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Still FM-X EW Series, Original Instructions Manual

The Still FM-X EW Series is a state-of-the-art industrial forklift, equipped with advanced features for effortless operation. Ensure optimal performance and safety by referring to the Original Instructions Manual. Download the comprehensive manual for free at manualshive.com to have all the necessary information at your fingertips.

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Table of contents

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Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Cleaning panes of glass and mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
After cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Crane loading (standard truck with overhead guard) . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Crane loading (trucks with a cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Re-commissioning after shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

5 Maintenance

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Maintenance - 1000 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Additional maintenance guidelines for using the truck in a cold store - 500 hours or

every 12 weeks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 298
Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Maintaining operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Checking the driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Maintaining wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Greasing the lift mast and roller tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Checking the battery change frame (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Replacing the heating system filter for the cab (variant) . . . . . . . . . . . . . . . . . . . . . . . . 304
Maintenance for trucks used in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Maintenance tasks for lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

50988078001 EN - 10/2018

IX

Summary of Contents for FM-X EW Series

Page 1: ...ach trucks FM X FM X N FM X W FM X EW Li ion FM X 10 FM X 12 FM X 14 FM X 17 FM X 20 FM X 20 HD FM X 25 1900 1901 1902 1903 1904 1905 1906 1907 1908 1909 1910 1914 1915 1916 1917 1918 1919 1920 1921 1922 50988078001 EN 10 2018 ...

Page 2: ......

Page 3: ...ies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for the safe operation of industrial trucks Information on the use of industrial trucks Information on transport initial commis sioning and storage of industrial trucks Internet address a...

Page 4: ......

Page 5: ...on about the documentation 12 Documentation scope 12 Supplementary documentation 13 Issue date and topicality of the operating instructions 14 Copyright and trademark rights 14 Explanation of information symbols used 14 List of abbreviations 15 Defining directions 17 Schematic views 18 Environmental considerations 19 Packaging 19 Disposal of components and batteries 19 2 Safety Definition of respons...

Page 6: ...t regular inspections on the truck 44 Insulation testing 44 Safety regulations for handling consumables 45 Permissible consumables 45 Oils 46 Hydraulic fluid 47 Battery acid 48 Brake fluid 49 Disposal of consumables 50 Commissioning the FleetManager variant 51 Activating the access control after delivery of the truck 51 Emissions 51 3 Overviews Overview 56 Overview of the driver s compartment 57 She...

Page 7: ...rrect function 91 Lighting 92 STILL SafetyLight variant 92 Switching the working spotlights variant on and off 93 Efficiency and drive modes 94 Blue Q efficiency mode 94 OPTISPEED Continuously variable reduction in driving speed or hydraulic functions variant 94 Driving 96 Safety regulations when driving 96 Roadways 98 Side chassis supports 101 Enabling truck functions using the foot switch and seat...

Page 8: ... loads 140 Danger area 142 Transporting pallets 143 Transporting suspended loads 143 Picking up a load 144 Transporting loads 147 Setting down loads 149 Driving on upward and downward gradients 151 Driving onto lifts 151 Attachments 153 Fitting attachments 153 Releasing the pressure from the auxiliary hydraulics 155 General instructions for controlling attachments 156 Controlling attachments varia...

Page 9: ...ry change frame 181 Battery replacement area 182 Lift height preselector easy Target variant 184 General 184 Definition of terms 185 AUTO MODE function 186 Operating the lift height preselector 189 Teach in general 192 Performing a teach in 193 easy Target easy Target Plus variants 196 Approaching target heights using easy Target 198 Positioning the fork horizontally using easy Target Plus 199 Cab ...

Page 10: ...on batteries GGS Li ion 48 V BG4 9 8 kWh and 39 2 kWh 234 Regulations for storing lithium ion batteries 235 Checking the battery charge status lithium ion battery 236 Charging the lithium ion battery upon delivery 238 Charging the lithium ion battery 239 Recommissioning the lithium ion battery following deep discharge 241 Replacing and transporting the battery 242 Commissioning batteries that are ...

Page 11: ...eral maintenance information 289 Personnel qualifications 289 Information for carrying out maintenance 290 Maintenance 1000 hours year 293 Maintenance 3000 hours every two years 297 Additional maintenance guidelines for using the truck in a cold store 500 hours or every 12 weeks 297 Ordering spare parts and wearing parts 298 Quality and quantity of the required operating materials 298 Maintenance d...

Page 12: ...DI datasheet for FM X 14 Li ion N W EW 313 VDI datasheet for FM X 17 Li ion N W EW 318 VDI datasheet for FM X 20 Li ion N W EW 323 VDI datasheet for FM X 20 HD Li ion 328 VDI datasheet for FM X 25 Li ion W EW 332 Wheels and tyres 335 Battery specifications for lithium ion batteries 336 X 50988078001 EN 10 2018 ...

Page 13: ...1 Foreword ...

Page 14: ...missioning the truck This will prevent accidents and ensure that the warranty remains valid CE Symbol CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is confirmed by the issued EC declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addit...

Page 15: ...113 Hamburg Germany We 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 50988078001 EN 10 2018 3 ...

Page 16: ... switch 2 pieces not for trucks with the FleetManager or PIN code variants Key for cab variant Hexagon socket wrench for emergency lowering in the driver s compartment below the steering wheel Battery change frame variant 4 50988078001 EN 10 2018 ...

Page 17: ... 1000 1150 1300 1400 1450 1500 1600 1700 mm 400 600 10200 9800 9500 9300 9000 8750 8300 7100 X 15mm X 17 12 1 15 13 7 18 2 6 4 7 17 12 9 10 11 14 13 8 1 2 18 15 16 2 3 4 5 6 5 5 5 14 16 BATTERIESERVICE Nächste Prüfung 50634391022 STILL GmbH Hamburg Berzeliusstraße 10 22113 Hamburg Tel 01804 784 55 24 Ihr STILL Service 9 3 50988078001 EN 10 2018 5 ...

Page 18: ...ion Read the oper ating instructions Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V D ...

Page 19: ...or Lithium Ion Batteries Do not crush Do not heat or incinerate Do not short circuit Do not dismantle Do not immerse in any liquid it may vent or rupture 8 1 9 10 11 12 13 14 15 16 17 7 6 5 2 3 4 Nameplate of a lithium ion battery NOTE The CE labelling confirms compliance with the EC machinery directive and with all regulations applicable to the lithium ion battery 1 Nameplate 2 Manufacturer 3 Addr...

Page 20: ...uitable for lifting transporting and stacking loads The truck may only be used for its proper purpose as set out and described in these operating instructions 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 regulatory authorities must be obtained beforehand to prevent haz ards The maxim...

Page 21: ...g responsible persons operating company and driver Use for purposes other than those described in these operating instructions is prohibited 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 The truck may not be operated in areas where there is a risk of fire explosion or corrosion or in areas that are particularly...

Page 22: ...ing company must ensure that sufficient fire protection is available for the rel evant application in the truck s surroundings Depending on the application additional fire protection must be provided on the truck If in doubt contact the relevant authorities NOTE Please observe the definition of the following responsible person operating company Parking in temperatures below 10 C CAUTION Batteries can ...

Page 23: ...rking platforms is regulated by na tional 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 national regulatory authorities 50988078001 EN 10 2018 11 ...

Page 24: ...er requirements UPA are documented in separate operating instructions If you have any questions please contact your authorised service centre Enter the production number and year of manufacture from the nameplate in the space provided Production number Year of manufacture Please quote the production number in all technical enquiries Each truck comes with a set of operating instructions These instr...

Page 25: ...the authorised service centre Supplementary documentation Unlike the standard equipment and the vari ants this truck may be fitted with unplanned equipment UPA This UPA may be for example Special sensors Special attachments Towing devices Customer specific attachments In this case the truck is supplied with addi tional documentation This may be in the form of an insert or separate operating instruct...

Page 26: ...ontact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts except with the express written approval of the manufacturer Explanation of information symbols used DANGER Indicates procedures that must be strictly adhered to in order to ...

Page 27: ...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 prevention regulations CE Communauté Européenne Confirms conformity with product specific European directives CE mark CEE C...

Page 28: ...rk 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 SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without ...

Page 29: ...d direction backwards 3 Travelling in the drive direction forwards 4 Movements of the reach carriage Extending the reach carriage in the load direction 5 Retracting the reach carriage in the drive direction 6 Tilting the lift mast or fork Backward tilt 7 Forward tilt 8 The driver sits crosswise to the drive direction 50988078001 EN 10 2018 17 ...

Page 30: ... reach truck are used NOTE These schematic views are not representative of the structural state of the documented truck The views are used solely for the purpose of clarifying procedures View of the display operating unit NOTE Views of operating statuses and values on the display operating unit are examples and partly dependent on the equipment on the truck As a result the displays shown of the ac...

Page 31: ...properly after delivery of the truck Disposal of components and batteries 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 dispo sing of batteries ENVIRONMENT NO...

Page 32: ...1 Foreword Environmental considerations 20 50988078001 EN 10 2018 ...

Page 33: ...2 Safety ...

Page 34: ...eer or a person who fulfils the following requirements A completed vocational qualification that demonstrably proves their professional expertise This proof should consist of a vocational qualification or a similar document Professional experience indicating that the qualified person has gained practical experience of industrial trucks over a proven period during their career During this time this per...

Page 35: ...trained in accordance with BGG General Employers Liability Insurance Association Act 925 Observe the national regulations for your country Driver rights duties and rules of be haviour The driver must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety helmet industrial goggles and gloves...

Page 36: ...e aforementio ned substances are not permitted to perform work of any kind on or with the truck Prohibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key 24 50988078001 EN 10 2018 ...

Page 37: ...ion batteries variant If this truck is equipped with a lithium ion battery variant rather than a conventional lead acid battery the following special notes apply for the operating company and driver DANGER Risk of explosion Heating to over 80 C mechanical stress and incorrect use may cause the battery to explode Never heat the battery to over 80 C or expose it to a naked flame Do not subject the ba...

Page 38: ...p WARNING Risk of burns due to hot surfaces The battery has an integrated brake resistor that can heat up to over 100 C during operation It can take several hours for the brake resistor to cool down to a safe temperature Do not touch the hot area 1 The position of the brake resistor depends on the battery model Observe the position of the warning sign WARNING Risk of injury Risk of injury if the s...

Page 39: ...ith humidity water or battery venting a fire or an explosion can occur depending on the surrounding circumstances The position of the safety valve 2 on the battery depends on the battery group Touching live components can lead to an electric shock which can have thermal or paralysing effects The latter can cause ven tricular fibrillation cardiac arrest or respiratory paralysis leading to death If a ...

Page 40: ...y by lithium ion batteries Observe the national regulations for the country in which the truck is being used Driver qualification The following qualification requirements for the driver are in addition to the conditions described in the chapter entitled Definition of responsible persons Driver section The driver must be trained in the operation of the lithium ion battery Only trained drivers may driv...

Page 41: ...re contact your authorised service centre prior to making any modifica tions or engaging in any such work Changes that will adversely affect stability load capacity safety systems etc must not be made without the manufacturer s approval The truck may only be converted with written approval from the manufacturer Approval from the relevant authority must be obtained where applicable In addition chang...

Page 42: ...ssembly instructions associated with the change must be archived and remain accessi ble at all times The capacity rating plate decal information hazard warnings and the operating instruc tions must be checked to ensure they are consistent with the changes and modified if required The modification must be designed checked and implemented by a design office that specialises in industrial trucks in acco...

Page 43: ...guard or the weather protection cab cold store cab DANGER Risk of explosion from additional bores on the truck chassis weather protection cab or cold store cab Explosive gases can escape and lead to potentially fatal injuries if they explode Sealing bores with plugs is not sufficient to prevent gas from escaping Do not drill any additional holes in the truck chassis weather protection cab or cold s...

Page 44: ...weight of the person who may also slip and suffer injury Do not step on the lateral cover sheets Warning regarding non original parts Original parts attachments and accessories are specially designed for this truck We specifically draw your attention to the fact that parts attachments and accessories supplied by other companies have not been tested and approved by STILL CAUTION Installation and or ...

Page 45: ...turer s written approval All electrical system interventions must be documented Even if they are removable roof panels may not be removed as they are designed to protect against small falling objects Wheels and tyres DANGER Risk to stability Failure to observe the following information and instructions can lead to a loss of stability The truck may tip over risk of accident The following factors ca...

Page 46: ...f other wheels are to be used authorisation from the manufacturer must be obtained beforehand Contact your authorised service centre regarding this matter Medical equipment WARNING Electromagnetic interference may occur on medical devices Only use equipment that is sufficiently protected against electromagnetic interference Medical equipment such as pacemakers or hearing aids may not work properly ...

Page 47: ...g tempe ratures over 80 C and heavy contamination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper installation of an accumulator results in an elevated risk of injury Before starting work on the accumulator it must be depressurised Contact the authorised service centre Length of the fork arms D...

Page 48: ... principles for safe operation 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 36 50988078001 EN 10 2018 ...

Page 49: ...cident or breakdown etc WARNING All persons that are in the vicinity of the truck must be instructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regulati ons in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as g...

Page 50: ...ect operation and losing stability can never be excluded The loss of stability can be avoided or min imised by the following actions Always secure the load against slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as centrally as possible with the truck and transport in t...

Page 51: ...sk time the truck is used in a manner that falls outside the scope of normal use and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci dents 50988078001 EN 10 2018 39 ...

Page 52: ...only for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when using working platforms Compliance with national regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability insurance associations Impaired visibilit...

Page 53: ...d labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note German ...

Page 54: ...ndustrial Safety and Health BetrSichV employers liability insurance association regulation 104 and the operating instructions O German Ordinance on Industrial Safety and Health BetrSichV and employers liability insurance association regulation 104 With driverless transport systems Roadway quality inadequate Clean clear driveways O German Ordinance on Industrial Safety and Health BetrSichV Load car...

Page 55: ...e hazard assessment At tachments possess their own CE labelling and likewise are not included for that reason The operating company must however select the type and equipment of the trucks so as to com ply with the local provisions for deployment The result must be documented 6 Arb SchG In the case of truck applications involv ing similar hazard situations the results may be summarised This overvi...

Page 56: ... 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 responsible for ensuring that any defects are remedied without delay Notify your authorised service centre NOTE In addition observe the national regulations for the country of use Insulation test...

Page 57: ...ruck Nominal voltage 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 regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relating to consumables may result in a risk of injury death or damag...

Page 58: ...er and then consult an eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There ...

Page 59: ...ot spill the fluids Follow the statutory regulations Do not allow the fluids to come into contact with hot engine parts WARNING These fluids are pressurised during operation of the truck and are hazar dous to your health Do not allow the fluids to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the skin is particularly danger ous if these fluids escape at high...

Page 60: ...e battery acid at all costs In case of injury seek medical advice immediately WARNING Battery acid contains dissolved sulphuric acid This is corrosive When working with battery acid use appropriate PSA rubber gloves apron protection goggles When working with battery acid never wear a watch or jewellery Do not allow any acid to get onto clothing or skin or into the eyes If this does happen rinse im...

Page 61: ...arting work Avoid prolonged or intensive skin contact In the event of skin contact clean the wetted skin with water and soap and subsequently apply a skin care product Prevent contact with the eyes In the event of contact with the eyes wash out the affected eye s with clean water for ten minutes and then ask a doctor for advice Change clothing soiled with brake fluid as soon as possible CAUTION Bra...

Page 62: ... truck is being used Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair maintenance and cleaning must be collected properly 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 the purpose Care must be taken to minimise any environmental pollution Soak up any ...

Page 63: ... truck to a different access control contact your authorised service centre The FleetManager regulates the access authorisation to the truck via a PIN code access chip or access card This means that the truck is effectively protected against unauthorised access The system can only be activated at the customer s premises as it uses essential customer data Therefore at the time of delivery the truck...

Page 64: ...8 Idling 58 Driving 24 However the noise levels indicated on 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 noise pollution If necessary these noise emissions must be determined by the operating company directly at the workplaces under the actual conditions there additional noise sources special ap...

Page 65: ... operating company at the actual place of use in order to consider all additional influences such as driving route intensity of use etc Battery DANGER Risk of explosion due to flammable gases During charging lead acid batteries release a mixture of oxygen and hydrogen oxyhydrogen gas This gas mixture is explosive and must not be ignited Make sure that there is always sufficient ventilation in working...

Page 66: ...2 Safety Emissions 54 50988078001 EN 10 2018 ...

Page 67: ...3 Overviews ...

Page 68: ...w 5 6 7 8 4 3 2 1 9 10 11 1 Overhead guard 2 Driver s compartment 3 Lift mast 4 Fork arms 5 Load wheel 6 Battery frame 7 Battery 8 Side support tilt protection 9 Control compartment 10 Drive wheel 11 Step 56 50988078001 EN 10 2018 ...

Page 69: ...potlight push button variant 5 Card reader or keypad for enabling the truck variant 6 Key switch or push button variant 7 Compartment reserved for add on sys tems 8 Display and operating unit 9 Cup holder for max 1 5 l bottles 10 Operating devices for hydraulic and traction functions 11 Emergency off switch 12 Push button for additional hydraulic func tions 13 Accelerator pedal 14 Brake pedal 15 F...

Page 70: ...e shelves 1 4 or out of the cup holder 2 Objects that fall into the footwell during travel as a result of steering or braking can slip between the pedals 3 and stop them working correctly Subsequently it may not be possible to brake the truck when necessary Bottles of 1 5 l or smaller may be stored in the cup holder Make sure that stored objects cannot fall from the shelves when the truck is start...

Page 71: ...ments Display and operating unit 1 Display of the operating statuses 2 Keypad for lift height preselection variant or PIN code access variant 3 Keypad for onboard diagnostics parame terising 4 Drive programme button P1 P4 5 Blue Q button 6 Parking brake button 50988078001 EN 10 2018 59 ...

Page 72: ...h drive direction 3 Time display digital 4 Joystick 4Plus operating error 5 Multifunction indicator Display is dependent on truck parameters e g driving speed reach position lift height 6 Display field for the selected default setting for the lift height preselector Display is only active in the lift height preselector variant 7 Display field for the current height in the main lift Display is only a...

Page 73: ...he truck seat switch 21 Parking brake activated 22 Seat belt on driver s seat not fastened not series production truck 23 Foot switch required 24 Symbol for FleetManager variant or PIN code access variant 25 Battery water level display too low variant 26 Battery not locked Display messages Event related operating information and malfunctions are shown in the display field 2 In addition the Caution ...

Page 74: ...stem If the message is still displayed after cleaning contact your authorised service centre EMERGENCY SWITCH Emergency off switch of the truck is actuated All truck functions are disabled Switch off the truck Unlock the emergency off switch Switch the truck on again EMERGENCY OPERATION Only for trucks with FleetMan ager variant Truck functions are restricted Check the FleetManager documentation T...

Page 75: ...and hydraulic speed are restricted Move the joystick 4Plus fingertip switch to the inactive position for 2 seconds 801 Lithium ion battery is in emergency operation Driving speed and hydraulic speed may be restricted Switch off the truck If the message is still displayed after restarting contact your authorised service centre 802 Messages relating to the lithium ion battery Battery service required...

Page 76: ...g contact your authorised service centre S5962 Insufficient temperature of the lithium ion battery All truck functions are disabled Observe the permissible ambient temperature for the battery Switch off the truck If the message is still displayed after restarting contact your authorised service centre S6620 Internal error in the lithium ion battery All truck functions are disabled Restart the truck...

Page 77: ...predefined ex works within the different authorisation levels Individual access rights can be moved to a higher authorisation level Level 1 driver Access Press the OK button for two seconds Authorisations Set the time can be moved to a higher authori sation level Set the date can be moved to a higher authori sation level Set the language can be moved to a higher authorisation level Level 2 fleet man...

Page 78: ...pass word authorisation levels 2 and 3 First of all press the OK and ESC buttons to open the input screen for the password at the required authorisation level Press OK and ESC for four seconds The display and operating unit shows the input screen for the password The first input position flashes PASSWORD _ _ _ _ A valid password consists of four digits from 0 to 9 Edit the digits one at a time using...

Page 79: ...entered incorrectly a third time the input screen is locked for five min utes A corresponding message appears on the display and operating unit PASSWORD DENIED 5 min The message appears for three seconds and then the display and operating unit shows the input screen for the password again If the password is entered again during the locked period the password is always rejected The remaining time fo...

Page 80: ...display flashes Press the arrow buttons to edit a value or status Briefly press the ESC button to return to the previous input position to make a correction Press and hold the ESC button for two seconds to cancel the current entry Press the OK button to confirm the entry Overview of the menu structure Authori sation level Main menu Submenu 1 2 3 CONFIGU RATION 1 2 3 Edit select Comment LANGUAGE List ...

Page 81: ...Edit select Comment HW1 HW2 SW1 SW2 SW3 VX XX UNITS DISTANCE km miles LOAD kg lb ERROR LIST MODE CUSTOMER SERVICE DEVICE X A Z all devices TYPE X 0 current error 1 since reset 2 since deletion X XX XX Error e g A 12 12 ADJUST Teach in Lift heights SERVICE IN XXX h ERROR RESET A Z all devices 50988078001 EN 10 2018 69 ...

Page 82: ...us 1 the temperature 2 and the charging status 3 of the lithium ion battery See the Display chapter in the operating instructions provided by the battery manu facturer BMZ Operating devices for hydraulic and traction functions Different versions of the operating devices are available for operating the truck s hydraulic and traction functions The truck can be equipped with the following operating d...

Page 83: ...on 6 Tilt rocker button 7 Signal horn button 8 Enable push button variant 9 Load measurement push button variant 10 Transition shift tilt centre position push button variant 11 Reserve 12 Pictograms for operation of the 5th and 6th hydraulic function variant 13 Pictograms for operation of the basic hy draulic functions 14 Pictograms for operation of the 3rd and 4th hydraulic function 15 LED indica...

Page 84: ...er 3 Tilt operating lever 4 Transition shift operating lever 5 Emergency off switch 6 Enable push button variant 7 Load measurement push button variant 8 Transition shift tilt centre position push button variant 9 Reserve 10 Auxiliary hydraulics push button variant 11 Drive direction switch 12 Signal horn button 72 50988078001 EN 10 2018 ...

Page 85: ...4 Operation ...

Page 86: ...fficient to prevent gas from entering Have unused bores in the cab wall sealed by the authorised service centre WARNING Risk of accident due to damage or other defects on the truck or on the attachment variant Damage to the truck or the attachment variant can lead to unpredictable and dangerous situations Do not remove or deactivate safety systems or switches Do not change any predefined set values ...

Page 87: ...d Ensure that the truck is safe for operation each day before it is used Component Course of action Fork arms general lifting accessories Perform a visual inspection for deformation and wear for example bent broken significant wear Check the condition and function of fuses 1 to prevent lifting and shifting Roller tracks 2 Make sure that there is a film of grease Load chains Perform a visual inspecti...

Page 88: ...heck the battery lock on the internal roller channel variant for condition and function Close the battery lock Battery frame Perform a visual inspection for integrity e g cracks or breaks Check that the battery frame is fully retracted to wards the drive side and is securely locked in this position Battery connection assembly Perform a visual inspection for integrity and defor mation Check the con...

Page 89: ...the truck if there is any damage or defects In this case contact your authorised service centre Any other necessary tasks are summarised under their own headings e g adjusting the driver s seat Climbing into and out of the truck WARNING Risk of injury when climbing into and out of the truck due to slipping or becoming stuck If the footwell cover is very dirty smeared with oil or iced over there is...

Page 90: ...esigned to be used for climbing in and out of the truck and may be damaged due to misuse Only use the fittings specifically designed for the purpose of climbing into and out of the truck 1 2 3 4 The truck must be at a standstill when climbing into or out of the truck To assist with climbing into and out of the truck the footwell must be used as a step 4 and the handle 1 must be used for support The ...

Page 91: ... seat and the seat backrest so that all operating devices can be actuated safely Ensure that the seat and the seat backrest are securely 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 head and the lower edge of the roofing sheet must be at least 40 mm NOTE Observe any separate operat...

Page 92: ...s seat is securely engaged 2 Adjusting the seat backrest Do not put pressure on the seat backrest while disengaging it Lift the lever 2 and hold Push the seat backrest into the desired position 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 structural condition of the truck 80 50988078001 EN 10 2018 ...

Page 93: ...elected when the arrow 4 is in the centre of the inspection window If the seat does not move any further when you pump the weight adjusting lever the minimum or maximum weight setting has been reached Return the weight adjusting lever to the initial central position before each new lift a click can be heard Fully fold in the weight adjusting lever once adjustment is complete 5 Adjusting the lumbar...

Page 94: ...t into the desired position To remove the backrest extension move it past the end stop by jolting it upwards 7 Switching the seat heater variant on and off NOTE The seat heater only functions if the seat contact switch is active i e when the driver is sitting on the driver s seat Switch the seat heater 7 on or off using the switch 82 50988078001 EN 10 2018 ...

Page 95: ...ding notch 1 Adjusting the steering column DANGER Risk of accident Ensure that the steering column is securely attached Never adjust the steering column while driving Push the steering column adjustment lever 1 forwards to release the steering column lock The lever can be moved back if it interferes with the panelling in front during adjustment Move the steering column horizontally and vertically ...

Page 96: ...mponents may become damaged due to the effects of frost Water expands when it freezes If there is no anti freeze in the washer system variant the system may become damaged due to the accumulation of ice in freezing conditions Always use washer fluid containing anti freeze Observe the maximum fill level of the reservoir approx 10 mm below the filler neck Close the filler cap Operate the washer system u...

Page 97: ...played briefly until the truck controllers have started up completely When the truck is switched on the fork carriage and the reach carriage must initially be in the basic position In the basic position the fork carriage is fully lowered and the reach carriage is fully retracted This ensures that the electronic support systems which prevent the truck from tipping over with a raised load are recalib...

Page 98: ...ge is shown in the display field NOTE After connecting a partially charged battery If the current battery charge level is higher than the value stored most recently by the truck the most recently stored value is initially displayed The correct battery charge levelis notdisplayeduntilthecurrent value drops below the most recently stored value Steering position 2 The symbol for the neutral steering p...

Page 99: ...NOTE If malfunctions are displayed refer to the information in the chapter entitled Display messages Access authorisation with PIN code variant The truck functions can be activated using a five digit PIN code A button is used in place of the key switch Press the button to activate the truck After the button is pressed a message appears in the display and the symbol flashes The five digit numerical co...

Page 100: ... a risk of accident Do not commission the truck with a defective brake system Checking the service brake There must be a distance of at least 60 mm between the pressure point and the brake pedal stop Accelerate the truck without a load in a clear area see Driving chapter Press the brake pedal firmly see the chapter entitled Operating the service brake The truck must decelerate noticeably Checking t...

Page 101: ...e electromagnetic parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away The truck must not be parked on a slope In emergencies secure with wedges on the side facing downhill Only leave the truck once the parking brake has been applied Accelerate the truck to walking speed Ensure that you have a secure grip on the truck hold onto the steering wheel with yo...

Page 102: ...90 1 Checking the emergency off function Accelerate the truck to walking speed Ensure that you have a secure grip on the truck hold onto the steering wheel with your left hand Press the emergency off switch 1 The parking brake is applied The truck must be braked to a standstill with a noticeable delay Pull the emergency off switch 1 upwards until it is unlocked The truck performs an internal self ...

Page 103: ...ction switches off automatically Tilt the fork carriage or the entire lift mast towards the drive side The fork carriage or the entire lift mast must tilt fully to the drive side and move gently as far as the end stop Push the transition shift tilt centre position push button 1 on the right hand side In the display operating unit the arrows 2 on the transition shift symbol must flash until the cent...

Page 104: ...ind junctions STILL SafetyLight is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations It projects one or more light blue light spots approximately 5 meters in front of or behind the truck and thus warns others about the approaching truck WARNING Danger of damage to eyes when looking into the STILL SafetyLight Do not look into the STILL SafetyLight 92 50...

Page 105: ...ve the truck fitted with one or several working spotlights 1 to improve illumination of the working area Switch on the truck Push the button 2 for the working spot lights The working spotlights 1 are switched on Push the button 2 again to switch the working spotlights off again 50988078001 EN 10 2018 93 ...

Page 106: ...ity Pulling force Braking characteristics Switching the Blue Q efficiency mode on and off Press the Blue Q button 2 The Blue Q symbol 1 appears in the display and operating unit which means that the Blue Q efficiency mode is switched on Pressing the Blue Q button once again turns the Blue Q efficiency mode off again OPTISPEED Continuously vari able reduction in driving speed or hydraulic functions va...

Page 107: ... if cornering speed is too high If the controller is switched off or fails while driving the driving speed will no longer be reduced on cornering Do not switch off the truck while driving Actuate the emergency off switch in emergen cies only Always adapt your driving style to the conditions Do not take risks with safety In the following situations the truck may overturn in extreme cases Cornering ...

Page 108: ...t height preselector Transition shift centre position Tilting centre position Driving Safety regulations when driving Driving conduct The driver must comply with the highway code when driving within the plant The speed must be appropriate to the local conditions For example the driver must drive slowly around corners in and around tight passage ways when driving through swing doors at blind spots ...

Page 109: ...timedia and communication devices or listening to these devices at an excessive volume during travel or when handling loads There is a risk of accident Do not use devices during travel or when hand ling loads Set the volume so that warning signals can still be heard WARNING In areas where the use of mobile phones is prohi bited it is absolutely not permitted to use a mobile phone or radio telephon...

Page 110: ...ys be clean and free of ice 1 Panoramic mirror The panoramic mirror 1 may only be used for observing the road area on the load side of the truck and not for travelling in the load direction Extra care should be taken when travelling in the load direction if you are using visual aids The panoramic mirror must always be clean and free of ice Any damage to the panoramic mirror that could restrict the...

Page 111: ...e g on ramps must not be exceeded when using the truck under any circumstances Max permissible gradient in Truck type With load Without load FM X 10 FM X 12 FM X 14 FM X 17 FM X 20 FM X 25 15 20 FM X 10N FM X 12N FM X 14N FM X 17N FM X 20N 15 20 Picking up a load putting down a load stack ing or unstacking is only permitted on a hori zontal level surface Warning in the event that components projec...

Page 112: ...est points of the truck or the load and the fixed elements of the surrounding area The height is based on the overall height of the truck s lift mast and the dimensions of the load Rules for roadways and the working area It is only permitted to drive on routes autho rised for traffic by the operating company see chapter Responsible persons or its rep resentatives Traffic routes must be free of obstac...

Page 113: ...y tray WARNING Risk of accident due to limited residual load capa city of the truck The side chassis supports have an important impact on the residual load capacity of the truck If the truck frequently bottoms out check the support distance X regularly and have it adjusted by the authorised service centre if necessary Enabling truck functions using the foot switch and seat switch The foot switch a...

Page 114: ... accelerator pedal has not The accelerator pedal is then actuated The switches are all functioning correctly If the switch malfunctions during operation the truck is braked to a standstill or to a speed of 2 5 km h according to truck type and a corresponding message appears in the display and operating unit NOTE Once the truck has been switched on the parking brake must first be released one time T...

Page 115: ...dstill or to a speed of 2 5 km h according to truck type and a corresponding message appears in the display and operating unit If the seat switch is defective or if the switch was not actuated at least once within an eight hour period the controller also assumes that there is a malfunction If the problem persists after the driver s seat has been occupied once and then vacated please contact the au...

Page 116: ...is delivered it is set to drive programme 4 P4 The factory set parameters are shown in the table Code 1 2 3 4 Vmax km h 10 12 14 14 m s2 0 6 1 1 1 4 1 8 m s2 0 8 1 0 1 0 1 2 NOTE Only the drive programme can be changed The characteristic for the relevant drive pro gramme can only be changed by authorised service personnel Adjustment process The drive profile changes each time the P button 1 is pres...

Page 117: ... the drive direction switch fingertip NOTE Thedrive direction canalsobechangedduring travel Your foot can remain on the accelerator pedal The truck decelerates and is then accelerated again in the opposite direction reversing After actuating the drive direction switch the drive direction is shown on the display and operating unit 2 Neutral position If the truck is stopped for an extended period sel...

Page 118: ...avelling in the load direction press the drive direction switch 1 up For travelling in the drive direction press the drive direction switch 1 down 1 Actuating the drive direction switch fingertip For travelling in the load direction press the drive direction switch 1 on the right hand side For travelling in the drive direction press the drive direction switch 1 on the left hand side 106 50988078001...

Page 119: ...when driving The driver s seat is equipped with a seat switch In the event of an operating error or malfunction see the chapter entitled Enabling truck functions using the foot switch and seat switch Lift the fork carriage until the necessary ground clearance is achieved Tilt the lift mast backwards Release the parking brake Select the desired drive direction The selected drive direction is shown ...

Page 120: ...l Select the desired drive direction Actuate the accelerator pedal The truck will travel in the selected drive direction NOTE The drivedirection can also be changed during travel Your foot can remain on the accelerator pedal while doing so The truck decelerates and is then accelerated again in the opposite direction reversing NOTE In the event of an electrical fault with the accelerator the drive ...

Page 121: ...ving The driver s seat is equipped with a seat switch In the event of an operating error or malfunction see the chapter entitled Enabling truck functions using the foot switch and seat switch Lift the fork carriage until the necessary ground clearance is achieved Tilt the lift mast backwards Release the parking brake 2 1 To travel in the load direction press the right hand accelerator pedal 1 To t...

Page 122: ...he parking brake anti roll brake for slopes The truck will then begin to creep downhill slowly Changing the drive direction Remove foot from actuated accelerator pedal Actuate the accelerator pedal for the opposite direction The truck will travel in the selected drive direction NOTE In the event of an electrical fault with the accelerator the drive unit is shut down The truck is braked by regenera...

Page 123: ...ly There is a risk of accident If the driver detects an abnormal decrease in the braking effect there may be a technical fault Press the emergency off switch to bring the truck to a standstill with the electromagnetic parking brake Notify the authorised service centre Do not operate the truck again until the service brake has been repaired DANGER At speeds that are too high there is a danger that ...

Page 124: ...king brake when the truck is at a standstill Release of the parking brake by the driver When the truck is ready for operation the driver can release the parking brake at any time by pushing the button Sit on the driver s seat Push the button 1 to release the parking brake The parking brake is released audibly and the symbol 2 on the display and operating unit disappears Application of the parking ...

Page 125: ...s switch off If the emergency off switch is actuated or as a result of an emergency off function The parking brake is applied immediately and audibly and the symbol 2 is shown on the display and operating unit 2 1 Functions of the parking brake when the truck is moving Application of the parking brake by the driver NOTE Braking with the parking brake while the truck is in motion will result in hea...

Page 126: ... in motion the parking brake is not applied The truck is then brought to a standstill by regenerative braking Steering NOTE Please do not steer when the truck is at a standstill as this causes the drive wheel to be put under extreme pressure and therefore increases wear 1 360 steering standard The steering wheel has no mechanical stops and can be continuously turned Starting in the straight ahead ...

Page 127: ... steering wheel is turned clockwise when travelling in the load direction the truck will move to the right If the steering wheel is turned anticlockwise when travelling in the load direction the truck will move to the left Trucks with reverse steering are marked with an adhesive label 1 next to the steering wheel adjustment mechanism Emergency operation of the reach measurement system When driving...

Page 128: ...foreign objects If the malfunction persists after the test contact your authorised service centre Re referencing the reach measurement system A temporary malfunction of the reach mea surement system can be corrected by ap proaching the reference points of the system To do this the reach carriage must be fully retracted and extended several times Fully retract the reach carriage Extend the reach ca...

Page 129: ...each travel measurement is located on the left load wheel support of the reach carriage To gain access to the measurement sys tem fully extend the truck battery with the reach carriage To do this observe the information in the chapter entitled Oper ation Handling the battery Actuating the battery lock Switch off the truck Disconnect the battery male connector If necessary remove any foreign object...

Page 130: ... 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 periods of time Actuate the pushbutton for the parking brake refer to the chapter entitled Applying the electromagnetic parking brake Retract the reach carriage fully Lower the fork to the ground Tilt the lift mast forwards until the tips of the fork arms r...

Page 131: ... chapter entitled Safety regulations for working with loads Lift mast versions DANGER Risk of accident due to collision of the lift mast or load 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 installed in the truck 1 Telescopic lift mast During lifting the...

Page 132: ...lift mast straight up to the max height 3 Lifting system operating devices The operation of the lifting system depends on the operating devices that are fitted on the truck Possible equipment variants include Joystick 4Plus refer to the chapter entitled Joystick 4Plus lifting system Fingertip switch refer to the chapter entitled Fingertip switch lifting system 120 50988078001 EN 10 2018 ...

Page 133: ...R Reaching or climbing between moving parts of the truck e g lift mast sideshifts working equipment load carrying devices etc can lead to serious injury or death and is therefore prohibited Always observe the safety regulations for hand ling loads see Chapter Safety regulations when handing loads P 4 138 Only operate the lifting system from the driver s seat 50988078001 EN 10 2018 121 ...

Page 134: ...c hydraulic functions and how they are controlled using the joystick The pictogram 2 shows the 3rd and 4th function and their operation 1 A B Lifting lowering the fork carriage To lift the fork carriage Pull the joystick 1 in the direction of B To lower the fork carriage Push the joystick 1 in the direction of A 122 50988078001 EN 10 2018 ...

Page 135: ...ackwards Push the rocker button 2 towards D To tilt the lift mast forwards Push the rocker button 2 towards C 3 E F Transition shift variant Depending on the truck equipment either the entire lift mast is shifted to the side or just the fork carriage fork sideshifter Transition shift to the left Slide the slider 3 towards E Transition shift to the right Slide the slider 3 towards F 50988078001 EN ...

Page 136: ... the joystick 4 in the direction of H NOTE The pictograms on the base of the joystick show the direction of movement for the corresponding hydraulic function Fingertip lifting system 1 3 4 2 1 Lowering lifting the fork carriage 2 Shifting 3 Tilting the lift mast or fork carriage variant 4 Transition shift variant 124 50988078001 EN 10 2018 ...

Page 137: ...rk carriage Push the lift lower operating lever 1 forwards Shifting To extend the reach carriage Push the shift operating lever 2 forwards To retract the reach carriage Pull the shift operating lever 2 back wards Tilting the lift mast or fork carriage variant Depending on the truck equipment either the entire lift mast is tilted or just the fork carriage fork tilt device To tilt the lift mast forw...

Page 138: ... pressing the acknowledge button 1 or by pressing shift key F 3 As soon as the fork is lowered below the limit height the lift cut out is active again As a result the lift cut out can be used in different hall areas with different lift heights Overriding the lift cut out by pressing the acknowledge button Press the acknowledge button 1 to over ride the cut out Overriding the lift cut out by pressi...

Page 139: ...op prevents the lift mast being extended up to the maximum possible lift height This helps to prevent lift mast collisions for example if the ceiling of the hall is lower than the maximum lift height of the truck The driver cannot cancel the lift cut out limit stop 50988078001 EN 10 2018 127 ...

Page 140: ...n be lowered fully without the lock It is not then possible to retract the reach carriage This prevents the load from being stripped The driver must first lift the load free again to a height greater than 400 mm or override the cut out by pressing the acknowledge button Overriding the reach lower lock by pressing the acknowledge button Press the acknowledge button 1 to over ride the cut out Overrid...

Page 141: ...ed until the function switches off automatically Depending on the truck version either only the fork carriage sideshift or the entire lift mast mast traversing is positioned Push the transition shift tilt centre position pushbutton 1 on the right hand side until the function switches off automatically The arrows 2 on the display and operating unit flash until the end position is reached The truck p...

Page 142: ...on the left hand side until the function switches off automatically The arrows 2 on the display and operating unit flash until the end position is reached The truck tilts the fork arms to the 0 position 1 2 1 Automatic tilt to centre position symbol 2 Automatic transition shift centre position symbol Additional button for automatic centre position variant The automatic centre position transition sh...

Page 143: ...aximum speed the truck brakes regeneratively to the set maximum speed The speed limitation is removed as soon as the current lift height is lowered to below the specified value The speed limitation cannot be deactivated The maximum speed can be set to a value of between 1 km h and 6 km h by the authorised service centre While the maximum speed is being limited the tortoise symbol 1 appears on the d...

Page 144: ...ands in the danger area Do not pull on the fork arms The fork arms must always be carried by two people if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used and should be dimensioned such that the fork arms do not protrude after being placed on the pallet This means the fork arms ...

Page 145: ...nd push the fork arms outwards onto the pallet Installation Position the fork arms on a pallet to the left or right of the fork carriage Pull the locking lever 1 upwards Push the fork arms onto the fork carriage from the outside towards the centre Move the fork arms into the desired position Ensure that the locking lever snaps into place Fit and tighten the locking screw 2 DANGER There is a risk t...

Page 146: ... be reduced in proportion to the actual load distance Observe load capacity see the Before picking up a load chapter 7071_003 104_V2 1 2 3 Attachment DANGER Risk to life from falling load At least 60 of the length of the fork extension must lie on the fork arm A maximum 40 overhang over the fork arm end is permissible The fork extension must also be secured against slipping from the fork arm If th...

Page 147: ...nch pin into the securing bolt and secure Removal Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork extension 1 Pull the fork extension from the fork arms Insert the securing bolt fully into the fork extension Insert the linch pin into the securing bolt and secure 1 Load backrest variant The load backrest 1 prevents individual packages from falling backwards wh...

Page 148: ...extend before the free lift has finished As a result the overall height is exceeded and damage can be caused when passing through entrances or in areas with low ceilings An incorrect extension sequence can be caused by the following The hydraulic oil temperature is too low The fork carriage is blocked in the inner lift mast The free lift cylinder is blocked The chain roller for the free lift cylind...

Page 149: ...on If the fork carriage or the load comes to an unexpected stop lift the fork carriage until the chains are under tension again and lower the load at another suitable location If the fork carriage rollers are blocked in the lift mast due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the ...

Page 150: ...ep 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 safety guard variant to prevent the load from falling on the driver Use a closed roof covering variant in addition Before picking up a load Load capacity The load capacity indicated for the truck on the capacity rating plate m...

Page 151: ...s prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These values apply to compact and homogeneous loads Otherwise the stability as well as the 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 50988078001 EN 10 2018 139 ...

Page 152: ...of the attachments va riant and the reduced load capacity of the combi nation of truck and attachment must not be excee ded Observe the special capacity rating plate infor mation shown on the truck and the attachment Picking up loads To make sure that the load is securely sup ported it must be ensured that the fork arms are sufficiently far apart and are positioned as far as possible under the load...

Page 153: ...n the fork arms may move forward and fall However If the fork arms are too long they can catch on loading units behind the load which then fall over when the load is raised For help with selecting the correct length of fork arms contact a qualified service engineer DANGER Risk of accident from falling load When transporting small items attach a load backrest variant to prevent the load from falling...

Page 154: ...Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all personnel except the driver in his normal operating position If persons fail to leave the danger area despite warnings Cease work with the truck immediately Secure the truck against use by unauthor...

Page 155: ...ational regulatory authorities in Germany the employer s liability insurance associations National regulations may place restrictions on these operations Contact the relevant authorities DANGER Swinging loads can result in the following risks Impaired braking and steering movement Tipping over the load wheels or drive wheels Tipping the truck at right angles to the drive direction Risk of crushing...

Page 156: ...ensure that no person is placed at risk DANGER Risk of accident When transporting suspended loads never per form or end driving and load movements abruptly Never drive on ascending or descending gradients with a suspended load It is not permissible to transport containers holding fluids as hanging loads Picking up a load NOTE Loads may only be picked up and set down on flat surfaces DANGER There is ...

Page 157: ...or clear entry into the pallet or load Release the brake Drive up to the racking until the truck chassis is as close as possible Brake Extend the reach carriage until the fork back is resting on the load The load centre of gravity must be midway between the fork arms Slowly raise the fork carriage until the load is lifted clear of the racking Tilt the fork tips or lift mast to the drive side only ...

Page 158: ...iage fully Release the brake DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway on the drive side is clear Move backwards carefully and slowly until the load is clear of the racking Brake 146 50988078001 EN 10 2018 ...

Page 159: ...s only until they are not resting on the posts Tilt the fork tips or lift mast fully to the drive side into the driving position Release the brake The load can be transported see the chapter entitled Transporting loads Transporting loads NOTE Observe the information in the chapter entitled Safety regulations when driving 50988078001 EN 10 2018 147 ...

Page 160: ...ng the reach carriage must be fully retracted and the fork carriage lowered until just above the load wheel legs If possible always travel on roadways in the drive direction as the load side view is restricted by the lift mast and the load If visibility is poor let someone guide you Drive slowly and carefully around corners Speed must be reduced on uneven or wet surfaces or when visibility is rest...

Page 161: ...may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take parti cular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during lowering the load may fall When removing from stock...

Page 162: ... lowered into its final position Brake Slowly lower the fork carriage until the load is positioned on the racking Retract the reach carriage fully Ensure that the roadway on the drive side is clear Move the truck back carefully and slowly until the fork arms can be lowered without touching the racking Lower the fork carriage until the necessary ground clearance is achieved Tilt the fork tips or lif...

Page 163: ...orklift truck must not be parked on a slope In case of emergency secure the truck with wedges The truck must not be used on upward and downward gradients with values that exceed those specified in the chapter entitled Road ways Driving onto lifts Do not drive the truck into a lift without specific authorisation The driver may only use this truck on lifts with a sufficient load capacity and for which ...

Page 164: ...eight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the attachment variant nameplate and if necessary by weighing the load to be lifted Add the determined unit weights to obtain the total actual weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Attachment net weight variant Weight of the load to be lifte...

Page 165: ...hment and the visibility from the driver s position with and without a load must be checked by a competent person If the visibility is deemed insufficient visual aids such as mirrors a camera monitor system etc must be used In addition it is essential that the warnings below are observed CAUTION Attachments must be CE certified If the truck is not fitted with an attachment specific residual load capac...

Page 166: ...allation Never grab or climb on moving parts of the truck 7090_900 001 Hydraulic connection Before installing the attachment release the pressure from the hydraulic system CAUTION Risk of damage to components Open connections of plug connectors can become dirty The plug connectors can become stiff and dirt can enter the hydraulic system Once the attachment has been disassembled attach the protecti...

Page 167: ... provided by the manufacturer and supplier of the attachments After each installation the attachment must be checked for correct function prior to initial commissioning Prior to assembling attachments the pressure must be released from the plug connectors arrows 2 1 Performing the truck function Release the pressure from the hydraulics Fully lower the lift mast and fork carriage In doing so wait u...

Page 168: ... operating devices joystick fingertip switch and their configuration refer to the chapter entitled Lifting system operating devices Release the ESC button and foot switch For trucks without a foot switch releasing the ESC button will suffice The assistance arrows will stop flashing The hydraulic system is switched off and remains deactivated until the next time the truck is started To re activate the ...

Page 169: ...ants and functions are available in addition to the functions described below The directions of movement can be seen on the pictograms on the operating devices or battery hood NOTE All the attachments described fall into the category of equipment variants An exact de scription of the respective movements actions of the attachment fitted can be found in the respective operating instructions 3 1 2 Co...

Page 170: ...tions of the fitted attachment NOTE The pictograms on the joystick are applied according to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Please contact the service centre if necessary Note the following attachment functions and pictograms Overview of pictograms...

Page 171: ... F Load retainer close open 6 Vertical rocker button shift button F Additional fork carriage lift lower Joystick shift button F Fork prong positioner close open 7 Vertical rocker button shift button F Rotator left right Joystick shift button F Fork prong positioner close open 8 Vertical rocker button shift button F Fork positioner forwards backwards In the pictograms for possible attachments the o...

Page 172: ... the following Move the operating lever forwards The attachment moves in the direction shown in the left part of the pictogram Move the operating lever backwards The attachment moves in the direction shown in the right part of the pictogram Actuate the switch 2 The additional function of the attachment is activated deactivated and can be controlled as an additional function using the operating lev...

Page 173: ...ions and pictograms No Function of the attachment 1 Fork prong positioner close open Fork prong positioner close open 2 Fork positioner forwards backwards 3 Rotator left right Fork prong positioner close open 4 Rotator left right 5 Fork positioner forwards backwards 6 Clamp close open 7 Load retainer close open 8 Additional fork carriage lift lower A Fingertip switch that performs the indicated fu...

Page 174: ...re that the additional clamp locking mechanism function is available NOTE The joystick actuation that has the clamp release function assigned to it is 1 marked by a pictogram also refer to the chapter entitled Working with attachments Closing the clamp with the joystick 4Plus It is not necessary to release the clamp locking mechanism in order to close the clamp Proceed as follows to close the clam...

Page 175: ...e clamp locking mechanism is locked again the LED will go out To open the clamp press and hold shift button F and move the horizontal rocker button to the right again NOTE The clamp locking mechanism is locked again as soon as shift button F is released if the clamp is not opened within a specified period of time 50988078001 EN 10 2018 163 ...

Page 176: ...eassembled see the chapter entitled Fitting at tachments Make sure that the additional clamp locking mechanism function is available NOTE The operating lever that has the clamp release function assigned to it is 1 marked by a pictogram also refer to the chapter entitled Working with attachments Closing the clamp with the fingertip switch It is not necessary to release the clamp locking mechanism in...

Page 177: ...achments WARNING Risk of accident Attachments must only be used for their intended purpose as described in the relevant operating instructions 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 they are securely grasped and attached Where necessary loads must also be secured against slipping rolling fallin...

Page 178: ...he truck Shock recognition variant The shock recognition is an equipment variant of the FleetManager variant in which an acceleration sensor is installed in the truck The acceleration sensor records the data generated in the event of a shock e g in the case of a collision This data can be electronically read out and evaluated Contact the authorised service centre for more information Active Load S...

Page 179: ...mplete the stock placement removal process without the support of active vibration damping Park the truck securely Notify the authorised service centre Active vibration damping of the lift mast helps the driver when placing loads into stock and removing loads from stock at great lift heights The hydraulic damping system suppresses load vibrations and thus shortens the stock placement and removal t...

Page 180: ...ravel The current lift height 3 is permanently displayed in the display The displayed lift height corresponds to the height of the upper edge of the fork A different value can be set by the authorised service centre The system functions across the entire fork lift height from ground level up to the maximum lift height of the truck When used properly the measurement accuracy is 5 mm The maximum mea...

Page 181: ... rain or fogging of the sensor Text message Description Remedy CLEAN HEIGHT SENSOR Contamination will affect the measuring signal between the LED height sensor and reflector Clean the sensor glass and reflector If the message is still displayed after cleaning contact your authorised service centre CAUTION Incorrect cleaning can damage the sensor glass and the reflector The components must never be cl...

Page 182: ...nterrup tion of the light signal due to contamination or foreign objects in the signal path If the malfunction in the system still exists please contact the authorised service centre In the event of a malfunction an error num ber is shown in the display The system is automatically available again as soon as the malfunction is no longer present or has been rectified Truck functions that are dependen...

Page 183: ...gency operation in the event of malfunctions in the height measuring system Avoid strong sunlight and proximity to other heat sources Allow the sensor to cool down If the error persists contact the authorised service centre Error number A3143 The reflector or sensor is very dirty or fogged up or Short interruption min 2 seconds in the light signal for example through packaging material Lifting func...

Page 184: ...alculated intermediate lift limitation a warning sound signals that there is a malfunction in the height measuring system After the joystick or fingertip is moved to the zero position further lifting can continue at a reduced speed If the intermediate lift limitation is can celled with the acknowledge button the lifting process can be continued without re striction Final lift limitation in emergenc...

Page 185: ...nce systems such as OPTISPEED and Active Load Stabilisation ALS To ensure correct functionality the load measurement must be performed once for testing purposes as one of the daily commissioning tasks for the truck Requirements for load measurement The load must be in the inactive position so that the weight sensor provides accurate results For this reason load measurement is disabled during the f...

Page 186: ...he ground during the measurement 1 2 Performing the load measurement Slightly lower the fork with the load This will increase the accuracy of the measurement Press the 1 button to start the load mea surement The measurement is performed once the load is in the inactive position On the display and operating unit 2 the measurement result is now displayed instead of the speed indicator The displayed ...

Page 187: ...eight has been ex ceeded the truck can be accelerated only up to a set maximum speed If the current driving speed is already above this maximum speed the truck brakes regeneratively to the set maximum speed The speed limitation is removed as soon as the current lift height is lowered to below the specified value The lift height and the value for the maximum speed can be set by the authorised servic...

Page 188: ...n 1 again to remove the speed limitation The tortoise symbol 2 on the display and operating unit disappears Camera monitor system variant CAUTION Risk of accident due to collision of the lift mast or load with the racking or low ceilings Also when using the system always consider the vibration characteristics of the lift mast and the load Note that the camera image only shows a small part of the s...

Page 189: ...nt damage Adjustment of the driver s compartment must only be carried out in the seated position by persons weighing a maximum of 150 kg Observe the total permissible weight during adjustment of the driver s compartment NOTE Before operating the seat adjustment me chanism make sure that there is sufficient clearance between the driver s seat and the side wall This will ensure that the driver s seat...

Page 190: ... of any damage to the roof panel particularly cracks the truck must be switched off immediately The roof panel must then be replaced safety relevant component Chips on the top of the panel are permissible if all of the following conditions are satisfied The chip is in the area of the screen print around the edge The chip only affects the upper pane panel The chip is no larger than 15 mm Roof panel ...

Page 191: ...riant General The battery rack is equipped with two adjacent roller channels The battery is pulled out of the truck by hand on to the battery rack and is pushed by hand off the battery rack into the battery compartment of the truck DANGER Risk of injury Due to the heavy weights to be moved by hand the operator is subject to an increased risk of trapping and crushing Always take particular care whe...

Page 192: ...y rack should always be used Under no circumstances should batteries be moved on battery racks not intended for them Load capacity Each battery rack is intended for a particular battery type This means that the dimensions and the maximum permissible weight are pre determined The dimensions and the tray number of the intended battery are to be taken from the order documentation The maximum load cap...

Page 193: ...the levelling feet must be bolted to the floor once any ad justments have been made Refer to the information in the original operating instruc tions from the manufacturer of the change frame 1 Locking the battery change frame DANGER Risk of physical injury Before unlocking the swing bolt check that the battery rack is on a horizontal surface and that the floor has a sufficient load capacity This is t...

Page 194: ...ea safely This area must be at least 0 5 m wide A first aid kit suitable for accidents involving acids must be available Persons trained in first aid must be available and within calling distance Requirements for positioning the change frames The transfer height of the frame and truck must be aligned with one another see the chapter entitled Battery change frame Adjusting the transfer height In orde...

Page 195: ...connecting the battery to the truck is required during battery replacement If an extension cable is required only a cable with an appropriate cross section and approved plugs must be used When an extension cable is in use the operator must take great care when positioning the truck not to pull the cable out of the socket 50988078001 EN 10 2018 183 ...

Page 196: ... into eight areas A H each with 20 levels After selecting one of these levels the user can read the following in the display Selected target level and area 1 Actual height 2 Target height or distance to target with pallet free lift included in the calculation 3 NOTE The fork arms must be in the 0 position to ensure their height position is calculated cor rectly The Automatic tilt to centre positio...

Page 197: ...eration the display shows only the direction arrows for function symbols that are currently allowed The individual symbols mean Main lift lowering lifting 6 Shift to drive side load side 7 Tilt to drive side load side 8 Transition shift left right 9 Pallet free lift The pallet free lift 10 is the difference in height by which the load support is raised or lowered after shifting in order to place a...

Page 198: ...height preselection there are four con figurations available for selection in the ser vice software The configuration can only be changed by the authorised service centre Truck options 1 page AUTO MODE height preselection Basic position AUTO MODE height preselection Any position AUTO MODE height preselection Without fork cycle AUTO MODE height preselection Start only with fork below target height AU...

Page 199: ...h carriage until the basic position is reached When the basic position has been reached the truck switches back to manual opera tion AUTO MODE height preselection Any position In the Any position configuration the assis tant specifies the height preselection without taking the respective position of the reach car riage into account Once the area and level have been entered the place into remove from...

Page 200: ... a height lower than the target height AUTOMODE height preselection Without fork cycle The target height can be reached directly regardless of whether the fork carriage is higher or lower than the target height The height preselector immediately specifies direct lifting or lowering to the target height After reaching the target height height preselection is complete AUTOMODE height preselection Sta...

Page 201: ...ion is a re tracted reach carriage shifting measurement system reports DS end position and a lift mast in free lift Other combinations are also possi ble However they lead to different displays on the assistant 1 The assistant specifies the function that must be carried out The fol lowing description is intended as an example When the truck has been switched ON area A 2 is automatically selected Th...

Page 202: ...e MAN button After entering the target level e g A1 press the button for placing into stock 1 The symbol for placing into stock 3 and auto for automatic operation 4 appear in the assistant 2 The display 5 changes from the target height to the distance to the target target difference CAUTION If the placing into stock button 1 is not pressed all hydraulic functions are available without restriction ...

Page 203: ... shown by the assistant 10 The automatic routine is complete All func tions are available again manual operation Back the truck away 11 1 3 4 5 2 Example Removing from stock in fully automatic mode NOTE Removing from stock can only be selected if valid heights were assigned to the levels during the teach in process Levels that are invalid or that have not had a height assigned to them are not acti...

Page 204: ... the racking 7 Activate the LS shifting function shown on the assistant and insert the fork arms all the way into the pallet 8 Activate the lift function displayed by the assistant The forks are raised by the pallet free lift height the load is picked up 9 Activate the DS shifting function and retract the reach carriage completely shown by the assistant 10 Back the truck away 11 The automatic rout...

Page 205: ...ne using the service software The following parameters among others can be changed using the service software Pallet free lift height Pallet free lowering height Accuracy and speed of pallet free lift and pallet free lowering Accuracy and speed of homing Performing a teach in The teach in for height preselection is carried out using the display and the enter keys for the display and operating unit...

Page 206: ...al Press the ESC 4 and OK 6 buttons for three seconds The following appears on the display field 1 PASSWORD _ _ _ _ Using the enter keys 3 enter a password for authorisation level 2 or 3 Confirm the entry with the OK button The selection menu appears in the display field 1 Press the arrow keys 5 until ADJUST appears in the display field Press the OK button The height currently saved on the system for ...

Page 207: ... area A H 2 A defined racking level 1 20 3 The programmed lift height in millimetres 4 NOTE Press the ESC button 5 to end the input and quit the menu item without saving Press the DEL button 9 to delete the input Programming the lift height example area A level 07 lift height 5500 mm Button Action Display Enter the area A H button 7 Press _ _ _ _ _ _ _ _ Enter the level A 0 Press A _ _ _ _ _ _ _ 0 ...

Page 208: ...eight preselector and the Automatic tilt to centre position function are simply controlled using the F button 1 on the joystick or on the fingertip console The adhesive label 2 shows the functions that can be carried out with easy Target or easy Target Plus easy Targetand easy Target Plusare additional comfort functions for the lift height preselector The general functionality setup and operation o...

Page 209: ... target height is automatically displayed When the required target height appears in the display this height is selected by releasing the F button The fork stops at the selected lift height NOTE As an alternative to using easy Target the target heights for the lift height preselector can also be entered using the buttons for the input field 3 4 Decal information easy Target Plus 3 easy Target Plus ...

Page 210: ...he F button can be released NOTE As an alternative to using easy Target Plus the function can also be executed using the Automatic tilt to centre position button Prerequisites for use To use the easy Target function the Lift height preselector option must be set up and operational on the truck The target heights that need to be controlled using the easy Target function must already be stored in th...

Page 211: ...e the F button The new target height is selected The AUTO symbol 3 is displayed The assistance arrows 5 indicate lifting or lowering Continue to lift or lower until the target height is reached The process stops automat ically at the required target height easy Target is complete The assistance arrows for lifting or lowering are no longer displayed If applicable continue to follow the assistance a...

Page 212: ...next steps until the placing into stock removing from stock procedure is complete Execute easy Target Plus after driving the fork out of the racking Move the joystick or the fingertip console to the inactive position Only then press and hold the F button again easy Target Plus is activated The fork is positioned horizontally One of the two assistance arrows 6 is visible indicating that the fork is ...

Page 213: ... keep his entire body within the protective cab or if he falls off the truck Always close the cab door before driving off and keep it closed when driving Opening the cabin door from the outside 1 2 Insert the key in the door lock 1 unlock and remove the key Pull the door handle 2 and release the door lock Open the cab door by pulling it outwards NOTE There is no monitoring switch for the cab door ...

Page 214: ...injured if he does not keep his entire body within the protective cab or if he falls off the truck Always close the cab door before driving off and keep it closed when driving DANGER There is a risk of damage caused by collision if the cab door opens while driving The cab door must be latched securely in the engaged position Close the door firmly The door must engage in the lock and the rubber seal...

Page 215: ...ystem rocker switch footwell 2 stage Selection of two heating levels for the warm air heating system under the steering wheel 4 Heating system rocker switch head area 2 stage Selection of two heating levels for the warm air heating system in the overhead guard post 5 Screen heating rocker switch tap mode Tapping the rocker switch starts the heating phase which switches off automatically after a fe...

Page 216: ...interior light Press switch 1 to switch on the cab light Adjust the reflector until the working area is optimally illuminated Heating system in the cab variant Switching on the blower and heating system 1 2 3 4 1 Rocker switch for heating system door 2 stage 2 Rocker switch for ventilation fan 2 stage 3 Rocker switch for heating system footwell 2 stage 4 Rocker switch for heating system head area 2...

Page 217: ...ing 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 outlets DANGER The heating system housing can become very hot when the heating system is operating There is a risk of burns if it is touched Do not touch the heating s...

Page 218: ...f the hot air cannot escape from it There is a risk of fire The blower may only be turned off if the heating system is turned off Always turn the heating system off first Only turn the blower off when the heating system is switched off Switch off the required heating function by actuating the relevant rocker switch For information about the functions of the rocker switches refer to the chapter entit...

Page 219: ...nside the cab in a hazardous situation for example if the truck has toppled over and the cab door can no longer be opened It is labelled EMERGENCY EXIT ONLY Switch off the truck To make it easier to climb out fold down the driver s seat backrest 1 2 Pull both locking knobs 1 upwards until the window 2 can be opened outwards Ensure that the surrounding area is safe push the window outwards and clim...

Page 220: ...tween various different modes of operation within these areas Area of application Cold store equipment Temperature range up to Operating time Comment 1 Not required 10 C Brief Typical application for trucks that take the load from the cooling truck into the cold store where the load is handled by storage and retrieval trucks 2 Required 30 C Continuous Alternating between indoor and outdoor use tim...

Page 221: ...e The cold store equipment for industrial trucks consists essentially of Oil types suitable for the cold store for use in the hydraulics and gearbox Lubricants suitable for the cold store for use on moving parts such as gearing and chains Chains treated with water repellent low temperature grease are fitted The paintwork on the trucks is designed for use at freezing temperatures Heating fans and he...

Page 222: ...ble capacity of the battery may be reduced The lower the temperature at which the battery is used the longer the charging time and the lower the available capacity The standard capacity is reached at 30 C If the temperature is reduced by 1 C this capacity is reduced by approximately 1 Impermissible use of the lithium ion battery in the shock cold store 45 C CAUTION Risk of component damage The lit...

Page 223: ...e system must be checked by actuating the brake several times during the warm up phase Alternating between the normal area and the cold store area Before entering the cold store any condensa tion water on the truck must be dried off NOTE In exceptional cases the truck may also be driven into the cold store with a small amount of condensation When doing so prevent the condensation water on the truc...

Page 224: ...nector while the truck is switched on except in the case of an emergency CAUTION Risk of accident in the event of an emergency shutdown of the truck whilst the load is raised In the event of an emergency shutdown of the truck whilst the load is raised the fork carriage must be fully lowered once and the reach carriage fully retracted once This ensures that the electronic support systems which prev...

Page 225: ...ially fatal conse quences There is a risk to life Failure to comply with the limits specified in these operating instructions e g driving on unacceptably steep gradients or failing to adjust speed when cornering can cause the truck to tip over If the truck starts to tip over do not leave the truck under any circumstances This increases the danger of being hit by the truck Never jump off the truck Y...

Page 226: ...he emergency lowering valve is operated remotely by means of a flexible drive The handle for operation is located on the reach carriage near the mast fixture WARNING The load is lowered Control the speed by turning the handle of the flexible drive by a smaller or larger amount Turning by a smaller amount load is lowered slowly Turning a larger amount load is lowered quickly After ensuring that no per...

Page 227: ... braking forces from the unbraked towed load total actual weight of the truck Check the tractive and braking forces of the towing vehicle DANGER The truck could drive into the towing vehicle when the towing vehicle brakes There is a risk of acci dent When towing the truck do not exceed the maximum recommended speed of 2 5 km h When towing on gradients reduce speed to an absolute minimum and keep w...

Page 228: ...braked and controlled effectively at all times CAUTION If the truck is not steered while it is being towed it may veer out in an uncontrolled manner The truck being towed must also be steered by a driver Release the parking brake Tow the truck After towing secure the truck against rolling away e g by activating the parking brake or using wheel chocks Do not remove the tow ropes Lifting points for ...

Page 229: ...tery male connector is disconnected Connecting and disconnecting the battery male connector 1 Connecting the battery male connec tor CAUTION Risk of component damage If the battery male connector is connected while the key switch is on under load a jump spark will be produced This can damage the contacts and considerably shorten their service life Do not connect the battery male connector while th...

Page 230: ...h considerably shortens their service life Do not disconnect the battery male connector while the key switch is switched on 1 Disconnect the battery male connector 1 from the plug connection by pulling in the direction of the arrow Place the battery male connector on the battery CAUTION There is a risk of short circuit if the cables are damaged Lay the battery cable on the battery Ensure that the ...

Page 231: ...he operating instructions for the charging station or battery charger and for the battery Observe the following safety regulations when maintaining charging and changing the battery Maintenance personnel Batteries may only be charged maintained or replaced by properly trained personnel in accordance with the instructions from the manufacturers of the battery battery charger and truck Follow the ha...

Page 232: ...manufacturer s maintenance instructions for the battery and battery charger Fire protection measures DANGER Risk of explosion due to flammable gases During charging the battery releases a mixture of oxygen and hydrogen oxyhydrogen gas This gas mixture 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 ...

Page 233: ...ssory with a load ca pacity see operating instructions or nameplate that at least matches the battery weight see bat tery identification plate Only remove the battery when the truck is on level smooth ground with sufficient load capacity Battery weight and dimensions DANGER Risk of tipping due to change in battery weight The battery weight and dimensions affect the sta bility of the truck When repla...

Page 234: ...s are not damaged CAUTION Potential for damage to the male battery connector If the battery male connector is disconnected or connected while the key switch is switched on or the battery charger is under load an arc is produced at the battery male connector This can lead toerosion at the contacts and can considerably shorten the service life of the contacts Switch off the key switch or battery cha...

Page 235: ...ing sections Checking the battery con dition acid level and acid density Checking the battery charge status Charging the bat tery and Equalising charge to prevent a deep discharge of the battery together Checking the battery condition acid level and acid density DANGER Danger to life and limb Observe the instructions in the chapter entitled Safety regulations when handling the battery WARNING Batt...

Page 236: ...hout caged cell plugs the liquid must reach a height of approx 10 to 15 mm above the lead plates Top up low fluid with distilled water only Rinse away spilt battery acid immediately using plenty of water Clean the battery cell cover and dry if necessary Remove any oxidation residue on the battery terminals and battery terminal clips and grease them with acid free grease Tighten the battery terminal...

Page 237: ... the remaining residual capacity you do not have to drive to the charging station immediately NOTE The battery discharge indicator characteristic curve must be set in accordance with the battery installed See Setting battery data Press the emergency off switch Switch the truck on Read the charge status on the display operating unit After connecting a fully charged battery All of the display segmen...

Page 238: ... discon nected or connected the truck and the battery charger must be switched off NOTE Battery maintenance is carried out in accor dance with the battery manufacturer s opera ting instructions The operating instructions of the battery charger used must also be follo wed If any of these instructions are missing they must be requested from the dealer Lead or gel batteries are used as traction batte...

Page 239: ...ons for the battery and the battery charger equalising charge NOTE Note the information in the operating in structions for the battery charger equalising charge After the charging operation is completed switch off the battery charger WARNING Risk of explosion The plug may only be disconnected from the socket when the truck and battery charger are switched off Disconnect the battery male connector ...

Page 240: ...Therefore a period when no shifts are running such as the weekend is ideal for performing the equalising charge Observe the information in the operating instructions of the charger regarding how to perform an equalising charge Starting the equalising charge Charge the battery After charging leave the battery in the charger The battery charger remains switched on Depending on the type of battery ch...

Page 241: ...ected from the battery male connector while the battery charger is switched on an arc is produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the battery charger before disconnec ting the charging cable Switch off the battery charger Disconnect the battery male connector from the battery charger plug Insert the battery male connector fully int...

Page 242: ... event of contact with the skin Thoroughly wash the skin with soap and water Eye irritation can occur in the event of contact with the eyes Immediately rinse eyes thoroughly with water for 15 minutes then consult a doctor Maintenance personnel The lithium ion battery is virtually mainte nance free and can be charged by the driver If you have any questions please contact your authorised service cen...

Page 243: ...ed in accor dance with the directions in these operating instructions When charging and maintaining the battery observe the manufacturer s maintenance instructions for the battery and battery charger Fire protection measures DANGER There is a risk of damage short circuiting and explosion Do not place any metal objects or tools on the battery Keep away from naked flames and do not smoke DANGER Incre...

Page 244: ...ot remove or change the position of ballast weights Observe the battery weight General safety regulations for lithium ion batteries The following safety regulations generally apply to operating lithium ion batteries Comply with the specifications stated in the safety data sheets of the battery manufacturer Protect the battery against mechanical damage to prevent internal short circuits If batteries...

Page 245: ...is approved for its battery tray Only use lithium ion batteries that have been approved by STILL for use with this truck The dimensions and the weight of the replacement battery must precisely match the dimensions and the weight of the original battery The truck may only be operated with a battery that is approved for its battery tray The installation of an incorrect battery poses a risk to the st...

Page 246: ... WARNING Risk of accident as a result of weakened lifting eyes If bent lifting eyes are straightened they will lose their rigidity The lifting eyes will then be unable to support the weight of the battery The battery may fall Do not straighten bent lifting eyes Have any bent lifting eyes replaced by your authorised service centre NOTE When changing from lead acid batteries to lithium ion batteries...

Page 247: ...o pallets and secured against overturning Observe the floor load capacity of the storage area refer to the manufacturer s specifications regarding battery weight To protect batteries against moisture do not store them directly on the floor Due to the fire risk store batteries outside buildings Store in a cool dry and well ventilated area Never subject the battery to temperatures below 35 C and above 8...

Page 248: ...ervice centre Checking the battery charge status lithium ion battery The charge state of the lithium ion battery can be read on the display operating unit of the truck and on the display of the lithium ion battery The two displays have different scale gradations and are therefore not identical 1 Reading the display operating unit of the truck All segments 1 of the display 100 light up a few moment...

Page 249: ...state in 10 increments The charge state LEDs can light up green and red A charge state of 0 to 10 is indicated by a red bar If this bar flashes the charge state is 2 The truck can no longer be moved A charge state of 10 to 30 is indicated by yellow bars A charge state of 30 to 100 is indicated by green bars When charging the charging state LEDs 3 light up green as a chaser light Service LED The ser...

Page 250: ...0 If the charge state drops below 15 drive to the charging station and recharge the battery If the battery switches off tow the truck to the charging station Charge the battery Charging the lithium ion battery upon delivery The lithium ion battery may not be fully charged at the time of delivery The battery management system for lithium ion batteries remains active even if the battery is in a quie...

Page 251: ...ced by the same manufacturer If the connectors are from different manufac turers please contact your authorised service centre NOTE To prevent deep discharge of the lithium ion battery truck performance limitations are imposed once the charge state of the battery drops to a certain level The battery must be charged before the charge state drops below 15 For information on reading the charge state ...

Page 252: ...icates when the battery is fully charged Only disconnect the battery from the charger if no current is flowing The battery has no memory effect Therefore it can be charged at any charge state without the capacity of the battery being impaired At ambient temperatures below 0 C the charging process will take much longer NOTE Observe the information in the operating instructions for the battery and th...

Page 253: ...ble battery due to cell damage Always charge the battery before deep dis charge begins When taking the battery out of operation for a prolonged period e g for company holidays always ensure the battery is charged 30 100 The battery management system remains active even if the battery is in a quiescent state Therefore the battery discharges even when the truck is switched off or during storage When...

Page 254: ...bly damaged No longer possible Display on the battery indicator during deep discharge Phase of the deep discharge Display on the battery indicator Phase 1 Start of the deep discharge It is no longer possible to drive the truck In this phase the customer can still charge the battery himself using the battery charger Initially The last charge state LED flashes red Later The battery display is OFF The...

Page 255: ... a lead acid battery to a lithium ion battery the authorised service centre must perform a one off conversion on the truck NOTE The only intended use of a lead acid battery in a truck with a lithium ion battery is in the event of an emergency for example if the lithium ion battery is faulty Trucks with lithium ion battery ex works Battery tray Truck operation ex works After the conversion 323 Lith...

Page 256: ...ttery If the battery installed is a lead acid battery the battery capacity and the battery type must be checked via the display operating unit Also refer to the chapter entitled Entering truck operating data via the display operating unit If the settings are incorrect then the battery charge is not displayed correctly In the worst case the battery may be damaged by a deep discharge General informa...

Page 257: ...ment The load capacity of the lifting accessory used must at least match the battery weight see the battery nameplate NOTE If the reach system of the truck is not working due to a battery problem the battery must be removed by your authorised service centre Incompatibility of battery connectors from different manufacturers CAUTION Risk of fire from using battery connectors from different manufactur...

Page 258: ...ing lever Af ter 5 seconds the lock 1 symbol appears in the display Release the actuating lever After approx 2 seconds the 2 arrow shows that the reach carriage can be retracted further into the end position If the end position is not reached within 2 minutes or if the accelerator pedal is pressed the operation is cancelled The lock symbol is hidden again Retract the reach carriage to the end posi...

Page 259: ...arning signal together with the lock and creep speed symbols indicate that the battery lock sensor has a mechanical defect Have any defects rectified by the authorised service centre 1 2 Adjusting the battery lock Adjustment instructions Battery trays for traction batteries are manu factured with relatively large tolerances To ensure that the lock of the battery frame in which the battery sits is i...

Page 260: ...ed slightly if necessary Check that the lock works correctly and whether it is possible to pull the release lever by hand refer to the chapter entitled Actuating the battery lock If the lock does not engage or if it is difficult to pull the release lever the washers must be reduced or the height of the rubber pads must be decreased If the lock does not engage it may also be necessary to increase th...

Page 261: ...rotrude The lifting eyes may bend in the event of a collision with the truck Lay the battery cable on the battery Make sure that the cable does not come into contact with the truck during installation Replacing the battery using a lifting device DANGER The battery weight and its dimensions affect the stability of the truck When replacing the battery the weight ratios must not be changed The batter...

Page 262: ...attery lock lever may be actuated only when the truck is stationary and the reach carriage is fully retracted The battery sits in a frame To replace the battery this frame is extended in the load direction together with the reach carriage Before the reach carriage is extended the battery lock lever must be actuated When the reach carriage is fully retracted the battery frame is mechanically locked...

Page 263: ...onnector 3 CAUTION There is a risk of short circuit if the cables are damaged Lay the battery cable on the battery Ensure that the cable is not crushed when removing and inserting the battery Check the connection cables for damage For batteries with a greater installation depth the battery cover of the truck must be re moved The screws on the battery cover can be loosened using the hexagon key for...

Page 264: ...ll the installation space with just a few millimetres of play This makes it impossible for the battery to slip or tip over while the truck is in motion The battery frame is intended for use with standard compliant batteries The batteries used must conform to the specified dimensional tolerances in accordance with this standard This is required to ensure that the battery lock functions correctly Use...

Page 265: ...ng handling in structions Follow the instructions provided by the respective manufacturer CAUTION Risk of component damage If the battery male connector is connected while the key switch is on under load a jump spark will be produced This can damage the contacts and considerably shorten their service life Do not connect the battery male connector while the key switch is switched on Connect the bat...

Page 266: ... replacing the battery the weight ratios must not be changed The battery weight must remain within the weight range specified on the nameplate The location of ballast weights must not be changed WARNING Risk of crushing if the battery falls out Releasing the battery lock as described below must only be carried out on horizontal level ground using a suitable battery change frame The battery lock lev...

Page 267: ...tery between the truck and the battery rack can be performed without mechanical resistance Make sure that the transfer height of the battery rack is correctly adjusted to that of the truck refer to the chapter entitled Bat tery change frame Adjusting the transfer height Position the truck and battery rack parallel to each other Position the truck and the battery rack so that the roller channels of...

Page 268: ...itch off the truck before the battery male connector is disconnected Do not disconnect the battery male connector while the truck is switched on except in the case of an emergency 3 4 Disconnect the battery male connector 3 CAUTION There is a risk of short circuit if the cables are damaged Position the battery cable on the battery in such a way that it cannot be crushed when removing or inserting ...

Page 269: ...the turning handle 1 anti clockwise to the stop 3 Swing the swing bolt 2 up to the stop 3 DANGER The battery can now move freely and may roll away unimpeded creating a risk of crushing People must not stand directly in the battery s direction of travel Do not place objects or any parts of the body between the battery and the truck chassis Do not attempt to keep hold of the battery if it rolls away...

Page 270: ...in is in the correct position The set voltage can be read through a display window 1 These trucks are operated with a 48 volt nominal battery voltage NOTE The battery must comply with the specifica tions on the nameplate regarding voltage and weight Compare the nameplates for the truck and battery Gel batteries are subject to special char ging maintenance handling instructions The guidelines from t...

Page 271: ...ctly traction is reduced and the message A3405 is shown on the display and operating unit This status can also be caused by the use of a non standard battery or by a technical fault If the battery is not included in the scope of delivery of the truck the battery lock must be adjusted by the authorised service centre Check or re enter the battery data battery type and battery capacity on the displa...

Page 272: ...ms are highlighted on the display The following menu items are available Information Parameter Diagnosis NOTE The height preselection option also offers the Teach in menu item Select the Parameter menu Push the OK button on the keypad 2 to confirm the selection The correct battery type batt_type and capacity batt_cap for the installed battery can now be selected from the six options by entering the...

Page 273: ...tery battery identification plate Note the load capacity of the lifting device Always lift the battery with suitable lifting gear bridge piece Do not use the methods described here to transport the battery over long distances When removing and inserting the battery using a lifting device always ensure that no one is standing directly next to the battery or between the battery and the lifting device...

Page 274: ...tray being compressed the lifting gear must lift vertically Slowly and using a vertical movement lift the battery out of the battery frame or insert it into the battery frame Ensure that there is sufficient distance from the lift mast and from the chassis of the truck Avoid any oscillating motions Transport the battery to the intended storage space CAUTION Risk of damage The battery must be stored ...

Page 275: ...at no one is standing directly next to the battery or between the battery and the lifting device WARNING Risk of crushing shearing The battery must be transported very carefully i e at low speed using slow steering movement and careful braking Before transporting the battery determine the weight of the battery battery identifi cation plate Note the load capacity of the lifting device To prevent the...

Page 276: ... lifting gear must lift vertically Slowly and using a vertical movement lift the battery out of the battery frame or insert it into the battery frame Ensure that there is sufficient distance from the lift mast and from the chassis of the truck Avoid any oscillating motions Transport the battery to the intended storage space CAUTION Risk of damage The battery must be stored on a suitable beam suppor...

Page 277: ...must only be accessed using the appropriate equipment Adhere strictly to the following steps Use only the steps provided for this purpose to climb onto the truck Use equipment such as stepladders or platforms to reach inaccessible areas CAUTION If water penetrates the electrical system there is a risk of a short circuit occurring Adhere strictly to the following steps Do not clean the battery elec...

Page 278: ...nents on the truck causing a risk of fire Adhere strictly to the following steps Do not use flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials CAUTION Abrasive cleaning materials can damage the surfa ces of components Using abrasive cleaning materials that are unsuita ble for plastics may dissolve plastic parts or make them brittle The screen on th...

Page 279: ... the electrical system with your bare hands CAUTION Cleaning electrical system parts with water can damage the electrical system Cleaning electrical system parts with water is forbidden Do not remove covers etc Only use dry cleaning materials according to the specifications in the section Cleaning the truck The components of the electrical system are fitted underneath the cover sheet of the counterw...

Page 280: ... the chain several times during this procedure Immediately after drying the chain spray it with chain spray Move the chain several times during this procedure For chain spray specifications refer to the chapter entitled Maintenance data table ENVIRONMENT NOTE Dispose of any fluid that has been spilled or collected in the collection vessel in an environmentally friendly manner Follow the statutory re...

Page 281: ...rst dry the battery male connector using compressed air Transporting the truck Transportation CAUTION Risk of material damage from overloading The load capacity lifting capacity of the means of transport the ramps and the loading bridges must be greater than the actual total weight of the truck Components can be permanently deformed or damaged due to overloading Determine the total actual weight o...

Page 282: ...ry the attachment nameplate variant Add the determined unit weights to obtain the total actual weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Attachment net weight variant 100 kg allowance for driver Total actual weight DANGER Risk of accident from the truck crashing Steering movements can cause the tail end to veer off the loading bridge towards the ed...

Page 283: ...lashing straps are tightened securely and that the pads cannot slip off Park the truck securely refer to the chapter entitled Parking the truck securely Disassemble the overhead guard grille or roof panel 1 and prevent these compo nents from being damaged Position slip resistant pads underneath the lifting points 2 e g rubber mats or foam Attach the lashing ropes in accordance with the illustratio...

Page 284: ... refer to the chapter entitled Parking the truck securely Position slip resistant pads underneath the lifting points 1 e g rubber mats or foam Attach the lashing ropes in accordance with the illustration Securely lash the truck Crane loading standard truck with overhead guard Crane loading is only intended for transporting the complete truck for its initial commission ing For application condition...

Page 285: ...ructions voir Mode d emploi siehe Betriebsanleitung D 22113 Hamburg Berzeliusstr 10 1 3 2 Determining the loading weight Park the truck securely refer to the chapter entitled Parking the truck securely Determine the unit weights by reading them off the truck nameplate and if necessary the attachment variant nameplate Add the determined unit weights together to obtain the loading weight of the truc...

Page 286: ...n the surface of the truck Particularly hard or sharp edged harnesses such as wires or chains can quickly damage the surface Use textile harnesses e g lifting straps with edge protectors or similar protective devices where necessary Retract the reach carriage fully in the drive direction Always use suitable edge protection be tween the hoist and any sharp edges on the truck to protect the hoist ag...

Page 287: ... the safety device 8 CAUTION Incorrectly fitted harnesses may damage attach ment parts Pressure from the harnesses can damage or destroy attachment parts when the truck is lifted If attachment parts are in the way e g lighting etc these must be removed before loading Ask your service centre about this Secure harnesses in such a way that they do not touch any attachment parts Loading the truck DANGE...

Page 288: ...re Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min kg kg kg kg kg kW V see Operating instructions voir Mode d emploi siehe Betriebsanleitung D 22113 Hamburg Berzeliusstr 10 1 3 ...

Page 289: ... damage the paintwork on the truck Harnesses may damage paintwork by rubbing and pressing on the surface of the truck Particularly hard or sharp edged harnesses such as wire ropes or chains can quickly damage the surface Use textile harnesses e g lifting straps with edge protectors or similar protective devices where necessary CAUTION Incorrectly fitted harnesses may damage attach ment parts Pressu...

Page 290: ...connector is discon nected Make sure that the emergency off switch is actuated Always use suitable edge protection 1 between the hoist and sharp edges on the truck The edge protection protects the hoist against damage when the truck is lifted Hook on the lifting straps load side on the right left Loop the lifting straps around the load arms of the truck just behind the load wheels as shown 278 509...

Page 291: ...onnected Make sure that the emergency off switch is actuated Guide the loop of the lifting strap 1 from below through the round opening 2 in the wheel arch Guide the loop of the lifting strap downwards again through the rectangular opening 3 below the reach travel measurement system Ensure that the straps do not put pressure on the teeth of the reach travel measurement system 4 Guide the loose end...

Page 292: ...ency off switch is actuated Guide the loop of the lifting strap 1 from below through the round opening 2 in the wheel arch Guide the loop of the lifting strap downwards again under the reach cylinder and through the rectangular opening 3 Ensure that the belts do not put pressure on the reach cylinder 4 NOTE The space under the reach cylinder for the lifting strap can be increased by extending the ...

Page 293: ...uck using guide ropes 90 1 2 Adjust the length of the harnesses 1 so that the bridge piece is in a horizontal position Adjust the length of the harnesses so that the bridge piece is vertically above the centre of gravity of the truck This ensures that the truck hangs level when it is being lifted Insert the safety device for the lifting eye 2 Visually inspect all belts and pieces of edge protectio...

Page 294: ...Measures to be implemented before shutdown Clean the truck thoroughly Fully extend and retract the reach carriage several times Lift the fork carriage to the stop several times Tilt the lift mast forwards and backwards several times If an attachment is fitted move the attachment several times To relieve the strain on the load chains lower the fork onto a suitable supporting surface e g a pallet Par...

Page 295: ...nden sation on the truck Many plastic films and synthetic materials are watertight Condensation water on the truck cannot escape through these covers Do not use plastic film as this facilitates the formation of condensation water Cover with vapour permeable material e g cotton Cover the truck to protect it against dust If the truck is to be decommissioned for an extended period contact the authorise...

Page 296: ...oning Change the brake fluid Put the truck into operation During commissioning the following must be checked in particular Drive controller steering Brakes service brake parking brake Reach carriage extension function retrac tion function Lifting system lifting accessories load chains mounting NOTE For further information see the workshop manual for the truck or contact the authorised service centr...

Page 297: ...5 Maintenance ...

Page 298: ...nd secure the lift mast to prevent it tilting backwards unintentionally Observe the maximum lift height of the lift mast and compare the dimensions from the technical data with the dimensions of the hall into which the truck is to be driven These steps are taken to prevent a collision with the ceiling of the hall and to avoid any damage caused as a result Working on the hydraulic equipment The hyd...

Page 299: ...airs and when changing hydraulic and electrical compo nents These are listed in the appropriate sections Lifting and jacking up DANGER There is a risk to life if the truck tips over If not raised and jacked up properly the truck may tip over and fall off Only the hoists specified in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity Only have th...

Page 300: ...safety measures are observed DANGER Risk of accident Use only chains with adequate lifting capacity to secure the particular lift mast CAUTION Potential damage to the ceiling Note the maximum lift height of the lift mast 1 Removing the lift mast DANGER Risk of accident Attach the lifting gear to the top of the bridge piece 1 on the outer mast of the lift mast This work must only be performed by a ...

Page 301: ...r the cross beam of the middle mast 2 Lower the lift mast until it strikes the chain Lower the fork carriage as far as it will go NOTE Extend the lift mast to slacken the chain General maintenance information Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work The annual testing must be carried out by a qualified person The examination and assessme...

Page 302: ...on like that of a specialist is not required to carry out this work The required operations are de scribed in sufficient detail in the corresponding sections in these operating instructions Information for carrying out mainte nance This section contains all information required to determine when the truck needs main tenance Maintenance must be carried out within the time limits according to the hou...

Page 303: ...ssitate shorter maintenance intervals Dirty poor quality roadways Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components 50988078001 EN 10 2018 291 ...

Page 304: ...5 Maintenance General maintenance information 292 50988078001 EN 10 2018 ...

Page 305: ... measuring system and limit stops Check the drive and brake actuations single and dual pedal for correct function and for damage Clean dust and dirt from the mechanisms Visually inspect the driver s compartment mounting on the battery side for trucks built up to and including 05 2015 Service Information 512015009 Load wheels Check the wheels for damage wear and ease of movement Check the wheel mou...

Page 306: ...f necessary Check the brake clearance Check the brake retardation values after each adjustment Check the brake fluid level If available check switch for the brake fluid Perform brake test Electric parking brake Clean and check the rotor Check the brake clearance Check the brake retardation values Electrical system Check the function of the drive and pump controller for driving acceleration braking a...

Page 307: ...ttery male connector contacts and cable for damage replace if neces sary Check the battery male connector contacts and cable on the battery charger for damage replace if necessary Perform insulation testing Hydraulic system Check the condition of the hydraulic system check that it is working correctly check for damage and check for leak tightness Check the hydraulic pump for leak tightness Check t...

Page 308: ...t there is a safety screw on the fork carriage or on the attachment Check the hydraulic hoses re adjust replace if necessary Lubricate the fork tilter sideshift Special equipment Replace the filter mat for the heating system Check the heating system for damage observe the manufacturer s maintenance instructions Check the optical height measuring system visual inspection clean the sensor and reflecto...

Page 309: ...000 3500 4000 4500 Truck components Perform a function check of the entire truck including all special equipment special heating systems switch off thermostats etc Check all important screw connections for secure attachment Check the condition and mounting of the wheels Check the function of the steering system Check the steering play check the setting of the steering chain if necessary Perform a ...

Page 310: ...he use of unapproved spare parts can result in an increased risk of accidents due to insufficient quality or incor rect assignment Anyone using unapproved spare parts shall assume unlimited liability in the event of damage or harm Quality and quantity of the required operating materials Only the operating materials specified in the maintenance data table may be used The required consumables and lubr...

Page 311: ...n refer to the workshop manual for the truck Insulation resistance of the electrical system DIN EN 1175 VDE 0117 For further information refer to the workshop manual for the truck Hydraulic oil HVLP68 DIN 51524 P3 ID no 0172025 1 l 0172026 5 l Hydraulic oil cold store variant Equivis XLT 15 ID no 7327400007 20 l Hydraulic system Hydraulic oil foodstuffs Food grade oil in accordance with NSFH1 7327...

Page 312: ...ner Brake fluid ATE SL DOT4 ID no 7327500020 1 l 0 2 l Steering Steering gears Lubrication Rivolta S K D 4002 As required Maintaining operational readiness Checking the driver s seat WARNING Risk of injury After an accident check the driver s seat and the mounting Check the operating devices for correct operation Check the condition of the seat e g wear on the upholstery and check that the seat is ...

Page 313: ...ear of the tyres WARNING Tyre quality affects the stability and handling of the truck Changes must only be made following consultation with the manufacturer When changing wheels or tyres ensure that this does not cause the truck to tilt to one side e g always replace right hand and left hand wheels at the same time NOTE The wear of the tyres must be approximately the same Polyurethane tyres can be...

Page 314: ...oses must not be used for a period longer than six years The BGR 237 specifications must be complied with Differing national laws must be taken into account Check pipe and hose connection screw joints for leaks traces of oil Hose lines must be replaced if The outer layer is damaged or becomes brittle and cracks begin to form They are leaking There are any unnatural deformations e g bubble formation...

Page 315: ... inner mast with a super pressure adhesive lubricant to reduce wear refer to the chapter entitled Maintenance data table NOTE Spray the tracks evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the device is ready for operation again Checking the battery change frame variant The screw joints and welded seams of the battery change frame must be subjected to a visual inspection 5...

Page 316: ...ve the filter mat 2 from the filter housing Check the filter mat for contamination and beat out NOTE Replace the filter mat when it is clearly grey but at least every two months Remove any dirt that has collected in the filter housing and recirculated air inlet Re insert the filter mat into the filter housing Make sure that the filter mat sits correctly and accurately in the filter housing Fit the heating ...

Page 317: ...ks for lithium ion batteries NOTE The lithium ion battery is maintenance free However a few tasks are required for maintenance of the battery and to ensure safe operation Regular tasks Cleaning the battery Checking the battery connections and cables Visually inspecting the covers Charging the battery Every 3 months Fully charge the battery when the truck is located within or outside the area of th...

Page 318: ...5 Maintenance Maintaining operational readiness 306 50988078001 EN 10 2018 ...

Page 319: ...6 Technical data ...

Page 320: ...6 Technical data Dimensions Dimensions Measurements h1 h3 h4 h6 and b1 are customised and can be taken from the order confirmation 308 50988078001 EN 10 2018 ...

Page 321: ... a 800 x 1200 pallet lengthwise For larger batteries increases by 66 mm for each battery size on the FM X FM X W FM X EW models For larger batteries increases by 85 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases...

Page 322: ... 1590 2610 1820 2610 1590 2610 Wheels chassis frame FM X 10 Li ion FM X 10 N FM X 12 Li ion FM X 12 N 3 1 Tyres Polyureth Polyureth Polyureth Polyureth 3 2 Front tyre size mm 360 x 130 360 x 130 360 x 130 360 x 130 3 3 Rear tyre size mm 285 x 100 285 x 100 285 x 100 285 x 100 3 5 Number of wheels x driven front rear 1x 2 1x 2 1x 2 1x 2 3 7 Rear track width b11 mm 1167 1037 1167 1037 Basic dimensio...

Page 323: ... 296 600 296 600 296 600 4 26 Width between load wheel supports b4 mm 920 790 920 790 4 28 Reach forward 1 l4 mm 449 364 449 364 4 31 Ground clearance with load under lift mast m1 mm 70 70 70 70 4 32 Ground clearance at centre of wheelbase m2 mm 70 70 70 70 4 34 1 Aisle width for a 1000 x 1200 pallet crosswise 2 Ast mm 2679 2733 2679 2733 4 34 2 Aisle width for a 800 x 1200 pallet lengthwise 2 Ast...

Page 324: ...e electrical hydraulic Electric motor FM X 10 Li ion FM X 10 N FM X 12 Li ion FM X 12 N 6 1 Traction motor power rating at S2 60 min kW 6 5 6 5 6 5 6 5 6 2 Lift motor power rating at S3 15 kW 14 13 14 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531 C 254 2 43531 B 254 2 43531 C 254 2 43531 B 254 2 6 4 Battery voltage nominal capacity K5 V Ah 48 465 Li ion 48 204 48 465 48 465 Li i...

Page 325: ...by 85 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases by 150 mm 6 For larger batteries increases by 72 mm for each battery size on the FM X FM X W FM X EW models For larger batteries increases by 90 mm for each b...

Page 326: ...olyureth ane Polyuret hane Polyuret hane 3 2 Front tyre size mm 360 x 130 360 x 130 360 x 130 360 x 130 3 3 Rear tyre size mm 285 x 100 285 x 100 285 x 100 285 x 100 3 5 Number of wheels x driven front rear 1x 2 1x 2 1x 2 1x 2 3 7 Rear track width b11 mm 1167 1037 1367 1567 Basic dimensions FM X 14 Li ion FM X 14 N FM X 14 W Li ion FM X 14 EW Li ion 4 1 Lift mast fork carriage tilt forwards backwa...

Page 327: ...ward 1 l4 mm 529 515 457 457 4 31 Ground clearance with load below lift mast m1 mm 70 70 70 70 4 32 Ground clearance at the centre of the wheelbase m2 mm 70 70 70 70 4 34 1 Aisle width for a 1000 x 1200 pallet crosswise 2 Ast mm 2727 2787 2821 2861 4 34 2 Aisle width for a 800 x 1200 pallet lengthwise 2 Ast mm 2782 2845 2887 2927 4 35 Turning radius Wa mm 1640 1691 1680 1720 4 37 Length across the...

Page 328: ... hydraulic Regen erative electrical hydraulic Regen erative electrical hydraulic Electric motor FM X 14 Li ion FM X 14 N FM X 14 W Li ion FM X 14 EW Li ion 6 1 Traction motor power rating at S2 60 min kW 6 5 6 5 6 5 6 5 6 2 Lift motor power rating at S3 15 kW 14 14 14 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531 C 254 2 43531 B 254 2 43531 C 254 2 43531 C 254 2 6 4 Battery volt...

Page 329: ...her FM X 14 Li ion FM X 14 N FM X 14 W Li ion FM X 14 EW Li ion 10 1 Working pressure for attachment bar 200 200 200 200 10 2 Oil flow for attachments l min 20 20 20 20 10 7 Sound pressure level in driver s compartment dB A 69 69 69 69 50988078001 EN 10 2018 317 ...

Page 330: ...by 85 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases by 150 mm 6 For larger batteries increases by 72 mm for each battery size on the FM X FM X W FM X EW models For larger batteries increases by 90 mm for each b...

Page 331: ...lyureth ane Polyuret hane Polyuret hane 3 2 Front tyre size mm 360 x 130 360 x 130 360 x 130 360 x 130 3 3 Rear tyre size mm 285 x 100 285 x 100 285 x 100 285 x 100 3 5 Number of wheels x driven front rear 1x 2 1x 2 1x 2 1x 2 3 7 Rear track width b11 mm 1167 1037 1367 1567 Basic dimensions FM X 17 Li ion FM X 17 N FM X 17 W Li ion FM X 17 EW Li ion 4 1 Lift mast fork carriage tilt forwards backwar...

Page 332: ...ward 1 l4 mm 591 505 519 519 4 31 Ground clearance with load below lift mast m1 mm 70 70 70 70 4 32 Ground clearance at the centre of the wheelbase m2 mm 70 70 70 70 4 34 1 Aisle width for a 1000 x 1200 pallet crosswise 2 Ast mm 2752 2795 2844 2879 4 34 2 Aisle width for a 800 x 1200 pallet lengthwise 2 Ast mm 2796 2854 2901 2936 4 35 Turning radius Wa mm 1710 1691 1750 1785 4 37 Length across the...

Page 333: ... hydraulic Regen erative electrical hydraulic Regen erative electrical hydraulic Electric motor FM X 17 Li ion FM X 17 N FM X 17 W Li ion FM X 17 EW Li ion 6 1 Traction motor power rating at S2 60 min kW 6 5 6 5 6 5 6 5 6 2 Lift motor power rating at S3 15 kW 14 14 14 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531 C 254 2 43531 B 254 2 43531 C 254 2 43531 C 254 2 6 4 Battery volt...

Page 334: ...her FM X 14 Li ion FM X 14 N FM X 14 W Li ion FM X 14 EW Li ion 10 1 Working pressure for attachment bar 200 200 200 200 10 2 Oil flow for attachments l min 20 20 20 20 10 7 Sound pressure level in driver s compartment dB A 69 69 69 69 322 50988078001 EN 10 2018 ...

Page 335: ...5 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases by 150 mm 6 For larger batteries increases by 72 mm for each battery size on the FM X FM X W FM X EW models For larger batteries increases by 90 mm for each batte...

Page 336: ...eth Polyureth Polyureth Polyureth 3 2 Front tyre size mm 360 x 130 360 x 130 360 x 130 360 x 130 3 3 Rear tyre size mm 350 x 100 350 x 100 350 x 100 350 x 100 3 5 Number of wheels x driven front rear 1x 2 1x 2 1x 2 1x 2 3 7 Rear track width b11 mm 1167 1037 1367 1567 Basic dimensions FM X 20 Li ion FM X 20 N FM X 20 W Li ion FM X 20 EW Li ion 4 1 Lift mast fork carriage tilt forwards backwards 3 α...

Page 337: ... forward 1 l4 mm 623 520 623 623 4 31 Ground clearance with load under lift mast m1 mm 70 70 70 70 4 32 Ground clearance at centre of wheelbase m2 mm 70 70 70 70 4 34 1 Aisle width for a 1000 x 1200 pallet crosswise 2 Ast mm 2820 2879 2857 2892 4 34 2 Aisle width for a 800 x 1200 pallet lengthwise 2 Ast mm 2864 2941 2901 2936 4 35 Turning radius Wa mm 1778 1762 1815 1850 4 37 Length across the loa...

Page 338: ...al hydraulic Regen erative electrical hydraulic Regen erative electrical hydraulic Electric motor FM X 20 Li ion FM X 20 N FM X 20 W Li ion FM X 20 EW Li ion 6 1 Traction motor power rating at S2 60 min kW 6 5 6 5 6 5 6 5 6 2 Lift motor power rating at S3 15 kW 14 14 14 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531 C 254 2 43531 B 254 2 43531 C 254 2 43531 C 254 2 6 4 Battery vo...

Page 339: ...her FM X 20 Li ion FM X 20 N FM X 20 W Li ion FM X 20 EW Li ion 10 1 Working pressure for attachment bar 200 200 200 200 10 2 Oil flow for attachments l min 20 20 20 20 10 7 Sound pressure level in driver s compartment dB A 69 69 69 69 50988078001 EN 10 2018 327 ...

Page 340: ...ies increases by 66 mm for each battery size on the FM X FM X W FM X EW models For larger batteries increases by 85 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases by 150 mm 6 For larger batteries increases by 72...

Page 341: ... front rear 1x 2 3 7 Rear track width b11 mm 1167 Basic dimensions FM X 20 HD Li ion 4 1 Lift mast fork carriage tilt forwards back wards 3 α β 2 4 4 2 Height with lift mast retracted h1 mm 5200 4 3 Free lift h2 mm 4578 4 4 Lift h3 mm 12 500 4 5 Height with lift mast extended h4 mm 13 122 4 7 Height of overhead guard cab 4 h6 mm 2200 4 8 Seat height h7 mm 1140 4 10 Height of load wheel supports h8...

Page 342: ...l7 mm 2066 4 43 Step height mm 345 Performance data FM X 20 HD Li ion 5 1 Driving speed with without load km h 14 14 5 1 1 Reverse driving speed with without load km h 14 14 5 2 Lifting speed with without load m s 0 34 0 50 5 3 Lowering speed with without load m s 0 52 0 50 5 4 Reach speed with without load m s 0 18 5 7 Climbing capability with without load 10 15 5 8 Max climbing capability with w...

Page 343: ... ion 48 817 6 5 Battery weight 5 depending on the manufacturer kg 1120 6 6 Energy consumption in accordance with VDI cycle kWh h 3 59 Other FM X 20 HD Li ion 10 1 Working pressure for attachment bar 200 10 2 Oil flow for attachments l min 20 10 7 Sound pressure level in driver s compart ment dB A 69 50988078001 EN 10 2018 331 ...

Page 344: ... larger batteries increases by 85 mm for each battery size on the FM X N model 3 Depending on the lift mast with sideshift fork tilt 2 4 4 When the cab weather protection option is selected the height h6 is 2180 mm 5 When the cab option is selected the length increases by 150 mm 6 For larger batteries increases by 72 mm for each battery size on the FM X FM X W FM X EW models For larger batteries i...

Page 345: ... tyre size mm 350 x 100 350 x 100 350 x 100 3 5 Number of wheels x driven front rear 1x 2 1x 2 1x 2 3 7 Rear track width b11 mm 1167 1367 1567 Basic dimensions FM X 25 Li ion FM X 25 W Li ion FM X 25 EW Li ion 4 1 Lift mast fork carriage tilt forwards backwards 3 α β 1 3 1 3 1 3 4 2 Height with lift mast retracted h1 mm 2450 2450 2450 4 3 Free lift h2 mm 1828 1828 1828 4 4 Lift h3 mm 5580 5580 558...

Page 346: ... x 1200 pallet crosswise 2 Ast mm 2908 2943 2978 4 34 2 Aisle width for a 800 x 1200 pallet lengthwise 2 Ast mm 2937 2972 3007 4 35 Turning radius Wa mm 1915 1950 1985 4 37 Length across the load wheel supports l7 mm 2066 2066 2066 4 43 Step height mm 345 345 345 Performance data FM X 25 Li ion FM X 25 W Li ion FM X 25 EW Li ion 5 1 Driving speed with without load km h 14 14 14 14 14 14 5 1 1 Reve...

Page 347: ...2 6 4 Battery voltage nominal capacity K5 V Ah 48 775 Li ion 48 817 48 775 Li ion 48 817 48 775 Li ion 48 817 6 5 Battery weight 5 depend ing on the manufacturer kg 1120 1120 1120 6 6 Energy consumption in accordance with VDI cycle kWh h 4 49 4 49 4 49 Other FM X 25 Li ion FM X 25 W Li ion FM X 25 EW Li ion 10 1 Working pressure for attachment bar 200 200 200 10 2 Oil flow for attachments l min 20 ...

Page 348: ...sions 360 x 130 FM X 22 standard versions 360 x 140 FM X 25 standard versions 360 x 140 Load wheels Polyurethane direct bond Model Tyres FM X 10 N standard versions 285 x 100 FM X 12 N standard versions 285 x 100 FM X 14 N standard versions 285 x 100 FM X 17 N standard versions 285 x 100 FM X 20 N W EW standard versions 350 x 100 FM X 22 standard versions 350 x 100 FM X 25 standard versions 350 x ...

Page 349: ...12 x 13s1p Nominal energy 9800 Wh 39200 Wh 39200 Nominal capacity 201 Ah 804 Ah 804 Ah Nominal voltage 48 V 48 V 48 V Max discharge current 400 A 400 A 400 A Max discharge power 18 kW 18 kW 18 kW Dimensions and weights Battery group L x W x H mm Weight kg Group 4 1 1223 x 283 x 784 750 Group 4 2 1223 x 355 x 784 939 Group 4 3 1223 x 385 x 784 1119 50988078001 EN 10 2018 337 ...

Page 350: ...6 Technical data Battery specifications for lithium ion batteries 338 50988078001 EN 10 2018 ...

Page 351: ...equipment Active Load Stabilisation ALS 166 Camera monitor system 176 Clipboard 179 Driver s compartment electrical 177 Load measurement 173 Shock recognition 166 Speed limitation 176 Working spotlight 93 B Battery Charging 225 Checking the acid level 223 Checking the charge status 225 Checking the condition 223 Disposal 19 Equalising charge 228 Lithium ion batteries 243 Maintaining 222 Safety reg...

Page 352: ...269 Load chains 268 Optical height measuring system 169 Panes of glass and mirrors 268 Truck 264 Cleaning the electrical system 267 Climbing into the truck 77 Climbing out of the truck 77 Cold store equipment Description 209 Commissioning 8 Commissioning batteries that are delivered separately 242 Consumables Brake fluid safety information 49 Disposal 50 Safety information for handling battery acid...

Page 353: ... 198 Overview 196 Positioning the fork horizontally using easy Target Plus 199 EC declaration of conformity in accordance with Machinery Directive 3 Electromagnetic parking brake 112 Emergencies Truck tipping over 213 Emergency lowering 214 Emergency operation of the reach measurement system 115 Emergency shutdown 212 Emissions 51 Battery 53 Noise emissions 52 Radiation 53 Vibrations 52 Enabling t...

Page 354: ...119 Telescopic lift mast 119 Triplex lift mast 120 Lifting 287 Lifting system Fingertip 124 Joystick 4Plus 121 Operating device 120 Lighting 93 STILL SafetyLight 92 List of abbreviations 15 Lithium ion batteries Approved batteries 233 Battery weight and dimensions 232 Charging 239 Charging the battery after delivery 238 Checking the charge state 236 Danger areas 26 Declaring the use 28 Display 70 ...

Page 355: ...Operating the service brake 111 Operating the signal horn 88 Optical height measuring system 168 Cleaning 169 Elimination of malfunctions 170 Emergency operation in the event of malfunctions 171 OPTISPEED 95 Ordering spare parts and wearing parts 298 Overhead guard Drilling 31 Modifications 31 Roof loads 31 Welding 31 Overhead guard with optimised visibility 178 Overview 56 Accessories 4 Labelling ...

Page 356: ...ions for working on the lift mast 288 Removing the lift mast 288 Securing the telescopic lift mast 289 Securing the triple mast 289 Safety regulations for working with lithium ion batteries 232 Safety regulations when driving 96 Safety regulations when handing loads 138 Safety regulations when handling the battery 219 Fire protection measures 220 Maintaining the battery 221 Maintenance personnel 2...

Page 357: ...nsporting the lithium ion battery 29 U Unlocking the emergency off switch 84 Using working platforms 11 V Variants Access authorisation with PIN code 87 Clamp locking mechanism with fingertip switch 164 Clamp locking mechanism with joystick 162 FleetManager 166 Fork extension 134 Lifting systems 119 View of functions and operating procedures 18 Visual inspections and function checking 74 W Warning ...

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Page 360: ...STILL GmbH 50988078001 EN 10 2018 ...

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