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Still R70-40T, Operating Instructions Manual

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Foreword

1

Information about documentation

Information about documentation

Documentation scope

• Operating and maintenance manual
• Operating and maintenance manual for

attachments (special equipment)

• Maintenance data table
• Spare parts list
• VDMA rules for the proper use of industrial

trucks

• Inspection and test log book for power-

driven industrial trucks (Germany only)

This operating and maintenance manual de-

scribes all necessary measures for safe oper-

ation and correct maintenance of your indus-

trial truck. It includes all variants available up

to the time of going to press. Special designs

to meet customer requirements are docu-

mented in a separate operating and mainte-

nance manual. For further information, please

contact your service centre.
Please enter the factory no. and year of

manufacture from the factory nameplate

in the space provided ⇒ Chapter "Name-

plate", P. 4-49 below:
Factory no. ...............................................
Year of manufacture

...................................................
Please provide these numbers for all technical

questions.
An operating and maintenance manual is pro-

vided with every industrial truck. This manual

must be stored carefully and must be available

to the driver and operator at any time. The

storage location is specified in the Overviews

chapter ⇒ Chapter "Overviews", P. 39.
If the operating instructions are lost, the op-

erator must obtain a replacement from the

manufacturer immediately.
The operating and maintenance manual is

included in the spare parts list and can be

reordered as a spare part.

171673 [EN]

3

Summary of Contents for R70-40T

Page 1: ...Operating Instructions LPG forklift truck R70 40T R70 45T R70 50T 7081 7082 7083 Ident no 171673 EN ...

Page 2: ......

Page 3: ...es during repair work 7 2 Introduction Use of truck 10 Proper use 10 Proper towing usage 10 Impermissible use 10 Place of use 11 Use of working platforms 12 Residual risk 13 Residual dangers residual risks 13 Special risks when using the forklift truck and attachments 14 Overview of hazards and countermeasures 16 Risk for employees 18 3 Safety Definition of terms used for responsible persons 20 Op...

Page 4: ...3 Battery acid 34 Coolant 35 Disposal of consumables 36 Emissions 37 4 Overviews General view 40 Versions of driver s compartment 42 Driver s compartment single pedal version 42 Driver s compartment dual pedal version 44 Operating and display elements 46 Display and operating unit 46 Direction of travel flasher fault multi function display 47 Mini console 47 Identification points 48 Overview 48 Na...

Page 5: ...tion of brake system 73 Checking function of steering system 74 Setting the traction programs 75 Driving 76 Safety regulations when driving 76 Driveways 78 Driving single pedal operation with multiple lever version 80 Driving single pedal operation with version including mini console 84 Driving two pedal operation 88 Service brake 91 Operating the parking brake 93 Steering 94 Lifting 95 Lifting sy...

Page 6: ... attachments 121 Operation of additional equipment 122 Switching lighting on and off special equipment 122 Switching flashing light off and on 123 Switching hazard warning system off and on special equipment 124 Switching direction indicators off and on 125 Operating the windscreen wiper washer 125 Cab 126 Heater 127 Driving with cruise control 127 Trailer operation 130 Towed load 130 Coupling the...

Page 7: ...54 Transport 154 Towing 156 Crane loading 156 Frequent short term operation 159 Jump starting 160 Behaviour in emergencies 162 Procedure if truck tips over 162 Emergency lowering 163 Disconnecting the battery 164 Refuelling 165 Changing the LPG cylinder 165 Filling the LPG tank 168 Shut down 171 Parking the truck securely 171 Measures for prolonged shutdown storage of truck 173 Returning to servic...

Page 8: ...he windscreens 198 After washing 198 Maintenance after first 50 operating hours 199 Maintenance during the break in period 199 Maintenance as required 200 Cleaning the radiator checking for leaks 200 Topping up coolant and checking coolant concentration 200 Changing the air filter insert 202 Servicing the battery 204 Maintaining hydraulic equipment 207 Servicing wheels and tyres 208 Checking adjus...

Page 9: ...cking the lambda control system 230 Checking the heating system for leaks 230 Check lift cylinders and connections for leaks 230 Maintain lifting system 231 Checking the clearance between fork carriage stop and run out stop 233 Checking the fork arms 233 Checking reversible fork arms 234 3000 hour maintenance two year maintenance 235 Work that must also be carried out 235 Changing the gear lubrica...

Page 10: ...heet 249 Wheels and tyres 252 Fuse assignment 253 Fuse assignment in main fuse holder 253 Fuse assignment special equipment 254 8 Circuit diagrams Hydraulics 256 Hydraulic circuit diagram 256 Electrical equipment 258 Legend for circuit diagrams 258 VIII 171673 EN ...

Page 11: ...1 Foreword ...

Page 12: ...ormation for this Read it and follow these instructions before bringing your industrial trucks into use This way you will avoid acci dents spare yourself worry and maintain the warranty CE Symbol EC declaration of conformity EC mark of conformity With the EC declaration of conformity the manufacturer confirms the compliance of the industrial truck with the standards and reg ulations valid at the t...

Page 13: ...u mented in a separate operating and mainte nance manual For further information please contact your service centre Please enter the factory no and year of manufacture from the factory nameplate in the space provided Chapter Name plate P 4 49 below Factory no Year of manufacture Please provide these numbers for all technical questions An operating and maintenance manual is pro vided with every ind...

Page 14: ...Issue date and currentness of man ual May 2007 STILL is constantly engaged in the further de velopment of industrial trucks Please note that these operating instructions are subject to change and any claims based on the informa tion and figures contained in these operating instructions cannot be asserted If you require technical support for your in dustrial truck please contact the responsible ser...

Page 15: ...In the case of procedures that must be strictly ad hered to in order to prevent material damage and or destruction NOTE For technical requirements that require spe cial attention ENVIRONMENT NOTE To prevent environmental damage Explanation of the cross references Cross references are used to direct the reader to the appropriate section or chapter Examples Cross reference to a section Chap ter Expl...

Page 16: ...sition the load is at the front 6210_001 009 Sample graphics This documentation explains the usually se quential sequence of certain functions or operations Schematic diagrams of a coun terbalance truck are used to illustrate these sequences NOTE These schematic diagrams are not represen tative of the constructed state of the docu mented industrial truck They serve only to illustrate the sequences...

Page 17: ...of the industrial truck Disposal of units and batteries during repair work It may be necessary to replace units as part of maintenance work Replaced units must then be disposed of Your vehicle is comprised of different materi als Each of these materials must be disposed of treated or recycled in accordance with regional and national regulations NOTE When disposing of batteries please refer to the ...

Page 18: ...1 Foreword Environmental considerations 8 171673 EN ...

Page 19: ...2 Introduction ...

Page 20: ...load diagram and may not be exceeded Proper towing usage This forklift truck is suitable for the occasional towing of trailers and is equipped with a towing device for this purpose This occasional tow ing may not exceed 2 of the daily operating time If you want to use the forklift truck for more frequent towing the manufacturer must be consulted The trailer operation provisions must be followed Se...

Page 21: ...city concrete asphalt It should have a rough surface The driveways work areas and aisle widths must correspond with the specifications in these operating instructions see Chapter Driveways P 5 78 Driving on ascending and descending slopes is permitted if the indicated data and specifi cations are observed see Chapter Drive ways P 5 78 The forklift truck is suitable for use in coun tries ranging fr...

Page 22: ...G The use of working platforms is governed by natio nal law This law must be observed This allowed only if the law allows the use of working platforms in your country Consult your national authorities in Germany the trade association before any use 12 171673 EN ...

Page 23: ...ons that are in the vicinity of the industrial truck must be instructed regarding these risks that arise through use of the industrial truck In addition we draw attention to the safety regulati ons in these operating instructions Risks can include Escape of consumables due to leaks rup ture of lines and containers etc Accident risk when driving over difficult ground such as gradients smooth or irr...

Page 24: ...s when using the forklift truck and attachments The manufacturer s approval must be ob tained for any unconventional use during which the driver cannot ensure proper and safe execution In particularly difficult cases such as the si multaneous use of two forklift trucks for trans porting heavy or bulky loads the supervisor must be present at the place of use and accept responsibility and control of...

Page 25: ...Introduction 2 Residual risk 171673 EN 15 ...

Page 26: ...k of skills and qualification of driver Driver training sit on and stand on O BGG 925 VDI 3313 driver permit Usage by unautho rised persons Access with key only for authorised persons O Industrial truck not in safe operating condition Recurrent testing and rectification of defects O BetrSichVO Workplace Safety Ordinance Impaired visibility through load Resource planning O BetrSichVO Workplace Safe...

Page 27: ... a Diesel Observe BetrSichVO Workplace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O b LPG Observe BGV D34 operating instructions and VDMA German Engineering Federation rules O When charging traction batteries Observe BetrSichVO Workplace Safety Ordinance operating instructions and VDMA German Engineering Federation rules O VDE 0510 In particular Ensure ven...

Page 28: ... the attachments likewise on account of their own CE marking The operator must however select the type and equipment of the industrial trucks so as to comply with the local provisions for usage The result must be documented Section 6 ArbSchG In the case of industrial truck usage involving similar hazard situations it is permit ted to summarise the results The overview provided see Chapter Overview...

Page 29: ...3 Safety ...

Page 30: ... specifications are adhered to Specialist A specialist is considered to be someone whose technical training and experience have enabled them to develop an appropri ate knowledge of industrial trucks and who is sufficiently familiar with the applicable na tional health and safety regulations accident prevention regulations directives and gener ally recognised technical conventions stan dards VDE re...

Page 31: ...river must wear appropriate protective equipment protective clothing safety shoes safety helmet protective goggles gloves for the conditions the job and the load to be lifted Strong footwear should be worn to ensure safe driving and braking The driver must be familiarised with the oper ating manual and it must be accessible to him at all times The driver must have read and understood the operating...

Page 32: ...ns Prohibition on use by unauthorised per sons The driver is responsible for the industrial truck during working hours He may not allow unau thorised persons to operate the truck When leaving the truck he must secure it against unauthorised use 22 171673 EN ...

Page 33: ... and the stability of the forklift truck and can result in accidents Therefore contact your service centre in ad vance Changes that will disadvantageously affect stability among other things may not be made without our approval The forklift truck can only be converted with our written approval Approval from the re sponsible authority must be obtained if neces sary We warn against the installation ...

Page 34: ...nts and accessories supplied by other companies have not been tested and approved by us CAUTION Installation and or use of such products may there fore have a negative impact on the design features of your industrial truck and thus impair active and or passive driving safety We recommend that you obtain approval from us and if necessary from the responsible regulatory authorities before installing...

Page 35: ... falling objects Tyres Tyre quality affects the stability and handling of the forklift truck Changes can only be made in consultation with the manufacturer When changing wheels or tyres always ensure that no tilting of the forklift truck occurs e g always change right and left wheels at the same time Medical equipment When a driver is wearing medical equipment e g heart pacemaker or hearing aids t...

Page 36: ...ete audit of the technical condition of the industrial truck is performed with regard to accident safety In addition the industrial truck must also be thoroughly checked for damage that could have potentially been caused by improper use An audit log must be created The results from the audit must be retained until a further two audits have been carried out The schedule is indicated by a sticker on...

Page 37: ...han one year The following is checked proper composition sealing function adjustment and the func tional ability of the safety devices The results of the tests must be retained in the test certification in accordance with BGG 936 please observe your national regulations that must be kept until the next test The test certification must be presented for authorities to look at upon request at any tim...

Page 38: ...ing The industrial truck insulation must have a sufficient insulation resistance For this rea son an insulation test in accordance with DIN 57117 and DIN 43539 VDE 0117 and VDE 0510 must be conducted at least once every year NOTE Contact your service centre to arrange for an insulation test Testing the insulation resistance of the electrical system NOTE Nominal battery voltage test voltage 500 V E...

Page 39: ...nance data table P 6 186 Oils WARNING Oils are flammable Comply with applicable legal regulations Do not allow oils to come into contact with hot engine parts Do not smoke WARNING Oils are toxic Avoid contact and consumption If oil mist or vapours have been inhaled seek fresh air If oil comes into contact with the eyes flush thoroughly at least 10 minutes with water and then seek medical assistanc...

Page 40: ...gent and then dispose of it in accordance with applicable regulations ENVIRONMENT NOTE Oils are water pollutants Always store oil in legally approved contain ers Avoid spilling oil Immediately treat spilled oil with an oil bind ing agent and then dispose of it in accor dance with applicable regulations Dispose of used oil in accordance with ap plicable regulations LPG Always observe the accident p...

Page 41: ...ioxide dry fire extinguishers or carbon dioxide gas extinguis hers should be used DANGER Risk of poisoning It must be ensured that trucks with LPG systems are only operated in rooms that are entirely or partially enclosed if no hazardous concentra tions of exhaust constituents harmful to health can be produced in the room air CAUTION Industrial trucks fuelled by LPG should only be par ked in rooms...

Page 42: ...operating a truck with an LPG system make sure that the floor opening 1 below the engine compartment is not closed Make sure there are sufficiently large ventilation openings at least 200 cm2 in total in the engine compartment floor so that gas cannot accumulate Storing pressurised gas vessels Cylinder and main shut off valves should be closed as soon as trucks are parked The special regulations g...

Page 43: ...with an enclosed sealed cover and a strong basket guard Storage rooms and maintenance workshops must be well ventilated Here it should be borne in mind that LPG is heavier than air It collects at floor level in work pits and other de pressions in the ground where it may produce hazardous explosive mixtures of gas and air Hydraulic fluid WARNING These fluids are pressurised during operation of the ...

Page 44: ...To avoid injury use appropriate personal protective equipment e g protective gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a substance hazardous to water Always store hydraulic fluid in containers complying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of according to t...

Page 45: ...Immediately rinse away spilt battery acid with plenty of water Follow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Coolant WARNING Coolant and coolant additive are hazardous to health Store only in original vessels do not spill Never use empty food containers bottles or other vessels for storing coolant The legal regulations must b...

Page 46: ...llow the national regulations for your country Work may only be carried out in areas designated for the pur pose Care must be taken to minimise as far as possible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of...

Page 47: ...k cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal noise pollution If necessary these should be determined directly at the workplace under the actual conditions there additional noise sources special operating conditions sound reflections by the operating company see Chapter Definition of terms used for respon...

Page 48: ...ses mainly consist of water vapour carbon dioxide CO2 carbon monoxide CO hydro carbons CH aldehydes and nitrogen oxide NOX The components CO CH and NOX are toxic or harmful to health and must not be inhaled in high concentrations For this reason the engine cannot be operated in closed areas without sufficient ventilation Heat WARNING The exhaust gases are very hot and can ignite combustible materi...

Page 49: ...4 Overviews ...

Page 50: ...4 Overviews General view General view 7081_003 001 1 2 3 4 5 6 7 8 1 Lift mast 2 Overhead guard 3 Steering wheel 4 Driver s seat 5 Steering axle 6 Drive axle 7 Tilt cylinder 8 Fork arms 40 171673 EN ...

Page 51: ...Overviews 4 General view 171673 EN 41 ...

Page 52: ...4 Overviews Versions of driver s compartment Versions of driver s compartment Driver s compartment single pedal version 7081_003 010 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 17 18 42 171673 EN ...

Page 53: ...ift lower operating lever 6 Tilt operating lever 7 Attachments operating lever 8 Attachments operating lever 9 Display and operating unit 10 Storage box 11 Bottle holder for 1 l PET bottles 12 Parking brake lever 13 Storage shelf for user and maintenance manual special equipment 14 Driver seat 15 Accelerator pedal 16 Bonnet release 17 Brake pedal 18 Alarm horn foot switch 171673 EN 43 ...

Page 54: ...4 Overviews Versions of driver s compartment Driver s compartment dual pedal version 7081_003 039 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 17 18 44 171673 EN ...

Page 55: ...er operating lever 6 Tilt operating lever 7 Attachments operating lever 8 Attachments operating lever 9 Display and operating unit 10 Storage box 11 Bottle holder for 1 l PET bottles 12 Parking brake lever 13 Storage compartment for operating and maintenance manual 14 Driver s seat 15 Forwards accelerator pedal 16 Bonnet release 17 Brake pedal 18 Reverse accelerator pedal 171673 EN 45 ...

Page 56: ...action program switch 8 Menu change key 9 Fleet Manager smart card reader 10 Interior light display 11 Interior light switch 12 Rear window heater display 13 Rear window heater switch 14 Rear searchlight display 15 Rear searchlight switch 16 Time symbol 17 Time 18 Operating hours symbol 19 Operating hours display 20 Traction program symbol 21 Current traction program 22 Fuel tank symbol 23 Fuel le...

Page 57: ...lasher fault multi func tion display is used to display the direction of travel In addition the flasher is used to indi cate that messages are shown on the display and operating unit 7311_003 056 1 2 1 Travel direction switch 2 Direction indicator switch Mini console The mini console is located on the steering column below the steering wheel NOTE Switch 1 is not assigned in trucks with the travel ...

Page 58: ...fung letzte Prüfung jährliche Prüfung Mängel siehe Prüfbuch STILL GmbH Hamburg gem UVV 20 20 19 5 16 3 6 7 11 14 9 8 4 12 UVV 15 15 15 18 17 STOP 6 10 11 12 8 9 6 7 5 4 19 3 4 10 bar STOP 10 13 14 1 2 16 17 18 15 2 1 13 WA L STOP 7081_003 040 98 T E C H N O L O G Y 48 171673 EN ...

Page 59: ... information special equipment 19 Company logo 1 2 3 4 5 6 7 8 9 10 11 12 6210_921 003 1 Type 2 Factory no 3 Year of construction 4 Tare weight kg 5 Permissible battery weight max only for electric lift trucks 6 Permissible battery weight min only for electric lift trucks 7 Ballast weight only for electric lift trucks 8 Refer to the technical data listed in these operating instructions for more de...

Page 60: ...g C U R data This label provides information on the weight and the load distribution of your truck 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Vehicle identification number NOTE Please state this serial number when making technical inquiries The serial number contains the following infor mation 1 Production site 2 Type 3 Variant 4 Serial number 50 171673 EN ...

Page 61: ...5 driver s seat Imitation leather lumbar support heater backrest extension Textile cover lumbar support heater back rest extension Overhead guard and cab Overhead guard Weather protection levels 1 to 3 Cab with heater Lift mast NOTE Overall height and lift height see Chap ter Technical data P 247 Tele Triple Load backrest Electrical equipment Lighting system various versions Dual pedal control tra...

Page 62: ... remover Shovel Sideshift Clamp forks without sideshift Bale clamp without sideshift Clamp forks with sideshift Bale clamp with sideshift Fork arm adjustment Accessory overview Key for key switch 2 pieces Key for cab special equipment Emergency lowering key Release tool for bonnet 52 171673 EN ...

Page 63: ...5 Operation ...

Page 64: ...uitable equipment for this Prior to start up a safe operating state must be ensured 1 2 6210_000 002 The retaining devices 1 of the fork arms for preventing lifting and shifting should not show any defects Fork arms or other load carrying equipment may not have any noticeable damage e g bends cracks significant wear The chains must be undamaged and evenly and adequately tensioned Check the area un...

Page 65: ...he case of versions with a cabin special equipment all windows must be clean and free of ice Switch on the heater special equipment and set the air vents so that the windows remain free of ice Report defects to the supervisor 7071_003 006 1 2 Opening the bonnet WARNING Risk of injury Before opening the bonnet switch off the engine Lock steering column 1 into the frontmost position Slide the driver...

Page 66: ... of accident The release tool must always remain with the truck so that the bonnet can be opened at any time even in an emergency 7081_003 035 1 Checking the engine oil level NOTE The vehicle should be as level as possible when performing this check Remove and wipe off dipstick Insert dipstick to contact and pull out again The oil level must be between the markings arrows If the oil level only rea...

Page 67: ...d exits from the spray nozzles 7071_003 043 2 1 Checking the condition of the wheels and tyres WARNING Risk of accident With uneven wear or incorrect air pressure the stability of the forklift truck decreases and the braking distance increases Renew left and right worn or damaged tyres without delay NOTE Only permissible tyre types may be used see Chapter Wheels and ty res P 7 252 Check tyres 1 fo...

Page 68: ...ere is a risk of explosion if LPG escapes Do not start engine if there are leaks the smell of gas among other things Contact your customer service office 7311_136 003 2 1 Check whether the hose 2 is securely connected to the gas cylinder DANGER Risk of explosion from spark discharge Opening and closing may not be aided with striking tools WARNING LPG can cause frostbite on the skin Protective glov...

Page 69: ...P 3 30 Check whether smell of gas is discernable DANGER There is a risk of explosion if LPG escapes Do not start the engine if a leak the smell of gas or the like is noted Contact your service centre Check whether the hose 1 is firmly con nected to the LPG tank DANGER Risk of explosion from spark discharge Striking tools should not be used for opening closing WARNING LPG can cause frostbite on the...

Page 70: ...e seat whilst driving Adjust the seat in such a way that you can safely reach and operate all the controls WARNING On some versions special equip ment the amount of head clearance on your forklift truck may be restric ted On these versions the distance between the head and the lower edge of the roofing sheet must be at least 40 mm NOTE If your truck comes with separate operating in structions for ...

Page 71: ...sure that there are no ob jects in the swivel area of the seat 7094_003 006 1 Moving the driver s seat Pull lever 1 up and move the seat Release the lever WARNING Risk of injury Make sure that the seat is securely engaged 7094_003 008 2 Adjusting the backrest Pull lever 2 upwards and adjust the incline of the seat backrest using your body weight Release the lever WARNING Risk of injury Make sure t...

Page 72: ...itial central position before each new lift audible click NOTE A noticeable empty lift on the operating handle shows you have reached the minimum or ma ximum weight setting The correct driver s weight has been selected when the arrow 4 is in the middle of the view ing window 6321_003 039 5 Adjusting the lumbar support special equipment Adjust the lumbar support by turning the hand wheel 5 By turni...

Page 73: ...osition To remove the backrest extension move it past the end stop by jolting it upwards 6321_003 041 7 Switching the seat heater special equip ment on and off Switch the seat heater on or off using switch 7 Adjusting the MSG 20 driver s seat DANGER Risk of accident Do not adjust the seat whilst driving Adjust the seat in such a way that you can safely reach and operate all the controls 171673 EN ...

Page 74: ...u must ad just the seat suspension to your own body weight This helps your back and protects your health To prevent injury make sure that there are no ob jects in the swivel area of the seat 6321_003 044 1 2 3 Moving the driver s seat Pull lever 2 up and move the seat Release the lever WARNING Risk of injury Make sure that the seat is securely engaged Adjusting the backrest Pull lever 3 upwards an...

Page 75: ...Adjust your individual suspension comfort using the adjusting lever 1 7071_003 008 2 1 Adjusting the steering column Loosen the knob 1 of the steering column locking device Position the steering column 2 and retighten the knob 1 DANGER Risk of accident Make sure that the steering column is secured in position Never adjust the steering column whilst driving 171673 EN 65 ...

Page 76: ...g see Chapter Checks and operations prior to start up P 54 If any malfunctions are detected do not put the truck into operation Please contact your supervisor or service centre DANGER Risk of accident Drive only with a secured bonnet Insert the ignition key 1 into the key switch and turn it to the right to operating position I 7071_003 099 This initiates a self test All lamps in the multi function...

Page 77: ... as either a percentage or bar display in the display field Top up if necessary see Chapter Refu elling P 165 3 Traction program The current traction program appears in the display 4 Operating hours The operating hours appear on the display Inform your service centre when a mainte nance interval is reached NOTE Have all repair and maintenance work per formed by your responsible service centre Defe...

Page 78: ...icity hazard from exhaust gases Do not allow the engine to run in unventilated rooms 7071_003 101 0 I 1 II Insert the key 1 into the key switch and turn it to position I When the display STARTEN START lights up turn the key to position II and hold in this position until the engine starts As soon as the engine has started release the key If the engine does not start after 20 seconds end the startin...

Page 79: ...ine immediately Refer to the information in the chapter en titled Fault displays see Chapter Error messages P 138 NOTE If the engine cannot be started due to a di scharged battery it can be jump started see Chapter Jump starting P 5 160 7071_003 010 1 Operating the signal horn On trucks with single pedal operation press foot switch 1 The signal horn sounds 171673 EN 69 ...

Page 80: ... seat belt is dange rous and never permitted Always fasten the belt before starting to drive DANGER Only a fully enclosed cab with closed fixed doors or bracket doors is an operator restraint system PVC doors are not a restraint system If the doors are open or removed you must use a different suitable restraint system e g restraining belt 70 171673 EN ...

Page 81: ...le switch special equip ment If there is an operating error or mal function the message SICHERHEITSGURT SAFETY BELT appears in the display and operating unit see Chapter SAFETY BELT message P 5 142 Pull the belt 3 smoothly out of the retrac tor and fasten belt tightly against the body above the thigh NOTE Sit back as far as possible so that your back is against the seat backrest The automatic blo ...

Page 82: ...ents the belt from being extended whenever the forklift truck is on a steep gradient It is not possible to pull the belt any further out of the retractor Drive off the slope carefully Fasten the belt Releasing the restraining belt 7090_342 005 1 4 Press the red button 4 on the buckle 1 72 171673 EN ...

Page 83: ...irty for exam ple by covering Malfunctions due to cold Thaw a frozen buckle or retractor and dry the parts to prevent repeated freezing CAUTION Risk of damage to components When thawing do not subject the buckle or retrac tor to excessive heat The temperature of the warm air should not ex ceed 60 C when thawing 7081_003 011 1 2 Checking function of brake system DANGER Risk of accident Do not put f...

Page 84: ...d on slopes In an emergency secure the forklift truck by inserting chocks on the downhill side 7071_003 015 1 Checking function of steering system Operate steering wheel 1 The play of the steering wheel while stationary may not be more than two finger widths DANGER Risk of accident If the hydraulics malfunction steering is stiff The forklift truck may not be operated with a defec tive steering sys...

Page 85: ...appears on the 2 display Traction programs 1 5 are available The basic principle is that the higher the trac tion program number is the greater the trac tion dynamics The following settings are possible Traction program 1 2 3 4 5 Speed km h 21 21 21 21 21 Acceleration forward backward 50 100 120 140 160 Deceleration forward backward 50 100 120 140 160 Reversing forward backward 50 100 120 140 160 ...

Page 86: ...Initial driving practice must be performed in an empty space or on a clear driving lane The following are forbidden during driving Allowing arms and legs to hang out Leaning over the outer edge of the forklift truck Crossing from one vehicle to another or to fixed components Moving the driver seat Adjusting the steering column Releasing the restraining belt Disabling the restraint system Driving w...

Page 87: ... must walk ahead of the vehicle Only drive at walking pace and always take extra care in such situations The forklift truck must be stopped immediately if eye contact with the guide is lost Driving with the load raised unnecessarily high is not permitted Rear view mirrors are only to be used for ob serving the road area behind the vehicle and not for driving backwards If visual aids mirror monitor...

Page 88: ... Ast depend on the dimensions of the load For pallets these are Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise R70 40T 4418 4618 R70 45T 4470 4670 R70 50T 4510 4710 The forklift truck may only be used on drive ways with curves that are not too tight slopes that are not too steep and thoroughfares that are not too narrow or low Driving on slopes The truck may be driv...

Page 89: ...ixed points of the surroundings The height is based on the overall height of the truck s lift mast and the dimensions of the load Observe the technical data see Chap ter Technical data P 247 Rules for driveways and the working area Only those routes authorised for traffic by the operator see Chapter Definition of terms used for responsible persons P 20 or his representative may be driven The traff...

Page 90: ...age SITZSCHALTER SEAT SWITCH appears in the display and operating unit see Chapter Message SITZSCHALTER SEAT SWITCH P 5 145 Fasten the safety belt The buckle has a buckle switch special equip ment If there is an operating error or mal function the message SICHERHEITSGURT SAFETY BELT appears in the display and operating unit see Chapter SAFETY BELT message P 5 142 Pull the raise lower 1 operating l...

Page 91: ...ves forwards The speed is controlled by the accelerator pedal posi tion Upon releasing the accelerator pedal the truck brakes electrically On a gradient the truck creeps downhill slowly after a stop DANGER Risk of accident Trucks with zero braking special equipment do not have an electrical braking func tion Use the footbrake to slow the truck NOTE You can stop the truck on ascending and de scendi...

Page 92: ... controlled by the accelerator pedal position Upon releasing the accelerator pedal the truck brakes electrically On a gra dient the truck creeps downhill slowly after a stop DANGER Risk of accident Trucks with zero braking special equipment do not have an electrical braking func tion Use the footbrake to slow the truck NOTE You can stop the truck on ascending and de scending slopes briefly without...

Page 93: ...ccelerated again in the opposite direction reversing Take your foot off the accelerator pedal 3 Operate the travel direction switch 5 to select the opposite direction up for reverse down for forwards Depress the accelerator pedal 3 again Neutral position 5 6210_501 003 To switch to the neutral position tap the di rection switch 5 briefly for the opposite di rection up for reverse down for forwards...

Page 94: ...message SITZSCHALTER SEAT SWITCH appears in the display and operating unit see Chapter Message SITZSCHALTER SEAT SWITCH P 5 145 Fasten the safety belt The buckle has a buckle switch special equip ment If there is an operating error or mal function the message SICHERHEITSGURT SAFETY BELT appears in the display and operating unit see Chapter SAFETY BELT message P 5 142 Pull the raise lower operating...

Page 95: ...es forwards The speed is controlled by the accelerator pedal position When releasing the accelerator pedal the forklift truck decelerates On a gradient the truck creeps downhill slowly after a stop DANGER Risk of accident Trucks with zero braking special equipment do not have an electrical braking func tion Use the footbrake to slow the truck NOTE You can stop the truck on ascending and de scendin...

Page 96: ... controlled by the accelerator pedal position When releasing the accelerator pedal the forklift truck decelerates On a gra dient the truck creeps downhill slowly after a stop DANGER Risk of accident Trucks with zero braking special equipment do not have an electrical braking func tion Use the footbrake to slow the truck NOTE You can stop the truck on ascending and de scending slopes briefly withou...

Page 97: ...the opposite direction reversing Take your foot off the accelerator pedal 3 Press the direction switch 5 for the oppo site direction of travel backwards to reverse and forwards to move forwards Depress the accelerator pedal 3 again Neutral position 7071_003 102 5 To switch to the neutral position tap the direction switch 5 briefly for the opposite direction of travel backwards to reverse and forwa...

Page 98: ...R SEAT SWITCH appears in the display and operating unit see Chapter Message SITZSCHALTER SEAT SWITCH P 5 145 Fasten the safety belt The buckle has a buckle switch special equip ment If there is an operating error or mal function the message SICHERHEITSGURT SAFETY BELT appears in the display and operating unit see Chapter SAFETY BELT message P 5 142 Pull the raise lower 1 operating lever backward a...

Page 99: ...lopes briefly without actuating the parking brake 6 electric brake The truck begins to creep downhill slowly DANGER Risk of accident This electric brake only functions while the key switch is switched on and the parking brake is re leased Press the brake pedal Do not leave the truck without applying the par king brake Reverse travel Release the parking brake 6 Depress the accelerator pedal 5 The a...

Page 100: ...e scending slopes briefly without actuating the parking brake 6 electric brake The truck begins to creep downhill slowly DANGER Risk of accident This electric brake only functions while the key switch is switched on and the parking brake is re leased Press the brake pedal Do not leave the truck without applying the par king brake 7081_003 042 3 5 4 6 Changing direction of travel Take your foot off...

Page 101: ...take account of this in his driving and braking style Electric brake function The electric brake converts the acceleration energy of the truck into electrical energy This causes the truck to slow Zero braking DANGER Risk of accident Trucks with zero braking special equipment do not have an electrical braking func tion Use the footbrake to slow the truck If your truck features zero braking special ...

Page 102: ...ion is not suffi cient use the footbrake 1 as well In the first section of the pedal s travel only the electric brake takes effect as the pedal is depressed further the mechanical brake is activated and acts on the drive wheels DANGER Risk of accident If the service brake fails the truck must be brought to a stop by operating the parking brake 92 171673 EN ...

Page 103: ...isplay 3 goes out DANGER The truck should not be parked on a slope Secure the truck in an emergency by placing chocks on the downhill side To release the parking brake press button 1 and lower the lever completely NOTE Once released the travel direction previously selected is retained and is shown on the travel direction flasher message multi function dis play 3 NOTE If you operate the accelerator...

Page 104: ...ering Steer the vehicle by turning the steering wheel 1 accordingly For turning radius information see Chap ter Technical data P 247 WARNING Risk of accident If the hydraulics fail steering is tight emergency steering property 94 171673 EN ...

Page 105: ...e basic specifications and procedures are to be complied with See Chapter Safety regulations when handling loads P 5 102 Lift mast versions The following lift masts may be installed in your truck 7071_003 058 1 Telescopic mast When moving the lift lower operating lever backwards the mast rises via two outer cylin ders and brings the fork carriage with it via the chains the fork carriage rises at t...

Page 106: ...iple masts special equipment an incorrect extension sequence can occur i e the in ner mast extends before the free lift is complete As a result the overall height is exceeded and damage may occur with passageways or low ceilings An incorrect extension sequence may for instance result from The hydraulic oil temperature being too low Blocking of the fork carriage in the inner mast Blocking of the fr...

Page 107: ...e lift mast due to dirt If the fork carriage or the load comes to an unexpected stop raise the fork carriage until the chains are under tension again and lower the load at some other suitable location If the fork carriage rollers in the lift mast be come blocked because of dirt raise the fork carriage until the chains are under tension again Remove the dirt before proceeding with work WARNING Risk...

Page 108: ...tion must be observed regardless of the equipment variation DANGER Risk of accident The lifting system must only be operated when the driver seat is occupied WARNING Risk of injury The safety guidelines Before taking up load should be observed exactly Chapter Prior to ta king up a load P 5 103 Reaching or climbing into moving parts of the fork lift truck e g lift mast si deshifts working equipment...

Page 109: ...r forward To tilt mast backwards Pull back Tilt operating lever 2 Lift lower fork carriage To raise fork carriage Pull back the Lift Lower operating lever 1 To lower the fork carriage Push forward the Lift Lower operating lever 1 NOTE The symbols on the levers show the move ment direction of the mast when the lever is pulled or pushed 171673 EN 99 ...

Page 110: ...fects the stability of the forklift truck The weights allowed according to the capacity ra ting plate must thus be reduced in relation to the actual load distance see Chapter Prior to taking up a load P 5 103 Operation with reversible forks 7090_862 013 Normal operation Like a normal fork the reversible fork arms special equipment can be lifted and tilted with the mast 100 171673 EN ...

Page 111: ...ng the centre of gravity of the load may not be 2 higher than 600 mm above the ground The fork extension special equipment may not be used WARNING Risk of accident Reverse operation is not permitted with the stan dard fork arms NOTE Conduct annual checks for cracks on the out side of the fork bend see Chapter Checking reversible fork arms P 6 234 171673 EN 101 ...

Page 112: ...tand underneath suspended loads or raised fork arms Never exceed the maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident Do not step onto the forks Do not lift people Never grab or climb on moving parts of the forklift truck DANGER Risk of accident When transporting small items attach a safety guard special equipment to prevent the l...

Page 113: ...mpact and homogenous loads Otherwise the stability and strength of the fork arms and lift mast are not ensured Improper or false operation or the boarding of persons to increase the load capacity is forbidden 1 Distance C of load centre from fork back mm 2 Lift height h in mm 3 Maximum loads Q in kg Example Weight of the load to be lifted 2220 kg 3 Load distance from the fork back 600 mm 1 Permiss...

Page 114: ...he driver A closed roof covering special equipment should also be used Removable roof segments may not be removed 1 6210_842 001 Setting forks Lift stopping lever 1 and move the fork arms to the desired position Allow the stopping lever to snap back into place The centre of gravity of the load must be posi tioned between the fork arms in the middle Only operate the fork arm adjustment spe cial equ...

Page 115: ... truck against un intentional use by unauthorised persons if persons do not leave the hazard area despite being warned DANGER Risk to life from falling loads Never walk or stand underneath overhead loads 6327_003 009 Transporting pallets Loading units e g pallets are generally to be transported individually Simultaneous trans port of several loading units is only allowed when instructed by the sup...

Page 116: ...duced visibility DANGER Loss of stability due to slipped unstable or in parti cular 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 can only be coupled to the industrial truck so that the load securing de vice cannot shift or re...

Page 117: ...dimensions do not exceed the specified maximum size Damaged loading equipment and improperly formed loading units may not be put into stor age Place the load on the loading equipment or secure the load on the loading equipment in such a manner that the load cannot shift or drop off The loading units should be stored so that the defined aisle width is not reduced by protruding parts 7090_800 004 Dr...

Page 118: ...ecial equip ment greater than 3 is in use a greater risk of slipping can be assumed during raising or lowering of the load Drive further forwards slowly CAUTION Risk of component damage Do not damage the racking and load when inserting the forks 7090_800 006 Insert the forks under the load as far as possible Stop the truck as soon as the fork backs contact the load The centre of gravity of the loa...

Page 119: ...0_800 007 Back out CAUTION Risk of component damage Watch behind you for a clear pathway Drive backward carefully and slowly until the load has cleared the racking Apply the brakes gradually 7090_800 008 Tilt the mast back 171673 EN 109 ...

Page 120: ...earance is reached not more than 300 mm The load should not be high enough to block the front view Otherwise drive backwards If this is not possible a second person acting as a guide must walk beside the truck Only drive at walking speed taking extra care Stop the truck immediately if contact with the guide is lost When using attachments special conditions apply see Chapter Assembling attach ments...

Page 121: ...7090_800 011 Only drive with the mast tilted back 7090_800 012 Drive slowly and carefully around sharp corners Always accelerate and brake gradually DANGER Risk of accident Do not start quickly do not apply brake fully 171673 EN 111 ...

Page 122: ...5 Operation Working with loads 7090_800 013 Never drive with a laterally protruding load e g with a sideshift or sideshift device 112 171673 EN ...

Page 123: ... tip over Lift the load to the stack height WARNING Risk of accident Tilt the mast forward with raised load carrying equipment only when it is directly over the stack Carefully drive the truck forward into the stack Lower the load until it is resting safety on the racking Look behind you Back the truck away until you can lower the fork arms without touching the stack Lower the fork arms to the gro...

Page 124: ...on an ascending or descending slope is not permitted The truck should not be parked on a slope In case of emergency secure the truck with chocks 7090_001 008 Driving on lifts For this truck the driver may only use lifts with a sufficient lifting capacity and for which the operator see Chapter Definition of terms used for responsible persons P 20 has au thorisation for use Drive the forklift truck ...

Page 125: ...loading bridge ensure that it is properly attached and secured and has adequate load bearing capacity lorry bridge Drive on the loading bridge slowly and cau tiously Ensure that the lorry onto which you will be dri ving is secured to prevent its shifting and can support the load of the forklift truck The lorry driver and the forklift truck driver must agree on the departure time 171673 EN 115 ...

Page 126: ...chment manufac turer must be followed CAUTION Attachments must be CE certified If there is no attachment specific residual lifting capacity plate mounted on the forklift truck the CE conformity is void Order the residual lifting capacity plate see Chapter Taking up a load using attach ments P 5 121 promptly from your service centre WARNING There is a risk of accident from a falling load If attachi...

Page 127: ...pacity and load moment of the forklift truck may not be exceeded in the combination of attachment and payload The specifications of the manu facturer and supplier of the attachment must be complied with When determining the lifting capacity the tare weight of the attachment and the resulting load moment must be taken into consideration 7090_900 001 Depressurising connections for at tachments NOTE ...

Page 128: ... zones etc Attachments may only be used for their intended purpose as described in the relevant operating instructions The driver must be instructed in the handling of the attachments Loads may only be picked up and transported with attachments if they can be seized and held pro perly If necessary the loads must also be secured against sliding rolling falling over swinging or fal ling off Note tha...

Page 129: ...tachment moves in the direction shown in the upper part of the pictogram Move operating lever 1 backwards The attachment moves in the direction shown in the lower part of the pictogram 7311_862 001 2 3 6 4 7 9 10 5 8 Please note symbols 2 to 10 2 Reach frame or forks forwards back wards 3 Sideshift moves to the left to the right 4 Adjust fork arms open close 5 Tilt lift mast or forks to the left t...

Page 130: ...lever then controls the 5th function The pictograms in the centre and lower parts of the operating levers always show the func tion controlled by that lever The pictogram in the upper part shows that the attachment has the 5th function The meanings are as follows Move the operating lever forward the at tachment moves in the direction shown in the centre of the pictogram Move the operating lever ba...

Page 131: ...accident Attachments may only be used for their intended purpose as described in the respective operating instructions Drivers must be instructed in the handling of the attachments WARNING Risk of accident Loads may only be picked up and transported with attachments if they are secure If necessary the load must also be secured against slipping rolling falling wobbling or tilting Note that any chan...

Page 132: ... 7071_003 061 4 Switching lighting on and off special equipment Press the switch 1 for the work lights The work lights are 3 switched on Press the light switch 2 The parking lights 4 are switched on Press the light switch again 2 The driving lights 5 are switched on NOTE Pressing the switch again switches each light back off 122 171673 EN ...

Page 133: ...uipment 2 2 3 6 0 4 h 2 100 1 7071_003 028 Switching flashing light off and on Press the switch 1 for the flashing light The flashing light 2 is switched on NOTE Pressing the switch again switches the flas hing light back off 171673 EN 123 ...

Page 134: ...equipment Press 1 warning light switch All flashing lights 3 and the two direc tion indicator lights 2 in the direction of travel flasher fault multi function display flash NOTE Pressing the switch again switches the hazard warning system back off NOTE The hazard warning system can also be swit ched on without the key switch connected 124 171673 EN ...

Page 135: ... wiper washer 2 3 6 0 4 h 2 12 15 100 7311_341 002 1 3 2 Press the switch 1 to activate the wind screen wiper washer special equipment Press the switch 2 to activate the rear windscreen wiper washer special equip ment The following table shows the different dis plays 3 for the operating stages of the wind screen wiper washer Every time the relevant button is pressed you will move forward one stage...

Page 136: ...doors are open or removed you must use a different suitable restraint system e g restraining belt Insert the key into the door lock 1 and turn it Withdraw the key and pull the door handle 2 until the latch opens Opening the side windows Pull the handle 3 and slide the front side window towards the rear Pull the handle 4 and slide the rear side window towards the front Radio The radio and loudspeak...

Page 137: ...on blower 1 switch The blower runs at the speed level set at the switch Set the desired temperature with the 2 lever The heater is in operation The air is heated up to the heating level set at the 2 switch Adjust the air flow 3 at the vent Driving with cruise control The cruise control function special equip ment permits the driver when travelling for wards to press a button and save any speed of ...

Page 138: ...al at least 6 0 km h WARNING Risk of accident The speed must be selected so that it is suitable for the entire distance that you intend to drive with active cruise control This is especially true when selecting speeds around corners Press the lower section of the travel direc tion switch again for at least one 1 second The selected speed is saved The forward travel direction 2 display changes from...

Page 139: ...direction switch in neutral or 1 re verse the accelerator pedal or by activating the seat switch seat not occupied There are two different ways of switching it off using the accelerator pedal depending on the individual vehicle programming Type 1 Even slightly depressing the accel erator pedal switches off the cruise control function Type 2 To switch off the cruise control function the accelerator...

Page 140: ...he capacity rating plate to the right of the driver s seat on the fork arms The maximum load may not be exceeded CAUTION Component damage possible The permissible towed load only applies to the to wing device If this maximum load is being towed no load may be transported on the fork arms However it is possible to transport part of the ma ximum load on the fork arms and at the same time tow the bal...

Page 141: ...ng characteris tics When towing operate the truck in such a way as to ensure safe transportation and braking of the towed load in all movements Coupling the trailer WARNING Risk of accident If you briefly leave the forklift truck to couple a trailer Apply the parking brake Turn off the key switch and remove the key Manual tow coupling 1 7090_900 008 Secure the parked trailer against unin tended mo...

Page 142: ...03 064 3 Press the towing pin 3 down turn it 90 and pull it out Insert drawbar into the recess in the coun terweight DANGER Risk of accident Use only genuine towing pins Make sure that the towing pin snaps into position Insert the towing pin press it down against the spring pressure and turn it 90 The towing pin is locked in this position 132 171673 EN ...

Page 143: ...re a sufficient minimum distance to fixed instal lations when turning and cornering The permissible length of the trailers depends on the routes to be driven and may need to be determined during the test drives It is the responsibility of the operating com pany to instruct the driver regarding the per missible number of trailers and possibly the need to reduce speed on individual sections of the r...

Page 144: ... operation It runs as soon as the engine starts 4 Time in hours and minutes The time can be set see Chapter Setting the date or time P 5 135 7071_003 108 990h 0 0km 0 0km T 1 2h T 6 7 5 8 9 Additional displays Upon pressing the menu change button 5 the following additional displays appear 6 SERVICE IN display Displays the re maining time in hours until the next service visit according to the maint...

Page 145: ...ily kilometres and daily operating hours P 5 136 Select language see Chapter Setting the language P 5 136 FleetManager functions see Chap ter Fleet Manager functions P 5 137 Other settings see Chapter Additional settings P 5 137 7071_003 110 4 3 1 2 UHRZEIT 03 14 Setting the date or time Switch to the KONFIGURATION CON FIGURATION menu see Chapter Set ting and changing the displays P 5 135 Press th...

Page 146: ... zero Switch to the KONFIGURATION CON FIGURATION menu see Chapter Set ting and changing the displays P 5 135 Reset the values by pressing RES RES Setting the language You can select additional languages for the displays Switch to the KONFIGURATION CON FIGURATION menu see Chapter Set ting and changing the displays P 5 135 6210_562 008 SPRACHE ENGLISH 1 2 3 Press the traction program key 1 or the me...

Page 147: ...7071_003 032 2 Accident recorder special equipment The accident recorder is an auxiliary device to the Fleet Manager An acceleration sensor 2 is installed in the truck The acceleration sensor can record data from an accident This data can be evaluated Ask your service cen tre Additional settings Entering a password makes it possible to set additional values Contact your customer ser vice office ab...

Page 148: ... and messages can appear on the display 2 A gra phic symbol and a message describing 3 the faulty function and an error code consisting of 4 a letter and a 4 digit number Fault displays are always displayed on a cyclic basis for a number of seconds depending on the fault If more than one fault occurs they are shown one after the other This is followed by a pause with its length also depending on t...

Page 149: ...clic display every 30 sec Traction and hydraulic drives not functioning Contact your service centre ACCELERATOR A3002 A3003 A3004 A3005 A3006 A3007 Cyclic display every 30 sec Sensor fault vehicle cannot be driven Contact your service centre ACCELERATOR A3811 Cyclic display every 30 sec Accelerator configuration incorrect Vehicle cannot be driven Contact your service centre BRAKE A3016 A3017 Cycli...

Page 150: ...r 8 hours Truck may still be running at reduced speed and with reduced lifting capacity Briefly stand up and sit down again If this does not resolve the problem contact the service centre STEERING A3202 A3215 A3221 A3226 Cyclic display every 30 sec Sensor fault vehicle can only be driven at crawling speed Contact your service centre TRAVEL DIRECTION A3020 Cyclic display every 30 sec Switch fault n...

Page 151: ...tre SURVEILLANCE A2817 A2818 Cyclic display every 30 sec Truck not ready for operation Place the key switch in the zero position and restart the truck If this fault occurs sporadically it can be tol erated If the truck s functionality is impaired contact your service centre DRIVE A5041 Cyclic display every 30 sec Temperature sensor fault Contact your service centre OIL PRESSURE A5631 Cyclic displa...

Page 152: ...ck coolant level and top up if necessary see Chapter Topping up coolant and checking coolant concentra tion P 6 200 If this does not resolve the problem contact the service centre SAFETY BELT message DANGER Driving without a seat belt is dangerous and never permitted Always fasten the seat belt before driving NOTE This mechanism special equipment ensures that if the seat belt is not being used or ...

Page 153: ...itch on key switch The message SAFETY BELT appears in the display if you operate an operating lever or the accelerator pedal The forklift truck drives slowly or does not drive at all depending on the selected version the working functions are either available as normal slowed down or not available at all Remove the seat belt from the buckle fit the belt in line with the instructions and fasten it ...

Page 154: ...while driving the message SAFETY BELT appears in the display The truck maintains or brakes to a slow speed DANGER This function does not release you from your duty of care to adjust the speed of the forklift truck to the driving situation The increased safety provided by this function may not be misused in order to take safety risks 7090_342 009 Fit the seat belt in line with the instructions and ...

Page 155: ...h is switched on The seat is not occupied while the accelera tor pedal or the steering wheel is operated The message SITZSCHALTER SEAT SWITCH appears in the display The fork lift truck cannot move Sit on the driver seat and fasten the belt The forklift truck can be driven again without restriction 7311_003 045 SITZSCHALTER The seat switch is not actuated while the operating lever is actuated The k...

Page 156: ...sit back down The forklift truck can again be operated with out restriction 7311_003 047 SITZSCHALTER Exceeding the operation time NOTE The operation time is adjustable If while the key switch is switched on and the parking brake is released the driver s seat is occupied longer than the set oper ation time and the accelerator pedal or an operating lever was not operated during this time the messag...

Page 157: ... without the parking brake being securely applied is dangerous and is not permitted The increased safety provided by this function may not be misused in order to take safety risks BREMSE ANZIEHEN 7081_003 024 1 Parking brake is not applied If you park the truck without applying the park ing brake and leave the driver s seat the mes sage BREMSE ANZIEHEN APPLY HAND BRAKE appears in the display An op...

Page 158: ... HANDBRAKE disappears GABELN ABSENKEN LOWER FORKS message DANGER Risk of accident Parking the forklift truck with the load lifted is dange rous and is not permitted under any circumstances The increased safety provided by this function may not be misused in order to take safety risks 6210_020 001 GABELN ABSENKEN Forks are not lowered The forks are above the height sensor You switch off the key swi...

Page 159: ...drive at a reduced speed You now have to perform a test lift reference cycle using the lifting system Lift the forks up until the message disap pears or if it was not previously displayed until it appears and then disappears again Then lower the forks again The truck can now be driven again with no speed limitation 7071_003 050 FAHRGEBER FAHRGEBER ACCEL SENSOR message If the FAHRGEBER ACCEL SENSOR...

Page 160: ...CE message If the UEBERWACHUNG SURVEILLANCE message appears a fault has occurred in the process monitoring This shuts off the traction drive Place the key switch in the 0 position and then back in the I position Start the engine see Chapter Starting the engine P 5 68 Take your foot off the accelerator pedal Select the direction of travel again NOTE If this error code appears sporadically it can be...

Page 161: ...ble is broken Stop working and allow the truck to cool However do not turn off the key switch NOTE If usability is impaired please contact your service centre 7071_003 052 LENKEN LENKEN STEERING message If the LENKEN STEERING message ap pears on the display and operating unit the truck only moves at emergency mode speed The accelerator must be checked Contact your service centre 171673 EN 151 ...

Page 162: ...l see Chap ter Checking the engine oil level P 5 56 Change the engine oil if necessary Contact your service office 7071_003 054 KUEHLMITTELSTAND KUEHLMITTELSTAND COOLANT LEVEL message If the KUEHLMITTELSTAND COOLANT LEVEL message appears the coolant level is too low Check the coolant level see Chap ter Topping up coolant and checking coolant concentration P 6 200 CAUTION Risk of engine damage If t...

Page 163: ...p ter Topping up coolant and checking coolant concentration P 6 200 Malfunction in the electrical fan Defective thermostat Radiator clogged see Chapter Cleaning the radiator checking for leaks P 6 200 7071_003 055 UEBERTEMPERATUR UEBERTEMPERATUR OVER HEATING message If the UEBERTEMPERATUR OVERHEAT ING message appears the traction motors are overheated Truck speed and accelera tion are reduced Allo...

Page 164: ...distance from edges load ing bridges ramps working platforms etc Remember that the tail end veers out from the loading bridge in the direction of the edge when turning the steering wheel dur ing forwards travel This can cause the forklift truck to crash Lower the forks completely Apply the parking brake and remove the key 7090_001 023 Setting chocks Use two chocks to block each of the front and re...

Page 165: ...l operating situations Lashing 7071_003 126 1 Attach the cable 1 to both sides of the truck and then secure the cable at the rear 7071_003 127 2 1 Attach the cable 1 to the towing pin 2 and secure the truck at the front 171673 EN 155 ...

Page 166: ...or towing the truck Don t start vehicle by pushing or pulling CAUTION Steering is heavy There is no power steering if the hydraulics are not active The maximum vehicle towing speed is walking speed After towing secure truck from rolling away e g by placing chocks Apply the parking brake Crane loading Crane loading is only intended for transport ing the complete truck including the lift mast for it...

Page 167: ...ailure to follow these instructions could result in damaged components Use textile harnesses and if necessary edge protectors or similar protective equipment to prevent damage to the truck DANGER Risk of accident Only use hoists and harnesses with adequate lifting capacity for the determined loading weight Only use the designated attachment points on your truck Make sure that harness parts such as...

Page 168: ...l Data section see Chapter Di mensions P 7 248 Set the length of the harnesses so that the crane eye 3 is vertically above the centre of gravity of the forklift truck This ensures that the forklift truck hangs level when lifting it Hang the lifting straps from the crane eye and engage the locking device 4 CAUTION Failure to follow these instructions could result in damaged components The harnesses...

Page 169: ...tor may ice up The cause is temporary insufficient heat conduction to the evaporator In this case close the gas shut off valve before the evaporator by separating 1 the connector and continue to run the engine at increased idling speed until it stalls on its own due to lack of gas If the engine died on its own while the gas shut off valve was still open start the engine with closed shut off valve ...

Page 170: ...sk of explosion If the forklift has been shut away for a long period in a closed room ventilate the area well before switching on the electrical system NOTE A power source with 12 V e g second forklift truck of same type must be available Open the bonnet see Chapter Opening the bonnet P 5 55 Disassemble base plate see Chap ter Installing and removing the floor plate P 6 194 Allow the engine in the...

Page 171: ... in special operating situations Start the engine see Chapter Starting the engine P 5 68 Once the engine is running remove the jumper cables in exactly the reverse order Replace the floorplate Close the bonnet 171673 EN 161 ...

Page 172: ... not under any circumstances attempt to jump clear Jumping increases the risk of injury Do not release your seat belt The correct behaviour is as follows Bend your upper body over the steering wheel Hold on tight to the steering wheel with both hands and brace yourself with your feet Bend your body against the direction of the fall 7071_003 026 1 On trucks with a cab if the door cannot be opened a...

Page 173: ...n in the truck Open the bonnet see Chapter Opening the bonnet P 5 55 Take out the angle screwdriver 1 7071_003 093 2 Unscrew the emergency lowering screw 2 in the control block a maximum of 1 5 revolutions using the angle screwdriver WARNING The load is lowered The speed can be controlled by the degree to which the screw is unscrewed Unscrewed minimally load is lowered slowly Unscrewed maximally l...

Page 174: ...provided with a quick dis connect battery terminal clip NOTE The battery is located on the left side under neath the floorplate Use the following procedure to quickly discon nect the battery 7071_003 068 1 Using the handle 1 lift the floorplate 7071_003 123 Pull the negative terminal battery terminal clip upward Lift the battery terminal clip off the negative terminal of the battery and place it t...

Page 175: ...nder is the applicable date Observe the national regulations for your country When changing cylinders do not smoke or use an open flame Only use LPG cylinders in well ventilated rooms and do not change near openings in the ground Switch off the engine Note safety regulations for working with LPG Chapter LPG P 3 30 DANGER Risk of explosion from spark discharge Impact tools should not be used to ope...

Page 176: ...t be checked for perfect condition After removal the cap of the cylinder must be im mediately screwed onto cylinders provided with a lock nut Valves should be opened slowly Leaking gas cylinders should no longer be used They must be emptied immediately by being re leased outside taking all precautions into account and marked as leaking If damaged gas cylinders are supplied the provider or his repr...

Page 177: ... protective cover 1 pull the release pin 2 and flip open the protective cover 3 4 5 7081_003 004 Close the cylinder valve 3 Securely grip the connection nipple with the handhold 5 and carefully release the union nut 4 left hand thread 171673 EN 167 ...

Page 178: ...er properly and check the connections for leaks 7081_003 028 1 2 Filling the LPG tank DANGER There is a risk of explosion if LPG escapes Smoking open flames and fire are forbidden when filling the LPG tank Stop the engine Note safety regulations for working with LPG Chap ter LPG P 3 30 DANGER Risk of explosion from spark discharge The shut off valve or locking cap must not be opened or closed with...

Page 179: ... observed or if the inspection interval has been exceeded Pipework and its accessories for gas in the liquid phase and LPG containers must not be exposed to an impermissible level of heat Explosions involving gas cylinders or LPG systems must be immediately reported to the employers liability insurance association and the industrial inspectorate responsible even where no accident occurs applies to...

Page 180: ...in stalled in the tank stops refilling Filling quantity approx 70 litres Release the actuating lever of the filler noz zle immediately after the tank valve shuts off and you cease filling Cut the pump motor off and close the main shut off valve at the LPG filling station The LPG tank should only be filled up until the tank valve switches off and not as shown on the display of the contents indicato...

Page 181: ...ylinders must be protected from impermissible heating Note safety regulations for working with LPG Chap ter LPG P 3 30 Apply the parking brake 1 Lower the forks to the ground and tilt the fork tips sufficiently forward until they touch the ground WARNING Risk of accident Before leaving truck fully lower the load NOTE In frosty conditions the truck should be left in an enclosed room where possible ...

Page 182: ...trucks with LPG tanks special equip ment close the shut off valve 2 ZU 7081_003 018 3 For trucks with LPG cylinders close the cylinder valve 3 NOTE Without explicit instructions the ignition key or FleetManager card special equipment should not be made available to other per sons NOTE Avoid parking the vehicle for long periods at temperatures lower than 0 C because the hydraulic fluids will be ver...

Page 183: ...aken to pro tect against corrosion If the truck is to be shut down for more than two months it must be parked in a clean and dry area The area should also be well ventilated and frost free The following additional mea sures must be taken Measures before shutdown Clean truck thoroughly see Chap ter Cleaning P 196 Lift fork carriage to full extent several times Tilt the mast forwards and backwards s...

Page 184: ...nd using a plastic sheet as this promotes the formation of condensation Cover the truck with a cotton sheet and protect against dust If the truck is to be shut down for even longer periods contact your service centre for addi tional recommended measures Returning to service after storage If the truck has been in storage for longer than six months it must be carefully checked be fore being put back...

Page 185: ...m for leaks with leak spray Check the connections of the gas fuel sys tem system for tightness DANGER Risk of explosion After a truck has been shut down in an enclosed room for a lengthy period ventilate thoroughly before switching on electrical system Put the truck into service Check during start up in particular tightness and function of gas fuel system drive control steering brakes service brak...

Page 186: ...5 Operation Shut down 176 171673 EN ...

Page 187: ...6 Maintenance ...

Page 188: ... techni cal conventions and the principles for testing forklift trucks Maintenance work for which no special qualifications are necessary Simple maintenance work e g checking the hydraulic oil level or checking the fluid level in the battery may be performed by untrained personnel This does not require training as described above Refer to this operating man ual for further information Information ...

Page 189: ...those listed in the enclosed operating instructions for the engine the values in this manual have priority Maintenance and lubrication 1 During the initial operating period desig nated by numbers in bold with a star 2 According to the operating hours meter numbers in bold After 3000 operating hours for example the following must be performed maintenance and lubrication after 500 and 1000 operating...

Page 190: ...6 Maintenance General maintenance information Overview of areas requiring maintenance 7081_003 020 1 2 3 5 4 6 7 8 9 180 171673 EN ...

Page 191: ...opping up coolant and checking coolant concentra tion P 6 200 Replace air filter insert see Chapter Changing the air filter in sert P 6 202 Service battery see Chapter Servicing the battery P 6 204 Service hydraulic equipment see Chapter Maintaining hydraulic equipment P 6 207 7 Service wheels and tyres see Chapter Servicing wheels and tyres P 6 208 Check foot brake setting see Chapter Checking ad...

Page 192: ...sary see Chapter Mainte nance as required P 200 5 Check evaporator and pressure regulator see Chapter Checking the evaporator and pressure regulator P 6 222 1000 hour maintenance annual maintenance Position Maintenance work Carry out maintenance work as necessary see Chapter Mainte nance as required P 200 Carry out all work for 500 hour maintenance semi annual mainte nance see Chapter 500 hour mai...

Page 193: ...earance between fork carriage stop and run out stop P 6 233 9 Check fork arms see Chapter Checking the fork arms P 6 233 Check reversible fork arms see Chapter Checking reversible fork arms P 6 234 3000 hour maintenance two year maintenance Position Maintenance work Carry out maintenance work as necessary see Chapter Mainte nance as required P 200 Carry out all work for 500 hour maintenance semi a...

Page 194: ...see Chapter Changing the hydraulic oil and filter P 6 239 9000 hour maintenance five year maintenance Position Maintenance work Carry out maintenance work as necessary see Chapter Mainte nance as required P 200 Carry out all work for 500 hour maintenance semi annual mainte nance see Chapter 500 hour maintenance semi annual mainte nance P 222 Carry out all work for 1000 hour maintenance annual main...

Page 195: ...event of dam age or harm Quality and quantity of the required operating materials Only the operating materials specified in the maintenance data table may be used Consult the maintenance data table for the consumables and lubricants needed for main tenance See Chapter Maintenance data table P 6 186 Different quality oil and grease types may not be mixed This negatively affects the lubricity If a c...

Page 196: ...L L2105 API GL4 As required Hydraulic oil HVLP68 DIN 51524 Part 3 Approx 48 l Hydraulic equipment Hydraulic oil for the foodstuffs industry special equipment USDA H1 DIN 51524 Approx 48 l Filter cover Torque wrench 30 Nm Tyres Pneumatic tyres Air pressure see information on truck Min profile height 1 6 mm Superelastic tyres Wear limit To wear mark Wheel nuts Drive axle Torque wrench M20x1 5 640 Nm...

Page 197: ...st to the top edge 15 mm Steering axle Axle stub nuts Torque wrench 310 Nm Wheel hub fastening Torque wrench 470 Nm Cooling system Coolant water G12 plus TL VW 774 F Approx 15 5 l LPG cylinder LPG DIN 51622 EN 589 11 kg Engine Engine oil VW 50700 With filter change approx 6 4 l Ignition system Spark plugs NGK IZKR 7B VW no 101 905 606 A Gap between electrodes 1 0 0 1 mm Tightening torque 20 Nm Air...

Page 198: ...all work See Chapter Depressuris ing connections for attachments P 5 117 Working on electrical equipment Work may only be performed on electrical equipment of the forklift truck in a voltage free state Only trained and commissioned per sons may perform functional tests checks and settings on parts under voltage while taking the suitable precautionary measures Rings metal bracelets etc must be remo...

Page 199: ... be washed when the ignition is switched off When performing electric or point welding completely disconnect the battery Trucks in which there is a defect in the igni tion system or one is suspected may only be towed if the plug for the ignition coil is unplugged Working on gas fuel LPG system DANGER Risk of explosion Note safety regulations for working with LPG Chapter LPG P 3 30 The condition of...

Page 200: ...down for a lengthy period the storage room must be ventilated thoroughly before starting up the vehicle or its electrical system When working in maintenance workshops cylinder and main shut off valves should be closed and the LPG cylinders protected from heat Before pauses in operation and finishing op eration it should be checked by a responsible person whether all valves in particular cylin der ...

Page 201: ...h sufficient lifting capacity are used that the truck is only jacked up on level ground and is secured against rolling and sinking WARNING Risk of accident Apply the parking brake and turn off engine when jacking up the truck WARNING Risk of injury Jack up the truck sufficiently high that shoes cannot get trapped under a turning wheel 7071_003 018 Jack up at the frame Place jack sideways under the...

Page 202: ...uck by rear weight 7081_003 009 1 2 Working at the front of the forklift truck WARNING Risk of accident If the lift mast or fork carriage is raised no work must be performed on the lift mast or at the front of the forklift truck without observing the following safety measures Removing the lift mast CAUTION This work must only be performed by a service tech nician Fasten the lifting gear to the upp...

Page 203: ...er neath the cross traverse of the inner mast 4 Lower the inner mast until it strikes the chain 7071_003 112 5 6 Securing the triple lift mast DANGER Risk of accident To secure the lift mast use a chain with sufficient load bearing capacity for the particular lift mast Note the maximum lift height Extend the lift mast Drape the chain over the cross traverse of the outer mast 5 and connect it under...

Page 204: ...alling and removing the floorplate Open the bonnet see Chapter Opening the bonnet P 5 55 Lift floorplate by using 1 the handle 7071_003 069 2 Separate connector on the accelerator 2 pedal Lift floorplate and place in a safe location Installation is carried out in reverse order 194 171673 EN ...

Page 205: ...6 Preparation for maintenance Removing and installing the rear covering 7071_003 044 1 2 Remove the fixing screws 1 Remove the covering 2 by lifting it up Installation is carried out in reverse order 171673 EN 195 ...

Page 206: ... on or in the vicinity of parts with high temperatures e g exhaust pipes must be removed regularly WARNING If the forklift truck is to be cleaned with hot water devices all sensitive particularly electric compo nents must be carefully covered Note the manufacturer s guidelines for working with cleaning agents Clean the vehicle on the outside with water soluble cleaning agents and water water jet s...

Page 207: ...tem parts with water can damage the electrical system Cleaning electrical system parts with water is forbidden Only use a dry cleaning agent according to the manufacturer s specifications Do not remove covers etc Clean and dry electrical system parts with weakly compressed air and a metal free brush 6327_003 016 Clean load chains WARNING Risk of accident Load chains are safety elements The use of ...

Page 208: ...ial equipment the glass windscreens 1 must always be kept free of dirt and ice in order to ensure clear vision Cleaning the windscreens NOTE The windscreens can be cleaned using a con ventional glass cleaner 7081_003 029 After washing Carefully dry truck e g with compressed air Sit on the driver s seat and start up the vehi cle in line with the regulations CAUTION Risk of short circuit If any mois...

Page 209: ...owing tests require special tools Contact the service centre Check the propellant system for leaks with leak spray Check the connections of the propellant system for secure seating Check status and tension of ribbed V belt see Chapter Checking the ribbed V belt P 6 226 Check exhaust gas system see Chap ter Checking the exhaust gas sys tem P 6 227 171673 EN 199 ...

Page 210: ... leak has been eliminated If not contact your service centre max min 7071_003 045 1 Topping up coolant and checking coolant concentration Remove the rear covering see Chap ter Removing and installing the rear cover ing P 6 195 CAUTION Risk of engine damage If the coolant level is low this indicates a leak in the cooling system Check for leaks in the cooling system see Chapter Cleaning the radiator...

Page 211: ...ve can be increased to up to 60 The percentage of the coolant additive must not exceed 60 otherwise the frost protection is redu ced In addition the cooling effect is also reduced Only use clean softened water for the water com ponent Frost protection up to C Water percentage Coolant additive percentage 25 60 40 30 55 45 35 50 50 40 40 60 Filling quantity in the cooling system see Chapter Maintena...

Page 212: ...y Reattach the rear covering 7311_003 005 LUFTFILTER Changing the air filter insert NOTE Changing the air filter insert is necessary only when the LUFTFILTER AIR FILTER message appears on the display and opera ting unit or every two years Open the bonnet see Chapter Opening the bonnet P 5 55 202 171673 EN ...

Page 213: ...ir filter cover 2 3 7071_003 114 Remove the main cartridge 3 CAUTION Risk of engine damage The safety cartridge must remain in the air filter housing until all residual dirt has been removed from the housing so that no dirt enters the induction system Blow out the air filter housing using com pressed air 171673 EN 203 ...

Page 214: ...tall the safety cartridge 4 Install a new main cartridge 3 7071_003 113 1 5 1 2 Fit the air filter cover 2 with the mark 5 pointing upward Snap the two clamps 1 back into place on the air filter Close the bonnet Servicing the battery NOTE Battery servicing is carried out in accordance with the battery manufacturer s operating ma nual 204 171673 EN ...

Page 215: ...ld be recharged After recharging the indicator changes back to green Transparent light coloured The charge state is no longer adequate for reliable start ing It is necessary to change the battery Charging the battery With batteries that are not maintenance free check the level of the battery acid WARNING The electrolyte dilute sulphuric acid is poisonous and caustic Follow the safety regulations w...

Page 216: ... battery cells must be exposed to ensure sufficient air ventilation The charging area must be properly ventilated Keep the bonnet open during charging avoid spark formation near the battery Immediately charge empty batteries until they are full again The charging current shall not exceed 1 10 of the capacity The cell lids of the batteries must be kept dry and clean Any spillage of battery acid mus...

Page 217: ...ing the floor plate P 6 194 Unscrew 1 the dipstick and pull it out 7094_700 002 1 2 Check oil level The oil level must be at least up to the mark 2 on the dipstick If the oil level is not up to the required level the hydraulic oil must be topped up ac cording to the maintenance data table see Chapter Maintenance data ta ble P 6 186 using the filler neck until the mark is reached Reinsert 1 the dip...

Page 218: ...r pressure for pneumatic tyres special equipment is based on the type of tyres used Observe the information on the stickers 2 on your vehicle Checking condition and wear of the tyres WARNING Tyre quality affects the stability and handling of the forklift truck Changes can only be made in consultation with the manufacturer When changing wheels or tyres always ensure that this does not cause the for...

Page 219: ...ce data table P 6 186 7071_003 125 4 1 2 3 0 Checking adjustment of the foot brake NOTE Readjust the brake cable only if it has become elongated Remove the floorplate see Chap ter Installing and removing the floor plate P 6 194 Check whether the clearance between the linkage bar lever 3 and the adjusting screw 4 is 0 mm CAUTION Risk of damage to components The adjusting screw 4 is set at the facto...

Page 220: ...1 Checking the parking brake setting NOTE Readjust the brake cable only if it has become elongated Remove the floorplate see Chap ter Installing and removing the floor plate P 6 194 NOTE The bonnet must be closed when checking and adjusting the setting 7081_003 043 1 Release the parking brake 210 171673 EN ...

Page 221: ...justing sleeve 1 Lubricating joints and controls Oil or grease other bearings and joints according to the maintenance data ta ble See Chapter Maintenance data table P 6 186 Driver s seat guide Cab door hinges lubricate grease nipples with grease Engine bonnet hinges lubricate grease nipples with grease Control linkage for valves Checking the door latch Inspect the condition of the catch bolts and ...

Page 222: ...ck the stub axle bearing 1 and tie rod joint 2 for play and wear 7311_003 017 3 4 Check the steering cylinder 4 for leaktight ness traces of oil NOTE In the case of excessive play or of wear have your service centre replace the appropriate parts 212 171673 EN ...

Page 223: ...en the truck is clea ned the more frequently it must be lubricated Checking the hoses for leaktightness Retighten leaky connections NOTE Have your service centre replace defective lines After repairs force out trapped air by re peatedly turning the steering wheel from stop to stop Checking the tightening torque of the stub axle nuts Set steering to end stop 7311_003 017 3 4 Use the torque wrench t...

Page 224: ...ta table P 6 186 of the mast bearing screws 1 with a wrench torque Lubricating the mast bearing Lubricate the mast bearings with grease at the lubricating nipples 2 on the left and right see Chapter Maintenance data table P 6 186 Load chain maintenance Testing the condition and wear of lift chains lubricating Checking the condition of the load chains and checking for wear The load chains must be c...

Page 225: ...n tension CAUTION Never compensate tyre wear by adjusting lift chain tension Only retighten the load chains after elongation due to wear The chains should be replaced once elon gation reaches 3 CAUTION If the load chains can no longer be retightened the chains must be replaced completely along with all associated connecting parts Please contact your service centre NOTE After adjusting the load cha...

Page 226: ...s triplex mast Fully lower the fork carriage Mast uprights must be flush at the top If not Unscrew the cap screw 1 and remove the safety 2 cap Retighten the load chains at the bail nuts 3 on the outer mast Replace the 2 safety cap Apply Loctite to the cap screw 1 and tighten 6 4 5 7071_003 075 Unscrew the cap screw 4 and remove the safety 6 cap With the lift cylinders fully extended retighten the ...

Page 227: ... evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Maintaining the restraining belt DANGER Malfunctions of the retraining belt lead to increased danger If the restraining belt is defective do not put the truck into operation instead have the restraining belt changed by your service centre immediately Use only genuine spare parts Do not make ...

Page 228: ...ld securely The belt latch 2 must release when the red button 4 is pushed Test the automatic blocking mechanism at least once a year Park the truck on a horizontal surface Pull out the belt with a jerk The automatic blocking mechanism must block extension of the belt Tilt the seat at least 30 by tilting the bonnet Pull out the belt slowly The automatic blocking mechanism must block extension of th...

Page 229: ...an accident have the driver s seat checked with attached restraining belt and fastening Check controls for proper functioning Check condition of seat e g for wear to upholstery and reliable fastening to hood WARNING Risk of injury Have the seat repaired by Technical Service if damage is observed during checking Replacing fuses DANGER Risk of fire Using the wrong fuses can result in lack of protect...

Page 230: ... remove the cover Replace the defective fuse fuse assign ment see Chapter Fuse assignment in main fuse holder P 7 253 Push down the cover until the cover fasten ings 1 snap back into place Close the motor hood 7071_003 096 3 2 Additional equipment for fuse carrier Undo the fixing screws 2 of the front cover and remove the cover 3 NOTE The fuse carrier additional equipment is positi oned on the rig...

Page 231: ...il the cover fasten ings 4 snap back into place Refit the cover 3 and tighten the fixing screws 2 7090_860 004 Attachment maintenance Lubricate the slide rails of attachments special equipment such as a sideshift or clamp according to the maintenance data table See Chapter Maintenance data table P 6 186appears on the display The diagram shows a clamp NOTE Observe the manufacturer s maintenance spe...

Page 232: ...ance 7081_003 031 Checking the evaporator and pres sure regulator NOTE Specialized knowledge and special tools are required for the following tests and overhau ling Contact the customer service office Check the evaporator pressure regulator for proper composition correct function leaks 222 171673 EN ...

Page 233: ...see Chap ter Oils P 3 29 Park the forklift on a level surface Unscrew the checking 1 screw The oil level must reach the lower edge of the bore Unscrew the filling plug if necessary 2 and fill with oil as per the maintenance data table see Chapter Maintenance data table P 6 186 until it escapes from the hole for the checking screw 1 Renew the sealing ring on the oil drain plug 1 Tighten the oil che...

Page 234: ...r bearing and ratchet Lightly lubricate the parking brake lever bearing and ratchet according to the main tenance data table See Chapter Main tenance data table P 6 186appears on the display Checking the counterweight attach ment Check the mounting screws of the counter weight on the frame to make sure they are secure Changing the engine oil and filter Open the bonnet see Chapter Opening the bonne...

Page 235: ...ccording to applicable regulations Renew the sealing ring 2 Tighten the drain plug with a torque of 30 Nm 4 5 6 7081_003 032 3 Place a suitable collection vessel under the oil drain plug 3 Unscrew the oil drain plug 3 and allow the oil to drain out completely Renew the sealing ring Tighten the drain plug Unscrew the oil filter 4 cover ENVIRONMENT NOTE Dispose of used oil and oil filter insert acco...

Page 236: ... level see Chapter Check ing the engine oil level P 5 56 Close the bonnet 7081_003 023 1 Checking the ribbed V belt NOTE If damage is found the ribbed V belt has to be replaced to prevent failures or functional errors Manually turn the motor and check ribbed V belt 1 for Support tears tear core breaks cross sectional breaks Layer separation cover layer anchor bars Broken support Frayed anchor bars...

Page 237: ...rding to mainte nance data table see Chapter Mainte nance data table P 6 186 Close the bonnet Checking the exhaust gas system Inspect the exhaust gas system for external damage secure fit and leaks 1 7311_003 036 Changing the LPG filter DANGER There is a risk of explosion if LPG escapes Note safety regulations for working with LPG Chap ter LPG P 3 30 Stop the engine For trucks with LPG cylinders c...

Page 238: ...81_003 036 2 For trucks with LPG tanks special equip ment close the shut off valve 2 ZU Remove the rear covering see Chap ter Removing and installing the rear cover ing P 6 195 7081_003 037 3 4 Unscrew the fixing screw from the 3 filter housing 228 171673 EN ...

Page 239: ...f necessary Screw the filter housing back on Open the cylinder valve 1 or shut off valve 2 Check all connections for leaks using leak spray Reattach the rear covering Overhauling the LPG system NOTE Spare parts and special tools are required for the following tests and overhauls Contact the customer service office CAUTION Risk of damage Only original spare parts may be used Overhaul service gas mi...

Page 240: ...oling and heating system special equipment for leaks NOTE A special tool is necessary for the test Con tact STILL service personnel 6327_003 016 Check lift cylinders and connections for leaks Lift the fork carriage and secure against accidental lowering WARNING Risk of injury Observe the safety regulations for working on lift masts see Chapter Working at the front of the forklift truck P 6 192 Che...

Page 241: ...lift mast and fork carriage for clearance condition and secure position ing Bearings are lubricated for life and are maintenance free Replace in the event of damage excessive clearance or stiffness WARNING Risk to stability No deliberate change in the tilt angle is permitted Readjustment after replacement or repair of tilt cylinders only permitted by your service centre 171673 EN 231 ...

Page 242: ...0 1 mm max 0 3 mm at narrowest point max 1 1 mm at any other point Check bearing clearance X NOTE Before this check make sure that the lateral clearance Y complies with the specified tole rances Park vehicle on a flat surface and lift fork carriage Position parallel base at tips of fork arms Lower fork carriage onto this base Measure clearance between support roller and lift mast bearing surface w...

Page 243: ...ge completely to the stop in the lift cylinder Check the clearance between the fork car riage stop and the roller of the run out stop 1 with a feeler gauge Clearance at least 2 mm 1 2 3 7094_842 001 Checking the fork arms Check the fork arms 1 for visible deforma tions The wear may not exceed 10 of the original strength CAUTION Worn fork arms must always be repaired as a pair Check the fork latch ...

Page 244: ...l maintenance 7090_800 006 1 7090_842 002 Checking reversible fork arms NOTE This check is only required for reversible fork arms special equipment Check the outside of the fork bend 1 for cracks Please contact the service centre 234 171673 EN ...

Page 245: ...7 Changing the gear lubricant oil WARNING Consumables are toxic Observe the safety regulations for handling gear lubricant oil see Chapter Oils P 3 29 Park the forklift truck on a level surface Raise the truck on blocks see Chap ter Raising and jacking up P 6 191 Remove the wheels from the drive axle Place a suitable collection vessel under the oil drain plug 1 Unscrew the oil drain plug 1 and all...

Page 246: ...torque of 10 Nm Change the sealing ring on the filling plug 3 Tighten the filling plug 3 to a torque of 24 Nm Change the gear lubricant oil of both wheel drives Refit the wheels to the drive axle for tight ening values see Chapter Maintenance data table P 6 186 Checking the wheel bearing Check the wheel bearing for excessive play stiffness damage and wear Have STILL service personnel replace parts...

Page 247: ...s in the LPG system DANGER There is a risk of explosion if LPG escapes Observe safety regulations for working with LPG Chap ter LPG P 3 30 Replace hoses of gas fuel system NOTE Spare parts and special tools are required for this purpose Contact the customer service office 171673 EN 237 ...

Page 248: ...6 Maintenance 3000 hour maintenance two year maintenance 238 171673 EN ...

Page 249: ...t 3000 hour maintenance see Chapter 3000 hour maintenance two year maintenance P 235 7311_003 029 1 Changing the hydraulic oil and filter WARNING Hydraulic oils are hazardous to your health and are under pressure during operation Observe the safety regulations for hand ling hydraulic oil see Chapter Hydraulic fluid P 3 33 Park the truck on a horizontal surface Tilt the mast back Lower the forks an...

Page 250: ...Dispose of used oil according to applicable regulations Screw the drain plug 2 back in together with a new seal and tighten it 7071_003 119 1 3 Pull the old filter insert 3 off the filter cover 1 and dispose of it in accordance with applicable regulations Place the new filter insert 3 on the filter cover and screw the filter cover 1 back on Tighten the filter cover for tightening torque see Chapte...

Page 251: ... dipstick with breather 4 Fill with fresh hydraulic oil in accordance with the maintenance data table using the opening for the dipstick see Chap ter Maintenance data table P 6 186 Change the dipstick with breather 4 and screw in the new one tightly 171673 EN 241 ...

Page 252: ... 5 on the lift cylinder heads of the outer cylinders one half to one turn NOTE Do not unscrew too far Place load on the fork arms and actuate the lift lower operating lever carefully until oil exits from the bleeder screws bubble free Retighten the bleeder screws Bleeding the tilt cylinders Tilt the mast forward and backward to the stop position several times The tilt cylinders bleed themselves au...

Page 253: ...see Chapter 1000 hour maintenance annual maintenance P 223 Carry out 3000 hour maintenance see Chapter 3000 hour maintenance two year maintenance P 235 Changing the coolant WARNING Coolant and coolant additive are hazardous to your health Please observe safety regulations when working with coolant see Chapter Coolant P 3 35 Draining the coolant Remove covering from the back see Chapter Removing an...

Page 254: ...ine remove the connection spigot to gether with the coolant regulator arrowed ENVIRONMENT NOTE Dispose of the coolant properly Topping up the coolant 7094_003 005 4 5 6 7 Rotate the coolant regulator 7 90 anti clockwise and remove it from the 5 con nection spigot Replace the sealing ring 6 and wet it with coolant Insert the coolant regulator 7 into the con nection spigot 5 and rotate it 90 clock w...

Page 255: ...ng coolant concentration P 6 200 CAUTION Coolant additive with a different specification must not be mixed in Use coolant additive and anti corrosion agent as shown in the maintenance data table see Chapter Maintenance data table P 6 186 max min 7071_003 045 1 Screw the lid back on again 1 tightly Start the engine see Chapter Starting the engine P 5 68 Run the engine at approx 1500 rpmfor a maximu...

Page 256: ...ar maintenance 10 year maintenance 7081_003 034 Checking the LPG tank Subject the LPG tank special equipment to TÜV Technical Inspection Authority inspection Follow the national regulations for your country 246 171673 EN ...

Page 257: ...7 Technical data ...

Page 258: ... Dimensions The customer specific dimensions for dimen sions h1 h3 h4 h6 and b1 can be found in your order acknowledgement Centre of gravity S distance from front axle R70 40T 1123 mm R70 45T 1139 mm R70 50T 1159 mm 248 171673 EN ...

Page 259: ... c mm 500 500 500 Load distance x mm 540 540 540 Wheelbase y mm 2005 2005 2005 Weight R70 40T R70 45T R70 50T Tare weight kg 5800 6086 6395 Axle weight with front rear load kg 8627 1173 9462 1124 10290 1105 Axle weight without front rear load kg 2552 3248 2628 3458 2697 3698 Wheels chassis frame R70 40T R70 45T R70 50T Tyres superelastic SE solid rubber V pneumatic L SE SE SE Front wheel size 250 ...

Page 260: ...ork arm dimensions s e l mm 50 120 1000 50 120 1000 50 150 1200 Fork carriage according to ISO 2328 Class Form A B Category III Form A Category III Form A Category III Form A Fork carriage width b3 mm 1310 1310 1410 Ground clearance with load under lift mast m1 mm 140 140 140 Ground clearance at centre of wheelbase m2 mm 165 165 165 Aisle width for pallet 1000 x 1200 crosswise Ast mm 4418 4470 451...

Page 261: ...70 45T R70 50T Engine manufacturer model VW BMF VW BMF VW BMF Engine output as per ISO 1585 kW 56 56 56 Nominal speed rpm 2400 2400 2400 Speed at max torque rpm 1600 1600 1600 Number of cylinders Cubic capacity cm3 6 3200 6 3200 6 3200 Fuel consumption according to VDI cycle kg h 3 8 4 1 4 4 Miscellaneous R70 40T R70 45T R70 50T Type of traction control Stilltronic Stilltronic Stilltronic Working ...

Page 262: ...3200 Twin 7 00 15 250 15 1364 1120 up to 3250 up to 3200 Continen tal 250 15 250 15 1136 1120 up to 3250 up to 3200 Pneumatic tyres 250 15 250 15 1136 1120 up to 3250 up to 3200 Twin XZM 10 10 7 00 15 250 15 1364 1120 up to 3250 up to 3200 Michelin XZM 10 10 250 15 250 15 1136 1120 up to 3000 up to 2300 Tyres R70 45T R70 50T Com ment Tyre pressure bar Tyres Track mm Mast type height in mm front re...

Page 263: ...Fuse 10 A 1F09 Fuse 10 A 1F10 Fuse 15 A 1F11 Fuse 5 A 1F12 Fuse 10 A 1F15 Fuse 10 A 1F16 Fuse 10 A 1F17 Fuse 10 A 1F18 Fuse 10 A 1F19 Fuse 10 A 1F21 Fuse 15 A 1F22 Fuse 15 A 4F01 Fuse 10 A 5F12 Fuse 30 A 5F11 Fuse 30 A 5F13 Fuse 20 A 5F14 Fuse 20 A 9F03 Fuse 10 A 9F04 Fuse 30 A 171673 EN 253 ...

Page 264: ...1_003 098 12345678910 X30 A B X36 X35 X38 X39 F1 5A K1 F3 F2 10A X34 X31 X33 X32 C B A 3 2 1 1 2 10A C B A B A C B A 3 2 1 3 2 1 1 2 2 1 2 1 A B A B 2 1 F1 Fuse 5 A F2 Fuse 10 A F3 Fuse 10 A Fuse assignment special equipment NOTE Depending on equipment not all fuses will be present in your truck 254 171673 EN ...

Page 265: ...8 Circuit diagrams ...

Page 266: ...8 Circuit diagrams Hydraulics Hydraulics Hydraulic circuit diagram 7071_003 083 256 171673 EN ...

Page 267: ...c oil tank 6 Breather plug 7 Return line filter 8 Suction screen 9 3 way directional control valve block 10 4 way directional control valve block 11 Burst pipe protection 12 Lift cylinders 13 Tilt cylinder 14 Lowering brake 15 Accumulator tank 16 Pressure reducing valve with housing 17 Fan motor 171673 EN 257 ...

Page 268: ...ed circuit board A11 Field regulator A12 Protective circuit printed circuit board A13 Fuses protective circuits printed circuit board F1 Fuse main fuse F2 Fuse control fuse F3 Fuse control fuse F4 Fuse control fuse F5 Fuse control fuse F6 Fuse control fuse F7 Fuse control fuse F8 Fuse control fuse F9 Fuse control fuse F10 Fuse control fuse F11 Fuse for A2 G1 Battery G2 Battery G3 Battery H1 Indica...

Page 269: ...ug for A9 X99 not used Z1 Protective circuit Traction drives 1A1 Traction control printed circuit board 1A2 Output stage 1A3 Biasing current excitation printed circuit board 1A4 Field control printed circuit board 1A5 Retardation printed circuit board 1A6 Current sensor printed circuit board 1A7 Start V engine printed circuit board 1A10 Impulse control system 1B1 Accelerator 1B2 Brake transmitter ...

Page 270: ...rature sensor 1R18 Excitation resistor for electric braking 1S1 Forwards travel direction switch 1S2 Backwards travel direction switch 1S3 Parking brake switch 1S4 Parking brake switch 1S5 Cornering switch 1S6 Cornering switch 1S7 Cornering switch 1S8 Cornering switch 1S9 Traction safety switch 1S10 Reversing button 1S11 Safety switch for 1S10 1S12 Brake switch 1S13 Switch for 2nd braking stage 1S...

Page 271: ...it 1Z26 Protective circuit 1Z27 Protective circuit 1Z28 Protective circuit 1Z29 Protective circuit 1Z30 Protective circuit Hydraulic drives for moving load 2A1 Pump control printed circuit board 2A6 Current sensor printed circuit board 2A7 Proportional technology control unit 2B1 Lift sensor 2B2 Tilt sensor 2B3 Auxiliary hydraulic sensor 1 2B4 Auxiliary hydraulic sensor 2 2B5 Auxiliary hydraulic s...

Page 272: ...Auxiliary hydr directional control solenoid valve 1 2Y6 Auxiliary hydr directional control solenoid valve 1 2Y7 Auxiliary hydr directional control solenoid valve 2 2Y8 Auxiliary hydr directional control solenoid valve 2 2Y9 Release valve 2Y10 Valve on fork carriage 2Z1 Protective circuit for 2V1 2Z2 Protective circuit for 2V2 2Z3 Protective circuit for 2V3 2Z4 Protective circuit for 2V4 Auxiliary ...

Page 273: ...earchlight 5E19 Interior lighting 5E20 Left rotating signal beacon 5E21 Right rotating signal beacon 5E22 Middle rotating signal beacon 5E23 Rotating signal beacon 5E24 Left reverse light 5E25 Right reverse light 5E26 Left corner marker light 5E27 Right corner marker light 5E28 Rear searchlight 5E29 Rear searchlight 5E30 Middle front searchlight 5F1 Fuse for right headlight 5F2 Fuse for left headl...

Page 274: ...ode 5V2 Diode 5V3 Diode Measurement and display devices 6A1 Carbon brush monitor printed circuit board 6A2 Carbon brush monitor printed circuit board 6A3 Discharge indicator printed circuit board 6A4 Impulse transmitter printed circuit board 6A5 Start delay printed circuit board 6A6 Carbon brush monitor printed circuit board 6B1 Oil temperature sensor 6B2 Coolant temperature sensor 6B3 Fuel level ...

Page 275: ...y for oil pressure 6K3 Relay for coolant light 6K4 Relay for coolant light 6K5 Relay for hour meter 6P1 Operating hour meter 6P2 Operating hour meter 6P3 Discharge indicator 6P4 Milometer 6P5 Coolant temperature indicator 6P6 Oil temperature indicator 6P7 Oil pressure indicator 6P8 Fuel level indicator 6P9 Wheel base indicator 6P10 Speed indicator 6P11 Ammeter indicator 6P12 Discharge indicator ho...

Page 276: ...9 Right solenoid valve fork carriage Automated functions not assigned Miscellaneous 9A1 Control unit for ignition 9A2 Shut down solenoid printed circuit board 9A3 Jetronik control unit 9A4 Generator start carbon brush monitor printed circuit board 9A5 Lambda control system control unit 9A6 Protective circuit printed circuit board 9A7 2 pedal printed circuit board with shut down device 9A8 2 pedal ...

Page 277: ...3 9H2 Generator indicator light 9H4 Indicator light for 9S4 9H5 GREEN soot burner indicator 9H6 RED soot burner alarm 9H7 Soot burner diagnostic LED 9H8 Soot burner signal transmitter 9K1 External start contactor 9K2 Relay for 9M1 9K3 Glow plug relay 9K4 Relay for ignition 9K5 Starter lockout relay 9K6 Starter lockout relay 9K7 Relay for 9E11 9K8 Auxiliary relay for diesel mode 9K9 Auxiliary relay...

Page 278: ...resistor 9R5 Series resistor 9R6 Varistor 9R7 Series resistor 9R8 Series resistor for sheathed element heater plug 9R9 Series resistor for sheathed element heater plug 9R10 Series resistor for sheathed element heater plug 9R11 Series resistor 9R12 Series resistor 9R13 Resistor 9R15 Series resistor for sheathed element heater plug soot burner 9S1 Wiper switch 9S2 Rear windscreen wiper switch 9S3 Sw...

Page 279: ...alve solenoid 9Y4 Solenoid valve for gas tank 9Y5 Shut down solenoid 9Y6 Actuator solenoid for automatic battery charging unit 9Y7 Start valve for catalytic converter 9Y8 Soot burner fuel injector 9Z1 Protective circuit for thermostatic switch 9Z2 Protective circuit for fan 9M5 9M6 171673 EN 269 ...

Page 280: ...8 Circuit diagrams Electrical equipment 270 171673 EN ...

Page 281: ...he air filter insert 202 Changing the LPG cylinder 165 Changing the LPG filter 227 Check driver s seat 219 Check lift cylinders and connections for leaks 230 Checking the clearance between fork carriage stop and run out stop 233 Checking the counterweight attach ment 224 Checking the door latch 211 Checking the engine mountings 236 Checking the engine oil level 56 Checking the evaporator and press...

Page 282: ...tting the language 136 Disposal Battery 7 Units 7 Documentation scope 3 Drive axle check for leaks 223 Check oil level 223 Maintenance 223 Driver s compartment Dual pedal version 44 Single pedal version 42 Drivers 20 Driveways 78 79 Driving on ascending and descending slopes 114 Single pedal operation with multiple lever version 80 Single pedal operation with version including mini console 84 Two ...

Page 283: ...ntification points 48 Impermissible use 10 Information regarding performing maintenance 178 Inserting a wheel chock 173 Instructions for washing 196 Insulation testing 28 Insurance coverage on company premises 23 Intervals for maintenance and inspec tion 181 Issue date of manual 4 J Jump starting 160 L Lashing 155 Lift mast Lubricating the roller track 217 Lift mast versions 95 Lifting system Cont...

Page 284: ...afety devices 24 MSG 20 driver s seat Adjusting 63 Adjusting the backrest 64 Adjusting the seat suspension to your weight 65 Moving 64 MSG 65 MSG 75 driver s seat Adjusting 60 Adjusting the backrest 61 Adjusting the backrest extension 63 Adjusting the lumbar support 62 Adjusting the seat suspension to your weight 62 Moving 61 Switching the seat heater on and off 63 Multi lever operation Lift lower...

Page 285: ...k for employees 18 Rules for driveways and the working area 79 S Safety check 26 Safety devices 190 Safety instructions for maintenance Raising and jacking up 191 Working at the front of the forklift truck 192 Working on the ignition system 189 Safety instructions for working on the lift mast Removing the lift mast 192 Securing against tilting back 192 Securing the telescopic lift mast 193 Securin...

Page 286: ...ds 106 Transporting pallets 105 Travel direction switch Single pedal operation with multiple lever version 81 Single pedal operation with version including mini console 85 Turning on the key switch 66 Tyres Safety principles 25 U Use of working platforms 12 V Variants 51 VDI datasheet 249 Vehicle identification number 50 Visual inspections 54 W Warning regarding non original parts 24 Washing outsi...

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Page 288: ...Still GmbH Berzeliusstrasse 10 D 22113 Hamburg Ident no 171673 EN ...

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