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Maintenance

6

General maintenance information

Table of maintenance data

Assembly

Aids/Lubricants

Symbol

Specification

Dimension

Battery

Distilled water

-

as

required

- Insulation

resistance

-

1000 Ohm

min.against

body

FL

NLGI Multi S2

Controls/joints

Lithium base

grease, gear oil

TOTAL

OG

MIL-L-2105,

API:GL4

as

required

Hydraulic

system

Hydraulic oil

AZOLLA

ZS46

DIN 51524 P2, HLP

ISO 6743/4 HM

Up to

centre of

filler elbow

approx.

3.8 l

Motor brushes

-

- Pump motor

Min.

residual

length

11 mm

- Steering motor

Min.

residual

length

11 mm

Wheels

-

- Traction wheel

Dimen-

sions

250 x 100

mm

- Stabiliser

wheel

Dimen-

sions

150 x 50

mm

- Load wheels

Dimen-

sions

85 x 100

mm

- Tandem load

wheels

Dimen-

sions

85 x 80

mm

Wheel nuts

Torque wrench

-

140 Nm

Gearbox

Gear oil 80W

90EP

OG

MIL-L-2105,

API:GL4

approx.

1.5 l

CAUTION: For cold store application only
Gearbox

Gear oil ELF

PERFORMANCE

2B30

API: CD/SF

MIL-L-2104D

approx.

1.5 l

Hydraulic

system

Hydraulic oil

EQUIVIS

XV 32

DIN 51524 P3,

HVLP ISO 6743/

4 HV

Up to

middle

of filler

elbow

approx.

3.8 l

4 499 284 [EN]

97

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Summary of Contents for CX-M 10

Page 1: ...Operating Instructions Floor level order picker CX M 10 1045 Ident no 4 499 284 08 09 EN ...

Page 2: ......

Page 3: ...air work 8 2 Introduction Use of the truck 10 Intended use of the trucks 10 Approved applications 10 Impermissible use 11 Site of operation 11 Residual risks 12 Residual hazards residual risks 12 Special risks arising from the use of the truck and attachments 13 Overview of hazards and preventive measures 14 Hazards for personnel 15 3 Safety Definition of terms used for responsible persons 18 Oper...

Page 4: ...iller 34 Marking positions 35 Location of plates and labels 35 Data plate 36 Options and variants 36 Overview of options and models 36 Overview of accessories 37 5 Operation Intended use of the trucks 40 Checks and actions prior to use 40 Daily pre operational checks and services 40 Checks before driving 41 Connecting the battery plug charging station 42 Commissioning 42 Turning on the truck 42 En...

Page 5: ...Emergency stop brake 59 Parking brake 60 Automatic shutdown 60 Lift 61 Lifting device controls 61 Handling loads 62 Load handling safety rules 62 Before picking up the load 62 Picking up a loading unit 63 Danger zone 63 Palletising a load 64 Transporting pallets or other containers 65 Driving on gradients 66 Carrying the load 66 Entering lifts 67 Driving on loading bridges 67 Cold store use 68 Des...

Page 6: ...ng time 88 Recommissioning after taking out of service 89 6 Maintenance General maintenance information 92 General 92 Staff training and qualifications for maintenance and repairs 93 Battery maintenance personnel 93 Services not requiring special qualifications 93 List of inspections 94 Maintenance and inspection intervals 95 Ordering spare parts 96 Table of maintenance data 97 Maintenance safety ...

Page 7: ...vicing the braking system 114 Checking the forks 115 Annual maintenance 117 Work that must also be carried out 117 Insulation resistance check earthing 117 Performing the accident prevention check 118 Maintenance every 2000 hours 119 Work that must also be carried out 119 Renewing the hydraulic oil and hydraulic oil filter 119 Checking and cleaning the battery 121 Servicing the battery according t...

Page 8: ...mensions 126 VDI data sheet 127 Wheels and tyres 129 Fork dimensions 129 Annex 8 Diagrams Hydraulic system 138 Hydraulic diagram 138 Electrical system 140 Circuit diagram 140 Circuit diagram 141 Description of components 142 VI 4 499 284 EN ...

Page 9: ...1 Foreword ...

Page 10: ...formation provided before com missioning the truck This will avoid accidents and prevent invalidation of the warranty CE Symbol EC declaration of conformity EC conformity mark In making the CE declaration of conformity the manufacturer confirms that the forklift truck complies with the standards and regulations applicable at the time it is brought into ser vice The EC conformity mark is shown on t...

Page 11: ...r Data plate P 4 36 in the space provided Production no Year of manufacture Please quote these numbers during all techni cal enquiries Operating instructions are provided with each truck These instructions must be stored care fully and must be available to the driver and operator at any time The storage location is specified in the Overviews chapter see Chapter General view P 4 32 If the operating...

Page 12: ... received read and understood these instruc tions Thank you for reading and complying with these instructions If you have any questions or suggestions for improvements or if you have found any faults please contact your service centre 4 4 499 284 EN ...

Page 13: ...ical assistance for your truck please contact your nearest STILL service centre We hope you enjoy your driving STILL S A S 4 Avenue de la Libération Square John Saxby BP 50129 60160 MONTATAIRE CEDEX France STILL GmbH Berzeliusstr 4 22113 Hamburg Germany Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third parties wi...

Page 14: ...r to the appropriate section or chapter Examples Cross reference to a section Chap ter Explanation of the cross refer ences P 1 6 Cross reference to a chapter Chap ter Definition of terms used for responsible persons P 18 Illustrations At many points in this documentation the mostly sequential operation of certain func tions or operating procedures is explained To illustrate these operations schem...

Page 15: ...t this documentation 1044_001 014 4 2 3 1 Definition of directions 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 4 499 284 EN 7 ...

Page 16: ...truck Disposal of units and batteries during repair work It may be necessary to replace units as part of maintenance work Replaced units must then be disposed of The truck is made up of different materials Each of these materials 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 ...

Page 17: ...2 Introduction ...

Page 18: ...ed out Any specific usage must be authorised by the site manager an analysis of the potential risks associa ted 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 de...

Page 19: ...on 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 con form to our specifications The ground surface influences the braking distance of the truck When driving and brak ing the drive...

Page 20: ...fety regulati ons in this operating manual The risks can include Release of fluids due to leaks and ruptured lines and tanks etc Risk of accidents when driving over difficult ground such as gradients soft or uneven ground or in areas with poor visibility etc Risk of falling or tripping when moving the truck especially on wet or icy ground or near fluid leaks Drive at a speed appropriate for the lo...

Page 21: ... unusual use where the driver is not sure if it can be carried out in an approved and safe way must first be approved by the manufac turer and if necessary by the responsible inspecting authorities In particularly difficult cases like the simultaneous use of two trucks to transport heavy or bulky loads the supervi sor must be present and assume responsibility for and supervise the transport 4 499 ...

Page 22: ...th key only for authorised staff O Truck not in safe operating condition Recurring inspection and elimination of faults O Please observe national regulations Visibility reduced by load Job planning O Please observe national regulations Assessment of diesel exhaust gases O Please observe national regulations Exhaust emissions Assessment of LPG exhaust gases O Please observe national regulations Mak...

Page 23: ... officer must be appointed Construction and equipment of the truck cor respond to the machinery directive 98 37 EEC and are therefore marked with the CE symbol They are therefore not included in the hazard assessment The same applies for attach ments on account of their own CE marking The operator however must select the type and equipment of trucks in such a way that they conform to local operati...

Page 24: ...2 Introduction Residual risks 16 4 499 284 EN ...

Page 25: ...3 Safety ...

Page 26: ...someone whose technical training and experience have enabled them to develop an appropri ate knowledge of industrial trucks and who is sufficiently familiar with the applicable na tional health and safety regulations accident prevention regulations directives and gener ally recognised technical conventions stan dards VDE regulations technical regulations of other member states of the European Unio...

Page 27: ... the load to be lifted Solid footwear should be worn to ensure safe driving and braking The driver must be familiarised with the oper ating manual and it must be accessible to him at all times The driver must have read and understood the operating manual have familiarised himself with safe opera tion of the truck be physically and mentally able to drive the truck safely DANGER The use of drugs alc...

Page 28: ... be used for work not speci fied in the guidelines and has to be converted or re equipped for such use remember that any alteration to the structural state can af fect the driving behaviour and stability of the truck and lead to accidents You should there fore contact your distributor beforehand No modifications affecting the stability of the truck negatively may be performed without our ap proval...

Page 29: ...iability for damages caused by the use of non genuine parts and accessories without our approval Damage faults Any damage or fault noticed on the truck or on the extra equipment must be reported im mediately to the staff in charge The truck or extra equipment must never be used before they have been repaired as they cannot be guaranteed safe for operating or driving The safety mechanisms and switc...

Page 30: ... caused by improper use An inspection record must be prepared The results of the inspection must be filed at least until after the following the inspection The date of the inspection is indicated by a sticker on the truck The Test manual for power driven trucks should be used Order No 135745 Refer to the guidelines for the inspection of your trucks according to the accident preven tion guidelines ...

Page 31: ...ast 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 suit able meter The insulation resistance is sufficient when it has a nominal value of at least 1000 Ohms V against the chassis A...

Page 32: ... see Chapter Table of maintenance data P 6 97 Oils WARNING Oils are flammable Follow the statutory regulations Do not allow oils to come into con tact with hot engine components Do not smoke WARNING Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled administer fresh air immediately After contact with the eyes rinse thoroughly for at least 10 minutes with water and then con...

Page 33: ...oil immediately using an oil bin ding agent and dispose of it in accordance with regulations ENVIRONMENT NOTE Oils are water pollutants Always store oil in vessels that comply with the applicable regulations Avoid spilling oils Collect spilled oil immediately using an oil binding agent and dispose of it in accor dance with regulations Dispose of old oils according to the applica ble regulations Hy...

Page 34: ... 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 substance hazardous to water Always store hydraulic fluid in containers complying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of according to the...

Page 35: ...ed battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that have to be disposed of follo wing maintenance repair and cleaning must be systematically collected and disposed of in accordance with regulations Observe the national regulations for your country Work may only be carried out in areas designated for the purpose Care must be taken to mi ni...

Page 36: ...stics The machine frequencies were determined on an identical machine in accordance with EN 13059 Safety industrial trucks Test meth ods 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 s For th...

Page 37: ...afety 3 Emissions ignited The risk of explosion can be avoided through sufficient ventilation and by avoiding naked flames Follow the safety precautions for handling the traction battery 4 499 284 EN 29 ...

Page 38: ...3 Safety Emissions 30 4 499 284 EN ...

Page 39: ...4 Overviews ...

Page 40: ...cockpit 3 Pedestrian mode traction button option 4 Backrest 5 Pedestrian mode traction button option 6 Load wheel 7 Forks 8 Lift cylinder 9 AC controller 10 Platform 11 Battery 12 Brake 13 Drive motor 14 Gearbox 15 Traction wheel 16 Steering motor 17 Stabiliser wheel 18 Hydraulic oil tank 19 Pump motor 20 Fuse mount 32 4 499 284 EN ...

Page 41: ...lements 123 456 789 PRG PRG 1044_000 008 5 4 3 2 1 10 9 7 6 8 1 Cubby hole 2 Battery compartment lock 3 Tiller 4 Battery plug 5 Presence area 6 Cubby hole 7 Pedestrian mode traction button option 8 Cushion 9 Pedestrian mode traction button option 10 Cubby hole 4 499 284 EN 33 ...

Page 42: ...2 Lift button 3 Horn button 4 Tortoise button 5 PRG scrolling button 6 Numbers 123 button 7 Display 8 I ON button 9 Numbers 456 button 10 PRG input enter button 11 Numbers 789 button 12 Hare button 13 Horn button 14 Lift button 15 Lower button 16 Handle 17 Travel control 18 Emergency brake switch 19 Travel control 20 Handle 34 4 499 284 EN ...

Page 43: ... 1 Warning label 2 Manufacturer s logo and product code 3 Manufacturer s plate 4 Hook symbol 5 Warning label 6 Do not mount label 7 Hook symbol 8 Cold store operation label option 9 Manufacturer s logo 10 Customer s logo option 11 Warning label 12 Do not attach lifting gear here label 13 Emergency stop label 4 499 284 EN 35 ...

Page 44: ...ease indicate the serial no for all technical enquiries Options and variants Overview of options and models Slow forward reverse speed with traction button on backrest for driving in pedestrian mode with slow speed forward via travel control Slow speed with pedestrian mode travel control Fork lowering cut off while moving Single load wheels Slow speed with forks lowered Continuous operation hour m...

Page 45: ...r 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 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 batter...

Page 46: ...4 Overviews Options and variants 38 4 499 284 EN ...

Page 47: ...5 Operation ...

Page 48: ...e 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 associa ted 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 ...

Page 49: ...aced by our after sales service Warning devices eg horn must be func tioning properly The wheels must not be damaged or worn Inspect the wheels and load wheels 8 for strings fibres and any other objects which could hinder their free rotation The battery cover 2 must be closed the key 3 for the battery compartment lock must be removed The bonnet 9 must be installed Check the notice and safety label...

Page 50: ...k is equipped with a digital con trol 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 know ledge of the code is like a key and should not be misused Do not tell third persons your dri ver code except if expressly ordered to do so Oth...

Page 51: ...e code in the same way as entering characters on a mobile phone Press the buttons 1 2 3 until the de sired number appears For code numbers 1 2 3 press 123 button 1 code numbers 4 5 6 press 456 button 2 code numbers 7 8 9 press 789 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 NOTE If a wrong numbe...

Page 52: ...ode NOTE The following information can be displayed by depressing the PRG scrolling button 7 repeatedly Hour meter Chapter Hour meter P 5 44 Battery charge Chapter Battery charge P 5 45 Display of time to next servicing Chap ter Display of time to next servic ing P 5 46 1044_505 004 2 1 Hour meter The display changes approx 4 5 s after powerup to show the operating hours 1 and the hour glass symbo...

Page 53: ... per cent and changes in steps of 5 NOTE The factory setting of the battery charge indi cator 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 Deep discharging damages the ba...

Page 54: ...s 6 and with the symbol of a span ner 5 Have the maintenance carried out according to service hours specified in the maintenance schedule NOTE The display of the time to the next servicing can be set by your Service Please contact your Service in this regard Other information can appear in the display Chapter Error code P 5 78 123 456 789 PRG PRG 1044_605 001 2 Operating the horn Press the horn bu...

Page 55: ...top 123 456 789 PRG PRG 1044_490 006 6 4 5 7 Checking the emergency brake Drive the truck slowly using the traction control 4 Press the belly button 5 The truck is braked to a stop SToP appears in the display 6 NOTE After the disappearance of StoP in the dis play press the I ON button 7 to restart work CAUTION This brake may only be used in an emergency 4 499 284 EN 47 ...

Page 56: ...ol He must avoid stop ping suddenly turning at speed and overtak ing 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 transport ing goods that obstruct visibilit...

Page 57: ...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 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 Condition of roadways Roadways must be solid enough free of de bris and dropped objects Drainage ...

Page 58: ...y by addi tional warning signs 123 456 789 PRG PRG 7 8 1044_001 009 Emergency stop procedure In an emergency all truck functions can be cut off To do so disconnect the battery plug 7 The truck comes to a stop CAUTION This safety feature may only be used in an emer gency NOTE To restart the start first reconnect the battery plug and then re enter the driver code Danger zone The danger zone is the a...

Page 59: ...ng 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 per sons refuse...

Page 60: ... in rider mode Step on the platform with both feet and step on the presence area 1 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 52 4 499 284 EN ...

Page 61: ...e 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 123 456 789 PRG PRG 1044_503 001 2 3 4 5 Selecting the driving mode NOTE The pallet truck has 2 selectable driving mo des For regular driving depress the hare button 3 For drivin...

Page 62: ...n 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 t...

Page 63: ... increases as you push the traction switch further up to a limit of 6 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 di rection of travel until you reach the required speed 4 499 284 EN 55 ...

Page 64: ...on for turning This function is designed to maintain a straight line Proceed from the cockpit with very slight move ments 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 Forward travel via push button Press push button 5 The truck mov...

Page 65: ...0 001 1 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 4 499 284 EN 57 ...

Page 66: ...braking behaviour of your truck Therefore take this into account when driving and braking Soft braking regenerative braking NOTE The truck is braked electrically The battery is charged by regenerative braking Release travel control 1 or 2 when driv ing 123 456 789 PRG PRG 3 1044_501 010 Leave the presence area 3 58 4 499 284 EN ...

Page 67: ...ppo site direction 123 456 789 PRG PRG 1044_490 007 7 1 6 2 8 Emergency stop brake CAUTION This brake may only be used in an emergency Depress the emergency brake switch 6 The truck is braked to a fast stop SToP appears in the display 7 NOTE After the disappearance of StoP in the dis play press the I ON button 8 to restart work 4 499 284 EN 59 ...

Page 68: ...y the electromagnetic brake 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 60 4 499 284 EN ...

Page 69: ...ing safety rules P 5 62 Do not put your hand or step into moving parts eg mast sideshift implements load lifting device etc Elevating the forks Press the Lift button 2 The forks are elevated to the maximum height Lowering the forks Press the Lower button 1 The forks are lowered to the lowest position The movement can be stopped any time by releasing the button 4 499 284 EN 61 ...

Page 70: ...er touch or stand on moving parts of the truck e g lifting device pushing de vices work installations or devices for picking up loads DANGER WARNING If the lift is used take care not to trap hands or feet The fork should never be lifted if there are people underneath Before picking up the load Load capacity Do not exceed the load capacity of the truck 62 4 499 284 EN ...

Page 71: ...e 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 prohibi ted 1 Loads may only be transported on the fork carriage 2 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 attachmen...

Page 72: ...one 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 1044_800 004 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...

Page 73: ...ents are met The driver must satisfy himself that the load is in proper condition Only properly and se curely 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 an...

Page 74: ... allowed to turn or park on gradi ents or to approach them at an angle Drive at reduced speed on slopes 1044_800 005 Carrying the load WARNING Raise or lower the load until ground clearance is obtained The load should only be so high that the driver s view to the front is not obstructed otherwise drive with the load trailing If this is not possible work with a guide walking beside the truck In thi...

Page 75: ... lift shaft The maximum weight of the truck dead weight with maximum load is Max weight 3120 kg 1044_001 017 Driving on loading bridges Before crossing a loading bridge the driver must satisfy himself that it is properly attached and secured and has a sufficient load capac ity Cross the bridge slowly and carefully The driver must be sure that the vehicle to be en tered is secured sufficiently agai...

Page 76: ...low 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 conden sation This water can freeze when the truck goes back into the cold store and jam the mov ing parts of the truck This is why the le...

Page 77: ... 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 th...

Page 78: ...f 200 driver s codes A driver s code can be added Chapter Adding a driver s code P 5 74 or deleted Chapter Deleting a driver s code P 5 76 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 72 ...

Page 79: ...dding the master code NOTE The pallet truck is turned off the battery is connected 123 456 789 PRG PRG 1044_505 009 1 2 3 4 5 6 Press the I ON button 5 Enter a valid 4 digit master code with the buttons 123 1 456 2 and 789 3 7 1044_505 010 Scroll with the PRG scrolling button 6 until Pin 7 appears in the display 10 1044_505 011 Confirm with the PRG enter button 4 until Add 10 appears in the displa...

Page 80: ...ttempts to add a sixth master code Err will appear in the display 9 1044_505 013 Confirm with the PRG enter button 4 until the new master code 9 blinks an example is shown 10 1044_505 011 Then release the button Add 10 will ap pear again in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge appears in the display The new master code is entered ...

Page 81: ...n the display 10 1044_505 015 Confirm with the PRG enter button 4 until dEL 10 appears in the display 8 1044_505 012 Confirm with the PRG enter button 4 A flashing line cursor 8 will appear in the display 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 c...

Page 82: ...pear again in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge appears in the display The master code is deleted Adding a driver s code NOTE The pallet truck is turned off the battery is connected 123 456 789 PRG PRG 1044_505 009 1 2 3 4 5 6 Press the I ON button 5 Enter the valid 4 digit master code with the buttons 123 1 456 2 and 789 3 74 ...

Page 83: ...ver 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 9 1044_505 013 Confirm with the PRG enter button 4 until the new driver s code 9 blinks an example is shown 10 1044_505 011 Then release the button Add 10 will ap pear again in the display 11 1044_505 014 P...

Page 84: ...044_505 016 Scroll with the PRG scrolling button 6 until USEr 7 appears in the display 10 1044_505 015 Confirm with the PRG enter button 4 until dEL 10 appears in the display 8 1044_505 012 Confirm with the PRG enter button 4 A flashing line cursor 8 will appear in the display 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 ...

Page 85: ...e driver s code 9 to be deleted blinks an example is shown 10 1044_505 015 Then release the button dEL 10 will ap pear again in the display 11 1044_505 014 Press the PRG scrolling button 6 until a normal readout 11 eg battery charge appears in the display The driver s code is deleted 4 499 284 EN 77 ...

Page 86: ...ft button operated at power up Release the left Lift button 2 E371 Left Lowering button operated at power up Release the left Lowering button 3 E372 Left Horn button operated at power up Release the left Horn button 4 E373 Tortoise button operated at power up Release the Tortoise button 5 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 Relea...

Page 87: ...t Lift button operated at power up Release the right Lift button 14 Handling the truck in specific situations 1 2 1 1044_001 012 Transporting the truck Disconnect the battery connector Chocking the truck Secure the truck against rolling and sliding with chocks 1 Lashing down the truck Attach the lashing ropes 2 at the frame Towing procedure As the electric brake is applied the truck can not be tow...

Page 88: ...st 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 Fire prevention measures WARNING Smoking and naked ...

Page 89: ...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 Battery weight and dimensions P 5 81 Notes on charging the battery see Chap ter Servicing the battery P 6 103 Follow steps in reverse order to reinstall and connect the charged battery Ensure that all covers are correctly installed Damage to cabl...

Page 90: ...tery 1044_001 006 1 Remove the female battery connector 1 1044_606 002 2 3 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 82 4 499 284 EN ...

Page 91: ...014 1 2 3 Closing 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 4 499 284 EN 83 ...

Page 92: ...ys of replacing the battery 1 Vertically with a lifting tackle all trucks 2 With a lateral battery removal trolley op tion 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 84 4 499 284 EN ...

Page 93: ...ackle is slack 1044_606 005 8 7 9 10 Battery replacement sideways onto a trolley WARNING Risk of hands getting squeezed 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 Stand on the side opposite the cover and s...

Page 94: ...rged and the charger The room must be well ventilated Keep fire extinguishers ready Safe parking When the battery is being worked on the truck must be properly parked and it may only be started when the battery cover is closed and the battery plug connected Battery servicing Keep the battery cell lid dry and clean Neu tralize spilled electrolyte immediately Termi nals and cable lugs should be clea...

Page 95: ...4_842 001 1 Lower the forks 1 to the ground WARNING Do not leave the truck with the load elevated 1044_001 018 2 Disconnect the battery connector 2 NOTE If you leave the pallet truck without disconnec ting the battery connector the control is shut off automatically after approx 15 minutes The pallet truck can only be operated again after re entering the driver s code 4 499 284 EN 87 ...

Page 96: ...top up if re quired 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 manu facturer Apply a suitable contact spray to all ex posed electrical contacts CAUTION Jack up the lift truck so that all the wheels are clear of the ground This...

Page 97: ...r 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 oper ation Take the truck into service During commissioning check the following points in particular Drive control steering Brake service ...

Page 98: ...5 Operation Storage 90 4 499 284 EN ...

Page 99: ...6 Maintenance ...

Page 100: ...ibing the maintenance procedures are located after the maintenance chart In a dusty environment and with fluctuating temperatures reduce all lubrication and main tenance intervals as required Quality and quantity of required lubri cants Only use the lubricants specified in these op erating instructions The fluids and lubricants and other materials required for the periodic maintenance of the truck...

Page 101: ...ve devices in accordance with the rules of technology and the basic principles of fork trucks Battery maintenance personnel Batteries may only be charged serviced and replaced by specially trained personnel and in accordance with the instructions of the battery charger Observe the battery handling and charger operating instructions Services not requiring special quali fications Simple maintenance ...

Page 102: ...000 hour maintenance and lubrication work should be carried out After 9000 hours of service continue as above therefore instead of 500 hours 9500 hours of service Truck Type No 500 1000 1500 2000 2500 3000 500 500 1000 500 500 1000 2000 500 500 1000 3500 4000 4500 5000 5500 6000 500 500 1000 2000 500 500 1000 500 500 1000 2000 6500 7000 7500 8000 8500 9000 500 500 1000 500 500 1000 2000 500 500 10...

Page 103: ...eels and rollers 1 Service the battery as required 5 Service the braking system 8 Service the gearbox 11 Service the hydraulic system 6 10 12 Service the electric motors 13 Service the electrical system 5 Service the braking system 3 Check the forks every 3 months 500 4 Check the lift cylinder 11 Service the hydraulic system 13 Service the electrical system Insulation resistance check annually 200...

Page 104: ...quired ordering information Only use spare parts as specified by the manu facturer Due to insufficient quality or incorrect assignment the use of parts not approved by the manufacturer can increase the risk of ac cidents The use of unapproved parts places full responsibility for any damage and liability on the part of the user 96 4 499 284 EN ...

Page 105: ...bow approx 3 8 l Motor brushes Pump motor Min residual length 11 mm Steering motor Min residual length 11 mm Wheels Traction wheel Dimen sions 250 x 100 mm Stabiliser wheel Dimen sions 150 x 50 mm Load wheels Dimen sions 85 x 100 mm Tandem load wheels Dimen sions 85 x 80 mm Wheel nuts Torque wrench 140 Nm Gearbox Gear oil 80W 90EP OG MIL L 2105 API GL4 approx 1 5 l CAUTION For cold store applicati...

Page 106: ...ed staff under observance of suit able 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 elec tronic 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 servic...

Page 107: ...ces 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 230 mm 1044_001 002 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 Secure the truck 4 499 284...

Page 108: ...d before servic ing Proceed as follows Remove 2 screws 1 and 2 Remove the bonnet 3 CAUTION Do not damage electric cables 1044_001 004 1 2 3 Installing the bonnet Install the bonnet 3 from above with the guiding lugs 1 in the openings 2 in the frame Fasten the bonnet with 2 screws from above 100 4 499 284 EN ...

Page 109: ...gh shorts disconnecting the battery plug When the truck is cleaned carefully cover all sensitive components particularly electric com ponents Follow the manufacturer s instructions for handling the cleaners Clean the truck exterior with water and cleaning agents soluble in water using sponge rags Especially clean the oil filler openings and the surrounding area and the lubricating nipples before l...

Page 110: ...y e g with com pressed 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 1045_460 001 1 2 3 Check tyres for wear and damage The running surface of the traction wheel 2 support wheel 1 and lo...

Page 111: ...e support wheel rests on the ground Tighten the clamping screw 4 1044_460 003 6 Tightening traction wheel mounting nuts Check the wheel mounting nuts 6 for tight ness tightening them if necessary Torque 140 Nm Servicing the battery CAUTION Before performing any work on the electrical in stallation remove any power from the system by disconnecting the battery connector Battery maintenance precautio...

Page 112: ... 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 main tenance and handling regulations Use of the wrong type of charging device can result in total battery fai lure Always obey the instructions issued by the relevan...

Page 113: ...xisting battery charge 2 NOTE 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 3 1044_606 017 If the display shows a residual charge of 20 3 the lift is cut off CAUTION The battery must immediately be charged as deep discharging begins Deep discharging damages t...

Page 114: ... of the charger unit 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 Never squeeze the battery cables 3 106 4 499 284 EN ...

Page 115: ...p SToP appears in the display 1 NOTE After the disappearance of StoP in the dis play press the I ON button 6 to restart work WARNING Should the brakes show signs of wear or be de fective 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 This safety fea...

Page 116: ...e 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 F4 Fuse 7 5 A F5 Fuse 20 A F8 Fuse 3 A 108 4 499 284 EN ...

Page 117: ... 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 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 t...

Page 118: ...ic 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 110 4 499 284 EN ...

Page 119: ...ng the cable connections Check the traction motor 3 and pump mo tor 1 and steering motor 2 cables for secure connection condition and insula tion NOTE Corroded connections and broken cables lead to drops in voltage leading to malfunctions Remove any corrosion and renew broken cables 4 499 284 EN 111 ...

Page 120: ...d 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 min length of x 11 mm pump motor min length of x 11 mm steering motor If the minimum brush length is reached on one brush renew all brushes as a set NOTE Always replace brushes below the wear limit in kits Check the armature for pitting before installing new brushes New brushes mus...

Page 121: ...ng fuses and cable connections DANGER Before starting the following work park the truck and disconnect the battery plug Remove the front cover Check the fuses 1 for condition Check all cable connections 2 for tight ness Tighten all cable clamping screws Checking the contactor tips Inspect the contactor tips for pitting and have them replaced if necessary Refit and secure the cover 4 499 284 EN 113...

Page 122: ...he max gap is reached 1 2 m 1044_490 005 Measuring the braking force Put the rated load on the truck WARNING 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 The truck must not be operated w...

Page 123: ...rmation cracks strong traces of use or hair cracks CAUTION Have the forks repaired and replaced by your after sales service 1044_842 002 2 Checking the lift cylinder and connec tions for leaks Check the hydraulic connections and lift cylinder 2 for leaks visual inspection Tighten leaky unions repair or replace a defective cylinder 4 499 284 EN 115 ...

Page 124: ...6 Maintenance Maintenance every 500 hours 116 4 499 284 EN ...

Page 125: ...uld 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 Measuring voltage rated voltage 500 V The insulation resistance of all live parts of the truck is sufficient provided it ...

Page 126: ...t by an expert must cover the condition of the assemblies and equipment and the completeness and efficacy of the safety features 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 ...

Page 127: ...Renewing the hydraulic oil and hy draulic oil filter every 2000 hours but at least every year WARNING Hydraulic oil is hazardous to health Follow the safety precautions for handling hy draulic oil Park the truck on a level surface Lower the forks Disconnect the battery plug and remove the cover 1045_700 002 3 2 1 Remove the hydraulic oil tank 2 from the pump motor 1 after removing the screws 3 Dis...

Page 128: ... 5 at the pump motor Install a new seal 4 Mount a new hydraulic oil reservoir on the pump motor and install both together 1044_700 005 Add fresh hydraulic oil OZ according to the table of maintenance data until the oil level reaches the middle of the filler elbow Filling capacity approx 0 8 l 120 4 499 284 EN ...

Page 129: ...ce check earth ing 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 Measuring voltage rated voltage 500 V The insulation resistance...

Page 130: ...l test by an expert must cover the condition of the assemblies and equipment and the completeness and efficacy of the safety features 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 d...

Page 131: ...gearbox Changing gear oil CAUTION Drain the oil at operating temperature Follow the safety precautions for handling gear oil Park and secure the truck and remove the cover Turn the tiller until the filler plug 1 is acces sible Remove the drain plug 2 and filler plug 1 and allow the oil to drain completely ENVIRONMENT NOTE Dispose of the used oil as specified Tighten the oil drain plug with a new s...

Page 132: ...6 Maintenance Maintenance every 5000 hours 124 4 499 284 EN ...

Page 133: ...7 Technical data ...

Page 134: ...7 Technical data Dimensions Dimensions 126 4 499 284 EN ...

Page 135: ...distance x mm 675 Wheelbase y mm 1906 Weight CX M 10 Dead weight with battery kg 1218 Axle loading with load driver s side load side kg 868 1350 Axle loading without load driver s side load side kg 842 376 Wheels chassis CX M 10 Tyres Superelastic SE pneumatic L Vulkollan V V Tyre dimensions driver s side 250 x 100 Tyre dimensions load side 85 x 80 Dimension of stabiliser wheel driver s side 150 x...

Page 136: ...rk thickness s mm 56 Fork width e mm 184 Fork length l mm 1190 Fork carrier width b3 mm 774 Outside fork distance b5 mm 564 Ground clearance m2 mm 29 Aisle width with 800 x 1200 pallets Ast mm 2951 Turning radius Wa mm 2091 Performances CX M 10 Driving speed with without load km h 9 12 Lifting time with without load s 5 35 3 45 Lowering time with without load s 6 7 5 Rated tractive force with with...

Page 137: ...pacity K5 Ah 450 Battery weight depending on model kg 5 410 Energy consumption acc to VDI cycle kWh h Other specifications CX M 10 Controller type AC controller Noise level at driver s ear dB A 73 3 Wheels and tyres Approved types of tyres Only the specified types of wheels may be installed Fork dimensions Values for turning radius Wa for working aisle width calculation NOTE all values in mm 4 499...

Page 138: ...16 1450 1265 2690 2776 1650 1105 2530 2616 2150 1605 3030 3116 2390 a 1845 3270 3356 2390 b 1615 3040 3126 2900 2125 3550 3636 3100 2125 3550 3636 a Wheelbase suitable for picking up 3 Euro pallets CROSSWAYS b Wheelbase suitable for picking up 2 Euro pallets LENGTHWAYS 130 4 499 284 EN ...

Page 139: ...9 Drivers 18 Driving on gradients 66 Driving on loading bridges 67 Driving safety instructions 48 E EC conformity mark 2 EC declaration of conformity 2 Electrical insulation test 22 Emissions 28 Entering lifts 67 Error code 78 F Fluids and lubricants 24 Fork dimensions 129 G General 2 General View 32 H Hazards 50 Hazards and preventive measures 14 Hazards for personnel 15 Hydraulic fluid 25 I Iden...

Page 140: ...ed persons 19 R Residual hazards residual risks 12 S Safety inspection 22 Signals 5 Site of operation 11 Specialist 18 U Update of this manual 5 V VDI data sheet 127 Visibility when driving 48 W Warning against the use of non genuine parts 21 Working materials Safety precautions for hydraulic fluid 25 132 4 499 284 EN ...

Page 141: ......

Page 142: ...Still GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 4 499 284 EN ...

Page 143: ...Operating Instructions Floor level order picker CX M 10 1045 Ident no 4 499 284 08 09 EN Annex ...

Page 144: ......

Page 145: ...8 Diagrams ...

Page 146: ...8 Diagrams Hydraulic system Hydraulic system Hydraulic diagram 138 4 499 284 EN ...

Page 147: ...c system 1 Lift cylinder 2 Hydraulic block 3 Lowering solenoid valve 4 Flow restrictor throttle 5 Hydraulic oil tank 6 Pump motor 7 Oil screen 8 Lift pump 9 Pressure limiter 10 Non return valve 11 Filter 4 499 284 EN 139 ...

Page 148: ...8 Diagrams Electrical system Electrical system Circuit diagram Standard equipment and options 140 4 499 284 EN ...

Page 149: ...Diagrams 8 Electrical system Circuit diagram Driving platform option 4 499 284 EN 141 ...

Page 150: ...nsor S9 Push button unlocking S10 Speed reduction sensor S11 Emergency stop S12 Emergency stop S13 Fold up platform sensor S14 Fold up railing sensor 1 S15 Fold up railing sensor 2 S16 Emergency stop S17 Push button forward travel right S18 Push button forward travel left S19 Push button driving platform lifting S20 Push button driving platform lowering S21 Driving platform raising sensor S22 Lift...

Page 151: ...ent Designation X19 Various connectors X20 Connector tiller case 1 X21 Connector tiller case 2 Compo nent Designation Y1 Lowering solenoid valve Y2 Brake Y3 Loading frame solenoid valve Y4 Low lift solenoid valve Compo nent Designation Y5 Driving platform raising solenoid valve Y6 Solenoid valve disconnection of hydraulic accumulator 4 499 284 EN 143 ...

Page 152: ...Still GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 4 499 284 EN ...

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