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Maintenance

5

General maintenance information

At operating hours

Carried

out

1000

3000

5000

7000

9000





Check the adjustment of the rubber stops on the battery locking system
Check the operation of the battery charger
Hydraulic circuits

Check the oil level in the lift and tilt circuit
Check the lift and tilt circuit for leaks
Change the pressure ﬁlter
Blow-clean and check the pump motor brushes

Mast / chains
Checking the condition of the mast and the chain mountings
Adjust the length of the mast chains

Clean and lubricate the chains
Lubricate the mast
Check the condition and mountings of the mast protectors

Final checks
Make a visual inspection of the condition of and wear on the side sliding shoes
Make a visual inspection of the general condition of the chassis and the forks
Resetting the maintenance intervals to zero on the multifunction display
Test driving the truck

1170 801 15 09 [EN]

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Summary of Contents for EXG-10

Page 1: ...Original instructions Counterweight pallet stacker EXG 10 EXG 12 EXG 16 1217 1218 1219 1170 801 15 09 EN 07 2012 ...

Page 2: ......

Page 3: ...f use 8 Residual risks 9 Residual dangers residual risks 9 Special risks associated with using the truck and attachments 9 Overview of hazards and countermeasures 10 Danger to employees 12 Environmental considerations 13 Packaging 13 Disposing of components and batteries 13 2 Safety Deﬁnition of responsible persons 16 Operating company 16 Specialist 16 Drivers 16 Basic principles for safe operatio...

Page 4: ...ing positions 31 Identiﬁcation label 32 4 Use Intended use of the trucks 34 Checks and actions prior to commissioning 35 List of checks prior to start up 35 Commissioning 36 Multifunction display settings 36 Checking the anti crush safety device 42 Checking the horn 43 Driving 44 Driving safety instructions 44 Driving 45 Braking 48 Lifting 49 Use of the mast 49 Capacity 52 Handling loads 54 Load h...

Page 5: ...ck storage 74 Recommissioning after storage 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 Maintenan...

Page 6: ...control modules and their connections 105 Electrical equipment testing and cleaning the fan 105 Cleaning the cooling ﬁns 106 Speciﬁc mast maintenance 107 Hydraulic systems 110 Transmission 113 Maintenance every 2000 hours 114 Hydraulic systems 114 Transmission 116 6 Technical data Technical Data Sheet EXG 10 12 16 118 Loads per axle 121 Mast table 123 Annex 7 Diagrams Hydraulic installation 134 Pr...

Page 7: ...1 Introduction ...

Page 8: ...plied 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...

Page 9: ...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 ...

Page 10: ...sed 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...

Page 11: ...ll 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...

Page 12: ...d 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 Berze...

Page 13: ...e 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 ...

Page 14: ...d 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 ...

Page 15: ...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...

Page 16: ...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 O BetrSichVO Workplace Safety Ordinance Risk of falling when using working platforms Compliance with national regulations different national laws O BetrSichVO Workplace Safety Ordinance and employer s liability insurance...

Page 17: ...ce 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 O VDE 0510 In particular Ensure ventilation Insulation value within permissible range When using ba...

Page 18: ...ible 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...

Page 19: ...rly 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...

Page 20: ...1 Introduction Environmental considerations 14 1170 801 15 09 EN ...

Page 21: ...2 Safety ...

Page 22: ...a This expertise allows him to assess the condition of indus trial trucks in terms of health and safety Drivers This truck may only be driven by suitable persons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been speciﬁcally designated to drive the truck Speciﬁc knowledge of the truck is also necessary Driver rig...

Page 23: ...ion of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use 1170 801 15 09 EN 17 ...

Page 24: ...tional modiﬁcation or transfor mation of your truck is forbidden without prior written permission from the manufacturer Authorisation from the relevant authority may also be required SPECIAL CASE if the manufacturer of the truck is no longer in business and its activity is unlikely to be taken over by a successor In this speciﬁc case you may plan a modiﬁca tion or alteration to your truck provided...

Page 25: ...ssories must be reported immediately to the responsible personnel The truck and accessories must never be used before they are correctly reconditioned as they cannot be guaranteed to be safe for operating or driving The safety mechanisms and switches must never be removed or disabled The predeﬁned setpoint values must not be modiﬁed Work on the electric installation e g connect ing a radio additio...

Page 26: ...truck must be thoroughly checked to detect any damage that may have been caused by improper use A test log must be created The results of the inspection must be retained until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe the guidelines fo...

Page 27: ... an eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk ...

Page 28: ...ydraulic ﬂuid is a water polluting substance Always store hydraulic ﬂuid in containers complying with the regulations Avoid spilling Spilt hydraulic ﬂuid should be removed with oil binding agents at once and disposed of according to the regulations Dispose of old hydraulic ﬂuid according to regulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact ...

Page 29: ...f in accordance with regulations Observe the national regulations for your country Work may only be carried out in areas designated for this purpose Take care to minimise as far as possible any impact on the environment Any spillage of ﬂuids such as hydraulic oil brake ﬂuid or gear lubricant oil must be immediately soaked up with an oil binding agent The regulations for disposal of used oil are ap...

Page 30: ...functional or safe may not be used until they have been properly repaired Do not remove and do not deactivate the safety systems and shifting devices Fixed parts may only be changed with the approval of the manufacturer Work on the electrical system for example connecting a radio additional headlights etc is only possible with the manufacturer s written approval All electrical system interventions...

Page 31: ...3 Overviews ...

Page 32: ...Tilt hydraulics 12 Pump unit 13 Drive wheel 14 Transmission gear 15 Traction motor 16 Steering motor 17 Traction and lift controller 18 Steering controller 19 Diagnostic connector 20 Emergency stop button 21 Tiller 22 Mast safety shield 23 Fixed or tilting lift mast depending on truck type 24 Mast joint 25 Mast tilt control 26 Foot protection Hydraulically assisted 26 1170 801 15 09 EN ...

Page 33: ...rd 1 Fork lowering 2 Fork lifting lowering proportional control 3 Fork lifting 4 Safety reverser 5 Direction reverser accelerator 6 Emergency stop button 7 Switch key 8 Diagnostic connector 9 Tilt selector 10 Mast tilt 11 Horn 12 Multifunction indicator 1170 801 15 09 EN 27 ...

Page 34: ...0 discharged 2 1 Recharge recommended 2 Recharge essential 2 Battery charge level represented by 5 bars 100 full charge 10 low charge 0 discharged 1 1 Battery discharged by 80 Lifting function deactivated 3 Hourglass ﬂashing Indicates that hour meter is running 4 Control button 1 To display a different screen Alternative function setting button 28 1170 801 15 09 EN ...

Page 35: ...larm still active Call service engineer 2 Message Brake worn audible alarm Alarm still active Call service engineer 13 BATTERY ALARM red indicator light 1 Flashing charge or 10 2 Lit battery discharged 1 Recharge recom mended Message Low battery charge level 2 Lifting disabled Recharge essential Message Battery level 0 Lifting restricted 14 Temperature alarm indicator light red Lit control module ...

Page 36: ...es slowly The hour meter displays hours and tenths of an hour When the power supply is disconnected the hours are stored in the memory 18 Information message display 19 Error code display Error code beginning with T Traction module error codes L Lifting module error codes S1 Main steering controller error codes S2 Safety controller error codes These codes will help the service department to decide...

Page 37: ...el 4 Identiﬁcation label see following page 5 Do not drive with high load label 6 Company label 7 WARNING label GB only 8 Label for compulsory foot protection 9 Mast tilt label 10 Capacity label 11 Truck model label 12 Cold store label 13 Passengers not allowed label 14 Still logo label 1170 801 15 09 EN 31 ...

Page 38: ...mbol this symbol means that the ma chine complies with European regulations for industrial trucks 4 Serial number year 5 Unladen weight 6 Battery Voltage 7 Minimum battery weight 8 Maximum battery weight 9 Nominal capacity of the truck 10 Model 11 Motor rated power 32 1170 801 15 09 EN ...

Page 39: ...4 Use ...

Page 40: ...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 hi...

Page 41: ...amage for example bending cracks signiﬁcant wear Check that there are no signs of leaking consumables under the truck Do not restrict the ﬁeld of vision Ensure the visible area speciﬁed by the manufacturer is observed Attachments special equipment must be properly secured and function according to their operating instructions Damaged or missing stickers must be replaced in compliance with the mark...

Page 42: ...Switch on the ignition The following display appears The truck is ready for operation Starting the truck using the digicode Plug in the battery connector Pull the emergency stop button The screen displays Enter PIN Code see arrow Enter your personal PIN code using buttons 1 to 4 The ﬁgures are represented by stars If the code is correct the welcome screen appears 36 1170 801 15 09 EN ...

Page 43: ... steps off the platform NOTE The default PIN code factory setting is 1 2 3 4 If the PIN code is incorrect repeat the operation Screen contrast Press the SET control button 4 to open the screen for adjusting the contrast button 1 increases the contrast button 2 reduces the contrast NOTE After 5 seconds with no action on the adjust ment buttons the settings are stored and the display automatically r...

Page 44: ...ales Service Address Press the SET 4 button for about 2 seconds until the date appears and then ﬂashes see arrow Use the SET 4 button to select the different areas day month year hour minute Conﬁrm the ﬂashing values selected using the buttons 1 and 2 NOTE All the settings are saved after 10 seconds if no data is entered and the display automatically returns to the welcome screen Settings by the s...

Page 45: ...is running slowly or has stopped are shown on the multifunction indicator in the form of error codes T traction controller error code L lift controller error code S1 steering controller error code S2 safety controller error code NOTE The appearance of a fault code causes the STOP indicator light to come on Make a note of the breakdown code Press the button 1 to display the After Sales Service Cent...

Page 46: ...notice a fault or any signs of wear on the truck Disconnecting the truck in digicode mode Go to the main screen Press button 3 see arrow for 3 seconds NOTE The truck s power supply shuts itself down automatically after 10 minutes if no control is activated This cut off time can be adjusted and reprogrammed by the service engineer To restart the truck the user must enter his PIN code again Changing...

Page 47: ...Use 4 Commissioning Enter the administrator code Enter the new PIN code Conﬁrm by pressing button 1 1170 801 15 09 EN 41 ...

Page 48: ...anti crush device on the tiller head comes into contact with the driver s body When the operator moves away from the anti crush device the vehicle stops even if forward travel is selected again Normal operation may be resumed after releasing the drive direction switches Checking the anti crush safety device WARNING Ensure that the test area is free of people and objects both in front of and behind...

Page 49: ...Use 4 Commissioning Checking the horn Press the horn button 1 located on the upper part of the tiller The horn sounds 1170 801 15 09 EN 43 ...

Page 50: ...front of him and must always have the truck under control He should avoid sudden stops making fast U turns overtaking other vehicles in potentially dangerous areas or areas with poor visibility Driving the truck while sitting on top of it is prohibited All EXG models are designed to be operated in pedestrian mode Therefore Never sit on the truck to drive it Do not use the truck as a stepping stool...

Page 51: ...TE Always adjust the truck speed to suit your route any hazards and the load Use the pallet stacker on ground that has the correct surface and hardness Emergency off switch During normal truck operation the emer gency off switch 2 must be pulled out In case of danger press the switch 2 to break the electrical circuit and apply the electromagnetic brake Direction of travel On a pallet stacker the c...

Page 52: ...ller in the driving area B Gradually and slowly press the drive direction switch backward with your thumb The truck speed depends on the angle of rotation of the drive direction switch Changing the drive direction Release the drive direction switch and activate it in the opposite direction The drive direction can be reversed while the truck is in motion In this case the truck is braked electricall...

Page 53: ...orner too fast can cause the truck to overturn Turning direction in forward travel Turn the tiller to the left L the truck turns to the left Turn the tiller to the right R the truck turns to the right Release the tiller it should return to the neutral position and the truck should move in a straight line Steering angle 180 The turning radius Wa depends on the length of the fork see technical chara...

Page 54: ...n and the truck is stationary When the emergency off switch is pressed NOTE The braking torque is automatically matched to the weight of the load on the forks Automatic braking When the drive direction switch is released braking is activated automatically It engages as soon as a certain travel speed is reached Braking by changing the drive direction Braking can be achieved by reversing the directi...

Page 55: ...correctly ﬁxed and clean to provide good visibility Elevation control Raising the mast Turn the switch key Pull control ﬂap 1 upwards Lowering the mast Push control ﬂap 1 downwards When releasing the control ﬂap 1 the mast stabilises at the required height NOTE The speed of lifting and lowering movements is determined by the degree to which the proportional control 1 is moved This ﬂap automaticall...

Page 56: ...en the lever 3 is released the mast stabilises at the required tilt NOTE The speed of forward and backward tilt is determined by moving the lever This lever automatically returns to neutral position when it is released CAUTION Always move the lever 3 gently and smoothly especially when the load is raised risk of truck tipping 50 1170 801 15 09 EN ...

Page 57: ...s when the position of the forks is 30 cm from the base of the mast triggers automatic slowing of the lowering action Pull the control ﬂap until the carriage is completely lowered The progressive shutoff device for the carriage avoids the buffer being hit at the end of travel 1170 801 15 09 EN 51 ...

Page 58: ...nce of the load s centre of gravity from the back of the fork and the lift height determine the maximum lift weight Check the pallet is in good condition Nominal capacity EXG 10 1000 kg with 500 mm centre of gravity EXG12 1200 kg with 500 mm centre of gravity EXG12 1600 kg with 500 mm centre of gravity CAUTION Deterioration or destruction of the equipment Be careful not to touch adjacent loads or ...

Page 59: ... 5 Maximum capacity on the forks Adjusting the fork arm span NOTE The load centre of gravity must always be at an equal distance from each fork Move the locking lever 1 upwards Set the fork arm span according to the load to be lifted The fork arms must be the same distance from the centre line of the truck Release the opposing lock by one detent on the carriage 1170 801 15 09 EN 53 ...

Page 60: ...closely observe the following instructions before picking up loads Never touch or stand on moving parts of the truck e g lifting device pushing devices work installations or devices for picking up loads WARNING Take care not to trap hands or feet when operating the truck 54 1170 801 15 09 EN ...

Page 61: ...r to avoid dropping any part of the load Check that the width of the load is compati ble with the width of the load arms CAUTION Safety footwear must be worn Transporting people is strictly prohibited DANGER It is essential to slow down when approaching a corner or on wet ﬂoors CAUTION Do not touch nearby loads or loads positioned at the side or in front of the load being handled Arrange the loads...

Page 62: ...thdraw the load slowly and in a straight line DANGER Ensure that the pallet is in good condition before commencing any operation Transporting a load Always drive forwards for optimum visibility and with the mast tilted as far back as possible When carrying a load on a slope always climb and descend with the load uphill Never travel across the slope or make a U turn Reverse gear must only be used f...

Page 63: ...er corresponds to the weight of the moving unit DANGER Never drive with the load in the upper position It is essential to lower the forks before setting off It is essential to slow down when approaching a corner or on wet ﬂoors WARNING Transporting people is strictly prohibited Setting a load down on the ground Carefully drive the machine to the required location Carefully move the load into the u...

Page 64: ... from the ground DANGER Personnel must not stand under or near the truck when the load is in the raised position Picking up a load at a height DANGER Check that the load does not exceed the maximum capacity of the truck in relation to the lift height Check the pallet is in good condition Carefully drive the machine to the required location Tilt the mast vertically Lift the forks to the height of t...

Page 65: ...fore leaving the machine CAUTION Always stop the machine on level ground away from trafﬁc routes Lower the fork arms to the bottom position Tilt the mast as far forward as possible Switch off the ignition In the case of a prolonged shutdown press the emergency stop switch and disconnect the battery 1170 801 15 09 EN 59 ...

Page 66: ... for this purpose and for which authorisation has been received from the operator Inside the lift the truck must be immobilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be observed Anyone transported with the truck must only enter the lift after the truck has been correctly immobilised and they must exit...

Page 67: ...trans ported one by one e g pallets Transporting several loading units at once is only authorised if the safetypreconditions are fulﬁlled by order of the supervisor The operator must ensure that the loading unit is properly packed He must only move load ing units that have been carefully prepared and are safe 1170 801 15 09 EN 61 ...

Page 68: ...plications the truck must be used alternately inside and outside of the cold store It can with stand temperatures between 30 C and 45 C Speciﬁc rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room ...

Page 69: ...ent damage to the truck Parking The truck must be parked outside of the cold store Parking inside the cold store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged 1170 801 15 09 EN 63 ...

Page 70: ...connection tow bar if the truck to be towed can no longer be braked Check that the towing vehicle is sufﬁciently powerful to pull and brake the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must only be carried out by authori sed personnel Unload the fork arms disconnect the battery...

Page 71: ...he brake is then deactivated CAUTION The truck must only be towed at low speeds After towing chock the truck to prevent it from moving To re establish brake operation unscrew and remove the two screws 2 Reﬁt the covers WARNING It is essential that the covers are correctly reﬁtted before the machine is used 1170 801 15 09 EN 65 ...

Page 72: ...not stand under or near the truck when it is being lifted Do not sling the truck by the mast Check that the battery is locked in position CAUTION Deterioration or destruction of the equipment Do not sling the truck by the operating device or by the seat Lifting the pallet stacker For some maintenance work it is necessary to lift the pallet stacker Use a jack with adequate lifting capacity To lift ...

Page 73: ...ution CAUTION Deterioration or destruction of the equipment Do not tow the truck by the control unit CAUTION Deterioration or destruction of the equipment Unload the truck before towing it Removing the mast WARNING Only use slings and a hoist of sufﬁcient capacity Protect all parts coming into contact with the lifting device Attach the lifting device as illustrated This work falls exclusively with...

Page 74: ...r has stopped unplug the charger and reconnect the battery connector to the truck Close the cover on the battery compart ment Check the charge status on the truck s multifunction indicator 2 after pulling out the emergency stop switch and switching on The truck is now ready for use WARNING Risk of serious injury and or serious damage to equipment To avoid any sparks connect the battery connector b...

Page 75: ...n connecting the battery and charger connec tors do not reverse the connectors The connectors are ﬁtted with a locating device to ensure that they are connected the right way round Regularly check the presence and condition of this device 1170 801 15 09 EN 69 ...

Page 76: ...e capacity and connectors Refer to the plate on the truck for the acceptable minimum and maximum weights CAUTION The battery is a heavy fragile component which must be handled with care It is recommended to wear gloves CAUTION When the forks are descending do not place your feet below the bottom fork plate CAUTION When handling the locking system and operating the battery never place your ﬁngers c...

Page 77: ...connector Position the lifting beam 5 above the battery compartment Fix the slinging hooks 6 to the battery box Withdraw the battery Replace the battery by carrying out these operations in reverse order When handling the locking system and operat ing the battery never place your ﬁngers close to moving parts to avoid risk of trapping 1170 801 15 09 EN 71 ...

Page 78: ...its rubber buffers have been turned around carry out the following 2 adjustments 1 Battery stop adjustment 2 Buffer adjustment 1 Battery stop adjustment When ﬁtting the buffer support stop ensure that it is correctly positioned against its 2 brackets without any play 4 2 Buffer adjustment Once the buffer support stop is locked in place ensure that the buffers 3 are adjusted to the correct height t...

Page 79: ...tery is unlocked CAUTION Once the battery is unlocked it can be moved NOTE Only locking the battery correctly prevents it from being accidentally dislodged from its compartment C Locking the battery Once the battery is against the buffers 3 Lock the battery by lowering the handle 1 towards the battery cells until it reaches the stop Close the battery cover CAUTION When operating the lock and insta...

Page 80: ...han two months it must be positioned in a clean and dry area The area must be well ventilated with no risk of freezing Work prior to storage Clean the truck thoroughly Check the hydraulic oil level and reﬁll if necessary Coat any unpainted metal parts with a thin layer of oil or grease Grease all hinges and joints Check battery condition and electrolyte density Maintain the battery in accordance w...

Page 81: ... truck safety Carry out the following operations Clean the truck thoroughly Grease all hinges and joints Check the condition and density of elec trolyte and if necessary recharge the battery Check that there are no traces of conden sation water in the hydraulic oil Drain if necessary Carry out the same maintenance work as for the ﬁrst time it was commissioned Commission the truck In particular che...

Page 82: ...4 Use Putting Out of Commission and Storage 76 1170 801 15 09 EN ...

Page 83: ...5 Maintenance ...

Page 84: ... other consumables speciﬁed in these operating instructions are authorised for use during maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance speciﬁcations table Never mix different qualities of grease or oil If it is absolutely necessary to change brands make sure to ﬂush thoroughly beforehand Before changing any ﬁlters or working on the...

Page 85: ...d staff by following the manufacturer s instructions of the battery the charger and the truck It is essential to follow the battery maintenance instructions and the battery charger operating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic ﬂuid level or checking the battery electrolyte level can be carried out by ...

Page 86: ...aking Check the condition and tightening of wheels Clean and lubricate the turntable Adjust the electromagnetic brake air gap Check the brake circuit for leaks Check the wear on the tyre tread of the wheels Check the tightness of nuts Clean and lubricate the steering motor pinions Lubricate load wheel axles Lubricate the mast tilt bearing Electrical equipment Clean and blow out the electrical pane...

Page 87: ...er Blow clean and check the pump motor brushes Mast chains Checking the condition of the mast and the chain mountings Adjust the length of the mast chains Clean and lubricate the chains Lubricate the mast Check the condition and mountings of the mast protectors Final checks Make a visual inspection of the condition of and wear on the side sliding shoes Make a visual inspection of the general condi...

Page 88: ...r on the tyre tread of the wheels Check the tightness of nuts Adjust the electromagnetic brake air gap Check the brake circuit for leaks Clean and lubricate the steering motor pinions Lubricate load wheel axles Lubricate mast tilt bearings Electrical equipment Clean and blow out the electrical panel Check the tightness of the line switch power terminals Clean and blow out the controller power term...

Page 89: ...Change the pressure ﬁlter Draining the main lift circuit Replace the breather plug Blow clean and check the pump motor brushes Final checks Make a visual inspection of the condition of and wear on the side sliding shoes Make a visual inspection of the general condition of the chassis and the forks Resetting the maintenance intervals to zero on the multifunction display Test driving the truck 1170 ...

Page 90: ...tem EXG 10 EXG 12 EXG 16 tilt pressure 160 bar Transmission gear Transmission gear oil 1 5 l Drive wheel Wheel nuts Tightening torque 140 Nm Load wheels Mounting screws Tightening torque 50Nm Traction and pump motor Fuses Power 250 A Quantity 1 Steering motor Fuses Power 80 A Quantity 1 Control cable harness Fuses Control 7 5 A Quantity 1 Cold store control cable harness Fuses Control 10 A quantit...

Page 91: ...recommended can cause damage that may be expensive to rectify Transmission gear oil Extreme pressure oil for mechanical transmis sion SAE 80W90 compliant with speciﬁca tions API GL5 and MIL L21DSC Aerosol can for chains Manufacturer s reference no 7326300602 For cold stores 7326300615 Grease for pinion gear and steering ring Aerosol can silicone grease 600 ml Refer ence no FM 8 107 219 CAUTION Det...

Page 92: ...arts supplied with voltage must only be carried out by qualiﬁed personnel who have received detailed instructions and have been authorised to perform this work They must take the required precautionary mea sures Rings metal bracelets etc must be removed before carrying out any operations on electrical components To avoid damaging electrical equipment including electrical components such as the tra...

Page 93: ...age to equipment The brake motor cables and other electrical components may be very hot Opening the engine cover Unscrew the 2 screws 1 which hold the cover in place Pull the cover 2 backwards Lift off the cover 2 and place it on the ground To close it place the tab 3 inside the chassis Tighten the 2 cover 2 screws 1 Removal of the dashboard Remove the front hood 2 Unscrew the 2 screws 3 which hol...

Page 94: ...rd The ﬂexibility of the dashboard 4 makes it easy to remove from the chassis Remove the tiller housing Remove the front hood 2 Remove the dashboard 4 Unscrew the 2 screws ﬁxing the housing 8 to the chassis The tiller housing 8 is freed Remove the tiller to free the housing com pletely 88 1170 801 15 09 EN ...

Page 95: ... and clean the mast protective screens if necessary Standard lifting mast OPERATION When lifting the inner strut the return pulley of the chain is also raised in such a way that the fork carriage is lifted at a ratio of 2 1 Safety device for the standard lift mast WARNING Risk of serious injury and or serious damage to equipment Choose a chain whose strength is far greater than the weight of the m...

Page 96: ...inner strut is lifted by the two side cylinders and brings the fork carriage with it The centre cylinder is mounted on the inner mobile strut Safety device for the Duplex lift mast WARNING Risk of serious injury and or serious damage to equipment Choose a chain whose strength is far greater than the weight of the mast Lift the mast Connect the chain after passing it over the cross member of the ﬁx...

Page 97: ...ted in the inner mobile mast Safety device for the Triplex lift mast DANGER Danger of death and or risk of serious damage to equipment Select a chain whose lifting strength is suitable for each type of mast Observe the maximum recommended elevations Raise the mast Connect the chain after passing it over the cross member of the outer mast 4 and under the cross member of the centre mast 3 Lower the ...

Page 98: ...tioned above must be follo wed to prevent sparks which could cause a short circuit remove the battery connector All compo nents that are sensitive to moisture particularly electrical components must be protected if the truck is to be cleaned Follow the manufacturer s instructions when using the cleaning product Clean the truck with a cleaning product mixed with water Use a sponge and cloths Speciﬁ...

Page 99: ...essed air for example Start the truck in accordance with the instructions If there are still traces of moisture in the motor despite the precautions taken dry it using compressed air clean and dry otherwise there is a risk of short circuit ONLY then may the truck be switched back on and returned to service while preventing any corrosion 1170 801 15 09 EN 93 ...

Page 100: ... the case and the chassis If there is only minimal sulphate build up just wipe the top of the cells with a damp cloth If sulphate build up is heavy you will need to take out the battery jet wash it and clean the frame Battery in sealed compartment Check that there is no electrolyte in the bottom of the compartment by connecting the rubber suction bulb supplied with the battery to the plastic plung...

Page 101: ...t if necessary then dry with compressed air Lubricate the pinion gear and the turntable with silicone spray see recommended lubricants NOTE There is a risk of dust clogging if non recom mended products are used CAUTION Deterioration or destruction of the equipment Always disconnect the battery connector when carrying out maintenance on the pinion gear and the turntable The wearing of gloves is rec...

Page 102: ...ate an explosive mixture Do not create sparks do not smoke and keep naked ﬂames away from a battery which is being charged or has recently been charged To prevent the accumulation of hydrogen keep the battery cover open during charging Charge the battery in a well ventilated room Do not place metal objects on the battery there is a risk of creating a short circuit Before using the truck check to e...

Page 103: ...cover to the 4 horizontal position using its handle CAUTION The cover is rather heavy and must be handled with care The wearing of gloves is recommended CAUTION Keep ﬁngers away from moving parts to avoid any risk of them being trapped NOTE It is possible to remove the cover 5 after opening it fully Release it vertically for easy access to the battery components NOTE A hook 6 makes it possible to ...

Page 104: ...ION Deterioration or destruction of the equipment It is essential to remove any wire that may have wound round the wheel hubs and bearings Wheel tightness Raise the truck so that the wheels are off the ground and carefully support the machine on suitable blocks Remove the front hood Check the tightness of the nuts on the drive wheel torque setting 140 Nm Check the tightness of the mounting screws ...

Page 105: ... fully and a risk of overheating If the air gap is close to the limit value of 0 5 mm it must be adjusted To do this it is necessary to Tilt the tiller support backwards Loosen the three mounting screws 3 Adjust the three banjo bolts 4 to set the air gap to its original value of 0 25 mm Retighten the three mounting screws 3 Check the air gap at three points at 120 intervals Make sure that the air ...

Page 106: ...re Do not create sparks do not smoke and keep naked ﬂames away from a battery which is being charged or has recently been charged To prevent the accumulation of hydrogen keep the battery cover open during charging Charge the battery in a well ventilated room Do not place metal objects on the battery as there is a risk of creating a short circuit Electrical equipment testing electrolyte level and t...

Page 107: ...tery 1 14 High density battery 100 charged 1 29 to 1 32 depending on manufacturer We recommend that you measure this every 1 to 2 weeks Note the values in your battery log book Lift the cap cover of each element as shown above Carefully measure the density of each element with the acidometer Replace the caps after taking the measure ment NOTE If the density in the cells differs or it is very low i...

Page 108: ...or or there is a risk that electronic components may be damaged Always use male and female battery connectors of the same brand CAUTION Deterioration or destruction of the equipment The points mentioned above can cause serious incidents Request assistance from our service engineers as quickly as possible Electromagnetic brake checking the brake assistance circuit for leaks Inspect the brake assist...

Page 109: ...ntenance every 1000 hours Lubricating the load wheel axles and mast tilt bearings Lubricate the 2 grease nipples on the load wheel axles 1 Lubricate the 2 grease nipples on the mast tilt bearing 2 1170 801 15 09 EN 103 ...

Page 110: ...pressed air Check that the connector pins of the cables are properly ﬁtted If necessary tighten the power terminals on the motors and switches IMPORTANT When repositioning the electrical plate push the cables well back to avoid trapping them NOTE Protect the electrical plate from moisture All adjustments and repairs must be carried out by our service engineers We recommend that you entrust this op...

Page 111: ...rminals 9 Nm Tightening torque for cables at the steering regulator terminals 5 Nm Tightening torque for cables at the switch terminals 9 Nm CAUTION Always disconnect the battery connector before working on an electrical component Electrical equipment testing and cleaning the fan Disconnect the battery connector Remove all material clogging the grilles beneath the truck Using a compressed air gun ...

Page 112: ...ing the cooling ﬁns Unplug the battery connector Open the technical compartment cover Blow the motor 1 with compressed air Check for signs of overheating at the power supply cable connections Check that the connections are tight 106 1170 801 15 09 EN ...

Page 113: ...e length of the mast chains NOTE Depending on the use of the truck the chains are liable to stretch and as a result they have to be adjusted regularly Lower the mast completely Undo the lock nut 2 Place the chains under slight tension by tightening the nut 1 Retighten the lock nut 2 CAUTION Deterioration or destruction of the equipment After this adjustment check that the lift carriage does not re...

Page 114: ...e equipment Chains are safety components Use of cold clea ning agents chemical products acid or chlorinated products could destroy the chains NOTE Use of high pressure liquid cleaning devices is not advisable DANGER Danger of death and or risk of serious damage to equipment On trucks ﬁtted with macrolon mast protection clean the translucent screen thoroughly after lubrication operations Lubricatin...

Page 115: ... to inspect the condition of the mast protection screens and to check that the mountings are tightened WARNING Risk of serious injury and or serious damage to equipment Keep hands away from moving parts and assem blies without ﬁrst lowering the equipment to the ground and disconnecting the battery 1170 801 15 09 EN 109 ...

Page 116: ...rioration or destruction of the equipment Only use hydraulic oil that complies with the speciﬁ cations see recommended lubricants Checking the system for leaks Inspect the hydraulic system Pipes Hoses and connections between the pump unit and the cylinders Tighten the connections if necessary Check that the hoses are attached correctly and show no signs of friction wear If you ﬁnd a leak please co...

Page 117: ...y ﬁt the new ﬁlter and O ring see illustration Tighten the plug 1 to a torque of 70 Nm Adjusting the main pressure cut off 2 Remove the safety plug 6 Unscrew the locknut 4 Adjust the pressure of the pressure cut off using an Allen key 5 To increase the pressure cut off setting turn the key 5 clockwise To lower the pressure cut off setting turn the key 5 anti clockwise When the pressure cut off set...

Page 118: ...5 Maintenance Maintenance every 1000 hours NOTE This operation must only be carried out by a person authorised by our network 112 1170 801 15 09 EN ...

Page 119: ...smission gear oil level Remove the front hood Turn the wheel to access the level plug 1 Unscrew the plug 1 the oil should just touch the bottom of the bore Top up if necessary Tighten the plug Check for signs of leakage around the seals and wheel shaft 1170 801 15 09 EN 113 ...

Page 120: ... Rotate the motor to access the desired brush 2 Lift the brush pressure springs 3 Remove the brushes 2 from their guide Change the brushes NOTE Do not ﬁt new brushes to a worn commutator 5 Draining the oil from the circuit Lower the forks to the ground to eliminate pressure in the hydraulic system Switch off the ignition and unplug the battery connector Use the vacuum drainage kit Remove the breat...

Page 121: ...he breather ﬁlter Tighten the plug Operate the lifting mechanism several times and bleed the circuit using the screws provided on the lift cylinders CAUTION Deterioration or destruction of the equipment Only use hydraulic oil that complies with the speciﬁ cations see lubrication table 1170 801 15 09 EN 115 ...

Page 122: ...l to provide access to the drain and level plugs 1 2 Place a container under the transmission gear Unscrew the level plug 2 Unscrew the magnetic drain plug 1 Drain the transmission gear oil Clean and screw the magnetic drain plug back in after ﬁtting a new gasket FILLING Fill the reducer through the top opening 2 up to the lower edge of this opening Screw the level plug 2 back in 116 1170 801 15 0...

Page 123: ...6 Technical data ...

Page 124: ...6 Technical data Technical Data Sheet EXG 10 12 16 Technical Data Sheet EXG 10 12 16 118 1170 801 15 09 EN ...

Page 125: ...ns mm 254 x 102 3 3 Front rear wheel dimensions load side mm 4 85 x 105 3 5 Number of front rear or drive side load side wheels 1 x 4 3 7 Rear track width load side mm 483 DIMENSIONS EXG16 EXG12 EXG10 4 1 Mast fork tilt front rear a b 1 6 4 9 Height of tiller in driving position min max h14 mm 1103 1287 4 15 Height of forks when lowered h13 mm 46 41 41 4 19Total length l1 mm 2920 2550 2550 4 20Len...

Page 126: ...itesse de levée avec sans charge m s 0 11 0 23 5 3 Vitesse de descente avec sans charge m s 0 29 0 39 5 10 Service brake Electromagnetic DRIVE EXG16 EXG12 EXG10 6 1 Traction motor 60 minutes kW 3 6 2 Lift motor 15 kW 3 6 3 Type de batterie selon la norme DIN 43 531 35 36 A B no 4 5 PzS SV 4 PzS SL 3 4 PzS SV SL 3 4 PzS SV SL 6 4 Voltage et capacité 5h de la batterie V Ah 24 6 5 Poids de la batteri...

Page 127: ...axle load unladen 785 880 840 kg Load bearing axle load unladen 550 620 590 kg Drive axle load laden 2535 2640 2595 kg Load bearing axle load laden 523 373 423 mm Free Space FS load chassis EXG 12 mast 2924D with tilt Non stan dard 80 X 40 1000 80 X 40 1000 80 X 40 1000 Non stan dard Forks 1930 1861 2035 1958 kg Weight in running order 1125 1099 1180 1144 kg Drive axle load unladen 805 762 855 814...

Page 128: ...6 Technical data Loads per axle SA Side Access Note Apron ISO 2B width 800 mm 122 1170 801 15 09 EN ...

Page 129: ...Free lift mm 150 150 150 150 150 879 1129 1379 1579 1829 1129 EXG12 Mast type 1924S 2424S 2924S 3324S 3824S 4224S h3 Lift mm 1924 2424 2924 3324 3824 4224 h3 h13 Lift fork height mm 1965 2465 2965 3365 3865 4265 h1 Mast height HT retracted mm 1515 1765 2015 2215 2465 2665 h4 Mast HT height extended mm 2485 2985 3485 3885 4385 4785 h2 Free lift mm 150 150 150 150 150 150 EXG12Mast type 1924D 2424D ...

Page 130: ...15 1765 2015 2215 2465 2665 h4 Mast HT height extended mm 2405 2905 3405 3805 4305 4705 h2 Free lift mm 150 150 150 150 150 150 EXG16 Mast type 1844D 2344D 2844D 3244D 3744D 4144D 3516T 4266T h3 Lift mm 1844 2344 2844 3244 3744 4144 3516 4266 h3 h13 Lift fork height mm 1890 2390 2890 3290 3790 4190 3562 4312 h1 Mast height HT retracted mm 1440 1690 1940 2140 2390 2590 1690 1940 h4 Mast HT height e...

Page 131: ...st 71 Changing the drive direction 46 Changing the hydraulic pressure ﬁlter 111 Changing the PIN code in digicode mode 40 Checking the condition and mountings of the mast protectors 109 Checking the condition of mast mounting and its chains 107 Checking the control modules 105 Checking the horn 43 Checking the steering geared motor pinion turntable 95 Checking their connections 105 Checks prior to...

Page 132: ...Hazards and countermeasures 10 Hydraulic diagram with mast tilt 136 Hydraulic diagram LLC SLI 134 Hydraulic ﬂuid 22 Hydraulic oil 85 Hydraulic system Checking the oil level 110 Checking the system for leaks 110 Cleaning the breather plug on the hydraulic tank 110 Hydraulic systems 110 114 I Identiﬁcation label 32 Insurance cover on company premises 18 L Lifting the pallet stacker 66 Load handling ...

Page 133: ...ngs by the service engineer 38 Side access battery selection of battery compartment opening side 72 Side access battery unlocking locking the battery 73 Slinging the truck 66 Slinging lifting towing and removal of the mast 66 Special risks 9 Specialist 16 Speciﬁc mast maintenance 107 Stacking a load 58 Standard lifting mast 89 Start up 45 Starting the truck using the digicode 36 Starting the truck...

Page 134: ...rding non original parts 18 Washing the outside of the truck 92 Wheels Checking that the wheels are tightened 98 Checking the condition of the wheels 98 Working on the lift mast 89 Working with loads 55 128 1170 801 15 09 EN ...

Page 135: ......

Page 136: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 1170 801 15 09 EN ...

Page 137: ...Original instructions Counterweight pallet stacker EXG 10 EXG 12 EXG 16 1217 1218 1219 1170 801 15 09 EN 07 2012 Annex ...

Page 138: ......

Page 139: ...7 Diagrams ...

Page 140: ...7 Diagrams Hydraulic installation Hydraulic installation Proportional control Without Initial Lift M LP S B 100µm T 2Y3 2Y11 1 2 5 7 8 9 14 15 18 19 20 22 37201_07 001 P 7B7 4 134 1170 801 15 09 EN ...

Page 141: ...m 7 Proportional lowering solenoid valve 2Y3 8 Pressure balance linked to the proportional solenoid valve 9 Load retainer solenoid valve 2Y11 14 Safety valve with diaphragm Ø 1 2 mm 15 Non return valve 18 Filter cartridge 20 µm 19 Main pressure relief valve set at 240 bar 20 Pump 22 Hydraulic tank 1170 801 15 09 EN 135 ...

Page 142: ...raulic installation Hydraulic diagram with mast tilt T 100µm 2Y3 2Y13 S LP B LI 2Y11 4 2 2Y20 2Y21 3 1 1 2 3 2Y5 LP S B 100µm T 2Y3 2Y11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1170 07 001 136 1170 801 15 09 EN ...

Page 143: ...ked to the proportional solenoid valve 7 Load retainer solenoid valve 2Y11 8 Non return valve 9 Safety valve 10 Diaphragm Ø 1 2 mm linked to the safety valve 9 11 Main pressure cut off 12 Pump 13 Hydraulic tank 14 Filter cartridge 20 µm 15 Filler plug ﬁtted with a breather ﬁlter 16 Needle solenoid valve 2Y5 17 Mast tilt solenoid valve 2Y20 2Y21 18 Tilt cylinder 1170 801 15 09 EN 137 ...

Page 144: ...0 Traction motor temperature gauge 61 Wheel position setting 62 Full lift authorisation 64 Inclinometer 68 Power supply to potentiometers 1B1 and 2B4 69 Power supply to speed sensor 1B2 3A1 Steering controller LES 1 Control card supply 2 Supply to setting potentiometer 3B2 3 Setting track 1 potentiometer 3B2 4 Setting track 2 potentiometer 3B2 5 Channel A speed sensor 6 CAN 2 high steering 7 CAN 2...

Page 145: ...nnector Y1 7X7 Pressure cut off connector 7X9 Control circuit opening connector 9X3 Cold store connector 9X6 Additional technical compartment hy draulic connector 9X7 Mast chassis link connector 9X11 Fan connector Y1 Electromagnetic brake 2Y3 Proportional solenoid valve 2Y5 Switching solenoid valve 2Y11 Load retaining solenoid valve 2Y13 Booster solenoid valve 2Y20 Mast tilt solenoid valve 2Y21 Ma...

Page 146: ...7 Diagrams Electrical installation 140 1170 801 15 09 EN ...

Page 147: ...2 1 35 35 3 U V W U V W 25 25 25 7 7 7 Li 1A1 1M1 2M1 1 2 3F1 3K1 4 3A1 M1 2 5 2 5 3M1 M2 BK RD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 L 4 RD BK L A WH 1 5 OG 621 0 5 35 35 30 40 BK 82 1 5 C 1 2 3 117000_06 002 1170 801 15 09 EN 141 ...

Page 148: ...7 Diagrams Electrical installation 142 1170 801 15 09 EN ...

Page 149: ... 29 BU 308 BU 329 1 5 14 WH 305 WH 314 16 27 BN 327 WH 316 6 WH 306 BN 307 7 BN 702 WH 701 BK 704 RD 703 RD 301 1 1 RD 318 1 18 RD 319 1 19 BU 328 28 BU 303 3 BU 320 20 BU 304 4 BU 302 2 BK BN WH BU WH BU 3B2 GN RD YE BK BU 330 3K1 BU 335 3B3 BU 313 BU 322 13 BU 312 12 21 22 BU 321 4 1 3X3 2 3 RD 310 9 10 BU 309 BK 704 6X7 4 L 7 WH 43 BN 44 6 BK 603 3 L 6X2 1 5 OG 601 RD 605 6P4 24 V 6X2 2 BK 602 ...

Page 150: ...7 Diagrams Electrical installation 144 1170 801 15 09 EN ...

Page 151: ...Diagrams 7 Electrical installation Mast tilt option EXG10 EXG12 EXG16 1170 801 15 09 EN 145 ...

Page 152: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 1170 801 15 09 EN ...

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