Still CX User manual

Original instructions
Low level order picker
CX CX-D CX-H
1063 1069
50108043405 EN - 02-04/2014

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Date of edition and latest update of this manual ............................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of symbols used ............................................ 7
Explanation of the cross-references ....................................... 7
Definitionofdirections ................................................. 8
Sample graphics ..................................................... 8
Environmental considerations ........................................... 9
Packaging .......................................................... 9
Disposal of components andbatteries ...................................... 9
2 Introduction
Technical description ................................................. 12
Use of the truck ..................................................... 14
Intended use of the trucks .............................................. 14
Approved applications . ............................................... 14
Impermissibleuse ................................................... 15
Site of operation ..................................................... 15
Residual risks ...................................................... 16
Residual dangers, residual risks ......................................... 16
Special risks associatedwithusingthetruckandattachments ................... 17
Overviewofhazardsandcountermeasures ................................. 18
Hazardstoemployees ................................................ 20
3Safety
Definition of terms used for responsible persons ............................. 24
Operatingcompany .................................................. 24
Specialist .......................................................... 24
Expert ............................................................ 25
Driver ............................................................ 25
Basic principles for safe operation ....................................... 27
Insurance cover on company premises .................................... 27
Warning regarding non-original parts ..................................... 27
Modificationsandrefitting .............................................. 27
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Medicalequipment .................................................. 28
Safety tests ........................................................ 29
Regular safety inspection of thetruck ..................................... 29
Electricalinsulationtest ............................................... 29
Safety regulations for handling consumables ............................... 31
Permissibleconsumables ............................................. 31
Oils .............................................................. 31
Hydraulicfluid ...................................................... 32
Batteryacid ........................................................ 33
Disposalofconsumables .............................................. 34
Emissions ......................................................... 35
Safety devices ...................................................... 37
Damage, defects and misuse of safety devices . . . ........................... 37
Battery connection cables ............................................. 37
4Overview
General view ....................................................... 40
Controls and display elements .......................................... 41
Viewofthecontrolelements ............................................ 41
CX20cockpit ....................................................... 42
Version with movable step plate (optional) .................................. 43
CX-Hversion ....................................................... 44
Marking positions .................................................... 45
Location of plates and labels . . .......................................... 45
Labels ............................................................ 46
Chassis frame labelling ............................................... 48
Dataplate ......................................................... 48
Options and variants ................................................. 49
Overview of options and models ......................................... 49
Overviewofaccessories .............................................. 51
BatteryelectrolytelevelindicatorLED(optional) ............................. 52
Load back rest with vertical pallet hook (optional) . ........................... 53
5 Operation
Intended use of the trucks .............................................. 56
Checks and actions prior to use ......................................... 56
Daily pre-operational checks and services ................................. 56
Dailychecksbeforeuse ............................................... 56
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Connecting the battery plug (charging station) ............................... 58
Commissioning ..................................................... 58
Turningonthetruck .................................................. 58
Enteringthedrivercode ............................................... 59
Starting with FleetManager (optional) ..................................... 60
Hourmeter ........................................................ 61
Batterycharge ...................................................... 61
Displayoftimetonextservicing ......................................... 62
Operatingthehorn ................................................... 62
Checkingthepresenceareaandbrake .................................... 63
Checking the emergency brake ......................................... 63
Driving ............................................................ 64
Drivingsafetyinstructions .............................................. 64
Visibilitywhendriving ................................................. 64
Beforedriving ...................................................... 65
Emergency stop procedure ............................................ 66
Danger zone ....................................................... 66
Persons in the danger area ............................................. 67
Drivinginridermode ................................................. 68
Selectingthedrivingmode ............................................. 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
Parkingbrake ...................................................... 75
Automaticshutdown .................................................. 7
5
Lifting ............................................................ 76
Liftingdevicecontrols ................................................. 76
Handling loads ...................................................... 77
Load handling safety rules ............................................. 77
Beforepickinguptheload ............................................. 77
Pickingupaloadingunit ............................................... 78
Danger zone ....................................................... 78
Palletisingaload .................................................... 79
Transporting palletsorothercontainers ................................... 80
Drivingongradients .................................................. 81
Carryingtheload .................................................... 81
Enteringlifts ........................................................ 82
Driving on loading bridges ............................................. 82
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Cold store use ...................................................... 83
Designation ........................................................ 83
Using the Digicode control ............................................. 85
Digicodecontrol .................................................... 85
Addingthemastercode ............................................... 86
Deletingamastercode ................................................ 87
Addingadriver’scode ................................................ 89
Deletingadriver’scode ............................................... 91
Fault displays ...................................................... 92
Errorcode ......................................................... 93
Battery electrolyte level indicator LED (optional) ............................. 94
Handling the truck in specific situations .................................... 94
Transportingthetruck ................................................ 94
Towing procedure ................................................... 94
Hoistingthetruck .................................................... 95
Handling the battery .................................................. 95
Preparation ........................................................ 95
Battery weight and dimensions .......................................... 96
Opening/closing the battery compartment .................................. 97
Batteryreplacement .................................................. 99
Battery replacement withcrane ..........................................100
Batteryreplacementsidewaysontoatrolley ................................100
Servicingthebattery .................................................101
Decommissioning ...................................................101
Parkingthetrucksecurely .............................................101
Storage ...........................................................103
Measures to take if thelifttruckistobeshutdownforalongtime .................103
Recommissioningaftertakingoutofservice ................................104
6 Maintenance
General maintenance information ........................................106
General . . .........................................................106
Staff training and qualifications for maintenance and repairs ....................107
Battery maintenance personnel .........................................107
Services not requiringspecialqualifications ................................107
Frequency of periodic checks . ..........................................108
Maintenanceandinspectionintervals .....................................109
Ordering spare parts .................................................110
Tableofmaintenancedata .............................................111
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Maintenance safety instructions .........................................112
Safety measures for maintenance and repair ...............................112
Work on the electrical equipment ........................................112
Safetydevices ......................................................112
Settings ...........................................................112
Preparatory tasks for maintenance .......................................112
Liftingandjackingupthetruck ..........................................112
Cleaning ..........................................................115
Cleaningthetruck ...................................................115
Maintenance as required ..............................................116
Servicing the wheels and rollers .........................................116
Servicingthebattery .................................................117
Chargingtheleadbattery ..............................................119
Chargingthegelbattery ...............................................119
Checking operation of the brake, checking the emergency brake .................121
Fuses ........................................................... . 122
Maintenance every 500 hours ...........................................123
Othertasks ...................................................... . . 123
Checking the gearbox oil level ..........................................123
Checking the gearbox for leaks ..........................................123
Checking the hydraulic oillevel,hydraulicsystemforleaks .....................124
Servicingtheelectricmotors ............................................125
Servicingtheelectricalsystem ..........................................127
Servicing the braking system ...........................................128
Checkingtheforks ...................................................129
Annual maintenance .................................................131
Work that must also be carriedout .......................................131
Insulationresistancecheck(earthing) .....................................131
Performingtheaccidentpreventioncheck ..................................132
Maintenance every 2000 hours ..........................................133
Workthatmustalsobecarriedout .......................................133
Renewingthehydraulicoilandhydraulicoilfilter .............................133
Checking and cleaningthebattery .......................................135
Servicingthebatteryaccordingtothemanufacturer’sinstructions ................135
Insulationresistancecheck(earthing) .....................................135
Performing the accidentpreventioncheck ..................................136
Maintenance every 5000 hours ..........................................137
Workthatmustalsobecarriedout .......................................137
Servicing the gearbox ................................................137
50108043405 [EN] V

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7 Technical characteristics
Dimensions ........................................................140
Datasheet (VDI) .....................................................141
Wheels and tyres ....................................................143
Fork dimensions ....................................................143
VI 50108043405 [EN]

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
Thetruckshavebeenfittedw
ith 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 will prevent
accidents and ensure that the warranty
remains valid.
25
0108043405 [EN]

Foreword 1
Your industrial truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
50108043405 [EN] 3

1Foreword
Information about documentation
Information about documentation
Documentation scope
• Operating instructions
• Operating instructions for attachment parts
(special equipment)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of the truck in all possible
variants at the time of printing. Special de-
signs to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
Enter the production number and the year
of production located on the nameplate
⇒ Chapter "Data plate", P.4-48inthefield
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 replacement
from the manufacturer.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
Personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company (see ⇒ Chapter "Def-
inition of terms used for responsible per-
sons", P. 24) must ensure that all operators
have received, read and understood these
instructions.
45
0108043405 [EN]

Foreword 1
Information about documentation
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any faults, please contact
your service centre.
50108043405 [EN] 5

1Foreword
Information about documentation
Date of edition and latest update of
this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
65
0108043405 [EN]

Foreword 1
Information about documentation
Explanation of symbols used
DANGER
Compulsory procedure that must be followed to
avoid danger to life or physical harm.
WARNING
Compulsory procedure that must followed to avoid
injury.
CAUTION
Compulsory procedure that must be followed to
avoid material damage and/or destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chap-
ter "Explanation of the cross-refer-
ences",P.1-7
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 24
50108043405 [EN] 7

1Foreword
Information about documentation
1044_001-014
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.
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.
85
0108043405 [EN]

Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
50108043405 [EN] 9

1Foreword
Environmental considerations
10 50108043405 [EN]

2
Introduction

2Introduction
Technical description
Technical description
Drive
TheCX20andCX-D20arefittedwitha3kW
traction motor driving the drive wheel via a
transmission gear:
• Asynchronous travel motor, 3 kW
• Starting and accelerating without jerking
• Regenerative braking
• The CX 20 has a speed of 9 km/h under load
and 12.5 km/h without load
• The CX-D 20 has a speed of 8 km/h under
load and 10.5 km/h without load
Raising
Nominal load of CX 20 and CX-D 20: 2000 kg
Pump assembly power output of CX 20:
2.2 kW
Pump assembly power output of CX-D 20:
2kW
12 50108043405 [EN]