Still CX-T-40 User manual

Original instructions
Electric tow tractor
CX-T-40
1066
51048070007 EN - 00-10/2013

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 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
Issue date and topicality oftheinstructions .................................. 6
Copyrightandtrademarkrights ........................................... 6
Explanation of symbols used ............................................ 7
Explanation of the cross-references ....................................... 7
Definingdirections .................................................... 8
Sample graphics ..................................................... 8
Environmental considerations ........................................... 9
Packaging .......................................................... 9
Disposal of components and batteries ...................................... 9
2 Introduction
Use of the tow tractor ................................................. 1
2
Intended use of the trucks .............................................. 12
Approved applications . ............................................... 12
Unintended use ..................................................... 12
Placeofuse ........................................................ 13
Residual risks ...................................................... 14
Residual dangers, residual risks ......................................... 14
Specialrisksassociatedwithusingthetruckandattachments ................... 15
Overviewofhazardsandcountermeasures ................................. 16
Hazards to employees ................................................ 18
3Safety
Definition of terms used for responsible persons ............................. 22
Operatingcompany .................................................. 22
Specialist .......................................................... 22
Driver ............................................................ 23
Basic principles for safe operation ....................................... 25
Insurance cover on company premises .................................... 25
Warning regarding non-original parts ..................................... 25
Modificationsandretrofitting ............................................ 25
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Medicalequipment .................................................. 27
Safety tests ........................................................ 27
Regular safety inspection of thetruck ..................................... 27
Electricalinsulationtest ............................................... 28
Safety regulations for handling consumable materials ......................... 29
Permissibleconsumables ............................................. 29
Oils .............................................................. 29
Hydraulicfluid ...................................................... 30
Batteryacid ........................................................ 31
Disposalofconsumables .............................................. 32
Emissions ......................................................... 33
Safety devices ...................................................... 35
Locationofsafetydevices ............................................. 35
Damage, defects and misuse of safety devices . . . ........................... 37
Battery connection cables ............................................. 37
4Overviews
Overview .......................................................... 40
Operating devices and display elements ................................... 41
Viewofcontrols ..................................................... 41
Tiller ............................................................. 42
Marking positions .................................................... 43
Location of plates and labels . . .......................................... 43
Labels ............................................................ 44
Chassisframelabelling ............................................... 46
Dataplate ......................................................... 46
Options and variants ................................................. 47
Overview of options and models ......................................... 47
Battery electrolytelevelindicatorLED(optional) ............................. 50
5 Operation
Pre-shift-checks ..................................................... 52
Visualinspections ................................................... 52
Check the operation and security of the trailer coupling ........................ 53
Connecting the battery plug (charging station) ............................... 53
Commissioning ..................................................... 54
Turningonthet
ruck .................................................. 54
Enteringtheusercode ................................................ 55
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Starting with FleetManager (optional) ..................................... 56
Hourmeter ........................................................ 56
Batterycharge ...................................................... 57
Displayoftimetonextservicing ......................................... 57
Operatingthehorn ................................................... 58
Check of brake and presence area ....................................... 58
Checking the emergency brake ......................................... 59
Driving ............................................................ 60
Drivingsafetyrules ................................................... 60
Visibilitywhendriving ................................................. 60
Beforedriving ...................................................... 61
Behaviour in emergency situations ....................................... 62
Differentdrivingmodes ............................................... 62
Driving, stand-on mode ............................................... 63
Selecting the driving mode ............................................. 64
Driving, pedestrian mode with cockpit, slow speed with throttle . ................. 65
Driving, pedestrian mode with traction button ............................... 67
Steering ........................................................... 68
Braking ........................................................... 68
Emergency stop brake . ............................................... 70
Parkingbrake ...................................................... 70
Automaticshutdown .................................................. 70
Handling trailers ..................................................... 71
Approved towing applications ........................................... 71
Coupling trailers ..................................................... 73
Single-positionormulti-positiontrailercoupling .............................. 74
Automatically closingtrailercoupling ..................................... 76
ROCKINGERtrailercoupling ........................................... 78
Towingatrailer ..................................................... 79
Digicode .......................................................... 80
Digicodecontrol ..................................................... 80
Addingthemastercode ............................................... 81
Deleting a master code ................................................ 82
Addingadriver’scode ................................................ 84
Deletingadriver’scode ............................................... 86
Error codes ........................................................ 87
Errorcode ......................................................... 88
Handling the truck in specific operating conditions ............................ 89
Transport .......................................................... 89
Towingprocedure ................................................... 89
Hoistingthetruck .................................................... 90
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Handling the battery .................................................. 90
Preparation ........................................................ 90
Battery weight and dimensions .......................................... 91
Opening/closing the battery compartment .................................. 91
Batteryreplacement .................................................. 94
Battery replacement with crane .......................................... 95
Replacingthebatterylaterallyonbatterytrolley .............................. 95
Servicingthebattery ................................................. 96
Decommissioning ................................................... 96
Leaving the truck unattended . .......................................... 96
Storage ........................................................... 97
Measures when taking the truckoutofserviceforalongperiod .................. 97
Recommissioningaftertakingoutofservice ................................ 97
6 Maintenance
General maintenance information ........................................100
General . . .........................................................100
Staff training and qualifications for maintenance and repairs ....................101
Maintenance personnel for batteries ......................................101
Services not requiringspecialqualifications ................................101
Maintenanceandinspectionintervals .....................................102
Orderingsparepartsandwearparts ......................................103
Maintenance data table ...............................................104
Safety regulations for maintenance .......................................104
Safety measures for maintenance and repair ...............................104
Work on the electricalequipment ........................................104
Safetydevices ......................................................105
Settings ...........................................................105
Preparatory tasks for maintenance .......................................105
Liftingandjackingupthetruck ..........................................105
Cleaning ..........................................................107
Cleanthetruck ......................................................107
Maintenance as required ..............................................109
Service the wheels and rollers ..........................................109
Servicing the battery .................................................109
Chargingtheleadbattery ..............................................111
Chargingthegelbattery ...............................................111
Fuses ........................................................... . 113
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Maintenance every 500 hours ...........................................115
Othertasks ...................................................... . . 115
Checking the gearbox oil level ..........................................115
Checking the gearbox for leaks ..........................................115
Servicetheelectricmotors .............................................116
Service the electrical system ...........................................118
Servicethebrakingsystem .............................................119
Annual maintenance .................................................121
Work that must also be carriedout .......................................121
Insulationresistancecheck(earthing) .....................................121
Maintenance every 2000 hours ..........................................123
Othertasks ...................................................... . . 123
Checkingandcleaningthebattery .......................................123
Servicingthebatteryaccordingtothemanufacturer’sinstructions ................123
Insulation resistance check(earthing) .....................................123
Maintenance every 5000 hours ..........................................125
Othertasks ...................................................... . . 125
Servicingthegearbox ................................................12
5
7 Technical data
Dimensions ........................................................128
Technical data (VDI) CX-T .............................................129
Wheels and tyres ....................................................131
51048070007 [EN] V

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.
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored andmadeavailabletothe
responsible authorities.
25
1048070007 [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
.
51048070007 [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.4-46inthefield
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. 22) must ensure that all operators
have received, read and understood these
instructions.
45
1048070007 [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.
51048070007 [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.
Issue date and topicalityofthe
instructions
The issue date of these instructions can be
found on the title page.
STILL is constantly working to improve its
trucks. These instructions are subject to
change and claims cannot be validly asserted
against the statements and images found in
these operating instructions.
If you require technical support for the truck,
please contact your service centre.
Have a good trip, your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg, Germany
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
1048070007 [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. 22
51048070007 [EN] 7

1Foreword
Information about documentation
Defining directions
Terms used in the text: forward travel (1),
reverse travel (3), to the right (2) and to the
left (4) refer to the installation position of
the components in relation to the driver’s
compartment, with the load positioned at the
rear.
1050_003-002
Sample graphics
This documentation explains the cycle (usu-
ally sequential) of certain functions or opera-
tions. Schematic diagrams of a truck are used
to illustrate these cycles.
NOTE
These schematic diagrams are not represen-
tative of the constructed state of the docu-
mented truck.
85
1048070007 [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.
51048070007 [EN] 9

1Foreword
Environmental considerations
10 51048070007 [EN]

2
Introduction

2Introduction
Use of the tow tractor
Use of the tow tractor
Intended use of the trucks
CAUTION
This machine is designed to tow industrial trailers
and for the storage of loads packed on pallets or in
industrial containers designed for this purpose.
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 of the potential risks
associated with this usage will enable him to put in
place any necessary additional safety measures.
Approved applications
The truck is suitable for carrying and transport-
ing loads in a way described and shown 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
potential dangers.
The maximum load that can be towed is
specified on the drawbar pull plate. Do not
exceed the maximum load capacity.
Unintended use
Any danger due to unauthorised use becomes
the responsibility of the operator or driver and
not of the manufacturer (also see ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 22).
Use for purposes other than those described
in these operating instructions is prohibited.
12 51048070007 [EN]