Still 6219 Original Instructions Manual Download Page 471

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Lubrication plan

Code

Lubrication point

(A) Swing axle: two lubricating nipples on each side of the steering axle on the steering arm

Steering turntable: not present

(B) Sliding surfaces on the lift mast
(C) Load chains

Maintenance

General maintenance information

455

56368011531 EN - 01/2021 - 05

Summary of Contents for 6219

Page 1: ...Electric truck RX20 14 20 Cat 2GD 3GD For use in potentially explosive areas Original instructions 6219 6220 6221 6222 6223 6224 6225 6226 6227 6228 6229 6230 6231 56368011531 EN 01 2021 05 ...

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Page 3: ...strial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable indus trial trucks for a particular area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Internet address and QR co...

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Page 5: ...ormation on explosion protection 20 Commissioning 22 Proper use 23 Proper use during towing 24 Improper use 24 Place of use 26 Parking in temperatures below 10 C 28 Using working platforms 28 Information about the documentation 30 Scope of the documentation 30 Supplementary documentation 31 Issue date and topicality of the operating instructions 32 Copyright and trademark rights 32 Explanation of ...

Page 6: ...s springs and accumulators 50 Length of the fork arms 50 Residual risk 52 Residual dangers residual risks 52 Special risks associated with using the truck and attachments 54 Overview of hazards and countermeasures 56 Danger to employees 58 Safety tests 60 Carrying out regular inspections on the truck 60 Explosion protection checks 61 Testing the electrical system 62 Insulation testing 62 Safety re...

Page 7: ...ic charge 99 Adjusting the driver s seat and armrest 99 Adjusting the steering column 99 Adjusting the swivelling display operating unit 100 Switching on the battery isolating switch 101 Unlock the emergency off switch 102 Checking the emergency off function 102 Operating the signal horn 103 Operating the pneumatic signal horn 103 Using the driver s cab 104 Checking the brake system for correct fu...

Page 8: ... Lighting 152 Meaning of the symbols 152 Driving lights 153 Working spotlights 153 Working spotlight for reverse travel variant 155 Turn indicators 155 Hazard warning system 157 StVZO equipment 158 Rotating beacon 159 STILL SafetyLight variant 160 Warning zone light variant 161 Tilt angle dependent assistance systems 162 Mast tilt angle display 162 Tilt end stop damping 162 Automatic mast vertical...

Page 9: ...ingertip version 196 Actuating the vertical rocker button for the drive direction with the Joystick 4Plus version 197 Actuating the drive direction selection lever with the travel direction selector and indicator module version 198 Starting drive mode 198 Starting drive mode dual pedal version variant 200 Operating the service brake 202 Parking brake 203 Applying the mechanical parking brake 204 A...

Page 10: ...ion 255 Handling loads 257 Safety regulations when handing loads 257 Before picking up a load 258 Picking up loads 259 Danger area 260 Transporting pallets 261 Transporting suspended loads 262 Transporting swinging loads 263 Calibrating the automatic mast vertical positioning 162 Automatic mast vertical positioning variant 162 Picking up a load 267 Transporting loads 271 Shake function variant 272...

Page 11: ...ng mechanism variant 307 Controlling attachments using multi lever operation 309 Controlling attachments using multi lever operation and the 5th and 6th function 311 Controlling attachments using a double mini lever 313 Controlling attachments using the double mini lever and the 5th function 315 Controlling attachments using a triple mini lever 317 Controlling attachments using the triple mini lev...

Page 12: ...about operation 366 Messages about the truck 373 Procedure in emergencies 375 Emergency shutdown 375 Actuating the reset button after automatic emergency shutdown 376 Procedure if truck tips over 378 Emergency hammer 378 Emergency driving via the drive direction switch drive direction selection lever 379 Emergency lowering 380 Emergency actuation of the electric parking brake variant 382 Towing 38...

Page 13: ...ter cleaning 430 Transporting the truck 431 Transport 431 Crane loading 434 Decommissioning 435 Safety information for shutting down and restarting 435 Decommissioning and storing the truck 435 Use after storage or decommissioning 437 5 Maintenance Safety regulations for maintenance 440 General information 440 Working on the hydraulic equipment 441 Working on the electrical equipment 441 Safety de...

Page 14: ...d tyres 469 Servicing the steering axle 470 Checking the battery 471 Adjusting the warning zone light 471 Replacing the fuses 472 Checking the hydraulic system for leak tightness 472 Check the hydraulic oil level 474 Lubricating the lift mast and roller track 476 Preserving operational readiness for cold store application 476 1000 hour maintenance annual maintenance 477 Other work that must be car...

Page 15: ...RX20 18 with swing axle 501 RX20 20 swing axle VDI datasheet 505 Eco design requirements for electric motors and variable speed drives 508 Battery specifications 509 Information on the auxiliary hydraulics 511 Table of contents XIII 56368011531 EN 01 2021 05 ...

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Page 17: ...1 Foreword ...

Page 18: ...ve functions and hydraulic functions The driving condition information and all messages are issued via a large colour display The display operating unit uses the current battery charge state and the selected drive programme to calculate the re maining available time until the battery has to be recharged and displays this information It also supports all FleetManager 4 x functions Assistance system...

Page 19: ...dstill A parking brake ensures that the truck remains securely in place when parked Hydraulic system The steering system the lift cylinders and the tilt cylinders in the lift mast are supplied with power via a hydraulic pump operated by an electric motor The proportional valve technology provides particularly sensitive movements and safe handling of the load The hydraulic functions can be paramete...

Page 20: ...controlled valves and proportional valve technology The acceleration behaviour and braking be haviour can be selected individually using dif ferent drive programmes For drive mode the truck features either sin gle pedal or dual pedal operation Accelera tion and braking electric brake via the accel erator pedal or dual pedal operation One ped al for the forwards drive direction and one pedal for th...

Page 21: ...idents and to keep the truck ready for operation beyond the warranty period Therefore Before commissioning the truck read the operating instructions and follow the instruc tions Always follow all of the safety information contained in the operating instructions and on the truck CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations v...

Page 22: ...on protection notice The explosion protection notice indicates that the manufacturer complies with the explosion protection licensing regulations 6036_001 001 Foreword 1 Your truck 6 56368011531 EN 01 2021 05 ...

Page 23: ...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 Foreword 1 Your truck 7 56368011531 EN 01 2021 05 ...

Page 24: ... switch not for trucks with the Switch on via push button variant Two keys for the cab variant A hexagon socket wrench for emergency lowering in the compartment A battery change frame Foreword 1 Your truck 8 56368011531 EN 01 2021 05 ...

Page 25: ...Foreword 1 Your truck 9 56368011531 EN 01 2021 05 ...

Page 26: ...lling points 6219_901 011_V2 II 1 2 6 7 10 11 4 9 16 8 15 8 2 17 18 19 20 3 5 4 13 14 1 12 3 4 5 6 7 8 9 10 13 14 12 11 18 15 CAT 2G 16 17 20 V Ah kg L 19 Foreword 1 Your truck 10 56368011531 EN 01 2021 05 ...

Page 27: ...mation Lifting gear fixing point Decal information Washer system filling 1 2 3 4 5 6 7 8 9 10 Warning sign Dangerous electrical voltage Decal information Load measurement Decal information ANTISTATIC CHECKED on the backrest of the driver s seat Decal information ELECTRICALLY CON DUCTIVE antistatic paint Decal information Explosion protection no tice and equipment category Decal information Potenti...

Page 28: ...g 6219_901 012_V3 0044 S r l I 20812 LIMBIATE MB Via Marconi 31 CBH 5 II 573714 3 CEC 14 ATEX 043X T amb 20 C to 60 C Ex d ia 6 IIC T Gb s n Year 20 T cable C Ex tb CABLE ENTRIES SEE INSTRUCTIONS USE SCREWS QUALITY 8 8 OR BETTER DO NOT OPEN WHEN ENERGIZED DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE PRESENT IIIC T II 2 1 GD C Db IP66 Foreword 1 Your truck 12 56368011531 EN 01 2021 05 ...

Page 29: ...ameplate Decal information Load capacity Attach ment Decal information Load capacity Basic ta ble 21 22 23 24 25 26 27 28 29 30 31 Decal information Regular testing Decal information Battery service Decal information Caution Read the oper ating instructions Decal information Lifting point Warning sign Danger due to shearing on rotary seat variant Warning sign Ventilator Decal information Explosion...

Page 30: ...ng 14 Explosion protection notice 15 Permissible area of application 16 Rated drive power kw 17 Battery voltage V 18 Rated capacity kg Production number NOTE The production number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of man...

Page 31: ...ation This label includes information on the weight and load distribution of the truck in kg 1 Tare weight 2 Total permissible weight 3 Permitted front axle load 4 Permitted rear axle load 5 Payload Foreword 1 Your truck 15 56368011531 EN 01 2021 05 ...

Page 32: ...en an explosive atmos phere may be present A warning sign is located in the immediate vi cinity of the nameplate Open only in a non potentially explosive at mosphere 5060_901 020_V2 0044 S r l I 20812 LIMBIATE MB Via Marconi 31 CBH 5 II 573714 3 CEC 14 ATEX 043X T amb 20 C to 60 C Ex d ia 6 IIC T Gb s n Year 20 T cable C Ex tb CABLE ENTRIES SEE INSTRUCTIONS USE SCREWS QUALITY 8 8 OR BETTER DO NOT ...

Page 33: ...ELLERZELLEN CONSTRUCTORELEMENTOS N DISERIE SERIALN 20812 LIMBIATE MB ACCUMULATORETIPO BATTERYTYPE ACCUMULATEURTYPE BATTERIETYP BATERIATIPO CAPACITÀ CAPACITY CAPACITÉ KAPAZITÄT CAPACIDAD TENSIONENOMINALE NOMINALVOLTAGE TENSIONNOMINAL NENNSPANNUNG TENSIONNOMINAL N DISERIE SERIENN N DELFABRICANTE N ELEMENTI N CELLS N ELEMENTS N ZELLEN N ELEMENTOS PESOINORDNEDIMARCIA RUNNINGWEIGHT POIDSENORDREDEMARCHE...

Page 34: ...the battery supplier If the truck is equipped with an explosion protected battery from another manufacturer the authorised service centre will provide assistance in de coding the nameplate of the battery Foreword 1 Your truck 18 56368011531 EN 01 2021 05 ...

Page 35: ...ring and reading out the truck control unit Only the authorised service centre may operate the diagnostic interface The di agnostic interface is identified by the decal in formation see illustration IRP 0017 01 C AN BU S 6219_901 019 Foreword 1 Your truck 19 56368011531 EN 01 2021 05 ...

Page 36: ...ary inform the safety officer Examples of this work are Battery replacement and battery charging Maintenance and repair Settings and safety checks Conversion and retrofitting Transportation and loading Areas with explosive atmospheres are divided into zones Equipment is divided into equip ment groups and equipment categories The equipment category determines the zones in which the explosion protec...

Page 37: ...ive atmosphere in the form of a flammable dust cloud Equipment is divided into groups I II and III Division of equipment Group Description I Mining equipment subterranean endangered by exposure to pit gas dust II Equipment in all other areas with gas explosion protection and dust explo sion protection outside of mining III Equipment in all other areas with dust explosion protection outside of mini...

Page 38: ... 2 Depending on the zone classification the operating and display elements on the trucks may be enclosed in a special housing Gases and vapours are divi ded into temperature classes T1 to T6 and permissible equipment surface temperatures are defined Temperature classes Temperature class Ignition temperature range Maximum surface temperature T1 450 C 450 C T2 300 C to 450 C 300 C T3 200 C to 300 C ...

Page 39: ... of explosion for which it is ap proved in accordance with the attached EC declaration of conformity and type approval NOTE For explanations of the various areas see the chapter entitled Basic information on explo sion protection If the truck is to be used for purposes other than those specified in the operating instruc tions the approval of the manufacturer and if applicable the relevant regulato...

Page 40: ...used by improper use Use for purposes other than those described in these operating instructions is prohibited NOTE Please note the definition of the following re sponsible persons operating company and driver DANGER There is a risk of fatal injury from falling off the truck while it is moving It is prohibited to carry passengers on the truck DANGER Risk of tipping over or tilting of the forklift ...

Page 41: ... in mining underground Areas of the equipment group III i e for use in potentially explosive dust atmospheres Areas of zone 0 and 20 Areas of zones for which the truck is not specifically approved for use as listed in the data on the nameplate Areas with temperature classes in which the truck is not specifically approved for use as listed in the data on the nameplate For towing trailers in potenti...

Page 42: ...ing without conductive flooring The truck must only be operated in potentially explo sive areas that are fitted with conductive flooring Avoid electrostatic charges NOTE More information concerning the requirements for conductive or dissipative floorings can be found in the guidelines relating to electrostatic hazards CLC TR 60079 32 1 The truck is approved in accordance with Di rective 2014 34 EU...

Page 43: ...ration due to gases steam mist or dusts Trucks approved for zone 1 are automatically also approved for zone 2 Trucks approved for zone 21 are automatically also approved for zone 22 Compare the permissible temperature classes for the potentially explosive areas with the specification on the nameplate See also the section entitled Basic informa tion on explosion protection Operation on public roads...

Page 44: ... relevant authorities NOTE Please observe the definition of the following responsible person operating company Parking in temperatures below 10 C CAUTION Batteries can freeze If the truck is parked in an ambient temperature be low 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batteries The truck is then not ready for opera tion When the ambient ...

Page 45: ...heck the area of application by com paring with nameplate information on the working platform If the area of application is not clear ask a safety official WARNING The use of working platforms is regulated by national law The use of working platforms is only permitted by virtue of the jurisdiction in the country of use Observe national legislation Before using working platforms consult the na tion...

Page 46: ...ter the production number year of manufacture and the Miretti job number from the nameplate Production number Year of manufacture Miretti Job number Please quote the production number in all technical enquiries Specify the Miretti job number for any spare parts orders Each truck comes with a set of operating in structions These instructions must be stored carefully and must be available to the dri...

Page 47: ...sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documentation This may be in the form of an insert or separate operating instructions The original operating instructions for this in dustrial truck are valid for the operation of standard equipment and variants without re striction The operational and safety informa tion in the origi...

Page 48: ...made accessible to third parties including as excerpts except with the ex press written approval of the manufacturer Explanation of signal terms used The signal terms Danger Warning Caution Note and Environmental note and the symbol are used in these instructions as haz ard warnings or for unusual information that requires special identification DANGER Risk of explosion There is a risk of explosio...

Page 49: ...on of the EU working equipment directive BG Berufsgenossenschaft German insurance company for the com pany and employees BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident...

Page 50: ...tment LSP Load centre of gravity Distance of the centre of gravity of the load from the front face of the fork backs MAK Maximum workplace concentration Maximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment...

Page 51: ... load is to the front Schematic views View of functions and operating proce dures At many points in this documentation the mostly sequential operation of certain func tions or operating procedures is explained Schematic diagrams of a counterbalance truck are used to illustrate these procedures NOTE These schematic views are not representative of the structural state of the documented truck The vie...

Page 52: ...display of the display and operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values may vary 12 6 h 10 35 6219_003 021_V3 Foreword 1 Information about the documentation 36 56368011531 EN 01 2021 05 ...

Page 53: ...osal of components and batter ies 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 dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man...

Page 54: ...Foreword 1 Environmental considerations 38 56368011531 EN 01 2021 05 ...

Page 55: ...2 Safety ...

Page 56: ...pany must provide training to its personnel regarding the special features of potentially explosive areas The operating company must provide training to its personnel at regular intervals regarding working with forklift trucks in potentially explo sive areas The operating company must have the exper tise required by law to guarantee explosion protection for equipment and operating materi als The o...

Page 57: ... the test in question or of carrying out similar tests Moreover this person must be aware of the latest techno logical developments regarding the industri al truck being tested and the risks being as sessed Sufficient knowledge in the field of industrial trucks that have been converted for use in potentially explosive areas A qualification certificate in accordance with standard DIN EN 60079 17 20...

Page 58: ...th the BGG General Employers Liability In surance Association Act 925 their training meets the training requirements under 3 of the Health and Safety at Work Act and 9 of the German Ordinance on Industrial Safety and Health Observe the national regulations for the country in which the truck is being used Rights obligations and codes of con duct DANGER Risk of accident due to consuming intoxicants ...

Page 59: ... footwear while working in potentially explosive areas The requirements for antistatic clothing are defined in the following standards Shoes EN ISO 20344 Personal protective equip ment Test procedure for shoes in the cur rent version Protection suit including gloves EN 1149 5 protection suit Electrostatic properties Part 5 Material performance and design requirements Prohibition of use by unauthor...

Page 60: ...t is not lis ted in the directives or in these instructions the truck must be converted or retrofitted by the authorised service centre as required Any structural modification can impair the handling and stability of the truck and can result in ac cidents Any modifications that adversely affect the stability the load capacity or the all round visi bility of the truck require written approval from ...

Page 61: ... drill any holes in the battery hood NOTE Welding operations are forbidden The operating company is only permitted to make modifications to the truck independently if the manufacturer goes into liquidation and the company is not taken over by another le gal person The operating company must also fulfil the fol lowing prerequisites Design documents test documents and as sembly instructions associat...

Page 62: ...y falling loads or the truck tipping over may result in buckling of the modified overhead guard and no pro tection for the driver Do not perform welding on the overhead guard Do not perform drilling on the overhead guard CAUTION Heavy roof loads damage the overhead guard To ensure the stability of the overhead guard at all times a roof load may only be mounted on the over head guard if the structu...

Page 63: ...be reported to the supervisor or responsible fleet manager immediately so that they can have the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g co...

Page 64: ...n marking tyres are identified by the safety information Observe the explosion protection regula tions Ensure that permissible tyres are used Check the presence and condition of the antistatic belts corona electrode If in doubt speak to the safety officer NOTE Electrically conductive tyres are required on both axles DANGER Risk to stability Failure to observe the following information and in struc...

Page 65: ...anufacturer must be ob tained beforehand NOTE Check with the authorised service centre be fore changing over to a different tyre size When changing wheels or tyres ensure that the truck is not tilting Always change wheels on the right and left e g at the same time Changes must only be made following consul tation with the manufacturer If the type of tyre used on an axle is changed for example from...

Page 66: ...t under pressure If required the authorised service centre will de pressurise the gas spring in accordance with the reg ulations before removal Gas springs must be dep ressurised before recycling Avoid damage lateral forces buckling tempera tures over 80 C and heavy contamination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators...

Page 67: ...k arms may move for wards and fall If the fork arms are too long they can catch on loading units behind the load that is to be picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre Safety 2 Basic principles for safe operation 51 56368011531 EN 01 2021 05 ...

Page 68: ...cannot be exclu ded even when the truck is used for its inten ded purpose and all instructions are observed A residual risk cannot be excluded even be yond the narrow limits of the danger area that the truck itself represents Persons in this area around the truck must exercise a heightened degree of awareness so that they can react immediately in the event of any malfunction incident or breakdown ...

Page 69: ...tervals The manufacturer shall not be liable for acci dents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or due to negli gence Stability The stability of the truck has been tested to the latest technological standards and is guar anteed provided that the truck is used properly and according to its intended purpose These st...

Page 70: ...ve areas with attachments that do not com ply with explosion protection regulations can lead to explosions in the surround ing atmosphere Only operate attachments that comply with the explosion protection regula tions Check the area of application by com paring with nameplate information on the attachments If the area of application is not clear ask a safety officer Approval from the manufacturer ...

Page 71: ...Safety 2 Residual risk 55 56368011531 EN 01 2021 05 ...

Page 72: ...rised persons O Truck not safe for op eration Periodic inspection and rectification of de fects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due t...

Page 73: ... O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Safety and Health BetrSichV DG...

Page 74: ...ds in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the German Ordinance on Indus trial Safety and Health BetrSichV and labour protection law ArbSchG the operating com pany must determine and assess hazards dur ing operation and establish the labour protec tion measures required for employees B...

Page 75: ... This overview see chapter Overview of hazards and counter measures provides help on complying with this regulation The overview specifies the main hazards that are the most frequent cause of accidents in the event of non compli ance If other major operational hazards are involved they must also be taken into consid eration The conditions of use for trucks are broadly similar in many plants so the...

Page 76: ... must be created The results of the inspection must be retained at least until a fur ther two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the authorised service centre to perform regular testing on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operating company is responsibl...

Page 77: ...son see also Definition of re sponsible persons Competent person How ever as a manufacturer STILL recommends that this test is carried out annually If the truck is subject to harsh application conditions the interval between tests must be shortened Create a test log The results of the inspection must be retained at least until a further two in spections have been carried out The inspection date is...

Page 78: ...ope of the checks is described in the workshop manual A test log book is to be kept if requested by the responsible authority Only a competent person may perform sys tem testing Observe the national regulations for the country in which the truck is being used Insulation testing The insulation of the truck must have sufficient insulation resistance For this reason insula tion testing in accordance ...

Page 79: ...es Battery 50 VDC Batt Batt Battery tray 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω 100 VDC 80 volts 4000 Ω Test values for the entire truck Nominal volt age Test voltage Test values for new trucks Minimum values over the duration of the service life 24 volts 50 VDC Min 50 kΩ 24 kΩ 48 volts 100 VDC Min 100 kΩ 48 kΩ 80 volts 100 VDC Min 200 kΩ 80 kΩ Safety 2 Safety tests 63 56368011531 EN 01 2021 05 ...

Page 80: ...he permissible con sumables can be found in the maintenance data table Oils DANGER Oils are flammable Follow the statutory regulations Do not allow oils to come into contact with hot engine parts No smoking fires or naked flames DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse thoroughly for...

Page 81: ...rding to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of ac cording to the regulations Dispose of old oils according to the regula tions Hydraulic fluid WARNING These fluids are pressurised during op erati...

Page 82: ...ve gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers that comply with regulations Avoid spills Spilt hydraulic fluid should be removed im mediately with oil binding agents and dis posed of according to the regulations Dispose of old hydraulic fluid according to the regulations ...

Page 83: ...f used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair main tenance and cleaning must be collected prop erly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas designated for that pur pose Care must be taken to minimi...

Page 84: ...ncer tainty KpA 66 3 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted val ues for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal noi...

Page 85: ...ave indicated that the amplitude of the hand and arm vibrations on the steering wheel or on the operating devices in the truck is less than 2 5 m s2 There are therefore no meas urement guidelines for these measurements The individual vibration load on the driver over the course of a working day must be deter mined by the operating company in accord ance with Directive 2002 44 EC at the actual plac...

Page 86: ... handling the battery DANGER Risk of explosion When handling or charging batteries in potentially explosive areas spark forma tion or overheating can lead to explo sions in the surrounding atmosphere No work may be performed on the truck in potentially explosive areas Charge batteries only outside of po tentially explosive areas Radiation In accordance with the guidelines DIN EN 62471 2009 03 VDE ...

Page 87: ...3 Overviews ...

Page 88: ...Overview Overviews 3 Overview 72 56368011531 EN 01 2021 05 ...

Page 89: ...xle with traction motors Front lighting Fork arms 1 2 3 4 5 6 7 Fork carriage Lift cylinder Rear lighting Battery door Steering axle Towing device Counterweight 8 9 10 11 12 13 14 NOTE The truck equipment may differ from the equipment shown Overviews 3 Overview 73 56368011531 EN 01 2021 05 ...

Page 90: ...Driver s compartment 6219_901 002_V3 8 10 11 12 13 14 15 16 17 18 Overviews 3 Driver s compartment 74 56368011531 EN 01 2021 05 ...

Page 91: ...r s seat Accelerator pedal Brake pedal Bottom plate Pneumatic signal horn Steering column adjustment lever Reset button Explosion protection warning lights 10 11 12 13 14 15 16 17 18 On category 2 explosion protected trucks the plastic parts are coated with a special antistat ic paint that prevents the build up of an elec trostatic charge The coated areas are identi fied with the decal information...

Page 92: ...Shelves 6219_901 015_V3 Overviews 3 Shelves 76 56368011531 EN 01 2021 05 ...

Page 93: ...ry Only store objects that fit on the shelves 1 2 Make sure that objects cannot fall from the shelves 1 2 when the truck sets off is steered or braked The truck is equipped with a compartment 2 for the operating instructions and the hexagon socket wrench for emergency lowering The safety officer must decide whether the operat ing instructions and the hexagon socket wrench may be carried in potenti...

Page 94: ...dynam ics display Right hand favourites bar 1 2 3 4 5 6 7 8 Lift height restriction Automatic mast vertical positioning Menu button Scrolling buttons Right turn indicator display Back button Main display button Driving speed or parking brake Left turn indicator display Reverse drive direction indicator Forward drive direction indicator Display for direction of movement of the truck Brightness sens...

Page 95: ...operating instructions entitled STILL Easy Control display operat ing unit The display operating unit is attached to the armrest except in trucks equipped with multi lever operation If the truck is equipped with multi lever operation the display operating unit is swivel mounted on the right A pillar For information on swivelling the display op erating unit see the section entitled Adjust ing the s...

Page 96: ... The explosion protection light insulation warning is not present in category 3 trucks See the section on Behaviour when the ex plosion protection warning lights are illumi nated in the Display messages chapter Battery isolating switch The battery isolating switch 1 is located on the right next to the storage compartment It switches the electrical system into a de ener gised state Use this switch ...

Page 97: ...lating switch can be secured in the OFF position by using a lead seal or a padlock to prevent the switch from being actu ated without authorisation 1 6219_901 018 1 6219_901 006 Overviews 3 Operating devices and display elements 81 56368011531 EN 01 2021 05 ...

Page 98: ...truck be driven out of the potentially explosive area The Reset button 1 is located to the left of the steering column If the truck has switched off automatically this key allows the truck to be manoeuvred out of the danger zone Only the safety officer may decide whether the truck can be removed from the potentially ex plosive area See also the Automatic emer gency shutdown section in the chapter ...

Page 99: ... Operating lever for attachments variant Function key for the 5th or 6th function variants Signal horn button 6 7 8 NOTE In the dual pedal version variant the drive direction switch 1 is used exclusively to acti vate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version Overviews 3 Operating devices and display elements 83 56368011...

Page 100: ...ss lever Attachments Function key for the 5th function Signal horn button 1 2 3 4 F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 Overviews 3 Operating devices and display elements 84 56368011531 EN 01 2021 05 ...

Page 101: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 5 Overviews 3 Operating devices and display elements 85 56368011531 EN 01 2021 05 ...

Page 102: ...g lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 Signal horn button F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 8 Overviews 3 Operating devices and display elements 86 56368011531 EN 01 2021 05 ...

Page 103: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 6 Overviews 3 Operating devices and display elements 87 56368011531 EN 01 2021 05 ...

Page 104: ...operating lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 5 Signal horn button F1 function key Lift lower operating lever Display field for the hydraulic functions 6 7 8 9 Overviews 3 Operating devices and display elements 88 56368011531 EN 01 2021 05 ...

Page 105: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 7 Overviews 3 Operating devices and display elements 89 56368011531 EN 01 2021 05 ...

Page 106: ...wer operating lever Tilt operating lever F1 function key LED for F1 7 8 9 10 11 NOTE In the dual pedal version variant the drive direction switch 7 is used exclusively to activate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 10 Overviews 3 ...

Page 107: ... the 4th hydraulic function Vertical rocker button for the drive direction Shift key F Signal horn button 5 6 7 8 9 NOTE In the dual pedal version variant the verti cal drive direction rocker button 7 is used exclusively to activate the cruise con trol function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign diff...

Page 108: ...uck stops in a danger area the drive direction selection lever on the travel direction selector and indicator module can be used for emergency driving Refer to the section entitled Emergency driv ing via the drive direction switch drive direction selection lever in the chapter entitled Proce dure in emergencies Drive direction selection lever Turn indicator switch 1 2 Overviews 3 Operating devices...

Page 109: ...4 Operation ...

Page 110: ...e truck or the attachment variant during the following inspections the truck must not be used until it has been properly repaired Damage or other defects must be reported to the supervisor or the responsible fleet manag er immediately so that repairs by the author ised service centre can be arranged Ensure that the truck is safe for operation each day before it is used Component Course of action F...

Page 111: ...erve the safety regulations in the section enti tled Tyres Axle Make sure that no consumables are escaping from the axle Check that the temperature sensors and wiring on the traction motor pump motor are in good condi tion and are securely attached The electric cables and line inlets must be free from damage The total damage to the antistatic paintwork and seat covering must amount to no more than...

Page 112: ...ty and to ensure that it is working correctly Check that the linchpin is present and working cor rectly chain rope split pin Labelling adhesive label Check that labels are present and intact legible Replace damaged or missing adhesive labels in ac cordance with the section entitled Labelling points Driver s seat seat belt Check the integrity and function Display operating unit assistance systems C...

Page 113: ...present do not operate the truck in potentially explo sive areas Notify the authorised service centre Climbing into and out of the truck WARNING Risk of injury when climbing into and out of the truck due to slipping striking parts of the truck or becom ing stuck If the footwell cover is very dirty or smeared with oil there is a risk of slipping There is a risk of hitting your head on the overhead ...

Page 114: ... misuse Only use the fittings specifically designed for the purpose of climbing into and out of the truck To assist with climbing into and out of the truck the footwell 4 must be used as a step and the handle 1 must be used for support The post of the overhead guard 2 can also be used for support Always climb into the truck facing forwards Grip the handle 1 with your left hand and do not let go Pl...

Page 115: ...one of the checks and tasks that must be per formed before daily use The truck can only be operated safely when the seat position is cor rect Refer to the following chapter entitled Driv er s seat Adjusting the steering column Pull up and hold the lever 2 for steering column adjustment Position the steering column 1 then push the lever down again and allow the steering column to engage DANGER Risk...

Page 116: ...e support for the display oper ating unit The hexagon socket wrench for emergency lowering can be used to loosen or tighten the socket head screws 2 Loosen the socket head screws 2 as re quired Hold the display operating unit 1 in place Adjust the display operating unit 1 so that it can be read without glare Tighten the socket head screws 2 as re quired NOTE If the angle of the display operating u...

Page 117: ...n Turn the battery isolating switch 1 clock wise until it unlocks Turn version Turn the battery isolating switch 1 in a clockwise direction to the ON position 1 6219_901 018 1 6219_901 006 Operation 4 Checks and tasks before daily use 101 56368011531 EN 01 2021 05 ...

Page 118: ... the truck forwards slowly Push the emergency off switch 1 The truck will coast to a stop The message Emergency off active appears on the display operating unit Stop the truck by actuating the brake pedal NOTE In trucks with an electric parking brake the electric parking brake will be applied as soon as the truck comes to a stop Turn the emergency off switch 1 clockwise until it pops out The truck...

Page 119: ...gnal horn is used to warn people against imminent danger or to announce your intention to overtake Press the signal horn button 1 The signal horn sounds 1 1 1 Operation 4 Checks and tasks before daily use 103 56368011531 EN 01 2021 05 ...

Page 120: ...sing a special antistat ic paint This paint prevents the parts from building up an electrostatic charge Otherwise static discharge may occur resulting in explosions in the surrounding atmosphere in potentially explosive areas The non conductive parts of the cab variant must also be covered with anti static materials or coated with antistatic paint Only drive into potentially explosive areas if the...

Page 121: ...er The cab door must be sturdy and be closed in order for the driver s cab to function as a driver restraint system Fabric covered cabs variant with doors made of plastic or canvas do not constitute a driver restraint system and offer no protection from the consequences of the truck tipping over Close the cab door before use If the door is open or has been removed use a comparably secure restraint...

Page 122: ...e speed Depending on the charge state of the battery regen erative braking may be insufficient when driving downhill meaning that the maximum permissible speed of the truck is exceeded Press the brake pedal 1 If the driving speed is restricted or if the oppo site drive direction is selected the truck is braked using the electric brake To actuate this release the accelerator pedal 2 The truck must ...

Page 123: ...e the parking brake being applied stop the truck using the service brake In an emergency secure the truck with wedges on the downhill facing side to pre vent it from rolling away Have the parking brake checked and re paired by the authorised service centre Checking the parking brake on a level surface WARNING Risk of accident from abrupt deceleration The truck will decelerate abruptly if the parki...

Page 124: ... re paired by the authorised service centre NOTE Special features of the electric parking brake The deceleration cannot be influenced The electric parking brake is applied moder ately until the truck comes to a stop The emergency off switch must be unlocked to release the electrical parking brake Warming up the hydraulic oil at cold ambient temperatures If the truck has been exposed to low ambient...

Page 125: ... correct function DANGER If the hydraulics fail there is a risk of accident as the steering characteristics have changed Do not operate the truck if it has a defective steer ing system Operate the steering wheel 1 The steer ing play while stationary must not be more than two finger widths 1 Operation 4 Checks and tasks before daily use 109 56368011531 EN 01 2021 05 ...

Page 126: ...l operating devices can be actuated safely Ensure that the seat and the seat backrest are se curely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the driver s head and the lower edge of the roofing sheet must be at least 40 mm NOTE Observe any separate operating instructions for the s...

Page 127: ... not apply pressure to the seat backrest when adjusting the seat backrest Raise the lever 2 and hold it in position Push the seat backrest into the required po sition Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structure of the truck 7094_003 006 1 7094_003 008 2 Operation 4 Driver s seat 111 563680...

Page 128: ... the lever 3 Fold out the weight adjusting lever 3 Pump the lever up or down to set the driv er s weight Return the weight adjusting lever to the ini tial central position each time before raising it again a click can be heard when this po sition is reached Retract the weight adjusting lever once the adjustment is complete NOTE The correct driver s weight has been selected when the arrow 4 is in t...

Page 129: ...rt of the backrest Turn the turning knob 6 up or down until the lumbar support is in the required posi tion Adjusting the backrest extension var iant Adjust the backrest extension 7 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by firmly pushing it upwards 6321_003 039_V3 6 6321_003 040_V3 7 Operation 4 Driver s seat 113 563680...

Page 130: ...t In addition the seat belt protects against the consequences of rear end collisions and falling off a lorry ramp Recommendation When operating the truck on a lorry ramp fasten the seat belt in addition to using the driv er s cab the bracket door or the re straining bracket DANGER Only bracket doors restraining brackets and the driver s cab variants with closed fixed doors con stitute driver restr...

Page 131: ...The message Close seat belt appears on the display operating unit The truck will not drive at speeds faster than 4 km h The hydraulic functions are blocked NOTE One variant prevents the truck from being driv en at all if the seatbelt is not fastened The message Close seat belt appears on the display Pull the seat belt 3 smoothly out of the belt retractor and place over the thighs close to the body...

Page 132: ...l if the cab door is open The mes sage Close cab door appears in the display Special feature for trucks with HSR re straint systems variant If the bracket is not closed the message Close restraint system appears in the display Fastening on a steep slope The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient It is no longer possible to pull ...

Page 133: ...around 10 to 15 mm out of the retractor to disengage the blocking mechanism Slowly allow the seat belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold If the buckle or belt retractor are frozen thaw the buckle or the belt retractor and dry the parts This prevents the parts from refreezing CAUTION The seat belt may be damaged by heat Do not subjec...

Page 134: ...s can be actuated safely Ensure that the armrest is securely tightened Adjusting the length of the armrest Release the star grip handle 1 by turning to the left Shift the armrest 2 into the desired posi tion Tighten the star grip handle by turning to the right Check that the armrest is firmly attached Adjusting the height of the armrest Release the hand wheel 3 by turning to the left Shift the arm...

Page 135: ... code variant the display initially changes to the input menu for access authorisation Once the truck is ready for operation the main screen is shown on the display Main screen 1 Selected drive programme with driving dynamics display 2 Load information variants 3 Status bar battery charge operating hours time 4 Selected load dynamics programme with dynamics bar 5 Right turn indicator display 6 Dri...

Page 136: ...uthorisation with PIN code variants In place of the key switch the truck has a push button 1 that is used to switch the truck on and off To switch on the truck press the push but ton 1 or sit on the driver s seat A mes sage on the display operating unit asks the operator to place the FleetManager card in position or to enter the PIN code Authorisation via the FleetManager card or the PIN code must...

Page 137: ...but ton 1 and hold for 1 second NOTE For the variant with Access authorisation with PIN code see the relevant section FleetManager see the original operating instructions for FleetManager Operation 4 Switching on 121 56368011531 EN 01 2021 05 ...

Page 138: ...using the control and enter keys 5 8 and the soft keys 4 10 The display 2 shows informa tion about the current driving programme load programme and the configuration of the fa vourites bars 1 3 The brightness sensor 9 automatically adjusts the brightness of the dis play based on the truck s surroundings Operation 4 Display operating unit 122 56368011531 EN 01 2021 05 ...

Page 139: ...his button clears input entered in the settings menus This button switches between upper case and lower case for alphanumeric entries Back button 7 When the back button is pressed the display switches to the next menu level up This button cancels input entered in the settings menus Main display button 9 Pressing the main display button at any menu level takes you directly back to the main display ...

Page 140: ... is ready for use If the input was incorrect enter the PIN code again NOTE The authorised service centre can configure access authorisation so that the PIN code has to be re entered each time after someone leaves the truck When the driver s seat is occupied again the message Log in appears The display then changes to the Access authorisation in put menu Changing the PIN codes The fleet manager can...

Page 141: ...can be con figured by the users themselves Access to these settings is protected by a fleet manager password The initial fleet manager password was sent with the invoicing documents For safety rea sons change this password after the first use See also the section entitled Changing the fleet manager password Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Chang...

Page 142: ...on Press the Settings softkey The first menu level appears Press the Access authorisa tion softkey The display changes to the Access au thorisation menu Enter the fleet manager password using the softkeys To confirm press the button Fleet manager Configure favourites Truck settings Service Access authorisation Display settings 6219_003 267_V2_en Enter password 6219_003 208_V3_en Operation 4 Displa...

Page 143: ...enter the password again NOTE While the Access authorisation for the fleet manager is activated Fleet manager is displayed in an orange bar at the bottom of the screen When the users switches to the main display the access authorisation expires again Changing the fleet manager password Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager access authorisat...

Page 144: ...ppears Press the Change password ac cess auth softkey Follow the instructions on the display Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Version list 6219_003 275_en Operation 4 Display operating unit 128 56368011531 EN 01 2021 05 ...

Page 145: ...t been compiled the only question stored by default is Truck ready for operation The authorised service centre can then restrict the truck functions in the event of a negative test result There are fixed responses No response Speed limitation Restriction of hydraulics to 33 In addition the fleet manager has the follow ing options The fleet manager can view the results of all checks via the History...

Page 146: ...st such as the functional test of the lighting NOTE The main display symbol appears only when it is required for the test To access the main display press the main display button or the softkey The main display contains the message To complete Pre Shift Check press This means that the Pre Shift Check is still ac tive and the truck functions are restricted To acknowledge the message press the softk...

Page 147: ...ns active shows that truck functions are restricted As long as the truck functions are restricted no further Pre Shift Check is re quested at the start of a new shift The check is only requested again after the fleet manager has reset the restrictions All questions The authorised service centre can use this question catalogue to put together the Pre Shift Check during commissioning Are the fork ar...

Page 148: ... brake work properly Does the service brake work properly Does the steering work properly Does the emergency off work Is the condition of the battery obviously not OK Are all decal information and adhesive labels present and legi ble Is the load backrest undamaged Does the accelerator pedal work properly Is the engine compartment dirty or does it contain foreign ob jects Are the lift mast or the f...

Page 149: ...nsciously by the driver This means that there is no rou tine aspect Activate the Access authorisation for the fleet manager Press the Service softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre shift check 133 56368011531 EN 01 ...

Page 150: ...tion To access the main display press the main display button Displaying the history The fleet manager can display a Pre Shift Check history Activate the Access authorisation for the fleet manager Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Random sequence Fixed sequence 6219_003 273_en Operation 4 Pre shift check 134 56368011531 EN 01 2021 0...

Page 151: ...ll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre shift check 135 56368011531 EN 01 2021 05 ...

Page 152: ...ager can define up to three shifts and their start times The Pre Shift Check is then always requested at this time NOTE If the truck is equipped with FleetManager the shifts are defined on the FleetManager inter face See the relevant operating instructions Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Pre Shift Check results 27 09 19 15 11 nicht ok Funktioni...

Page 153: ...rvice softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre shift check 137 56368011531 EN 01 2021 05 ...

Page 154: ...time The orange activation bar indicates which shifts are activated To edit a shift press the corresponding soft key Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operation 4 Pre shift check 138 56368011531 EN 01 2021 05 ...

Page 155: ... requested from this shift start time The display returns to the previous menu To deactivate a certain shift start select the relevant shift Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate Save Cancel 6219_003 272_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operation 4 Pre shift check 139 56368011531 EN 01 2021 05 ...

Page 156: ... main display button Resetting the truck restrictions If truck functions are restricted due to checks with a bad result the fleet manager can reset these restrictions The fleet manager can also do this if a problem on the truck has been rec tified Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate S...

Page 157: ...ift Check menu appears Press the Reset restriction softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Operation 4 Pre shift check 141 56368011531 EN 01 2021 05 ...

Page 158: ...The display returns to the previous menu To cancel press the softkey The truck functions remain restricted The dis play returns to the previous menu To access the main display press the main display button 6219_003 274_en Fleet manager Reset the truck restrictions The entry remains in the history Operation 4 Pre shift check 142 56368011531 EN 01 2021 05 ...

Page 159: ...r profile Selected drive programme 1 to 3 Load dynamics Efficiency and drive modes Blue Q sprint mode If a driver without an existing driver profile logs in using the Access authorisation with PIN code or FleetManager variants a driver pro file is generated This driver profile corre sponds to the settings when the truck was de livered If the truck is not equipped with these variants drivers must s...

Page 160: ...g brake is applied If the parking brake is re leased prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the Settings softkey Press the Driver profiles soft key Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Operation 4 Driver profiles 144 56368011531 EN 01 2021 05 ...

Page 161: ...oth the fleet manager and the driver can cre ate up to ten driver profiles NOTE If the truck is equipped with the Access au thorisation with PIN code or FleetManager variants the driver profile is generated auto matically when logging in for the first time Apply the parking brake Press the button Press the Settings softkey Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Oper...

Page 162: ...on NOTE Unoccupied storage locations that do not con tain a driver profile are indicated by Availa ble storage position Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operation 4 Driver profiles 146 56368011531 EN 01 2021 05 ...

Page 163: ...then be available the next time that the driver logs in Renaming driver profiles Driver profiles can be renamed Drivers can only rename their own driver profile The fleet manager has access authorisation to rename all driver profiles Renaming by the driver Apply the parking brake Press the button Press the Settings softkey Press the Truck settings softkey Enter driver name Clear Driver name Horst ...

Page 164: ... press the button Renaming by the fleet manager Activate the Access authorisation for the fleet manager Press the Truck settings softkey Rename driver profiles Driving programme 6219_003 298_en Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Operation 4 Driver profiles 148 56368011531 EN 01 2021 05 ...

Page 165: ... softkey Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Operation 4 Driver profiles 149 56368011531 EN 01 2021 05 ...

Page 166: ...Activate the Access authorisation for the fleet manager Press the Truck settings softkey Press the Manage driver profiles softkey Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Operation 4 Driver profiles 150 56368011531 EN 01 2021 05...

Page 167: ...he driver profile to be deleted The driver profile is deleted Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operation 4 Driver profiles 151 56368011531 EN 01 2021 05 ...

Page 168: ...e selected When one of the lighting devices is switched on the activation bar next to the relevant sym bol lights up orange NOTE If the truck is equipped with the StVZO Ger man Road Traffic Licensing Regulations var iant the hazard warning system works even when the truck is switched off 1 This function is not available if the truck is equipped with the StVZO German Road Traffic Licensing Regulati...

Page 169: ...nt variant and a licence plate lamp then this also lights up To switch off the driving light 2 press the Softkey again The driving light and licence plate lamp go out To switch off the parking light 1 push the Softkey again The front side lights and the tail lights go out If the truck does not have StVZO German Road Traffic Licensing Regulations equip ment variant then the parking light and driv i...

Page 170: ...ions variant the parking light is al so switched on when the working spotlights are switched on The licence plate lamp if present is also switched on when the forward facing working spotlights are switched on Working spotlights on the roof and the side of the lift mast The roof spotlights light up the working area when the fork carriage is raised To switch on the roof spotlights 5 push the associa...

Page 171: ...ss the softkey The activation bar next to the symbol lights up The working spotlight does not yet light up Set the drive direction to Reverse The working spotlight for reverse travel lights up If the drive direction is set to Forward the working spotlight goes out Turn indicators The turn indicators are switched on and off via the travel direction selector and indicator mod ule Operation 4 Lightin...

Page 172: ...is play 2 or 3 on the display operating unit flash To switch off the turn indicators push the lever 1 back to the centre position All turn indicators and the turn indicator dis plays on the display operating unit stop flash ing 6219_003 098 2 71 m 7 1 6 t 2 3 6219_003 301 432 h 08 20 Operation 4 Lighting 156 56368011531 EN 01 2021 05 ...

Page 173: ...n All direction indicators and the turn indicator displays on the display operating unit stop flashing Specific features of the StVZO German Road Traffic Licensing Regulations variant For the StVZO German Road Traffic Licens ing Regulations variant the hazard warning system cannot be switched on and off via the display operating unit It is switched on and off using the hazard warning button on the...

Page 174: ...key is stored in the favourites bar This softkey is used to switch off all light ing devices that are not permitted on roads subject to the StVZO This relates to the following variants of lighting equipment STILL SafetyLight Warning zone light Working spotlight Rotating beacon To switch off this lighting equipment push the StVZO softkey The orange activation bar lights up next to the softkey To sw...

Page 175: ...that fewer lighting devices or more lighting devices are switched off The softkey is also located in the Driving menu Rotating beacon To switch on the rotating beacon push the associated Softkey on the display operating unit The rotating beacon is switched on To switch off the rotating beacon push the Softkey again The rotating beacon goes out Operation 4 Lighting 159 56368011531 EN 01 2021 05 ...

Page 176: ...ots in front of or behind the truck and thus warns others about the approaching truck Several light spots are projected as a chase light The chase light indicates the location of the truck with its direction of travel Depending on the configuration of the truck the STILL SafetyLight automatically switches itself on when the truck is moving This means that during reverse travel variant for exam ple...

Page 177: ...ntitled Handling loads The warning zone light switches on and off again together with the truck If the truck has StVZO German Road Traffic Licensing Regulations equipment the warn ing zone light can be switched on and off via the display operating unit To do so push the softkey NOTE If the truck is to be operated on public roads the warning zone light must be switched off Before using the truck ma...

Page 178: ...llid ing with racks or other objects Before using the automatic mast vertical position ing assistance system position the truck at a suf ficient distance from racks and other objects The automatic mast vertical positioning as sistance system can be used to set down the goods so that the goods are exactly vertical e g paper rolls This prevents damage when setting down the load Automatic mast verti ...

Page 179: ...tical positioning function Push the automatic mast vertical position ing softkey The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast stops in the vertical position NOTE The lift mast also stops in the vertical position if it is tilted forwards by 3 from a backward tilt NOTE The automatic mast vertical positioning must be...

Page 180: ...ion proceed as fol lows Push the automatic mast vertical position ing softkey The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast must stop in the vertical position The automatic mast vertical positioning can be used If the lift mast does not stop in the vertical position do not use the assistance system In this case con...

Page 181: ...Once the automatic mast vertical positioning assistance system has been calibrated a pal let can be stored horizontally in a rack when the truck is standing on a HGV ramp for ex ample Lift the fork carriage slightly Apply the parking brake Attach a tilt angle template with a spirit level to the outer lift mast Bring the lift mast to the vertical position ac cording to the spirit level Press the bu...

Page 182: ...keys until the Cal ibration menu appears Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Operation 4 Tilt angle dependent assistance systems 166 56368011531 EN 01 2021 05 ...

Page 183: ...alibration has been completed suc cessfully the message Successful cal ibration appears Switch the truck off and on again The calibration is now complete NOTE If the message A6701 Fault Monitor ing of assistance system ap pears during the calibration perform the cali bration again Fleet manager Load measurement Lift mast tilting 6219_003 278_en Operation 4 Tilt angle dependent assistance systems 1...

Page 184: ...igher than the nominal load The overload detection restricts the hydraulic functions as follows If the rated capacity or the maximum load set by the authorised service centre is ex ceeded the lifting speed is reduced If the rated capacity or the set maximum load are exceeded by more than 10 the Lifting function is disabled NOTE Please note the following special considera tions If the load pressure...

Page 185: ...ics of the hydraulic move ments section in the chapter entitled Lifting Dynamic Load Control 1 improves the han dling of the load This function protects the truck and the load from abrupt movements Dynamic Load Control 1 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria Lift height Load weight Load movements which could lead to critical conditi...

Page 186: ...mics the lifting system responds after a delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately instead it takes approx one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 2 Work with particular attention and care Observe the Dynamics of the hydraulic move ments section in the chapter ent...

Page 187: ...mitation again Re lease the accelerator pedal for a short period to do this The bar display on the display of the display operating unit is part of the load information It is part of the Dynamic Load Control 2 The number and colour of the bars indicates to what extent the determined load weight and load centre of gravity affect the stability of the truck The bar display is divided into three secti...

Page 188: ...oad measurement variant Knowing the weight of the load to be transpor ted gives the driver greater security If the truck is equipped with the load measurement assistance system the weight of the lifted load is measured and displayed in the display op erating unit 1 The measuring accuracy is 5 of the rated capacity Observe the following safety information DANGER Risk of accident from a falling load...

Page 189: ...obviously incor rect If t is displayed permanently this means that the function is calibrated incorrect ly load 0 kg See the section entitled Calibrating the load measurement Calibrating the load measurement If the truck is equipped with the load meas urement assistance system then this assis tance system must be calibrated The load measurement is calibrated using a wizard on the display operating...

Page 190: ...for the fleet manager Press the Service softkey Press the scroll keys until the Cal ibration menu appears Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Operation 4 Load dependant assistance systems 174 56368011531 EN 01 2021 05 ...

Page 191: ...tion again Precision load measurement var iant This assistance system is available only if the truck is equipped with the load measurement variant The Precision load measurement variant al lows the weight of the load being picked up to be measured and displayed on the display op erating unit accurate to within 1 of the rated capacity of the truck NOTE If the load is to be measured exclusive of the...

Page 192: ...wly lowering the fork carriage increases the measurement accuracy in trucks with multi lever operation The value is calculated The Calc ongo ing message appears 0 0 0 70 m 1 5 t t 6219_003 222 1 0 0 0 70 m 1 5 t 6219_003 223_V3_en Lower fork slightly Operation 4 Load dependant assistance systems 176 56368011531 EN 01 2021 05 ...

Page 193: ...on should not factor in the weight of a load container the tare function must be run It is then possible to determine the net weight of the raised load NOTE During the following process the fork carriage must be lowered slightly When doing so the fork must not touch the ground as otherwise the result will be inaccurate Set the lift mast to vertical Pick up the empty load container such as a crate ...

Page 194: ... dis played The Precision load measurement can be performed To clear the tare weight press the tare softkey again WARNING Risk of accident due to incorrect load specification If the requirements for the precision load measure ment function change the tare function must be run again for example if a precision load measurement needs to be performed without a crate Otherwise the new precision load me...

Page 195: ... up the load and call up the load menu 2 Measure the load 3 Add subtract the load WARNING Risk to stability If the weight determined by a load measurement ex ceeds the permissible residual load capacity of the truck the truck cannot be operated safely Do not lift the load higher than 800 mm Set down and reduce the load immediately If necessary use another truck with sufficient load bearing capacit...

Page 196: ...d here using Press the softkey The Total load menu storage space ap pears This menu provides the following functions Tare Precision load measurement Add a load Subtract a load Delete load summation Measuring the load Press the Precision load measure ment Softkey Measure the load 0 00 0 00 0 00 t 0 00 t Operation 4 Load dependant assistance systems 180 56368011531 EN 01 2021 05 ...

Page 197: ...To subtract the current load press the Softkey The current load is subtracted from the sum The load is saved automatically NOTE If for instance this load was added to the wrong total load it is also possible to perform a subtraction with the previously measured and added load Delete total load To delete the total load press the soft key The Clear total load message is displayed To delete press the...

Page 198: ...40 m lower speeds are reached than would be the case if the efficiency mode was not activated As in STILL Classic mode the maximum speed is 20 km h has no influence on Maximum speed Climbing capability Pulling force Braking characteristics Effects on additional consumers The following table shows the specific conditions that cause certain auxiliary devices to shutdown when Blue Q is activated The ...

Page 199: ...at switch Truck is stationary Drive direction Screen heating X No shut off for StVZO German Road Traffic Licensing Regulations equipment variant Operation 4 Efficiency and drive modes 183 56368011531 EN 01 2021 05 ...

Page 200: ...mode is switched on To switch off Blue Q efficiency mode push the associated softkey again The Blue Q symbol disappears and Blue Q ef ficiency mode is switched off NOTE The fleet manager can also use his access authorisation to activate Blue Q efficiency mode permanently See the next section Operation 4 Efficiency and drive modes 184 56368011531 EN 01 2021 05 ...

Page 201: ...tkey The orange activation bar appears next to the pushed softkey The main display button takes you to the main display STILL Classic and sprint mode The drive modes affect the handling of the truck Two different drive modes are available 1 STILL Classic This mode is active after the truck has been switched on This mode is the de fault setting and provides a balance be tween hydraulic functions an...

Page 202: ...l the truck will consume more energy As a result the battery is discharged faster and the traction drives and energy supply may become too hot The battery voltage and the temperature of the traction drives and energy supply are moni tored continuously If under voltage does not apply to lithium ion batteries or overheating occurs sprint mode is automatically deactiva ted If the truck is automatical...

Page 203: ... quickly and overtaking at dangerous or blind spots must be avoided Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden during driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Adjusting the steering column Releasing the seat be...

Page 204: ...ne is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walk ing pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be used for ob serving the...

Page 205: ... for areas outside the EU The required aisle widths depend on the di mensions of the load Required aisle widths with pallet Model Type Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX20 14C 6219 3186 3311 RX20 16C 6220 3186 3311 RX20 16 6221 3269 3394 RX20 16L 6222 3377 3502 RX20 18 6223 3269 3394 RX20 18L 6224 3377 3502 RX20 20L 6225 3390 3516 RX20 16P 6226 3362 3...

Page 206: ...ending gradients greater than 15 NOTE The values specified in the Maximum climb ing capability table can be used only to com pare the performance of forklift trucks in the same category The specified values in no way represent the normal daily operating con ditions Trucks can theoretically be driven on the as cending and descending gradients specified in the following table Maximum climbing capabi...

Page 207: ...and be damaged or torn off Examples of these components are An unfolded roof panel in the driver s cab Open cab doors Condition of the roadways Roadways must be sufficiently firm and even The surface must be free from contamination and fallen objects Drainage channels level crossings and similar obstacles must be evened out and if necessa ry ramps must be provided so that trucks can drive over the...

Page 208: ...the following responsible person operating company Hazardous areas Hazardous areas on roadways must be indica ted by standard traffic signs or if necessary by additional warning signs Selecting drive programmes 1 to 3 The truck has three drive programmes with different preset driving and braking character istics The basic principle is that the higher the number of the drive programme selected the ...

Page 209: ...like the fixed drive programmes 1 to 3 the programs A and B can be configured The procedure for this is described in the following section The drive programme is selected using the display operating unit under the Drive menu item Press the or softkey to select the de sired drive programme If the drive programmes are saved as a fa vourite on a softkey press the Drive pro gramme Softkey until the le...

Page 210: ...plained here The menu Set drive programme A appears The following parameters can be set max speed Determines the maximum speed max 20 km h Agility Determines the acceleration behaviour and the reversing behaviour using five levels 1 indicates the lowest agility and 5 indi cates the greatest agility Deceleration Determines the electrical brake retardation when the accelerator pedal is released in f...

Page 211: ... is located on the travel direction selector and indicator module variant NOTE The drive direction can also be changed dur ing travel Your foot can remain on the accel erator pedal while you do so The truck is then decelerated and accelerated again in the op posite direction reversing The indicator for the selected drive direction forwards 1 or backwards 2 lights up on the display operating unit N...

Page 212: ...efer to the sec tion entitled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergen cies Actuating the drive direction switch with the mini lever version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction pull the drive direction switch 1 backwards NOTE If the drive di...

Page 213: ... Procedure in emergen cies Actuating the vertical rocker button for the drive direction with the Joy stick 4Plus version For the forwards drive direction push the vertical rocker button for the drive direc tion 1 upwards For the backwards drive direction push the vertical rocker button for the drive di rection 1 downwards NOTE If the drive direction switch 1 is defective and the truck stops in a d...

Page 214: ... enti tled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergencies Starting drive mode DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations whe...

Page 215: ...travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the accelerator pedal is released NOTE The truck is also held in place on ascending or descending gradients even if the electric park ing brake is not engaged DANGER Risk of accident due to brake failure The regenerative brake only functions if the truck is switched on the emer...

Page 216: ...e truck still cannot be operated park the truck securely and con tact the authorised service centre Starting drive mode dual pedal ver sion variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations when driving The...

Page 217: ...rds 1 or reverse 2 lights up on the display operating unit NOTE Depending on the equipment the following variants of warning units for reverse travel may be present An acoustic signal will be heard The STILL SafetyLight lights up The hazard warning system flashes The truck travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the ...

Page 218: ...ted it will be possible to drive the truck again by releasing the accelerator pedal and then actuating the accelerator pedal again If the truck still cannot be operated park the truck securely and con tact the authorised service centre Operating the service brake The electric brake converts the acceleration energy of the truck into electrical energy This causes the truck to decelerate Electrical b...

Page 219: ... conditions and the level of contamination on the roadway Note that the basic braking distance in creases with the square of the speed Adapt your driving and braking style to suit the weather conditions and the level of contamination on the roadway Always choose a driving speed that will provide a sufficient stopping distance Brake the truck by releasing the accelerator pedal 1 If the braking effe...

Page 220: ...arking brake symbol appears on the display in place of the speed information When a drive direction is selected and the ac celerator pedal is actuated the message Re lease parking brake appears Releasing the parking brake Pull the parking brake lever 1 back Push down the knob 2 and hold it down Move the parking brake lever 1 forwards and release both the lever and the knob The parking brake is rel...

Page 221: ...pplying the parking brake The truck starts moving approximately 20 seconds after the parking brake is applied Activation and intervention of the function Cause Effect The driver s seat is vacated and the parking brake has not been applied A warning signal sounds Sitting in the driver s seat silences the warning signal The truck needs to be switched off but the park ing brake has not been applied T...

Page 222: ...cy secure the truck with wedges on the downhill facing side to prevent it from rolling away This truck is equipped with an electric parking brake The parking brake must not be applied manually when the driver leaves the truck The parking brake is applied automatically Despite these automatic aids the driver is al ways responsible for parking the truck safely The safety information about parking th...

Page 223: ...electric parking brake when the truck is stationary Applying the parking brake manually Press the push button 1 The electric parking brake will make a noise when it is applied and the LED 2 lights up continuously The symbol appears in the display Releasing the parking brake manually Sit on the driver s seat Press the push button 1 The electric parking brake will make a noise when it releases and t...

Page 224: ...teady light until the control units switch off The emergency off switch is actuated The electric parking brake is immediately ap plied with an audible sound The LED 2 lights up with a steady light If the electric parking brake has applied auto matically the symbol appears in the dis play operating unit The LED 2 lights up To release the electric parking brake the driver must sit down on the driver...

Page 225: ...al times The electric parking brake cannot be released by actuating the accelerator pedal WARNING Risk of accident The truck may decelerate abruptly Fasten the seat belt Automatically triggered actuation when the truck is in motion Cause Effect The driver s seat is vacated The truck is braked in accordance with the se lected drive programme Once the truck has come to a standstill the electric park...

Page 226: ...he truck accelerates sharply even though the accelerator pedal has not been actuated The parking brake is immediately applied with an audible sound The LED 2 lights up with a steady light The symbol appears in the display Malfunctions in the electric parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Do not leave the...

Page 227: ...ulty parking brake when the truck is stationary There are two ways to apply the parking brake Press and hold the push button 1 for at least five seconds and then release the push button OR Press the push button 1 several times in succession until a total of five seconds is reached The parking brake is applied with an audible sound After the push button is released the parking brake should not make...

Page 228: ... in the Safe parking function Cause Effect The driver s seat is vacated The electric park ing brake cannot be applied or previously could not be applied The following message is shown on the display Parking brake cannot be applied To acknowledge this press the Softkey If the driver s seat is vacated a warning signal sounds Sitting on the driver s seat silences the warning signal The truck needs to...

Page 229: ...actuation process secure the truck with wedges so that the truck can not roll away Have the parking brake repaired by the au thorised service centre Message Parking brake cannot be applied If the truck control unit detects a malfunction in the parking brake the truck cannot be switch ed off The message Parking brake can not be applied is shown on the dis play operating unit The LED 2 on the push b...

Page 230: ...ng brake cannot be applied auto matically or via the push button apply the parking brake via the emergency actuation process See the section entitled Emergen cy actuation of the parking brake variant in the chapter entitled Behaviour in emer gencies If the parking brake cannot be applied via the emergency actuation process secure the truck with wedges so that the truck can not roll away Have the p...

Page 231: ... the truck by turning the steering wheel 1 accordingly Turning the steering wheel to the left L steers the truck to the left L Turning the steering wheel to the right R steers the truck to the right R The arrow 2 displays the direction in which the truck is moving For information on the turning radius see the Technical data 1 L L R L R R 6219_003 109 2 Operation 4 Driving 215 56368011531 EN 01 202...

Page 232: ... Before using this function familiarise yourself with the change to the driving and steering characteris tics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steer ing Do not turn off the key switch while driving Actua...

Page 233: ... the cab door is opened while the truck is in motion the truck brakes automatically Keep the cab door closed when driving With the cab equipment variant the truck has a cab door monitoring function via a sen sor The signal from this sensor is linked with the signal from the buckle switch in the control electronics of the truck If the cab door is not closed and the seat belt is not fastened the dri...

Page 234: ... first menu level appears Press the Drive softkey The Drive menu appears Press the Speed limitation softkey The activation bar appears next to the symbol The speed limitation is switched on To switch off the speed limitation press the softkey again Configuring the speed limitation NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If...

Page 235: ...be used to set the maximum truck speed when speed limitation is active To adjust the maximum speed press the Enter max speed softkey The Speed restriction menu opens Using the softkeys set a maximum speed between 2 km h and 20 km h The maximum speed is dependent on the truck equipment and may be restricted by a factory setting To save press the button The maximum speed is entered To clear press th...

Page 236: ...he hydraulic functions When the cruise control function is activated the driver can save the speed when driving forwards at a speed of at least 6 0 km h by pressing a button and can continue driving without actuating the accelerator pedal The pictogram 3 for operating the cruise control function is located on the operating de vice for the hydraulic functions Putting the cruise control function on ...

Page 237: ...control symbol 1 goes out Activating cruise control WARNING Risk of accident from failing to adjust speed Driving at excessive speeds can cause accidents e g the truck could tip over when cornering Adjust speed along the entire distance being trav elled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise con trol function ...

Page 238: ...for for wards travel NOTE In the dual pedal version variant the drive direction switch 2 is used exclusively to acti vate and deactivate the cruise control function variant 2 F 2 2 2 3 3 3 3 Operation 4 Driving 222 56368011531 EN 01 2021 05 ...

Page 239: ...tiva ted at any time when the accelerator pedal is depressed by pressing the drive direction switch for forwards travel again When the cruise control function is deactiva ted the symbol 1 is greyed out NOTE The easiest way to deactivate the cruise con trol function is to touch the accelerator pedal The following actions deactivate the cruise control function Actuating the foot brake Actuating the ...

Page 240: ... the truck is initially braked via the drive unit The following message appear on the display Release the accelerator pedal The truck will continue to drive only when the accelerator pedal is released and then actu ated again If these conditions have changed again the speed that was initially saved is set again NOTE If the truck is configured with automatic func tions to reduce the driving speed a...

Page 241: ...ents are being lowered Lower the load fully before leaving the truck CAUTION Batteries may freeze If the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down For lead acid batteries the electrolyte can freeze and damage the batteries The truck is then not ready for operation At ambient temperatures of below 10 C only park the truck for short p...

Page 242: ...ps of the fork arms rest on the ground If attachments variant are fitted retract the working cylinders see the chapter entitled General instructions for controlling attach ments Turn the switch key to position 0 and re move the key Operation 4 Parking 226 56368011531 EN 01 2021 05 ...

Page 243: ... In the push button ignition variant press the button 1 Depending on the truck version Push the battery isolating switch 1 OR 1 6219_901 018 Operation 4 Parking 227 56368011531 EN 01 2021 05 ...

Page 244: ...variant is used to prevent the truck from rolling away on a slope It is lo cated on the right hand mudguard Pull the latch forward 1 and hold it in place Grip the wheel chock by its handle 3 Re move the wheel chock from the support mounting via the guide 2 Push the wheel chock under a front axle wheel on the side facing the descending gradient After use reinsert the wheel chock in the support moun...

Page 245: ...s when handing loads Page 257 Lift mast versions DANGER Risk of accident if the lift mast or the load collides with low ceilings or entrances Note that the inner lift mast or load may be higher than the fork carriage Observe the heights of ceilings and entrances One of the following lift masts may be attach ed to the truck Telescopic lift mast When lifting the lift mast rises above the outer lift ...

Page 246: ...ximum height 2 NOTE When lifting above the free lift the fork car riage always remains at the upper edge of the extending lift mast Triple mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the maximum height 2 2 3 2 3 Operation 4 Lifting 230 56368011531 EN 01 2021 05 ...

Page 247: ...r has an unobstructed view past the lift mast to the left and right and can also see over the lift mast Data Height lift mast re tracted h1 1650 mm Height lift h3 2137 mm Rated capacity load Q 2000 kg Operating devices for the lifting sys tem The method of operating the lifting system de pends on the operating devices included in the truck s equipment Possible equipment variants include Multi leve...

Page 248: ...due to delayed response from the truck If the lifting movements are configured to use low dy namics the lifting system responds after a delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control...

Page 249: ...fferent configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 1 The adhesive label with the corresponding pictogram 4 is located on the operating lever The tilting movement of the lift mast is contro...

Page 250: ...direction of the arrow C To tilt the lift mast backwards Move the tilting operating lever 2 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 234 56368011531 EN 01 2021 05 ...

Page 251: ...aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic functions 1 or 2 is affixed at the designated po...

Page 252: ...he lift mast 360 lever 4 in the di rection of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 236 56368011531 EN 01 2021 05 ...

Page 253: ...drivers aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic functions 1 or 2 is affixed at the desig...

Page 254: ...he lift mast 360 lever 4 in the di rection of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 238 56368011531 EN 01 2021 05 ...

Page 255: ... all drivers aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 3 The adhesive label bearing the corresponding pictograms 1 is affixed at the designated point 6 ...

Page 256: ...the lift mast operating lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast operating lever 4 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 240 56368011531 EN 01 2021 05 ...

Page 257: ...iguration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 4 The adhesive label with the corresponding pictogram 3 is located on the operating lever The tilting movement of the lift mast is control led using ...

Page 258: ...e safety regulations for handling loads Operate the lifting system from the driver s seat only WARNING Risk of accident as a result of an operating error These operating instructions describe how to operate the lifting system in the factory configuration If the authorised service centre has configured a dif ferent configuration the newly applied pictograms must be observed to ensure safe operation...

Page 259: ...ork carriage To lift the fork carriage Pull the Joystick 4Plus 1 backwards B To lower the fork carriage Push the Joystick 4Plus 1 forwards A Tilting the lift mast To tilt the lift mast forwards Tilt the horizontal rocker button 3 to the left C To tilt the lift mast backwards Tilt the horizontal rocker button 3 to the right D F 6219_003 167_V3 1 2 A B F 6219_003 165_V3 D C 3 4 Operation 4 Lifting 2...

Page 260: ...oes not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 1 2 assistance systems Work with particular attention and care The authorised service centre can reduce the dynamics of the hydraulic movements to adapt the hydraulic movements to the application re quirements The hydra...

Page 261: ...nt only decelerates slow ly The fork carriage therefore continues to run for some time before the movement comes to a standstill Selecting load programs 1 to 3 The truck has three load programs for the dif ferent lifting behaviours of the fork carriage and the lift mast The higher the number of the load program selected the greater the load dynamics Differences between the load programs Load progr...

Page 262: ...n variant ensures that the fork arms do not touch the ground The fork arms are protected against wear and the building floor is protected against damage The lift cylinders have in built fixed stops to prevent the fork arms from hitting the ground The lower stop makes inserting the forks into a pallet more comfortable The driver cannot adjust the fork wear protec tion manually However the fork wear...

Page 263: ...on regulations may be used These fork arms are specially coated to prevent sparks forming when coming in to contact with the load or floor The coating does not extend to the area in side the fork bends so that it is possible to check for cracks Fit only fork arms that correspond to explosion protection regulations Check that the cladding is complete Do not use fork arms with worn clad ding DANGER ...

Page 264: ...fork arms The fork arms must always be carried by two peo ple if necessary use a hoist NOTE It is advisable to use a transport pallet to sup port the fork arms when they are being instal led or removed The pallet size depends on the size of fork arms in use It should be large enough that the fork arms do not protrude af ter being placed on the pallet This means the fork arms can be safely placed d...

Page 265: ...ge Push the fork arms onto the fork carriage from the outside towards the centre Pull the locking lever 1 upwards and push the fork arms into the required position En sure that the locking lever snaps into place Fit and tighten the locking screw 2 DANGER There is a risk of fatal injury from a falling load or fork It is not permitted to drive or to transport loads with out the locking screw in plac...

Page 266: ...ng when coming in to contact with the load or floor The coating does not extend to the area in side the fork bends so that it is possible to check for cracks Fit only fork arms that correspond to explosion protection regulations Check that the cladding is complete Do not use fork arms with worn clad ding DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park...

Page 267: ... of fatal injury from falling load At least 60 of the length of the fork extension must lie on the fork arm No more than 40 of the length of the fork extension may overhang the end of the fork arms In addition the fork extension must be se cured against slipping from the fork arm If the fork extension 1 is not secured with a secur ing bolt 2 and linch pin 3 the load may fall along with the fork ex...

Page 268: ...bolt fully into the fork ex tension Insert the linch pin into the securing bolt and secure Operation with reversible fork arms variant DANGER Risk of explosion Working on a truck within potentially ex plosive areas can lead to explosions in the surrounding atmosphere No work must be performed on the truck in potentially explosive areas Do not perform any work on trucks in potentially explosive are...

Page 269: ...n reverse operation using reversible fork arms 1 WARNING Risk of accident from slipping load Loads may slip on the reversible fork arms if there is no load support A fork extension variant cannot be secured against slipping Do not use a fork extension variant WARNING Risk of accident from the truck tipping over When driving the centre of gravity of the load 2 must not be more than 600 mm above the...

Page 270: ... of accidents In the case of Hi Lo lift masts variant and triplex lift masts variant an incorrect extension sequence may occur i e the inner lift mast may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for in stance result from The hydraulic oil temperature being too low...

Page 271: ... the lift mast be come blocked due to contamination lift the fork carriage until the chains are under ten sion again Remove the contamination be fore resuming work WARNING Risk of injury Observe the safety regulations for working on the lift mast see the chapter entitled Working at the front of the truck Hydraulic blocking function The hydraulic blocking function ensures that all the functions of ...

Page 272: ...NOTE Only the emergency steering function remains available Operation 4 Lifting 256 56368011531 EN 01 2021 05 ...

Page 273: ...e maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver Use ...

Page 274: ...crease the load capacity is prohibited DANGER Risk of fatal injury from the truck losing stability Never exceed the maximum loads shown These val ues apply to compact and homogeneous loads If these values are exceeded the stability and rigidity of the fork arms and lift mast cannot be guaranteed Improper or incorrect operation or the placement of persons to increase load capacity is prohibited 660...

Page 275: ...rma tion shown on the truck and the attachment Picking up loads To make sure that the load is securely suppor ted it must be ensured that the fork arms are sufficiently far apart and are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the lo...

Page 276: ...d centre of gravity must be midway be tween the fork arms Only actuate the fork prong positioner var iant when the fork is not carrying a load Danger area The danger area is the area in which people are at risk due to the movements of the truck its working equipment its load carrying equip ment e g attachments or the load Also in cluded are the areas where loads could fall or working equipment cou...

Page 277: ...orised par ties DANGER Danger of death from falling loads Never walk or stand underneath sus pended loads Transporting pallets As a rule loads e g pallets must be trans ported individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the technical requirements have been met The driver must ensure proper condition of the load Only safely ...

Page 278: ... of stability and cause the truck to tip over When transporting suspended loads observe the following instructions Instructions for transporting suspended loads Swinging loads must be prevented by using the proper driving speed and driving style careful steering braking Hanging loads must be hooked on to the truck in such a way that the harness cannot shift or release unintentionally and cannot be...

Page 279: ...in the surrounding at mosphere Transportation of swinging loads is not permitted Do not transport swinging loads Calibrating the automatic mast verti cal positioning The automatic mast vertical positioning is cali brated using a wizard on the display operating unit NOTE The wizard requires access authorisation for the fleet manager Access to the settings menu is only available if the truck is at a...

Page 280: ... carriage slightly Apply the parking brake Attach a tilt angle template with a spirit level to the outer lift mast Bring the lift mast to the vertical position ac cording to the spirit level Press the button Press the Settings Softkey Activate the Access authorisation for the fleet manager Press the Service softkey 80 90 80 7 0 6 0 7 0 6 0 Operation 4 Handling loads 264 56368011531 EN 01 2021 05 ...

Page 281: ...completed suc cessfully the message Successful cal ibration appears Switch the truck off and on again The calibration is now complete NOTE If the message A6701 Fault Monitor ing of assistance system ap pears during the calibration perform the cali bration again Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Fleet manager L...

Page 282: ...ibrations and impacts Oscillating mo tions of the truck are minimised thus increas ing work safety Automatic mast vertical posi tioning reduces wear on various components thereby reducing repair costs The automatic mast vertical positioning as sistance system consists of the following indi vidual functions Display of the Automatic mast vertical posi tioning feature Automatic startup of the Automat...

Page 283: ...tion See the section entitled Calibrating the au tomatic mast vertical positioning Picking up a load DANGER There is a risk to life from a falling load or from truck components being lowered Never walk or stand underneath suspended loads or raised fork arms Never exceed the maximum load values specified on the capacity rating plate Otherwise stability cannot be guaranteed Only store pallets that d...

Page 284: ...rack Position the forks Set the lift mast to vertical Lift the fork carriage to the stacking height CAUTION Risk of component damage When the fork is inserted into the rack take care not to damage the rack or the load Operation 4 Handling loads 268 56368011531 EN 01 2021 05 ...

Page 285: ...l the load is resting entirely on the fork DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear DANGER Due to the risk of tipping never tilt the lift mast with a raised load Lower the load before tilting the lift mast Reverse carefully and slowly until the load is clear of the rack Brake gently Operation 4 Handling loads 269 56368011531 EN 01 ...

Page 286: ... Lower the load while maintaining ground clearance Tilt the lift mast backwards The load can be transported Operation 4 Handling loads 270 56368011531 EN 01 2021 05 ...

Page 287: ...d and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards Drive slowly and carefully around corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating ...

Page 288: ... to perform tasks such as emptying containers of bulk material The shake function moves the fork carriage quickly up and down via the Lifting function This function may only be used for a limited load and must not be used with a full nominal load Maximum permissible load for the shake function Maximum 30 of the nominal load If an at tachment is being used its weight must be subtracted from this va...

Page 289: ...o start the shaking If the two seconds elapse without the shake function being used the shake function is deactivated again WARNING The shake function remains active for two seconds following activation If the driver simply wants to lift or lower the load dur ing this time note that the fork carriage may move significantly more jerkily with the load than in normal operation If the two seconds elap...

Page 290: ... four times Then continue to move the component in the same way Double mini lever Move the 360 lever 2 back and forth be tween positions A and B four times Then continue to move the component in the same way 6210_003 089 1 A B Operation 4 Handling loads 274 56368011531 EN 01 2021 05 ...

Page 291: ...e same way Quadruple mini lever Move the operating lever 4 back and forth between positions A and B four times Then continue to move the component in the same way Fingertip Move the operating lever 5 back and forth four times Then continue to move the com ponent in the same way Operation 4 Handling loads 275 56368011531 EN 01 2021 05 ...

Page 292: ...ards take particu lar care to ensure that the truck does not tip for wards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during low ering the load may fall When removing from stock move the truck far enough back so that the load and the fork can be lowered freely Drive up to the stack with the load lowered in accordance with re...

Page 293: ...es special dangers Always follow the instructions below On ascending and descending gradients the load must be carried facing uphill It is only permitted to drive on ascending and descending gradients that are marked as traffic routes and that can be used safe ly Ensure that the ground to be traversed is clean and provides a good grip Do not turn on ascending and descending gradients Do not drive ...

Page 294: ...s place loads into stock and remove loads from stock on a horizontal plane Driving onto lifts The driver may only use this truck on lifts with a sufficient load capacity and for which the op erating company has granted authorisation See the chapter entitled Definition of respon sible persons DANGER There is a risk of fatal injury from being crushed or run over by the truck There must not be any pe...

Page 295: ...otal actual weight of the truck Net weight 1 Max permissible battery weight 2 Ballast weight variant 3 Net weight of attachment variant Weight of the load to be lifted 100 kg allowance for driver Total actual weight Drive the truck into the lift with the forks fac ing forwards Make sure not to touch the shaft walls Park the truck securely in the lift and switch it off to prevent uncontrolled movem...

Page 296: ...ing bridge is properly at tached and secured and has a sufficient load ca pacity e g lorry bridge Ensure that the lorry onto which you will be driving is secured to prevent it from shifting and that it can support the load of the truck Determining the total actual weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the nameplate on the attachme...

Page 297: ... persons The specifications provided by the manufacturer and supplier of the attach ments must be observed during installation of the attachments Before changing attachments the hydraulic system must be depressurised This is done using a wizard on the display operating unit If the truck has a 5th hydraulic function or 6th hydraulic function the hydraulic circuits of these functions must also be de...

Page 298: ...es access authorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is released prematurely the settings menu will close Set the load down if necessary Apply the parking brake Starting the wizard Press the button Press the Settings Softkey Activate the Access authorisation for the fleet ma...

Page 299: ... menu appears Push the Relieve hydraulics soft key The following message appears Caution the lift mast may move To confirm push the softkey Press the softkey to exit the wizard Operation 4 Depressurising the hydraulic system 283 56368011531 EN 01 2021 05 ...

Page 300: ...e function for relieving the hy draulics becomes inactive Depressurising the hydraulic sys tem using multi lever operation Start the wizard for depressurising the hy draulic system Depressurising the hydraulic circuits for the basic functions The basic functions include the first four hy draulic functions The basic functions are con trolled via the first two hydraulic circuits The basic functions ...

Page 301: ...ions In this case press the button 1 and hold it down Push the operating lever 2 once in the di rection of the arrow until the end position is reached Release the button 1 The hydraulic circuits of the sideshift and fork adjustment are now depressurised The plug connectors on the lift mast are depressurised Completing the depressurisation To complete the depressurisation observe the section entitl...

Page 302: ...ng lever 4 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Press the button 2 and hold it down Push the operating lever 3 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 6th hydraulic func tion is depre...

Page 303: ...justment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the cross lever 1 for controlling the additional functions once in the direction of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To complete...

Page 304: ...ctuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the cross lever 1 once in the direc tion of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Completi...

Page 305: ...t Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To compl...

Page 306: ...tuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Compl...

Page 307: ... Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To comple...

Page 308: ...Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Com...

Page 309: ...k adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisati...

Page 310: ...elevant pictogram for the 5th function Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Push the operating levers 1 or 4 once in the direction of the arrow until the end posi tion is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func t...

Page 311: ... functions The additional features include features such as the sideshift and fork adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Push the Joystick 4Plus 1 once in the direc tion of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurise...

Page 312: ...nction Press and hold shift key F 1 Push the Joystick 4Plus 3 once in the di rection of the arrow until the end position is reached Push the horizontal rocker button 2 once in the direction of the arrow The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Release shift key F 1 Completing the depressurisation To complete the de...

Page 313: ...ed Clamp locking mechanism variant in the chapter entitled Attachments Exiting the wizard After the hydraulics have been depressur ised press the softkey to confirm The wizard for depressurising the hydraulics is switched off The truck is ready for operation Operation 4 Depressurising the hydraulic system 297 56368011531 EN 01 2021 05 ...

Page 314: ...ttachments If the area of application is not clear ask the safety officer If the truck is equipped with an integrated at tachment variant at the factory the specifica tions in the STILL operating instructions for in tegrated attachments must be observed If attachments are fitted at the place of use the specifications in the operating instructions from the attachment manufacturer must be ob served ...

Page 315: ...ver grab or climb on moving parts of the truck WARNING Risk of accident due to incorrect labelling The use of attachments can cause accidents if the labelling is incorrect or missing If the truck is not fitted with an attachment specific residual load capacity rating plate and the operating devices are not marked with the relevant pictograms the truck must not be used Use only CE certified attachm...

Page 316: ...ment has been disassembled seal the plug connectors using the protective caps Mounting attachments Only competent persons are permitted to mount and connect the energy supply to the attachment Observe the information provided by the manufacturer and supplier or sub supplier of the attachment when doing so After each installation the function of the at tachment must be tested prior to initial com m...

Page 317: ... of the manufacturer and suppli er of the attachment Observe the residual load capacity rating plate see the chapter entitled Picking up a load using attachments Operation 4 Attachments 301 56368011531 EN 01 2021 05 ...

Page 318: ... included in the truck s equipment Possible equipment variants include Multi lever Multi lever with a 5th or 6th function var iant Double mini lever Double mini lever with a 5th function var iant Triple mini lever Triple mini lever with a 5th function variant Quadruple mini lever Quadruple mini lever with a 5th function variant Fingertip Fingertip with a 5th function variant Joystick 4Plus Joystic...

Page 319: ...ibed below The directions of movement can be seen in the pictograms on the operating devices All the attachments described fall into the category of equipment variants An exact description of the respective movements or actions of the at tachment fitted can be found in the relevant operating instructions With fleet manager access authorisation var iant the fleet manager can adjust the speed of the...

Page 320: ...s fed from the auxiliary hydraulics 2 2 and is implemented by an additional connec tion for a switch valve that is not shown here NOTE If one switch valve is used the auxiliary hy draulic functions 1 3 and 2 4 that are sup plied by this switch valve cannot be operated simultaneously The switch valve supplies ei ther auxiliary hydraulics 1 3 or 2 4 Adjusting the hydraulic speed for at tachments If ...

Page 321: ...ion for the fleet manager Push the Auxiliary hydraulics Softkey This menu lists all the available hydraulic axles for attachments Refer to the operating instructions of the at tachment to determine which hydraulic axle is occupied by the attachment The authorised service centre will help you de termine the axles Setting the revolution speed Push the softkey for the hydraulic axle to be configured ...

Page 322: ...nus softkey To save the setting press the Confirm softkey The settings are saved To cancel the setting press the Can cel softkey The settings return to the most recently set value Locking the flow rate You can also lock the hydraulic oil flow rate in full To do this push the Deactivate auxiliary hydraulics softkey The hydraulic oil flow rate for this hydraulic axle is locked Setting the return flo...

Page 323: ...e from a falling load If other attachments in addition to the clamp are used on this truck the clamp locking mechanism must be reassigned to the corresponding operating device ev ery time the clamp is reassembled Make sure that the authorised service centre reas signs the function of the clamp locking mechanism to the corresponding operating device Make sure that the additional clamp locking mech ...

Page 324: ... See the section concerning the relevant op erating device Operation 4 Attachments 308 56368011531 EN 01 2021 05 ...

Page 325: ...in the upper part of the pic togram Move the operating lever backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Note the following attachment functions and pictograms Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adju...

Page 326: ...ns is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism NOTE For technical reasons no clamp locking mech anism is available for the multi lever operating device Operation 4 Attachments 310 56368011531 EN 01 2021 05 ...

Page 327: ...c togram Move the operating lever 3 4 backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Press and hold the switch 1 The additional function of the attachment is activated and can be controlled as the 5th function with the operating lever 4 NOTE The movement action of the 5th function can be found in the operating instructions of the at tachment t...

Page 328: ... to the right Tip shovel over Tip shovel back Swivel the fork to the left Swivel the fork to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary If the at tachment is known the re...

Page 329: ...this lever The pictograms are arranged according to the direction of movement of the attach ments cross lever 1 The following applies Move the attachments cross lever 1 in the direction of arrow A B C or D The attachment moves accordingly in the di rections A B C or D as shown in the pictogram Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or f...

Page 330: ...chanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er 2 forwards again It is not nece...

Page 331: ...l becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 2 The pictograms on the attachments cross lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 3 The LED for the 5th function lights up Move the attachments cros...

Page 332: ...nction Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service cen...

Page 333: ...spective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment func...

Page 334: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 335: ...dhesive label becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 3 The pictograms on the operating lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating le...

Page 336: ...hment function Auxiliary hydraulics 5th function Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the co...

Page 337: ...espective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment fun...

Page 338: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 339: ...sentially involves the following Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating lever 1 in the direc tion E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram Example using the pictograms for configura tion 1 If the operating lever 1 is moved in the direc tion of the arrow E the sideshift moves to th...

Page 340: ...ating lever 2 and the adhesive label 4 for the op erating lever 1 are affixed at the designated points If the adhesive labels become illegible or are missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive labels 3 4 The pictograms on the operating levers show the respective functions that are activated by these levers The following...

Page 341: ... au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism To release the clamp locking mechanism push the operating lever 2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for...

Page 342: ...sing please contact your authorised service centre The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Move the operating lever 4 or 6 in the di rection of the arrow E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram NOTE The place where the adhesive label bearing the pictograms 1 or 5 is affixed s...

Page 343: ...NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Operation 4 Attachments 327 56368011531 EN 01 2021 05 ...

Page 344: ...show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus The following applies Move the Joystick 4Plus 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the slider 4 in the direction of the ar row C or D The attachment moves accordingly in the di rections C or D as show...

Page 345: ...ush the slider 1 to the left The clamp locking mechanism is released The LED for the clamp release 2 lights up and remains lit while the clamp locking mech anism is released To open the clamp push the slider 1 to the left again NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is...

Page 346: ... on the adhesive label regard ing operation of the Joystick 4Plus show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus Note the following attachment functions and pictograms Operating device Function of the at tachment 1 Shift key F and Joystick 4Plus Adjust fork arms close open 2 Shift key F and horizontal rocker button Adjust fork back wards...

Page 347: ...ments must only be deployed for their inten ded use as described in the relevant operating in structions Drivers must be taught how to operate the attach ments WARNING Risk of accident Loads may only be picked up and transported with attachments if the loads are securely grasped and at tached Where necessary loads must also be se cured against slipping rolling falling over swinging or tipping over...

Page 348: ...The acceleration sensor records data arising from rapid accelerations or decelerations of the truck e g in the event of an accident This da ta can be electronically read out and evalu ated If you have any questions please contact your authorised service centre Driver restraint systems variants Different driver restraint systems are available as variants for this truck The description and operation...

Page 349: ...own with an orange back ground To activate the Washer operating stage press and hold the softkey The Washer operating stage is activated The symbol 4 is displayed for as long as the softkey is pressed Once the window is clean release the soft key The previous operating stage is reactivated To switch this operating stage off press the softkey repeatedly until the symbol 1 ap pears again on the disp...

Page 350: ...ss the softkey repeatedly until the symbol 1 ap pears again on the display Roof panel wiper and washer To activate the On operating stage press the corresponding softkey 9 The On operating stage is activated The symbol 11 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 10 is shown with an orange background To activate the Washer operating stage press a...

Page 351: ...isk of frost use fluid that is suitable for winter use Close the filler cap Operate the screen washer system until washer fluid is discharged from the spray nozzles Operating the rear window heating DANGER Risk of explosion Operating the rear window heating sys tem within potentially explosive areas classified as zones 1 and 21 can lead to explosions in the surrounding atmos phere Rear window heat...

Page 352: ...of observing the speed limits on company prem ises Depending on the system setting the ceiling sensor can detect overhead structures above the truck at a height of 2 m to 24 m above the sensor If the truck is equipped with a ceiling sensor this assistance system is listed in the Assis tance systems menu in the display operating unit Operating the ceiling sensor system The drivers must be instructe...

Page 353: ... accel erator briefly and then operate the accelera tor again Switching on the truck in a hall If the truck is switched on inside a hall the ceiling sensor system detects the hall ceil ing and reduces the driving speed to the maximum speed that is set for halls Possible limitations for object recogni tion If the truck moves under larger overhead structures outdoors e g a pedestrian bridge the ceil...

Page 354: ...to loosen it Disconnect the electrical connec tion assembly by pulling out the plug On the underside of the assembly base plate on the overhead guard hold four nuts 3 in place Unscrew four socket head screws 2 The key 5 is secured with a nut under the as sembly baseplate Carefully remove the ceiling sensor 1 Deckensensor_Anbau 1 4 2 3 5 Deckensensor_Einstellschlüssel_V2 Operation 4 Auxiliary equip...

Page 355: ...rewdriver CAUTION The settings for DIP switches 6 to 8 are the factory settings of the manufacturer Do not change the factory settings of the manufac turer Factory settings of the manufacturer DIP switch 6 7 8 1 1 0 The possible settings for DIP switches 1 to 5 are shown in the following tables DIP switch 1 2 3 Range 0 0 0 2 m 0 0 1 3 m 0 1 0 4 m 0 1 1 6 m 1 0 0 8 m 1 0 1 12 m 1 1 0 16 m 1 1 1 24 ...

Page 356: ...nsor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following ta ble Sensitivity Range Beam angle Low 1 2 m 22 5 4 m 22 5 8 m 20 16 m 15 24 m 5 Medium 2 2 m 35 4 m 30 8 m 25 16 m 22 5 24 m 10 2 3 4 1 2 3 4 Operation 4 Auxiliary equipment 340 56368011531 EN 01 2021 05 ...

Page 357: ... 8 m 22 5 16 m 20 24 m 15 Very high 4 2 m 45 4 m 43 8 m 30 16 m 22 5 24 m 18 After the adjustment refit the cover Refit the ceiling sensor and connect it Check that it is working correctly Operation 4 Auxiliary equipment 341 56368011531 EN 01 2021 05 ...

Page 358: ...k of component damage If the cab door opens while driving there is risk of damage from a collision The cab door must be latched securely in the en gaged position The truck has a cab door sensor that is used to monitor the closing of the cab door If the seat belt is not fastened and the cab door is not closed the driving speed is limited to 4 km h The message Close cab door or seat belt appears in ...

Page 359: ...Opening and closing the side win dow WARNING There is a risk of crushing between the window frame and side window due to the side windows slip ping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the front side window Squeeze the handle 3 Slide the front side window 1 backwards Opening the rear side window The rear side window 2 can be ...

Page 360: ... If the truck is equipped with a ra dio and loudspeakers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the ra dio WARNING The driver s attention is adversely affected by operat ing the radio or listening to it at excessive volumes while driving or handling loads Risk of accident Do not operate the radio when driving o...

Page 361: ... of fire due to overheating The heating system can overheat if the hot air cannot escape from it The heating system may only be switch ed on if the blower is running and the heating system is not covered by objects such as a jacket or cover Always switch the blower on first Do not switch the heating system on until the blower is switched on Move any objects away from the heating system or air dist...

Page 362: ...red position Selecting blower settings To select a lower fan output turn the fan control knob 2 anticlockwise To select a high blower output turn the fan control knob 2 clockwise Setting heating levels To set a lower heater power turn the heat ing level control knob 1 anticlockwise To set a higher heater power turn the heat ing level control knob 1 clockwise Setting the air vent control knob To di...

Page 363: ...lways supplied with air It is not necessary to adjust the heating system using the operating devi ces To open the air distributor push the inden tation 1 on the disc The discs open Grasp the discs to align the air flow The discs can be adjusted to the desired an gle The air distributor can be rotated Press down again to close the discs Changing fuses DANGER Risk of fire as a result of short circui...

Page 364: ...ff Push the on off switch 5 The LED on the switch lights up green The air conditioning is switched on Press the on off switch 5 again The LED on the switch goes out The air con ditioning is switched off Defrost function The defrost function can be used to de ice and dehumidify the windscreen quickly To do this turn the air vent control knob 3 clockwise to the position Open the air distributors and...

Page 365: ...shed up to and locked in three positions Pushed up at the front Pushed up at the rear Completely pushed up Two handles 2 5 and two locking bolts 3 4 are located on the right hand side for this pur pose To push up and close the roof window stop the truck and apply the parking brake Pushing up and closing the roof window at the front To push up the roof window pull out the locking bolt 4 with your r...

Page 366: ...f window pull out the locking bolt 3 with your left hand and keep hold of the locking bolt Use your right hand to take hold of the han dle 2 on the roof window 1 and push up wards until the locking bolt 3 engages The roof window 1 is held in the pushed up position To close the roof window pull out the lock ing bolt 3 with your left hand and keep hold of the locking bolt Use your right hand to take...

Page 367: ...ront 4 To adjust the sun visor 2 grasp it and move it to the desired position To move the sun blind 4 up and down grasp the tab 3 and move the sun blind If necessary fully unroll the sun blind for the roof 1 and attach the ends 5 in the ex tended position To roll up slowly roll the blind 1 back up Operation 4 Cab 351 56368011531 EN 01 2021 05 ...

Page 368: ... in the surrounding atmosphere within potential ly explosive areas Only use trailers tow couplings and coupling pins that meet explosion protection regulations Check the area of application by re ferring to the information on the nameplates of the trailers and tow couplings If the area of application is not clear ask the safety officer Operation 4 Trailer operation 352 56368011531 EN 01 2021 05 ...

Page 369: ...st not exceed the rated capacity If the towed load present corresponds to the rated capacity of the truck it is not permitted to transport a load on the fork at the same time The load can be distrib uted between the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe the permissible rigidity value of the tow coupling CAUTION Risk of damage to...

Page 370: ...in the counterweight Coupling the trailer DANGER Risk to life if the truck rolls away If you briefly leave the truck to couple it or uncouple it there is a risk of fatal injury caused by the truck rolling away and running you over Apply the parking brake Lower the fork to the ground Switch off the truck Remove the switch key or block access Take measures to prevent the trailer from rolling away e ...

Page 371: ...nts If the coupling pin or securing bush is lost or dam aged during towing the trailer will become loose and uncontrollable Only use original coupling pins that have been checked Ensure that the coupling pin is correctly inserted and secured Insert the coupling pin into the counter weight press downwards against the spring pressure and turn it by 90 The coupling pin is now locked in this position ...

Page 372: ...ruck and the trailer DANGER Never jack up the truck on the tow coupling or use it for crane lifting The tow coupling is not designed for this and could be deformed or damaged This could cause the truck to fall with potentially fatal consequences Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER The tow coupling is not designed for s...

Page 373: ...ng can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow cou pling check the tow coupling for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufficient room In the case of a collision check the tow coupling for damage Replace tow coupling if damaged if necessary contact the authorised service...

Page 374: ... a tow bar eye in accordance with DIN 74054 bore diameter 40 mm or DIN 8454 bore diameter 35 mm Take measures to prevent the trailer from rolling away e g using wedges Adjust the tow bar eye of the tiller so that it is at the centre of the towing jaws Push the hand lever 2 upwards until it snaps into place The tow coupling is opened CAUTION When being coupled the tow bar eye must engage in the mid...

Page 375: ... control pin does not protrude out of its guide Remove any items used to prevent the trail er from rolling away Tow the trailer Closing the coupling DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for exam ple a tow rope is to be secured in the tow coupling only actuate the tow coupling via the closing lever 1 Press the closing lever 1 downwards as far a...

Page 376: ...railers ensure a suf ficient minimum distance to fixed installa tions when turning and cornering The permissible length of the trailer trains de pends on the roadways to be driven and may need to be determined during the test drive It is the responsibility of the operating compa ny to instruct the drivers regarding the permis sible number of trailers and where required any additional speed reducti...

Page 377: ...nguished by two dif ferent temperature ranges 1 Constant use in the temperature range down to 5 C short term use at temper atures down to 10 C Operation possible with standard equip ment and standard hydraulic oil 2 Alternating between indoor use down to 32 C and outdoor use up to 25 C briefly up to 40 C Operation possible only with cold store equipment and low temperature hydraulic oil NOTE When ...

Page 378: ...is paid to the dura tion of deployment in the different temperature rang es for both types of application Before being used in the cold store the truck must be dry and warmed up The truck must not leave the cold store area for more than 10 minutes By adhering to this rule condensa tion water will not have time to form If the truck stays outside for more than 10 minutes it must remain there at leas...

Page 379: ...ta tion and the parking area for trucks and batter ies must be at normal room temperature not below 10 C Charging is extremely slow at low temperatures At temperatures below 10 C the battery cannot be fully charged with the usual charging parameters Charge the battery fully before each shift During the gassing phase always top up with distilled water The distilled water will mix with the battery a...

Page 380: ...explosion protection warning lights 1 2 illuminates The hydraulic functions of the truck are switched off as soon as the explosion protection warning light 3 illuminates The driving functions of the truck are switched off as soon as the explosion protection warning light 4 il luminates Stop the truck safely This section describes the actions required when an explosion protection warning light is f...

Page 381: ...ximum surface temperature of the pump motor has been reached No hydraulic functions are available Set down the load Actuate the reset button and drive the truck out of the potentially explosive area Safely bring the truck to a standstill Allow the overheated motor to cool down If one of the warning lights 1 3 remains il luminated after the motor has cooled down notify the authorised service centre...

Page 382: ... messages about operation and messages about the truck If a message about operation appears the display operating unit will prompt you to perform an action A mes sage about the truck means that the truck con trol unit has detected a fault The following types of message may appear individually or in combination A graphic symbol The message A code consisting of a letter and a four digit number The m...

Page 383: ...rent causes The battery is defective The wrong battery is connected Contact the authorised service centre Check battery acid lev el The acid level of the lead acid battery is too low Check the acid level of the battery Correct if necessary V6965 Battery temperature high The charging process has been automatically terminated due to the battery temperature being too high This message about the on bo...

Page 384: ...tion not working The electrolyte circulation pump is not working The charging process is continued without elec trolyte circulation Intermediate charging can cause damage to the battery Cancel the charging process Contact the authorised service centre Development mode ac tive This message is not displayed during normal operation Contact the authorised service centre Drive unit blocked This message...

Page 385: ... Switch the truck off and on again If the message continues to appear please contact the authorised service centre V7074 V7051 Mains voltage error This message about the on board charger is triggered by different causes The fuse for the power supply has been trig gered There is a defect in the power supply There is a power failure Re establish the power supply When the power supply has been re est...

Page 386: ...ake by pressing the but ton Parking brake Mainte nance required The truck control unit detects that the electric parking brake needs servicing Secure the truck with wedges so that it cannot roll away Contact your authorised service centre Lower forks This message appears e g for precision load measurement variant Lower the fork carriage Lift height restriction active The lift height restriction va...

Page 387: ... that is too low this message appears Observe the previous message Emerg direct via drive direction lever The drive direction switch on the hydraulic oper ating device has failed Emergency driving is possible to do so Move the drive direction selection lever on the travel direction selector and indicator module to the desired direction of travel and hold the drive direction selection lever in posi...

Page 388: ...on the truck Shock event detected If the truck control unit detects a very strong ac celeration or deceleration e g in the event of an accident this message appears Service required If the maintenance interval has been reached this message appears Contact the authorised service centre Service mode active This message is not displayed during normal operation Contact the authorised service centre Cl...

Page 389: ...control unit detects an excessive battery temperature this message appears Allow the truck to cool down Working mode active This message is not displayed during normal operation Contact the authorised service centre Access expired If the truck is equipped with this variant this message might appear See the associated instructions Access denied Access expires in 1 month Access expires in 1 day If t...

Page 390: ... and reflector Lift height sensor measurement error A5934 Re insert charging plug Error on the charging connector detection Disconnect the connection assembly and re connect it A5961 Battery overtempera ture Overtemperature of the lithium battery Switch off the truck and leave it to cool down A5962 Battery too cold Insufficient lithium battery temperature Move the truck to a warmer environment A59...

Page 391: ...ts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male connector while the truck is switched on except in an emer gency In an emergency all functions of the truck can be shut down Press the emergency off switch 1 or turn the battery isolating switch 2 to OFF In drive mode pressing the emergency off switch 1 or turning the battery isolating swi...

Page 392: ...he message EMER GENCY OFF ac tive appears on the display operating unit The display operating unit does not work Actuating the reset button after au tomatic emergency shutdown DANGER Risk of explosion During operation the current tempera tures wear values and insulation values of various components are monitored by sensors If dangerous limit values are detected the truck controller automatically s...

Page 393: ... is essential that the safety officer gives ap proval to the following operation In an emergency e g if the truck stops on train tracks the truck can be immediately moved out of a danger area despite the auto matic emergency shutdown having been trig gered To do this push and hold the reset button 1 and simultaneously actuate the acceler ator pedal The truck will move in the preselected drive di r...

Page 394: ...k You must adhere to the rules of behaviour if the truck tips over Rules of behaviour if truck tips over Hold onto the steering wheel with your hands Brace your feet in the footwell Bend your upper body over the steering wheel Bend your body against the direction of the fall Emergency hammer The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazard ous situation fo...

Page 395: ...conditions the emergency driv ing function can be used to remove the truck from a hazardous area As the truck can only be moved to a limited extent this poses a risk of an accident This function is possible in the following situa tions The drive direction switch on the operating device for the hydraulic functions has failed The message Emerg direct via drive direction lever ap pears The drive dire...

Page 396: ...y lowering If the hydraulic controller fails whilst a load is raised emergency lowering can be performed An emergency lowering screw designed for this purpose is located on the valve block DANGER There is a risk to life from falling loads or from truck components being low ered Do not walk beneath the raised load Adhere to the steps detailed below Remove the lid 1 on the right hand side of the foo...

Page 397: ...he emergency lowering screw slightly The load is lowered slowly Unscrewing the emergency lowering screw further The load is lowered quickly After lowering Re tighten the emergency lowering screw Return the hexagon socket wrench to the support mounting in the compartment Refit the lid DANGER If the truck is operated while the hydraulic controller is blocked there is an increased risk of accidents A...

Page 398: ...rking brake can be released and applied via an emergency actuation mechanism The electric parking brake must be manually actuated under the following conditions The electric parking brake is not operating properly The truck is being transported without a bat tery NOTE If the parking brake is released via the emer gency actuation mechanism it is possible to drive the truck at a low speed The truck ...

Page 399: ... the parking brake To apply the parking brake push down the hand wheel 1 and turn it clockwise until the force required to do so increases signifi cantly and the truck is held securely Remove the hand wheel 1 turn it round and then insert it again Fold the cover down again If the condition of the parking brake cannot be reliably determined secure the truck with wedges 1 2 6219_003 228 1 6219_003 0...

Page 400: ...l Risk of accident If the brake system of the towing vehicle is not ade quately sized the vehicle may not brake safely or the brakes may fail The towing vehicle must be able to absorb the pulling and braking forces from the un braked towed load total actual weight of the truck Check the pulling and braking forces of the towing vehicle DANGER The truck could drive into the towing vehicle when the t...

Page 401: ...he steering will be stiff Select a towing speed that allows the truck and towing vehicle to be braked and controlled effec tively at all times WARNING Risk of accident due to unguided truck If the towed truck is not steered the truck may veer out in an uncontrolled manner The truck being towed must also be steered by a driver The driver of the truck being towed must sit in the driver s seat and fa...

Page 402: ...cer Set down the load and lower the fork arms close to the ground Set the drive direction switch to the neutral position Apply the parking brake Switch off the truck Disconnect the battery male connector Check the pulling and braking forces of the towing vehicle With the help of a guide move the towing vehicle to the truck Secure the tow bar to the tow coupling on the towing vehicle and the truck ...

Page 403: ...After towing secure the truck so that it can not roll away e g by applying the parking brake or by using wheel chocks Remove the tow bar Operation 4 Procedure in emergencies 387 56368011531 EN 01 2021 05 ...

Page 404: ...ctor is connected while the truck is switched on under load a transition spark will be produced This transition spark can damage the contacts and considerably shorten the service life of the contacts Do not connect the battery male connector with the truck switched on Make sure that the truck is switched off before connecting the battery male connector CAUTION There is a risk of short circuit if t...

Page 405: ...1 to secure the battery male connectors in place WARNING Risk of accident The battery male connectors are only protected against disconnection when the screws 2 are tight ened Otherwise the battery male connectors may work loose during operation If this happens the power supply of the truck is interrupted and it is no longer possible to operate the truck If necessary connect the potential equalisa...

Page 406: ...be performed on the truck in potentially explosive areas Disconnect battery male connectors only outside potentially explosive areas CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the con...

Page 407: ... marking is routed through one groove Open the battery door Loosen the screws 2 Disconnect the battery male connectors 2 from the sockets 3 by unscrewing the bat tery male connectors out of the grooves 4 Screw the screws 1 back in so that they do not get lost Before removing the battery also disconnect the potential equalisation 5 The potential equalisation point is marked with decal information C...

Page 408: ...et it down safely CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery door Ensure that the battery cable does not come into contact with the battery door Close the battery door 1 2 3 4 6219_901 008 Operation 4 Connecting and disconnecting the battery male connector 392 56368011531 EN 01 2021 05 ...

Page 409: ...se of the truck Only use explosion protected batter ies of the same type in accordance with the Battery specifications sec tion Batteries may be checked only by a competent person Observe the explosion protection reg ulations Compare the permissible operating areas of the truck and battery as lis ted on the respective nameplates DANGER Risk of explosion When handling or charging batteries in poten...

Page 410: ...so apply to trucks with a battery cover They apply 1 1 Parking the truck securely If work is being performed on the battery park the truck outside the potentially explo sive areas The following points must be satisfied for the truck to be used The battery male connectors must be con nected and secured The battery door must be closed Maintenance personnel Batteries may only be charged maintained or...

Page 411: ... maintenance in structions for the battery and the battery charger Fire protection measures DANGER Risk of explosion due to flammable gases During charging the battery releases a mixture of oxygen and hydrogen This gas mixture oxyhydrogen is explosive and must not be ignited There must be no flammable materials or spark forming operating materials within 2 m of either the truck when it is parked f...

Page 412: ... plate Check the load capacity of the lifting accessory Remove the battery on suitable ground Battery weight and dimensions DANGER Risk of tipping due to change in battery weight The battery weight and dimensions affect the stability of the truck When replacing the battery the weight ratios must not be changed The battery weight must remain within the weight range specified on the nameplate Do not...

Page 413: ... con nected while the truck is switched on or while the battery charger is under load an electrical arc or a transition spark will be produced at the battery male connector This can lead to erosion at the contacts and can considerably shorten the service life of the contacts Switch off the truck or the battery charger before disconnecting or connecting the battery male con nector Do not disconnect...

Page 414: ...ions The operating instructions for the battery charger must also be followed Only the instructions that came with the battery charger are valid If any of these instructions are missing request the relevant instructions from the dealer The battery maintenance information is com posed of the following sections Checking the status acid level and acid density of the bat tery Checking the battery char...

Page 415: ...ty protection of the battery male connectors must be checked Observe the information in the operating instruc tions for the battery Ensure that the battery tray is closed correctly all the way round Ensure that a tray lid is present for category 2 ver sions Only use batteries and plug connectors that are approved for potentially explosive areas and for the truck The safety officer will allocate a ...

Page 416: ...ean the battery cell covers and dry if nec essary Remove any oxidation residue on the bat tery terminals then coat the terminals with acid free grease At regular intervals have the battery termi nal clips 2 tightened by the authorised service centre in accordance with the bat tery manufacturer s instructions Check the acid density with an acidimeter After charging the acid density must be be tween...

Page 417: ...ged state Apply the parking brake Switch on the truck Read the charge status on the display of the display operating unit Charge a discharged or partly discharged battery Meaning of the colours in the display 1 Green The battery is sufficiently charged 2 Yellow Charge the battery soon 3 Red Stop working Charge the battery imme diately The battery is at risk of deep dis charge Charging the lead aci...

Page 418: ...n of the battery DANGER There is a risk of damage short circuiting and ex plosions Do not place any metal objects or tools on the bat tery Keep away from naked flames Do not smoke WARNING Battery acid is toxic and corrosive Observe the safety regulations in the chapter enti tled Battery acid CAUTION Risk of damage to the battery charger Incorrect connection or incorrect opera tion of the charging ...

Page 419: ... gaps on the truck are unobstructed and are not blocked Fully open any protective structures e g fabric covered cab Open the battery door completely Disconnect the battery male connector Do not place any metal objects or tools on the battery Keep away from naked flames Do not smoke Check the battery cables for damage If necessary have the battery cables re placed by the authorised service centre C...

Page 420: ...y open position After charging CAUTION Risk of danger to components Switch off the battery charger before disconnect ing the charging cable Switch off the battery charger Swing the support bracket 1 back into po sition and lock it into the support eyelet 2 on the battery door Open the battery door and lock it into the open position Disconnect the battery male connector from the plug for the batter...

Page 421: ... unit The truck will not move Equalising charging to preserve the battery capacity Equalising charges ensure that unevenly charged battery cells are evenly charged again This preserves the service life of the battery and the battery capacity An equalising charge should be carried out in accordance with the battery manufacturer s in structions several times a month after the nor mal charging proces...

Page 422: ...e battery is required during this process you can interrupt the equalising charge by pushing the stop button on the battery charger Please refer to the operating instructions from the manufacturer of the battery charg er CAUTION Damage to the connection assembly is possible If you disconnect the charging cable while the battery charger is switched on an arc will be produced This can lead to erosio...

Page 423: ...apacity lifting accessories and the battery can roll away in an uncontrolled manner Follow the operating instructions for the lifting ac cessories used Always remove the battery on a level smooth floor with sufficient load capacity Batteries can be removed with a truck and with a lift truck equipped with a battery change frame The load capacity of the lifting accessory used must at least match the...

Page 424: ... to TENSOR batteries the authorised service centre must limit the maxi mum speed of the truck to 17 km h for techni cal reasons Setting the new battery capacity and the new battery type Stop the truck Actuate the parking brake Press the button Press the Settings softkey The first menu level appears Activate the Access authorisation for the fleet manager The Settings menu opens on the display Press...

Page 425: ...xt to the selection lights up The main display button takes you to the main display Opening closing the battery door Opening the battery door Take hold of the door handle 1 of the bat tery door and open the battery door by pull ing it forwards The battery door locks into place automatical ly Operation 4 Replacing and transporting the battery 409 56368011531 EN 01 2021 05 ...

Page 426: ...osing the battery door limbs could become trapped risk of crush ing When closing the battery door nothing should come between the battery door and the edge of the chassis Carefully close the battery door Only close the battery door if there are no parts of the body in the way WARNING When closing the battery door there is a risk of trapping the battery cable If the cable is crushed or sheared off ...

Page 427: ... shut Drive the truck only when the battery door is locked NOTE The apertures in the door are necessary for forced ventilation and must not be blocked If the battery door is fully open take hold of the battery door by its handle and open it slightly further This will release the latch in the hinge Close the battery door by hand until it en gages in the lock The battery door must be locked in place...

Page 428: ...850 mm It is useful to mark this measurement B measured from the fork tips on the fork arms Removing the battery Park the truck safely and switch it off Open the battery door CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which conside...

Page 429: ...los ing the battery door Open the battery locks 1 NOTE If the battery locks cannot be opened by hand the coupling pin 2 from the counterweight can be used as a lever extension Carefully drive the truck under the battery Carefully lift the battery until it maintains a sufficient distance from the seating and from the chassis above Position the fork arms horizontally CAUTION Damage to the battery po...

Page 430: ... down the battery Installing the battery Pick up the battery and transport it to the truck Carefully insert the battery into the battery compartment When doing so ensure that Before inserting the battery cable is posi tioned on the battery in such a way that it will not become trapped when the battery is inserted The load carrying equipment is at a right angle to the truck The gaps are maintained ...

Page 431: ... to the battery male connector If the battery male connector is connected while the truck is switched on under load a transition spark will be produced This transition spark can damage the contacts and considerably shorten the service life of the contacts Do not connect the battery male connectors when the truck is switched on Make sure that the truck is switched off before connecting the battery ...

Page 432: ... Insert the battery male connector fully into the plug connection on the truck Close the battery door 6219_901 010 Operation 4 Replacing and transporting the battery 416 56368011531 EN 01 2021 05 ...

Page 433: ...nge frame The battery remains on the change frame for charging and storage Preparing Check the nameplate 3 on the change frame to ensure that the selected change frame has the required load capacity Check the change frame for deformation and breaks or cracks Faulty change frames must not be used They must be replaced by the authorised service centre The distance between the feet 6 can be ad justed...

Page 434: ... mm between the outer edges of the fork arms the stop 8 must be removed When using pallet trucks with a distance of 525 mm between the outer edges of the fork arms the stop must be installed The stop 8 is connected to the battery change frame via the screw joint 7 Types of change frames Observe the nameplate of the change frame The following information is listed on the nameplate 1 The type of cha...

Page 435: ...ry Park the truck securely Open the battery door CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not...

Page 436: ...ttery CAUTION Potential for damage to the battery ca ble Position the battery cable on the bat tery in such a way that it cannot be crushed either when removing or in serting the battery or when closing the battery door Open the battery lock 1 NOTE If the battery lock cannot be opened by hand the coupling pin 2 from the counterweight can be used as a lever extension 6219_901 009 Operation 4 Replac...

Page 437: ...bat tery WARNING Risk of injury when transporting the battery The battery must be transported very carefully i e at a low speed using a slow steering movement and careful braking Do not use the methods described here to trans port the battery over long distances Transport the battery to the intended stor age space CAUTION Damage to the battery possible The change frame and battery must be stored o...

Page 438: ... of crushing or shearing When inserting do not allow your hands to come between the battery and the chassis CAUTION Potential for damage to the battery ca ble Position the battery cable on the bat tery in such a way that it cannot be crushed either when removing or in serting the battery or when closing the battery door When the battery is correctly positioned in the battery compartment carefully ...

Page 439: ...e the truck is switched on or the battery charger is under load a transition spark will be produced This can lead to erosion at the contacts and can considerably shorten the service life of the contacts Switch off the truck and the battery charger before connecting the battery male connector Close the battery door 6219_901 010 Operation 4 Replacing and transporting the battery 423 56368011531 EN 0...

Page 440: ...with open terminals or connectors with a rubber mat Observe the operating instructions for the lifting gear Attach the battery 1 to suitable lifting gear 2 Lift the battery carefully and ensure that it hangs straight on the lifting gear The lifting gear must be vertical when lifting so that no lateral pressure is applied to the tray Set the battery down carefully Remove the lifting gear after the ...

Page 441: ...here can penetrate the housing during operation in at risk areas this can cause an explosion which can in turn spread to the surrounding environment Do not open pressure tight housings CAUTION If water penetrates the electrical system there is a risk of a short circuit occurring The flame proof enclosures have a nar row gap that could allow water to pene trate Do not use high pressure cleaning equ...

Page 442: ...ose to climb onto the truck Use equipment such as stepladders or platforms to reach inaccessible areas CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck bef...

Page 443: ...ctly at adhe sive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot com ponents Use only non flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials Clean plastics only with cleaning materials intended for plastics Observe the manufacturer s guidelines for working with cleaning materials Cle...

Page 444: ...tc Clean the electrical system parts with a metal free brush and blow the dust off with low pressure compressed air Cleaning load chains WARNING Risk of accident Load chains are safety elements The use of cold cleaning solvents chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains use of these items is forbid den Observe the manufacturer s guidelines for ...

Page 445: ...ly manner Observe the national regulations for the country in which the truck is being used Cleaning the windows Any glass for example cab windows variant must always be kept clean and free of ice This is the only means of guaranteeing good visibility CAUTION Do not damage the rear window heater inside 1 Clean the rear window very carefully Do not use sharp objects Clean the windows with a soft cl...

Page 446: ...tion before connecting them Use compressed air to remove any foreign objects that may be lodged in the battery male connector and the plug connection Carefully dry the truck e g using com pressed air Lubricate the joints and actuators Lubricate the truck according to the lubrica tion plan NOTE The more often the truck is cleaned the more frequently the truck must be lubricated Operation 4 Cleaning...

Page 447: ...mponents can be per manently deformed or damaged due to overloading Determine the total actual weight of the truck Only load the truck if the load capacity of the means of transport HGV ramps and loading bridges is greater than the total actual weight of the truck Determining the total actual weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary ...

Page 448: ...Wedging the wheels Park the truck securely Secure the truck from rolling away by plac ing a wedge in front of each front wheel and behind each rear wheel CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the se...

Page 449: ...ned securely and that the pads cannot slip off CAUTION Abrasive lashing straps tension belts can rub against the surface of the truck and cause damage Position slip resistant pads e g rubber mats or foam underneath the lifting points Hook the lashing straps tension belts onto both sides of the curves in the mudguard and lash the truck towards the rear Operation 4 Transporting the truck 433 5636801...

Page 450: ...loading Crane loading is only intended for transporting the complete truck including the lift mast for its initial commissioning This may be per formed only by the authorised service centre with the harnesses expressly provided and ap proved for this purpose Do not load the truck by crane Operation 4 Transporting the truck 434 56368011531 EN 01 2021 05 ...

Page 451: ...mosphere in potentially explosive areas The entire explosion protected system must be checked before re commission ing Have the explosion protection equip ment inspected by the authorised service centre before re commission ing Decommissioning and storing the truck CAUTION Damage to components due to incorrect storage Improper storage or decommissioning for a period of more than two months can res...

Page 452: ... actuators CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an electric arc will be produced This can lead to erosion of the con tacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male...

Page 453: ... truck to protect it from dust If the truck needs to be shut down for even longer periods contact the authorised serv ice centre to find out about additional cour ses of action Use after storage or decommission ing If the truck has been decommissioned for lon ger than six months it must be checked care fully before being used again As with the an nual safety inspection this inspection must al so i...

Page 454: ...ections and func tional checks The following points in particular must be checked Drive Controller Steering Brakes service brake parking brake Lifting system lifting accessories load chains mounting NOTE For further information see the workshop manual for the truck or contact the authorised service centre Operation 4 Decommissioning 438 56368011531 EN 01 2021 05 ...

Page 455: ...5 Maintenance ...

Page 456: ... disconnection with screws To prevent loss of the screws screw the screws back in place after disconnecting the battery male connector Ensure that the truck cannot move uninten tionally or start up inadvertently If necessary have the truck jacked up by the authorised service centre Components specifically for explosion protec tion are attached on the underside of the truck If these components are ...

Page 457: ...competent person Any interference with the electrical equipment of the truck is forbidden For work on the electrical equipment contact the authorised service centre Safety devices After maintenance and repair work all safety devices must be reinstalled and tested for op erational reliability Set values The device dependent set values must be ob served when making repairs and when chang ing hydraul...

Page 458: ...oists is described in the truck s workshop manual Working at the front of the truck DANGER Risk of accident due to an unsecured lift mast If the lift mast or fork carriage is raised no work may be performed on the lift mast or at the front of the truck unless the appropriate safety measures are put in place When securing only use chains with sufficient load bearing capacity Contact the authorised ...

Page 459: ...rised service centre to re move the lift mast Securing the lift mast against falling off DANGER Risk of accident This work must only be performed by an authorised service technician To secure the lift mast against falling contact the authorised service centre Maintenance 5 Safety regulations for maintenance 443 56368011531 EN 01 2021 05 ...

Page 460: ...explosive areas Only perform truck maintenance or repairs outside potentially explosive areas Only qualified and authorised personnel are allowed to perform maintenance work Regu lar safety checks and checks after unusual in cidents must be performed by a competent person See also the section entitled Competent person for explosion protection checks in the chapter entitled Definition of responsi b...

Page 461: ...entre Maintenance work without special quali fications Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel A qualification of the type held by a competent person is not required to carry out this work The required tasks are de scribed in the chapter entitled Preserving op erational readiness Maintenance of the explosion pro tection components ...

Page 462: ... the correct maxi mum gap at the closure line of pressure tight housings verification of the lack of excessive wear and axial play of brake linings and brakes in compliance with structural design safety and of the correct positioning of the temper ature sensor and the brake lining wear sen sor after repair depending on the series verification of the minimum thickness of 1 mm for the fork arm cladd...

Page 463: ...tremely high or low ambient tempera tures and extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components Service menu The date when the truck requires maintenance is stored in the Service menu NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If th...

Page 464: ... 900 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000 3150 3300 3450 3600 3750 3900 4050 4200 4350 4500 4650 4800 4950 5100 5250 5400 5550 5700 5850 6000 6150 6300 6450 6600 6750 6900 7050 7200 7350 7500 7650 7800 7950 8100 8250 8400 8550 8700 8850 10000 Carried out Electrical system Check the mounting and condition of the electric cables of explosion protection components Che...

Page 465: ...ittings Check the driver s seat Check the antistatic paint coat Lift mast Check the fork arms Check lubricate the lift mast bearings Check the fork arm adjustment Maintenance by the authorised service centre Explosion protection compo nents 1000 hours yearly At operating hours 1000 2000 3000 4000 5000 6000 7000 9000 10000 Carried out Note Perform all 150 hour maintenance tasks Perform periodic tes...

Page 466: ...orrectly and check for damage Check the battery lock for damage Grease the battery door hinges Variant Check the oil level of the hydraulic battery carrier and check for leaks Check all moving parts for wear and lubricate them Wheels and tyres Check tyres for wear and check the air pressure if necessary Check the wheels for damage and check the tightening torques Drive axle Check the mounting chec...

Page 467: ...ge Clean the fans and the air ducts Clean the cooling fins on the converter and the traction motors Battery and accessories Check the lead acid battery for damage and check the acid density observe the manufacturer s maintenance instructions Variant Replace the non return valve on lead acid batteries with electrolyte circula tion Variant Observe the manufacturer s maintenance instructions for lith...

Page 468: ...un out barrier Check the tilt cylinders and connections for damage and for leaks Check the fork carriage for damage and for wear Check the fork arm interlock for damage and check that it is working correctly Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Special equipment Check the condition of the antistatic belt or antist...

Page 469: ...proved for use in potentially explosive areas Spare parts are provided by our spare parts service department The information required for ordering parts can be found in the spare parts list Only use spare parts as per the manufactur er s instructions The use of unapproved spare parts may result in an increased risk of acci dents due to insufficient quality or incorrect as signment Anyone using una...

Page 470: ...f a different quality must not be mixed This negatively affects the lu bricity If a change between different manufac turers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part in volved When topping up working materials use only clean containers Maintenance 5 General maintena...

Page 471: ...t A Swing axle two lubricating nipples on each side of the steering axle on the steering arm Steering turntable not present B Sliding surfaces on the lift mast C Load chains Maintenance 5 General maintenance information 455 56368011531 EN 01 2021 05 ...

Page 472: ...d in the Maintenance data table section be low under this Code This lubrication plan describes the series production truck with standard equipment For mainte nance points on variant trucks see the relevant chapter and or instructions provided by the man ufacturer Maintenance 5 General maintenance information 456 56368011531 EN 01 2021 05 ...

Page 473: ...aterials Specifications Dimension System filling Distilled water As required Insulation resistance DIN 43539 VDE 0510 For further informa tion refer to the workshop manual for the truck in question Electrical system Code Unit Operating materials Specifications Dimension Insulation resistance DIN EN 1175 VDE 0117 For further informa tion refer to the workshop manual for the truck in question Contro...

Page 474: ...mum tread depth Air pressure see in formation on truck Min tread depth 1 6 mm Steering axle Code Unit Operating materials Specifications Dimension A Axle stub bearing spherical bearing Multi purpose grease DIN 51825 KPF2 As required Wheel nuts Torque wrench Swing axle For further informa tion refer to the workshop manual for the truck in question Steering axle For further informa tion refer to the...

Page 475: ...als Specifications Dimension C Lubrication High load chain spray Fully synthetic Temperature range 35 C to 250 C ID no 0156428 As required Washer system Code Unit Operating materials Specifications Dimension System filling Screen wash Winter ID no 172566 As required Flame proof enclosure Code Unit Operating materials Specifications Dimension Gap Feeler gauge 0 05 mm Cover screws Torque wrench M5 M...

Page 476: ...the truck is designed to enable it to enter approved zones Other light bulbs increase sur face temperatures Use in potentially explosive areas is prohibited if other light bulbs are employed Light bulbs must only be changed by an author ised service centre Maintenance 5 Preserving operational readiness 460 56368011531 EN 01 2021 05 ...

Page 477: ...is a danger of being crushed to death If the interlock is deformed damaged or difficult to move inform the authorised service centre imme diately Do not operate the truck Check that the interlocks function correctly The interlocks must be greased and must move easily Always check the interlock after an accident NOTE The interval for greasing is influenced signifi cantly by the application conditio...

Page 478: ...ulty it may tear or open during an accident and no longer keep the driver in the driver s seat The driver may therefore be hurled against the truck components or out of the truck Ensure operational reliability by continually test ing Do not use a truck with a defective seat belt Only have a defective belt replaced by your serv ice centre Only use genuine spare parts Do not make any changes to the ...

Page 479: ...g mechanism must be tested at least once a year Park the forklift truck on level ground Pull out the belt with a jerk The automatic blocking mechanism must block extension of the belt Tilt the seat at least 30 if necessary re move the seat Slowly extend the belt The automatic blocking mechanism must block extension of the belt Cleaning the seat belt Clean the seat belt as necessary but with out us...

Page 480: ...ent mechanism for correct operation Check the condition of the seat e g wear on the upholstery and the secure fastening to the hood The driver s seat of the truck has anti static characteristics Driver s seats with anti static characteristics are identified on the backrest with decal in formation ANTISTATIC CHECKED The surface resistance must be less than or equal to 1 GΩ 109 Ω at a test voltage o...

Page 481: ...mosphere in potentially explosive areas Have any damage repaired by your authorised service centre Check the paint layer on the plastic parts for damage and abrasion The antistatic paint is applied to the following plastic parts Panelling Consoles Steering column panelling Document holders Compartments The protected areas are identified with the decal information ELECTRICALLY CON DUCTIVE Non coate...

Page 482: ...s Category of the truck Maximum permissi ble damaged area IIA 100 cm2 IIB IIB H2 20 cm2 IIB C2H2 IIB H2 C2H2 Please contact your authorised service cen tre for repair or advice if you have any questions Servicing the heating system or air conditioning Replacing the filter mat Loosen the screw 1 Remove the cover 2 2 1 Maintenance 5 Preserving operational readiness 466 56368011531 EN 01 2021 05 ...

Page 483: ...eaning the fresh air inlet The fresh air inlet must be cleaned if the filter mat Is damaged Is incorrectly seated in the filter frame Has not been replaced every two months Remove the filter mat Loosen the screws 1 on the filter frame 2 Remove the filter frame 2 1 1 2 Maintenance 5 Preserving operational readiness 467 56368011531 EN 01 2021 05 ...

Page 484: ... Remove any dust and dirt from the fresh air inlet 1 beneath the filter mat carrier 1 Maintenance 5 Preserving operational readiness 468 56368011531 EN 01 2021 05 ...

Page 485: ...changing wheels or tyres ensure that this does not cause the truck to tilt to one side e g al ways replace right hand and left hand wheels at the same time WARNING Risk of accident due to the use of non approved wheels The quality of the tyres and of the rims affects the stability of the truck Changes must only be made fol lowing consultation with the manufacturer Rim parts must never be changed a...

Page 486: ...tening screws 3 of the drive axle and the wheel fastening nuts of the steering axle are securely in place and re tighten as necessary Observe the torques specified in the main tenance data table Servicing the steering axle Park the truck safely Lubricate the steering axle ENVIRONMENT NOTE Dispose of old grease and contaminated devi ces in accordance with the national regula tions for the country i...

Page 487: ...e battery For information on checking the battery see the chapter entitled Checking the battery condition acid level and acid density Adjusting the warning zone light Switch on the truck Make sure that the parking brake is applied Loosen the nuts 2 to adjust each head light Adjust the headlight 1 The distance from the light bar to the truck must be between 70 75 cm Re tighten the nuts 2 6219_003 2...

Page 488: ...lic hoses for more than two years Do not use hydraulic hoses for more than six years if they are subject to normal wear Do not use hydraulic hoses for more than two years if they are subject to a high level of wear Comply with the specifications of DGUV 113 020 in Germany Outside of Germany observe the national regula tions for the country of use Check pipe and hose connection screw joints for lea...

Page 489: ...Replace pipes if they display the following ab normalities Abrasion Deformation and bending Leaking Maintenance 5 Preserving operational readiness 473 56368011531 EN 01 2021 05 ...

Page 490: ...is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male connector while the truck is switched on except in an emer gency Disconnect the battery male connector Turn t...

Page 491: ...ew Telescopic lift mast NiHo and triple mast 2 0 t 1 6 to 1 8 t 2 0 t 1 6 t 1 8 t 2 0 t 1 2610 3010 2610 2110 2160 1910 23 3 2 3060 3260 2660 3260 2160 2660 2210 2710 1960 2310 25 3 3 2710 2760 2360 29 9 CAUTION Risk of damage If the hydraulic oil level is too low the steering is re stricted and the pump may be damaged If the oil level is too low do not use the truck and contact the authorised ser...

Page 492: ...ce data table Page 457 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Preserving operational readiness for cold store application On trucks for cold store application var iant check all rollers and chains in the lift mast for ease of movement once a week 1 6210_800 020 6210_900 002 Maintenance 5 Preserving oper...

Page 493: ...e centre Checking the fork arms DANGER Risk of explosion If fork arms are used that do not corre spond to the explosion protection regula tions this can lead to spark formation resulting in explosions in the surrounding atmosphere Only use fork arms that are approved for use in potentially explosive areas according to the nameplate of the truck If the cladding is worn do not operate the truck in p...

Page 494: ...service cen tre Perform a visual inspection of the fork arms 1 Check the cladding 2 4 for wear It must satisfy the minimum thickness of 1 mm Check the fork bends 3 for cracks Compare the Miretti job number on the fork arm heads 5 with the data on the name plate of the truck Ensure that only fork arms that comply with explosion protection regulations are fitted Thickness and material of the claddin...

Page 495: ...ecialist welder All straightening work hot and cold on deformed fork arms is forbidden Contact the authorised service centre Checking the reversible fork arms DANGER Risk of explosion If reversible fork arms are used that do not correspond to the explosion protec tion regulations this can lead to spark formation resulting in explosions in the surrounding atmosphere Only use reversible fork arms th...

Page 496: ...l Remove the floorplate Check that the support and springs of the double pedal mechanism are securely posi tioned Check that all screws are sealed with lock ing varnish Checking the battery changeover frame The screw joints and welded seams of the battery changeover frame must be subjec ted to a visual inspection 6327_003 026 Maintenance 5 1000 hour maintenance annual maintenance 480 56368011531 E...

Page 497: ...6 Technical data ...

Page 498: ...ements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clear ance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into ac count and in accordance with EN ISO 3411 In general from the seat position the operator has sufficient space to reach th...

Page 499: ...Dimensions L α C x 2 1 y Q h 2 h 3 h 4 b3 b1 b10 b11 m 2 h 10 h 7 h 1 h 6 m 1 l2 s e β Seat is adjustable 90 mm 1 Fork spacing is adjustable 2 Technical data 6 Dimensions 483 56368011531 EN 01 2021 05 ...

Page 500: ...NOTE Measurements h1 h3 h4 h6 and b1 are cus tomised and can be taken from the order con firmation Technical data 6 Dimensions 484 56368011531 EN 01 2021 05 ...

Page 501: ...Load centre of gravity distance c mm 500 Load distance x mm 374 Wheelbase y mm 1319 Weights Model RX20 14C Type number 6219 Net weight kg 2926 Front axle load laden kg 3826 Rear axle load laden kg 500 Front axle load unladen kg 1498 Rear axle load unladen kg 1428 Wheels chassis frame Model RX20 14C Type number 6219 Tyres Superelastic Tyre size front 180 70 8 Tyre size rear 125 75 8 Number of front...

Page 502: ... Coupling height h10 mm 473 Overall length l1 mm 2661 Length including fork back l2 mm 1861 Overall width b1 mm 1099 Fork arm thickness s mm 40 Fork arm width e mm 80 Fork arm length l mm 800 Fork carriage Standard class form ISO 2328 II A Fork carriage width b3 mm 980 Ground clearance with load below lift mast m1 mm 90 Ground clearance at the middle of the wheelbase m2 mm 114 Aisle width for pall...

Page 503: ... Max climbing capability with load 30 3 Max climbing capability without load 27 9 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 Service brake Electr mech Gradients The values specified in the Performance da ta table as the maximum climbing capability can be used only to compare the performanc...

Page 504: ... capacity K5 Ah 625 Battery weight kg 856 Miscellaneous Model RX20 14C Type number 6219 Working pressure for attachments bar 160 Oil flow for attachments l min 30 Sound pressure level LpAZ Driver s compartment dB A 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 Tow coupling DIN type model Bolt Technical data 6 VDI datasheet RX20 14C with steering turntable 488 56368011531 EN 01 20...

Page 505: ...stance x mm 374 374 374 Wheelbase y mm 1319 1409 1517 Weights Model RX20 16C RX20 16 RX20 16L Type number 6220 6221 6222 Net weight kg 3125 3057 3127 Front axle load laden kg 4160 4112 4133 Rear axle load laden kg 565 545 594 Front axle load unladen kg 1500 1520 1611 Rear axle load unladen kg 1625 1537 1516 Wheels chassis frame Model RX20 16C RX20 16 RX20 16L Type number 6220 6221 6222 Tyres Super...

Page 506: ... 965 Coupling height h10 mm 473 473 473 Overall length l1 mm 2661 2744 2852 Length including fork back l2 mm 1861 1944 2052 Overall width b1 mm 1099 1099 1099 Fork arm thickness s mm 40 40 40 Fork arm width e mm 80 80 80 Fork arm length l mm 800 800 800 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A ISO 2328 II A Fork carriage width b3 mm 980 980 980 Ground clearance with load below...

Page 507: ...Max pulling force without load N 7700 7900 8500 Climbing capability with load 18 6 18 6 18 6 Climbing capability without load 24 24 24 Max climbing capability with load 27 6 28 27 4 Max climbing capability without load 26 27 4 28 7 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 5 7 5 4 5 1 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4...

Page 508: ...ery Standard circuit DIN 43531 B DIN 43531 B DIN 43531 B Battery voltage U V 48 48 48 Battery capacity K5 Ah 625 625 750 Battery weight kg 856 855 1013 Miscellaneous Model RX20 16C RX20 16 RX20 16L Type number 6220 6221 6222 Working pressure for attachments bar 160 160 160 Oil flow for attachments l min 30 30 30 Sound pressure level LpAZ Driver s compartment dB A 66 66 66 Human vibration accelerat...

Page 509: ...0 500 500 Load distance x mm 374 374 388 Wheelbase y mm 1409 1517 1517 Weights Model RX20 18 RX20 18L RX20 20L Type number 6223 6224 6225 Net weight kg 3231 3419 3486 Front axle load laden kg 4440 4450 4860 Rear axle load laden kg 590 769 623 Front axle load unladen kg 1524 1612 1689 Rear axle load unladen kg 1707 1806 1794 Wheels chassis frame Model RX20 18 RX20 18L RX20 20L Type number 6223 6224...

Page 510: ...7 mm 965 965 965 Coupling height h10 mm 473 473 473 Overall length l1 mm 2744 2852 2866 Length including fork back l2 mm 1944 2052 2066 Overall width b1 mm 1149 1149 1149 Fork arm thickness s mm 40 40 40 Fork arm width e mm 80 80 80 Fork arm length l mm 800 800 800 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A ISO 2328 II A Fork carriage width b3 mm 980 980 980 Ground clearance wit...

Page 511: ...pability without load 24 24 18 1 Max climbing capability with load 25 1 25 3 23 Max climbing capability without load 26 28 3 27 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 2 5 8 5 5 5 2 5 8 5 5 5 3 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Electr mech Gradients The values ...

Page 512: ...y K5 Ah 625 750 750 Battery weight kg 855 1013 1013 Miscellaneous Model RX20 18 RX20 18L RX20 20L Type number 6223 6224 6225 Working pressure for attachments bar 160 160 160 Oil flow for attachments l min 30 30 30 Sound pressure level LpAZ Driver s compartment dB A 66 66 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 6 0 6 Tow coupling DIN type model Bolt Bolt Bolt Technical dat...

Page 513: ...ce c mm 500 500 Load distance x mm 374 374 Wheelbase y mm 1429 1537 Weights Model RX20 16P RX20 16PL Type number 6226 6227 Net weight kg 3018 3178 Front axle load laden kg 4098 4121 Rear axle load laden kg 520 657 Front axle load unladen kg 1520 1612 Rear axle load unladen kg 1498 1567 Wheels chassis frame Model RX20 16P RX20 16PL Type number 6226 6227 Tyres Superelastic Superelastic Tyre size fro...

Page 514: ... 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2837 2945 Length including fork back l2 mm 2037 2145 Overall width b1 mm 1099 1099 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 90 Ground clearance at ...

Page 515: ...lity without load 24 24 Max climbing capability with load 27 8 27 6 Max climbing capability without load 27 8 28 9 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as the m...

Page 516: ...ery capacity K5 Ah 625 750 Battery weight kg 855 1013 Miscellaneous Model RX20 16P RX20 16PL Type number 6226 6227 Working pressure for attachments bar 160 160 Oil flow for attachments l min 30 30 Sound pressure level LpAZ Driver s compartment dB A 66 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 6 Tow coupling DIN type model Bolt Bolt Technical data 6 VDI datasheet RX20 16 wit...

Page 517: ...e c mm 500 500 Load distance x mm 374 374 Wheelbase y mm 1429 1537 Weights Model RX20 18P RX20 18PL Type number 6228 6229 Net weight kg 3254 3178 Front axle load laden kg 4439 4435 Rear axle load laden kg 616 543 Front axle load unladen kg 1538 1612 Rear axle load unladen kg 1717 1567 Wheels chassis frame Model RX20 18P RX20 18PL Type number 6228 6229 Tyres Superelastic Superelastic Tyre size fron...

Page 518: ... 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2837 2945 Length including fork back l2 mm 2037 2145 Overall width b1 mm 1149 1149 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 90 Ground clearance at ...

Page 519: ...ility without load 24 24 Max Climbing capability with load 24 8 25 4 Max climbing capability without load 26 28 6 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 2 5 8 5 5 5 2 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as the ma...

Page 520: ...ery capacity K5 Ah 625 750 Battery weight kg 855 1013 Miscellaneous Model RX20 18P RX20 18PL Type number 6228 6229 Working pressure for attachments bar 160 160 Oil flow for attachments l min 30 30 Sound pressure level LpAZ Driver s compartment dB A 66 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 6 Tow coupling DIN type model Bolt Bolt Technical data 6 VDI datasheet RX20 18 wit...

Page 521: ...ce c mm 500 500 Load distance x mm 388 388 Wheelbase y mm 1429 1537 Weights Model RX20 20P RX20 20PL Type number 6230 6231 Net weight kg 3474 3449 Front axle load laden kg 4858 4851 Rear axle load laden kg 616 598 Front axle load unladen kg 1616 1696 Rear axle load unladen kg 1858 1754 Wheels chassis frame Model RX20 20P RX20 20PL Type number 6230 6231 Tyres Superelastic Superelastic Tyre size fro...

Page 522: ...mm 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2851 2959 Length including fork back l2 mm 2051 2159 Overall width b1 mm 1149 1149 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 90 Ground clearance a...

Page 523: ...ity without load 18 1 18 1 Max climbing capability with load 22 9 23 1 Max climbing capability without load 25 1 27 2 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 3 5 8 5 5 5 3 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as th...

Page 524: ... 6 Tow coupling DIN type model Bolt Bolt Eco design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation EU 2019 1781 because these motors do not meet the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors desig...

Page 525: ...battery weight against the information on the nameplate Only use a battery tray that is closed at the bot tom NOTE The batteries for this truck are designed for the special area of application If a battery is to be exchanged or replaced use a structurally identical explosion protected battery with the same characteristics If a battery is replaced with a battery of a different type check that the t...

Page 526: ...ttery requirements for use in poten tially explosive areas Batteries for use in potentially explosive areas are designed and specifically tested in respect of the zones and temperature ranges in which they are to be used The permitted area of use is permanently and clearly indicated on the nameplate of the battery If you have any questions relating to the re quirements contact your authorised serv...

Page 527: ...on on the auxiliary hydraulics dif fers depending on the truck Take this into consideration when selecting the attachment Maximum system pressure Pmax 280 bar Maximum volume flow rate Qmax 30 l min Trigger of the switch valve 12 V 2 A Technical data 6 Information on the auxiliary hydraulics 511 56368011531 EN 01 2021 05 ...

Page 528: ...Technical data 6 Information on the auxiliary hydraulics 512 56368011531 EN 01 2021 05 ...

Page 529: ...ng the triple mini lever and the 5th function 319 Controlling with multi lever operation and the 5th function 311 Controlling with multi lever operation and the 6th function 311 Controlling with the fingertip 324 Controlling with the fingertip and the 5th function 326 General controlling 302 Information on the auxiliary hydraulics 511 Load capacity 300 Mounting 300 Picking up a load 331 Safety inf...

Page 530: ...trical system 428 Cleaning the truck 425 Flame proof enclosure 425 Cleaning the windows 429 Clean the truck After cleaning 430 Climbing into the truck 97 Climbing out of the truck 97 Clipboard 349 Cold store application 361 Batteries 363 Operation 361 Types of application 361 Commissioning 22 Competent person 41 Condition of the roadways 191 Consumables 64 Disposal 67 Safety information for handli...

Page 531: ...fts 278 Dynamic Load Control 1 169 Dynamic Load Control 2 170 E EC declaration of conformity in accordance with Machinery Directive 7 Efficiency and drive modes 182 Electric parking brake Emergency actuation 382 Electrostatic charge Safety information 99 Emergencies Actuating the reset button 376 Emergency actuation of the electric parking brake 382 Truck tipping over 378 Using the emergency hamme...

Page 532: ...ng the quadruple mini lever and the 5th function 291 Depressurising using the triple mini lev er and the 5th function 289 Exiting the wizard 297 Need to depressurise 281 Special feature for clamping attach ments 296 Wizard for depressurising 282 I Improper use 24 Information about the documentation 30 Information for carrying out maintenance 445 446 Maintenance timeframe 447 Next maintenance inter...

Page 533: ...ns 440 Maintenance data table 457 Battery 457 Controls joints 457 Drive axle 458 Electrical system 457 Flame proof enclosure 459 General lubrication points 457 Hydraulic system 458 Lift mast 459 Load chains 459 Steering axle 458 Tyres 458 Washer system 459 Maintenance personnel for batteries 445 Maintenance work without special qualifi cations 445 Malfunctions during lifting mode 254 Malfunctions ...

Page 534: ...lay operating unit 207 Parking brake mechanical Applying 204 Parking the truck securely 225 Personnel qualifications 444 Picking up loads 259 Place of use 26 Pre Shift Check All questions 131 Description 129 History 134 Process 130 Question sequence 133 Shift start 136 Truck restrictions 140 Precision load measurement 175 Preserving operational readiness 460 Procedure if truck tips over 378 Proced...

Page 535: ...nction due to cold 117 Replacement after an accident 463 Unlocking 117 Servicing the heating system or air condi tioning 466 Cleaning the fresh air inlet 467 Replacing the filter mat 466 Set values 441 Shake function 272 Double mini lever 274 Fingertip switch 275 Joystick 4Plus 274 Quadruple mini lever 275 Triple mini lever 275 Shelves 76 Shock recognition 332 Shutting down and restarting Safety i...

Page 536: ...ing platforms 28 V Variant Ceiling sensor 336 Variants Access authorisation for the fleet man ager 125 Access authorisation with PIN code 123 Air conditioning 348 Automatic mast vertical positioning 162 164 266 Blue Q 182 Clamp locking mechanism 307 Clipboard 349 Cruise control 220 Driver profiles 143 Dynamic Load Control 1 169 Dynamic Load Control 2 170 FleetManager 332 Fork extension 250 Fork we...

Page 537: ...arts 46 Warning zone light Adjusting 471 Operating 161 Wearing parts 453 Wedging the wheels 432 Wheel chock 228 Wheels and tyres Checking the condition and wear of the tyres 470 Checking wheel fastenings 470 Servicing 469 Usage in winter weather conditions 470 Windscreen wipers and washers Switching on and off 332 Winter tyres 470 Working at the front of the truck 442 Working on the electrical equ...

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