Zoeller MEDIUM X2 User manual

Operating manual
MEDIUM X2
MEDIUM X4

Contents 1
CONTENTS
Contents .................................................................................................................................... 1
1Guide .................................................................................................................................. 4
1.1 Symbols used in this manual............................................................................................................. 4
2Vehicle identification data ............................................................................................... 6
2.1. Rating plate.................................................................................................................................................... 6
3Safety instructions ............................................................................................................ 7
3.1 Terms of use............................................................................................................................................. 7
3.2 Improper use............................................................................................................................................ 7
3.3 Residual risks............................................................................................................................................ 8
3.4 General safety.......................................................................................................................................... 8
3.5 Operational safety................................................................................................................................11
3.5.1 Emergency stop button............................................................................................................11
3.5.2 Release button .............................................................................................................................12
3.6 What to do in an emergency...........................................................................................................12
3.7 Additional safety instructions..........................................................................................................12
3.8 Health and safety issues....................................................................................................................13
3.9 Warning labels.......................................................................................................................................14
4Technical data.................................................................................................................. 15
4.1 Dimensions, masses and additional information.....................................................................15
4.2 Noise.........................................................................................................................................................16
4.3 Hand-arm an whole body vibrations............................................................................................16
5Vehicle components and controls ................................................................................. 17
5.1 Main components................................................................................................................................17
5.2 Control elements..................................................................................................................................19
5.2.1 Terminal..........................................................................................................................................20
5.2.2 Control panels..............................................................................................................................21
5.2.3 Lowering the tailgate.................................................................................................................23
5.2.4 Safety devices...............................................................................................................................24
6Operating instruction .....................................................................................................26
6.1 OPERATING HAZARDS............................................................................................................................26
6.2 WHAT TO DO IN AN EMERGENCY ........................................................................................................26
6.3 Starting and finishing a workday ...................................................................................................27

Contents 2
6.3.1 Start..................................................................................................................................................27
6.3.2 End of the workday ....................................................................................................................28
6.4 Loading ....................................................................................................................................................28
6.5 Travelling.................................................................................................................................................29
6.6 Bulky waste collection ........................................................................................................................30
6.7 Discharging.............................................................................................................................................31
6.7.1 Safety during unloading...........................................................................................................31
6.7.2 Unloading mode –outside control elements...................................................................32
7Additional equipment.....................................................................................................33
7.1 Shovel and broom handle ................................................................................................................33
7.2 Hydraulic oil level monitoring.........................................................................................................34
7.3 Axle Load signalling ............................................................................................................................34
7.4 Liquid drainage valve..........................................................................................................................34
7.5 Additional working lights..................................................................................................................35
7.6 Inspection door ladder.......................................................................................................................35
7.7 Handle heating......................................................................................................................................35
7.8 Hydraulic installation covers............................................................................................................36
8Maintenance ....................................................................................................................37
8.1 Maintenance safety .............................................................................................................................37
8.2 Test of warning signals ......................................................................................................................39
8.3 Maintenance plan.................................................................................................................................40
8.3.1 Table of consumables................................................................................................................42
8.4 Cleaning...................................................................................................................................................42
8.5 Hydraulic installation ..........................................................................................................................44
8.5.1 Notes on hydraulic oil...............................................................................................................44
8.5.2 Mixing hydraulic oils..................................................................................................................45
8.5.3 Checking the hydraulic oil level.............................................................................................46
8.5.4 Hydraulic oil change ..................................................................................................................46
8.6 Lubrication..............................................................................................................................................49
8.6.1 Central lubrication system.......................................................................................................49
8.7 Fuses..........................................................................................................................................................52
9Lifter ................................................................................................................................. 53
9.1.1 Technical data of lifters, according to EN 1501-5...........................................................53

Contents 3
9.1.2 Dismantling of the mounting frame....................................................................................54
10 Possible faults.................................................................................................................. 56
10.1 Error message at terminal.................................................................................................................56
10.1.1 System errors................................................................................................................................56
10.1.2 Messages on operating conditions and errors................................................................56
10.2 Troubleshooting ...................................................................................................................................57
Contact.....................................................................................................................................60
ANNEX-SAFETY TEST...................................................................................................................61

Guide 4
1GUIDE
This operating manual applies to refuse collection vehicle (RCV).
All users of the vehicle (RCV) or people carrying out maintenance and repair work must be
trained for the appropriate operation of the vehicle. Furthermore, they must be made aware of
any dangers that might occur when operating the device and be informed about the existing
safety guidelines. Manual should be kept in the vehicle for further use.
ZOELLER TECH Sp. z o. o. assumes no liability or warranty for:
oNot complying with operating manual
oUse of the RCV for other purposes than indicated in this manual
oDamages which are due to negligent operation
oDamages or injuries which are due to manipulation of components or safety devices
oDamages or injuries due to lack of maintenance or use of wrong materials
oDamages or injuries which result from the use of unlicensed spare parts
oDamages or injuries which result from the use of improper consumables
Please study the operating instructions closely before operating the vehicle or carrying out
maintenance or repair work.
Please read the operating manual for:
oTerminal
oLifter
oChassis
ATTENTION
Chassis meeting the EURO 6 emission standard
Read the chassis operating instructions before starting the vehicle or undertaking any maintenance and
repair work.
Particular attention should be paid to information regarding the increased emission gas temperature
during regeneration of the diesel particulate filter (DPF).
1.1 SYMBOLS USED IN THIS MANUAL
When studying these operating instructions, you will notice several symbols and text formats
designed to give you a visual orientation in this manual. The following five symbols are of
major importance since they indicate such information or warnings which you must
absolutely take account of when using the vehicle.

Guide 5
DANGER
These warnings indicate dangerous situations which cause immediate injury to people and must be
observed. Severe injuries or death can be caused by disregarding these warnings.
WARNING
These warnings give you important information on how to avoid dangerous situations and what to do in
cases of emergency or any malfunction.
ATTENTION
These phrases warn about possible damage to the vehicle itself or its direct environment which may
occur if the instructions are ignored.
IMPORTANT
Passages marked with this symbol contain important instructions and functional characteristics of the
vehicle.
FOR YOUR INFORMATION
This symbol indicates helpful advice on how to use the vehicle.
Apart from these symbols you will also find the following formats:
Main Components
This format is used to mark main components and operational controls in pictures and text
passages
Elements of components
This format is used to mark elements of components and operational controls in pictures and
text passages

Vehicle identification data 6
2VEHICLE IDENTIFICATION DATA
Manufacturer
Zoeller Tech Sp. z o.o.
ul. Nowa 8
84-123 Rekowo Górne
POLAND
T: [phone]
F: [phone]
[email protected]
www.zoeller.pl
Copyright
Zoeller Tech Sp. z o.o.
Name
See: rating plate
Type
See: rating plate
Size
See: rating plate
Serial number
See: rating plate
Production year
See: rating plate
2.1. RATING PLATE
RCV rating plate (fig. 2.1) contains information about construction type, catalogue number and
size of the body. Rating plate is placed on the bottom right side of the body.
Fig. 2.1 Rating plate

Safety instructions 7
3SAFETY INSTRUCTIONS
WARNING
RCV can be used only for its intended purpose. Intended use includes:
oDomestic waste disposal
oBulky waste disposal
oIndustrial waste disposal
3.1 TERMS OF USE
oThe waste collection vehicle was built solely for the purpose of waste disposal.
oThe vehicle may only be driven, used and operated by trained drivers and operators.
oProfessional personnel responsible for maintenance and inspections include: locksmith,
electrician, electronics, mechatronics, mechanic - with appropriate training in operating
waste collection vehicles.
oIn case of failure to comply with the regulations, users are in danger. Follow the accident
prevention regulations and other generally applicable health and safety rules and traffic
rules.
3.2 IMPROPER USE
It is forbidden to transport:
oClosed containers/barrels with contents
oSteel gas cylinders
oSpecial, chemical and radioactive waste
oPoisonous waste
oAcids or waste containing acids
oFluids
oFlammable and/or explosive materials
Also:
oThe RCV must not be used in an easily flammable, corrosive and/or explosive
atmosphere.
oThe vehicle may only be used within a temperature range of -20ºC to + 40ºC. These
conditions correspond to the temperate zone.
oIntended use also includes compliance with the commissioning, operation and
maintenance conditions provided by the manufacturer, as well as consideration of
foreseeable operating errors.
oWarning labels on the vehicle must be observed.
oAny use not in accordance with the above description will be considered as improper.
The manufacturer is not responsible for any damage resulting from such use.

Safety instructions 8
3.3 RESIDUAL RISKS
Despite all precautionary measures taken, residual risks, or potential hazards, may occur
during the use of the vehicle, including:
oPossibility of catching clothing, hands, arms or hair by lifter or large waste
oPossibility of hitting the user with flying parts or waste
oAllergies, mucosal irritations and dust formation during waste collection
oRoad hazards caused by other road users
oThermal hazards, e.g. by touching hot surfaces
oBiological hazards, e.g. through contact with waste
3.4 GENERAL SAFETY
FOR YOUR INFORMATION
Driving on the footboards is permitted only if the regulations of the country where the vehicle is used
allow it.
The RCV body (hereinafter referred to as the vehicle) is constructed in accordance with the
current state of technology and safe in operation. Due to the need to perform various
operations, the vehicle has, however, such places and parts that cannot be secured, without
limiting the functionality and serviceability. Therefore, to protect personnel and the vehicle, it
is necessary to comply with the safety rules.
oFor the vehicle to be completely safe, the driver/operator cannot be colour blind,
because the operating elements are marked with different colours. The driver/operator
must also not have hearing impairment, as he must hear alarm and signal sounds.
oAll safety devices installed on the body must be used for their intended purpose and
their correct operation must be checked before each start-up.
oVehicle operating personnel must be trained to operate the vehicle in accordance with
the operating instructions.
oThe vehicle may only be operated and maintained by authorized, trained and qualified
personnel.
oCommunication devices should be used to ensure safety (space control system behind
the vehicle, signalling buttons, buzzer, signal lamps) and check their operation before
starting the vehicle.
oIn case of weighted footboards, the following limitations are activated:
▪Max 30km/h when driving forward
▪Reverse driving is blocked

Safety instructions 9
Fig. 3.1 Driving limitations with weighted footboards
Footboards monitoring function (see chapter 5.2.4) must be tested each time the engine is
started. In case of negative test results, the compaction mechanism is blocked.
oIn the event of malfunctioning reverse driving blockade or an emergency traffic
situation it is possible to restore vehicle manoeuvrability by pressing the restriction
override button on the ZCS-Command module in the cab. To activate button, the
footboards must be weighted.
oAfter the fault has been rectified or the emergency road situation has ended, the
restriction override button can be returned to its original position. For this
purpose, the vehicle with the engine running must be stationary. Safety devices and
travel restrictions will be reactivated. After 5 minutes, the vehicle will be ready to work.
IMPORTANT
Do NOT use the restriction override button as an emergency stop button, because the vehicle is
ready to work after 5 minutes.
oUnder no circumstances operators can stand on the vehicle parts that are not intended
for this purpose. Driving is only allowed in the driver's cab or on the footboards. When
driving on footboards, hold on to the handles at the rear of the vehicle. Driving on
footboards with a speed exceeding 30km/h is prohibited. Only one operator can travel
on the unfolded footboard.
oWhen working with the tailgate raised, it is forbidden to lean it on the road
DANGER
It is forbidden to stand under raised, unsecured tailgate! It is also forbidden to stand on the footboards
during raising the tailgate!
oIt is allowed to drive with the tailgate raised only when emptying the body, and on a
distance not longer than the body length.

Safety instructions 10
oEach vehicle is equipped with a space control system behind the vehicle (camera and
video on the display of the terminal in the cab) to monitor the work area. The camera
must be positioned so that the operator's working area behind the vehicle is visible.
oBefore starting work, check if the space control system behind the vehicle is working
properly. Reverse gear must not be engaged without a functional space control system
behind the vehicle!
oObserve the information on the information and warning signs. Make sure that they are
visible before each start-up.
oDuring work, personal protective equipment must be used (see chapter 3.8: Safety and
health issues).
oKeep long hair under the headgear.
oIn the event of injury, accident, skin irritation or allergic reaction, contact a doctor
immediately.
oFor work that generates large amounts of dust and aerosols, wear a suitable protective
mask!
oDuring travel and bodywork operation, all tailgate covers must be closed. Example of
placement of the covers on the tailgate is shown below. Type and placement of the
covers depends on type of the vehicle.
Fig. 3.2 Example of covers on tailgate
oSpace between the body and driver’s cab and space in the body behind the pushing
wall should always be empty –do not gather there any waste or other materials.
DANGER
High temperatures occur in the spaces between the body and the driver's cab and behind pushing wall.
It should be ensured that there is no waste (especially flammable) left there, because they may cause the
fire.

Safety instructions 11
3.5 OPERATIONAL SAFETY
oOnly a qualified driver and trained operators are authorized to work with the vehicle
and are responsible for third parties in the vehicle zone.
oUnauthorized people should be sent outside the danger zone without exception,
because with the compaction mechanism working there is a risk of injury from ejected
fragments of waste etc.
oThe vehicle cannot be used if the safety devices have been changed or deactivated. If
the safety devices are worn or lost, they must be replaced immediately.
oThe directions used in the manual (right side, left side, front, back) mean the positions
seen in the driving direction.
oTo ensure vehicle stability, place it on solid ground with a maximum slope of 5 degrees.
oWhen working on inclines or slopes, make sure that the vehicle is stable. Also secure
the vehicle against rolling away with at least two wedges located under the vehicle's
wheels.
oBefore each start-up of the vehicle, the hydraulic system must be checked. Worn or
damaged hydraulic hoses must be replaced immediately using original spare parts.
oIn the event of downtime at work, the vehicle must be secured against unauthorized
starting by removing the keys from the ignition.
oThe permissible total weight of the vehicle must be strictly observed and thus not
reloaded.
oThe inspection door may only be opened for maintenance and cleaning work.
When the door is opened, all body functions are blocked.
oThe picture below shows work zones of the operators
Fig. 3.3 Working zones of the operator
3.5.1 Emergency stop button
In case of danger the compaction mechanism should be stopped by pressing emergency stop
button / / . Emergency stop buttons are placed on the left or right side of the
body, on the tailgate and in the driver’s cab. After pressing the button, an alarm signal is heard
in the driver’s cab in form of the pulsating sound.

Safety instructions 12
3.5.2 Release button
If people are trapped in the compaction mechanism, use the release button / . It also
works when the emergency stop button is activated. Check the correct functioning of the
release button before each start-up!
3.6 WHAT TO DO IN AN EMERGENCY
1. Press the emergency stop button. Body will stop working.
2. Stop the vehicle immediately.
3. Do not turn off the engine or auxiliary drive of the vehicle.
4. Release trapped people using the release button. The release button is also active after
using the emergency stop.
5. Determine the cause and rectify any defects.
6. Unlock the emergency stop button by pulling or turning it.
7. Restart the body.
3.7 ADDITIONAL SAFETY INSTRUCTIONS
oIf the safety instructions on the vehicle and the instructions in the manual are not
observed, real life and health risks to personnel and bystanders may arise.
oMaintain special caution when the visibility of the work area is limited.
oDuring work, pay attention to sufficient lighting of the work area. Before starting the
body, make sure that the lighting installation is functional.
oIn the event of a power failure on the body, notify Zoeller immediately. If necessary,
check the fuses of the individual body functions (see chapter 8.6 Fuses).
oIf the operator cannot see the work area, he should, if possible, ask a second person to
supervise the space behind the vehicle.
oWhen reversing, a second person should always supervise the space behind the vehicle.
oThe vehicle driver should adapt his driving style to the specific body characteristics. In
particular, pay attention to:
•Vehicle overhang when cornering
•Total height of the vehicle
•Variable distribution of load during operation

Safety instructions 13
3.8 HEALTH AND SAFETY ISSUES
No
Issue
Regulations
1
User responsibility
The user is obliged to assess the danger zone of the vehicle himself and train the
personnel accordingly.
The user is obliged to indicate a person responsible for the safety of the vehicle.
2
Employment of
personnel
All work on the body may only be carried out by trained, qualified personnel and
service personnel who have been authorized by the user.
Qualified personnel responsible for maintenance and inspection: e.g. locksmith,
electrician, electronics, mechatronics, mechanic with appropriate training in
operating RCV.
Service personnel: e.g. professional drivers with appropriate RCV training.
People whose fitness is reduced due to the use of drugs, alcohol or medicines may
not be employed.
Local regulations concerning the age of the employee must be observed!
3
Staff responsibility
The staff is obliged to comply with safety and security regulations.
Before using the vehicle, read and understand the operating instructions!
Use personal protective equipment.
4
Protective
equipment
The vehicle may only be used with properly functioning protective devices.
Before each use, make sure that the protective equipment is in working order.
After carrying out work during which safety devices have been deactivated,
check that they are working correctly before restarting.
5
Reactivation
protection
Before carrying out any work on body components, the vehicle must be switched
off and secured against being switched on again!
6
Movable parts
All work on the body that is NOT related to normal operation (maintenance, repair)
must be carried out on a stationary vehicle.
Before restarting, properly install and inspect all previously removed components
(e.g. covers, protective devices, screw connections).
7
Plates, symbols
and markings
Ensure that all vehicle markings, signs, warnings and symbols are visible.
Missing or damaged signs should be immediately installed or replaced.
8
Personal
protective
equipment
During work wear:
safe footwear protective clothing
protective gloves
In road traffic wear:
protective vest
In the case of special works (noisy, heavy or dusty waste) wear:
light protective mask eye and ear protection
Special protection measures for long-haired people:
cap

Safety instructions 14
3.9 WARNING LABELS
Fig. 3.4 Do not stand under opened tailgate
Fig. 3.5 Use safety supports
Fig. 3.6 Switch off the engine and remove the
ignition key prior to service work
Fig. 3.7 Do not ride on the sack platform while
driving
Fig. 3.8 Never drive with refuse in the hopper
Fig. 3.9 Keep safety distance from the lifter –
150mm from lifter arms
Fig. 3.10 Keep away from moving parts
Fig. 3.11 Do not use a phone while operating
lifters

Technical data 15
4TECHNICAL DATA
4.1 DIMENSIONS,MASSES AND ADDITIONAL INFORMATION
Documents attached to every vehicle:
1. Calculations of axle loads
2. Calculations of axle loads 50% and 75% load with loading
3. Declaration of conformity
4. Spare parts catalogue
Fig. 4.1 Example of calculations of axle loads

Technical data 16
Fig. 4.2 Example of declaration of conformity
4.2 NOISE
The value of the sound power level of the garbage truck was tested in accordance with EN
1501-4 standard. Refuse collection vehicles and their associated lifting devices - general
requirements and safety requirements - part 4: noise test code for refuse collection vehicles.
The obtained values are placed on the side of the body of each vehicle.
4.3 HAND-ARM AN WHOLE BODY VIBRATIONS
The measurements showed that the effective value of the weighted acceleration of vibration
of the arms and hands on the steering wheel or on the joysticks is lower than the limit value of
2.5m/s2, i.e. it meets the requirements of the EN 1501-1 standard.
The data on whole-body vibration to which vehicle operators are exposed are given in the
chassis manufacturer's documentation.

Vehicle components and controls 17
5VEHICLE COMPONENTS AND CONTROLS
The following chapter presents the main components of a refuse collection vehicle (RCV), with a brief
description of their operation.
IMPORTANT
The design and arrangement of components and controls depends on the chassis type. The image in the
picture may differ slightly from your special vehicle type.
5.1 MAIN COMPONENTS
Fig. 5.1 Main components of RCV
Body
Hopper
Pushing wall
Footboard
Tailgate
Handle
Press (compaction mechanism)
Anti-bike protection
Mounting frame
Inspection door

Vehicle components and controls 18
Fig. 5.2 Back side of the vehicle with press
Slider
Scraper
The useful loading volume of RCV is determined by the size of the body depending on
the chassis. The body is bolted to the chassis. The tailgate is attached to the body at two
points of rotation. When emptying the body, the tailgate is lifted by hydraulic cylinders. The
rear part also has a compaction mechanism for grinding and pressing waste. The compaction
mechanism (press) consists of a slider and scraper . Both units are hydraulically
moved independently of each other. For this purpose, slider has two hydraulic cylinders, with
which it can be moved up and down the guide rail. The scraper is connected to the slider in
such a way that it can be tilted forward and backward by means of two hydraulic cylinders.
Waste loaded manually or by means of a mounted lifter into the hopper , is crushed and
pre-compressed by means of compaction mechanism movements. Then the hopper is emptied
by the movement of the scraper and then as a result of lifting the press, compaction occurs in
the body. In the body there is a pushing wall , which participates in compaction and
emptying of waste. Its movement is carried out along the guides by hydraulic cylinder. The
pushing wall in empty RCV is positioned in the rear part of the body and is moved, as the waste

Vehicle components and controls 19
is being charged, towards the driver's cabin. To unload the waste at the landfill, the tailgate is
raised, and the pushing wall is moved towards the rear of the vehicle, thus emptying the
contents of the body. After unloading, the tailgate is closed again, and the vehicle is ready for
further operation.
5.2 CONTROL ELEMENTS
Fig. 5.3 and Fig. 5.4 Control elements on the vehicle