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3 Safety

Battery connection cables

50108043405 [EN]

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Table of Contents3
Foreword9
Your Industrial Truck10
General10
EC Declaration of Conformity in Accordance with Machinery Directive11
Information about Documentation12
Documentation Scope12
Date of Edition and Latest Update of this Manual14
Copyright and Trademark Rights14
Explanation of Symbols Used15
Explanation of the Cross-References15
Definition of Directions16
Sample Graphics16
Environmental Considerations17
Packaging17
Disposal of Components and Batteries17
Introduction19
Technical Description20
Use of the Truck22
Intended Use of the Trucks22
Approved Applications22
Impermissible Use23
Site of Operation23
Residual Risks24
Residual Dangers, Residual Risks24
Special Risks Associated with Using the Truck and Attachments25
Overview of Hazards and Countermeasures26
Hazards to Employees28
Safety31
Definition of Terms Used for Responsible Persons32
Operating Company32
Specialist32
Expert33
Driver33
Basic Principles for Safe Operation35
Insurance Cover on Company Premises35
Warning Regarding Non-Original Parts35
Modifications and Refitting35
Medical Equipment36
Safety Tests37
Regular Safety Inspection of the Truck37
Electrical Insulation Test37
Safety Regulations for Handling Consumables39
Permissible Consumables39
Oils39
Hydraulic Fluid40
Battery Acid41
Disposal of Consumables42
Emissions43
Safety Devices45
Damage, Defects and Misuse of Safety Devices45
Battery Connection Cables45
Overview47
General View48
Controls and Display Elements49
View of the Control Elements49
CX 20 Cockpit50
Version with Movable Step Plate (Optional)51
CX-H Version52
Marking Positions53
Location of Plates and Labels53
Labels54
Chassis Frame Labelling56
Data Plate56
Options and Variants57
Overview of Options and Models57
Overview of Accessories59
Battery Electrolyte Level Indicator LED (Optional)60
Load Back Rest with Vertical Pallet Hook (Optional)61
Operation63
Intended Use of the Trucks64
Checks and Actions Prior to Use64
Daily Pre-Operational Checks and Services64
Daily Checks before Use64
Connecting the Battery Plug (Charging Station)66
Commissioning66
Turning on the Truck66
Entering the Driver Code67
Starting with Fleetmanager (Optional)68
Hour Meter69
Battery Charge69
Display of Time to Next Servicing70
Operating the Horn70
Checking the Presence Area and Brake71
Checking the Emergency Brake71
Driving72
Driving Safety Instructions72
Visibility When Driving72
Before Driving73
Emergency Stop Procedure74
Danger Zone74
Persons in the Danger Area75
Driving in Rider Mode76
Selecting the Driving Mode77
Driving, Pedestrian Operation with Tiller, Slow Approach with Drive Switch78
Driving, Pedestrian Operation with Push Button80
Steering81
Brakes81
Emergency Stop Brake83
Parking Brake83
Automatic Shutdown83
Lifting84
Lifting Device Controls84
Handling Loads85
Load Handling Safety Rules85
Before Picking up the Load85
Picking up a Loading Unit86
Danger Zone86
Palletising a Load87
Transporting Pallets or Other Containers88
Driving on Gradients89
Carrying the Load89
Entering Lifts90
Driving on Loading Bridges90
Cold Store Use91
Designation91
Using the Digicode Control93
Digicode Control93
Adding the Master Code94
Deleting a Master Code95
Adding a Driver's Code97
Deleting a Driver's Code99
Fault Displays100
Error Code101
Battery Electrolyte Level Indicator LED (Optional)102
Handling the Truck in Specific Situations102
Transporting the Truck102
Towing Procedure102
Hoisting the Truck103
Handling the Battery103
Preparation103
Battery Weight and Dimensions104
Opening/Closing the Battery Compartment105
Battery Replacement107
Battery Replacement with Crane108
Battery Replacement Sideways Onto a Trolley108
Servicing the Battery109
Decommissioning109
Parking the Truck Securely109
Storage111
Measures to Take if the Lift Truck Is to be Shut down for a Long Time111
Recommissioning after Taking out of Service112
Maintenance113
General Maintenance Information114
General114
Staff Training and Qualifications for Maintenance and Repairs115
Battery Maintenance Personnel115
Services Not Requiring Special Qualifications115
Frequency of Periodic Checks116
Maintenance and Inspection Intervals117
Ordering Spare Parts118
Table of Maintenance Data119
Maintenance Safety Instructions120
Safety Measures for Maintenance and Repair120
Work on the Electrical Equipment120
Safety Devices120
Settings120
Preparatory Tasks for Maintenance120
Lifting and Jacking up the Truck120
Cleaning123
Cleaning the Truck123
Maintenance as Required124
Servicing the Wheels and Rollers124
Servicing the Battery125
Charging the Lead Battery127
Charging the Gel Battery127
Checking Operation of the Brake, Checking the Emergency Brake129
Fuses129
Maintenance Every 500 Hours131
Other Tasks131
Checking the Gearbox Oil Level131
Checking the Gearbox for Leaks131
Checking the Hydraulic Oil Level, Hydraulic System for Leaks132
Servicing the Electric Motors133
Servicing the Electrical System135
Servicing the Braking System136
Checking the Forks137
Annual Maintenance139
Work that Must also be Carried out139
Insulation Resistance Check (Earthing)139
Performing the Accident Prevention Check140
Maintenance Every 2000 Hours141
Work that Must also be Carried out141
Renewing the Hydraulic Oil and Hydraulic Oil Filter141
Checking and Cleaning the Battery143
Servicing the Battery According to the Manufacturer's Instructions143
Insulation Resistance Check (Earthing)143
Performing the Accident Prevention Check144
Maintenance Every 5000 Hours145
Work that Must also be Carried out145
Servicing the Gearbox145
Technical Characteristics147
Dimensions148
Datasheet (VDI)149
Wheels and Tyres151
Fork Dimensions151

Still CX - Page 46

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