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Still CX, Original Instructions Manual

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Still CX Original Instructions Manual Download Page 136

6

Maintenance

Maintenance every 500 hours

Servicing the braking system

1044_490-004

1

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

WARNING

– Renew the brake disk, when the 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 with a defective

brake.

128

50108043405 [EN]

Summary of Contents for CX

Page 1: ...Original instructions Low level order picker CX CX D CX H 1063 1069 50108043405 EN 02 04 2014 ...

Page 2: ......

Page 3: ...mponents and batteries 9 2 Introduction Technical description 12 Use of the truck 14 Intended use of the trucks 14 Approved applications 14 Impermissible use 15 Site of operation 15 Residual risks 16 Residual dangers residual risks 16 Special risks associated with using the truck and attachments 17 Overview of hazards and countermeasures 18 Hazards to employees 20 3 Safety Definition of terms used ...

Page 4: ...0 Controls and display elements 41 View of the control elements 41 CX 20 cockpit 42 Version with movable step plate optional 43 CX H version 44 Marking positions 45 Location of plates and labels 45 Labels 46 Chassis frame labelling 48 Data plate 48 Options and variants 49 Overview of options and models 49 Overview of accessories 51 Battery electrolyte level indicator LED optional 52 Load back rest...

Page 5: ... 66 Danger zone 66 Persons in the danger area 67 Driving in rider mode 68 Selecting the driving mode 69 Driving pedestrian operation with tiller slow approach with drive switch 70 Driving pedestrian operation with push button 72 Steering 73 Brakes 73 Emergency stop brake 75 Parking brake 75 Automatic shutdown 75 Lifting 76 Lifting device controls 76 Handling loads 77 Load handling safety rules 77 ...

Page 6: ... battery compartment 97 Battery replacement 99 Battery replacement with crane 100 Battery replacement sideways onto a trolley 100 Servicing the battery 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 106 General 1...

Page 7: ... the gearbox for leaks 123 Checking the hydraulic oil level hydraulic system for leaks 124 Servicing the electric motors 125 Servicing the electrical system 127 Servicing the braking system 128 Checking the forks 129 Annual maintenance 131 Work that must also be carried out 131 Insulation resistance check earthing 131 Performing the accident prevention check 132 Maintenance every 2000 hours 133 Wo...

Page 8: ...Table of contents g 7 Technical characteristics Dimensions 140 Datasheet VDI 141 Wheels and tyres 143 Fork dimensions 143 VI 50108043405 EN ...

Page 9: ...1 Foreword ...

Page 10: ...s for the country in which it is being used The driving permit must be obtained from the appropriate office The trucks have been fitted with state of the art technology All 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 wil...

Page 11: ...ße 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 ...

Page 12: ...d 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 oper ator must immediately request a replacem...

Page 13: ...ut 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 ...

Page 14: ...d 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 par ties including as excerpts except with the express ...

Page 15: ...d 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 Chap ter Explanation of the cross refer ences P 1 7 Cross reference to a chapter Ch...

Page 16: ...the operator s station The load is at the rear 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 represen tative of the constructed state of the docu mented truck They serve only to illustrate the sequences 8 50108043405 EN ...

Page 17: ... 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 dispo sing of batteries ENVIRONMEN...

Page 18: ...1 Foreword Environmental considerations 10 50108043405 EN ...

Page 19: ...2 Introduction ...

Page 20: ...nous 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 ...

Page 21: ... 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 com partment comprises a fixed oscillating platform damped to absorb vibrations with lowered bevelled entry steps wit...

Page 22: ...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...

Page 23: ...truck must not be operated on public roads or in the cold store special equipment 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 gr...

Page 24: ...ion 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 regulati ons 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...

Page 25: ...ises 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 ...

Page 26: ...G 925 VDI 3313 driver permit Usage by unautho rised persons Access with key only for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O BetrSichVO Workplace Safety Ordinance Risk of falling when using working platforms Compliance with national regulations different national laws O BetrSichVO Workplace Safety Ordinance and employer s liability insuran...

Page 27: ...lace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O b LPG Observe BGV D34 operating instructions and VDMA rules O When charging the traction battery Observe BetrSichVO Workplace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O VDE 0510 In particular Ensure ventilation Insulation value within permissible range When using ...

Page 28: ...mployees In accordance with the operating safety ordi nance BetrSichVO and the German law on health and safety at work ArbSchG the oper ator see Chapter Definition of terms used for responsible persons P 24 must iden tify 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 appropr...

Page 29: ...o 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...

Page 30: ...2 Introduction Residual risks 22 50108043405 EN ...

Page 31: ...3 Safety ...

Page 32: ... 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 ...

Page 33: ... by suitable per sons 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 rep resentative and have been specifically in structed 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 o...

Page 34: ... 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 aforementio ned substances are not permitted to perform any work on or with an industrial truck Prohibition on use by unauthorised persons The opera...

Page 35: ...uch products may there fore 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 da mage caused by the use of non original parts and accessories wit...

Page 36: ...d 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 modific...

Page 37: ...ecked 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 The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on t...

Page 38: ...st 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 ...

Page 39: ...ble substances that are necessary for operation see Chapter Table of mainte nance 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...

Page 40: ...oved 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 regula tions Hydrauli...

Page 41: ... 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 Dispos...

Page 42: ...ollow 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 d...

Page 43: ...e 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 s For this reason...

Page 44: ...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 ...

Page 45: ...epaired 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 ba...

Page 46: ...3 Safety Battery connection cables 38 50108043405 EN ...

Page 47: ...4 Overview ...

Page 48: ...ller 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 18 Hydraulic oil tank 19 Pump motor 20 Fuse mount 40 50108043405 EN ...

Page 49: ...ontrol elements 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 50108043405 EN 41 ...

Page 50: ...utton 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 42 50108043405 EN ...

Page 51: ...te 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 50108043405 EN 43 ...

Page 52: ... Kg 2259 1 2260 The capacity plate 1 indicates truck load capacity in kg according to the centre of gravity 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 44 50108043405 EN ...

Page 53: ...nd 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 sling symbol 13 Emergency stop label 14 Serial number label bar code on the chas sis 50108043405 EN 45 ...

Page 54: ...cturer s logo 8 Truck identification example 9 Company decal 10 Do not fold the forks when they are holding a load 11 Do not lift a load with the initial lift in the upper position 12 Do not step under a raised load 13 Do not climb 14 Do not stand on the forks 15 Risk of crushing hands 16 Risk of crushing feet 17 Slinging point 18 Do not sling here 19 Electrical plate example 20 Gel battery 46 5010...

Page 55: ...c mode confirmation EXU H autolift only 32 Automatic mode selection indicator EXU H autolift only 33 Manual or automatic mode selection EXU H autolift only 34 Automatic lifting lowering mode selection 35 Arrows 36 Cold store 37 Traction controller label 38 Slow forward travel pedestrian mode 39 Raising lowering of forks 40 Slow forward travel pedestrian mode raising lowering of forks NOTE The label...

Page 56: ...3 Serial no 4 Year of manufacture 5 Unladen weight without battery in kg 6 Maximum battery weight 7 Minimum battery weight 8 Additional weight ballast in kg 9 Nominal power rating in kW 10 Battery voltage V 11 Rated capacity in kg 12 EC conformity symbol Data plate NOTE Please indicate the serial no for all technical enquiries 48 50108043405 EN ...

Page 57: ...mm Load distance x 1105 mm u 545 mm Optional Length 2150 mm section 172 mm Load distance x 1605 mm u 545 mm Optional Length 2390 mm section 172 mm Load distance x 1845 mm u 545 mm Optional Length 2390 mm section 172 mm Load distance x 1615 mm u 775 mm Standard Length 2900 mm section 172 mm Load distance x 2125 mm u 775 mm Optional Forks Length 3100 mm section 172 mm Load distance x 2125 mm u 975 m...

Page 58: ... cockpit forward reverse inching control using buttons on either side of the backrest Optional Optional Pedestrian mode With forward reverse gear using buttons on either side of the backrest Optional Optional Lower fork side Optional Upper fork side Optional Rear accessory bar Upper with fork side bridge piece Optional Display Programmable maintenance intervals Optional Optional With forks lowered...

Page 59: ...er socket Depending on the fixed battery socket Optional Optional 160 A DIN 43589 Optional Optional SBE 160 red Standard Standard Fixed battery socket SBE 320 red Optional Optional 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 supply interface cable with a 3 pole socket and a standard VESA75 bracket with holes P...

Page 60: ...There are two versions of the LED 1 Located on the battery 2 Located next to the battery plug 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 ...

Page 61: ...ps 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...

Page 62: ...ition 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 ...

Page 63: ...5 Operation ...

Page 64: ... 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 inspec tions Safety features and switc...

Page 65: ...rectly Check that the start stop key works cor rectly 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 cor rectly positioned and fastened Check that the lifting chain retaining device if present is in good condition and properly fastened Check th...

Page 66: ...ning 123 456 789 PRG PRG 1044_505 007 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 t...

Page 67: ... code in the same way as entering characters on a mobile phone Press the buttons 1 2 3 until the desired 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 number w...

Page 68: ...ribed in the chapter Operation of the Digicode control section Error Code 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 Chap ter Display of time to next servic ing P 5 62 123 456 789 PRG PRG 1044_505 001 1 2 3 4 5 6 7 Starting wit...

Page 69: ...ttery charge 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 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 Wh...

Page 70: ...s 6 and with the symbol of a spanner 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 The display can show subsequent informa tion Chapter Error code P 5 93 123 456 789 PRG PRG 1044_605 001 2 Operating the horn Press the horn but...

Page 71: ...op 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 display press the I ON button 7 to restart work CAUTION This brake may only be used in an emergency 50108043405 EN 63 ...

Page 72: ...l 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 th...

Page 73: ...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 debris and dropped objects Drainage d...

Page 74: ...by additional 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 area ...

Page 75: ...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 persons refuse ...

Page 76: ... 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 68 50108043405 EN ...

Page 77: ... 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 modes For regular driving depress the hare button 3 For driving ...

Page 78: ...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...

Page 79: ...the drive switch in the opposite di rection of travel until you reach the required speed 1044_501 006 1 2 3 Driving pedestrian operation with push button 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 truc...

Page 80: ...d then activate it again 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 sp...

Page 81: ...0 2430 2516 1450 2690 2776 1650 2530 2616 2150 3030 3116 2390 3270 3356 2390 3040 3126 2900 3550 3636 3100 3550 3636 123 456 789 PRG PRG 1044_501 009 1 2 Brakes WARNING The floor surface properties influence the driving and 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 c...

Page 82: ...g 123 456 789 PRG PRG 3 1044_501 010 Leave the presence area 3 1044_501 007 4 5 Release the pedestrian mode traction button 4 or 5 Average braking Operate travel control 1 or 2 in the opposite direction 74 50108043405 EN ...

Page 83: ...e display press the I ON button 8 to restart work 123 456 789 PRG PRG 1044_501 009 1 2 Parking brake Release traction control 1 or 2 The truck is braked by 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 i...

Page 84: ...dling safety rules P 5 77 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 76 50108043405 EN ...

Page 85: ...ands or feet The forks must never be used if there are people underneath 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 fo...

Page 86: ...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 attachment ...

Page 87: ...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 88: ...nts 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 ...

Page 89: ...t allowed to turn or park on gradients 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 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 ...

Page 90: ... 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 capacity Cross the bridge slowly and carefully The driver must be sure that the vehicle to be entered is secured sufficiently against ...

Page 91: ...ow 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 lengt...

Page 92: ...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...

Page 93: ...f 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 ...

Page 94: ...ding 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 display ...

Page 95: ...tempts 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 appear 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 Del...

Page 96: ...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 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 cod...

Page 97: ...ar 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 50108...

Page 98: ...r 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 appear again in the display 11 1044_505 014 Press...

Page 99: ...1044_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 an...

Page 100: ...044_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 Fault displays 123 456 789 PRG PRG 1044_505 024 3 2 4 5 6 7 8 11 12 14 13 10 9 1 Error code If an error code such as E380 15 appears shut the truck off by pressing button 10 and repeat the start up Chapter Commission ing P 58 If the error code persists call y...

Page 101: ... 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 button operated at power up Release the button PROG 9 E378 ON button operated at power up Release the ON button 10 E379 Hare button operated at power up Release the Hare button 11 E380 Right ...

Page 102: ...e 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 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 Lashi...

Page 103: ...mbol CAUTION It is strictly forbidden to attach the lifting slings to the tiller or to other points not intended for this purpose 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...

Page 104: ...r 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 ...

Page 105: ...tment Opening Park and shut off the truck 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 50108043405 EN 97 ...

Page 106: ...14 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 98 50108043405 EN ...

Page 107: ...ys 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 ...

Page 108: ...ckle 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 sl...

Page 109: ...ishers 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 clean slightly greased and secure Battery charging Switch off the truck and...

Page 110: ...h 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 102 50108043405 EN ...

Page 111: ... 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 pr...

Page 112: ... 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 bra...

Page 113: ...6 Maintenance ...

Page 114: ...ribing 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 lubri cants 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...

Page 115: ... 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...

Page 116: ...ple 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 ...

Page 117: ...els 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 2000...

Page 118: ...quired 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 ...

Page 119: ...w 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...

Page 120: ...orized 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 servi...

Page 121: ...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 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 50108...

Page 122: ...ved before servicing 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 114 50108043405 EN ...

Page 123: ... 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 lubr...

Page 124: ... 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 1044_460 001 1 2 3 Check tyres for wear and damage The running surface of the traction wheel 2 support wheel 1 and load...

Page 125: ... 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 tightness 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 precautions...

Page 126: ...s suitable for your battery CAUTION Gel batteries are subject to special charging mai ntenance 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 conta...

Page 127: ... 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 the battery Before charging inspect the battery and charging cables for damage replace them if necessary Charging the gel battery Refer to instructions fo...

Page 128: ...g charging are explosive Ensure that the room is well ventilated CAUTION Never squeeze the battery cables 3 123 456 789 PRG PRG 1044_490 002 1 2 3 6 Checking operation of the brake checking the emergency brake Drive the truck Leave presence area 5 The truck will brake to a stop Drive the truck slowly with the traction control 2 Press the belly button 3 The truck is braked to a stop SToP appears in...

Page 129: ...the battery plug 4 The truck comes to a stop CAUTION This safety feature may only be used in an emer gency NOTE To restart the truck first reconnect the battery connector and then re enter the driver code 1044_604 001 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 ...

Page 130: ...6 Maintenance Maintenance as required 1044_604 002 1 3 2 F1 F5 F3 F4 F8 1044_604 003 F5 Fuse 20 A F8 Fuse 3 A 122 50108043405 EN ...

Page 131: ... 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 the brake disc 5010804...

Page 132: ...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 124 50108043405 EN ...

Page 133: ...les lead to drops in voltage leading to malfunctions Remove any corrosion and renew broken cables 1044_110 002 6 5 Change the pump motor and the steering motor brushes 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 Open the cover band 4 on the steering motor Lift the brush springs up ...

Page 134: ...or 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 must be ground in If refitting the existing brushes do not interchange or turn them Please contact your Service 126 50108043405 EN ...

Page 135: ... 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 50108043405 EN 127 ...

Page 136: ...e 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 wit...

Page 137: ...4_842 001 1 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 CAUTION Have repairs and replacements on the reach legs carried out by the service department 50108043405 EN 129 ...

Page 138: ...6 Maintenance Maintenance every 500 hours 130 50108043405 EN ...

Page 139: ...rucks 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...

Page 140: ...cle must be tested at least once a year by an expert This annual 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...

Page 141: ... 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 1044_700 003 3 2 1 Remove the hydraulic oil tank 2 from the pump motor 1 after removing the screws 3 Disca...

Page 142: ...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 neck Filling capacity approx 0 8 l 134 50108043405 EN ...

Page 143: ...t Insulation resistance 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 Measurement voltage nominal voltage 500 V I...

Page 144: ... vehicle must be tested at least once a year by an expert This annual 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 inspectio...

Page 145: ...e 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 accessible 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 sea...

Page 146: ...6 Maintenance Maintenance every 5000 hours 138 50108043405 EN ...

Page 147: ...7 Technical characteristics ...

Page 148: ...7 Technical characteristics Dimensions Dimensions 140 50108043405 EN ...

Page 149: ... load side kg 1250 1895 1256 2132 2 3 Load per unladen axle drive side load side kg 880 265 934 446 WHEELS CX 20 CX D 20 3 1 Tyre material Vulkollan Polyurethane 3 2 Wheel sizes drive side Ø x l mm Ø 250 x 100 Ø 250 x 100 3 3 Wheel sizes load side Ø x l mm Ø 85 x 80 Ø 85 x 61 5 3 4 Rollers Ø x l mm Ø 150 x 50 Ø 150 x 50 3 5 Number of wheels drive side load side x drive wheel 1 x 1 4 1 x 1 4 3 6 Tr...

Page 150: ...us Wa mm 30461 2495 PERFORMANCE DATA 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 ...

Page 151: ...s 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 Battery tray Forks length Distance X 450 Ah 600 Ah 1190 1005 2430 2516 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 ...

Page 152: ...7 Technical characteristics Fork dimensions 144 50108043405 EN ...

Page 153: ...oadways and aisles 65 Disposal Battery 9 Components 9 Documentation scope 4 Driver 25 Driving on gradients 81 Driving on loading bridges 82 Driving safety instructions 64 E EC declaration of conformity in accordance with Machinery Directive 3 Electrical insulation test 29 Emissions 35 Entering lifts 82 Error code 93 Expert 25 F Fork dimensions 143 G General 2 General View 40 H Hazards 66 Hazards a...

Page 154: ...oad 79 Preparation 95 R Residual dangers 16 Residual risks 16 S Safety devices Misuse 37 Safety inspection 29 Sample graphics 8 Signals 7 Site of operation 15 Special risks 17 Stability 17 T Technical description 12 U Update of this manual 6 V Visibility when driving 64 W Warning regarding non original parts 27 146 50108043405 EN ...

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Page 156: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 50108043405 EN ...

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