PAXSTER XL L7e-CU User manual

OPERATING INSTRUCTIONS
Applicable for all Paxster XL vehicles
Rev: 03 –04.04.2023

Paxster user manual Paxster XL rev. 03-04.04.2023
Page 1
Foreword
Notes on the operating instructions
The present original operating instructions are designed to provide sufficient instruction for the safe operation of the
Paxster electric vehicle.
The operator manual details different Paxster models. When operating and servicing the Paxster, make sure that the
section applies to your Paxster model.
Our vehicles are subject to ongoing development. We reserve the right to alter the design, equipment, and technical
features of the system. No guarantee of particular features of the Paxster should therefore be assumed from the present
operating instructions.

Paxster user manual Paxster XL rev. 03-04.04.2023
Page 2
Safety notices and text mark-ups
Indicates a very hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and
even death.
Indicates a very hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and
even death.
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Indicates a procedure or information to reduce the ecological footprint and act ecofriendly.
!
WARNING
!
CAUTION
i
NOTICE
i
INFORMATION 
!
DANGER

Paxster user manual Paxster XL rev. 03-04.04.2023
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Content
1Correct use and application ..................................................................................................................................................... 12
1.1 General ....................................................................................................................................................................12
1.2 Correct application.................................................................................................................................................12
1.3 Approved application conditions .........................................................................................................................12
1.4 Proprietors’ responsibilities...................................................................................................................................14
1.5 Adding attachments and/or optional equipment ...............................................................................................14
2Vehicle description..................................................................................................................................................................... 15
2.1 Application ..............................................................................................................................................................15
2.2 Assemblies and functional description ................................................................................................................16
2.2.1 Assembly overview ................................................................................................................................................... 16
2.2.2 Loading areas............................................................................................................................................................. 18
2.2.3 Functional description.............................................................................................................................................. 21
3Technical specifications............................................................................................................................................................. 25
3.1 General performance data ....................................................................................................................................25
3.2 Dimensions..............................................................................................................................................................26
3.3 Weights....................................................................................................................................................................27
3.4 Battery data .............................................................................................................................................................28
3.5 Range.......................................................................................................................................................................29

Paxster user manual Paxster XL rev. 03-04.04.2023
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3.6 Tire types .................................................................................................................................................................30
3.7 Noise emission level...............................................................................................................................................31
3.8 Electromagnetic compatibility (EMC)...................................................................................................................31
3.9 Specification acc. to radio equipment directive..................................................................................................32
4Identification points and data plate......................................................................................................................................... 34
4.1 Identification points and data plates ....................................................................................................................34
4.1.1 Vehicle identification plate ...................................................................................................................................... 35
5Transport and commissioning.................................................................................................................................................. 37
5.1 Preparing for first time use ....................................................................................................................................37
5.1.1 Removing the wrapping........................................................................................................................................... 38
5.1.2 Adjusting mirrors....................................................................................................................................................... 39
5.1.3 Starting the Paxster ................................................................................................................................................... 40
5.1.4 Removing the Paxster from the pallet ................................................................................................................... 41
5.2 Lifting by jacks.........................................................................................................................................................42
5.3 Lifting by forklift ......................................................................................................................................................46
5.4 Lifting by hydraulic hoists ......................................................................................................................................46
5.5 Transport .................................................................................................................................................................47
5.5.1 Transport on wheels ................................................................................................................................................. 47
5.5.2 Transport on a pallet................................................................................................................................................. 49

Paxster user manual Paxster XL rev. 03-04.04.2023
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6Battery........................................................................................................................................................................................... 50
6.1 Safety regulations for handling the traction battery ...........................................................................................50
6.1.1 Fire hazard.................................................................................................................................................................. 52
6.1.2 Extinguishing fires ..................................................................................................................................................... 54
6.1.3 Special protective equipment for firefighting...................................................................................................... 55
6.1.4 Additional firefighting information ........................................................................................................................ 55
6.2 Safety regulations for handling the auxiliary battery ..........................................................................................56
6.3 Battery types and position .....................................................................................................................................56
6.3.1 Traction battery.......................................................................................................................................................... 57
6.3.2 Auxiliary battery......................................................................................................................................................... 58
6.3.3 Battery locations........................................................................................................................................................... 59
6.4 Charging the traction battery ................................................................................................................................60
6.4.1 Connecting the vehicle to the grid ........................................................................................................................ 62
6.4.2 Disconnecting the charging cable ......................................................................................................................... 65
6.5 Charging the auxiliary battery ...............................................................................................................................66
6.5.1 Forced internal charging ......................................................................................................................................... 67
6.5.2 External 12V charging .............................................................................................................................................. 69
7Operation..................................................................................................................................................................................... 70
7.1 Safety regulations for the operation of the Paxster vehicle................................................................................70

Paxster user manual Paxster XL rev. 03-04.04.2023
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7.2 Display and controls...............................................................................................................................................73
7.2.1 Left handle.................................................................................................................................................................. 74
7.2.2 Left control unit.......................................................................................................................................................... 75
7.2.3 Main instrument......................................................................................................................................................... 79
7.2.4 Throttle........................................................................................................................................................................ 90
7.2.5 Brake pedal ................................................................................................................................................................ 93
7.2.6 Ignition lock and keys............................................................................................................................................... 94
7.2.7 Key fob ........................................................................................................................................................................ 95
7.2.8 Other keys .................................................................................................................................................................. 96
7.2.9 Switch board .............................................................................................................................................................. 97
7.2.10 12V fuses................................................................................................................................................................... 102
7.2.11 Outlet 12V................................................................................................................................................................. 104
7.2.12 Setting the time and units...................................................................................................................................... 105
7.3 Preparing the Paxster for operation .................................................................................................................. 106
7.3.1 Checks and operations to be performed before daily use ............................................................................. 106
7.3.2 Preparing the Paxster for operation..................................................................................................................... 109
7.4 Entry and exit ....................................................................................................................................................... 110
7.5 Operator seat....................................................................................................................................................... 112
7.5.1 Adjusting the seat ................................................................................................................................................... 112

Paxster user manual Paxster XL rev. 03-04.04.2023
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7.5.2 Seat switch function ................................................................................................................................................ 114
7.6 Seatbelt................................................................................................................................................................. 115
7.7 Parking the Paxster securely............................................................................................................................... 118
7.8 Loading and unloading the Paxster................................................................................................................... 120
7.8.1 Rear cargo compartment....................................................................................................................................... 123
7.8.2 Front cargo area ...................................................................................................................................................... 139
7.8.3 Side compartments................................................................................................................................................. 143
7.9 Travel .................................................................................................................................................................... 146
7.10 Steering ................................................................................................................................................................ 147
7.11 Braking.................................................................................................................................................................. 151
7.11.1 Braking ...................................................................................................................................................................... 153
7.11.2 Service brake............................................................................................................................................................ 156
7.12 Long term storage ............................................................................................................................................... 158
8Troubleshooting ....................................................................................................................................................................... 159
8.1 Paxster does not start.......................................................................................................................................... 159
8.1.1 Charger not disconnected..................................................................................................................................... 159
8.1.2 Throttle fault ............................................................................................................................................................. 160
8.1.3 Seat fault ................................................................................................................................................................... 161
8.1.4 No reaction of the vehicle at all ............................................................................................................................ 162

Paxster user manual Paxster XL rev. 03-04.04.2023
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8.2 Paxster does not charge ..................................................................................................................................... 163
8.2.1 Charge indicator flashing ...................................................................................................................................... 163
8.2.2 Charge indicator not flashing ............................................................................................................................... 164
8.3 Paxster gets slower and / or stops ..................................................................................................................... 165
8.3.1 Slowing down: power issues................................................................................................................................. 165
8.3.2 Slowing down: battery low .................................................................................................................................... 166
8.4 Error messages in the display ............................................................................................................................ 168
8.5 Changing a direction indicator bulb ................................................................................................................. 169
8.6 Changing headlight bulbs.................................................................................................................................. 170
8.7 LED headlight or taillight not working .............................................................................................................. 171
8.8 Rescuing the Paxster ........................................................................................................................................... 172
8.8.1 Preparations to release the APBU ........................................................................................................................ 173
8.8.2 Releasing the APBU ................................................................................................................................................ 174
8.8.3 Manual pushing ....................................................................................................................................................... 175
8.8.4 Vehicle operated towing out of dangerous areas............................................................................................. 176
8.8.5 Vehicle operated towing over longer distances (> 500m) .............................................................................. 177
9Optional equipment................................................................................................................................................................. 178
9.1 LED cargo compartment light ............................................................................................................................ 178
9.2 Cabin light ............................................................................................................................................................ 179

Paxster user manual Paxster XL rev. 03-04.04.2023
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9.3 Lateral working light cab .................................................................................................................................... 179
9.4 Lateral working light cargo box ......................................................................................................................... 180
9.5 Front parcel box................................................................................................................................................... 180
9.6 Canvas front ......................................................................................................................................................... 181
9.7 Key FOB................................................................................................................................................................ 182
9.8 Wind deflectors.................................................................................................................................................... 183
9.9 Rear-view camera ................................................................................................................................................ 183
9.10 3rd brake light...................................................................................................................................................... 184
9.11 PaxCon.................................................................................................................................................................. 185
9.12 Third-party equipment........................................................................................................................................ 186
10 Maintenance .............................................................................................................................................................................. 187
10.1 Spare parts ........................................................................................................................................................... 187
10.2 Maintenance safety regulations and environment........................................................................................... 188
10.2.1 Maintenance regulations ....................................................................................................................................... 188
10.2.2 Working on the electrical system ......................................................................................................................... 189
10.3 Consumables and used parts............................................................................................................................. 190
10.4 Wheels .................................................................................................................................................................. 191
10.5 Lubricants and lubrication schedule ................................................................................................................. 192
10.6 Preparing the Paxster for maintenance ............................................................................................................. 195

Paxster user manual Paxster XL rev. 03-04.04.2023
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10.7 Cleaning ............................................................................................................................................................... 196
10.7.1 Preparation for cleaning ........................................................................................................................................ 196
10.7.2 Cleaning plastic surfaces ....................................................................................................................................... 197
10.7.3 Cleaning the wind screen and wind deflectors ................................................................................................. 198
10.7.4 Cleaning the floor ................................................................................................................................................... 199
10.7.5 Cleaning the interior............................................................................................................................................... 199
10.7.6 Cleaning the wheels ............................................................................................................................................... 201
10.8 Replacing wheels................................................................................................................................................. 202
10.9 Tightening the wheel nuts .................................................................................................................................. 204
10.10 Checking brake fluid level .................................................................................................................................. 206
10.10.1 PPM planned preventive maintenance.................................................................................................................. 207
10.10.2 Maintenance schedules ..................................................................................................................................... 207
10.10.3 6-month maintenance........................................................................................................................................ 208
10.10.4 12-month maintenance...................................................................................................................................... 209
10.10.5 24-month maintenance...................................................................................................................................... 210
10.10.6 36-month maintenance...................................................................................................................................... 211
10.10.7 48-month maintenance...................................................................................................................................... 212
10.10.8 60-month maintenance...................................................................................................................................... 213
10.10.9 Further maintenance intervals.......................................................................................................................... 214

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11 Inspection after accidents ....................................................................................................................................................... 215
12 Disposal –second drive program .......................................................................................................................................... 217

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1Correct use and application
1.1 General
The Paxster must be used, operated, and serviced in accordance with this present operating instruction. All
other types of use are beyond its scope of application and may result in damage to personnel, property or the
Paxster vehicle.
1.2 Correct application
The Paxster electric vehicle is designed to carry loads in two compartments, the front cargo area and the rear
cargo cabinet. Additional spaces for personal belongings are situated on both sides of the operator seat.
The maximum loads for the rear cargo area and front cargo area must not be exceeded.
Do not carry passengers.
1.3 Approved application conditions
The Paxster is designed to operate in the following conditions:
▪Operation in industrial and commercial environments.
▪Operation on public roads
▪Permissible temperature range -20°C to 40°C.
▪Operation only on secure, level surfaces with sufficient capacity.
▪Negotiating of slopes up to a maximum of 18%.
▪Do not travel across or at an angle on inclines of more than 18%
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NOTICE

Paxster user manual Paxster XL rev. 03-04.04.2023
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Use under extreme conditions.
Using the Paxster under extreme conditions can result in malfunctions and accidents.
Special equipment and authorization are required if the Paxster is to be constantly used in extreme conditions,
especially in dusty or corrosive atmospheres.
The Paxster cannot be used in areas at risk of explosion.
Driving in winter conditions requires winter tires and special attention to safe speed, braking distance, and
steering capabilities.
Driving in severe weather with wind gusts of more than 80km/h may lead to instable driving behavior.
Do not drive in weather conditions with wind gusts of more than 110km/h. The vehicle might tilt.
Depending on the height of the center of gravity driving on inclines of 20% or more may lead to tipping to the
rear!
Depending on the height of the center of gravity driving across inclines of 25% or more may lead to tipping to
the side!
Do not drive under the influence of alcohol, drugs or medications.
Do not drive if you are wearing a plaster cast or orthosis / leg or arm brace.
!
WARNING
!
WARNING
!
WARNING

Paxster user manual Paxster XL rev. 03-04.04.2023
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1.4 Proprietors’ responsibilities
For the purposes of the present operating instructions the “operating company” or owner is defined as any
natural or legal person who either uses the Paxster himself, or on whose behalf it is used. In special cases (e.g.
leasing or renting) the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the Paxster, is charged with operational duties.
The proprietor must ensure that the Paxster is used only for the purpose it is intended for and that danger to life
and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety
regulations and operating, servicing and repair guidelines must be followed. The operating company must
ensure that all users have read and understood these operating instructions.
Failure to comply with the operating instructions invalidates the warranty. The same applies if improper work is
carried out on the Paxster by the customer or third parties without the permission of the manufacturer.
1.5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the performance of the Paxster
requires the written permission of the manufacturer. Local authority approval may also need to be obtained.
Local authority approval however does not constitute the manufacturers approval.
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NOTICE

Paxster user manual Paxster XL rev. 03-04.04.2023
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2Vehicle description
2.1 Application
The Paxster XL electric vehicle is designed for last mile logistics and postal- and packaging distribution and in
customized versions for other distribution and delivery types like hospital supply, food delivery, battery
transport, and film camera platform.
The Paxster is designed for outdoor and indoor use and is road approved.
The maximum permissible load is stated in the vehicle ID documents and on data stickers in the cargo cabinet
and in the front cargo area.

Paxster user manual Paxster XL rev. 03-04.04.2023
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2.2 Assemblies and functional description
2.2.1 Assembly overview
Item
description
1
Headlights LED or Halogen
2
Heated windscreen
3
Windscreen wiper
4
Mirror
5
Wind deflector
6
Rear cargo compartment
7
Reflector
8
Door magnet
9
Side compartment
10
Jump start button
1
2
3
4
5
6
7
8
9
10
8

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Item
description
11
Direction indicator front
12
Cabin light
13
Rear view display
14
3rd brake light
15
Rear view camera
16
Rear door opener and handle
17
Rear lights LED
18
Registration plate
19
Brake pedal
20
Steering bar
11
12
13
14
15
16
17
18
19
20

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2.2.2 Loading areas
The Paxster offers three loading areas:
- Cargo compartment
- Front cargo area
- Side compartments (left and right)
- Optional side cargo compartment
Item
description
6
Rear cargo compartment
21
Optional side cargo compartment
22
Front cargo area
23
Right side compartment
24
Left side compartment
22
24
6
23
21

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2.2.2.1 Rear cargo compartment
The Paxster XL vehicles offer a rear cargo space of:
▪volume app. 1800liter
▪floor space app 1,46m²
The rear cargo compartments can be accessed via to rear doors and two lateral doors. The standard XL cargo
compartment’s load capacity is 330kg. See chapter 7.8.1 for further information.
The maximum loads for the rear cargo area and front cargo area must not be exceeded.
If your Paxster is a special build, the cargo capacity might deviate from above mentioned standard values. Please
refer to the sticker on the vehicle and the special build manual if applicable.
2.2.2.2 Front cargo area
The front cargo area between steering column and windscreen is a customized area. Depending on regional
post box sizes or load type, this area may look different. The standard load capacity for the front cargo area is
50kg.See chapter 7.8.2 for further information.
The maximum loads for the rear cargo area and front cargo area must not be exceeded.
!
WARNING
!
WARNING