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Still FM-X, Original Instructions Manual

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Table of contents

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Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Battery replacement using a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Changing the battery using the internal roller channel (variant) . . . . . . . . . . . . . . . . . . . 205
Battery commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Adjusting the battery lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Setting the battery data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Battery transport with crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Parking the truck securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Re-commissioning after shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
After cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

6 Maintenance

General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Maintenance - 1000 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Additional maintenance guidelines for using the truck in a cold store - 500 hours or

every 12 weeks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 239
Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Checking the battery condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . 245
Maintaining wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

VI

50988078001 [EN]

Summary of Contents for FM-X

Page 1: ...ns Reach trucks FM X FM X N FM X W FM X EW FM X 10 FM X 12 FM X 14 FM X 17 FM X 20 FM X 22 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 04 2015 ...

Page 2: ......

Page 3: ...posal of components and batteries 11 2 Introduction Using the truck 14 Proper usage 14 Impermissible use 14 Place of use 15 Parking in temperatures below 10 C 15 Using working platforms 16 Residual risk 17 Residual dangers residual risks 17 Special risks associated with using the truck and attachments 18 Overview of hazards and countermeasures 20 Danger to employees 22 3 Safety Definition of terms ...

Page 4: ...isposal of consumables 41 Emissions 41 4 Overviews Overview 46 Overview of the driver s compartment 47 Operating devices and display elements 48 Display and operating unit 48 Operating devices for hydraulic and traction functions 48 Joystick 4Plus 49 Fingertip 50 Identification points 51 Overview 51 Nameplate 52 Production number 53 5 Operation Checks and tasks to be carried out prior to commission...

Page 5: ... 83 OPTISPEED Continuously variable reduction in driving speed or hydraulic functions variant 84 Driving 85 Safety regulations when driving 85 Roadways 88 Side chassis supports 90 Selecting the drive direction 91 Actuating the drive direction switch joystick 4Plus 92 Actuating the drive direction switch fingertip 92 Starting drive mode single pedal version 92 Starting drive mode dual pedal version ...

Page 6: ...ystick 4Plus 5th 6th hydraulic function 138 Controlling attachments variant with the fingertip 5th 6th hydraulic function 141 Operating the clamp locking mechanism variant with a joystick 4Plus 143 Operating the clamp locking mechanism variant with the fingertip switch 145 Picking up a load using attachments 146 Operating auxiliary equipment 147 Switching the working spotlights variant on and off 14...

Page 7: ...e cold store 177 Description of the cold store equipment 177 Warming up the truck 178 Operating the display and operating unit 178 Operating status displays on the display and operating unit 178 Blue Q efficiency mode 180 Functional description 180 Switching the Blue Q efficiency mode on and off 180 Fault displays 181 View on the display and operating unit 181 Operating in special operating situatio...

Page 8: ... qualifications 228 Information for carrying out maintenance 228 Maintenance 1000 hours year 231 Maintenance 3000 hours every two years 235 Additional maintenance guidelines for using the truck in a cold store 500 hours or every 12 weeks 238 Ordering spare parts and wearing parts 239 Quality and quantity of the required operating materials 239 Maintenance data table 240 Safety regulations for maint...

Page 9: ...ecking the battery change frame 249 7 Technical data Dimensions 252 VDI datasheet FM X 10 N FM X 12 N 253 VDI datasheet FM X 14 N FM X 17 N 257 VDI datasheet FM X 20 N W EW 261 VDI datasheet FM X 22 264 VDI datasheet FM X 25 269 Wheels and tyres 272 50988078001 EN VII ...

Page 10: ......

Page 11: ...1 Foreword ...

Page 12: ... commissioning 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 a...

Page 13: ...D 22113 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 3 ...

Page 14: ...facturer from the nameplate in the space provided Production number Year of manufacture Please quote the production number during all technical enquiries Each truck comes with a set of operating instructions These instructions must be stored carefully and must be available to the driver and operating company at any time The storage location is specified in the Overviews chapter If the operating ins...

Page 15: ...lopment of trucks These operating instructions are subject to change and any claims based on the information and or illustrations contained in them cannot be asserted Please contact 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...

Page 16: ...operating instructions Abbreviation Meaning C Degrees Celsius F Degrees Fahrenheit A Amperes ABE Display operating unit ArbSchG German labour protection law BetrSichV German Ordinance on Industrial Safety and Health BG Employers liability insurance association BGG Employers liability insurance association act BGR Employers liability insurance association rule BGV Employers liability insurance asso...

Page 17: ... Hours per day time driven each day in hours ID no ID number ISO International standard kg Kilograms kg m3 Kilograms per cubic metre km h Kilometres per hour km d Kilometres per day kilometres driven each day kN Kilonewtons kW Kilowatts kWh h Energy consumption l Litres l h Litres per hour l min Litres per minute LAN Local area network LED Light emitting diode Lp Sound pressure level LpAZ Continuo...

Page 18: ...tres PIN Personal identification number SE Superelastic SIT Snap in tyre for simplified assembly StVZO German Road Traffic Licensing Regulations t Tonnes TRGS Technical Regulations for Hazardous Substances a s And similar V Volts VDE Association for Electrical Electronic Information Technologies VDI Association of German Engineers VDMA German Engineering Federation W Watts WLAN Wireless local area ne...

Page 19: ...e load 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 9 ...

Page 20: ... of a 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 and operating unit NOTE Views of operating statuses and values in the display of the display and operating unit are examples and partly dependent on the truck equipment As a result the dis...

Page 21: ... of 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 ENVIRONMEN...

Page 22: ...1 Foreword Environmental considerations 12 50988078001 EN ...

Page 23: ...2 Introduction ...

Page 24: ...ng plate load diagram and must not be exceeded see also the chapter entitled Before picking up a load Impermissible use The operating company or driver and not the manufacturer is liable for any hazards caused by improper use NOTE Please observe the definition of the following responsible persons operating company and driver Use for purposes other than those described in these operating instruction...

Page 25: ... cold store it must be configured accordingly and if necessary approved for such an environment see the chapter entitled Cold store application The operating company see the chapter en titled Definition of terms used for responsible persons must provide sufficient fire protec tion in the area surrounding the truck in accor dance with its application Depending on the application additional fire protecti...

Page 26: ... of working 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 16 50988078001 EN ...

Page 27: ...on incident 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 The risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground ...

Page 28: ...ses from improper use or incorrect operation cannot be excluded in extreme cases and will impact stability The risks can include loss of stability due to unstable or sliding loads etc cornering at excessive speeds moving with the load raised moving with a load that is protruding to the side e g sideshift turning and driving diagonally across slopes driving on slopes with the load on the downhill s...

Page 29: ...Introduction 2 Residual risk 50988078001 EN 19 ...

Page 30: ... 925 VDI 3313 driver permit Usage by unautho rised persons Access with key only for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O BetrSichVO Workplace Safety Ordinance Risk of falling when using working platforms Compliance with national regulations different national laws O BetrSichVO Workplace Safety Ordinance and employer s liability insuranc...

Page 31: ...ace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O b LPG Observe BGV D34 operating instructions and VDMA rules O When charging the traction battery Observe BetrSichVO Workplace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O VDE 0510 In particular Ensure ventilation Insulation value within permissible range When using b...

Page 32: ...loyee training O BetrSichVO Workplace Safety Ordinance Danger to employees According to the German workplace safety ordinance BetrSichVO and labour protection law ArbSchG the operating company must determine and assess hazards during oper ation and establish the occupational health and safety measures required for employ ees BetrSichVO The operating company must therefore draw up appropriate opera...

Page 33: ...ay be summarised This overview see chapter Overview of hazards and countermeasures provides help on complying with this regula tion The overview specifies the main hazards that are the most frequent cause of accidents in the event of non compliance If other major operational hazards are involved they must also be taken into consideration The conditions of use for trucks are broadly similar in many ...

Page 34: ...2 Introduction Residual risk 24 50988078001 EN ...

Page 35: ...3 Safety ...

Page 36: ... as a service engineer 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...

Page 37: ...r has been 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...

Page 38: ...uence of the 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 28 50988078001 EN ...

Page 39: ...n lead to accidents You should therefore contact your service centre beforehand 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 changes to the brakes steering...

Page 40: ...ng into liquidation and the company not being taken over by another legal person the operating company can make changes to the truck To do so the operating company must fulfil the following prerequisites Design documents test documents and assembly instructions associated with the change must be archived and remain accessi ble at all times The capacity rating plate decal information hazard warnings...

Page 41: ...that the driver is no longer protected Do not weld on the overhead guard or the weather protection cab cold store cab Do not drill on the overhead guard or the weather protection cab cold store cab Do not make any incisions on the overhead 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 ...

Page 42: ...by the 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 ...

Page 43: ...ditional headlights etc is only permitted with the manufacturer 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 Tyres DANGER Using different tyres has a negative effect on the stability of the truck There is a risk of accident Only original tyres may be ...

Page 44: ... functions on the truck can be supported by gas springs Gas springs are complex components that are subject to high internal pressures up to 300 bar They may under no circumstances be opened unless instructed to do so and may be installed only when not under pressure If required the authorised service centre will depressurise the gas spring in accordance with the regulations before removal Gas spr...

Page 45: ...ained until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service cent...

Page 46: ...connected from the circuit to be tested Measure the insulation resistance with a suitable measuring device The insulation resistance can be considered sufficient if it measures at least 1000 V for the nominal battery voltage against ground Contact the authorised service centre Safety regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relati...

Page 47: ... water 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 Th...

Page 48: ... Do not 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 hazardous 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 dangerous if these fluids escape at h...

Page 49: ...wing the 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 always wear a protection suit and eye protection When working with battery acid never wear a watch or any jewellery Do not allow any acid to get onto clothing or skin or into the eyes if this does happen rinse i...

Page 50: ...to starting 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 CAUTIO...

Page 51: ...cted 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 spilt fluids such as hydraulic oil brake fluid or gearbox oil using an oil binding agent Neutralise any spilt battery acid immedi ately Always...

Page 52: ...llution If necessary these values must be determined directly at the workplace in the actual condi tions present there additional noise sources special application conditions sound reflec tions Vibrations The vibrations of the machine have been determined on an identical machine in ac cordance with the standards DIN EN 13059 Safety of industrial trucks Test methods for measuring vibration and DIN E...

Page 53: ...ng route intensity of use etc Battery 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 Make sure that there is always sufficient ventilation in working areas that are entirely or partially enclosed Keep away from open flames and flying sparks Observe the safety reg...

Page 54: ...3 Safety Emissions 44 50988078001 EN ...

Page 55: ...4 Overviews ...

Page 56: ...rview 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 46 50988078001 EN ...

Page 57: ... button variant 4 Reserved 5 Electrical seat adjustment push button variant 6 Compartment reserved for add on sys tems 7 Display and operating unit 8 Cup holder for max 1 5 l bottles 9 Operating devices for hydraulic and traction functions 10 Emergency off switch 11 Push button for additional hydraulic func tions 12 Accelerator pedal 13 Brake pedal 14 Foot switch 15 Driver s seat 50988078001 EN 47...

Page 58: ... access variant 3 Keypad for onboard diagnostics parame terising 4 Drive programme button P1 P4 5 Blue Q button 6 Parking brake button 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 devices Joystick 4Plus Fingertip 48 50...

Page 59: ...nction 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 in...

Page 60: ... lever 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 50 50988078001 EN ...

Page 61: ...970 1050 1080 1160 1200 1270 850 kg kg 800 mm kg mm 980 1110 1200 1240 1320 1600 1700 700 mm 1000 1150 1300 1400 1450 1500 1600 1700 mm 400 600 10200 9800 9500 9300 9000 8750 8300 7100 X 15mm X 15 12 4 1 13 14 8 2 3 7 5 8 14 15 12 11 10 13 2 9 1 3 2 4 5 6 7 5 5 6 50988078001 EN 51 ...

Page 62: ...ttachments example 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 1 2 3 4 5 6 7 8 9 10...

Page 63: ...TE The production number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequential number 50988078001 EN 53 ...

Page 64: ...4 Overviews Identification points 54 50988078001 EN ...

Page 65: ...5 Operation ...

Page 66: ...n working on high parts of the truck Use only the steps provided on the truck Do not stand on truck components or use them to help you climb onto the truck Use suitable equipment 1 2 Prior to commissioning ensure that the truck is safe for operation All covers must be fitted and closed The fork arms must be secured against lifting and shifting The locking devices 1 of the fork arms must not be dama...

Page 67: ...le connector for damage e g cracks breaks or deformation of the housing and whether the contacts are bent or damaged If necessary have the battery male connector replaced by the authorised service centre With an internal roller channel variant the swing bolt of the battery lock must be closed and must not be damaged or deformed The battery frame must show no noticeable damage e g cracks or breaks ...

Page 68: ...cessible from above Open the washer system filler cap 1 Fill the washer reservoir with washer fluid and anti freeze according to the maintenance data table see the chapter entitled Maintenance data table CAUTION Components 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 accum...

Page 69: ...amaged inform the authorised service centre immediately NOTE Only approved tyre types may be used see the chapter entitled Technical data Wheels and tyres 1 1 Check the tyres 1 on the drive wheel and load wheels for wear and damage Tyres must not be damaged or excessively worn They must be worn evenly on both sides NOTE Observe the safety principles for tyres refer to the chapter entitled Basic pr...

Page 70: ...he seat or seat backrest while driving Adjust the seat and seat backrest so that all operating devices can be actuated safely Ensure that the seat and seat backrest are securely engaged WARNING To obtain optimum seat cushioning you must ad just the seat suspension to your own body weight This is better for your back and protects your health To prevent injury make sure that there are no objects wit...

Page 71: ...ctric switch instead of a lever 3 The driver s seat can be adjusted to suit the weight of the individual driver To achieve the best seat suspension setting the driver must perform the adjustment whilst sitting on the seat Fully extend the weight adjusting lever 3 Pump it up or down to set the driver s weight The correct driver s weight has been selected when the arrow 4 is in the centre of the ins...

Page 72: ... the lumbar support moves a convex support cushion into the upper or lower part of the backrest Turn the turning knob 5 up or down until the lumbar support is in the desired position 6 Adjusting the backrest extension variant Adjust the backrest extension 6 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by jolting it upwards 62 ...

Page 73: ...he driver is sitting on the driver s seat Switch the seat heater 7 on or off using the switch 1801_342 002 9 8 Adjusting the horizontal suspension variant Push the lever 8 in sideways and slide the driver s seat to the locked position To release push the lever outwards Using the lever 9 the driver can adjust the hardness in several levels Move the lever 9 to the corresponding notch 50988078001 EN ...

Page 74: ...stment of the driver s compartment has stopped CAUTION Risk of component damage Adjustment of the driver s compartment must be carried out in the seated position by persons weighing a maximum of 150 kg only Observe the total permissible weight during adjustment of the driver s compartment The electrical driver s compartment adjust ment together with the seat and steering column adjustment is a sys...

Page 75: ...n the locking lever 1 Make sure that the steering column is locked securely Commissioning 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 a risk of slipping There is a risk of getting caught by your clothing when climbing out of the truck Ma...

Page 76: ...o 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 post of t...

Page 77: ... be stored in the cup holder Make sure that stored objects cannot fall from the shelves when the truck is started up steered or braked 1 Connecting the battery male connec tor CAUTION Risk of component damage If you connect the battery male connector when the truck is switched on under load an arc will be produced This can cause the contacts to erode which considerably shortens their service life ...

Page 78: ...The seat switch and the foot switch have been actuated The required hydraulic function is then selected The switches are all functioning correctly The drive function is only enabled if The parking brake has been released The seat switch and the foot switch have been actuated but the accelerator pedal has not The accelerator pedal is then actuated The switches are all functioning correctly If the s...

Page 79: ...the driver select the drive function or the hydraulic functions 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 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 ...

Page 80: ...n the key switch WARNING Before switching on the key switch all tests prior to commissioning must be performed without any defects being detected Carry out tests before the commissioning see the chapter Checks and tasks to be carried out prior to commissioning Do not operate the truck if defects have been identified Notify your authorised service centre 70 50988078001 EN ...

Page 81: ... 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 recalibrated If the lifting forks and the reach carriage are not in the basic position when the truck is switched on fully lower the load once and fully retract the reach carriage NOTE The switch key FleetManager card...

Page 82: ...isplay 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 will initially be displayed The battery charge level will not be displayed correctly again until the current value drops below the most recently stored value Steering position 2 The symbol for the neutral steerin...

Page 83: ...ult displays observe the information in the corresponding chapter see the chapter entitled Fault displays 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 numeric...

Page 84: ...d 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 manager Acc...

Page 85: ...d 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 the arr...

Page 86: ...ncorrectly 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 for the loc...

Page 87: ...ashes 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 of availa...

Page 88: ...ect 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 78 50988078001 EN ...

Page 89: ...ommission 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 the generator brake Accelerat...

Page 90: ...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 your left hand Apply the par...

Page 91: ...king 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 test and ...

Page 92: ...function 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 and operating unit the arrows 2 pointing toward the transition shift symbol must...

Page 93: ... truck 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 ...

Page 94: ...lity limits defined by the laws of physics are still in effect even when the reduction of speed when turning function is active There is a risk of tipping Before using this function familiarise yourself withthe change to the truck s driving and steering characteristics DANGER Risk of tipping if cornering speed is too high If the controller is switched off or fails while driving the driving speed wi...

Page 95: ...Always adapt the use of the hydraulic functions to suit the situation Do not take risks with safety The optimisation of the hydraulic functions affects the following functions Shifting the reach carriage Tilting the lift mast Transition shift of the lift mast This variant can also be equipped with the following additional functions Lift height indicator Lift height preselector Transition shift cen...

Page 96: ...uck Climbing out of the truck Moving the driver s seat Adjusting the steering column Disabling the restraint system Raising the load higher than 500 mm above the ground with the exception of manoeuvring processes when placing loads into stock removing loads from stock Using electronic devices for example radios mobile phones etc WARNING The driver s attention is adversely affected by operating mul...

Page 97: ... not for travelling in the load direction If visual aids mirror monitor are required to achieve sufficient visibility it is necessary to practise using them Extra care should be taken when travelling in the load direction if you are using visual aids When using attachments special conditions apply see the chapter entitled Fitting attach ments Any glass and mirrors must always be clean and free of i...

Page 98: ...ing values being exceeded Do not drive up or down longer gradients Do not exceed the maximum permissible gra dients for roadways see table below The truck is designed for normal operation on smooth even roadways without major gradients up to a maximum of 3 The following gradients e g on ramps must not be exceeded when using the truck under any circumstances Max permissible gradient in With load Wi...

Page 99: ...ted area load and point load of the roadways must not be exceeded There must be sufficient distance between the highest 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...

Page 100: ...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 Selecting the drive direction The desired drive direction of the truck must be selected using the drive direction switch before attempting to drive When the truck is switched on there is initially no drive di...

Page 101: ...l position If the truck is stopped for an extended period select the neutral position to prevent the truck from suddenly starting if the accelerator pedal is pressed inadvertently Lightly actuate the drive direction switch for the drive direction opposite to the current direction The drive direction indicator on the display and operating unit changes to show the neutral position symbol Actuate the...

Page 102: ...g 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 Starting drive mode single pedal version DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit down on the driver s seat During work ensure that you have a secure grip on the truck and a stabl...

Page 103: ...ve direction is shown on the display and operating unit 1 NOTE Depending on the equipment an acoustic or visual warning signal is issued in relation to the drive direction variant 2 Actuate the accelerator pedal 2 The truck will travel in the selected drive direc tion The speed is controlled by the accelera tor pedal position When the accelerator pedal is released the truck decelerates NOTE The tr...

Page 104: ...still cannot be operated park it securely and contact your authorised service centre Starting drive mode dual pedal version variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit down on the driver s seat During work ensure that you have a secure grip on the truck and a stable seat position Hold on tight to the steering wheel with your left hand Observe the in...

Page 105: ...ssued in relation to the drive direction variant The truck will travel in the selected drive direc tion The speed is controlled by the accelera tor pedal position When the accelerator pedal is released the truck decelerates NOTE The truck can be held at a standstill briefly on upward or downward gradients without actuating the parking brake anti roll brake for slopes The truck will then begin to cr...

Page 106: ...ation energy of the truck into electrical energy as soon as the accelerator pedal is released This causes the truck to brake The truck can also be braked with the me chanical brake by actuating the brake pedal 2 When the pedal is pressed gently the mechanical brake acts on the load wheels in addition to the electric brake When the pedal is pressed firmly the braking effect of both brake systems inc...

Page 107: ...raking effect is inadequate use the brake pedal 2 as well to apply the mechanical brake Applying the 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 The parking brake helps...

Page 108: ... the foot switch is released After 3 seconds the parking brake is applied audibly and the symbol 2 is shown on the display and operating unit If the truck is switched off The parking brake is applied immediately and audibly The symbol 2 is shown briefly on the display and operating unit until the control units switch off If the emergency off switch is actuated or as a result of the truck emergency ...

Page 109: ...er s seat Sit down on the driver s seat Select the drive direction single pedal version only Press the foot switch Actuate the accelerator pedal The parking brake is released automatically and audibly and the symbol on the display and operating unit disappears 2 1 Functions of the parking brake when the truck is moving Actuation by the driver NOTE Braking with the parking brake while the truck is ...

Page 110: ...til the control units switch off If the emergency off switch is actuated or as a result of the truck emergency off function The parking brake is applied immediately and audibly and the symbol 2 is shown on the display and operating unit NOTE If the driver s seat is vacated or the foot switch is released while the truck is in motion the parking brake is not applied The truck is then brought to a st...

Page 111: ...om this position 1 which reverses the drive direction The drive direction indicator on the display and operating unit shows the actual drive direction 1 180 steering variant The steering wheel has no mechanical stops and can be continuously turned The path of travel 1 is determined by turning the steering wheel The maximum steering angle of the steered wheel is 90 to each side To reverse the drive...

Page 112: ...eering wheel adjustment mechanism Lifting Lifting system variants The movement of the fork carriage and the lift mast heavily depends on the following equipment The lift mast fitted on the truck see the chapter entitled Lift mast versions The operating device that is used to control the hydraulic functions see the chapter entitled Lifting system operating devices Regardless of the equipment variant...

Page 113: ... cut out by pressing the acknowledge button 1 or by pressing shift button F 2 If the sensor on the lift mast is passed again the lift cut out is reactivated 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 pressing shift F Move the joystick or the relevant fingertip switch to the zero position Withi...

Page 114: ...ully extended the fork carriage can be lowered fully without the interlock 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 and lower cut out by pressing the acknowledge button Press the acknowl...

Page 115: ...rrows 2 on the display and operating unit flash until the end position is reached The truck positions the transition shift in the centre position Automatic tilting centre position variant The driver can use the automatic tilt to centre position function to change the tilt of the fork arms to 0 automatically To do this the push button must be actuated until the function switches off automatically De...

Page 116: ...sion 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 Note the heights of ceilings and entrances 3 2 Triplex lift mast variant During lifting the inner lift cylinder raises the fork carriage up to the free lift 2 and then the outer lift cylinders raise the inner lift mast straight up to the max height 3 DANGER Risk o...

Page 117: ...emperature is too low slowly actuate the lift mast functions several times in order to raise the oil temperature In the event that the fork carriage is blocked in the inner lift mast or the free lift cylinder or chain roller are blocked the cause of the blockage must be eliminated before resuming work Notify your service centre Load chains not under tension DANGER Danger caused by a falling load M...

Page 118: ...perating 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 The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck e g lift mast sides...

Page 119: ...ANGER 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 5 119 Only operate the lifting system from the driver s seat 50988078001 EN 109 ...

Page 120: ...basic 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 110 50988078001 EN ...

Page 121: ...st backwards 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...

Page 122: ...Push 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 112 50988078001 EN ...

Page 123: ...e fork 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 ...

Page 124: ... movement for the corresponding hydraulic function 1 Load backrest variant The load backrest 1 prevents individual packages from falling backwards when stacking high loads Changing the fork arms DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Apply the parking brake Change the fork arms in a separate safe location on a level su...

Page 125: ...e stands 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 a...

Page 126: ...ds and 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 ri...

Page 127: ...must 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 I...

Page 128: ...rk 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 Working platforms The use of working platforms in conjunction with industrial trucks is regulated by national law This legislation should be observed The use of working platforms is only permitted by virtue of the legislation in the...

Page 129: ...t step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load 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 pla...

Page 130: ...ability 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 Example Weight of load to be lifted 1 Permissible lift height 2 Load distance from fork back 3 WARNING Risk of accident from the truck losing stability The permissible loading of the attachments va riant and the redu...

Page 131: ...est on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the load Loads must be picked up and transported as close to the middle as possible If the length of the fork arms is not matched to the depth of the load this increases the risk of accidents If the fork arms are too short the load may fall off the arms after it has ...

Page 132: ...alling on the driver A closed roof covering variant should also be used Removable roof panels must not be removed 1 Adjusting the fork Lift the locking lever 1 and move the fork arms to the desired position Allow the locking lever to snap back into place The load centre of gravity must be midway between the fork arms Only actuate the fork prong positioner variant when the fork is not carrying a lo...

Page 133: ...warnings Cease work with the truck immediately Secure the truck against use by unauthorised parties DANGER Danger of death from falling loads Never walk or stand underneath suspended loads 6327_003 009 Transporting pallets As a rule loads e g pallets must be transpor ted individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the techn...

Page 134: ...ns Reduced visibility DANGER Loss of stability due to slipped unstable or in particular hanging loads The following information should be noted when transporting hanging loads Swinging of the load is to be prevented by using the proper driving speed and driving manner careful steering braking Hanging loads must be coupled to the truck in such a way that the harness cannot shift or release unintent...

Page 135: ...sk to life caused by a falling load or if parts of the truck are being lowered Never walk or stand underneath suspended loads or raised fork arms Never exceed the maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed Only store pallets that do not exceed the per missible measurements Damaged loading equipment and incorrectly formed loads must not be stored St...

Page 136: ...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 as far as necessary to stabilise the load 126 50988078001 EN ...

Page 137: ...carriage 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 50988078001 EN 127 ...

Page 138: ...posts 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 128 50988078001 EN ...

Page 139: ...elling 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 ...

Page 140: ... the load slips The truck 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 fal...

Page 141: ...ion the load centrally Extend the reach carriage fully Release the brake Drive up to the racking so the truck chassis is as close as possible until the load can be 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...

Page 142: ...he forklift 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 wh...

Page 143: ...t 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 lifted 10...

Page 144: ...insufficient visual aids such as mirrors a camera monitor system etc must be used NOTE Please observe the definition of the following responsible person competent person CAUTION Attachments must be CE certified If the truck is not fitted with an attachment specific residual load capacity rating plate and the operating devices are not marked with corresponding pictograms the truck must not be used Order...

Page 145: ...e plug connectors Mounting attachments Mounting an attachment and connecting the energy supply for an attachment must only be performed by competent persons in accordance with the information provided by the manufacturer and supplier of the attachment After each installation the attachment must be checked for correct function prior to initial commissioning NOTE Please observe the definition of the ...

Page 146: ...sed 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 until the lift mast which is braked by the mast slowdown at the end of the lowering process is fully lowered Rest the fork tips fully on the ground by tilting Switch off the key switch Wait for five seconds then switch on the key...

Page 147: ...stick 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 hydraulics switch the ...

Page 148: ...urther variants 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 instructio...

Page 149: ...ing instructions 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...

Page 150: ...ift button 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 attachm...

Page 151: ...y involves 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 ope...

Page 152: ...ng attachment functions and pictograms No Function of the attachment 1 Fork prong positioner close open 2 Fork positioner forwards backwards 3 Rotator left right 4 Clamp close open 5 Load retainer close open 6 Additional fork carriage lift lower Fork prong positioner close open 7 Rotator left right Fork prong positioner close open 8 Turn to the left right 142 50988078001 EN ...

Page 153: ...ts Make sure 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 clos...

Page 154: ...ened If the 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 144 50988078001 EN ...

Page 155: ... 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 order to close the clamp Proceed a...

Page 156: ...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 falling over swinging or tipping over No...

Page 157: ...off There is an option to have 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 147 ...

Page 158: ...can be fitted to the truck in different versions The description and operation information can be found in the separate operating instructions for the corresponding FleetManager versions Accident recorder variant The accident recorder is an equipment variant to the FleetManager variant which is in stalled in the truck s acceleration sensor The acceleration sensor records data in the event of an acc...

Page 159: ...lift mast is inactive the driver can still operate all of the truck s hydraulic functions If active vibration damping fails take the change in vibration characteristics into consideration Complete 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...

Page 160: ...g neck and shoulder strain Refer to the manufacturer s operating instructions for information about operation of the camera monitor system Load measurement NOTE Calibration of the load measurement system must be carried out by the authorised service centre General The load measurement variant helps the driver by displaying the weight of the lifted load on the display and operating unit The weight ...

Page 161: ... inactive position the measured load weight is displayed NOTE The displayed value of the load measurement is invalid if the fork carriage is positioned exactly between the free lift height and main lift height during the measurement In this case the measurement must be repeated at a different position In addition the load must be lifted completely off the ground during the measurement 1 Performing...

Page 162: ...ariant 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 wh...

Page 163: ...sms on the truck and battery 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 documen...

Page 164: ...nut On stationary systems 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 sufficie...

Page 165: ...ound the area 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 ...

Page 166: ...e out of the socket Lift height preselector variant General The lift height preselector supports the user when placing loads into stock removing loads from stock There are 160 programmable levels grouped 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 distan...

Page 167: ... the insertion of a pallet into the rack Removing from stock Removing from stock 4 is the removal of a pallet from the rack Assistant The display includes an assistant 5 that shows the possible movements via symbols and corresponding direction arrows During automatic operation the display shows only the direction arrows for function symbols that are currently allowed The individual symbols mean Ma...

Page 168: ...ter switching on If the load support is not in free lift a reference drive is required In this process the load support is lowered until it is below the reference switch then raised again Reference height The reference height is the distance from the upper edge of the load support to the floor when switching the reference switch 1 The reference height differs according to the lift mast height and c...

Page 169: ...fied by the assistant accordingly The lifting or lowering procedure stops automatically at the target point If the target point is reached then shifting tilting and transition shifting are enabled The assistant now specifies extend reach carriage As soon as the reach carriage is extended to the target point lifting or lowering is enabled Depending on the function selected at the start place into rem...

Page 170: ...ection Without fork cycle and Start only with fork below target height In the two modes Basic position and Any position an additional selection can be made between the options Without fork cycle and Start only with fork below target height The selection specifies whether the target height can be reached directly or whether the fork carriage must first be lowered to a height lower than the target hei...

Page 171: ...e will light up on the function symbols in the assistant 1 The required movement is identified in each case by a corresponding flashing arrow symbol Function symbols without arrow symbols mean that the function is blocked If the load support is above the free lift height a reference drive must be performed after switching on to activate the height display The initial position for this description is...

Page 172: ...se lection level and area can be cancelled using the DEL button 1 2 3 4 5 Example Placing into stock in fully automatic mode NOTE Placing into 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 activated in automatic mode All programmable heights are set at the factory to...

Page 173: ...plus the pallet free lift height is reached and the automatic stop is performed 6 The display 5 shows a distance to the target 6 mm Drive up to the racking 7 Activate the LS shifting function shown by the assistant and push the pallet onto the shelf 8 Activate the lowering function shown by the assistant The forks are lowered by the pallet free lift 9 height Activate the DS shifting function and r...

Page 174: ...t at the factory to 5500 mm Automatic mode can be interrupted at any time using the MAN button After entering the target level e g A2 press the button for removing from stock 1 The symbol for removing from 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 removing from sto...

Page 175: ...arriage completely shown by the assistant 10 Back the truck away 11 The automatic routine is complete All func tions are available again manual operation Teach in general The teach in for height preselection is carried out using the truck display In order to carry out the teach in the user must be logged in to the truck with a PIN code with authorisation level 2 or 3 NOTE Before a new height can b...

Page 176: ...h in The teach in for height preselection is carried out using the display and the enter keys for the display and operating unit The values for the programmable lift heights must be entered via the enter keys on the numeric keypad It is not possible to move the fork to a lift height and transfer this value to the height preselection system Opening the lift height preselector menu 1 2 3 4 For infor...

Page 177: ... 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 the first area and the lowest level is displayed in the display field 2 50988078001 EN 167 ...

Page 178: ...rea 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 Pr...

Page 179: ...laced A07 0550 X flashes cursor remains in the last position OK button 6 Press Input complete the value you have entered is displayed Cab operation variant General information about the cab Depending on the area of application the truck can be equipped with a weather protection cab or a cold store cab Operating devices variants The operating devices for the hydraulic functions and driving are posit...

Page 180: ...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 To operate the truck functions actuate the foot switch as in the basic truck Opening the cabin door from the inside 3 ...

Page 181: ...cy exit window in the cab CAUTION The emergency exit window is only intended for leaving the truck in the event of an emergency There is a risk of damage caused by collision if the truck is driven with the window open or if the window opens while driving Do not drive with the emergency exit window open If the window has been opened make sure that the window is latched securely in the engaged posit...

Page 182: ...urely in the engaged position before driving off again Cab operating devices 1 2 3 4 5 6 7 8 WARNING Risk of accident from actuating the operating devices in the cab while the truck is in motion If the driver briefly stands up from the driver s seat in order actuate operating devices the driver may be injured due to an insecure grip or may lose control of the truck Only actuate the operating device...

Page 183: ...phase which switches off automatically after a few minutes 6 Intercom system rocker switch Activates the intercom system 7 Intercom system volume controller Controls the volume of the intercom system 8 Intercom button While speaking the operator must keep the intercom button pressed down The operator switches on the function by pressing the upper half of the relevant rocker switch Pressing the low...

Page 184: ...s or gas cartridges to the flow of hot air DANGER The heating system overheats if the hot air cannot escape from it There is a risk of fire The heating system may only be switched on if the blower is running and the heating system is not covered by objects such as a jacket or cover Always switch the blower on first Do not switch the heating system on until the blower is switched on Move any objects a...

Page 185: ...ocker switch see the chapter entitled Cab operating devices Changing fuses DANGER Using the wrong fuses can result in short circuits There is a risk of fire To change the fuses contact the authorised service centre Cold store application General In order to make industrial trucks suitable for use in cold stores the trucks must be fitted with auxiliary equipment and subjected to technical modification...

Page 186: ...ere the load is handled by storage and retrieval trucks 2 Required 30 C Continuous Alternating between indoor and outdoor use time spent outdoors long enough for the condensation to drain off at least generally min 30 minutes or short enough so that no condensation can form generally max 10 minutes Parking outside of the cold area 3 Required 30 C Continuous Truck is parked outside of the cold stor...

Page 187: ...r the temperature at which the battery is used the longer the charging time and the smaller 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 Description of the cold store equip ment Cold store equipment components CAUTION Only trucks with Vulkollan wheels may be used in cold stores Check Vulkollan wheel...

Page 188: ...5 minutes before it can be put into normal operation in the cold store To warm the truck up all possible movements must be carried out several times This warm up phase is necessary in order for the oil temperature to increase Proportional valves and seals will only work perfectly after this warm up phase has been completed Checking the brake system The operational safety of the brake system must b...

Page 189: ...lift height preselector Target difference is only active in the lift height preselector variant or lift height display variant 9 Function assistant Only relevant for the lift height preselec tor variant 10 Function assistant centre position for transition shift 11 Function assistant centre position for tilting 12 Operating hours error messages drive profile information text The meter displays up to...

Page 190: ...n If the efficiency mode has been activated the acceleration behaviour of the truck changes to make acceleration more moderate Blue Q has no influence on Maximum speed Climbing capability Tractive 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 mo...

Page 191: ...n special operating situations Transportation CAUTION Risk of material damage from overloading If the truck is driven onto a means of transport the load capacity of the means of transport the ramps and loading bridges must be greater than the total actual weight of the truck Components can be permanently deformed or damaged due to overloading Determine the total actual weight of the truck Only loa...

Page 192: ... if necessary the attachment variant nameplate 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 tow...

Page 193: ...y so that it cannot move during transportation Make sure that the lashing straps are tightened securely and that the pads cannot slip off Park the truck securely see the chapter entitled Parking the truck securely Disassemble the overhead guard grille and roof panel and prevent these components from being damaged Attach lashing straps according to the illustration and lash the truck securely After...

Page 194: ... tractive and 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 minim...

Page 195: ...ehicle to be 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 Liftin...

Page 196: ...t presented here please contact the manufacturer with regard to particular variants Trucks may only be laden by persons with suf ficient experience with the suitable harnesses and hoists 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 Ant...

Page 197: ...ally fatal consequences Only use hoists and harnesses with sufficient load capacity for the total actual weight of the truck Only use the truck s designated lifting points Make sure that harness parts such as hooks shackles straps and similar items are only used in the indicated load direction The harnesses must not be damaged by truck parts Use suitable edge protection Retract the reach carriage f...

Page 198: ... lifting strap Loop another lifting strap around the two posts of the overhead guard 5 6 and guide the lifting strap upwards 8 7 Adjust the length of the harnesses so that the lifting eye 7 is vertically above the truck s centre of gravity This ensures that the truck hangs level when lifting it Connect the lifting straps to the lifting eye and insert the safety device 8 CAUTION Incorrectly fitted h...

Page 199: ...when setting it down at the intended location Procedure in emergencies 1 Emergency shutdown CAUTION If the battery male connector 1 is disconnected or the emergency off switch 2 is actuated the truck s electrical functions are switched off This safety system must only be used in an emer gency or to safely park the truck CAUTION Risk of component damage If you remove the battery male connector when...

Page 200: ...brated Before continuing to drive the truck fully lower the load and fully retract the reach carriage Switching off the truck in an emergency while stationary In an emergency all functions of the truck can be shut down Disconnect the battery male connector 1 see the chapter entitled Disconnecting the battery male connector None of the truck functions are now available Switching off the truck in an...

Page 201: ... of being hit by the truck Never jump off the truck You must adhere to the rules of behaviour if the truck tips over Rules of behaviour if truck tips over Hold onto the steering wheel with your hands Brace your feet in the footwell Keep your body in particular your arms and legs within the driver s compartment in the truck Lean your body away from the direction of the fall 1 Emergency lowering DAN...

Page 202: ...owly Turning a larger amount load is lowered quickly After ensuring that no persons are in the vicinity of the truck use the hexagon key 1 to slowly release the emergency lowering valve 2 so that the fork carriage can be lowered Ensure that the valve is re tightened once the forks have been lowered Notify your authorised service centre Handling the battery Safety regulations when handling the batt...

Page 203: ...s a risk of tipping When changing the battery the weight ratios must not be changed The battery weight must remain within the weight range prescribed on the nameplate Do not remove or change the position of ballast weights Note the battery weight on the nameplate CAUTION Incorrect connection or operation of the charging station or battery charger may result in damage to components Follow the opera...

Page 204: ...smoke Do not use an open flame Always have fire extinguishing equipment ready Parking the truck securely If the battery is being worked on the truck must be parked securely see the chapter entitled Parking the truck securely The truck may only be commissioned if the battery male connector is plugged in again and the battery door is closed Battery weight and dimensions DANGER The battery weight and t...

Page 205: ...t be ignited Fully extend the battery together with the reach carriage to the load side before charging the battery in the truck Doing so prevents any gases produced when charging the battery from building up in the truck Always ensure adequate ventilation in the vicinity Disconnect the battery male connector before charging and only when the truck and battery charger are switched off The cab door...

Page 206: ... with sufficient load bearing capacity according to the operating instructions for the lifting accessory you are using The battery sits in a frame To replace the battery the frame is moved in the fork direction by the reach movement of the lift mast When retracted this battery frame is locked mechanically WARNING Risk of crushing from moving parts Observe the information signs see the chapter entit...

Page 207: ...lever for the battery lock can be pulled the battery lock must be re leased The battery lock is released via the Retract reach carriage to the drive side op erating function on the joystick 4Plus or via the corresponding fingertip switch Releasing the battery lock Press and hold the foot switch Use the actuating lever joystick or fingertip switch to retract the reach carriage to the drive side until...

Page 208: ...ked extend the battery to the load side by at least one third of the reach travel to complete the unlocking process NOTE Once unlocked the battery must be exten ded to the load side by at least one third of the reach travel to complete the unlocking process Only then can the battery be locked again by retracting the battery together with the reach carriage Locking the battery Press and hold the fo...

Page 209: ...acoustic warning signal and the lock and creep speed symbols of the truck indicate that a mechanical fault has occurred with the battery lock sensor The fault must be rectified by the authorised service centre Disconnecting the battery male connector CAUTION Risk of component damage If you remove the battery male connector while the truck is switched on under load an arc will be produced This can c...

Page 210: ...e truck When replacing the battery the weight ratios must not be changed The battery weight must remain within the weight range specified on the nameplate 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 may only be carried out on horizontal level ground using suitable devices Suitable devices include...

Page 211: ... with a crane Maintenance personnel for batteries Batteries may only be charged maintained or changed by properly trained personnel in accordance with the instructions of the manufacturers of the battery battery charger and truck The handling instructions for the battery and the operating instructions for the battery charger must be followed Removing the battery Retract the reach carriage fully Ap...

Page 212: ...t 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 the battery Check the connection cables for damage For batteries with a greater installation depth the battery cover on the truck must be re moved in order to remove the battery The screws on the battery cover can be loosened using the hexagon key for the...

Page 213: ...llation 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 batteries The batteries used must conform to the specified dimensional tolerances in accordance with this standard This is required for the battery lock to function without any problems Insert the battery into...

Page 214: ...ay 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 the respective manu facturer must be observed CAUTION Risk of component da...

Page 215: ... 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 display and operating unit see the chapter entitled Setting the battery data Changing the battery using the internal roller channel variant As an option this truck can a...

Page 216: ...accordance with the instructions of the manufacturers of the battery battery charger and truck The handling instructions for the battery and the operating instructions for the battery charger must be followed Positioning the truck correctly in relation to the battery rack CAUTION Before replacing the battery ensure that the rollers for the battery transport in the battery rack are aligned with the...

Page 217: ...chanically locked again Retract the reach carriage fully Apply the parking brake Release the battery lock refer to the chapter entitled Actuating the battery lock Press the foot switch 2 Extend the reach carriage fully together with the battery 2 Switch off the truck Press the emergency off switch CAUTION Risk of component damage If you remove the battery male connector while the truck is switched...

Page 218: ...CAUTION If the battery rolls out of the battery compartment when no external device is present this can lead to material damage Before removing the battery always have an external device in position CAUTION Risk of injury from crushing and shearing points Always actuate the swing bolts with just one hand and make sure that fingers are kept away from the rotation and clamping range The battery is he...

Page 219: ... battery is installed and secured in the reverse sequence Activities after installation of the battery DANGER If the battery is not locked correctly the battery can slide out of the truck with potentially fatal consequences Before commissioning the truck the battery lock must be checked for correct operation and secure locking If your truck is equipped with a Euro battery male connector make sure ...

Page 220: ...ery Unlock the emergency off switch Switch on the truck Press the foot switch Retract the reach carriage with the battery fully until the battery lock engages The lock must audibly engage Push the release lever down if necessary If the battery frame is locked incorrectly traction is reduced and the message A3405 is shown on the display and operating unit This status can also be caused by the use o...

Page 221: ...ic curve 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 in good working or der its bump stops must be adjusted This happens in the factory during commissioning However if the customer procures the battery himself or if the battery...

Page 222: ...ry 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 the insertion distance of the battery frame This is achieved by placing suitable washers beneath rubber buffers 2 on the load side If the lock still does not function proper...

Page 223: ...o scroll within the menus The selected menu items 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 b...

Page 224: ...ad 2 The capacity is read from the nameplate on the battery and is input as a column of numbers The numbers are selected using the arrow buttons on the keypad 2 Confirm that each number in the column is set correctly by pushing the OK button on the keypad 2 Exit the settings by pushing the ESC button on the keypad 2 for approx 2 seconds 214 50988078001 EN ...

Page 225: ...crane when removing and inserting the battery with a crane Before transporting the battery by crane establish the weight of the battery 1 Observe the load capacity of the crane Ensure that there is sufficient distance between the truck and any obstacles when setting down so that the truck is not damaged when the crane is used To avoid short circuits batteries with open terminals or connectors shoul...

Page 226: ...ed Only theinstructions that camewith the battery charger are valid If any of these instructions are not available please request them from the dealer 1801_560 001 1 Checking the battery charge status The discharge process should be monitored so that the battery is protected against deep discharge The hydraulic lifting function is switched off when 20 residual capacity is reached NOTE The battery ...

Page 227: ...ten the service life of the battery Avoid discharging below 20 of nominal capacity corresponding to 0 on the display as this is considered deep discharging of the battery Charge discharged batteries immediately if a residual capacity of 0 is displayed Never leave batteries in a discharged state This also applies to partially discharged batteries Charging the battery Park the truck securely see the...

Page 228: ...e battery male connector If fitted open the driver s cab door variant fully DANGER There is a risk of damage short circuiting and explosions Do not place any metal objects or tools on the battery Keep away from naked flames no smoking WARNING The electrolyte diluted sulphuric acid is poisonous and caustic Observe safety regulations for handling battery acid see the chapter entitled Battery acid Rins...

Page 229: ...e battery male connector to the battery charger plug Start the battery charger NOTE Note the information in the operating in structions for the battery charger equalising charge Once the charging process is complete Switch off the battery charger CAUTION Risk of component damage If you disconnect the charging cable while the bat tery charger is switched on an arc will be produced This can cause th...

Page 230: ...ill Only leave the truck once the parking brake has been applied DANGER There is a risk to life caused by a falling load or if parts of the truck are being lowered Before leaving the truck lower the load fully CAUTION Batteries may freeze If the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batt...

Page 231: ...under load an arc will be produced This can cause the contacts to erode which considerably shortens their service life Switch off the truck before the battery male connector is disconnected Do not disconnect the battery male connector while the truck is switched except in the case of an emergency 1 Disconnect the battery male connector NOTE The switch key FleetManager card variant FleetManager tra...

Page 232: ... 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 and if fitted move attachment repeatedly To relieve the strain on the load chains lower the fork onto a suitable supporting surface e g a pallet Park the truck with all pistons and cylinders fully retr...

Page 233: ... use plastic film as this facilitates the formation of condensation water Cover with vapour permeable material e g cotton Cover the truck to protect against dust If the truck is to be decommissioned for a long time we recommend it is decommissioned by the authorised service centre Re commissioning after shutdown If the truck has been shut down for longer than six months it must be carefully checked...

Page 234: ...itched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connector WARNING There is a risk of injury due to falling ...

Page 235: ...r fluids that are corrosive or contain acid or chlorine can damage the chains use of these items is forbidden Observe the manufacturer s guidelines for working with cleaning materials Place a collection vessel under the lift mast Clean using paraffin derivatives such as benzine Before spraying the load chains with chain spray the cleaning agent must have evapo rated and the chain must be dry As soon...

Page 236: ... s seat and start up the truck in accordance with the regulations CAUTION Risk of short circuit If any moisture has penetrated the motors despite the precautionary measures taken first dry them using compressed air The truck must then be started up to prevent possible corrosion damage 226 50988078001 EN ...

Page 237: ...6 Maintenance ...

Page 238: ...ned personnel in accordance with the instructions from the manufacturers of the battery battery charger and truck The handling instructions for the battery and the operating instructions for the battery charger must be followed Maintenance work without special qualifications Simple maintenance work such as checking the fluid level in the battery may be carried out by untrained personnel A qualificati...

Page 239: ...efined for standard use Shorter maintenance intervals can be defined in consultation with the operating company depending on the application conditions of the truck The following factors may necessitate 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 oper...

Page 240: ...6 Maintenance General maintenance information 230 50988078001 EN ...

Page 241: ...nd stops and adjust if necessary Check the reach travel 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 Load wheels Check the wheels for damage wear and ease of movement Check the wheel mountings for operating noise and play Check the wheel fastenings using a torque wrench Drive ...

Page 242: ... system Check the function of the drive and pump controller for driving acceleration braking and reversing Check the cable connections and plug contacts for secure positioning and corrosion Check the electrostatic discharge ESD devices Check the main fuses and control fuses Check the contacts of the main contactor Check the switch lock and emergency off switch for correct function Check all operat...

Page 243: ...mage and wear Adjust and lubricate the load chains Replace the main lift chains after 5000 operating hours recommendation Check the lift cylinders and connections for damage and leaks Check the guide pulleys for damage and wear Check the mast rollers and chain rollers for damage and wear Check the tilt cylinders and connections for damage and leaks Check the joints of the tilt attachment for play ...

Page 244: ...t from the battery change frame and check it for deformation da mage Check the freedom of movement of the rollers and keep the surface of the rollers free of corrosion using a film of oil Lubricating Lubricate using approved lubricants in accordance with the lubrication plan General Read out and check the error numbers and delete list Reset the maintenance interval Check labelling to ensure it is c...

Page 245: ... reach travel 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 Load wheels Check the wheels for damage wear and ease of movement Check the wheel mountings for operating noise and play Check the wheel fastenings using a torque wrench Drive wheel Check the tyres for damage and wear ...

Page 246: ...ake fluid 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 and reversing Check the cable connections and plug contacts for secure positioning and corrosion Check the electrostatic discharge ESD devices Check the main fuses and control fu...

Page 247: ... faces Check the mast profiles for damage and wear Lubricate the mast profiles Check the load chains for damage and wear Adjust and lubricate the load chains Replace the main lift chains after 5000 operating hours recommendation Check the lift cylinders and connections for damage and leaks Check the guide pulleys for damage and wear Check the mast rollers and chain rollers for damage and wear Check ...

Page 248: ... maintenance interval Check labelling to ensure it is complete Perform a test drive Additional maintenance guidelines for using the truck in a cold store 500 hours or every 12 weeks At operating hours 500 1000 1500 2000 2500 Carried out 3000 3500 4000 4500 Truck components Perform a function check of the entire truck including all special equipment special heating systems switch off thermostats et...

Page 249: ...he manufac turer s instructions The 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 ...

Page 250: ...y DIN 43539 VDE 0510 Min 500 V against ground Insulation resistance of the electrical system DIN EN 1175 VDE 0117 Min 1000 V against ground 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 accor dance with NSFH1 7327400020 46 grade oil 10 l 7327400024 68 ...

Page 251: ... SKD 3400 ID no 0147873 As required Load chains Chain lubrication Stabylan 2100 ID no 8010100 As required Setting Distance to support roller 35 mm under the top edge of the inner mast Brake system Container Brake fluid ATE SL DOT4 ID no 7327500020 1 l 0 2 l Steering Steering gears Lubrication Rivolta S K D 4002 As required 50988078001 EN 241 ...

Page 252: ...o avoid damage Working on the hydraulic equipment The hydraulic system must be depressurised prior to all work on the system Working on the electrical equipment Work may only be performed on the electrical equipment of the truck when it is in a voltage free state Function checks inspections and adjustments on energised parts must only be performed by trained and authorised persons taking the neces...

Page 253: ...e workshop manual for this truck are allowed and are tested for the necessary safety and load capacity Only have the truck raised and jacked up by the authorised service centre Only jack the truck up at the points specified in the workshop manual The truck must be raised and jacked up for various types of maintenance work The authorised service centre must be informed that this is to take place Saf...

Page 254: ... 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 service technician 1 2 Securing the telescopic lift mast Extend the lift mast Route the chain over the cross beam of the outer mast 1 and under the cross beam of the inner mast 2 Lower the inner mast until it strikes the chain NOTE Ext...

Page 255: ...he chain Servicing Checking the battery condition acid level and acid density CAUTION Risk of damage Follow the information in the operating instructi ons for the battery Remove battery from truck Inspect battery for cracked housing raised plates and acid leaks WARNING The electrolyte diluted sulphuric acid is poisonous and caustic Observe the safety regulations for handling battery acid Rinse awa...

Page 256: ...ls Tighten the battery terminal clips 2 Check the acid density using an acid siphon After charging this value must be between 1 24 and 1 29 kg l Maintaining wheels and tyres WARNING Risk of accident Uneven wear reduces the stability of the truck and increases the braking distance Worn or damaged tyres left or right must be replaced immediately WARNING Risk of tipping Tyre quality affects the stabi...

Page 257: ...ly the same Polyurethane tyres can be worn down to the wear mark 3 The tyres must be replaced if Large cracks have formed in the tread This can be detected by a whirring sound when driving The tread has broken away significantly The tyre diameter has reduced by approx 9 A wear mark 1 in the lateral flank of the lining serves as a visual indication of the wear limit Checking the wheel fastenings Chec...

Page 258: ...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 or buckling A fitting is detached from the hose A fitting is heavily damaged or corroded Pipes must be replaced if There is a...

Page 259: ...er 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 The screw joints and welded seams of the battery change frame must be subjected to a visual inspection 50988078001 E...

Page 260: ...6 Maintenance Servicing 250 50988078001 EN ...

Page 261: ...7 Technical data ...

Page 262: ...7 Technical data Dimensions Dimensions Measurements h1 h3 h4 h6 and b1 are customised and can be taken from the order confirmation 252 50988078001 EN ...

Page 263: ... STILL STILL 1 2 Manufacturer s type designation FM X 10 FM X 10 N FM X 12 FM X 12 N 1 3 Drive Electric Electric Electric Electric 1 4 Operation Seated Seated Seated Seated 1 5 Load capacity load Q kg 1000 1000 1200 1200 1 6 Load centre of gravity c mm 600 600 600 600 1 8 Load distance x mm 278 184 278 184 1 9 Wheelbase y mm 1275 1275 1275 1275 Weights FM X 10 FM X 10 N FM X 12 FM X 12 N 2 1 Net w...

Page 264: ...ft h2 mm 1890 1890 1890 1890 4 4 Lift h3 mm 5750 5750 5750 5750 4 5 Height with lift mast extended h4 mm 6310 6310 6310 6310 4 7 Height of overhead guard cab h6 mm 2270 2270 2270 2270 4 8 Seat height h7 mm 1140 1140 1140 1140 4 10 Height of load wheel supports h8 mm 308 308 308 308 4 19 Total length l1 mm 2366 2462 2366 2462 4 20 Length including fork back l2 mm 1216 1312 1216 1312 4 21 Total widt...

Page 265: ... 4 43 Step height mm 345 345 345 345 Performance data FM X 10 FM X 10 N FM X 12 FM X 12 N 5 1 Driving speed with without load km h 14 14 14 14 14 14 14 14 5 11 Driving speed with without load when reversing km h 14 14 14 14 14 14 14 14 5 2 Lifting speed with without load m s 0 47 0 7 0 47 0 7 0 47 0 7 0 47 0 7 5 3 Lowering speed with without load m s 0 56 0 5 0 56 0 5 0 56 0 5 0 56 0 5 5 4 Reach s...

Page 266: ... V Ah 48 420 48 420 48 420 48 420 6 5 Battery weight 5 depending on the manufacturer kg 750 750 750 750 6 6 Energy consumption in accordance with VDI cycle kWh h 6 7 Handling performance t h 6 8 Energy consumption at max handling performance kWh in 1 h kWh h Other FM X 10 FM X 10 N FM X 12 FM X 12 N 10 1 Working pressure for attachment bar 254 254 254 254 10 2 Oil flow for attachments l min 20 20 2...

Page 267: ... STILL STILL 1 2 Manufacturer s type designation FM X 14 FM X 14 N FM X 17 FM X 17 N 1 3 Drive Electric Electric Electric Electric 1 4 Operation Seated Seated Seated Seated 1 5 Load capacity load Q kg 1400 1400 1700 1700 1 6 Load centre of gravity c mm 600 600 600 600 1 8 Load distance x mm 348 335 410 325 1 9 Wheelbase y mm 1381 1453 1453 1453 Weights FM X 14 FM X 14 N FM X 17 FM X 17 N 2 1 Net w...

Page 268: ...t h2 mm 1890 1890 1880 1880 4 4 Lift h3 mm 5750 5750 5750 5750 4 5 Height with lift mast extended h4 mm 6310 6310 6320 6320 4 7 Height of overhead guard cab h6 mm 2270 2270 2270 2270 4 8 Seat height h7 mm 1140 1140 1140 1140 4 10 Height of load wheel supports h8 mm 308 308 308 308 4 19 Total length l1 mm 2402 2489 2484 2499 4 20 Length including fork back l2 mm 1252 1338 1262 1349 4 21 Total width...

Page 269: ...3 Step height mm 345 345 345 345 Performance data FM X 14 FM X 14 N FM X 17 FM X 17 N 5 1 Driving speed with without load km h 14 14 14 14 14 14 14 14 5 11 Driving speed with without load when reversing km h 14 14 14 14 14 14 14 14 5 2 Lifting speed with without load m s 0 45 0 68 0 45 0 68 0 45 0 68 0 45 0 68 5 3 Lowering speed with without load m s 0 56 0 52 0 56 0 52 0 55 0 52 0 55 0 52 5 4 Rea...

Page 270: ... 420 48 420 48 420 6 5 Battery weight 5 depending on the manufacturer kg 750 750 750 750 6 6 Energy consumption in accordance with VDI cycle kWh h 3 26 3 26 6 7 Handling performance t h 61 28 61 28 6 8 Energy consumption at max handling performance kWh in 1 h kWh h 3 4 3 4 Other FM X 14 FM X 14 N FM X 17 FM X 17 N 10 1 Working pressure for attachment bar 254 254 254 254 10 2 Oil flow for attachment...

Page 271: ... 1 Manufacturer STILL STILL STILL STILL 1 2 Manufacturer s type designation FM X 20 FM X 20 N FM X 20 W FM X 20 EW 1 3 Drive Electric Electric Electric Electric 1 4 Operation Seated Seated Seated Seated 1 5 Load capacity load Q kg 2000 2000 2000 2000 1 6 Load centre of gravity c mm 600 600 600 600 1 8 Load distance x mm 410 307 400 400 1 9 Wheelbase y mm 1525 1525 1525 1525 Weights FM X 20 FM X 20...

Page 272: ...t h2 mm 1880 1880 1880 1880 4 4 Lift h3 mm 5580 5580 5580 5580 4 5 Height with lift mast extended h4 mm 6150 6150 6150 6150 4 7 Height of overhead guard cab h6 mm 2270 2270 2270 2270 4 8 Seat height h7 mm 1140 1140 1140 1140 4 10 Height of load wheel supports h8 mm 373 373 373 373 4 19 Total length l1 mm 2484 2589 2484 2484 4 20 Length including fork back l2 mm 1334 1439 1334 1334 4 21 Total width...

Page 273: ...3 Step height mm 345 345 345 345 Performance data FM X 20 FM X 20 N FM X 20 W FM X 20 EW 5 1 Driving speed with without load km h 14 14 14 14 14 14 14 14 5 11 Driving speed with without load when reversing km h 14 14 14 14 14 14 14 14 5 2 Lifting speed with without load m s 0 37 0 58 0 37 0 58 0 37 0 58 0 37 0 58 5 3 Lowering speed with without load m s 0 53 0 5 0 53 0 5 0 53 0 5 0 53 0 5 5 4 Reac...

Page 274: ... 5 Battery weight 5 depending on the manufacturer kg 940 940 940 940 6 6 Energy consumption in accordance with VDI cycle kWh h 6 7 Handling performance t h 6 8 Energy consumption at max handling performance kWh in 1 h kWh h Other FM X 20 FM X 20 N FM X 20 W FM X 20 EW 10 1 Working pressure for attachment bar 254 254 254 254 10 2 Oil flow for attachments l min 20 20 20 20 10 7 Sound pressure level i...

Page 275: ...n FM X 20 1 3 Drive Electric 1 4 Operation Seated 1 5 Load capacity load Q kg 2200 1 6 Load centre of gravity c mm 600 1 8 Load distance x mm 482 1 9 Wheelbase y mm 1669 Weights FM X 22 2 1 Net weight including battery kg 5100 2 3 Front rear axle load without load kg 3020 2070 2 4 Front rear axle load with fork forwards and with load kg 2780 4520 2 5 Front rear axle load with fork backwards and wi...

Page 276: ...m 1270 4 22 Fork arm dimensions s e l mm 50 120 1150 4 23 ISO 2328 fork carriage class model A B 2 A 4 24 Fork carriage width b3 mm 760 4 25 Width across forks min max b5 mm 336 640 4 26 Width between load wheel supports b4 mm 920 4 28 Reach forward l4 mm 695 4 31 Ground clearance with load under lift mast m1 mm 70 4 32 Ground clearance at centre of wheelbase m2 mm 70 4 34 1 Working width when han...

Page 277: ...load s 4 5 4 0 5 10 Service brake Gen hydr mech Electric motor FM X 22 6 1 Traction motor power rating S2 60 min kW 6 5 6 2 Lift motor power rating S3 15 kW 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531C 254 2 6 4 Battery voltage nominal capacity K5 V Ah 48 775 6 5 Battery weight 5 depending on the manufacturer kg 1120 6 6 Energy consumption in accordance with VDI cycle kWh h 6 ...

Page 278: ...7 Technical data VDI datasheet FM X 22 FM X 22 Distributed load in accordance with VDI 2199 kg m2 268 50988078001 EN ...

Page 279: ...y size 3 Dependent on the lift mast sideshift fork tilt 2 4 Characteristics FM X 25 1 1 Manufacturer STILL 1 2 Manufacturer s type designation FM X 25 1 3 Drive Electric 1 4 Operation Seated 1 5 Load capacity load Q kg 2500 1 6 Load centre of gravity c mm 600 1 8 Load distance x mm 482 1 9 Wheelbase y mm 1669 Weights FM X 25 2 1 Net weight including battery kg 4240 2 3 Axle load without front rear...

Page 280: ...ight h7 mm 1140 4 10 Height of load wheel supports h8 mm 373 4 19 Total length l1 mm 2556 4 20 Length including fork back l2 mm 1406 4 21 Total width b1 b2 mm 1270 4 22 Fork arm dimensions s e l mm 50 120 1150 4 23 ISO 2328 fork carriage class model A B 2 A 4 24 Fork carriage width b3 mm 760 4 25 Width across forks min max b5 mm 336 640 4 26 Width between load wheel supports b4 mm 920 4 28 Reach f...

Page 281: ...ng capability with without load 10 15 5 8 Max climbing capability with without load 15 20 5 9 Acceleration time over 10 metres with without load s 5 10 Service brake Gen hydr mech Electric motor FM X 25 6 1 Traction motor power rating S2 60 min kW 6 5 6 2 Lift motor power rating S3 15 kW 14 6 3 Battery in accordance with DIN 43531 35 36 A B C no 43531C 254 2 6 4 Battery voltage nominal capacity K5...

Page 282: ...ents Only use the types of tyre listed below Observe the basic principles of safe operation see the chapter entitled Tyres It is recommended that you consult your ser vice centre before carrying out any modifica tions Drive wheel Polyurethane direct bond Model Tyres FM X 10 N standard versions 360 x 130 FM X 12 N standard versions 360 x 130 FM X 14 N standard versions 360 x 130 FM X 17 N standard v...

Page 283: ...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 100 50988078001 EN 273 ...

Page 284: ...7 Technical data Wheels and tyres 274 50988078001 EN ...

Page 285: ...l and acid density 245 Checking the charge status 216 Disposal 11 Maintaining 216 Safety regulations 192 Battery acid 39 Battery change frame Adjusting the transfer height 154 Area of application 153 Battery replacement area 155 General 152 Load capacity 153 Locking the swing bolt 154 Safe handling 153 Battery commissioning 211 Battery lock 197 Adjusting 211 Locking the battery 198 Releasing the b...

Page 286: ...area 122 Danger to employees 22 Declaration of conformity 3 Defects 33 Defining directions 9 Dimensions 252 Dimensions of roadways 88 Display and operating unit 48 Accessing the main menu with a password 75 Accessing the main menu without a password 75 Authorisation levels for accessing operating data 74 Displays during the switch on process 72 Entering operating data 74 Entering operating data in ...

Page 287: ...rying out mainte nance 228 Maintenance timeframe 229 Information symbols 5 Insulation testing 35 Insurance cover on company premises 29 Issue date of the operating instructions 5 J Jacking up 243 Joystick 4Plus 49 Lifting lowering the fork carriage 110 Shifting 112 Tilting the lift mast 111 Transition shift 111 L Lift height preselector AUTO MODE function 158 Definition of terms 157 General 157 Ope...

Page 288: ... 239 Operating procedures 10 Operating the service brake 96 Operating the signal horn 79 OPTISPEED 84 Ordering spare parts and wearing parts 239 Overhead guard Drilling 31 Modifications 31 Roof loads 31 Welding 31 Overview 46 Identification points 51 Overview of the driver s compartment 47 P Packaging 11 Parking the truck securely 220 Personnel qualifications 228 Picking up loads 121 Place of use 15 ...

Page 289: ...2 General 91 Set values 243 Setting the battery data 213 Shutting down the truck 222 Side chassis supports 90 Special risks 18 Stability 18 Standard steering 100 Starting drive mode Dual pedal version 94 Single pedal version 92 Steering 100 Steering column Adjusting 65 Steering system Checking for correct function 81 Storing the truck 222 Switching on the key switch 70 T Technical data Dimensions ...

Page 290: ...ing the condition 59 Checking the condition and wear of the tyres 247 Checking the wheel fastenings 247 Maintaining 246 Technical data 272 Working at the front of the truck 243 Working on the electrical equipment 242 Working on the hydraulic equipment 242 280 50988078001 EN ...

Page 291: ......

Page 292: ...STILL GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 50988078001 EN ...

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