Still CX-S 16 User manual

OperatingInstructions
Floor-levelorderpicker
CX-S 16
1046
Identno.4401697- 08.09 - EN

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
ECdeclarationofconformity,ECconformitymark ............................. 2
Information about this documentation ...................................... 3
Documentationscope ................................................. 3
Date of edition and update of this manual . . ................................. 5
Copyrightandpropertyrights ............................................ 5
Explanation of symbols used ............................................ 5
Explanation of the cross-references ....................................... 6
Sample graphics ..................................................... 6
Definitionofdirections ................................................. 7
Environmental considerations ........................................... 8
Packaging .......................................................... 8
Disposal of units and batteries during repairwork ............................. 8
2 Introduction
Use of the Truck ..................................................... 10
Intended use of the trucks .............................................. 10
Approved applications . ............................................... 10
Impermissibleuse ................................................... 11
Site of operation ..................................................... 11
Residual risks ...................................................... 12
Residual hazards, residual risks ......................................... 12
Specialrisksarisingfromtheuseofthetruckandattachments ................... 13
Overview of hazards and preventive measures .............................. 14
Hazardsforpersonnel ................................................ 15
3Safety
Definition of terms used for responsible persons ............................. 18
Operatingcompany .................................................. 18
Specialist .......................................................... 18
Drivers ........................................................... 18
Basic principles for safe operation ....................................... 20
Insurance cover on company premises .................................... 20
Modificationsandretrofits .............................................. 20
Warning against the use of non-genuine parts ............................... 21
Damage, faults ..................................................... 21
Medicaldevices ..................................................... 21
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Safety tests ........................................................ 22
Regularsafetyinspectionofthetruck ..................................... 22
Electricalinsulationtest ............................................... 22
Safety regulations for handling consumables ............................... 24
Permittedfluidsandlubricants .......................................... 24
Oils .............................................................. 24
Hydraulicfluid ...................................................... 25
Batteryacid ........................................................ 26
Disposalofconsumables .............................................. 27
Emissions ......................................................... 28
Emissions ......................................................... 28
4Overviews
General view ....................................................... 32
Controls and display .................................................. 33
Viewofthecontrolelements ............................................ 33
Tiller ............................................................. 34
Marking positions .................................................... 35
Location of plates and labels . . .......................................... 35
Dataplate ......................................................... 36
Options and variants ................................................. 36
Overview of options and models ......................................... 36
Overviewofaccessories .............................................. 37
5 Operation
Intended use of the trucks .............................................. 40
Checks and actions prior to use ......................................... 40
Daily pre-operational checks and services ................................. 4
0
Checksbeforedriving ................................................ 41
Connecting the battery plug (charging station) ............................... 42
Commissioning ..................................................... 42
Turningonthetruck .................................................. 42
Enteringthedrivercode ............................................... 43
Hourmeter ........................................................ 44
Batterycharge ...................................................... 45
Displayoftimetonextservicing ......................................... 46
Operatingthehorn ................................................... 46
Checkingthepresenceareaandbrake .................................... 47
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Checking the emergency brake ......................................... 47
Driving ............................................................ 48
Drivingsafetyinstructions .............................................. 48
Visibilitywhendriving ................................................. 48
Beforedriving ...................................................... 49
Emergency stop procedure ............................................ 50
Danger zone ....................................................... 50
Persons in the danger area ............................................. 51
Drivinginridermode ................................................. 52
Selectingthedrivingmode ............................................. 53
Driving, pedestrian operation with push button .............................. 54
Driving, pedestrian operation with tiller, slow approach with drive switch ............ 55
Steering ........................................................... 56
Brakes ............................................................ 57
Emergency stop brake . ............................................... 58
Parkingbrake ...................................................... 59
Automaticshutdown .................................................. 59
Lift ............................................................... 60
Liftingdevicecontrols ................................................. 60
Handling loads ...................................................... 61
Load handling safety rules ............................................. 61
Beforepickinguptheload ............................................. 61
Pickingupaloadingunit ............................................... 62
Danger zone ....................................................... 62
Palletisingaload .................................................... 63
Transportingpalletsorothercontainers ................................... 64
Drivingongradients .................................................. 65
Carryingtheload .................................................... 65
Enteringlifts ........................................................ 66
Driving on loading bridges ............................................. 66
Cold store use ...................................................... 67
Designation ........................................................ 67
Using the Digicode control ............................................. 69
Digicodecontrol .................................................... 69
Addingthemastercode ............................................... 70
Deletingamastercode ................................................ 71
Addingadriver’scode ................................................ 73
Deletingadriver’scode ............................................... 75
Fault displays ...................................................... 77
Errorcode ......................................................... 77
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Handling the truck in specific situations .................................... 78
Transportingthetruck ................................................ 78
Towing procedure ................................................... 78
Hoistingthetruck .................................................... 79
Handling the battery .................................................. 79
Preparation ........................................................ 79
Batteryweightanddimensions .......................................... 80
Opening/closing the battery compartment .................................. 80
Batteryreplacement .................................................. 83
Batteryreplacementwithcrane .......................................... 84
Batteryreplacementsidewaysontoatrolley ................................ 84
Servicingthebattery ................................................. 85
PuttingoutofCommission ............................................. 86
Parkingthetrucksecurely ............................................. 86
Storage ........................................................... 87
Measurestotakeifthelifttruckistobeshutdownforalongtime ................. 87
Recommissioningaftertakingoutofservice ................................ 88
6 Maintenance
General maintenance information ........................................ 90
General . . ......................................................... 90
Staff training and qualifications for maintenance and repairs .................... 91
Battery maintenance personnel ......................................... 91
Servicesnotrequiringspecialqualifications ................................ 91
Listofinspections ................................................... 92
Maintenanceandinspectionintervals ..................................... 93
Orderingspareparts ................................................. 94
Tableofmaintenancedata ............................................. 95
Maintenance safety instructions ......................................... 96
Safety measures for maintenance and repair ............................... 96
Workontheelectricalequipment ........................................ 96
Safetydevices ...................................................... 96
Settings ........................................................... 96
Preparation for maintenance ........................................... 96
Liftingandjackingupthetruck .......................................... 96
Cleaning .......................................................... 99
Cleaning the truck ................................................... 99
Maintenance as required ..............................................101
Servicingthewheelsandrollers .........................................101
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Servicingthebattery .................................................102
Chargingtheleadbattery ..............................................103
Chargingthegelbattery ...............................................104
Checking operation of the brake, checking the emergency brake .................105
Fuses ........................................................... . 106
Servicingtheliftingdevice .............................................107
Maintenance every 500 hours ...........................................109
Othertasks ...................................................... . . 109
Checking the gearbox oil level ..........................................109
Checking the gearbox for leaks ..........................................109
Checkingthehydraulicoillevel,hydraulicsystemforleaks .....................110
Servicingtheelectricmotors ............................................111
Servicingtheelectricalsystem ..........................................113
Servicingthebrake ..................................................114
Checkingtheforks ...................................................115
Servicingthemast ...................................................116
Annual maintenance .................................................119
Workthatmustalsobecarriedout .......................................119
Insulationresistancecheck(earthing) .....................................119
Performingtheaccidentpreventioncheck ..................................120
Maintenance every 2000 hours ..........................................121
Workthatmustalsobecarriedout .......................................121
Renewingthehydraulicoilandhydraulicoilfilter .............................121
Checkingandcleaningthebattery .......................................123
Servicingthebatteryaccordingtothemanufacturer’sinstructions ................123
Insulationresistancecheck(earthing) .....................................123
Performingtheaccidentpreventioncheck ..................................124
Maintenance every 5000 hours ..........................................125
Workthatmustalsobecarriedout .......................................125
Servicingthegearbox ................................................125
4 401 697 [EN] V

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g
7 Technical Data
Dimensions ........................................................128
VDI data sheet ......................................................129
Wheels and tyres ....................................................131
Fork dimensions ....................................................131
Annex
8Diagrams
Hydraulic system ....................................................140
Hydraulicdiagram ...................................................140
Electrical system ....................................................142
Circuitdiagram .....................................................142
Circuitdiagram .....................................................143
Description of components . . . ..........................................144
VI 4 401 697 [EN]

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The trucks described in these operating in-
structions comply with the applicable stan-
dards and safety regulations. If the truck is
used on public roads, it must comply with the
applicable statutory national regulations. The
necessary vehicle permit must be obtained
from the appropriate office.
The trucks have been fitted with the latest
technology. It is now a matter of handling them
safely and maintaining their functionality.
These operating instructions provide the nec-
essary information to do this. Read and ob-
serve the information 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 markisshownonthe
nameplate and indicates compliance with the
above regulations.
Changes or additions to the forklift truck made
on the user’s own initiative can affect the
safety of the truck in ways that are not per-
missible, thus rendering the CE declaration of
conformity invalid.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
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1 697 [EN]

Foreword 1
Information about this documentation
Information about this documentation
Documentation scope
• Operating instructions
• Operating instructions for attachments
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of your truck in all pos-
sible variants at the time of printing. Special
designs based on customer request are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Please enter the production no. and year of
manufacture from the nameplate ⇒ Chap-
ter "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 instructions are lost, the op-
erator must obtain a replacement from the
manufacturer immediately.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 18) must ensure that all users have
4 401 697 [EN] 3

1Foreword
Information about this documentation
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.
4440
1 697 [EN]

Foreword 1
Information about this documentation
Date of edition and update of this
manual
The publication date of this operating manual
is printed on the cover.
STILL makes continuous efforts to enhance
and improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
If you require any technical 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 without the express
written permission of the manufacturer.
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
4 401 697 [EN] 5

1Foreword
Information about this documentation
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require spe-
cial 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. 1-6
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 18
Sample graphics
This documentation explains the (usually se-
quential) 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.
6440
1 697 [EN]

Foreword 1
Information about this documentation
1046_003-001
42
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.
4 401 697 [EN] 7

1Foreword
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts are
packaged to provide protection during trans-
port. This packaging must be removed com-
pletely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the 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
•disposedof,
• 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.
ENVIRONMENT NOTE
We recommend working with a waste ma-
nagement company for disposal purposes.
8440
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2
Introduction

2Introduction
Use of the Truck
Use of the Truck
Intended use of the trucks
CAUTION
This machine is designed for order picking (coll-
ecting and gathering together items stored in the
warehouse before dispatch), horizontal transport
tasks and entering and removing pallets to and from
stock.
The dimensions and capacity of the trailers, pallets
or containers must be adapted to the load being
transported and must ensure stability.
The table of characteristics and performance at-
tached to this user manual gives you some of the
information you need to check that the equipment
is suitable for the work being carried out.
Any specific usage must be authorised by the site
manager; an analysis of the potential risks 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-
scribed in this manual.
If the truck is to be used in a way other than
established in the operating instructions, the
written approval of the manufacturer and, if
necessary, of the responsible authorities must
be obtained beforehand to prevent any poten-
tial dangers.
The maximum load that can be lifted is speci-
fied on the load capacity plate (load diagram).
Do not exceed the maximum load capacity.
10 4 401 697 [EN]

Introduction 2
Use of the Truck
0252_003-092
Impermissible use
The user, and not the manufacturer, is liable
for any hazards caused by improper use.
Use for purposes other than those described
in these operating instructions is prohibited.
Passengers are not allowed.
The lift truck may not be operated in areas
with a risk of fire or explosion or in corrosive or
in high-dust areas. The lift truck must not be
operated on public roads or in the cold store
(special equipment).
Site of operation
Thetruckcanbeusedinenclosedspacesor
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 driver must take the quality of the
ground on which he is driving into considera-
tion. Please observe local regulations.
The truck can be used in tropical and north-
ern countries (temperature range -20 °C to
+40 °C). As an option the truck can also be
equipped for cold stores (option).
4 401 697 [EN] 11

2Introduction
Residual risks
Residual risks
Residual hazards, residual risks
Despite careful operation and compliance
with standards and regulations, not all risks in
using the truck can be entirely excluded.
The truck and all other system components
comply with current safety regulations. Even
when the truck is operated correctly and all
safety requirements are met, residual risks
exist.
Persons in an area near the truck must be
particularly cautious and ready to react imme-
diately in the event of a malfunction, incident
or breakdown.
WARNING
All persons near the truck must be informed of the
risks associated with the use of these trucks.
In addition, we draw attention to the safety 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 load
and ground conditions.
• The stability of the truck has been tested to
the latest standards. These standards only
take into account the static and dynamic
tipping forces that can be produced when
the truck is used according to the operating
requirements and rules. Risks arising from
improper use or incorrect operation that
results in tipping forces that may impact
stability cannot be excluded in extreme
cases.
• Loss of stability due to unstable or sliding
loads etc.
12 4 401 697 [EN]