Original instructions
Low level order picker
CX CX-D CX-H
1063 1069
50108043405 EN - 02-04/2014
Table of contents
g
1
Foreword
Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 3
Information about documentation . . . . . . . . . .
Documentation scope . . . . . . . . . . . . . . . . . .
Date of edition and latest update of this manual
Copyright and trademark rights . . . . . . . . . . . .
Explanation of symbols used . . . . . . . . . . . . .
Explanation of the cross-references . . . . . . . .
Definition of directions . . . . . . . . . . . . . . . . . .
Sample graphics . . . . . . . . . . . . . . . . . . . . . .
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4
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6
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7
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8
8
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2
Introduction
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Use of the truck . . . . . . .
Intended use of the trucks
Approved applications . .
Impermissible use . . . . .
Site of operation . . . . . . .
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Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . .
Special risks associated with using the truck and attachments . .
Overview of hazards and countermeasures . . . . . . . . . . . . . . . .
Hazards to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15
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18
20
Safety
Definition of terms used for responsible persons
Operating company . . . . . . . . . . . . . . . . . . . . .
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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24
24
24
25
25
Basic principles for safe operation . . .
Insurance cover on company premises
Warning regarding non-original parts .
Modifications and refitting . . . . . . . . . .
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27
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50108043405 [EN]
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I
Table of contents
g
Medical equipment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical insulation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Safety regulations for handling consumables . . . .
Permissible consumables . . . . . . . . . . . . . . . . . .
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal of consumables . . . . . . . . . . . . . . . . . . .
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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31
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32
33
34
35
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Damage, defects and misuse of safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Battery connection cables
4
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Overview
General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5
Controls and display elements . . . . . . . .
View of the control elements . . . . . . . . . .
CX 20 cockpit . . . . . . . . . . . . . . . . . . . . .
Version with movable step plate (optional)
CX-H version . . . . . . . . . . . . . . . . . . . . .
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41
41
42
43
44
Marking positions . . . . . . . .
Location of plates and labels
Labels . . . . . . . . . . . . . . . .
Chassis frame labelling . . .
Data plate . . . . . . . . . . . . .
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45
45
46
48
48
Options and variants . . . . . . . . . . . . . . . . . . . .
Overview of options and models . . . . . . . . . . . .
Overview of accessories . . . . . . . . . . . . . . . . .
Battery electrolyte level indicator LED (optional)
Load back rest with vertical pallet hook (optional)
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49
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53
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Operation
Intended use of the trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checks and actions prior to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Daily pre-operational checks and services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Daily checks before use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
II
50108043405 [EN]
Table of contents
g
Connecting the battery plug (charging station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Commissioning . . . . . . . . . . . . . . . . . . . . .
Turning on the truck . . . . . . . . . . . . . . . . . .
Entering the driver code . . . . . . . . . . . . . . .
Starting with FleetManager (optional) . . . . .
Hour meter . . . . . . . . . . . . . . . . . . . . . . . .
Battery charge . . . . . . . . . . . . . . . . . . . . . .
Display of time to next servicing . . . . . . . . .
Operating the horn . . . . . . . . . . . . . . . . . . .
Checking the presence area and brake . . . .
Checking the emergency brake . . . . . . . . .
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61
61
62
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63
63
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visibility when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency stop procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Persons in the danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving in rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the driving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving, pedestrian operation with tiller, slow approach with drive switch . . . . . . . . . .
Driving, pedestrian operation with push button . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency stop brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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64
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67
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69
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73
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75
75
75
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Lifting device controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Handling loads . . . . . . . . . . . . . . . . . .
Load handling safety rules . . . . . . . . .
Before picking up the load . . . . . . . . .
Picking up a loading unit . . . . . . . . . . .
Danger zone . . . . . . . . . . . . . . . . . . .
Palletising a load . . . . . . . . . . . . . . . .
Transporting pallets or other containers
Driving on gradients . . . . . . . . . . . . . .
Carrying the load . . . . . . . . . . . . . . . .
Entering lifts . . . . . . . . . . . . . . . . . . . .
Driving on loading bridges . . . . . . . . .
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50108043405 [EN]
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77
77
77
78
78
79
80
81
81
82
82
III
Table of contents
g
Cold store use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Using the Digicode control
Digicode control . . . . . . .
Adding the master code . .
Deleting a master code . . .
Adding a driver’s code . . .
Deleting a driver’s code . .
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85
85
86
87
89
91
Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Battery electrolyte level indicator LED (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Handling the truck in specific situations
Transporting the truck . . . . . . . . . . . .
Towing procedure . . . . . . . . . . . . . . .
Hoisting the truck . . . . . . . . . . . . . . . .
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Handling the battery . . . . . . . . . . . . . . . . .
Preparation . . . . . . . . . . . . . . . . . . . . . . .
Battery weight and dimensions . . . . . . . . .
Opening/closing the battery compartment .
Battery replacement . . . . . . . . . . . . . . . . .
Battery replacement with crane . . . . . . . . .
Battery replacement sideways onto a trolley
Servicing the battery . . . . . . . . . . . . . . . .
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94
95
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95
95
96
97
99
100
100
101
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Parking the truck securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Measures to take if the lift truck is to be shut down for a long time . . . . . . . . . . . . . . . . . 103
Recommissioning after taking out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6
Maintenance
General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Staff training and qualifications for maintenance and repairs . . . . . . . .
Battery maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Services not requiring special qualifications . . . . . . . . . . . . . . . . . . . .
Frequency of periodic checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV
50108043405 [EN]
............
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106
106
107
107
107
108
109
110
111
Table of contents
g
Maintenance safety instructions . . . . . . . . .
Safety measures for maintenance and repair
Work on the electrical equipment . . . . . . . .
Safety devices . . . . . . . . . . . . . . . . . . . . . .
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .
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112
112
112
112
112
Preparatory tasks for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Lifting and jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Maintenance as required . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the wheels and rollers . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging the lead battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging the gel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking operation of the brake, checking the emergency brake
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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116
116
117
119
119
121
122
Maintenance every 500 hours . . . . . . . . . . . . . . . . . . . . .
Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gearbox oil level . . . . . . . . . . . . . . . . . . . .
Checking the gearbox for leaks . . . . . . . . . . . . . . . . . . . .
Checking the hydraulic oil level, hydraulic system for leaks
Servicing the electric motors . . . . . . . . . . . . . . . . . . . . . .
Servicing the electrical system . . . . . . . . . . . . . . . . . . . .
Servicing the braking system . . . . . . . . . . . . . . . . . . . . .
Checking the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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123
123
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124
125
127
128
129
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131
131
131
132
Maintenance every 2000 hours . . . . . . . . . . . . . . . . . . . . . . . . .
Work that must also be carried out . . . . . . . . . . . . . . . . . . . . . .
Renewing the hydraulic oil and hydraulic oil filter . . . . . . . . . . . .
Checking and cleaning the battery . . . . . . . . . . . . . . . . . . . . . .
Servicing the battery according to the manufacturer’s instructions
Insulation resistance check (earthing) . . . . . . . . . . . . . . . . . . . .
Performing the accident prevention check . . . . . . . . . . . . . . . . .
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133
133
135
135
135
136
Annual maintenance . . . . . . . . . . . . . . . . .
Work that must also be carried out . . . . . . .
Insulation resistance check (earthing) . . . . .
Performing the accident prevention check . .
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.
Maintenance every 5000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Work that must also be carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Servicing the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
50108043405 [EN]
V
Table of contents
g
7
Technical characteristics
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Datasheet (VDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Fork dimensions
VI
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
50108043405 [EN]
1
Foreword
1
Foreword
Your industrial truck
Your industrial truck
General
The truck described in these operating instructions 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 regulations 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-theart technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
2
50108043405 [EN]
1
Foreword
Your industrial truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck
according to these operating instructions
Model
according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
50108043405 [EN]
3
1
Foreword
Information about documentation
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all measures necessary for the safe operation and
proper maintenance of the truck in all possible
variants at the time of printing. Special designs to meet customer requirements are documented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year
of production located on the nameplate
⇒ Chapter "Data plate", P. 4-48 in the field
provided:
Production no. ...........................................
Year of production
...................................................
Please quote these numbers for all technical
enquiries.
Operating instructions are provided with each
truck. These instructions must be stored
carefully and must be available to the driver
and operator at all times.
If the operating instructions are lost, the operator must immediately request a replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Definition of terms used for responsible persons", P. 24) must ensure that all operators
have received, read and understood these
instructions.
4
50108043405 [EN]
1
Foreword
Information about documentation
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
50108043405 [EN]
5
1
Foreword
Information about documentation
Date of edition and latest update of
this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third parties—including as excerpts—except with the
express written approval of the manufacturer.
6
50108043405 [EN]
1
Foreword
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chapter "Explanation of the cross-references", P. 1-7
• Cross reference to a chapter: ⇒ Chapter "Definition of terms used for responsible
persons", P. 24
50108043405 [EN]
7
1
Foreword
Information about documentation
Definition of directions
1
The references forward (1), backward (3),
right (2) and left (4) when describing location
are made relative to the operator’s station.
The load is at the rear.
4
2
3
Sample graphics
This documentation explains the (usually
sequential) sequence of certain functions or
operations. Schematic diagrams of a truck are
used to illustrate these sequences.
NOTE
These schematic diagrams are not representative of the constructed state of the documented truck. They serve only to illustrate the
sequences.
8
50108043405 [EN]
1044_001-014
1
Foreword
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when disposing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste management company for disposal purposes.
50108043405 [EN]
9
1
Foreword
Environmental considerations
10
50108043405 [EN]
2
Introduction
2
Introduction
Technical description
Technical description
Drive
The CX 20 and CX-D 20 are fitted with a 3 kW
traction motor driving the drive wheel via a
transmission gear:
Asynchronous travel motor, 3 kW
Starting and accelerating without jerking
Regenerative braking
The CX 20 has a speed of 9 km/h under load
and 12.5 km/h without load
• The CX-D 20 has a speed of 8 km/h under
load and 10.5 km/h without load
•
•
•
•
Raising
Nominal load of CX 20 and CX-D 20: 2000 kg
Pump assembly power output of CX 20:
2.2 kW
Pump assembly power output of CX-D 20:
2 kW
12
50108043405 [EN]
2
Introduction
Technical description
Driving
All functions and controls—which are both
sturdy and ergonomic—are centralised in the
cockpit, enabling the operator to direct the
drive wheel and steering wheel effortlessly.
The following controls can be activated from
the cockpit: "Start", "Tortoise" and "Hare" buttons, number buttons, "Confirmation" button,
steering, front and rear traction throttles, warning horn, emergency brake push button.
Braking system
• Progressive service braking with energy
recovery. This braking system is activated
when the throttle is released, when the
direction of travel is reversed or if the
operator’s presence is not detected
• Emergency electromagnetic braking,
activated by the emergency stop button
in the cockpit
• The shift to maximum speed can only be
activated if the operator is present on the
platform.
Driver’s compartment
The standard equipment in the driver’s compartment comprises:
• a fixed, oscillating platform (damped to
absorb vibrations), with lowered, bevelled
entry steps with a non-slip surface
• an ergonomically enhanced backrest,
• a padded "backrest" for comfort and support
while cornering, featuring two side handles
for driving sideways
• two side holders for rolls of film, 120 mm in
diameter
• two holders for one-litre bottles,
• a large, deep tray in the lower section of the
cockpit,
• an A4 vertical clipboard with paper holder,
• a storage tray on the battery cover.
50108043405 [EN]
13
2
Introduction
Use of the truck
Features of the CX-D 20
• Initial lift and main lift of 1580 mm. Allows
two pallets to be lifted at the same time.
• Max. load of 2000 kg on the initial lift or two
times 1000 kg on the initial lift AND main lift.
• Designed for Euro pallets.
• Standard lifting and lowering using a button
on the side of the truck and in the cockpit.
• Automatic speed limitation with raised loads
to keep loads stable when taking bends.
• Automatic lift cut-out at 400 mm to protect
the feet.
Use of the truck
Intended use of the trucks
CAUTION
This machine is designed for order picking (collecting and gathering together items stored in the
warehouse before dispatch), horizontal transport
tasks and entering and removing pallets to and from
stock.
The dimensions and capacity of the trailers, pallets
or containers must be adapted to the load being
transported and must ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of 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 him to put in
place any necessary additional safety measures.
Approved applications
The truck can be used for lifting and carrying
loads. It is equipped with forks and allows the
fast transport of loads on the ground. The truck
may only be used as approved and described
in this manual.
If the truck is to be used in a way other than
established in the operating instructions, the
written approval of the manufacturer and,
if necessary, of the responsible authorities
14
50108043405 [EN]
2
Introduction
Use of the truck
must be obtained beforehand to prevent any
potential dangers.
The maximum load that can be lifted is specified on the load capacity plate (load diagram).
Do not exceed the maximum load capacity.
Impermissible use
The user, and not the manufacturer, is liable
for any hazards caused by improper use.
Use for purposes other than those described
in these operating instructions is prohibited.
Passengers are not allowed.
The lift truck may not be operated in areas
with a risk of fire or explosion or in corrosive or
in high-dust areas. The lift truck must not be
operated on public roads or in the cold store
(special equipment).
0252_003-092
Site of operation
The truck can be used in enclosed spaces or
occasionally outside except in bad weather.
The service area must have a sufficient ground
load capacity. Contact your dealer for the data
concerning the wheel loads or specific ground
pressure for your truck. The ground must
conform to our specifications.
The ground surface influences the braking
distance of the truck. When driving and braking, the driver must take the quality of the
ground on which he is driving into consideration. Please observe local regulations.
The truck can be used in tropical and northern
countries (temperature range -20 °C to
+40 °C). As an option the truck can also be
equipped for cold stores (option).
50108043405 [EN]
15
2
Introduction
Residual risks
Residual risks
Residual dangers, residual risks
Despite careful working and compliance with
standards and regulations, the occurrence
of other risks when using the truck cannot be
entirely excluded.
The truck and all other system components
comply with current safety requirements.
Nevertheless, even when the truck is used
for its proper purpose and all instructions
are followed, some residual risk cannot be
excluded.
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck
must be instructed regarding these risks that arise
through use of the truck.
In addition, we draw attention to the safety regulations in these operating instructions.
The risks can include:
• Escape of consumables due to leakages,
rupture of lines and containers etc.
• Risk of accident when driving over difficult
ground such as gradients, smooth or
irregular surfaces, or with poor visibility
etc.
• Falling, tripping etc. when moving on
the truck, especially in wet weather, with
leaking consumables or on icy surfaces
• Fire and explosion risks due to batteries and
electrical voltages
• Human error resulting from failure to
observe the safety regulations,
• Unrepaired damage or defective and worn
components,
• Insufficient maintenance and testing
• Use of incorrect consumables
• Exceeding test intervals
16
50108043405 [EN]
2
Introduction
Residual risks
The manufacturer is not held responsible for
accidents involving the truck caused by the
failure of the operating company to comply
with these regulations either intentionally or
carelessly.
Stability
The stability of the truck has been tested to
the latest technological standards and is
guaranteed if the truck is used properly and
according to its intended purpose. These
standards only take into account the static
and dynamic tipping forces that can arise
during specified use in accordance with the
operating rules and intended purpose. The
risk of exceeding the moment of tilt that arises
from improper use or incorrect operation
cannot be excluded in extreme cases, and
will impact stability.
The risks can include:
• loss of stability due to unstable or sliding
loads etc.
• cornering at excessive speeds,
• moving with the load raised,
• moving with a load that is protruding to the
side (e.g. sideshift),
• turning and driving diagonally across
slopes,
• driving on slopes with the load on the
downhill side,
• loads that are too wide,
• swinging loads,
• ramp edges or steps.
Special risks associated with using
the truck and attachments
Approval from the manufacturer and attachment manufacturer must be obtained each
time the truck is used in a manner that falls
outside the scope of normal use, and in cases
where the driver is not certain that he can use
the truck correctly and without the risk of accidents.
50108043405 [EN]
17
2
Introduction
Residual risks
Overview of hazards and countermeasures
NOTE
This table is intended to help evaluate the
hazards in your facility and applies to all drive
types. It does not claim to be complete.
NOTE
Observe the national regulations for your
country!
Hazard
Measure
Check note
√ actioned
- not applicable
O
Truck equipment does Test
not comply with local
regulations
Lack of skills and
qualification of driver
Usage by unauthorised persons
Truck not in a safe
condition
Driver training (sit-on
and stand-on)
Access with key only
for authorised persons
Recurrent testing and
rectification of defects
O
Risk of falling when
using working
platforms
Compliance with
national regulations
(different national
laws)
O
Impaired visibility due
to load
Resource planning
O
Contamination of
respiratory air
Assessment of diesel
exhaust gases
O
Assessment of LPG
exhaust gases
O
18
Notes
If in doubt, consult
competent factory
inspectorate or
employers’ liability
insurance association
BGG 925
VDI 3313 driver permit
O
O
50108043405 [EN]
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace
Safety Ordinance)
and employer’s
liability insurance
associations
BetrSichVO
(Workplace Safety
Ordinance)
TRGS 554 and
BetrSichVO
(Workplace Safety
Ordinance)
MAK (Maximum
Workplace
Concentrations) list
and BetrSichVO
(Workplace Safety
Ordinance)
2
Introduction
Residual risks
Hazard
Measure
Impermissible usage
(improper usage)
Issuing of operating
instructions
Check note
√ actioned
- not applicable
O
Written notice of
instruction to driver
O
Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
O
Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
Observe BGV D34,
operating instructions
and VDMA rules
Observe BetrSichVO
(Workplace Safety
Ordinance), operating
instructions and
VDMA (German
Engineering
Federation) rules
Observe BetrSichVO
(Workplace Safety
Ordinance), BGR
104 and operating
instructions
Observe BetrSichVO
(Workplace Safety
Ordinance), BGR
104 and operating
instructions
O
Notes
BetrSichVO
(Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
BetrSichVO
(Workplace Safety
Ordinance) and
ArbSchG (Health and
Safety at Work Act)
When fuelling
a) Diesel
b) LPG
When charging the
traction battery
When using battery
chargers
When parking LPG
trucks
50108043405 [EN]
O
O
VDE 0510: In
particular
- Ensure ventilation
- Insulation value
within permissible
range
O
BetrSichVO
(Workplace Safety
Ordinance) and BGR
104
O
BetrSichVO
(Workplace Safety
Ordinance) and BGR
104
19
2
Introduction
Residual risks
Hazard
Measure
Check note
√ actioned
- not applicable
Notes
With driverless transport systems
Roadway quality
inadequate
Clean/clear driveways
O
Load carrier
incorrect/slipped
Reattach load to pallet
O
Drive behaviour
unpredictable
Employee training
O
Driveways blocked
Mark driveways
Keep driveways clear
O
Driveways intersect
Announce right-ofway rule
O
No person detection
during depositing and
retrieval
Employee training
O
.
Hazards to employees
In accordance with the operating safety ordinance (BetrSichVO) and the German law on
health and safety at work (ArbSchG), the operator (see ⇒ Chapter "Definition of terms used
for responsible persons", P. 24) must identify and assess hazards during operation and
establish health and safety measures at the
workplace necessary to protect employees
(BetrSichVO). The operator must therefore
draw up appropriate operating instructions (§
6 ArbSchG) and make them available to the
driver. A person responsible for health and
safety must be appointed.
Truck construction and equipment is regulated
by the Machines Directive 2006/42/CE and
therefore bears the CE mark. On account of
their own CE mark, the attachment parts are
not included in the hazard assessment. The
operator must, however, select the type and
equipment of the trucks so as to comply with
local regulations relating to deployment.
20
50108043405 [EN]
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace Safety
Ordinance)
BetrSichVO
(Workplace Safety
Ordinance)
2
Introduction
Residual risks
The results must be documented (§ 6 ArbSchG). In the case of truck deployment involving similar hazard situations it is permitted to
summarise the results. This overview (see
⇒ Chapter "Overview of hazards and countermeasures", P. 2-18) is designed to assist
in satisfying the conditions of this regulation.
The overview specifies the main causes of
accidents in the event of non-compliance. If
other major operational hazards are involved,
these must also be taken into consideration.
The conditions of use for trucks are broadly
similar in many plants, so that the hazards
can be summarised in one overview. Follow
the information provided by the relevant
employers’ liability insurance company in this
regard.
50108043405 [EN]
21
2
Introduction
Residual risks
22
50108043405 [EN]
3
Safety
3
Safety
Definition of terms used for responsible persons
Definition of terms used for responsible persons
Operating company
The operating company is the natural or legal
person or group who operates the truck or on
whose authority the truck is used.
The operating company must ensure that the
truck is only used for its proper purpose and in
compliance with the safety regulations set out
in these operating instructions.
The operating company must ensure that
all users read and understand the safety
information.
The operating company is responsible for the
scheduling and correct performance of regular
safety checks.
We recommend that the national performance
specifications are adhered to.
Specialist
A qualified person is defined as a service
engineer or a person who fulfils the following
requirements:
• A completed vocational qualification that
demonstrably proves their professional
expertise. This proof should consist of
a vocational qualification or a similar
document.
• Professional experience indicating that
the qualified person has gained practical
experience of trucks over a proven period
during their career. During this time, they
have become familiar with a wide range of
symptoms that require checks to be carried
out, for example from the results of a hazard
assessment or from a daily inspection.
• Recent professional involvement in the field
of the truck test in question and an appropriate further qualification are essential. The
qualified person must have experience of
carrying out the test in question or of carrying out similar tests. Moreover, such a
person must also be aware of the latest
technological developments regarding the
24
50108043405 [EN]
3
Safety
Definition of terms used for responsible persons
truck to be tested and the risk being assessed.
Expert
An expert is considered to be someone whose
technical training and experience have enabled them to develop appropriate knowledge
of industrial trucks and who is sufficiently familiar with the applicable national health and
safety regulations, directives and generally
recognised technical conventions (standards,
VDE regulations, technical regulations of
other member states of the European Union
or other countries that are signatories to the
treaty establishing the European Economic
Area) capable of assessing the condition of
industrial trucks in terms of health and safety.
Driver
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 to
the operating company or an authorised representative, and have been specifically instructed to drive the truck. Specific knowledge
of the truck to be operated is also required.
The training obligations under §3 of the Health
and Safety at Work Act and §9 of the plant
safety regulations are deemed to have been
satisfied if the driver has been trained in
accordance with BGG (General Employers’
Liability Insurance Association Act) 925.
Comply with the national regulations in force
in the country.
Driver rights, duties and rules of behaviour
The driver must be trained in his rights and
duties.
The driver must be granted the required rights.
The operator must wear appropriate protective equipment (protective clothing, safety
footwear, safety helmet, industrial goggles
50108043405 [EN]
25
3
Safety
Definition of terms used for responsible persons
and safety gloves) suited to the operating conditions, the job and the load to be lifted. The
driver must wear safety footwear for driving
and braking in complete safety.
The drive must be familiar with the operating
instructions, which must remain accessible at
all times.
The driver must:
• Have read and understood the operating
instructions
• Know how to operate the truck in complete
safety
• Be physically and mentally capable of
driving the truck safely
DANGER
The use of drugs, alcohol or medications that have
an effect on reactions impair a person’s ability to
drive the truck!
Individuals under the influence of the aforementioned substances are not permitted to perform any
work on or with an industrial truck.
Prohibition on use by unauthorised
persons
The operator is responsible for the truck during
working hours. He must prohibit any operation
of the machine by unauthorised persons.
When leaving the truck, the driver must secure
it against any unauthorised use.
26
50108043405 [EN]
3
Safety
Basic principles for safe operation
Basic principles for safe operation
Insurance cover on company
premises
In many cases, company premises are
restricted public traffic areas.
NOTE
The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.
Warning regarding non-original parts
Original parts, attachments and accessories
are specially designed for this truck. We
specifically draw your attention to the fact that
parts, attachments and accessories supplied
by other companies have not been tested and
approved by STILL.
CAUTION
Installation and/or use of such products may therefore have a negative impact on the design features
of the truck and thus impair active and/or passive
driving safety.
We recommend that you obtain approval from the
manufacturer and, if necessary, from the relevant
regulatory authorities before installing such parts.
The manufacturer accepts no liability for any damage caused by the use of non-original parts and
accessories without approval.
Modifications and refitting
If your truck is to be used in specific conditions (refrigerated warehouse or flameproof
protection), it must be specially equipped and
approved for this purpose, if applicable.
If your truck is used for work that is not specified in the guidelines or in this manual and it
must be modified or refitted for this purpose,
please remember that any structural modification may affect truck handling while driving
and its stability, and may lead to accidents.
50108043405 [EN]
27
3
Safety
Basic principles for safe operation
You should therefore contact the manufacturer before carrying out any modification. No
modification that may affect stability is permitted without the manufacturer’s authorisation.
Any constructional modification or transformation of your truck is forbidden without prior
written permission from the manufacturer.
Authorisation from the relevant authority may
also be required.
You may only make a modification or alteration
to your truck, if the manufacturer is no longer
in business and is unlikely to be taken over by
another company, and only on condition that:
• the modification or alteration is designed,
tested and implemented by one or more
engineers who are experts in the field of
industrial trucks and their safety
• records are kept of the design, test(s)
and implementation of the modification
or alteration
• appropriate changes are approved and
made to the capacity plate(s), decals, labels
and operating instructions
• a permanent and clearly visible label is
attached to the truck indicating the nature of
the modification or alteration as well as the
date of the modification or alteration, and
the name and address of the company that
carried out the work.
Medical equipment
When a driver is wearing medical equipment,
e.g. heart pacemaker or hearing aids, the
operation of this equipment may be affected.
A doctor or the manufacturer of the medical
equipment should be asked whether the
equipment is sufficiently protected against
electromagnetic interference.
28
50108043405 [EN]
3
Safety
Safety tests
Safety tests
Regular safety inspection of the truck
Safety inspection based on time and
extraordinary incidents
As part of this inspection, a complete check
of the technical condition of the truck must be
performed with regard to accident safety.
In addition, the truck must be thoroughly
checked for damage that could potentially
have been caused by improper use. A test
log must be created. The results from the
inspection must be retained until a further two
inspections have been carried out.
STILL GmbH Hamburg
Regelmäßige Prüfung
(FEM 4.004)
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
95/63/EG, 99/92/EG, 2001/45/EG
Nächste Prüfung
56344391019
The operating company must ensure that the
truck is checked by a specialist at least once a
year or after particular incidents.
The inspection date is indicated by an adhesive label on the truck.
– Arrange for the service centre to perform
periodic safety inspections on the truck.
– Observe guidelines for checks carried out
on the truck in accordance with FEM 4.004.
The operator is responsible for ensuring any
defects are remedied without delay.
Die Prüfplakette ersetzt nicht das Prüfprotokoll
Mitglied der:
Fédération
Européene
de la Manutention
0000_003-001_V3
– Contact your service centre.
NOTE
Observe the national regulations for your
country!
Electrical insulation test
The truck’s electrical insulation must have
sufficient insulation resistance. Insulation
resistance must be tested in accordance with
DIN 57117 and DIN 43539, VDE 0117 and
VDE 0510 at least once a year.
NOTE
The truck’s electrical system and the batteries
must be checked separately.
50108043405 [EN]
29
3
Safety
Safety tests
Measuring battery insulation resistance
NOTE
Nominal battery voltage < test voltage < 500V.
– Measure insulation resistance using a
suitable meter.
The insulation resistance is sufficient when it
has a nominal value of at least 1000 Ohms/V
against the chassis.
Ask our service department.
Measuring the insulation resistance of
the electrical system
NOTE
Nominal battery voltage < test voltage < 500V.
– Before testing the circuit, check that it is
electrically dead.
– Measure insulation resistance using a
suitable meter.
The insulation resistance is sufficient when it
has a nominal value of at least 1000 Ohms/V
against the chassis.
Ask our service department.
30
50108043405 [EN]
3
Safety
Safety regulations for handling consumables
Safety regulations for handling consumables
Permissible consumables
DANGER
Failure to observe the safety regulations relating to
consumables may result in a risk of injury, death or
damage to the environment.
– Observe the safety regulations when handling
such materials.
Refer to the maintenance data table for the
permissible substances that are necessary for
operation (see ⇒ Chapter "Table of maintenance data", P. 6-111).
Oils
DANGER
Oils are flammable!
– Follow the statutory regulations.
– Do not allow oils to come into
contact with hot engine parts.
– No smoking, fires or naked flames!
DANGER
Oils are toxic!
– Avoid contact and consumption.
– If vapour or fumes are inhaled,
move to fresh air immediately.
– In the event of contact with the
eyes, rinse thoroughly (for at least
10 minutes) with water and then
consult an eye specialist.
– If swallowed, do not induce
vomiting. Seek immediate medical
attention.
50108043405 [EN]
31
3
Safety
Safety regulations for handling consumables
WARNING
Prolonged intensive contact with the
skin can result in dryness and irritate
the skin!
– 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 of slipping on spilled oil, particularly
when combined with water!
– Spilt oil should be removed immediately with
oil-binding agents and disposed of according to
the regulations.
ENVIRONMENT NOTE
Oil is a water-polluting substance!
• Always store oil in containers that comply
with the applicable regulations.
• Avoid spilling oils.
• Spilt oil should be removed immediately
with oil-binding agents and disposed of
according to the regulations.
• Dispose of old oils according to the regulations.
Hydraulic fluid
WARNING
These fluids are pressurised during
operation of the truck and are
hazardous to your health.
– Do not spill the fluids.
– Follow the statutory regulations.
– Do not allow the fluids to come into
contact with hot engine parts.
32
50108043405 [EN]
3
Safety
Safety regulations for handling consumables
WARNING
These fluids are pressurised during
operation of the truck and are
hazardous to your health.
– Do not allow the fluids to come into
contact with the skin.
– Avoid inhaling spray.
– Penetration of pressurised
fluids into the skin is particularly
dangerous if these fluids escape
at high pressure due to leaks in
the hydraulic system. In case of
such injury, immediate medical
assistance is required.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
ENVIRONMENT NOTE
Hydraulic fluid is a water-polluting substance.
• Always store hydraulic fluid in containers
that comply with regulations
• Avoid spills
• Spilt hydraulic fluid should be removed
immediately with oil-binding agents and
disposed of according to the regulations
• Dispose of old hydraulic fluid according to
the regulations
Battery acid
WARNING
Battery acid contains dissolved
sulphuric acid. This is toxic.
– Avoid touching or swallowing the
battery acid at all costs.
– In case of injury, seek medical
advice immediately.
50108043405 [EN]
33
3
Safety
Safety regulations for handling consumables
WARNING
Battery acid contains dissolved
sulphuric acid. This is corrosive.
– When working with battery acid,
always wear a protection suit and
eye protection.
– When working with battery
acid, never wear a watch or any
jewellery.
– Do not allow any acid to get
onto clothing or skin or into the
eyes; if this does happen, rinse
immediately with plenty of clean
water.
– In case of injury, seek medical
advice immediately.
– Immediately rinse away spilt
battery acid with plenty of water.
– Follow the statutory regulations.
ENVIRONMENT NOTE
– Dispose of used battery acid in line with the
applicable regulations.
Disposal of consumables
ENVIRONMENT NOTE
Materials that accumulate during repair,
maintenance and cleaning must be collected
properly and disposed of in accordance with
the national regulations for the country in
which the truck is being used. Work must
only be carried out in areas designated for the
purpose. Care must be taken to minimise any
environmental pollution.
– Soak up any spilt fluids such as hydraulic
oil, brake fluid or gearbox oil using an
oil-binding agent.
– Neutralise any spilt battery acid immediately.
– Always observe national regulations concerning the disposal of used oil.
34
50108043405 [EN]
3
Safety
Safety regulations for handling consumables
Emissions
Noise emissions
The noise specifications in the technical data
were determined according to CEN standard
"Noise measurement of industrial trucks,
sound level at the workplace and sound power
level" (in preparation). The sound power level
at the driver’s station is 65 dB(A).
According to directive 86/188/EEC, however,
the specified truck noise levels cannot be
used for determining the noise emission at the
workplace (daily personal noise allowance).
If required, these must be determined directly
at the workplace under actually existing
influences (further sources of noise, special
operating conditions, sound reflections).
Frequency characteristics
The machine frequencies were determined
on an identical machine in accordance with
EN 13059. "Safety industrial trucks. Test
methods for measuring vibration".
Weighted effective value
of acceleration on the
human body (feet or
cushion)
+1.10 m/s2
Uncertainty K
±0.17 m/s2
Studies have shown that the frequency of
hand and arm vibrations at fork truck steering
wheels or controls is under 2.5 m/s². For this
reason no test specifications are available for
these measurements.
The personal vibration load on the driver
for one work day must be determined, if
necessary, at the site of operation in order
to take all other influencing factors such as
road stretch, intensity of operation, etc., into
consideration.
Battery emissions
During charging, the drive battery emits a
mixture of oxygen and hydrogen (detonating
gas). This gas mixture is explosive and it must
not be ignited. The risk of explosion can be
50108043405 [EN]
35
3
Safety
Safety regulations for handling consumables
avoided through sufficient ventilation and by
avoiding naked flames. Follow the safety
precautions for handling the traction battery.
36
50108043405 [EN]
3
Safety
Safety devices
Safety devices
Damage, defects and misuse of
safety devices
The driver must report any damage or other
defects to the truck or attachment immediately
to the supervisory personnel.
Trucks and attachments that are not functional
or safe may not be used until they have been
properly repaired.
Do not remove or deactivate safety devices
and switches.
Fixed set values may only be changed with the
approval of the manufacturer.
Work on the electrical system (e.g. connecting
a radio, additional headlights etc.) is only
permitted with the manufacturer’s written
approval. All electrical system interventions
must be documented.
Battery connection cables
CAUTION
Using sockets with NON-ORIGINAL battery connection cables can be dangerous (see purchase
references in the parts catalogue)
50108043405 [EN]
37
3
Safety
Battery connection cables
38
50108043405 [EN]
4
Overview
4
Overview
General view
General view
2
3
5
4
6
7
1
20
19
8
18
9
10
17
11
16
1
2
3
4
5
6
7
8
9
10
40
15
14
13
Battery connector
Tiller
Pedestrian mode traction button (option)
Backrest
Pedestrian mode traction button (option)
Load wheel
Forks
Lift cylinder
AC controller
Platform
12
1044_000-005
11
12
13
14
15
16
17
18
19
20
Battery
Brake
Drive motor
Gearbox
Traction wheel
Steering motor
Stabiliser
Hydraulic oil tank
Pump motor
Fuse mount
50108043405 [EN]
4
Overview
Controls and display elements
Controls and display elements
View of the control elements
2
1
3
4
123
456
789
PRG
PRG
5
6
10
9
7
8
1
2
3
4
5
Cubby hole
Battery compartment lock
Tiller
Battery plug
Presence area
6
7
8
9
10
50108043405 [EN]
1044_000-008
Cubby hole
Pedestrian mode traction button (option)
Cushion
Pedestrian mode traction button (option)
Cubby hole
41
4
Overview
Controls and display elements
CX 20 cockpit
4
5
6 7 8
9
10
3
11
12
13
2
14
1
123
789
456
15
PRG
PRG
16
20
19
17
18
1044_000-006
1
2
3
4
5
6
7
8
9
10
42
Lower button
Lift button
Horn button
Tortoise button
PRG ↑ (scrolling) button
Numbers 123 button
Display
I (ON) button
Numbers 456 button
PRG ↲ input (enter) button
11
12
13
14
15
16
17
18
19
20
Numbers 789 button
Hare button
Horn button
Lift button
Lower button
Handle
Travel control
Emergency brake switch
Travel control
Handle
50108043405 [EN]
4
Overview
Controls and display elements
Version with movable step plate
(optional)
•
•
•
•
•
(1) Step plate lowering pedal
(2) Step plate raising pedal
(3) Emergency stop button
(4) Handholds
(5) Button for slow movement of truck
towards the motor side (where present)
• (6) Button for slow movement of truck
towards the fork side (where present)
• (7) Fork raising button (where present)
• (8) Fork lowering button (where present)
7
5
8
4
1
2
50108043405 [EN]
6
3
4
2258
43
4
Overview
Controls and display elements
800 Kg
600 mm
800 Kg
h3= 1580 mm
1
600 mm
CX-H version
1800 mm
800 Kg
800 Kg
2259
The capacity plate (1) indicates truck load
capacity in kg according to the centre-ofgravity distance and lift height. If two loads
are transported at the same time, arrange the
loads as shown on the plate (1).
Forbidden! It is strictly forbidden to use the
truck as a double stacker (2).
2260
44
50108043405 [EN]
4
Overview
Marking positions
Marking positions
Location of plates and labels
1
2
3
4
5
6
7
8
Warning label
Manufacturer’s logo and product code
Manufacturer’s plate
Hook symbol
Warning label
"Do not mount" label
Hook symbol
Cold store operation label (option)
9
10
11
12
13
14
50108043405 [EN]
Manufacturer’s logo
Customer’s logo (option)
Warning label
"Do not sling" symbol
Emergency stop label
Serial number label (bar code on the chassis)
45
4
Overview
Marking positions
Labels
1
2
3
4
5
6
7
8
9
10
46
Operating instructions
Slinging - See the operating instructions
UVV support (Germany only)
UVV plate (Germany only)
Company plate
Load capacity plate (example)
Manufacturer’s logo
Truck identification (example)
Company decal
Do not fold the forks when they are holding a
load
11
12
13
14
15
16
17
18
19
20
Do not lift a load with the initial lift in the upper
position
Do not step under a raised load
Do not climb
Do not stand on the forks
Risk of crushing hands
Risk of crushing feet
Slinging point
Do not sling here
Electrical plate (example)
Gel battery
50108043405 [EN]
4
Overview
Marking positions
21
22
23
24
25
26
27
28
29
30
31
On-board charger label
Mains connector (on-board charger)
"Plugs" label
Hydraulic filler
Maximum pressure (example)
Platform pressure diagram (example)
Operating mode indication label
"Cockpit" label
Stop
Nacelle
Automatic mode confirmation (EXU-H
autolift only)
32
33
34
35
36
37
38
39
40
Automatic mode selection indicator (EXU-H
autolift only)
Manual or automatic mode selection
(EXU-H autolift only)
Automatic lifting/lowering mode selection
Arrows
Cold store
Traction controller label
Slow forward travel (pedestrian mode)
Raising/lowering of forks
Slow forward travel (pedestrian mode) +
raising/lowering of forks
NOTE
The labels listed below are not necessarily
affixed to all trucks.
50108043405 [EN]
47
4
Overview
Marking positions
Chassis frame labelling
1
The truck’s serial number is marked on the
chassis frame (1).
OM2271
Data plate
NOTE
Please indicate the serial no. for all technical
enquiries.
1
2
3
4
5
6
7
8
9
10
11
12
48
Model
Manufacturer
Serial no.
Year of manufacture
Unladen weight (without battery) in kg
Maximum battery weight
Minimum battery weight
Additional weight (ballast) in kg
Nominal power rating in kW
Battery voltage V
Rated capacity in kg
EC conformity symbol
50108043405 [EN]
4
Overview
Options and variants
Options and variants
Overview of options and models
Optional
CX
20/CX-H
CX-D 20
Optional
Optional
520 mm
Standard
–
560 mm
Optional Standard
670 mm
Optional
Dimensions
Lowering locking during
travel
115 mm
Exterior fork width b5
Battery housing
Forks
Boot 97 for 24 V / 345–465 Ah battery with
rollers
Boot 91 for 24 V / 520–620 Ah battery with
rollers
Length 1150 mm, section 180 mm
Load distance x = 967 mm
Length 1190 mm, section 172 mm
Load distance x = 1005 mm, u = 185 mm
Length 1450 mm, section 172 mm
Load distance x = 1265 mm, u = 185 mm
Length 1650 mm, section 172 mm
Load distance x = 1105 mm, u = 545 mm
Length 2150 mm, section 172 mm
Load distance x = 1605 mm, u = 545 mm
Length 2390 mm, section 172 mm
Load distance x = 1845 mm, u = 545 mm
Length 2390 mm, section 172 mm
Load distance x = 1615 mm, u = 775 mm
Length 2900 mm, section 172 mm
Load distance x = 2125 mm, u = 775 mm
Length 3100 mm, section 172 mm
Load distance x = 2125 mm, u = 975 mm
–
Standard Standard
Optional
Optional
–
Standard
Optional
–
Optional
–
Optional
–
Optional
–
Optional
–
Standard
–
Optional
–
Optional
–
Load backrest
Height 1875 mm
Optional
–
Single fork rollers
Polyurethane 85 x 100 mm, required to
collect 800 mm pallets crosswise
Optional
–
Twin fork rollers
Polyurethane 85 x 80 mm
Standard
–
Single fork rollers
Polyurethane 85 x 80 mm
–
Optional
Polyurethane, 85 x 59.9 mm
–
Standard
Twin fork rollers
Drive wheel
Ø 250 x 100 mm polyurethane tyre
Standard Optional
Ø 250 x 100 mm notched polyurethane tyre
Standard Optional
50108043405 [EN]
49
4
Overview
Options and variants
Optional
Dimensions
Fork end pieces
With input/output sliding shoes
Bumpers
Type with rubber buffer, 165 mm high, fitted
on the drive area
Type with a metal guard, 545 mm high, fitted
on the drive area
Metal battery cover
For boot 97
Padded backrest
Step plate
CX
20/CX-H
CX-D 20
Optional
–
Optional
Optional
Optional
Optional
Optional
Optional
Standard Standard
Folding, 400 mm high from the platform
Optional
–
Lower drive area
Optional
Optional
Front accessory bar
Upper drive area
Optional
Optional
Upper with drive-area-side bridge piece
Optional
Optional
Optional
Optional
Pedestrian mode
With forward/reverse gear and throttle
release in the cockpit
With forward/reverse gear and throttle
release in the cockpit + forward/reverse
inching control using buttons on either side
of the backrest
With forward/reverse gear using buttons on
either side of the backrest
Optional
Optional
Optional
Optional
Rear accessory bar
Display
Speed limitation
Platform
Hour meter
Combi/hour meter
50
Lower fork side
Optional
–
Upper fork side
Optional
–
Upper with fork-side bridge piece
Optional
–
Programmable maintenance intervals
Optional
Optional
With forks lowered
Optional
–
at 6 km/h
Optional
Optional
at 8 km/h
Optional
Optional
at 10 km/h
Optional
Optional
750-mm lift with battery boot 97
Optional
–
750-mm lift with battery boot 91
Optional
–
Standard connected to travel and lifting
Standard Standard
Permanent reading standard connected to
travel and lifting
For open lead-acid batteries with speed
limitation
For sealed batteries with speed limitation
50108043405 [EN]
Optional
Optional
Standard Standard
Optional
Optional
4
Overview
Options and variants
CX
20/CX-H
CX-D 20
Optional
Dimensions
Cold store performance
Protection for intermittent use at -30°C
Reducer oil at -30°C
Special hydraulic fluid at -30°C
Cockpit panel heated using resistors
Steering regulator heated using resistors
Non-slip step plate and greased axles
Optional
Optional
160 A SBE red with handle
Optional
Optional
160 A DIN Rema with handle
Optional
Optional
Red SBE 160 A with handle with air intake
Optional
Optional
160 A with Rema DIN air intake with handle
Optional
Optional
320 A SBE red with handle
Optional
Optional
Red SBE 320 A with handle with air intake
Optional
Optional
Clipboard
Adjustable DIN A4-format mounted on the
accessory bar
Optional
Optional
Charger socket
Depending on the fixed battery socket
Optional
Optional
160 A, DIN 43589
Optional
Optional
SBE 160 red
Standard Standard
SBE 320 red
Optional
Power supply connector
Fixed battery socket
MMS Preparation
Hook
Electrically and mechanically set up on the
front part for scanner and 8.4" or 12.1" STILL
terminal including 24 V/5 A electrical power
Optional
supply, interface cable with a 3-pole socket
and a standard VESA75 bracket with holes.
Position: accessories bar on the motor side
Rear part for terminal and 24 V power supply,
Optional
DIN connector plug and support on the
accessories bar on the fork side
Fitted to the accessory bar
FleetManager
Optional
Optional
Optional
–
Optional
.
Overview of accessories
• Master code (factory setting "1 2 3 4")
• Key for battery compartment (2 items). With
its locking function, this key prevents the
battery cover from being opened so that
non-authorised persons cannot work on
the battery. This locking function can be
50108043405 [EN]
51
4
Overview
Options and variants
released by pulling the key out with the
battery cover open, thus leaving the cover
unlocked. The instructions for the use of
the key for opening and closing the battery
cover do not apply then.
Battery electrolyte level indicator
LED (optional)
1
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the battery plug.
2
The LED indicates whether it is necessary to
top up the distilled water in the battery.
Operation:
• If the LED (1) or (2) is green, there is a
sufficient level of electrolyte in the battery.
The battery must not be topped up with
distilled water.
• If the LED (1) or (2) is red, there is an
insufficient level of electrolyte in the battery.
The battery must be topped up with distilled
water.
2256
52
50108043405 [EN]
4
Overview
Options and variants
Load back rest with vertical pallet
hook (optional)
Hand protective guard (L):
• Do not remove the guard
• Before using the truck, check that there is a
protective guard and that this guard is intact
The system allows you to transport empty
pallets in a vertical position in the following two
ways:
• See image (1)— The pallet (F) is held by the
clamp (D)
• See image (2)— The pallet (F) is held by the
clamp (E)
If the pallet to be transported is positioned as
shown in image (1), the clamp (E) should be
turned backwards (H). Procedure:
• Pull the bar (G) upwards (B) to lower the
clamps (D) and (E)
• Unscrew the knob (C)
• Turn the clamp (E) backwards (H)
• Completely screw in the knob (C)
• Repeat the preceding steps for the other
clamp (E)
• Push the bar (G) downwards (A) to raise
clamps (D) and (E)
• Position the pallet in the position defined
(1) and clamp it between the clamps (D),
pulling the bar (G) towards (B)
CAUTION
Risk of crushing hands and feet
While moving the bar (G) towards (A) or (B), keep
your hands away from the clamps (D - E) of the
pallet lock.
When manually positioning the pallet, be careful
that the pallet does not fall.
If the pallet to be transported is positioned as
shown in image (2), the clamp (E) should be
turned forwards (I). Procedure:
• Pull the bar (G) upwards (B) to lower the
clamps (D) and (E)
• Unscrew the knob (C)
• Turn the clamp (E) forwards (I)
• Completely screw in the knob (C)
50108043405 [EN]
53
4
Overview
Options and variants
• Repeat the preceding steps for the other
clamp (E)
• Push the bar (G) downwards (A) to raise
clamps (D) and (E)
• Position the pallet in the position defined (2)
and clamp it between the clamps (E), pulling
the bar (G) towards (B)
CAUTION
Risk of crushing hands and feet
While moving the bar (G) towards (A) or (B), keep
your hands away from the clamps (D - E) of the
pallet lock.
When manually positioning the pallet, be careful
that the pallet does not fall.
54
50108043405 [EN]
5
Operation
5
Operation
Intended use of the trucks
Intended use of the trucks
CAUTION
This machine is designed for order picking (collecting and gathering together items stored in the
warehouse before dispatch), horizontal transport
tasks and entering and removing pallets to and from
stock.
The dimensions and capacity of the trailers, pallets
or containers must be adapted to the load being
transported and must ensure stability.
The table of characteristics and performance
attached to this user manual gives you some of 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 him to put in
place any necessary additional safety measures.
Checks and actions prior to use
Daily pre-operational checks and
services
WARNING
Do not operate the truck until it is properly repaired
if any damage or faults are detected on the truck
or attachment (Option) during the following inspections. Safety features and switches must not be
removed or disabled. Fixed settings must not be
altered.
– Report any faults to the supervisors.
WARNING
Operation of the truck is only permissible with the
lids and flaps closed and with all covers in place.
Daily checks before use
The following checks must be performed on a
daily basis in order to keep your truck in good
condition and to operate safely. These checks
supplement and do not replace the scheduled
maintenance operations.
56
50108043405 [EN]
5
Operation
Checks and actions prior to use
• Visually check that the various truck components are in good condition
• Check that the fork arms are in good
condition
• Check that all of the commands work
correctly: buttons, throttles etc.
• Turn the cockpit and check that, when
released, it automatically returns to the
centre position
• Check that the battery plug/outlet are
correctly positioned and intact
• Check that the wheels (traction, load, pivot)
are in good condition
• Check that the buzzer signalling when the
truck is travelling in the direction of the fork
arms works correctly (if present)
• Check that the emergency stop button
works correctly
• Check that the horn works correctly
• Check that the start/stop key works correctly
• Check that the electromagnetic brake works
effectively
• Check that the battery cover is fastened
correctly
• Check that the battery cover is closed and
locked correctly
• Check that the battery retainers are correctly positioned and fastened
• Check that the lifting chain retaining device
(if present) is in good condition and properly
fastened
• Check that the truck slows down on curves
• Check that the buttons and throttle automatically return to their correct position after
release
• Check that the truck brakes and stops when
the throttle is released
• Check the battery electrolyte level and density as indicated in the battery instructions
• Check tyre wear
• Check that the battery wiring is intact
• Check that the pallet hook, if present, is
working correctly and that it has a protective
guard (optional).
50108043405 [EN]
57
5
Operation
Commissioning
DANGER
DO NOT use the truck, but call the technical service
department, if you notice any malfunctions or if you
have any doubts about its correct operation.
Connecting the battery plug (charging station)
– Disconnect the battery socket (1) from the
charging station and insert into the plug on
the truck.
1
1044_606-013
Commissioning
Turning on the truck
NOTE
The pallet truck is equipped with a digital
control and is taken into operation by entering
a driver code. The driver code consists of four
figures and is assigned by the pool manager.
It is used for normal use and operation of
the truck by the driver and operator. The
knowledge of the code is like a key and should
not be misused. Do not tell third persons your
driver code except if expressly ordered to do
so.
– Other codes can be entered, ⇒ Chapter "Digicode control ", P. 5-85.
58
123
456
789
PRG
PRG
1044_505-007
50108043405 [EN]
5
Operation
Commissioning
Entering the driver code
1
2
3
4
– Press the I (ON) button (6). The message
CodE (8) will appear in the display (4) and
disappear after approx. 1 s. This is the
prompt to enter your valid 4-digit driver
code. Enter the code in the same way as
entering characters on a mobile phone.
123
– Press the buttons (1), (2), (3) until the
desired number appears:
789
456
For:
• code numbers 1-2-3 press
• code numbers 4-5-6 press
• code numbers 7-8-9 press
123
456
789
button (1)
button (2)
button (3)
After you have entered a number, the cursor
goes to the next digit. A flashing line cursor
appears in the display (9) (code shown is an
example).
PRG
PRG
5
7
6
1044_505-001
8
NOTE
If a wrong number was entered, you can delete
it by pressing the PRG ↑ (scrolling) button (7).
1044_505-002
50108043405 [EN]
59
5
Operation
Commissioning
– The number is deleted, the flashing line
cursor (9) appears again. The code number
can be re-entered.
9
– After the 4th number is entered, confirm the
input by depressing the PRG ↲ button (5).
The manufacturer’s name appears briefly
in the display. The pallet truck can now be
operated.
NOTE
%
If an error code such as E380 (10) appears,
shut the truck off by pressing button (6) and
repeat the start-up as described in the chapter
"Operation of the Digicode control", section
"Error Code".
10
1044_505-017
NOTE
The following information can be displayed by
depressing the PRG ↑ (scrolling) button (7)
repeatedly.
• Hour meter⇒ Chapter "Hour meter", P. 5-61
• Battery charge⇒ Chapter "Battery
charge", P. 5-61
• Display of time to next servicing⇒ Chapter "Display of time to next servicing", P. 5-62
Starting with FleetManager (optional)
1
2
3
4
– Push the I key (START) (6). Do not pay
attention to the Code alert that appears in
the display
– Start the truck directly via the FleetManager
keyboard or reading device, depending on
the version.
123
456
789
PRG
PRG
5
7
60
50108043405 [EN]
6
1044_505-001
5
Operation
Commissioning
Hour meter
1
The display changes approx. 4-5 s after
powerup to show the operating hours (1) and
the hour-glass symbol (2). These are the total
number of hours since the commissioning
of the pallet truck. The meter always runs
when the pallet truck is driven or a load is
raised. Have the maintenance carried out
according to the service hours specified in the
maintenance schedule.
2
NOTE
1044_505-004
The meter goes to 9999.
Battery charge
3
– Press the PRG ↑ (scrolling) button (4) to
display the available battery charge (3).
NOTE
%
After the battery is connected, the correct state
of charge appears only after about 1 minute.
The charge is shown in per cent and changes
in steps of 5 %.
1044_505-005
NOTE
The factory setting of the battery charge
indicator is for a lead battery. The indicator
can also be set to a gel battery. Please contact
your Service.
• When a residual charge of 25 % is reached,
the display flashes. The battery must be
charged soon.
• If the display shows a residual charge of 20
%, the lifting device switches off.
CAUTION
123
456
789
PRG
PRG
4
1044_505-006
Deep discharging damages the battery.
The battery must immediately be charged as deep
discharging begins.
50108043405 [EN]
61
5
Operation
Commissioning
Display of time to next servicing
– Press the PRG ↑ (scrolling) button (4) to
display the time remaining until the next
scheduled servicing. The time is shown in
hours (6) and with the symbol of a spanner
(5). Have the maintenance carried out
according to service hours specified in the
maintenance schedule.
789
456
123
PRG
PRG
NOTE
4
The display of the time to the next servicing
can be set by your Service. Please contact
your Service in this regard.
– The display can show subsequent information ⇒ Chapter "Error code", P. 5-93.
1044_505-006
5
6
1044_505-018
Operating the horn
2
– Press the horn button (2) on the tiller.
123
456
789
PRG
PRG
1044_605-001
62
50108043405 [EN]
5
Operation
Commissioning
Checking the presence area and
brake
7
– Drive the truck.
123
– Leave the presence area (8). The truck will
brake to a stop.
456
789
PRG
PRG
8
1044_001-009
Checking the emergency brake
7
6
– Drive the truck slowly using the traction
control (4).
– Press the belly button (5). The truck is
braked to a stop.
123
– SToP appears in the display (6).
456
789
PRG
PRG
NOTE
After the disappearance of StoP in the
display, press the I (ON) button (7) to restart
work.
CAUTION
4
This brake may only be used in an emergency.
50108043405 [EN]
5
1044_490-006
63
5
Operation
Driving
Driving
Driving safety instructions
Driving conduct
The driver must follow the public rules of
the road when driving in company traffic.
The speed must be appropriate to the local
conditions. For example, the driver must drive
slowly around corners, in tight passageways,
when driving through swing-doors, at blind
spots, or on uneven surfaces. The driver
must always maintain a safe braking distance
from vehicles and persons in front and always
have the vehicle under control. He must
avoid stopping suddenly, turning at speed
and overtaking in dangerous places or in blind
spots.
Other people must not sit on the truck during
travel.
Visibility when driving
The driver must look in the direction of travel
and have a clear view of the route travelled
on. He must always ensure that the way
is clear, particularly when reversing. When
transporting goods that obstruct visibility, the
truck must be driven with the load trailing.
If this is not possible, a guide must walk
ahead of the truck. In this case, the truck may
only be driven at walking pace and with the
utmost caution. The truck must be stopped
immediately when eye contact with the guide
is lost.
64
50108043405 [EN]
5
Operation
Driving
Before driving
Dimensions of roadways and aisles
100
The dimensions and aisle widths contained in
section description apply under established
conditions to ensure safe driving. Check,
when necessary, if a wider aisle is required
when the load dimensions differ.
The required aisle widths (Ast) depend on the
dimensions of the load and may be calculated
following the formula: Ast = Wa - X + Length of
pallet + 200 mm.
Offset X
450 Ah
600 Ah
1190
1005
2430
2516
1450
1265
2690
2776
1650
1105
2530
2616
2150
1605
3030
3116
2390
1845
3270
3356
2390
1615
3040
3126
2900
2125
3550
3636
3100
2125
3550
3636
Ast
Wa
Fork
lengths
X
100
Turning radius (WA) values for
the calculation of aisle widths
(All values in mm)
Obey the national regulations.
The truck may only be used on roadways not
having too tight curves, too large gradients
and too narrow and too low passages.
1044_000-011
Condition of roadways
Roadways must be solid enough, free of
debris and dropped objects. Drainage ducts,
railway crossings and the like must be level
and, if necessary, provided with ramps so that
they can be crossed without jolts, if possible.
There must be sufficient clearance between
the highest parts of the truck or load and fixed
parts of the surroundings. The height depends
on the height of lift and the dimensions of the
load. Refer to the technical data.
50108043405 [EN]
65
5
Operation
Driving
Rules for roadways and work area
Only the roads released for traffic by the
operator or his representative may be driven
on. The roadways must be free of obstacles.
The load may only be stacked and stored at
the appropriate places. The operator and his
representative must ensure that unauthorized
persons keep away from the work area.
Hazards
Hazards on roadways must be marked with
the usual traffic signs or, if necessary, by
additional warning signs.
Emergency stop procedure
In an emergency, all truck functions can be cut
off.
7
123
– To do so, disconnect the battery plug (7).
The truck comes to a stop.
456
789
PRG
PRG
CAUTION
This safety feature may only be used in an emergency.
NOTE
8
To restart the start, first reconnect the battery
plug and then re-enter the driver code.
1044_001-009
Danger zone
The danger zone is the area in which persons
are endangered through the movement of the
truck, working devices, load-lifting devices (eg
attachment) or the load. This also includes
the area within the range of falling loads or a
descending working device.
66
50108043405 [EN]
5
Operation
Driving
WARNING
Danger of personal injury
Do not step on the forks.
WARNING
Persons can be injured in the danger zone of the
truck.
No person, except the driver in his normal operating
position, may stand in the danger zone of the truck.
If persons refuse to leave the danger zone despite
warnings, stop working with the truck immediately
and secure it against use by unauthorized persons.
DANGER
Danger of accidents through falling
loads!
Do not step or stand under a raised
load.
Persons in the danger area
Before starting up, the driver must ensure that
no person is standing in the danger area of the
truck.
A warning signal must be given in the event of
an impending danger to persons. If these
persons refuse to leave the danger area
despite the warning, the driver must stop work
with the vehicle immediately.
50108043405 [EN]
67
5
Operation
Driving
Driving in rider mode
– Step on the platform with both feet and step
on the presence area (1).
123
456
789
PRG
PRG
NOTE
The pallet truck is turned on.
WARNING
There should be no objects lying on the floor of the
driver’s platform, whose weight could activate the
dead man’s switch under the mat.
1
1044_501-001
1044_501-002
68
50108043405 [EN]
5
Operation
Driving
Driving forward
– Depress the top part of the throttle (2) or (3)
with the thumb.
– Truck speed is increased by depressing the
travel control further.
123
– When the travel control is released, the
truck is braked electrically.
456
789
PRG
PRG
Reversing
– Depress the lower part of the throttle (2) or
(3) with the thumb.
– Truck speed is increased by depressing the
travel control further.
3
2
1044_501-003
– When the travel control is released, the
truck is braked electrically.
Reversing direction
– Allow the travel control to return to its neutral
position.
– Operate the travel control progressively
in the opposite direction of travel until the
desired speed is reached.
Selecting the driving mode
2
3
NOTE
The pallet truck has 2 selectable driving
modes.
– For regular driving depress the
(3).
hare
123
button
456
789
PRG
PRG
– For driving with gentle acceleration depress
the tortoise button (2).
NOTE
The travel control (4) and (5) can be operated
with both the left and the right hand. Always
operate the travel control slowly to avoid jerky
starting, braking or reverslng.
50108043405 [EN]
5
4
1044_503-001
69
5
Operation
Driving
Driving, pedestrian operation with
tiller, slow approach with drive switch
– From the side, grip the handle (1) or (4) on
the tiller.
NOTE
123
The lift truck is switched on.
456
789
PRG
PRG
CAUTION
Take care when operating, especially if the user is
not familiar with using this function.
4
DANGER
1
3
Risk of crushing feet.
2
1044_501-004
Do not use this function for turning.
This function is designed to maintain a straight line.
Proceed from the cockpit with very slight movements.
NOTE
The traction switch (special equipment) (2)
or (3) on the tiller can be operated with either
hand. The speed is reduced; the tiller can
be used at any time to steer so that the truck
keeps going forward in a straight line. Always
use the traction switch carefully; the truck
reacts immediately to any given command.
Avoid jerky movements, braking or change of
direction. If the traction switch is pushed in for
quite a long time, a safety circuit immobilises
the truck. If this occurs, simply release the
traction switch and then activate it again.
Forward gear
– Press the upper part of the drive switch with
your thumb.
– The speed of the fork lift truck increases as
you push the traction switch further, up to a
limit of 2,5 km/h.
– When the traction switch is released, the
fork lift truck brakes electrically.
70
50108043405 [EN]
1044_501-005
5
Operation
Driving
Backwards driving
– Press the lower part of the drive switch with
your thumb.
– The speed of the fork lift truck increases as
you push the traction switch further, up to a
limit of 2,5 km/h.
– When the traction switch is released, the
fork lift truck brakes electrically.
Reversing direction of travel
– Cease current direction of travel.
– Operate the drive switch in the opposite direction of travel until you reach the required
speed.
Driving, pedestrian operation with
push button
1
NOTE
The fork lift truck is fitted with push buttons
(1) and (2) on both sides of the seat backrest,
enabling the truck to be driven in pedestrian
mode from either side. The speed is reduced;
the tiller (3) can be used at any time to steer so
that the truck keeps going forward in a straight
line.
2
3
CAUTION
Take care when operating, especially if the user is
not familiar with using this function.
1044_501-006
50108043405 [EN]
71
5
Operation
Driving
DANGER
5
Risk of crushing feet.
4
Do not use this function for turning.
This function is designed to maintain a straight line.
Proceed from the cockpit with very slight movements.
NOTE
The lift truck must be switched on. If the push
button (4) or (5) are pushed in for quite a long
time, a safety circuit immobilises the truck. If
this occurs, simply release the push button
and then activate it again.
1044_501-007
Forward travel via push button
– Press push-button (5). The truck moves
forwards; the speed is restricted to 2,5 km/h.
CAUTION
The speed cannot be adjusted. The driver must
walk alongside the fork lift truck.
– Release push button (5) to stop the truck.
The forklift truck will roll to a stop.
Reverse travel via push button
– Press the pressure switch (4). The lift truck
moves backwards; the speed is restricted
to 2,5 km/h.
CAUTION
The speed cannot be adjusted. The driver must
walk alongside the fork lift truck.
– Release push button (4) to stop the truck.
The forklift truck will come to a stop.
72
50108043405 [EN]
1044_501-008
5
Operation
Driving
Steering
The truck is steered by turning the tiller in
range (1).
The turning radius (Wa) depends on the fork
length and the battery (refer to the table).
Turning radius (Wa) values
for the calculation of aisle
widths (all values in mm)
Fork lengths
450 Ah
600 Ah
1190
2430
2516
1450
2690
2776
1650
2530
2616
2150
3030
3116
2390
3270
3356
2390
3040
3126
2900
3550
3636
3100
3550
3636
1
1044_420-001
.
Brakes
WARNING
The floor surface properties influence the driving
and braking behaviour of your truck.
Therefore take this into account when driving and
braking.
123
456
789
PRG
PRG
Soft braking (regenerative braking)
NOTE
The truck is braked electrically. The battery is
charged by regenerative braking.
– Release travel control (1) or (2) when
driving.
50108043405 [EN]
2
1
1044_501-009
73
5
Operation
Driving
– Leave the presence area (3).
123
456
789
PRG
PRG
3
1044_501-010
– Release the pedestrian mode traction
button (4) or (5).
Average braking
5
4
– Operate travel control (1) or (2) in the
opposite direction.
1044_501-007
74
50108043405 [EN]
5
Operation
Driving
Emergency stop brake
7
8
CAUTION
This brake may only be used in an emergency.
– Depress the emergency brake switch (6).
123
The truck is braked to a fast stop.
PRG
456
789
PRG
– SToP appears in the display (7).
NOTE
After the disappearance of StoP in the
display, press the I (ON) button (8) to restart
work.
1
2
6
1044_490-007
Parking brake
– Release traction control (1) or (2).
The truck is braked by the electromagnetic
brake.
123
456
789
PRG
PRG
2
1
1044_501-009
Automatic shutdown
NOTE
If you leave the truck with the control turned
on, it will be shut off automatically after approx.
15 minutes. The truck can only be operated
again after the driver code is entered.
The delay time is adjustable. Please contact
your Service Engineer in this regard.
50108043405 [EN]
75
5
Operation
Lifting
Lifting
Lifting device controls
2
WARNING
Risk of injury!
Always follow the safety rules exactly ⇒ Chapter "Load handling safety rules", P. 5-77.
123
Do not put your hand or step into moving parts (eg
mast, sideshift, implements, load lifting device,
etc.).
456
789
PRG
PRG
Elevating the forks
– Press the
Lift
button (2).
The forks are elevated to the maximum height.
1
Lowering the forks
– Press the
Lower
1044_800-001
button (1).
The forks are lowered to the lowest position.
The movement can be stopped any time by
releasing the button.
1044_800-002
76
50108043405 [EN]
5
Operation
Handling loads
Handling loads
Load handling safety rules
WARNING
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).
DANGER
WARNING
DANGER
If the lift is used, take care not to trap
hands or feet.
The forks must never be used if there are
people underneath.
1044_713-001
DANGER
Risk of accident when forks are changed:
If the forks are changed and a different type of
forks to the original forks is fitted, the residual load
capacity changes.
When forks are changed, a new residual load
capacity rating plate must be affixed.
If a truck is supplied without forks, the residual load
capacity rating plate for standard forks is affixed
(see chapter 6 "Technical Data").
Before picking up the load
Load capacity
Do not exceed the load capacity of the truck.
50108043405 [EN]
77
5
Operation
Handling loads
Picking up a loading unit
In order to guarantee load stability, ensure
that the load is balanced and centred on the
fork arms and that the fork arms have been
sufficiently slid underneath the load. The load
should not excessively extend over the fork
arms , nor should the fork arms excessively
protrude out from the load.
CAUTION
Transporting loads on the sidemembers is prohibited (1).
Loads may only be transported on the fork carriage
(2).
1044_800-003
2
1
0252_003-111
Danger zone
The danger zone is the area in which persons
are endangered through the movement of the
truck, working devices, load-lifting devices (eg
attachment) or the load. This also includes
78
50108043405 [EN]
5
Operation
Handling loads
the area within the range of falling loads or a
descending working device.
WARNING
Danger of personal injury
Do not step on the forks.
WARNING
Persons can be injured in the danger zone of the
truck.
No person, except the driver in his normal operating
position, may stand in the danger zone of the truck.
If persons refuse to leave the danger zone despite
warnings, stop working with the truck immediately
and secure it against use by unauthorized persons.
DANGER
Danger of accidents through falling
loads!
Do not step or stand under a raised
load.
Palletising a load
Only stack pallets not exceeding the specified
maximum dimensions. Do not stack damaged
transport aids and improperly formed load
units.
Place and secure the load on the lifting device
in such a way that it cannot move or fall off.
Stack the load units so that the specified aisle
width is not reduced by protruding parts.
1044_800-004
50108043405 [EN]
79
5
Operation
Handling loads
Transporting pallets or other containers
Under normal circumstances, unit loads (e.g.
pallets) should be transported individually.
Simultaneous transport of more than one unit
load is only permitted
P
• on instruction of the supervisor and
• if the technical requirements are met.
The driver must satisfy himself that the load
is in proper condition. Only properly and
securely positioned loads may be moved.
There are marks on the forks which make
positioning of the load unit on the forks easier.
When the forks are moved under the load unit
exactly as far as the appropriate marking (see
arrow), the tips of the forks will not project from
under the load at the front and a wider aisle
width will not be required.
1044_001-010
R
Possible markings are:
P for pallets
R for roll containers
1044_001-011
80
50108043405 [EN]
5
Operation
Handling loads
Driving on gradients
When driving on gradients, the load must
be positioned on the uphill side. It is only
permitted to drive on gradients which are
identified as suitable for traffic and which can
be safely negotiated. The driver must satisfy
himself that the ground is clean and provides
good grip. It is not allowed to turn or park on
gradients or to approach them at an angle.
Drive at reduced speed on slopes.
1044_001-015
Carrying the load
WARNING
– Raise or lower the load until ground clearance is
obtained.
The load should not be so high as to block the view
to the rear. If the load does block the view to the
rear, a second person must walk next to the truck
and act as a guide while it is reversing. Only drive at
walking pace and always take extra care. The truck
must be stopped immediately if visual contact with
the guide is lost.
1044_800-005
50108043405 [EN]
81
5
Operation
Handling loads
Entering lifts
The driver may only enter lifts with a sufficient
load capacity and with the permission of the
operator. Inside the lift, the truck must be
secured so that no part of it will come into
contact with the wall of the lift shaft.
The maximum weight of the truck (dead weight
with maximum load ) is:
Max. weight
3120 kg
.
1044_001-016
Driving on loading bridges
1044_001-017
Before crossing a loading bridge, the driver
must satisfy himself that it is properly attached
and secured and has a sufficient load capacity.
Cross the bridge slowly and carefully. The
driver must be sure that the vehicle to be
entered is secured sufficiently against moving
and that it can bear the load of the truck.
82
50108043405 [EN]
5
Operation
Cold store use
Cold store use
Designation
Your truck is fitted with special equipment
for use in cold stores. It can be used for two
operating ranges and carries a cold store
label.
The cold store equipment for the truck consists
of using specialised oils (for the hydraulic
installation and the gears) suitable for cold
stores.
Proper usage
Operating range 1: permanent use in areas
with temperatures of –5 °C and for short
periods of time down to –10 °C. Parking
outside the cold store.
1044_920-001
Operating range 2: alternating use indoors
and outdoors in compliance with the rules
below, temperature range from –32 °C to +40
°C. Parking outside the cold store. This use
requires hydraulic oil for cold stores as given
on the list of maintenance characteristics.
Use
General
The change in temperature between the
cold indoors and the heat outside causes
condensation. This water can freeze when
the truck goes back into the cold store and jam
the moving parts of the truck. This is why the
length of time the truck remains in the different
temperature areas given below for the two
operating ranges must be strictly adhered to.
The temperature of the traction batteries must
never fall to the temperature of the cold store,
otherwise they will stop working.
Prior to start-up
CAUTION
The truck must be dry and at operating temperature
before being used in the cold store.
50108043405 [EN]
83
5
Operation
Cold store use
– Drive the truck for approximately 5 minutes
and operate the brakes several times to
ensure the truck operates safely.
– Operate all the lifting functions several
times. This warming up phase is required to
allow the oil to reach operating temperature.
Use
Operating range 1
Permanent use in areas with temperatures
of–5 °C and for short periods of time down to
–10 °C.
Operating range 2
Alternating use indoors with temperatures
down to –32 °C and outside with temperatures
up to +25 °C for short periods of time even
up to +40 °C. The truck must not leave the
cold area for more than 10 minutes, because
this length of time is not long enough for the
formation of condensation. If the truck stays
outside for longer than 10 minutes, it must
remain outside for long enough to allow the
condensation to run away. This generally
takes at least 30 minutes.
DANGER
If the condensation freezes in the cold store, the
moving parts that have become jammed must not
be freed by hand.
Parking
– Always park the truck outside the cold store.
CAUTION
The batteries must not remain discharged or unused in the cold store overnight.
– Charge the battery outside the cold store
and use a spare battery.
84
50108043405 [EN]
5
Operation
Using the Digicode control
Using the Digicode control
Digicode control
Access to the electronic control is granted with
three different codes:
• Driver’s code
• master code
• service code
123
456
789
PRG
PRG
Driver’s code
The driver’s code consists of four digits and
must be created by the Pool Manager.
It is used for the regular utilisation and operation of the truck by the driver and operator.
The knowledge of the code should be regarded as a key and must not be misused.
The driver’s code must not be given to other
persons without express order.
1044_505-007
The control can store a maximum of 200
driver’s codes. A driver’s code can be added
⇒ Chapter "Adding a driver’s code", P. 5-89 or
deleted ⇒ Chapter "Deleting a driver’s code
", P. 5-91 with the master code.
Master code
The master code consists of four digits and is
reserved for the Pool Manager.
The factory setting of this code is "1234". The
pool manager is advised to replace this code
with a new master code ⇒ Chapter "Deleting
a master code", P. 5-87 or ⇒ Chapter "Adding
the master code", P. 5-86.
Like the driver’s code, it is used for the regular
operation and use of the truck, but it also
allows the addition or deletion of a driver’s
code. This control can store a maximum of
five master codes.
NOTE
If master codes or driver’s codes are forgotten
or get lost, please contact the Service Engineer, for he alone can make the stored codes
visible.
50108043405 [EN]
85
5
Operation
Using the Digicode control
Service code
The service code is only intended for the
after-sales service. It allows the diagnosis
of the truck for inspections and the access to
the driver’s and master code.
Adding the master code
NOTE
The pallet truck is turned off, the battery is
connected.
– Press the
I
(ON) button (5).
– Enter a valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).
1
2
123
3
789
456
PRG
PRG
4
6
– Scroll with the PRG ↑ (scrolling) button (6)
until Pin (7) appears in the display.
– Confirm with the PRG ↲ (enter) button (4)
until Add (10) appears in the display.
86
5
1044_505-009
1044_505-010
7
1044_505-011
10
50108043405 [EN]
5
Operation
Using the Digicode control
– Confirm with the PRG ↲ (enter) button (4).
A flashing line cursor (8) will appear in the
display.
1044_505-012
8
– Enter the desired new 4-digit master code
with the buttons (1), (2) or (3) as described
above.
NOTE
The controller can store a maximum of five
master codes. If one attempts to add a sixth
master code, Err will appear in the display.
– Confirm with the PRG ↲ (enter) button (4)
until the new master code (9) blinks (an
example is shown).
– Then release the button. Add (10) will
appear again in the display.
– Press the PRG ↑ (scrolling) button (6) until
a normal readout (11) (eg battery charge)
appears in the display. The new master
code is entered.
1044_505-013
9
1044_505-011
10
1044_505-014
11
%
Deleting a master code
NOTE
The pallet truck is turned off, the battery is
connected.
50108043405 [EN]
87
5
Operation
Using the Digicode control
– Press the
I
(ON) button (5).
1
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).
2
123
3
789
456
PRG
PRG
4
6
– Scroll with the PRG ↑ (scrolling) button (6)
until Pin (7) appears in the display.
1044_505-009
1044_505-010
7
– Confirm with the PRG ↲ (enter) button (4)
until dEL (10) appears in the display.
1044_505-015
10
– Confirm with the PRG ↲ (enter) button (4).
A flashing line cursor (8) will appear in the
display.
1044_505-012
8
– Enter the 4-digit master code to be deleted
with the buttons (1), (2) or (3) as described
above.
NOTE
If one attempts to delete an erroneous master
code, Errwill appear in the display. If only
one master code remains, None will appear in
the display.
88
5
50108043405 [EN]
5
Operation
Using the Digicode control
– Confirm with the PRG ↲ (enter) button (4)
until the master code (9) to be deleted blinks
(an example is shown).
– Then release the button. dEL (10) will
appear again in the display.
– Press the PRG ↑ (scrolling) button (6) until
a normal readout (11) (eg battery charge)
appears in the display. The master code is
deleted.
1044_505-013
9
1044_505-015
10
1044_505-014
11
%
Adding a driver’s code
NOTE
The pallet truck is turned off, the battery is
connected.
– Press the
I
(ON) button (5).
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).
1
2
123
3
456
789
PRG
PRG
4
6
50108043405 [EN]
5
1044_505-009
89
5
Operation
Using the Digicode control
– Scroll with the PRG ↑ (scrolling) button (6)
until USEr (7) appears in the display.
– Confirm with the PRG ↲ (enter) button (4)
until Add (10) appears in the display.
– Confirm with the PRG ↲ (enter) button (4).
A flashing line cursor (8) will appear in the
display.
1044_505-016
7
1044_505-011
10
1044_505-012
8
– Enter the new 4-digit driver’s code with the
buttons (1), (2) or (3) as described above.
NOTE
The controller can store a maximum of 200
driver’s codes. If one attempts to add a 201st
driver’s code, Err will appear in the display.
– Confirm with the PRG ↲ (enter) button (4)
until the new driver’s code (9) blinks (an
example is shown).
– Then release the button. Add (10) will
appear again in the display.
– Press the PRG ↑ (scrolling) button (6) until
a normal readout (11) (eg battery charge)
appears in the display. The new driver’s
code is entered.
90
1044_505-013
9
1044_505-011
10
1044_505-014
11
%
50108043405 [EN]
5
Operation
Using the Digicode control
Deleting a driver’s code
NOTE
The pallet truck is turned off, the battery is
connected.
– Press the
I
(ON) button (5).
– Enter the valid 4-digit master code with the
buttons 123 (1), 456 (2) and 789 (3).
1
2
123
3
789
456
PRG
PRG
4
6
– Scroll with the PRG ↑ (scrolling) button (6)
until USEr (7) appears in the display.
– Confirm with the PRG ↲ (enter) button (4)
until dEL (10) appears in the display.
– Confirm with the PRG ↲ (enter) button (4).
A flashing line cursor (8) will appear in the
display.
5
1044_505-009
1044_505-016
7
1044_505-015
10
1044_505-012
8
– Enter the 4-digit driver’s code to be deleted
with the buttons (2), (3) or (3) as described
above.
NOTE
If one attempts to delete an erroneous driver’s
code, Err will appear in the display.
50108043405 [EN]
91
5
Operation
Fault displays
– Confirm with the PRG ↲ (enter) button (4)
until the driver’s code (9) to be deleted blinks
(an example is shown).
– Then release the button. dEL (10) will
appear again in the display.
1044_505-013
9
1044_505-015
10
– Press the PRG ↑ (scrolling) button (6) until
a normal readout (11) (eg battery charge)
appears in the display. The driver’s code is
deleted.
1044_505-014
11
%
Fault displays
Error code
4
If an error code such as E380 (15) appears,
shut the truck off by pressing button (10) and
repeat the start-up ⇒ Chapter "Commissioning", P. 58. If the error code persists, call your
Service.
5
7
6
8
11 12
14
2
13
3
123
456
789
PRG
PRG
1
10
92
50108043405 [EN]
9
1044_505-024
5
Operation
Fault displays
15
1044_505-019
Error code Description
Action
E350
Travel control operated at power-up.
Release the travel control (1).
E370
Left
Lift
Release the left
Lift
E371
Left
Lowering
Release the left
Lowering
E372
Left
Horn
Release the left
Horn
button operated at power-up.
button operated at power-up.
button operated at power-up.
button operated at power-up.
Release the
button (2).
button (3).
button (4).
button (5).
E373
Tortoise
E374
Button
1-2-3
operated at power-up.
Release the button
1-2-3
(6).
E375
Button
4-5-6
operated at power-up.
Release the button
4-5-6
(7).
E376
Button
7-8-9
operated at power-up.
Release the button
7-8-9
(8).
E377
PROG
Release the button
PROG
E378
ON
E379
Hare
E380
Right
button operated at power-up.
button operated at power-up.
button operated at power-up.
Horn
button operated at power-up.
E381
Right
Lowering
E382
Right
Lift
button operated at power-up.
button operated at power-up.
Tortoise
Release the
ON
Release the
Hare
(9).
button (10).
button (11).
Release the right
Horn
Release the right
(13).
Lowering
button (12).
Release the right
Lift
button
button (14).
.
50108043405 [EN]
93
5
Operation
Battery electrolyte level indicator LED (optional)
Battery electrolyte level
indicator LED (optional)
1
There are two versions of the LED:
• 1) Located on the battery
• 2) Located next to the battery plug.
2
The LED indicates whether it is necessary to
top up the distilled water in the battery.
Operation:
• If the LED (1) or (2) is green, there is a
sufficient level of electrolyte in the battery.
The battery must not be topped up with
distilled water.
• If the LED (1) or (2) is red, there is an
insufficient level of electrolyte in the battery.
The battery must be topped up with distilled
water.
2256
Handling the truck in specific situations
Transporting the truck
– Disconnect the battery connector.
Chocking the truck
– Secure the truck against rolling and sliding
with chocks (1).
1
Lashing down the truck
– Attach the lashing ropes (2) at the frame.
2
1
1044_001-012
Towing procedure
As the electric brake is applied, the truck cannot be towed without functioning electrically.
94
50108043405 [EN]
5
Operation
Handling the battery
NOTE
The brake can be released. Please contact
your after-sales service.
Hoisting the truck
CAUTION
Only use a lifting sling and crane with sufficient
lifting capacity. See the type plate for the hoisting
weight.
3
– To hoist the truck with a crane, attach slings
in the positions (3) identified by the hook
symbol.
3
CAUTION
3
It is strictly forbidden to attach the lifting slings to the
tiller or to other points not intended for this purpose.
1044_001-013
3
CAUTION
– Insert pieces of wood to protect the truck against
damage.
DANGER
Danger of loss of life!
Do not step or stand under a raised load.
Handling the battery
Preparation
Maintenance personnel
Batteries may only be changed by specially
trained personnel and in accordance with the
instructions of the manufacturer of the battery,
battery charger and pallet stacker. Observe
the battery handling instructions.
50108043405 [EN]
95
5
Operation
Handling the battery
Fire prevention measures
WARNING
Do not smoke or use a naked flame
when handling batteries. In the
area designated for parking the
truck to recharge the battery or
battery charger, there should be no
flammable materials or substances
that can cause sparks within a radius
of at least 2 metres. The charging
area must be well ventilated. Keep a
fire extinguisher at hand.
Safe parking
Park the truck securely before carrying out
work on the battery. The truck can only be
operated when the battery cover is closed
and the battery outlet is inserted. If the truck
is enabled for side removal of the battery, the
truck can only be operated once the battery
is fixed in place properly using the battery
locking system.
Battery weight and dimensions
The battery weight and the dimensions affect
the stability of the lift truck. When changing the
battery, the weight ratios must not be changed.
Ballast weights must not be removed and their
position must not be changed.
Take note of the description of batteries that
can be used; see ⇒ Chapter "Datasheet
(VDI)", P. 7-141.
Notes on charging the battery; see ⇒ Chapter "Servicing the battery", P. 6-117.
– Follow steps in reverse order to reinstall and
connect the charged battery. Ensure that all
covers are correctly installed.
Damage to cables
CAUTION
When removing and reinstalling the battery, make
sure not to damage the battery cables.
96
50108043405 [EN]
5
Operation
Handling the battery
Opening/closing the battery compartment
Opening
– Park and shut off the truck.
– Remove the female battery connector (1).
1
1044_001-006
– Insert the key (2) into the battery lock and
turn it 180°. Press the battery lock. The
battery cover (3) is unlocked and can be
opened to the rear.
2
3
1044_606-002
50108043405 [EN]
97
5
Operation
Handling the battery
– Turn the battery latch (4) up 90°.
4
1044_606-003
Closing
1
2
3
WARNING
Danger of squeezing cables.
When closing the cover, be sure that there is
nothing between the bonnet and chassis edge.
– Reconnect the battery female connector
(3).
– Turn the battery latch (1) down.
– Push the battery cover (4) forward until it
engages in the lock (2).
4
98
50108043405 [EN]
1044_606-014
5
Operation
Handling the battery
– Turn the battery compartment key (5) 180°
and remove it.
5
1044_606-015
Battery replacement
There are 2 ways of replacing the battery:
1. Vertically with a lifting tackle (all trucks)
2. With a lateral battery removal trolley
(option)
To avoid short circuits, cover batteries with
unprotected terminals or connectors with a
rubber mat.
DANGER
Danger!
Do not step or stand under a raised
load.
– Carefully lift the battery out of the truck.
50108043405 [EN]
99
5
Operation
Handling the battery
Battery replacement with crane
– Disconnect the battery connector.
– Open the battery cover.
5
– Release the battery.
– Attach the battery (6) to a suitable lifting
tackle (5).
– The lifting tackle should exercise a vertical
pull so that the battery tray is not squeezed
together. Hooks must be attached in such
a way that they cannot fall onto the battery
cells when the lifting tackle is slack.
6
1044_606-004
Battery replacement sideways onto
a trolley
7
8
WARNING
Risk of hands getting squeezed.
9
Do not put your hands between the frame and the
battery during battery removal and installation.
Removal
– Disconnect the battery connector (7).
– Open the battery cover (8).
– Release the battery.
– Place a suitable trolley (10) (option) beside
the battery.
1044_606-005
– Stand on the side opposite the cover and
slide the battery (9) on to the trolley (10).
Installation
– Place a new battery (9) on the trolley
(option) (10) beside the side opening.
– Slide the battery into the battery compartment.
– Close the battery cover.
100
50108043405 [EN]
10
5
Operation
Decommissioning
Servicing the battery
Observe the applicable national regulations
for the installation and operation of battery
charging units. Obey the operating instructions for the charging unit or charger and the
battery. The following safety regulations must
be observed when servicing, charging and
replacing batteries:
Fire precautions
Smoking and naked flames are prohibited
in the vicinity of batteries. No inflammable
materials or spark-producing materials may
be located within at least 2 metres of the truck
to be charged and the charger. The room must
be well ventilated. Keep fire extinguishers
ready.
Safe parking
started when the battery cover is closed and
the battery plug connected.
Battery servicing
Keep the battery cell lid dry and clean. Neutralize spilled electrolyte immediately. Terminals and cable lugs should be clean, slightly
greased and secure.
Battery charging
Switch off the truck and charger before
removing the plug from the socket. During
charging, keep the surface of the battery
cells exposed in order to provide sufficient
ventilation. Do not place any metallic objects
on the batteries. While charging the battery
keep battery cover open.
When the battery is being worked on, the truck
must be properly parked and it may only be
Decommissioning
Parking the truck securely
WARNING
Do not park the truck on gradients. In special cases
secure the truck with chocks.
50108043405 [EN]
101
5
Operation
Decommissioning
– Lower the forks (1) to the ground.
WARNING
1
– Do not leave the truck with the load elevated.
1044_842-001
– Disconnect the battery connector (2).
NOTE
If you leave the pallet truck without disconnecting the battery connector, the control is shut
off automatically after approx. 15 minutes.
2
The pallet truck can only be operated again
after re-entering the driver’s code.
1044_001-018
102
50108043405 [EN]
5
Operation
Storage
Storage
Measures to take if the lift truck is to
be shut down for a long time
If the lift truck is to be shut down for a long
time, the following measures must be taken
to protect against corrosion. If the lift truck is
to be shut down for more than two months, it
must be parked in a clean and dry area. The
area should also be well ventilated and frost
free. The following additional measures must
be taken:
Measures before shutdown
– Clean the lift truck thoroughly.
– Lift forks to the stop several times.
– Check hydraulic oil level and top up if
required.
– Apply oil or grease thinly to all uninsulated
moving parts.
– Check the condition and acid density of
the battery and maintain the battery as
specified by the manufacturer. (Follow
the instructions provided by the battery
manufacturer).
– Apply a suitable contact spray to all exposed
electrical contacts.
CAUTION
– Jack up the lift truck so that all the wheels are
clear of the ground. This prevents permanent
deformation of the tyres.
– Cover the lift truck with a cotton sheet and
protect against dust.
CAUTION
We do not recommend using a plastic sheet as this
promotes the formation of condensation.
If the lift truck is to be shut down for even longer
periods, contact your service centre to find out
about additional measures.
50108043405 [EN]
103
5
Operation
Storage
Recommissioning after taking out of
service
If the truck has been out of service for over six
months, it must be inspected carefully before
recommissioning. Similar to the accident
prevention check, the inspection should also
cover all points relating to truck safety.
– Thoroughly clean the truck.
– Check the condition and specific gravity of
the battery, charge the battery if necessary.
– Check the hydraulic oil for condensate and
renew the oil, if necessary.
– Perform the services as before initial
operation.
– Take the truck into service.
– During commissioning check the following
points in particular:
• Drive, control, steering.
• Brake (service brake, parking brake).
• Lifting device.
104
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6
Maintenance
6
Maintenance
General maintenance information
General maintenance information
General
These instructions contain all the information
required to perform the routine maintenance
on your fork truck. Carry out the maintenance
at the correct interval according to the maintenance chart to keep your truck ready for
operation, maintain its efficiency and prolong
its service life and to benefit from the warranty.
Maintenance chart
The maintenance on the truck must be performed according to the hour meter. Refer
to the maintenance chart for the services required at a particular interval.
The instructions describing the maintenance
procedures are located after the maintenance
chart.
In a dusty environment and with fluctuating
temperatures, reduce all lubrication and
maintenance intervals as required.
Quality and quantity of required lubricants
1044_001-001
Only use the lubricants specified in these
operating instructions.
The fluids and lubricants and other materials
required for the periodic maintenance of the
truck are listed in the table of maintenance
data.
Oils and greases of different grades may not
be mixed, as this affects lubricity. If changing
from one brand to another is unavoidable,
drain the previous oil particularly thoroughly.
Carefully clean the area surrounding a component prior to filter renewal or working on the
hydraulic system.
Use only clean containers when replenishing
lubricants and other fluids!
106
50108043405 [EN]
6
Maintenance
General maintenance information
Staff training and qualifications for
maintenance and repairs
Only qualified and authorized staff may
carry out the maintenance. The annual
inspection must be performed by an expert.
The expert must provide his opinion and
safety assessment irrespective of the internal
and financial circumstances of the company.
Only the safety aspect is decisive. He must
have adequate knowledge and experience
to assess the state of the vehicle and the
effectiveness of the protective devices in
accordance with the rules of technology and
the basic principles of fork trucks.
Battery maintenance personnel
Batteries can only be recharged, maintained
and changed by specially trained personnel
who follow the manufacturer’s instructions for
the battery, the battery charger and the truck.
Follow the battery maintenance instructions
and the battery charger operating instructions.
Services not requiring special
qualifications
Simple maintenance operations such as
checking the hydraulic fluid level or checking
the battery electrolyte level can be carried
out by persons with no special training. A
qualification such as that outlined above is not
necessary. Refer to the maintenance section
of this manual for further information.
50108043405 [EN]
107
6
Maintenance
General maintenance information
Frequency of periodic checks
Maintenance and lubrication
Carry out maintenance according to the hour
meter (bold typeface)
For example, after 4000 hours of service, all
of the "1000 and 2000 hour" maintenance and
lubrication work should be carried out.
After 9000 hours of service, continue as
above, therefore instead of 1000 hours:
10,000 hours of service.
Truck:
Type No:
1000
2000
3000
1 000
1 000
2000
1 000
4000
5000
6000
1 000
2000
1 000
5 000
1 000
2000
7000
8000
9000
1 000
1 000
2000
1 000
.
108
50108043405 [EN]
6
Maintenance
General maintenance information
Maintenance and inspection intervals
3
2
1
13
12
4
11
1044_010-001
10
5
9
8
6
7
The services must be performed according to
the following maintenance intervals.
h
Item
Cleaning the truck
as required
2, 7, 9
annually/2000
5000
Service the wheels and rollers
1
Service the battery
5
Service the braking system
8
Service the gearbox
11
Service the hydraulic system
6, 10, 12
every 3 months/500
Maintenance work
Service the electric motors
13
Service the electrical system
5
Service the braking system
3
Check the forks
4
Check the lift cylinder
11
Service the hydraulic system
13
Service the electrical system
-
Insulation resistance check
-
Accident prevention check
8
Service the gearbox
.
50108043405 [EN]
109
6
Maintenance
General maintenance information
Ordering spare parts
Spare parts are supplied by our Service. Refer
to the Parts List for the required ordering
information.
Only use spare parts as specified by the
manufacturer. Due to insufficient quality or
incorrect assignment, the use of parts not
approved by the manufacturer can increase
the risk of accidents. The use of unapproved
parts places full responsibility for any damage
and liability on the part of the user.
110
50108043405 [EN]
6
Maintenance
General maintenance information
Table of maintenance data
Assembly
Aids/Lubricants
Battery
Distilled water
- Insulation
resistance
-
Controls/joints
Lithium base
grease, gear oil
TOTAL
Hydraulic
system
Hydraulic oil
AZOLLA
Motor brushes
-
Symbol
-
Specification
as required
FL
NLGI Multi S2
OG
MIL-L-2105,
API:GL4
DIN 51524 P2, HLP
ISO 6743/4 HM
ZS46
- Pump motor
- Steering motor
Wheels
-
- Traction wheel
- Stabiliser
wheel
- Load wheels
- Tandem load
wheels
Wheel nuts
-
Torque wrench
Gearbox
Gear oil 80W
OG
90EP
CAUTION: For cold store application only
Gearbox
Hydraulic
system
Gear oil ELF
PERFORMANCE
Hydraulic oil
EQUIVIS
2B30
XV 32
Dimension
1000 Ohm
min.against
body
as required
Up to
centre of
filler elbow
approx.
3.8 l
Min.
residual
length
Min.
residual
length
11 mm
Dimensions
Dimensions
Dimensions
Dimensions
250 x 100
mm
150 x 50
mm
85 x 100
mm
85 x 80 mm
11 mm
140 Nm
MIL-L-2105,
API:GL4
approx.
1.5 l
API: CD/SF
MIL-L-2104D
DIN 51524 P3,
HVLP ISO 6743/
4 HV
approx.
1.5 l
approx.
3.8 l
Up to
middle of
filler elbow
.
50108043405 [EN]
111
6
Maintenance
Maintenance safety instructions
Maintenance safety instructions
Safety measures for maintenance
and repair
To prevent accidents during maintenance and
repair, perform all necessary safety measures
such as:
– Ensure that the truck is secured against inadvertent movement or accidental starting
(disconnect the battery connector).
Work on the electrical equipment
Work on the electrical equipment of the truck
is only allowed with the electrical system dead.
Function checks, inspections and adjustments
on live parts may only be carried out by trained
and authorized staff under observance of
suitable precautions. Rings, metal bracelets,
etc. must be removed before working on
electric components.
To prevent damage to electrical equipment
with electronic components such as an
electronic travel control, remove them from
the vehicle before doing any electric welding.
Safety devices
Refit and check all safety devices for proper
operation after maintenance and servicing.
Settings
Retain the vehicle-specific settings when
repairing and replacing hydraulic and electric
components. They are specified in the
appropriate sections.
Preparatory tasks for maintenance
Lifting and jacking up the truck
When jacking up the truck, components and
attachments, the lifting tackle may only be
attached at the designated points. When
112
50108043405 [EN]
6
Maintenance
Preparatory tasks for maintenance
jacking up the equipment, secure it against
sliding or tipping with suitable means (wedges,
wooden blocks).
Jacking up the truck
The truck must be jacked up for various
services. Always be sure that:
• the load capacity of the jack is sufficient,
• the truck is only jacked up on level ground
and that it is secured against rolling and
lowering.
WARNING
When jacking up the truck, disconnect the battery
plug!
Jacking up on the frame
– Park the truck with the forks against a wall.
– Jack up the truck until the wheels are clear
of the ground.
230 mm
– Secure the truck.
1044_001-002
50108043405 [EN]
113
6
Maintenance
Preparatory tasks for maintenance
Removing the bonnet
The bonnet must be removed before servicing.
Proceed as follows:
1
– Remove 2 screws (1) and (2).
– Remove the bonnet (3).
CAUTION
2
3
Do not damage electric cables.
1044_001-003
Installing the bonnet
– Install the bonnet (3) from above with the
guiding lugs (1) in the openings (2) in the
frame.
3
– Fasten the bonnet with 2 screws from
above.
1
2
1044_001-004
114
50108043405 [EN]
6
Maintenance
Cleaning
Cleaning
Cleaning the truck
Washing instructions
1
– Always park the truck as specified.
– Disconnect the battery plug (1).
CAUTION
– Disconnect the battery plug before washing the
truck.
Washing the exterior of the truck
WARNING
Do not use inflammable fluids for cleaning. Observe the above safety precautions for preventing
sparks through shorts (disconnecting the battery
plug). When the truck is cleaned , carefully cover
all sensitive components, particularly electric components. Follow the manufacturer’s instructions for
handling the cleaners.
– Clean the truck exterior with water and
cleaning agents soluble in water (using
sponge, rags).
1044_001-005
1
– Especially clean the oil filler openings and
the surrounding area, and the lubricating
nipples before lubrication.
Please note: Lubricate more frequently if the
truck is cleaned often.
WARNING
Do not spray directly onto the electric motors and
other electric components.
1044_001-006
50108043405 [EN]
115
6
Maintenance
Maintenance as required
Cleaning the electrical system
WARNING
Do not spray directly onto the electric motors, other
electric components, brakes and bearings.
NOTE
Use only dry cleaning agents suited for this
purpose. Do not remove shielding covers, etc.
– Clean and blow dry electrical components
using a non-metallic brush and a weak jet of
air.
After washing the truck
1044_001-007
– Dry the truck thoroughly (e.g. with compressed air).
– Start the truck as described.
If moisture has penetrated the motors despite
the precautionary measures, first dry them to
prevent a short! ONLY then operate the truck
to prevent damage due to corrosion.
Maintenance as required
Servicing the wheels and rollers
Check tyres for wear and damage
3
The running surface of the traction wheel (2),
support wheel (1) and load wheels (3) must be
undamaged.
Dimensions
Traction wheel
250 x 100 mm
Support wheel
150 x 50 mm
Single load wheels
85 x 100 mm
Tandem load wheels 85 x 80 mm
– Renew damaged or worn wheels with new
ones.
1
116
50108043405 [EN]
2
1044_460-001
6
Maintenance
Maintenance as required
Adjusting the support wheel
4
NOTE
The wear of the traction wheel can be partially
compensated by adjusting the support wheel.
– Secure the pallet truck and place the
traction wheel on a support 5 - 8 mm thick.
– Loosen the support wheel clamping screw
(4).
– Screw in stop screw (5) on the support
wheel until the support wheel rests on the
ground.
– Tighten the clamping screw (4).
5
1044_460-002
Tightening traction wheel mounting nuts
– Check the wheel mounting nuts (6) for
tightness, tightening them if necessary.
Torque:
6
140 Nm
.
1044_460-003
Servicing the battery
CAUTION
Before performing any work on the electrical installation, remove any power from the system by
disconnecting the battery connector.
Battery maintenance precautions
Keep the battery cell lid dry and clean. Neutralise spilled electrolyte immediately. Terminals and cable lugs should be clean, slightly
50108043405 [EN]
117
6
Maintenance
Maintenance as required
greased with terminal grease and screwed on
securely.
Battery charging
During charging, keep the surface of the
battery cells exposed in order to provide
sufficient ventilation. Do not place any metallic
objects on the batteries. While charging the
battery keep battery cover open.
Battery type
Lead or gel batteries are used as traction
batteries. As the various types are structured
differently, always use the correct type of
charging device without fail. Before charging,
check if the battery charger is suitable for your
battery!
CAUTION
Gel batteries are subject to special charging/maintenance and handling regulations. Use of the
wrong type of charging device can result in total
battery failure.
Always obey the instructions issued by the relevant
manufacturer.
NOTE
The factory setting of the battery charge
indicator is for a lead battery. The indicator
can also be set to a gel battery. Please contact
your Service.
Charging the lead battery
WARNING
123
The battery could be damaged, shorted or an
explosion could occur.
Do not place any metallic objects or tools on the
battery. No naked lights, no smoking permitted!
456
789
PRG
PRG
WARNING
The electrolyte (diluted sulphuric acid) is poisonous
and caustic!
118
1
50108043405 [EN]
1044_606-008
6
Maintenance
Maintenance as required
Follow the safety precautions for handling battery
electrolyte.
– Press the PRG ↑ (scrolling) button (1) to
display the existing battery charge (2).
NOTE
2
%
After the battery is connected, the correct state
of charge appears only after approx. 1 minute.
– When a residual charge of 25 % is reached,
the display flashes. The battery must be
charged soon.
1044_606-016
– If the display shows a residual charge of 20
% (3), the lift is cut off.
CAUTION
3
– The battery must immediately be charged as
deep discharging begins. Deep discharging
damages the battery.
%
– Before charging, inspect the battery and
charging cables for damage; replace them,
if necessary.
1044_606-017
Charging the gel battery
– Refer to instructions for this battery.
WARNING
Disconnect the battery plug only when the truck and
charger are switched off.
50108043405 [EN]
119
6
Maintenance
Maintenance as required
– Connect the battery plug (2) to the connector of the charger unit.
2
NOTE
Please follow the information in the operating
instructions for the battery and the charging
station (equalising charge).
WARNING
The gases released during charging are explosive.
– Ensure that the room is well ventilated.
CAUTION
3
Never squeeze the battery cables (3).
1044_606-011
Checking operation of the brake,
checking the emergency brake
1
– Drive the truck.
– Leave presence area (5). The truck will
brake to a stop.
123
– Drive the truck slowly with the traction
control (2).
456
789
PRG
PRG
– Press the belly button (3). The truck is
braked to a stop.
– SToP appears in the display (1).
NOTE
After the disappearance of StoP in the
120
2
6
50108043405 [EN]
3
1044_490-002
6
Maintenance
Maintenance as required
display, press the
work.
I
"ON" button (6) to restart
WARNING
4
123
456
789
PRG
PRG
– Should the brakes show signs of wear or be
defective, please contact your Service.
CAUTION
This brake may only be used in an emergency.
Emergency stop of the truck
– To make an emergency stop, disconnect
the battery plug (4). The truck comes to a
stop.
CAUTION
5
1044_490-003
This safety feature may only be used in an emergency
NOTE
To restart the truck, first reconnect the battery
connector and then re-enter the driver code.
Fuses
CAUTION
– Before performing any work on the electrical
installation, remove any power from the system
by disconnecting the battery connector.
– Remove the 2 screws (1) and (2).
– Remove the front cover (3).
The following fuses are located on the fuse
carrier:
F1 Line fuse 400 A
F3 Fuse 7.5 A
1044_604-001
F4 Fuse 7.5 A
50108043405 [EN]
121
6
Maintenance
Maintenance as required
F5 Fuse 20 A
F8 Fuse 3 A
1
.
2
3
1044_604-002
F1
F5 F3
F4 F8
1044_604-003
122
50108043405 [EN]
6
Maintenance
Maintenance every 500 hours
Maintenance every 500 hours
Other tasks
– Perform all maintenance work; see the
"Maintenance" chapter.
Checking the gearbox oil level
NOTE
The truck must stand on level ground.
– Turn the tiller until the level plug (1) is visible.
– Remove the level plug (1). The oil level
must reach up to the edge the opening.
If necessary, add oil OG according to the
table of maintenance data.
1
1044_223-007
Checking the gearbox for leaks
– Inspect the gearbox for leaks (traces of oil).
CAUTION
During lubrication services and oil changes, do not
allow any oil or grease to get on the brake disc.
50108043405 [EN]
123
6
Maintenance
Maintenance every 500 hours
Checking the hydraulic oil level,
hydraulic system for leaks
– Remove the front cover.
– Check the pipe and hose connections for
leaks (traces of oil).
– Lower the forks.
– Check the oil level on the reservoir (2). The
oil level (3) should be up to the middle of the
filler elbow.
– If required, fill hydraulic oil OZ according to
the table of maintenance data.
2
1044_700-001
3
1044_700-002
124
50108043405 [EN]
6
Maintenance
Maintenance every 500 hours
Servicing the electric motors
Checking the cable connections
– Check the traction motor (3) and pump
motor (1) and steering motor (2) cables
for secure connection, condition and
insulation.
4
1
NOTE
Corroded connections and broken cables lead
to drops in voltage, leading to malfunctions.
– Remove any corrosion and renew broken
cables.
2
Change the pump motor and the steering
motor brushes
3
1044_110-001
6
– Shut down the pallet truck, remove the
battery connector. Remove the front
bonnet.
To access the motor brushes:
– Remove the pump motor screws (6) and
take off the cap (5).
5
– Open the cover band (4) on the steering
motor.
– Lift the brush springs up and take out the
brushes.
The brushes (7) may only be worn down to a
50108043405 [EN]
1044_110-002
125
6
Maintenance
Maintenance every 500 hours
• min. length of x = 11 mm (pump motor)
• min. length of x = 11 mm (steering motor)
1044_110-003
– If the minimum brush length is reached on
one brush, renew all brushes as a set.
7
NOTE
Always replace brushes below the wear limit
in kits. Check the armature for pitting before
installing new brushes. New brushes must be
ground in. If refitting the existing brushes, do
not interchange or turn them. Please contact
your Service.
1044_110-004
x
126
50108043405 [EN]
6
Maintenance
Maintenance every 500 hours
– Close the cover band (4) again, refit the cap
(5).
4
– Refit the removed parts.
5
1044_110-005
Servicing the electrical system
Checking fuses and cable connections
DANGER
– Before starting the following work, park the truck
and disconnect the battery plug.
1
2
F1
– Remove the front cover.
– Check the fuses (1) for condition.
– Check all cable connections (2) for tightness.
– Tighten all cable clamping screws.
Checking the contactor tips
F5 F3
F4 F8
1044_600-003
– Inspect the contactor tips for pitting and
have them replaced if necessary.
– Refit and secure the cover.
50108043405 [EN]
127
6
Maintenance
Maintenance every 500 hours
Servicing the braking system
Checking the air gap
– Release the brake.
– Measure the gap (1) with a feeler gauge.
Min air gap: 0.3 mm
Max air gap: 0.8 mm
1
WARNING
– Renew the brake disk, when the max. gap is
reached.
1044_490-004
Measuring the braking force
– Put the rated load on the truck.
WARNING
1,2 m
Keep the braking distance and a sufficient safety
distance clear.
– Drive the truck forward at 6 km/h.
– Operate the brake and measure the braking
distance.
Max. braking distance: 1.2 m
– If the braking distance is longer, have the
brake adjusted by your Service.
WARNING
1044_490-005
The truck must not be operated with a defective
brake.
128
50108043405 [EN]
6
Maintenance
Maintenance every 500 hours
Checking the forks
Checking the condition of the forks
– Check that the fork arms (1) do not have
any deformations, cracks, significant signs
of use or hairline cracks.
1
CAUTION
– Have repairs and replacements on the reach
legs carried out by the service department.
1044_842-001
50108043405 [EN]
129
6
Maintenance
Maintenance every 500 hours
130
50108043405 [EN]
6
Maintenance
Annual maintenance
Annual maintenance
Work that must also be carried out
– Carry out maintenance work as necessary, see ⇒ Chapter "Maintenance as required", P. 116.
– Carry out 500-hour maintenance, see
⇒ Chapter "Maintenance every 500
hours", P. 123.
Insulation resistance check (earthing)
The insulation of industrial trucks should have
sufficient insulation resistance. Test the truck
and battery separately.
Testing the insulation resistance of the
electrical system
Have the insulation resistance of all active
electrical components checked in accordance
with DIN 57117 and DIN 43539, VDE 0117
and VDE 0520.
Measurement voltage > nominal voltage <
500 V. Insulation is considered correct when
it is measured in relation to the chassis and is
higher than 1000 ohm/V of nominal voltage.
Please contact your Service for this test.
50108043405 [EN]
131
6
Maintenance
Annual maintenance
Performing the accident prevention
check
The vehicle must be tested (at least once a
year) by an expert.
STILL GmbH Hamburg
This annual test by an expert must cover the
condition of the assemblies and equipment
and the completeness and efficacy of the
safety features.
Regelmäßige Prüfung
(FEM 4.004)
95/63/EG, 99/92/EG, 2001/45/EG
Nächste Prüfung
740294
The truck must also be examined thoroughly
for damage which may have occurred through
improper operation. An inspection report must
be prepared. The results must be kept on file
until the next inspection. The operator must
ensure that any defects are remedied without
delay.
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
Please contact your Service.
Mitglied der:
Fédération
Européene
de la Manutention
0000_003-001
132
50108043405 [EN]
6
Maintenance
Maintenance every 2000 hours
Maintenance every 2000 hours
Work that must also be carried out
– Carry out maintenance work as necessary, see ⇒ Chapter "Maintenance as required", P. 116.
– Carry out 500-hour maintenance, see
⇒ Chapter "Maintenance every 500
hours", P. 123.
– Carry out 1000-hour maintenance, see
⇒ Chapter "Annual maintenance", P. 131.
Renewing the hydraulic oil and
hydraulic oil filter
(every 2000 hours, but at least every year)
WARNING
Hydraulic oil is hazardous to health.
– Follow the safety precautions for handling
hydraulic oil.
– Park the truck on a level surface.
– Lower the forks.
– Disconnect the battery plug and remove the
cover.
– Remove the hydraulic oil tank (2) from the
pump motor (1) after removing the screws
(3).
– Discard the hydraulic oil from the hydraulic
oil tank.
1
ENVIRONMENT NOTE
Dispose of used oil as specified by local
regulations.
2
3
1044_700-003
50108043405 [EN]
133
6
Maintenance
Maintenance every 2000 hours
– Remove and renew the hydraulic oil filter
screen (5) at the pump motor.
– Install a new seal (4).
– Mount a new hydraulic oil reservoir on the
pump motor and install both together.
4
5
1044_700-004
– Add fresh hydraulic oil OZ according to the
table of maintenance data until the oil level
reaches the middle of the filler neck.
Filling capacity approx. 0.8 l
1044_700-005
134
50108043405 [EN]
6
Maintenance
Maintenance every 2000 hours
Checking and cleaning the battery
WARNING
Risk of short circuit and even explosion.
Do not smoke, keep away from naked flames and
do not place metal objects on the battery.
1044_606-012
Servicing the battery according to
the manufacturer’s instructions
WARNING
Risk of personal injury due to arcing!
– Do not reverse the battery poles or cause a short.
Insulation resistance check (earthing)
The insulation of industrial trucks should have
sufficient insulation resistance. Test the truck
and battery separately.
Testing the insulation resistance of the
electrical system
Have the insulation resistance of all active
electrical components checked in accordance
with DIN 57117 and DIN 43539, VDE 0117
and VDE 0520.
Measurement voltage > nominal voltage <
500 V. Insulation is considered correct when
it is measured in relation to the chassis and is
higher than 1000 ohm/V of nominal voltage.
Please contact your Service for this test.
50108043405 [EN]
135
6
Maintenance
Maintenance every 2000 hours
Performing the accident prevention
check
The vehicle must be tested (at least once a
year) by an expert.
STILL GmbH Hamburg
This annual test by an expert must cover the
condition of the assemblies and equipment
and the completeness and efficacy of the
safety features.
Regelmäßige Prüfung
(FEM 4.004)
95/63/EG, 99/92/EG, 2001/45/EG
Nächste Prüfung
740294
The truck must also be examined thoroughly
for damage which may have occurred through
improper operation. An inspection report must
be prepared. The results must be kept on file
until the next inspection. The operator must
ensure that any defects are remedied without
delay.
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
Please contact your Service.
Mitglied der:
Fédération
Européene
de la Manutention
0000_003-001
136
50108043405 [EN]
6
Maintenance
Maintenance every 5000 hours
Maintenance every 5000 hours
Work that must also be carried out
– Carry out maintenance work as necessary, see ⇒ Chapter "Maintenance as required", P. 116.
– Carry out 500-hour maintenance, see
⇒ Chapter "Maintenance every 500
hours", P. 123.
– Carry out 1000-hour maintenance, see
⇒ Chapter "Annual maintenance", P. 131.
Servicing the gearbox
Changing gear oil
CAUTION
– Drain the oil at operating temperature.
– Follow the safety precautions for handling gear
oil.
1
– Park and secure the truck and remove the
cover.
– Turn the tiller until the filler plug (1) is
accessible.
– Remove the drain plug (2) and filler plug (1)
and allow the oil to drain completely.
2
1044_223-008
ENVIRONMENT NOTE
Dispose of the used oil as specified.
– Tighten the oil drain plug with a new seal
again.
Filling gear oil
– Fill fresh oil OG according to the table of
maintenance data through the hole for the
oil filler plug (1).
Capacity: approx. 1.5 l
50108043405 [EN]
137
6
Maintenance
Maintenance every 5000 hours
138
50108043405 [EN]
7
Technical characteristics
7
Technical characteristics
Dimensions
Dimensions
140
50108043405 [EN]
7
Technical characteristics
Datasheet (VDI)
Datasheet (VDI)
DESCRIPTION
CX 20
CX-D 20
1.1
Manufacturer
–
STILL
STILL
1.2
Model type
–
CX 20
CX-D 20
1.3
Power source
–
Electric
Electric
1.4
Driving mode
–
Order picking
Order picking
1.5
Nominal capacity/load
Q (kg)
2000
2000
1.6
Load centre
c (mm)
1200
600
1.8
Load front offset
x (mm)
1615
942
1.9
Wheelbase
y (mm)
28431
2308
WEIGHT
CX 20
CX-D 20
2.1
Weight in running order (with battery)
kg
1145
1380
2.2
Load per laden axle, drive side/load side
kg
1250/1895
1256/2132
2.3
Load per unladen axle, drive side/load
side
kg
880/265
934/446
CX 20
CX-D 20
Vulkollan®
Polyurethane
Ø 250 x 100
Ø 250 x 100
Ø 85 x 80
Ø 85 x 61.5
Ø 150 x 50
Ø 150 x 50
1 x 1/4
1 x 1/4
WHEELS
3.1
Tyre material
–
Øx
l [mm]
Øx
l [mm]
Øx
l [mm]
3.2
Wheel sizes, drive side
3.3
Wheel sizes, load side
3.4
Rollers
3.5
Number of wheels, drive side/load side
(x = drive wheel)
3.6
Track width, drive side
b10 [mm]
475
475
3.7
Track width, load side
b11 [mm]
348
380
CX 20
CX-D 20
–
1280
130
1580
135
136
1165
1165
–
DIMENSIONS
h1 [mm]
4.2
4.4
Lift
4.8
Floor height
4.9
Tiller height/steering wheel in driving
position, min./max.
h3
(mm)
h7
(mm)
h14
(mm)
50108043405 [EN]
141
7
Technical characteristics
Datasheet (VDI)
DIMENSIONS
4.15
Height of forks when lowered
4.19
Overall length
4.20
Drive area length to front of forks
4.21
Overall width of truck
4.22
Fork dimensions
h13
(mm)
l1
(mm)
l2
(mm)
b1
(mm)
b3 [mm]
Outside fork spread
4.33
Ground clearance at centre of wheelbase
Aisle width with an 800 x 1200 pallet
lengthwise (b12 x l6)
4.35
Turning radius
4.32
CX-D 20
85
91
38051
2700
14251
1550
800
800
s/e/l [mm] 61/172/2390
4.24
4.25
CX 20
b5
(mm)
m2
(mm)
Ast
(mm)
Wa
(mm)
PERFORMANCE DATA
52/180/1150
–
711
520
560
24
25
41271
1400
30461
2495
CX 20
CX-D 20
5.1
Travel speed, laden/unladen
km/h
9/12.5
8/10.5
5.2
Lifting time, laden/unladen
m/s
2.1/1.7
0.15/0.23/2/1.8
5.3
Lowering time, laden/unladen
m/s
1.7/3.2
0.23/0.28/1.6/1.6
5.7
Gradient, laden/unladen
%
6/62
–
5.9
Acceleration time, laden/unladen (over
10 m)
s
6.4/5.2
5.5/4.8
5.10
Service brake
–
Electromagnetic
Electromagnetic
DRIVE
CX 20
CX-D 20
6.1
Travel motor, power S2 = 60 mn
kW
3
3
6.2
Lift motor, power S3 = 15%
kW
2.2
2
–
IEC 254 - 2; B
IEC 254 - 2; B
V/Ah
24/450
24/450
kg
410
410
kW/h
0.99
–
6.3
6.4
6.5
6.6
142
Battery type in accordance with DIN 46
531/35/36 A, B, C, no
Battery voltage
Battery weight ±5 % (depending on
supplier)
Energy consumption according to VDI
cycle
50108043405 [EN]
7
Technical characteristics
Wheels and tyres
MISCELLANEOUS
8.1
Speed control
8.4
Noise level at operator’s ear
CX 20
CX-D 20
–
AC controller
AC controller
dB (A)
66.5
73.3
1
With 600 Ah battery case: + 85 mm
2
Max. gradient limited by the geometry of the truck
.
Wheels and tyres
Approved types of tyres
Only the types of wheels indicated in this
manual can be used.
Fork dimensions
Values for turning radius Wa for working
aisle width calculation
NOTE
all values in mm
Forks length
Distance X
1190
Battery tray
450 Ah
600 Ah
1005
2430
2516
1450
1265
2690
2776
1650
1105
2530
2616
2150
1605
3030
3116
a)
1845
3270
3356
2390 b)
1615
3040
3126
2900
2125
3550
3636
3100
2125
3550
3636
2390
a) Wheelbase suitable for picking up 3 Euro pallets CROSSWAYS
b) Wheelbase suitable for picking up 2 Euro pallets LENGTHWAYS
.
50108043405 [EN]
143
7
Technical characteristics
Fork dimensions
144
50108043405 [EN]
Index
g
A
Driving safety instructions . . . . . . . . . . . . 64
Approved applications . . . . . . . . . . . . . . 14
Attachments
Special risks . . . . . . . . . . . . . . . . . . . 17
E
B
Battery
Disposal . . . . . . . . . . . . . . . . . . . . .
Battery acid . . . . . . . . . . . . . . . . . . . . .
Battery replacement . . . . . . . . . . . . . . .
Battery replacement sideways onto a
trolley . . . . . . . . . . . . . . . . . . . .
Battery replacement with crane . . . . . . .
Battery weight . . . . . . . . . . . . . . . . . . .
.. 9
. 33
. 99
100
100
. 96
EC declaration of conformity in
accordance with Machinery
Directive . . . . . . . . . . . . . .
Electrical insulation test . . . . . . . .
Emissions . . . . . . . . . . . . . . . . . .
Entering lifts . . . . . . . . . . . . . . . . .
Error code . . . . . . . . . . . . . . . . . .
Expert . . . . . . . . . . . . . . . . . . . . .
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. 3
29
35
82
93
25
F
Fork dimensions . . . . . . . . . . . . . . . . . 143
G
C
Closing the battery compartment . . . . . .
Consumables . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . .
Safety information for handling
battery acid . . . . . . . . . . . . . . . . .
Safety information for handling oils . . .
Safety information for hydraulic fluid . .
Copyright and trademark rights . . . . . . . .
Cross references . . . . . . . . . . . . . . . . . .
97
31
34
33
31
32
. 6
. 7
D
Danger zone . . . . . . . . . . . . . . . . . . 66, 78
Datasheet (VDI) . . . . . . . . . . . . . . . . . . 141
Date of edition of this manual . . . . . . . . . . 6
Declaration of conformity . . . . . . . . . . . . . 3
Definition of directions . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . 96, 140
Dimensions of roadways and aisles . . . . 65
Disposal
Battery . . . . . . . . . . . . . . . . . . . . . . . . 9
Components . . . . . . . . . . . . . . . . . . . . 9
Documentation scope . . . . . . . . . . . . . . . 4
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Driving on gradients . . . . . . . . . . . . . . . . 81
Driving on loading bridges . . . . . . . . . . . 82
General . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General View . . . . . . . . . . . . . . . . . . . . . 40
H
Hazards . . . . . . . . . . . . . . . . . . .
Hazards and countermeasures . .
Hazards to employees . . . . . . . .
Hydraulic fluid . . . . . . . . . . . . . .
.
.
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.
.
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.
.
66
18
20
32
I
Identification points . . . . . . . . . . . . . . . . 45
Impermissible use . . . . . . . . . . . . . . . . . 15
Insurance cover on company premises . . 27
Intended use of the trucks . . . . . . . . . 14, 56
L
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Lifting device controls . . . . . . . . . . . . . . . 76
Load handling safety rules . . . . . . . . . . . 77
M
Measuring battery insulation resistance .
Measuring the insulation resistance of
the electrical system . . . . . . . . . . .
Medical equipment . . . . . . . . . . . . . . . . .
Modifications and refitting . . . . . . . . . . . .
50108043405 [EN]
30
30
28
27
145
Index
g
O
Oils . . . . . . . . . . . . . . . . . . . . . . . .
Opening the battery compartment . .
Operating company . . . . . . . . . . . .
Overview of accessories . . . . . . . . .
....
....
....
....
31
97
24
51
P
Packaging . . . . . . . . . . . . . . . . . . . . . . . . 9
Palletising a load . . . . . . . . . . . . . . . . . . 79
Preparation . . . . . . . . . . . . . . . . . . . . . . 95
Safety inspection
Sample graphics
Signals . . . . . . .
Site of operation .
Special risks . . .
Stability . . . . . . .
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29
. 8
. 7
15
17
17
T
Technical description . . . . . . . . . . . . . . . 12
U
R
Update of this manual . . . . . . . . . . . . . . . . 6
Residual dangers . . . . . . . . . . . . . . . . . . 16
Residual risks . . . . . . . . . . . . . . . . . . . . 16
V
S
Safety devices
Misuse . . . . . . . . . . . . . . . . . . . . . . . 37
146
Visibility when driving . . . . . . . . . . . . . . . 64
W
Warning regarding non-original parts . . . 27
50108043405 [EN]
STILL GmbH
Berzeliusstrasse 10
D-22113 Hamburg
Ident no. 50108043405 EN