Still GX-X Original Instructions Manual
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Still GX-X Original Instructions Manual

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

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  • Page 1 Original instructions GX-X, GX-Q Turret truck 2201 5220 804 2501 EN - 12/2012...

  • Page 3: Table Of Contents

    Table of contents Foreword General ............2 EC declaration of conformity in accordance with Machinery Directive .
  • Page 4 Table of contents Functions ............28 Operation Commissioning .
  • Page 5 Table of contents Maintenance Fuses ............60 Servicing - General .

  • Page 7: Foreword

    Foreword...

  • Page 8: General

    Foreword General General Our industrial trucks comply with applicable European regulations. Any other applicable country-specific regulations or operating conditions for the use of industrial trucks must also be observed. The aim of this manual is to inform you about how to safely handle your industrial truck and how to keep it operational.

  • Page 9: Ec Declaration Of Conformity In Accordance With Machinery Directive

    Foreword EC declaration of conformity in accordance with Machinery Directive EC declaration of conformity in accordance with Machinery Di- rective Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 10: Safety Instructions

    Foreword Safety instructions Safety instructions Explanations of the terms used in this manual: DANGER There is the risk of fatality to the operator. The procedures indicated should be complied with in full in order to avoid this danger. WARNING There is a hazard that could cause major damage to property or to the health of the operator.

  • Page 11: Truck Identification, Factory Nameplate

    Foreword Truck identification, Factory nameplate Truck identification, Factory nameplate The nameplate is fitted in the area of the driving seat and contains the following details: Factory nameplate CE symbol. The CE symbol confirms that Nominal loading capacity the EU machine guidelines and all the Unladen weight relevant guidelines, which are valid for this Battery voltage...

  • Page 12: Product Support Documentation

    Foreword Product support documentation Product support documenta- tion This includes: • Spare parts list • Operating and maintenance manual • VDMA (German Engineering Federation) information booklet on proper usage • Any additional documentation for the driver’s seat • Any additional documentation for an attach- ment •...

  • Page 13: Safe-Keeping And Passing On

    Foreword Safe-keeping and passing on Safe-keeping and passing on • These operating and maintenance instruc- tions must be kept safely so that the opera- tor always has access to them. • Documents can be ordered retrospectively. Please give the ID or the order number. •...
  • Page 14 Foreword Operator, form of address • The ergonomic conditions may be less favourable. For example, it may not be possible to reach pedals such as the accelerator and brake pedals, the overhead guards might be too low or the adjustment ranges for the steering wheel and seat may no longer be sufficient.

  • Page 15: Safety

    Safety...

  • Page 16: General Safety Advice

    Safety General safety advice General safety advice • All personnel must be kept clear of the working area (danger zone) of the truck. Should anyone enter the working area, all truck movements must be brought to an immediate standstill and the person instructed to vacate the area.

  • Page 17: General Safety Information

    Safety General safety information General safety information • Essentially, all safety information located on the truck must be observed. • Missing or illegible safety information is to be changed. • When cornering and driving past parts of buildings that restrict visibility, use the horn to warn others that the truck is approaching.

  • Page 18: Non-Ionising Radiation

    Safety Non-ionising radiation Non-ionising radiation WARNING Risk of injury Persons with active or non-active medically implan- ted devices must take it upon themselves to ensure that they are not exposed to dangerous electroma- gnetic radiation. The table below indicates the limit values for the maximum electric field strength of the electromagnetic radiation emitted by this truck.

  • Page 19: Special Safety Advices For Engaging Loads

    Safety Special safety advices for engaging loads accordance with the Directive 2002/44/EC by the operating company at the actual place of use, in order to consider all additional influences, such as driving route, intensity of use etc. Special safety advices for engaging loads Discuss this with your contractor.

  • Page 20: Safe Handling Of Operating Media

    Safety Safe handling of operating media Safe handling of operating media The following operating media are used in this truck: • Gear oill • Hydraulic oil • Battery acid The handling of these materials is governed by comprehensive safety regulations. The most important points include: For gear and hydraulic oil DANGER...

  • Page 21: Risk Assessment

    DANGER Danger of explosion – When charging batteries, an explosive gas mixture can be generated which can still remain present for a long period after completion of the charging process. Ensure adequate ventilation. – Within a 2 metre area of charged batteries, smoking, fires and open flames are strictly...

  • Page 22: Residual Dangers

    Safety Residual dangers Residual dangers Despite adherence to all valid safety regula- tions relating to the design and construction of our trucks and irrespective of correct operation by the user, a certain danger element does re- main. Any such possible hazards are referred to in the individual chapters where relevant.

  • Page 23: Original Parts

    Safety Original parts 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 conducive to corro- sion – in atmospheres containing large amounts of dust –...

  • Page 24: Personal Protective Equipment

    Safety Personal protective equipment Please check whether a driver permit is required to operate this truck in your country. You as the operator are responsible for this. We recommend that you contact your branch or specialist representative. These will be able to offer you the relevant training and tests to obtain your driver permit.

  • Page 25: Overview

    Overview...

  • Page 26: View Of The Truck

    Overview View of the truck View of the truck Lift mast Drive-side antenna for inductive guidance Lift cylinder Sensor system for aisle detection Steps Turret head Driver’s seat Load wheel Steering wheel Guide rollers for mechanical guidance MZF Overhead guard post and objects for holding Battery lock onto when entering and exiting Battery...

  • Page 27: Display And Operating Panel

    Overview Display and Operating panel Display and Operating panel Display field for truck operating status A selection can be made for retrieval by Key "P3", no function. If equipped with the using the up arrow button and/or with the option PIN-Code* for keying in the figure 1. "fork cycle/height preselection without Sensor for the automatic display brightness automatic load detection"...
  • Page 28 Overview Display and Operating panel Selection key for additional hydraulic func- Selection key for additional hydraulic func- tion (e.g. fork adjustment, single fork posi- tion (e.g. fork adjustment, single fork posi- tioner, side shift limitation). tioner, side shift limitation) *Option 5220 804 2501 [EN]...

  • Page 29: Displays

    Overview Displays Displays General display Parking brake active Horizontal positioning* Speed limitation: display lights up: 2.5km/h, Height preselection displays* display flashes: 1.0km/h Display field Steering angle and drive direction IZF* active Manual steering Additional hydr. functions* Battery discharge indicator Enabling required MPSE mode or error Battery lock* IZF* wire search...
  • Page 30 Overview Displays Response: Driving speed restricted to 2.5 km/h, main lift lifting deactivated, auxiliary lift lifting deactivated Possible cause: Battery charge < 20% Remedy: Charging the battery Info 2 Description Emergency off switch actuated. Response: Drive stop, hydraulic stop. Possible cause: Emergency off switch actuated.
  • Page 31 Overview Displays Info 7 Description Drive profiles programming mode. Response: The battery discharge indicator segments in the display are flashing. Possible cause: "Driver profiles" mode was activated by pressing the two arrow buttons in the display for longer than 4 sec. Remedy: Press Enter.
  • Page 32 Overview Displays Possible cause: Remedy: Info 13 Description With inductive guidance (optional): inadmissibly switched from AUTO to MANUAL in the aisle. Response: After 3 seconds, drive stop. Possible cause: Inadmissibly switched from AUTO to MANUAL in the aisle. Remedy: Shift to AUTO. The truck can be driven at 1 km/h if the enable button is pressed.

  • Page 33: Purpose Of Use

    Overview Purpose of use Purpose of use Turret trucks are designed for use in very narrow aisles. They are used for placing complete loading units such as boxes or pallets into stock and removing them from stock. In the aisle, the turret trucks are guided mechanically or inductively.

  • Page 34: Functions

    Overview Functions Functions NOTE You will find information about how to operate the individual functions in the corresponding chapters. Driving Converter controller with reversing gear (AC motor). The position of the accelerator pedal deter- mines the driving speed, as it does in other vehicles.
  • Page 35 Overview Functions In the event of a power failure or defect, immediate braking via the spring loaded brake on the traction motor. Lifting system Different lift mast variants can be installed according to the order. See the order papers for the variant and dimensions. Driver’s compartment ergonomics The position of the driver’s seat can be adjusted so that the driver’s compartment...
  • Page 36 Overview Functions 5220 804 2501 [EN]...

  • Page 37: Operation

    Operation...

  • Page 38: Commissioning

    Operation Commissioning Commissioning Commissioning If the vehicle is delivered only partially assem- bled, ensure before commissioning that the whole truck has been professionally assem- bled. All hydraulic and electrical connections have to be checked. The connections, which must be disassembled for shipping should be reassembled carefully.
  • Page 39 Operation Commissioning Hooking on the chassis 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 the two posts on the overhead guard and the post between the load wheels.

  • Page 40: Installing The Battery

    Operation Commissioning Hooking on the horizontal lift mast If the lift mast has to be crane-loaded in a horizontal position, suitable shackles should be used in the indicated bores at the top end of the mast. At the lower end, a textile strap can be wound around the cross web in the beam support of the sideshift.
  • Page 41 Operation Commissioning WARNING Risk of explosion For newly charged batteries in particular, be aware of the risk of explosion in the gassing area. The openings in the gassing area of the battery must not be covered or fully closed. An unrestricted air supply is required to prevent the formation of potentially explosive gas mixtures.
  • Page 42 Operation Commissioning NOTE Gel batteries are subject to special char- ging/maintenance/handling instructions. The guidelines from the respective manufacturer must be observed. CAUTION Risk of damage to property Incorrect battery chargers can cause total battery failure. Commissioning If your truck is equipped with a Euro battery male connector, make sure that the voltage index pin is in the correct position.

  • Page 43: Battery Lock

    Operation Commissioning CAUTION Risk of short circuit Do not clamp or crush battery cables. Battery replacement The battery rests on roller channels as stan- dard and can be installed and removed from the side using a crane or a suitable truck. The battery can optionally be replaced using an optional battery change frame.
  • Page 44 Operation Commissioning The battery is held in position by a swing bolt . By actuating the turning handle, the swing bolt is pressed against the battery , securing the battery so that there is no play. Releasing the swing bolt •...

  • Page 45: Battery Discharge Indicator

    (1). As the capacity decreases, these go out one after another. If the permissible discharge depth of 80% is reached, only the last segment still flashes. This indicates that the lift cut out has been reached. Symbol (2) indicates that the battery lock is open.

  • Page 46: Daily Commissioning

    Operation Daily commissioning Daily commissioning Checklist before starting work CAUTION If defects that could influence operational and road safety are determined during the daily pre-shift- checks, measures must be taken immediately to ensure that proper repairs are carried out. It is prohibited to continue operation of the truck until the repairs have been made.
  • Page 47 Operation Daily commissioning Check the access control • The key must be able to be removed and it must not be possible to operate the truck when the key is in the O position or when it is removed. • In electronic access control*: in the event of access being blocked, the truck must not able to be operated.

  • Page 48: Control Devices

    Operation Control devices Control devices Entering and leaving For safe entering and leaving the truck use the steps (3). For easier entering the support of the over- headguard (1) may be grabed with the left hand. Optionally the truck can be equipped with an additional handle (2).
  • Page 49 Operation Control devices • The switches are all functioning correctly. • The parking brake has been released. NOTE The parking brake is released as soon as the accelerator pedal is actuated slightly. Trucks with two accelerators pedals (dual- pedal controller) The hydraulic functions are only enabled if: •...
  • Page 50 If the switch is not actuated at least once within 8 hours, the controller assumes there is a defect and issues this message: • Info 10 If the message is still displayed after the switch has been pressed once, call the service department. 5220 804 2501 [EN]...

  • Page 51: Setting The Display Brightness

    Operation Control devices Setting the display brightness The brightness of the display is adjustable. – Switch on the truck. – Keep the programming button (1) pressed down for a minimum of 6 seconds. The display P1 -P2- P3 (7) appears. –...

  • Page 52: Switching The Display

    Different information can be displayed at any time by switching the display. To do this, the corresponding button must be pressed briefly. The setting is still saved after the truck is switched off. • Display operating hours: briefly press button (1). Displayed at (5).
  • Page 53 Operation Driving Initial driving practice WARNING Danger of accidents In order to become familiarised with the driving and braking characteristics of this truck, driving exercises must first be carried out in a flat, obstacle- free area of the warehouse. Switching on the control Connect the battery coupling (1).

  • Page 54: Pedal Operation

    Operation Driving Setting the steering column CAUTION Danger of accidents All settings are to be performed at standstill of the truck only. Unscrew the clamping screw, (5)bring the steering column into the required position and tighten clamping screw (5). Check that it is tightly screwed in.
  • Page 55 Operation Driving Foot switch If none of the pedals are actuated or all pedals Brake pedal are released while the truck is in motion, the Accelerator pedal truck brakes to a standstill immediately. 5220 804 2501 [EN]...

  • Page 56: Joystick Functions

    Operation Driving Joystick functions The joystick can be used for accurate and continuously variable control of all hydraulic movements. Jerky movements are to be avoided as they can cause unnecessary impacts and pulses. Electronic monitoring can prevent operating errors to a large extent. Selecting the load side drive direction Selecting the drive side drive direction Lifting the fork with the main lift...

  • Page 57: Mechanical Guidance Mzf

    Operation Driving Mechanical guidance MZF Mechanical guidance consists of one or two rails, on or between which the truck is guided with a maximum permissible play of 5 mm. For automatic guidance, the controller automatically adapts the maximum possible driving speed to suit the lift height. Entering the aisle In order to enter rail guidance, the truck is to be positioned as centrally as possible and...

  • Page 58: Load Pick-Up

    Operation Load pick-up Changing the aisle If the truck is to be driven out of one aisle and into another, the following notes must be observed: – Drive the truck completely out of the aisle. – Drive out of the aisle slowly and beware of any people or other trucks in the transfer aisle.

  • Page 59: Adjustable Forks

    Operation Load pick-up Load capacity diagram The load capacity specified on the load capacity diagram (1) is dependent on the configuration and can therefore vary from truck to truck. The load capacity diagram and the load capacity restrictions indicated for certain application conditions must be observed without fail so that stability of the truck is not impaired.

  • Page 60: Parking And Leaving The Truck

    Operation Emergency operation NOTE Ensure that the fork arrest mechanism is always latched in place and that the lateral fork safeguard (2) is mounted and in correct working order. Otherwise the fork could be pushed off the load carriage as a result of lateral forces and fall to the ground.
  • Page 61 Operation Emergency operation In order to avoid strong lateral tension and • thus the risk of tilting, take all corners as wide as possible. The driver of the towing vehicle must use • particular foresight, respond in good time and avoid sudden braking actions. Mechanical brake release The magnetic brake is located under the cover below the driver’...

  • Page 62: Retrieving The Truck

    Emergency operation Retrieving the truck Towing with functioning steering. If the truck’s steering still functions and the brake is released, the truck can be towed either with a rope or with the tow bar. Towing off with steering system out of...

  • Page 63: Parking And Decommissioning The Truck

    Operation Parking and Decommissioning the truck Lashing points for towing Lashing points mast side: Loop around the frame of the side shift. Lashing points driver’s seat side: Loop around the spars of the driver’s overhead guard. Parking and Decommissioning the truck Decommissioning ENVIRONMENT NOTE If the truck described here has to be decom-...
  • Page 64 Operation Parking and Decommissioning the truck 5220 804 2501 [EN]...

  • Page 65: Maintenance

    Maintenance...

  • Page 66: Fuses

    Maintenance Fuses Fuses CAUTION Risk of short circuit, risk of electric shock Before carrying out any work on the electrical system, disconnect the battery female connector to remove the power supply to the system. Fuses of certain sizes and types must always be exchanged for identical versions.

  • Page 67: Servicing - General

    Maintenance Servicing - General Servicing - General WARNING – Appropriate precautions for safe working must be made for all servicing work. – As well as the usual occupational safety guideli- nes, the safety notes specifically outlined in this brochure must also be adhered to. –...

  • Page 68: Maintenance Plan

    Maintenance Maintenance plan Maintenance plan This maintenance schedule is valid for normal loading during single-shift operation. For heavy-duty and/or multi-shift operation, the intervals must be reduced accordingly. Please observe the information in the section entitled Area of application. *option Maintenance every six months or every 1000 hrs Drive unit •...
  • Page 69 Maintenance Maintenance plan Brake • Check the function of the foot switch. • Check seat switch function. • Check the function of the reverse brake. • Check the thickness and condition of the brake lining and replace if necessary. • Check the brake release clearance, (0.4–1.0 mm).
  • Page 70 Maintenance Maintenance plan • Check the function and condition of the stops and limit stop*. • Check the mounting and bearing points of the lift cylinders for good condition. • Check the chain condition, wear, elonga- tion, damage, lubrication and tension. For correct conversion, the information in the corresponding test documents must be ob- served.
  • Page 71 Maintenance Maintenance plan • Check the condition of the contactors and for erosion, replacing if necessary. • Check the fuse values and condition. NOTE Battery maintenance is not part of the truck maintenance and must be carried out in accor- dance with the guidelines from the respective battery manufacturer.
  • Page 72 Maintenance Maintenance plan • Lubrication in accordance with the lubrica- tion plan. Maintenance is annual or every 2000h A regular safety inspection must be performed by an expert in accordance with the factory regulations. The corresponding national guidelines must also be observed. 5220 804 2501 [EN]...

  • Page 73: Lubricants

    Maintenance Lubricants Lubricants CAUTION Risk of damage to property. Trucks used in refrigerated environments must be lubricated using different lubricants. Please observe the operating instructions refrigerated warehouse trucks. The following lubricants must be used: Hydraulic system • HLP DIN 51524/T2 •...

  • Page 74: Battery Check

    Maintenance Battery check • Apply a film of grease to the bearing sur- faces of the lift mast profiles to prevent corrosion. • Change the gearbox oil after the first 1000h and then every 12 months or every 2000h. Every 2000h or every 12 months •...
  • Page 75 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. 5220 804 2501 [EN]...
  • Page 76 Maintenance Battery check 5220 804 2501 [EN]...
  • Page 77 Technical Data...

  • Page 78: Technical Data

    Technical Data Technical data Technical data The technical data 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 68dB(A) 5220 804 2501 [EN]...

  • Page 79: Optional Equipment

    Optional Equipment...
  • Page 80 Optional Equipment Inductive guidance IZF System description A frequency generator supplies AC to a wire installed in the floor. This AC is registered as a signal by a load-side and a drive-side antenna and is evaluated for guiding the truck. After signal evaluation, a computer guides the truck along the wire groove.

  • Page 81: Inductive Guidance Izf

    Optional Equipment Inductive guidance IZF – Drive the truck further towards the wire groove. As soon as the controller has de- tected the induction signal via the first an- tenna, the steering starts to move automat- ically and guides the truck at creep speed onto the wire groove.

  • Page 82: Working Platforms

    Optional Equipment Working platforms Working platforms The use of working platforms in conjunction with industrial trucks is regulated by national law. This legislation should be observed. The use of working platforms is only permitted by virtue of the legislation in the country of use. Before using working platforms, consult your national regulatory authorities.

  • Page 83: Clipboard

    Optional Equipment Clipboard Clipboard You have the option of using a clipboard (1) to secure your work papers to. This clipboard can be inserted into a slot in the multifunctional panel. To do so, the standard cover of the multifunctional panel must be removed. Working spotlights For safety reasons, there is an option to have the truck fitted with one or several working...

  • Page 84: Working Spotlights

    Optional Equipment Working spotlights Electronic access control The truck can be equipped with electronic access control as an option. In this case, the key switch is replaced by a button in the operating panel. Access control using a chip card To switch on the truck, either first press the button in the operating panel for approximately one second and then insert the correct chip...
  • Page 85 Optional Equipment Electronic access control Access control using a "PIN code" The truck functions can be activated via a 5-digit PIN code. After the button in the op- erating panel has been actuated, a message appears on the display (1) and the symbol (3) flashes.

  • Page 86: Two-Pedal Design

    Optional Equipment Two-pedal design As with other vehicles, the position of the accelerator pedal defines the speed of travel. Cancelling the accelerator pedal automatically throttles back the speed of travel (braked, no idling). The vehicle then continues to move at the speed thus selected. If the pedal is released fully, the vehicle is braked to a standstill.

  • Page 87: Attachments

    Optional Equipment Attachments NOTE The fork arm positioner can only be actuated without a load on the fork. Programming the intermediate stop As an option, an intermediate stop* can be programmed within the adjustment range. – Actuate the fork adjustment. –...
  • Page 88 CAUTION Risk of accident, risk of crushing – Make settings only when the truck is at a stand- still. – The pedal plate and seat console move during the adjustment. Therefore, keep your fingers away from the moving parts. Actuate the rocker switch with one hand and place the other hand on the joystick.

  • Page 89: Electrical Seat Adjustment

    Optional Equipment Electrical seat adjustment For optimum adaptation of the driver’s com- partment to suit the size of the operator, you can use this option to electrically adjust both the position of the driver’s seat and the pedal plate. Press the rocker switch (1) in the operating panel up or down accordingly until the position is comfortable.

  • Page 90: Telescopic Table

    Optional Equipment Telescopic table Telescopic table Description The load capacity specified on the load capac- ity diagram is dependent on the configuration and can therefore vary from truck to truck. The load capacity diagram and the load capacity restrictions indicated for certain application conditions must be observed without fail so that stability of the truck is not impaired.
  • Page 91 Optional Equipment Telescopic table • Do not subject to extreme atmospheric conditions • The inspection and maintenance intervals are shortened in volatile and very damp environments • Do not subject to shear forces, e.g. shifting of the load with the fork profile extended in a longitudinal and lateral direction.

  • Page 92: Height Preselection System

    Optional Equipment Height preselection system without function without function Horn Height preselection system The heights of the available racking supports must be entered into the system. This hap- pens via a teach-in process. A maximum of 8 different storage areas (A–H) may be defined. However, this is only useful if there are areas in the high racks with different rack clear- ances.
  • Page 93 Optional Equipment Height preselection system on the fork, the controller can automatically switch to "deposit procedure" or "remove from stock procedure". If this option is not available, the operator must use the buttons to select the appropriate procedure. NOTE The teach-in process must be carried out by authorised service personnel.
  • Page 94 Optional Equipment Height preselection system read. See also the section entitled Switching the display. Deactivating the system Briefly press button (5) once to cancel a process that has been selected or to deac- tivate the height preselection system. 5220 804 2501 [EN]...
  • Page 95 Index Checklist before starting work ..32, 40 Chip card ......78 Accelerator pedal .
  • Page 96 Index Ending the guidance ....75 Entering ......42 Joystick .
  • Page 97 Index Steering performance test ... 40 Steps ......42 Parking brake .
  • Page 100 STILL GmbH Berzeliusstrasse 10 D-22113 Hamburg Ident no. 5220 804 2501 EN...

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