steering angle measurement ac...

Page 92: ...our health use a protective mask Check the brake retardation values after each adjustment dynometer Check that the automatic braking mech anism is working correctly Observe the functional description for the order Check that the inductive transmitter is working correctly Clean the photo eyes light barriers and check they are working correctly Undercarriage Check the condition and ease of movement ...

Page 93: ...n is 3 Check the chain rollers for ease of move ment Check the condition of the lift mast guide surfaces and check for wear and lubrication condition Check the condition of the lift mast rollers and check the setting Check the condition of the guide elements and check for lateral play between the lift mast parts replace if necessary Check the fork latches and safety devices Visually inspect the fo...

Page 94: ... lift cylinder for leakages and function Check the auxiliary lift cylinder for leakages and function Check the oil level in the tank top up if necessary Observe the correct oil grade as per the lubricant table Check all hydraulic screw joints for leak ages tighten or replace if necessary Check all lines and hoses for leakages Check the condition of all lines and hoses and check for pinch points Ch...

Page 95: ...he lubrication plan Maintenance annual or every 2000 hours Replace the breather ﬁlter of the hydraulic tank Regular safety testing must be carried out by a competent person The relevant national guidelines must be observed Option Battery check NOTE Battery maintenance is not part of the vehicle maintenance routine and must be carried out as speciﬁed by the battery manufacturer DANGER Electrolyte b...

Page 96: ...d by the relevant manufacturer To protect the battery from becoming ex hausted a discharge display with cut out function for the main lift is installed as stan dard CAUTION Is the battery plug pulled out when a consumer is still active it is possible for all the contacts to burn Plug battery plug in or out only when key switch is switched off Lubricants CAUTION Risk of damage to property Trucks fo...

Page 97: ...tween the min and max marking Gearbox SAE 75W 90 API GL 5 ID no 732 600 0007 The gearbox holds 2 9 l of gearbox oil Grease lubrication points Lithium soap grease LITH EP2 ID no 8 010 107 Chain lubrication Stabylan 2100 ID no 8 010 100 5213 804 2501 EN 01 2016 91 ...

Page 98: ...l lift chains with chain spray Lubricate all moving parts with oil Keep sliding surfaces of the mast sections free of corrosion with a ﬁlm of grease First gear oil change after 1000 h thereafter every 24 months or every 4000 h Every year or 2000 hours Change hydraulic oil Every two years or 4000 hours Change gear oil 92 5213 804 2501 EN 01 2016 ...

Page 99: ...6 Technical data ...

Page 100: ...ata for this truck depends on the order You will therefore receive a datasheet specially prepared for your truck when it is delivered Please use this accompa nying datasheet to ﬁnd all the technical data Sound level driver s ear 61dB A 94 5213 804 2501 EN 01 2016 ...

Page 101: ...7 Special equipment ...

Page 102: ...ignals are analysed Extensive safety circuits and a diagnostic program simplify system servicing work The operating devices for inductive guidance are integrated into the operating panel The operating status display indicates the active operating status 4 of the system After switching on the control system a self test runs in the guidance system Entering the aisle Guidance procedure Drive the truc...

Page 103: ...cted the aisle the maximum permissi ble speed within the aisle is possible Automatic driving within the aisle If the steering knob is turned accidentally to its straight ahead position middle stop during automatic drive mode the truck is automatically braked to a standstill Switching from automatic to manual operation within the aisle If the truck is accidentally switched to manual steering within...

Page 104: ...ple who have entered the braking area of the truck unplanned One safety laser scanner for each drive direction scans the braking area and triggers braking in the truck as soon as a person or object is detected in this area protective ﬁeld As a rule these personal protection systems are active only with the guidance function Optionally the functional range can also be expanded to include front end ...

Page 105: ...ing speed of the truck is restricted to 2 5km h Operation with a bridging plug is therefore only permitted for the retrieval of a truck This bridging plug must be kept locked away by the warehouse manager responsible and is only to be used under his instruction Two person cab General With the non standard equipment Two person cab it is possible for a second person to travel in the cab while it is ...

Page 106: ...position when carrying a passenger NOTE Trucks which feature a cab that permits two operators must also be equipped with two abseil systems In such trucks it must be ensured that only the suspension points approved by the manufacturer are used Function When the operator intends to take a passen ger the relevant operating mode must be set by turning the key switch to the correct symbol The passenge...

Page 107: ...d Trucks for use in cold storage Trucks for use in cold storage are provided with extensive extra equipment in order to guarantee full functioning at low temperatures 30 C Special instructions for the operation of these trucks must be observed which are not contained in this operating manual Trucks designed for operation in refrigerated environments are marked with the adjacent symbol CAUTION Icy ...

Page 108: ...d on NOTE For switching on follow the notes in the operating instructions in the chapter entitled Switching on the controller Changing the active operating panel CAUTION During the operating panel switchover the steering in addition to all other functions can be switched to the other operating panel As a result the switcho ver can cause a major change in the steering angle Move the steering to the...

Page 109: ...f the truck Carefully set off Operating panel load side only A truck can be equipped with an operating panel only on the load side 1 as special equipment A switchover is not required here The key switch 4 and the display 5 remain on the lift mast side There is no steering knob or operating console on this side If trucks are equipped with IZF the selecting and the deselecting of the inductive wire ...

Page 110: ...ruck will stop WARNING Every time before starting work the battery locks 2 must be checked for perfect condition and function Option Setting the battery lock CAUTION Risk of crushing and damage to property An improperly ﬁxed battery may fall out of the truck when cornering and put people and property at risk If the battery cannot be clamped securely the responsible service centre must be called Fu...

Page 111: ...n both sides of the battery Gently move the battery to the side if necessary The maximum adjustment range for each rubber buffer is approximately 20 mm If the useable threads on both rubber buffers are not long enough to fasten the buffers to the battery the knurled head screws must be screwed in further to increase the adjustment range At the same time the rubber buffers must rotate with the knur...

Page 112: ...ier consists essentially of a mobile upper part a ﬁxed bottom part and a hinge connecting the upper and bottom parts For safety reasons the tilt barrier is unlocked only under certain conditions Function The barrier can only be opened if The truck is in an aisle The barriers are closed The two hand sensors are not actuated The operating levers for driving hydraulics are in the neutral position The...

Page 113: ...n the metal bracket against the spring force Latch the leaning cushion back into the required position Height adjustable operating panel To ensure optimum ergonomics for the operator in going about their work the height of the operating panel can be electrically adjusted The adjustment range is 130 mm WARNING Risk of crushing hands When adjusting the height of the operating panel the operator must...

Page 114: ...isle using an additional transmitter By using the drive direction detection function the truck can only be driven in the opposite direction from this stop position Pressing and holding the enable button allows the truck to be driven at max 2 5 km h in the braking direction The truck is then not shut off before the end of the aisle If the truck leaves the braking area and drives towards the centre ...

Page 115: ...7 Chain spray 92 Change gearbox oil 92 Change hydraulic oil 92 Changing the rack aisles 62 Checking access control 50 Checking the connecting device 50 Checking the load suspension device 50 Checklist before starting work 40 50 Clearance 71 Climbing in 52 Climbing out 52 Closing the barriers 52 cold store 19 Commissioning 40 Commissioning the battery 46 Container number 45 Control compartment 82 C...

Page 116: ...ion check of the operating devices 50 Fuses 82 G Gear oil 15 Gearbox oil 90 Gel batteries 45 General safety information part 2 11 Guide 11 H Hand and arm vibrations 12 Handhold 31 Handhold sensor 58 Harness 41 Height adjustable operating panel 107 Hooking on the lift mast 41 Horn 11 36 Horn button 31 Hydraulic oil 15 90 Hydraulic system 85 I Indicators 34 Inductive guidance 57 62 96 Information 34...

Page 117: ...al safety 11 Operator s console 31 Options 101 Order picking 20 Order related documentation 6 Original parts 21 P Parking brake 53 Passive operating panel 102 Personal protection 15 Personal protection system 98 Personal protective equipment 23 Personal protective gear 15 Picking up a load 65 Primary current fuses 82 Product support documentation 6 Proper usage 6 PzS 45 R Recycling 70 Regular test...

Page 118: ...l steering 71 Towing with operational steering 71 Training 22 Transportation safety device 41 Transporting 41 Transporting loads 30 Truck identiﬁcation 5 Two hand control 62 Two hand controls 36 Two hand operation 31 Two person cab 76 99 Types of guidance 57 U Undercarriage 85 Use in cold storage 101 V VDE0117 19 VDI2695 19 VDMA 20 VDMA German Engineering Federa tion information booklet 6 Vibratio...

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Page 120: ...STILL GmbH 5213 804 2501 EN 01 2016 ...

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