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
51048070007 [EN] I

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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]