Still EXG-10 Original Instructions Manual
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Still EXG-10 Original Instructions Manual

Still EXG-10 Original Instructions Manual

Counterweight pallet stacker
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Original instructions
Counterweight pallet stacker
EXG-10
EXG-12
EXG-16
1217 1218 1219
1170 801 15 09 EN - 10/2017

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  • Page 1 Original instructions Counterweight pallet stacker EXG-10 EXG-12 EXG-16 1217 1218 1219 1170 801 15 09 EN - 10/2017...
  • Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 1170 801 15 09 EN - 10/2017...

  • Page 5: Table Of Contents

    Table of contents Introduction Your industrial truck ........... 2 General .
  • Page 6 Table of contents Overviews Truck overview ........... . . 20 Overview .
  • Page 7 Table of contents Order picking ............62 Opening the battery cover .
  • Page 8 Table of contents Steering and wheels ..........93 Servicing the wheels .

  • Page 9: Introduction

    Introduction...

  • Page 10: Your Industrial Truck

    Introduction Your industrial truck Your industrial 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.

  • Page 11: Ec Declaration Of Conformity

    Introduction EC declaration of conformity EC declaration of conformity Declaration STILL GmbH Berzeliusstrasse 10 22113 Hamburg GERMANY We declare that the machine 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 12: Identification Label

    Introduction Identification label Identification label Identification label Battery Voltage Manufacturer Minimum battery weight CE symbol (this symbol means that the ma- Maximum battery weight chine complies with European regulations Nominal capacity of the truck for industrial trucks) Model Serial number/year Motor rated power Unladen weight Rules for the operating...
  • Page 13 Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 1170 801 15 09 EN - 10/2017...

  • Page 14: Proper Usage

    Introduction Proper usage Proper usage The truck described in these operating in- If the truck needs to be used for purposes other structions is suitable for lifting, transporting than those specified in these instructions, you and stacking loads. should first: •...

  • Page 15: Unauthorised Use

    Introduction Unauthorised use Unauthorised use Any danger caused as a result of unauthorised The forklift truck should not be used in areas use becomes the responsibility of the operator where there is a risk of fire, explosion or or driver and not that of the manufacturer. corrosion, or in areas that are particularly dusty.
  • Page 16 Introduction Disposing of components and batteries 1170 801 15 09 EN - 10/2017...

  • Page 17: Safety

    Safety...

  • Page 18: Safety Regulations

    Safety Safety regulations Safety regulations These operating instructions, which come • Regular checks and technical inspections with the truck, must be communicated to all • Recycling of lubricants, oils and batteries those concerned and in particular to personnel • Residual risks. responsible for maintenance and driving.

  • Page 19: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Refer to the maintenance data table for the permissible substances necessary for Consumables can be dangerous. operation. It is necessary to follow the safety regulations when handling these substances.

  • Page 20: Hydraulic Fluid

    Safety Safety regulations for handling consumables Hydraulic fluid WARNING Hydraulic fluid is a water-polluting substance! During operation of the forklift truck, Always store hydraulic fluid in containers hydraulic fluids are pressurised and complying with the regulations. are hazardous to your health. Avoid spilling.

  • Page 21: Disposal Of Consumables

    Safety Safety regulations for handling consumables – Dispose of used battery acid in line with the applicable regulations. Disposal of consumables • Any spillage of fluids such as hydraulic oil, ENVIRONMENT NOTE brake fluid or gear lubricant oil must be Materials that have to be disposed of following immediately soaked up with an oil-binding maintenance, repair and cleaning must be...

  • Page 22: Emissions

    Safety Emissions Emissions Noise emission values Calculated during the test cycle performed in NOTE accordance with standard EN12053. Lower or higher noise values may occur when Acoustic pressure level in the driver's com- using industrial trucks, e.g. due to the mode partment of operation, environmental factors and other sources of noise.

  • Page 23: Residual Dangers, Residual Risks

    Safety Residual dangers, residual risks Residual dangers, residual risks Despite all operational precautions and • Falling, tripping etc. when moving on the compliance with standards and rules, the industrial truck, especially in the wet, with possibility of additional risks when using the leaking consumables or icy surfaces.

  • Page 24: Specialist

    Safety Definition of responsible persons in compliance with the safety guidelines set The operating company is responsible for the out in these operating instructions. scheduling and correct performance of regular safety checks. The operating company must ensure that all users read and understand the safety It is recommended that these checks comply information in these instructions.

  • Page 25: Safety Tests

    Safety inspection based on time and extraordinary incidents The operating company (see chapter entitled "Definition of responsible persons") must STILL GmbH Hamburg ensure that the truck is checked by a specialist at least once a year or after noteworthy Regelmäßige Prüfung incidents.
  • Page 26 Safety Safety tests 1170 801 15 09 EN - 10/2017...

  • Page 27: Overviews

    Overviews...

  • Page 28: Truck Overview

    Overviews Truck overview Truck overview Overview Mast slinging point Transmission gear Lift cylinder Traction motor Chains ES30–24 steering unit Fork carriage Traction and lift controller Battery socket Diagnostic connector Electromagnetic brake* Emergency stop button Panel Tiller Battery Mast safety shield Tilt cylinder Fixed or tilting lift mast (depending on truck Load wheels...

  • Page 29: Controls And Display

    Overviews Controls and display Controls and display Tiller and dashboard Fork lowering Switch key Fork lifting/lowering proportional control Diagnostic connector Fork lifting Tilt selector Safety reverser Mast tilt Direction reverser/accelerator Horn Emergency stop button Multifunction indicator 1170 801 15 09 EN - 10/2017...

  • Page 30: Display Function

    Overviews Controls and display Display function COMMENTS / SCREEN DESIGNATION EXPLANATION MESSAGES 100% = full charge 1) Recharge recommended Battery charge level as a % 10% = low charge 1) 2) Recharge essential 0%= discharged 2) 100% = full charge 1) Battery discharged Battery charge level 10% = low charge...
  • Page 31 See "Setting the date and Time display time" 1) Message: "Motor fault" - Try to restart by resetting ignition key - Alarm still active: Call "STOP INDICATOR LIGHT" service engineer Various faults Red indicator light 2) Message: "Brake worn "+...
  • Page 32 Overviews Controls and display COMMENTS / SCREEN DESIGNATION EXPLANATION MESSAGES - The meter starts running when the machine is switched on and a control is used. - When the meter is running, Indicates the number of the hourglass flashes slowly Hour meter operating hours of the -The hour meter displays...

  • Page 33: Display Settings

    Overviews Controls and display Display settings Starting the truck using the ignition key (standard version) – Plug in the battery connector. – Pull the emergency stop button. – Switch on the ignition. The following display appears: The truck is ready for operation. Starting the truck using the digicode –...
  • Page 34 Overviews Controls and display Driver on the platform When the driver steps onto the platform, the green "Driver present" indicator light comes on (see arrow). It stays on for 10 seconds and then switches off. The green indicator light starts to flash when the driver steps off the platform.
  • Page 35 Overviews Controls and display The following display appears (see arrow): "After Sales 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 - hours: minutes).
  • Page 36 Overviews Controls and display Error codes All the reasons why the truck is running slowly or has stopped are shown on the display, in the form of error codes. • T: traction controller error code • L: lift controller error code •...
  • Page 37 Overviews Controls and display The following message appears on the display: – Enter the administrator code. – Enter the new PIN code. – Confirm by pressing button (1) "(+)". 1170 801 15 09 EN - 10/2017...

  • Page 38: Markings

    Capacity label Identification label (see following page) Truck model label "Do not drive with high load" label Cold store label Company label Passengers not allowed label WARNING label (GB only) Still logo label 1170 801 15 09 EN - 10/2017...

  • Page 39: Serial Number

    Overviews Markings Serial number xx xxxx x xxxxx NOTE Indicate the serial number for all technical enquiries. The serial number contains the following information: 1 Production location 2 Type 3 Year of production 4 Count number 7090_921-004 1170 801 15 09 EN - 10/2017...
  • Page 40 Overviews Markings 1170 801 15 09 EN - 10/2017...

  • Page 42: Electric Pallet Stacker

    Electric pallet stacker Electric pallet stacker Electric counterweight pallet stacker types – Side access EXG 10, EXG 12 and EXG 16 are designed for The power supply to the traction motor is stacking. controlled by an electronic control module They can also be used to transport pallets of a which provides complete control of the speed, maximum weight 1000 kg (EXG 10), 1200 kg acceleration and braking.
  • Page 43 Electric pallet stacker Options is released and when the direction of travel is reversed. Various options are available on EXG trucks: • Cold Store option Driver's compartment • gradual carriage stop Pedestrian model: • digicode • the speed is limited to 6 km/h •...

  • Page 44: List Of Checks Prior To Start-Up

    List of checks prior to start-up List of checks prior to start-up WARNING – Damaged or missing stickers must be replaced in compliance with the marking Damage or other defects on the forklift truck or position table. attachments (special equipment) can result in accidents.

  • Page 45: Checks And Actions Prior To Commissioning

    Checks and actions prior to commissioning Checks and actions prior to commissioning Checking the brake NOTE Perform this check on a flat surface. – Drive the machine forward. – Tilt the tiller in areas (A) and (C). In these two areas, the machine is braked and the drive unit is no longer powered.

  • Page 46: Checking The Anti-Crush Safety Device

    Checks and actions prior to commissioning Checking the anti-crush safety device Anti-crush safety function The truck moves in reverse when the anti- crush button (2) is pressed. If the truck is being operated in narrow areas (such as in a lift for example), the operator may get stuck against the wall if care is not taken.

  • Page 47: Checking The Horn

    Checks and actions prior to commissioning Checking the horn – Press the horn button (4) located on the upper part of the tiller. The warning sounds. 1170 801 15 09 EN - 10/2017...

  • Page 48: Truck Operating Instructions

    Truck operating instructions Truck operating instructions The trucks are designed for indoor and It is important to use pallets that are in good outdoor use in non-hazardous atmospheres. condition. The temperature should be between -10°C Speed must be reduced when moving over and +45°C and the relative humidity of the air obstacles to prevent the truck from becoming less than 95%.
  • Page 49 Truck operating instructions WARNING CAUTION Driving safety guidelines: Risk of injury – The driver must drive slowly around corners and Before using a side access truck, check that the when entering narrow passageways. battery is correctly locked. – The driver must always maintain a safe braking distance from vehicles or people in front of him.

  • Page 50: Driving

    Driving Driving Driving safety instructions Behaviour when driving Driving the truck while sitting on top of it is prohibited. The operator must obey the same rules within the plant as he would on the road. He must All EXG models are designed to be operated drive at a speed appropriate for the driving in pedestrian mode.

  • Page 51: Driving

    Driving Driving Start-up – Open the battery cover (1). – Plug in the battery connector. – Close the battery cover (1). – Pull the emergency off switch to the raised position (2). – Turn the switch key (3) to the right or enter the start-up PIN code on the multifunction indicator (4) depending on the version.
  • Page 52 Driving Forward travel – Tilt the tiller in the driving area (B) – Move the drive direction switch forward – The truck speed depends on the angle of rotation of the drive direction switch. WARNING The operator must remain as far as possible from the truck (arms outstretched) in order to avoid injuries to the feet.
  • Page 53 Driving Steering The EXG model is fitted with electric steering controlled by a tiller (8). The electric power steering enables the truck to be manoeuvred gently and precisely with one hand. WARNING Risk of serious injury and/or serious damage to the machine.

  • Page 54: Driving On Upward And Downward Slopes

    Driving Driving on upward and downward slopes Slopes should always be approached with the load facing towards the top of the slope. Only slopes marked as clear traffic routes compat- ible with the truck's technical specifications can be safely used. DANGER Risk of accident The operator must ensure that the ground is clean...

  • Page 55: Braking

    Driving Braking Safety or parking electromagnetic brake system The electromagnetic brake is applied auto- matically: • If a fault is detected by the traction and/or steering controller. • When the tiller is in upper braking cut-out position (A) or in lower braking cut-out position (C) •...

  • Page 56: Transporting Loads

    Transporting loads Transporting loads Load handling safety rules WARNING It is necessary to 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).

  • Page 57: Transporting Pallets Or Other Containers

    Transporting loads Transporting pallets or other contain- As a general rule, loading units must be trans- ported one by one (e.g. pallets). Transporting several loading units at a time is only autho- rised: • when the safety preconditions are fulfilled. •...

  • Page 58: Lift Control Elements

    Transporting loads Lift control elements Lifting the fork arms – Push the control flap (1) downwards. Lowering the fork arms – Push the control flap (1) upwards. Tilting the mast – Move the tilt selector up or down (2) 1170 801 15 09 EN - 10/2017...
  • Page 59 Transporting loads – Push or pull the joystick lever (3) forwards (4): maximum tilt 1°. – Push or pull the joystick lever (3) backwards (5): maximum tilt 6°. 1170 801 15 09 EN - 10/2017...

  • Page 60: Capacity

    Transporting loads Capacity CAUTION Deterioration or destruction of the equipment. Before picking up a load, make sure that its weight does not exceed the lifting capacity of the machine. Refer to the nominal capacity specified on the truck's capacity rating plate. The values shown are for compact, homogeneous loads.
  • Page 61 Transporting loads Reading the capacity rating plate Example of a current label: • (2) - Maximum lift height • (3) - Type of lift mast • (4) - Distance from the back of the fork to the load centre of gravity •...

  • Page 62: Working With Loads

    Transporting loads Working with loads Before picking up a load Ensure that its weight does not exceed the truck's capacity. – Refer to the nominal capacity specified on the truck's capacity rating plate. – You must also make sure that the load is stable, well-balanced and centred between the load arms in order to avoid dropping any part of the load.
  • Page 63 Transporting loads Picking up a load from the ground – Approach the load carefully. – Tilt the mast vertically. – Lower the fork arms so that they are easily inserted into the pallet. – Move the forks under the load. –...
  • Page 64 Transporting loads CAUTION Always drive with the mast tilted as far back as possible to ensure optimum distribution of the load over the axles. The axles will thus have better longitudinal stability and maximum braking capacity. CAUTION The driver must remain as far as possible from the truck (arms outstretched) in order to avoid injuring his/her feet.
  • Page 65 Transporting loads Stacking a load DANGER Check that the load does not exceed the maximum capacity of the truck in relation to the lift height. – Carefully drive the machine to the required location. – Raise the forks clearly above the level where the load is to be placed.
  • Page 66 Transporting loads DANGER Personnel must not stand under or near the truck when the load is in the raised position. Before leaving the machine CAUTION Always stop the machine on level ground away from traffic routes. – Lower the fork arms to the bottom position. –...

  • Page 67: Cold Store (Option)

    Cold store (option) Cold store (option) Cold store usage (optional) CAUTION Standard trucks risk being subject to significant damage if used in extreme conditions. Only trucks with the Cold Store option may be used inside cold storage. Specific oil designed for cold stores must be used.
  • Page 68 Cold store (option) DANGER If the condensation freezes in the cold store, it is prohibited to operate the jammed parts. This could cause permanent 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).

  • Page 69: Parking The Truck

    Parking the truck. Parking the truck. WARNING – Lower the fork arms. Risk of injury – Switch off the ignition (key or electronic key). Do not park the truck on a slope. If this is absolutely necessary, make sure it is safely secured using –...

  • Page 70: Handling The Battery

    Handling the battery Handling the battery Battery type Trucks can be fitted with different types of battery. Comply with the information indicated on your battery's type plate, as well as with its features. WARNING The weight and size of the battery influence the stability of the truck.

  • Page 71: Opening The Battery Cover

    Handling the battery restarted when the covers and connectors have been put back in the operating position. Opening the battery cover – Stop the truck and lower the forks. – Turn off the ignition and remove the key. – Press the emergency off switch. –...

  • Page 72: Battery Charging With An External Charger

    Handling the battery Battery charging with an external charger – After use, move the truck to the charging station. – Stop the truck, lower the forks and switch off the ignition. – Press the emergency stop switch (1). – Open the cover on the battery compart- ment.
  • Page 73 Handling the battery – Gel electrolyte batteries require a specific setting for the discharge indicator and the charger. – Ensure correct "+" and "-" polarity when 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.

  • Page 74: Vertical Access Battery

    Handling the battery Vertical access battery Changing the battery using a hoist – Lower the fork arms completely. – Open and remove the battery compartment cover. – Disconnect the battery connector. – Position the handling device (1) above the battery compartment. –...

  • Page 75: Side Access Battery: Selection Of Battery Compartment Opening Side

    Handling the battery Side access battery: selection of battery compartment opening side Depending on the installation, you can choose which side the battery is changed. To switch the battery removal direction: – Turn around the stop with its rubber buffers (3).

  • Page 76: Side Access Battery: Unlocking - Locking The Battery

    Handling the battery Side access battery: unlocking - locking the battery Battery locked The handle is in the horizontal position and the battery tabs (2) are held by the hooks (3). Unlocking the battery – Open the battery hood. – Raise the handle (1) vertically until it reaches the stop to unlock the battery.

  • Page 77: Handling The Truck In An Emergency

    Handling the truck in an emergency Handling the truck in an emergency Emergency mast lowering The safety valve (1) allows the mast to be lowered manually if the truck breaks down. Proceed as follows: – Loosen the valve (1) to empty the oil from the pump-motor unit.

  • Page 78: Truck Towing Procedure

    Handling the truck in an emergency Truck towing procedure It is not possible to tow the truck with no electrical function. The electromagnetic brake remains in the closed position. You may only tow the truck with a rigid connec- tion (tow bar) if the truck to be towed can no longer be braked.
  • Page 79 Handling the truck in an emergency – Screw the screws (2) all the way in the holes (4) in the brake (3). The brake is then deactivated. CAUTION The truck must only be towed at creep speed and with care. –...

  • Page 80: Handling The Truck In Specific Situations

    Handling the truck in specific situations Handling the truck in specific situations Slinging the truck CAUTION Risk of truck falling Only use slings and a hoist of sufficient capacity. The slinging points are marked by a label (3). Remove the load before slinging the truck. Check the weight of the truck (including battery) to select a suitable device.

  • Page 81: Lifting The Truck

    Handling the truck in specific situations Lifting the truck DANGER Danger of truck tipping over Truck lifting must be performed carefully. For some work it is necessary to lift the truck. – Switch off the ignition and disconnect the battery connector. –...

  • Page 82: Truck Towing Procedure

    Handling the truck in specific situations Truck towing procedure It is not possible to tow the truck with no – Remove the engine cover. electrical function. The electromagnetic brake – Two M5 X 35 screws (1) are required. remains in the closed position. –...

  • Page 83: Driving On Loading Bridges

    Handling the truck in specific situations Anyone transported with the truck must only enter the lift after the truck has been correctly immobilised and they must exit the lift first. Driving on loading bridges Before crossing a loading bridge, the operator be entered is secured sufficiently against must make sure it is properly attached and movement and that it can support the load of...
  • Page 84 Handling the truck in specific situations 1170 801 15 09 EN - 10/2017...

  • Page 85: Maintenance

    Maintenance...

  • Page 86: General Maintenance Information

    Maintenance General maintenance information General maintenance information General The following instructions contain all the in- formation needed for truck maintenance. It is necessary to carry out the various main- tenance operations according to the mainte- nance plan. The truck will then be ready for service, will continue to be reliable and the warranty can be applied.

  • Page 87: Battery Maintenance Staff

    Maintenance General maintenance information The person responsible for carrying out the the protective installations in accordance inspection must have sufficient knowledge with the technical regulations and principles and experience to be able to assess the established for checking industrial trucks. condition of the truck and the efficiency of Battery maintenance staff Batteries must only be recharged, maintained...

  • Page 88: Maintenance Safety Instructions

    Maintenance Maintenance safety instructions Maintenance safety instructions Servicing and maintenance measures To avoid accidents during servicing and ensuring that there is no risk of the truck maintenance operations, take all necessary moving or starting up unexpectedly (remove safety measures, such as, for example: the battery connector).

  • Page 89: Recommended Lubricants

    Maintenance Recommended lubricants Recommended lubricants Aerosol can for chains CAUTION Damage to equipment if non-recommended lubri- Standard chain spray. cants are used. If in doubt, please ask your local dealer for Only use recommended lubricants. Only the lu- advice. You should also consult your local bricants listed below are approved by the manu- dealer if a representative of a third party facturer.

  • Page 90: Technical Data For Inspection And Maintenance

    Maintenance Technical data for inspection and maintenance Technical data for inspection and maintenance Assembly Capacities/Setting values Consumables/lubricants Main hydraulic system Maximum hydraulic oil 9.5 l Transmission gear Transmission gear oil 1.5 l Traction and pump motor Power 250 A, Quantity: 1 Fuses Steering motor Power 40 A, Quantity: 1...

  • Page 91: Accessing The Technical Compartment

    Maintenance Accessing the technical compartment Accessing the technical compartment – Fully raise the truck's fork arms to facilitate these operations. CAUTION Electrical hazards Before removing anything from the truck: – Switch off the ignition. – Press the emergency off switch. Opening the front hood –...

  • Page 92: Maintenance Plan As Required

    Maintenance Maintenance plan as required Maintenance plan as required Depending on the application, environmental conditions and driving style, the following proce- dures should be carried out as required Preparation Cleaning the truck Chassis and equipment Checking the brake operation Checking the condition of the roller frame Wheels Checking the wheels for wear Electrical equipment...

  • Page 93: 1000-Hour Maintenance Plan

    Maintenance 1000-hour maintenance plan 1000-hour maintenance plan At operating hours 1000 2000 4000 5000 7000 Carried out 8000   Depending upon use, environmental conditions and driving style, the following pro- cedures must be carried out in line with the intervals shown below. Before performing the procedures Clean the truck Error code history: read and delete...
  • Page 94 Maintenance 1000-hour maintenance plan At operating hours 1000 2000 4000 5000 7000 Carried out 8000   Wheels: check for damage, the presence of foreign objects and for wear on the wheels Brakes Brakes: check for wear Brakes: check for any damage and check for leaks Operating component Accelerator: check Electrical equipment...
  • Page 95 Maintenance 1000-hour maintenance plan At operating hours 1000 2000 4000 5000 7000 Carried out 8000   Carry out a functional test and a test drive Attach the maintenance label 1170 801 15 09 EN - 10/2017...

  • Page 96: 3000-Hour Maintenance Plan

    Maintenance 3000-hour maintenance plan 3000-hour maintenance plan Additional maintenance operations every 3000 hours Depending upon use, environmental conditions and driving style, the following procedures must be performed every 3000, 6000 and 9000 hours Information Carry out all 1000-hour maintenance work Transmission Drain the transmission gear oil Hydraulic system...

  • Page 97: Chassis, Bodywork And Fittings

    Maintenance Chassis, bodywork and fittings Chassis, bodywork and fittings Cleaning the truck Cleaning instructions – Always park the truck following the instruc- tions provided. – Disconnect the battery connector (1). Washing the outside of the truck Disconnect the battery before cleaning the truck.

  • Page 98: Clean The Battery And Its Compartment

    – 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.

  • Page 99: General Information On Battery Maintenance

    Maintenance Chassis, bodywork and fittings Lead battery – Check that there are no electrolytes at the bottom of the compartment by connecting the rubber suction bulb supplied with the battery to the plastic pump tube. – Pump off any electrolyte that may have spilled between the cells.
  • Page 100 Maintenance Chassis, bodywork and fittings – Open the battery hood. CAUTION Do not obstruct the ventilation. Allow the charger to – Do not disconnect the battery plug. cool down for 10 minutes after charging is complete CAUTION before touching it. Do not use the charger out of the truck.

  • Page 101: Steering And Wheels

    Maintenance Steering and wheels Steering and wheels Servicing the wheels Checking the tyres and the wear on the wheels The tyre tread of the drive wheel and the load wheels must not be damaged. Dimensions Drive wheel 254 x 102 mm Load wheels 85 x 105 mm –...

  • Page 102: Electrical Equipment

    Maintenance Electrical equipment Electrical equipment Electrical system maintenance Checking the cable and fuse connection mountings WARNING Electrical hazards Stop the truck and disconnect the battery before carrying out the following checks. – Remove the front hood. – Check the condition of the fuses. –...

  • Page 103: Checking The Battery Acid Level And Electrolyte Density

    Maintenance Electrical equipment Checking the battery acid level and electrolyte density WARNING The electrolyte (diluted sulphuric acid) is poisonous and caustic! – Always wear suitable protective equipment (industrial goggles, safety gloves) when working on a battery. – Never wear a watch or jewellery when handling battery acid.

  • Page 104: Checking The Condition Of Cables, Terminals And Battery Connector

    Maintenance Electrical equipment Checking the condition of cables, terminals and battery connector – Check that the cable insulation is undam- aged and that there are no signs of over- heating at the connections. – Check that the "+" and "-" output terminals are not sulphated (presence of white salt).

  • Page 105: Hydraulic Systems

    Maintenance Hydraulic systems Hydraulic systems Checking the hydraulic oil level To check the hydraulic oil level, proceed as follows: – Immobilise the truck. – Lower the forks completely. – Switch off the truck and press the emer- gency off switch. –...
  • Page 106 Maintenance Hydraulic systems NOTE Dismantling the pump unit is not recommen- ded. Filling up – Fill up the tank through the filler hole. – Change the breather filter. – Tighten the plug. – Operate the lifting mechanism several times and bleed the circuit using the screws provided on the lift cylinders.

  • Page 107: Lift Mast

    Maintenance Lift mast Lift mast Types of lifting masts Working on the lift mast WARNING Risk of serious injury and/or serious damage to equipment. When working on the front of the truck with the mast or fork carriage raised, fit a safety device to prevent the mast from being lowered accidentally.
  • Page 108 Maintenance Lift mast – Raise the mast. – Connect the chain after passing it over the fixed strut (2) and beneath the cross member of the inner strut (1). – Lower the inner strut until the safety chain is under tension. Dual lifting mast NOTE The advantage of this mast is that it can be...
  • Page 109 Maintenance Lift mast – Lower the inner strut until the safety chain is under tension. – Lower the fork carrying carriage to the bottom of its travel. Triple lifting mast OPERATION The fork carriage is raised until free lifting through the return pulley of the centre cylinder chain.

  • Page 110: Specific Mast Maintenance

    Maintenance Lift mast Specific mast maintenance Checking the condition of mast mounting and its chains – Thoroughly clean the mast guide rails and the chains. – Inspect surfaces for wear and check rota- tion of rollers. – Inspect the chains for wear, especially around the return pulleys.
  • Page 111 Maintenance Lift mast – 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 fork carriage does not reach the mechanical stop at the top of the mast during the maximum lift.
  • Page 112 Maintenance Lift mast 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. Lubricating the mast – Coat the guidance surfaces, the return pulleys and chains with a special aerosol chain lubricant.

  • Page 113: Putting Out Of Commission And Storage

    Maintenance Putting Out of Commission and Storage Putting Out of Commission and Storage Long-term truck storage The following work must be carried out on with the manufacturer's requirements. the truck to prevent corrosion if it needs to be (Follow the instructions). stored for a long period of time.
  • Page 114 Maintenance Putting Out of Commission and Storage 1170 801 15 09 EN - 10/2017...

  • Page 115: Technical Data

    Technical data...

  • Page 116: Technical Data Sheet Exg 10-12-16

    Technical data Technical Data Sheet EXG 10-12-16 Technical Data Sheet EXG 10-12-16 1170 801 15 09 EN - 10/2017...
  • Page 117 Technical data Technical Data Sheet EXG 10-12-16 DESCRIPTION 1.1 Manufacturer STILL 1.2 Model type EXG16 EXG12 EXG10 1.3 Drive type: battery, diesel, petrol, LPG, mains power Battery Driving: manual, pedestrian, standing, seated, order Pedestrian picking 1.5 Rated capacity Q (kg)
  • Page 118 Technical data Technical Data Sheet EXG 10-12-16 Aisle width with a 1000 x Ast (mm) See calculation formulas 1200 pallet crosswise Aisle width with an 800 x Ast (mm) See calculation formulas 1200 pallet lengthwise Turning radius Wa (mm) 1845 1480 1480 PERFORMANCE DATA...

  • Page 119: Loads Per Axle

    Technical data Loads per axle Loads per axle 3 Pzs 3 Pzs B 4 Pzs 4 Pzs B 5 Pzs (VA) (SA) (VA) (SA) (VA) Weight in running 2020 2085 2230 order Drive axle load, 1310 1295 1360 unladen Load-bearing axle load, unladen Drive axle load, EXG16 (mast 2844D) with tilt Non-standard...
  • Page 120 Technical data Loads per axle Note: Apron ISO 2B width: 800 mm. 1170 801 15 09 EN - 10/2017...

  • Page 121: Mast Table

    Technical data Mast table Mast table Mast type EXG10 1924S 2424S 2924S 3324S 3824S Lift (mm) 1924 2424 2924 3324 3824 Lift + fork height (mm) h3 + h13 1970 2470 2970 3370 3870 Mast height HT retracted 1515 1765 2015 2215 2465...
  • Page 122 Technical data Mast table 3744 1844 Mast type EXG16 1844S 2344S 2844S 3244S 4144S Lift (mm) 1844 2344 2844 3244 3744 4144 1844 Lift + fork height (mm) h3 + h13 1895 2395 2895 3295 3795 4195 1895 Mast height HT 1515 1765 2015...
  • Page 123 Index Checking the electrical connections ..96 Checking the emergency shutdown ..37 Accessing the technical compartment . . . 83 Checking the horn ....39 Address of manufacturer .
  • Page 124 Index Driving safety instructions ... . 42 Dual lifting mast ....100 Maintenance plan 3000 hours .
  • Page 125 Index Safety Inspection ....17 Safety or parking electromagnetic Technical data for inspection and brake system ....47 maintenance .
  • Page 128 STILL GmbH 1170 801 15 09 EN – 10/2017...

This manual is also suitable for:

Exg-12Exg-16

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