Zoeller MEDIUM X5 User manual

Operating manual
MEDIUM X5
DLL Lifter

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 Operating control.................................................................................................................................19
5.2.1 Outside control elements.........................................................................................................20
5.2.2 Inside control elements ............................................................................................................30
5.2.3 Safety elements............................................................................................................................40
6Operating instructions.................................................................................................... 42
6.1 Operating hazards ...............................................................................................................................42
6.2 What to do in an emergency...........................................................................................................42
6.3 Starting and finishing a workday ...................................................................................................43
6.3.1 Start..................................................................................................................................................43

Contents 2
6.3.2 End of the workday ....................................................................................................................44
6.4 Compaction............................................................................................................................................44
6.5 Loading ....................................................................................................................................................46
6.6 Travelling.................................................................................................................................................46
6.7 Discharging.............................................................................................................................................47
7Additional equipment.....................................................................................................50
7.1 Shovel and broom handle ................................................................................................................50
7.2 Liquid drainage valve..........................................................................................................................51
7.3 Additional working lights..................................................................................................................51
7.4 Inspection door ladder.......................................................................................................................51
8Maintenance ....................................................................................................................53
8.1 Maintenance safety .............................................................................................................................53
8.2 Test of warning signals ......................................................................................................................55
8.3 Maintenance plan.................................................................................................................................56
8.4 Cleaning...................................................................................................................................................58
8.5 Tailgate lock adjustment ...................................................................................................................63
8.6 Hydraulic installation ..........................................................................................................................64
8.6.1 Notes on hydraulic oil...............................................................................................................64
8.6.2 Permitted hydraulic oils............................................................................................................64
8.6.3 Checking the hydraulic oil level.............................................................................................65
8.6.4 Hydraulic oil change ..................................................................................................................66
8.6.5 Oil leak or hydraulic hose break............................................................................................68
8.7 Electric installation...............................................................................................................................69
8.7.1 Diagnostics - sensors, buttons, I/O modules, CAN bus................................................70
8.8 Boost charging......................................................................................................................................72
8.9 Fuses..........................................................................................................................................................73
9Lifter ................................................................................................................................. 74
9.1 Safety information ...............................................................................................................................74
9.2 Lifter components and controls......................................................................................................75
9.2.1 Lifter working cycle ....................................................................................................................76
9.2.2 Bin catcher.....................................................................................................................................80
9.2.3 Transport position ......................................................................................................................80
9.3 Maintenance ..........................................................................................................................................81

Contents 3
9.3.1 Daily checks and maintenance work....................................................................................81
9.3.2 Lubrication instructions ............................................................................................................81
9.4 Troubleshooting ...................................................................................................................................82
9.4.1 Faults or damage to safety system.......................................................................................82
9.4.2 Oil leak or hydraulic hose brake............................................................................................82
9.4.3 The container falls into the hopper......................................................................................82
9.5 Types of supported containers .......................................................................................................83
Troubleshooting .....................................................................................................................84
Contact.....................................................................................................................................85
Annex- safety test................................................................................................................... 86
Annex- List of icons on terminal........................................................................................... 87

Guide 4
1GUIDE
This operating manual applies to refuse collection vehicle (RCV) Medium X5.
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:
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
Please study the operating instructions closely before operating the vehicle or carrying out
maintenance or repair work.
Please read the operating manual of the chassis manufacturer as well.
Medium X5 RCV is a multiple compartment RCV intended for the collection of domestic refuse,
recyclables or bio-waste. It has two separate tailgates and a split body, so that there is no
mixing of the recycling materials in the separate compartments. The division between the
different compartments is approx. 65/35%. The RCV is equipped with lifters designed to handle
the most common containers.
1.1 SYMBOLS USED IN THIS MANUAL
When studying these operating instructions, you will notice a number of 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
production date. 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.

Safety instructions 8
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.
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.
oIn order for 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 5.2.3) 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 terminal.
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.
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.