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Still RX50-10, Original Instructions Manual

The Still RX50-10 offers exceptional performance and versatility for all your material handling needs. With its user-friendly design, this forklift ensures seamless operation. For complete guidance on maximizing its potential, you can easily access and download the Original Instructions Manual for free from our website.

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Index

g

View of operating procedures . . . . . . . . . . 9
Views of the display operating unit . . . . . 10
Visual inspections . . . . . . . . . . . . . . . . . 68

W

Warning regarding non-original parts . . . 32
Wedging . . . . . . . . . . . . . . . . . . . . . . . 238
Wheel chock . . . . . . . . . . . . . . . . . . . . 284
Wheels and tyres

Checking condition and wear of the

tyres . . . . . . . . . . . . . . . . . . . . . 319

Checking the condition . . . . . . . . . . . 71
Checking wheel fastenings . . . . . . . 320
Servicing . . . . . . . . . . . . . . . . . . . . 318

Windscreen wiper/washer . . . . . . . . . . 203
Working at the front of the truck . . . . . . . 308
Working on the electrical equipment . . . 306
Working on the hydraulic equipment . . . 306
Working spotlights

Automatically switching on/off . . . . . 202
Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 202

Manually switching on/off . . . . . . . . 201
Switching on and off . . . . . . . . . . . . 201

Z

Zero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 101

360

55048011501 EN - 12/2015

Summary of Contents for RX50-10

Page 1: ...Original instructions Electric forklift truck RX50 10 RX50 13 RX50 15 RX50 16 5060 5061 5063 5065 5066 55048011501 EN 12 2015 ...

Page 2: ......

Page 3: ...g Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de 55048011501 EN 12 2015 I ...

Page 4: ......

Page 5: ...al considerations 11 Packaging 11 Disposal of components and batteries 11 2 Introduction Use of truck 14 Proper usage 14 Proper use during towing 14 Impermissible use 14 Place of use 15 Parking in temperatures below 10 C 16 Using working platforms 16 Residual risk 17 Residual dangers residual risks 17 Special risks associated with using the truck and attachments 18 Overview of hazards and counterm...

Page 6: ...mables 39 Permissible consumables 39 Oils 39 Hydraulic fluid 40 Battery acid 41 Brake fluid 42 Disposal of consumables 44 Emissions 45 4 Overviews General view of truck 50 General view of driver s compartment 52 Operating devices and display elements 53 Display and operating unit 53 Operating devices for hydraulic and traction functions 55 Multi lever 56 Double mini lever 57 Three way mini lever 58 ...

Page 7: ... of the load measurement variant 101 Checking the vertical lift mast position variant for correct function 103 Driving 104 Safety regulations when driving 104 Driveways 106 Setting the drive programs 108 Reducing speed with a raised load variant 109 Special overhead guard for drive in racks variant 109 Selecting the drive direction 111 Actuating the drive direction switch multiple lever version 11...

Page 8: ... regulations when handing loads 147 Before taking up load 148 Load measurement variant 149 Picking up loads 152 Danger area 153 Transporting pallets 154 Transport of swinging loads 154 Picking up a load 155 Transporting loads 159 Setting down loads 160 Driving on ascending and descending slopes 162 Driving on lifts 162 Driving on loading bridges 164 Working with attachments 165 Fitting attachments...

Page 9: ...f 198 Switching the double working spotlights on and off 201 Operating the windscreen wiper washer 203 FleetManager variant 203 Accident recorder variant 204 Driver restraint systems variants 204 Clipboard variant 204 Trailer operation 205 Towed load 205 Tow coupling RO 230 206 Tow coupling RO 244 208 Towing trailers 210 Cold store application 211 Operating the display and operating unit 214 Indic...

Page 10: ...battery door 259 Disconnecting the battery male connector 261 Battery replacement using a bridge 262 Battery transport with crane 269 Changing the battery using the internal roller channel 270 Battery replacement using an external roller channel 273 Battery installation or battery replacement without onboard devices 277 Maintaining the battery 278 Decommissioning 282 Parking the truck securely and...

Page 11: ...ant 313 Maintenance 315 Lubricating the joints and controls 315 Checking the battery hood lock 315 Maintaining the seat belt 316 Checking the driver s seat 318 Servicing wheels and tyres 318 Checking the drive axle for oil level leaks and general condition 320 Checking the brake fluid level 321 Checking the brake fluid level sensor 322 Checking the battery condition acid level and acid density 324 C...

Page 12: ...aks 334 Checking fork arms 335 Checking the reversible fork arms 335 7 Technical data Dimensions 338 VDI datasheet RX50 10 and RX50 13 339 VDI datasheet RX50 15 and RX50 16 343 Ergonomic dimensions 347 Battery specifications 348 Fuse assignment 351 X 55048011501 EN 12 2015 ...

Page 13: ...1 Foreword ...

Page 14: ...tions provide the necessary information to do this Read and observe the information provided before commissioning the truck This will prevent accidents and ensure that the warranty remains valid CE Symbol CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is confirmed by the issued EC declaratio...

Page 15: ...ccording to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH Accessories Key for key switch two pieces Hexagon socket wrench for emergency lowering not in multi lever operation 55048011501 EN 12 2015 3 ...

Page 16: ...turer from the nameplate in the space provided Production number Year of manufacture Please quote the production number during all technical enquiries Each truck comes with a set of operating instructions These instructions must be stored carefully and must be available to the driver and operating company at any time The storage location is specified in the Overviews chapter If the operating instru...

Page 17: ...opment of trucks These operating instructions are subject to change and any claims based on the information and or illustrations contained in them cannot be asserted Please contact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts ...

Page 18: ... instructions Abbreviation Meaning C Degrees Celsius F Degrees Fahrenheit A Amperes ABE Display operating unit ArbSchG German labour protection law BetrSichV German Ordinance on Industrial Safety and Health BG Employers liability insurance association BGG Employers liability insurance association act BGR Employers liability insurance association rule German Social Accident Insurance Employers liab...

Page 19: ...adio Service h d Hours per day time driven each day in hours ID no ID number ISO International standard kg Kilograms kg m3 Kilograms per cubic metre km h Kilometres per hour km d Kilometres per day kilometres driven each day kN Kilonewtons kW Kilowatts kWh h Energy consumption l Litres l h Litres per hour l min Litres per minute LAN Local area network LED Light emitting diode Lp Sound pressure lev...

Page 20: ...on metres PIN Personal identification number SE Superelastic SIT Snap in tyre for simplified assembly StVZO German Road Traffic Licensing Regulations t Tonnes TRGS Technical Regulations for Hazardous Substances a s And similar V Volts VDE Association for Electrical Electronic Information Technologies VDI Association of German Engineers VDMA German Engineering Federation W Watts WLAN Wireless local ar...

Page 21: ...the front Schematic views 6210_003 062 View of functions and operations This documentation explains the usually sequential chain of certain functions or oper ations Schematic diagrams of a counterbal ance truck are used to illustrate these proce dures NOTE These schematic diagrams are not represen tative of the structural state of the documented truck The diagrams are used solely for the purpose o...

Page 22: ...ting statuses and values in the display of the display operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values can vary Information that is not relevant for descriptions is not shown 10 55048011501 EN 12 2015 ...

Page 23: ...properly after delivery of the truck Disposal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispo sing of batteries ENVIRONMENT NO...

Page 24: ...1 Foreword Environmental considerations 12 55048011501 EN 12 2015 ...

Page 25: ...2 Introduction ...

Page 26: ... exceeded see also the chapter entitled Before picking up a load Proper use during towing This truck is suitable for the occasional towing of trailers and is equipped with a towing device for this purpose This occasional towing may not exceed 2 of the daily operating time If the truck is to be used for towing on a more regular basis the manufacturer should be consulted The regulations regarding tr...

Page 27: ...public roads it must conform to the existing national regula tions for the country in which it is being used The ground must have an adequate load capacity concrete asphalt and a rough surface Routes work areas and aisle widths must conform to the specifications in these operating instructions see the Routes chapter Driving on upward and downward gradients is permitted provided the specified data an...

Page 28: ...thorities NOTE Please observe the definition of the following responsible person operating company Parking in temperatures below 10 C CAUTION Batteries can freeze If the truck is parked in an ambient temperature below 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batteries The truck is then not ready for operation When the ambient temperature is ...

Page 29: ...ncident or breakdown etc WARNING All persons that are in the vicinity of the truck must be instructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regulati ons in these operating instructions The risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such...

Page 30: ...orrect operation and losing stability can never be excluded The loss of stability can be avoided or min imised by the following actions Always secure the load against slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as centrally as possible with the truck and transport i...

Page 31: ... risk time the truck is used in a manner that falls outside the scope of normal use and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci dents 55048011501 EN 12 2015 19 ...

Page 32: ...ey only for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when using working platforms Compliance with national regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability insurance associations Impaired visibi...

Page 33: ... and labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note Germ...

Page 34: ...trSichV and employers liability insurance association regulation 104 When parking LPG trucks Note the German Ordinance on Industrial Safety and Health BetrSichV employers liability insurance association regulation 104 and the operating instructions O German Ordinance on Industrial Safety and Health BetrSichV and employers liability insurance association regulation 104 With driverless transport sys...

Page 35: ...ust be appointed NOTE Please observe the definition of the following responsible persons operating company and driver The construction and equipment of the truck correspond to the Machinery Directive 2006 42 EC and are therefore marked with CE labelling These elements are therefore not included in the hazard assessment At tachments possess their own CE labelling and likewise are not included for th...

Page 36: ... be taken into consideration The conditions of use for trucks are broadly similar in many plants so the hazards can be summarised in one overview Observe the information provided by the relevant employers liability insurance association on this subject 24 55048011501 EN 12 2015 ...

Page 37: ...3 Safety ...

Page 38: ...eer or a person who fulfils the following requirements A completed vocational qualification that demonstrably proves their professional expertise This proof should consist of a vocational qualification or a similar document Professional experience indicating that the qualified person has gained practical experience of industrial trucks over a proven period during their career During this time this per...

Page 39: ...trained in accordance with BGG General Employers Liability Insurance Association Act 925 Observe the national regulations for your country Driver rights duties and rules of be haviour The driver must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety helmet industrial goggles and gloves...

Page 40: ...e aforementio ned substances are not permitted to perform work of any kind on or with the truck Prohibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key 28 55048011501 EN 12 2015 ...

Page 41: ...ge to its structural state can affect the handling and stability of the truck which in turn can lead to accidents You should therefore contact your service centre beforehand Changes that will adversely affect stability load capacity and safety systems among other things must not be made without the manufacturer s approval The truck can only be converted with written approval from the manufacturer ...

Page 42: ... and all connections to the electronic control cards are disconnected Contact the authorised service centre on this matter DANGER Risk of explosion from additional holes in the battery hood Explosive gases can escape and lead to potentially fatal injuries if they explode Sealing holes with plugs is not sufficient to prevent gas from escaping Do not drill any holes in the battery hood DANGER Risk of...

Page 43: ...o so the operating company must fulfil the following prerequisites Construction documents test documents and assembly instructions associated with the change must be archived and remain accessible at all times Check that the capacity rating plate decal in formation hazard warnings and the operating instructions are consistent with regard to the changes and modify if necessary The change must be des...

Page 44: ...oad may only be mounted on the overhead guard if the structural design has been tested and the manufacturer has given approval Seek advice from the authorised service centre for the mounting of roof loads Warning regarding non original parts Original parts attachments and accessories are specially designed for this truck We specifically draw your attention to the fact that parts attachments and acc...

Page 45: ...l headlights etc is only permitted with the manufacturer s written approval All electrical system interventions must be documented Even if they are removable roof panels may not be removed as they are designed to protect against small falling objects Tyres DANGER Risk to stability Failure to observe the following information and instructions can lead to a loss of stability The truck may tip over r...

Page 46: ...s not cause the truck to tilt to one side e g always replace right hand and left hand wheels at the same time Changes must only be made following consultation with the manufacturer If the type of tyre used on an axle is changed for example from superelastic tyres to pneu matic tyres the load diagram must be changed accordingly Contact the authorised service centre on this matter Medical equipment ...

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

Page 48: ...sentials for safe operation picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre 36 55048011501 EN 12 2015 ...

Page 49: ...d until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service centre N...

Page 50: ...nst ground Contact the authorised service centre Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage test voltage 500 V Ensure that all voltage sources have been disconnected from the circuit to be tested Measure the insulation resistance with a suitable measuring device The insulation resistance can be considered sufficient if it measures at least 1000 V for t...

Page 51: ...e substances that are necessary for operation see Chapter Maintenance data table P 6 303 Oils DANGER Oils are flammable Follow the statutory regulations Do not allow oils to come into contact with hot engine parts No smoking fires or naked flames DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse...

Page 52: ... immediately with oil binding agents and disposed of according to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of according to the regulations Dispose of old oils according to the regula tions Hydraulic flu...

Page 53: ... appropriate personal protective equipment e g protective gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers that comply with regulations Avoid spills Spilt hydraulic fluid should be removed immediately with oil binding agents and disposed of according to the regulations Dispose of...

Page 54: ...ith plenty of clean water In case of injury seek medical advice immediately 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 Brake fluid WARNING Brake fluid is poisonous Avoid swallowing In the event of swallowing do not induce vomiting Rinse out your mouth thoroughly ...

Page 55: ...iled with brake fluid as soon as possible CAUTION Brake fluid is flammable Do not allow brake fluid to come into contact with hot motor parts Smoking fires and naked flames are prohibited CAUTION Brake fluid has strong dissolving and colour chan ging properties Immediately rinse off any brake fluid that has splashed on paint clothing and shoes with plenty of water ENVIRONMENT NOTE Brake fluid is a water po...

Page 56: ...al regulations for the country in which the truck is being used Work must only be carried out in areas designated for the purpose Care must be taken to minimise any environmental pollution Soak up any spilt fluids such as hydraulic oil brake fluid or gearbox oil using an oil binding agent Neutralise any spilt battery acid immedi ately Always observe national regulations con cerning the disposal of u...

Page 57: ... driver s compartment LpAZ 70 dB A The values were determined in the test cycle on an identical machine from the weighted values for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal no...

Page 58: ... m s2 0 204 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than 2 5 m s2 There are therefore no measure ment guidelines for these measurements The individual vibration load on the driver over the course of a working day must be determined by the operating company in accordance with Directive 2002 44 EC at...

Page 59: ... and hydrogen oxyhydrogen gas This gas mixture is explosive and must not be ignited Make sure that there is always sufficient ventilation in working areas that are entirely or partially enclosed Keep away from open flames and flying sparks Do not smoke Observe the safety regulations for handling the battery 55048011501 EN 12 2015 47 ...

Page 60: ...3 Safety Emissions 48 55048011501 EN 12 2015 ...

Page 61: ...4 Overviews ...

Page 62: ..._003 094_V2 3 1 Lift mast 2 Overhead guard 3 Driver s compartment 4 Battery door 5 Battery hood 6 Connection for towing bracket tow coupling optional 7 Drive wheel 8 Right hand bottom plate 9 Left hand bottom plate 10 Running axle 11 Fork arms 12 Lift cylinder 50 55048011501 EN 12 2015 ...

Page 63: ...Overviews 4 General view of truck 55048011501 EN 12 2015 51 ...

Page 64: ...splay operating unit 5 Document holder and storage location for operating instructions 6 Operating devices for hydraulic and traction functions 7 Emergency stop switch only in multiple lever version 8 Storage box 9 Cup holder for bottles max 1 l 10 Battery hood handle 11 Battery hood release 12 Driver s seat 13 Accelerator pedal 14 Brake pedal 15 Signal horn foot switch 52 55048011501 EN 12 2015 ...

Page 65: ...ght direction indicator light 13 Malfunction display 14 Reverse travel display 15 Steering position display degrees 16 Time display digital 17 Not assigned 18 Rotating beacon display 19 Not assigned 20 Not assigned 21 Not assigned 22 Not assigned 23 Menu change button 24 Lighting button 25 Blue Q button 26 Rear window wiper button NOTE The buttons 5 21 22 and the corresponding indicators 6 7 18 19...

Page 66: ...4 Overviews Operating devices and display elements If you have any questions please contact your authorised service centre 54 55048011501 EN 12 2015 ...

Page 67: ...erent versions of the operating devices are available for operating the truck s hydraulic and traction functions The truck can be equipped with the following operating devices Multiple lever Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip Mini console 55048011501 EN 12 2015 55 ...

Page 68: ...2 Tilt operating lever 3 Operating lever for attachment variant 4 Operating lever for attachment variant 5 5th function function switch variant 6 Drive direction switch NOTE In the dual pedal version variant the truck is equipped with a signal horn button instead of the drive direction switch 56 55048011501 EN 12 2015 ...

Page 69: ...ion key F2 4 Drive direction turn indicator cross lever 5 Function key 5th function 6 Attachments cross lever 7 Emergency stop switch 8 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre 55048011501 EN 12 2015 57 ...

Page 70: ... turn indicator cross lever 5 Function key 5th function 6 Auxiliary hydraulics 1 operating lever 7 Auxiliary hydraulics 2 operating lever 8 Emergency stop switch 9 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre 58 55048011501 EN 12 2015 ...

Page 71: ...Drive direction turn indicator cross lever 6 Function key 5th function 7 Auxiliary hydraulics 1 operating lever 8 Auxiliary hydraulics 2 operating lever 9 Emergency stop switch 10 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 3 and 4 Changes must only be made by the authorised service centre 55048011501 EN 12 2015 59 ...

Page 72: ...the basic hydraulic functions 3 Pictograms for the 5th hydraulic function and the clamp locking mechanism variant 4 Pictograms for the 3rd 4th hydraulic functions 5 LED for clamp locking mechanism variant 6 Slider for the 4th hydraulic function e g reach frame forwards backwards 7 Vertical rocker button for the drive direction 8 Shift key F 9 Signal horn button 60 55048011501 EN 12 2015 ...

Page 73: ...and turn indicator button 6 Button for 5th function 7 Emergency stop switch 8 Attachments operating lever 9 Attachments operating lever 10 Tilt operating lever 11 Lift lower operating lever 12 Travel direction switch NOTE Depending on the specification various electric attachment parts can be controlled via function keys 1 and 2 Changes must only be made by the authorised service centre 55048011501...

Page 74: ...ing devices and display elements 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 62 55048011501 EN 12 2015 ...

Page 75: ...Overviews 4 Operating devices and display elements 55048011501 EN 12 2015 63 ...

Page 76: ...en der Haube den Fahrersitz und die Armlehne ganz nach hinten und die Armlehne ganz nach hinten schieben und letztere zusätzlich in schieben und letztere zusätzlich in unterste Position bringen unterste Position bringen To open the batteryhood the driver seat To open the batteryhood the driver seat and the armrest must be moved and the armrest must be moved completely back and the last one complet...

Page 77: ...s are not allowed Do not jump off if the truck is tipping over Lean in the opposite direction to which the truck is tipping 17 Manufacturer s label text 18 Decal information Caution read operating instructions drive slowly with raised load Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batterie...

Page 78: ...on number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequential number 7094_003 098 1 2 3 4 5 1 Tare weight in kg 2 Permitted total weight in kg 3 Permitted front axle weight in kg 4 Permitted rear axle weight in kg 5 Payload in kg StVZO Road Traffic Licensing Regulations information This label includes information on the weight and load distribut...

Page 79: ...5 Operation ...

Page 80: ...ARNING There is a risk of falling when working on high parts of the truck Use only the steps provided on the truck Do not stand on truck components or use them to help you climb onto the truck Use suitable equipment 1 2 6210_000 002 Prior to start up ensure that the truck is safe to be operated The fork arms must be secured against lifting and shifting The locking devices 1 of the fork arms must n...

Page 81: ... be closed correctly and the door lock must be properly secured The battery lock latches the battery door and the battery hood must not be damaged or deformed The battery hood must be closed correctly and the hood lock must be properly secured The battery hood and battery door must show no noticeable damage e g cracks or breaks Steps must be clean and free of ice Any panes of glass variant e g win...

Page 82: ...battery compartment can penetrate the cab through unsealed bores in the battery hood A build up of hydrogen can lead to explosions There must be no unsealed bores in the battery hood Sealing bores with plugs is not sufficient to prevent gas from escaping Have unused bores in the battery hood sealed by the authorised service centre Filling the washer system CAUTION If there is no anti freeze in the ...

Page 83: ... of accident Uneven wear reduces the stability of the truck and increases the braking distance Renew left and right worn or damaged tyres without delay WARNING Risk of tipping Tyre quality affects the stability of the truck If you wish to use a different type of tyre on the truck from the tyres approved by the truck manufacturer or tyres from a different manufacturer you must first obtain approval ...

Page 84: ...ional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the seat or seat backrest while driving Adjust the seat and the seat backrest so that all operating devices can be actuated safely Ensure that the seat and seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the tru...

Page 85: ...sition Release the lever and make sure that the driver s seat engages Adjusting the seat backrest Turn the knob 2 to the right or left until the seat backrest is in the desired position Adjusting the seat suspension NOTE The driver s seat is designed for people weig hing between 50 kg and 120 kg Depending on the driver s weight three different weight classes can be set for the seat light medium an...

Page 86: ... all operating devices can be actuated safely Ensure that the seat and seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment va riants the distance between the head and the lower edge of the roofing sheet must be at least 40 mm NOTE If there are separate operating instructions for the seat they mu...

Page 87: ...ver s seat is securely engaged 7094_003 008 2 Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it Lift the lever 2 and hold Push the seat backrest into the desired position Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structural condition of the truck 55048011501 EN...

Page 88: ...g lever to the central initial position before each new lift audible click Fully fold in the weight adjusting lever once adjustment is complete NOTE The correct driver s weight has been selected when the arrow 4 is in the centre of the inspection window A noticeable empty lift on the weight adjusting lever shows that you have reached the minimum or maximum weight setting 6321_003 039 5 Adjusting t...

Page 89: ...ntact switch is active i e when the driver is sitting on the driver s seat Switch the seat heater 7 on or off using the switch Adjusting the armrest DANGER There is a risk of accident if the armrest lowers sud denly causing the driver to move in an uncontrolled manner This can result in unintentional actuation of the steering or the operating devices and thus cause uncontrolled movements of the tr...

Page 90: ...he armrest 2 into the desired posi tion Tighten the star grip handle by turning it clockwise Check that the armrest is firmly attached Adjusting the height of the armrest Release hand wheel 3 by turning it anti clockwise Shift the armrest 2 into the desired posi tion Tighten the hand wheel by turning it clock wise Check that the armrest is firmly attached 78 55048011501 EN 12 2015 ...

Page 91: ...u are jumping out of the truck this can lead to serious injuries e g from falling loss of fingers etc It is forbidden to jump off the truck Do not jump off the truck Do not wear jewellery at work Do not wear loose fitting workwear CAUTION Component damage through incorrect use Truck components such as the driver s seat steering wheel parking brake lever etc are not designed to be used for climbing o...

Page 92: ... enter the truck and sit down on the driver s seat 3 Always climb off the truck backwards Grip the handle 1 with your left hand and hold on Stand up from the driver s seat and climb out of the truck with your right foot first 80 55048011501 EN 12 2015 ...

Page 93: ...are damaged Do not crush the battery cable when closing the battery cover Ensure that the battery cable does not come into contact with the battery cover Close the battery door 4 5060_003 165 1 2 4 3 Shelf and cup holder WARNING Objects may fall into the footwell and obstruct the pedals there is risk of accident Objects to be stored must be of the correct size so they do not fall from the shelves ...

Page 94: ...5 Operation Commissioning Unlocking the emergency off switch 6321_003 145 F1 F1 F2 F2 1 IV I III II F1 F2 1 1 1 Pull out turn the emergency off switch 1 until it unlocks 82 55048011501 EN 12 2015 ...

Page 95: ...ected Notify the authorised service centre NOTE If the truck is switched on with the steering wheel turned the maximum driving speed is limited The driving speed limitation is disabled as soon as the truck is steered out of cornering to drive in a straight line A change in steering angle of around half a revolution is sufficient for this to be the case I 1 0 5060_003 029_V2 Insert switch key 1 into...

Page 96: ...2_003 085 This initiates a self test All lamps in the drive direction and turn indicator displays light up briefly When the key switch is switched on the display shows the welcome screen in the set language 84 55048011501 EN 12 2015 ...

Page 97: ...ard display elements 1 Battery charge The useable battery capacity appears in the display field as a percentage 2 Drive programme The current drive program 1 5 appears in the display field 3 Steering position The position of the steering appears in the display field 4 Time The current time appears in the display field NOTE After connecting the battery the correct charge status is not displayed until a...

Page 98: ...put menu for the driver PIN appears on the display and operating unit screen All of the truck s functions driving hydraulics additional electrical installations and the display and operating unit displays are blocked The function of the hazard warning system variant is guaranteed Enter the five digit driver PIN possible entries from 00000 to 99999 to enable the blocked functions Once the correct dr...

Page 99: ...k control unit These are still available if the display and operating unit has been changed The authorised service centre can use a diagnostic device to read out the driver PIN and if necessary restore the factory default driver PIN ACCESS CODE input menu The driver enters the five digit driver PIN 00000 to 99999 in this input menu The driver PIN is entered using the buttons 1 The digits entered fo...

Page 100: ...message INVALID appears for a short time When the message goes out the driver PIN can be re entered 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three invalid entry attempts the mes sage CODE DENIED appears The input is then locked for five minutes before another attempt can be made 88 55048011501 EN 12 2015 ...

Page 101: ...s password protected After entering the password the fleet manager can configure general settings for the truck To change the password see the chapter entitled Changing the password Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the four digit password factory default...

Page 102: ...lecting the driver PIN In the ACCESS CODE menu there are fifty possible driver PINs to choose from The digit sequences can be set or changed in the NEW CODE submenu Once the ACCESS CODE menu has been ac cessed the CODE selection field 2 contains the number 1 The first of the fifty driver PINs can now be defined Use the drive program selection button 1 and the menu change button 4 to select the desired ...

Page 103: ... 7 3 4 5 8 9 0 BQ_026_en CONFIRM appears in the display The CONFIRM submenu is used to confirm the new driver PIN Enter the new driver PIN for a second time in the CONFIRM field 8 using the buttons 7 If the entry matches the new driver PIN previously entered the system will accept the new driver PIN once the last digit has been entered The display switches back to the ACCESS CODE menu Another driver...

Page 104: ...nu the message INVALID will appear The message will then disappear after a short time The new driver PIN can be entered in the CONFIRM submenu for further confirma tion 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three incorrect entries the CODE DE NIED message appears The display switches back to the ACCESS CODE menu The desired driver PIN must be re defined 92 55048011501 EN 12 2015 ...

Page 105: ...can only be changed when the parking brake is applied Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the current password using the buttons 1 Confirm the entry by pressing the ENTER button 2 55048011501 EN 12 2015 93 ...

Page 106: ...utton 3 to select the PASSWORD menu Confirm your selection by pressing the ENTER button 2 8 9 6 7 4 2 0 1 3 5 1 3 4 BQ_033_en 2 1 PASSWORD PASSWORD LEVEL appears in the display Use the drive program selection button 1 and the menu change button 4 to select the desired PASSWORD LEVEL 2 Confirm your selection by pressing the ENTER button 3 94 55048011501 EN 12 2015 ...

Page 107: ...isations can only be reset by the autho rised service centre Enter the new desired password using the buttons 1 The digits entered are shown in plain text in the NEW CODE field 4 Confirm your selection by pressing the ENTER button 3 In the NEW CODE field appears briefly The new password is confirmed To correct the new password push the ESC button 2 The display switches back to PASS WORD PASSWORD LEVEL ...

Page 108: ...2 6210_003 095 1 1 1 1 1 Operating the signal horn Push the signal horn button 1 The signal horn sounds NOTE The signal horn is used to warn people against imminent danger or toannounce yourintention to overtake 96 55048011501 EN 12 2015 ...

Page 109: ...he can be hurled out of the truck The driver could slide under the truck or collide with an obstacle There is a risk of fatal injury Fasten the seat belt before every trip Do not twist the seat belt when fastening it Only use the seat belt to secure one person Have any malfunctions repaired by the authori sed service centre NOTE The buckle has a buckle switch variant In the event of an operating e...

Page 110: ... 4 on the buckle 1 Slowly guide the belt tongue back to the retractor by hand NOTE Do not allow the seat belt to retract too quickly The automatic blocking mechanism may be triggered if the belt tongue strikes the housing It will then no longer be possible to pull the seat belt out with the usual force Using increased force pull the seat belt around 10 15 mm out of the retractor to disengage the b...

Page 111: ...If the brake system fails the truck is insufficiently braked or not braked at all so there is a risk of accident Do not commission trucks with a defective brake system Checking the foot brake Check pedal clearance There must be a distance of at least 60 mm between the pressure point and the pedal stop Accelerate the truck without a load in a clear area see Driving chapter Press the brake pedal 1 fir...

Page 112: ...s in spite of an actuated parking brake contact your service centre 5060_003 031 1 Checking the steering system for correct function DANGER If the hydraulics fail there is a risk of accident as the steering characteristics have changed Do not operate the truck if it has a defective steering system Operate steering wheel 1 The steering play while stationary must not be more than two finger widths NO...

Page 113: ...2 1 IV I III II F1 F2 1 1 1 Press the emergency off switch 1 The truck will roll to a stop The display and operating unit shows the message EMERGENCY SWITCH periodically Brake the truck to a standstill by depressing the brake pedal Pull out turn the emergency off switch 1 The truck performs an internal self test and is then ready for operation again Zero adjustment of the load mea surement variant...

Page 114: ...ter Lifting system operating devices P 5 131 Set lift mast to vertical Raise the fork to a height of 300 800 mm 6210_003 071_V2 2 1 Keep button 1 for the zero adjustment pressed for at least four seconds the zero adjustment 2 symbol will appear in the display NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touc...

Page 115: ...to switch on the comfort feature lift mast vertical position Function display 2 must appear in the display Tilt the lift mast backwards The lift mast must tilt back fully and move gently as far as the end stop Tilt the lift mast forward The lift mast must tilt forwards and stop in the vertical position Release the operating device to tilt and actuate again The lift mast must tilt forwards fully an...

Page 116: ...ol He must avoid stopping suddenly turning at speed and overtaking in dangerous places or in blind spots Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden during driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Releasing the ...

Page 117: ...sure that the driving lane is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walking pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be ...

Page 118: ...allets these are Aisle width mm Model Type With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX50 10 compact 5060 2888 3010 RX50 10 5061 2942 3064 RX50 13 5063 3050 3172 RX50 15 5065 3104 3226 RX50 16 5066 3109 3231 The truck may only be used on driveways that do not have curves that are too tight have gradients that are too steep and entrances that are not too narrow or low Driving ...

Page 119: ...e truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers The trucks are dimensioned for this purpose However movable parts may project beyond the truck contour and be damaged or torn off Examples of such components include A folding roof panel in the driver s cab Cab doors Fold out LPG cylinders Condition of the roadways Roadways must b...

Page 120: ...sentatives must ensure that unauthorised third parties do not enter the working area NOTE Please observe the definition of the following responsible person operating company Hazard areas Dangerous locations on the driveways must be designated by the signs typical for traffic or if necessary by additional warning signs 2 5060_003 092_V2 1 2 Setting the drive programs The driving and braking character...

Page 121: ...ing forwards backwards 50 60 70 80 90 Brake retardation electric brake booster 60 70 80 90 100 7321_003 052_en_V2 Reducing speed with a raised load variant This function variant reduces the speed of the truck with a raised load Special overhead guard for drive in racks variant NOTE In order to be able to enter drive in racks the truck can be equipped with a special overhead guard variant 550480115...

Page 122: ... from the racks may protrude into the contour neck and seriously injure the driver When travelling arms and legs must remain within the truck When travelling do not lean your body outside the overhead guard contour a c b 5060_003 172 The following height and width dimensions for the truck with special overhead guard may deviate from the standard equipment Max height to top of overhead guard a mm 2...

Page 123: ...k decelerates and is then accelerated again in the opposite direction reversing The indicator for the selected drive direction forwards 1 or reverse 2 lights up on the display and operating unit Neutral position If the truck is stopped for an extended period select the neutral position to prevent the truck from suddenly starting if the accelerator pedal is pressed inadvertently Briefly select the d...

Page 124: ...g the drive direction P 5 111 For the forwards drive direction push the drive direction switch 1 downwards For the backwards drive direction push the drive direction switch upwards 5060_003 096 F1 F2 1 Actuating the drive direction switch mini lever version For the forwards drive direction push the cross lever 1 forwards For the backwards drive direction push the cross lever backwards 112 55048011...

Page 125: ...r the drive direction 1 upwards A For the reverse drive direction push the vertical rocker button for the drive direction 1 downwards B F1 F1 F2 F2 5060_003 097 1 Actuate the drive direction switch fingertip version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction push the drive direction switch backwards 55048011501 EN 12 2015 113 ...

Page 126: ...s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter entitled Safety regulations when driving The driver s seat is equipped with a seat switch This checks whether the driver s seat is occupied If it is not occupied or in the case of malfunction of the seat switch the truck cannot be moved and all lift functions are locked out In such a case th...

Page 127: ... pedal is released the truck decelerates NOTE The truck can briefly be stopped on upward or downward gradients without actuating the parking brake electric brake The truck begins to creep downwards slowly DANGER Risk of accident due to brake failure The electric brake only functions while the key switch is switched on the emergency off switch has not been actuated and the parking brake is released ...

Page 128: ...ct your authorised service centre Starting drive mode dual pedal version variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit down on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter entitled Safety regulations when driving The driver s seat is equipped with a seat switch This checks wheth...

Page 129: ...operating unit NOTE Depending on the equipment an acoustic signal variant may sound a warning during reverse travel the warning light variant may light up or the hazard warning system variant may flash The truck will travel in the selected drive direc tion The speed is controlled by the accelera tor pedal position When the accelerator pedal is released the truck decelerates NOTE The truck can be st...

Page 130: ...m actuated accelerator pedal Actuate the accelerator pedal for the opposite direction The truck will travel in the selected drive direction NOTE In the event of an electrical fault with the accelerator the drive unit is shut down The electric brake service brake causes the truck to decelerate The truck cannot be driven again until the accelerator pedal has been released and then actuated again pro...

Page 131: ...y 50 and that the drive torque has decreased to 50 of the normal level a component failure may have occurred Bring the truck to a standstill using the brakes Use the parking brake if necessary to assist in this process Notify the authorised service centre Do not operate the truck again until the service brake has been repaired DANGER At speeds that are too high there is a danger that the truck cou...

Page 132: ...irection is retained and is shown on the drive direction indicator NOTE If you operate the accelerator pedal while the parking brake is applied and a drive direction is selected the message PARKING BRAKE appears on the display 2 1 5060_003 035_V3 Applying the parking brake Apply the parking brake lever 2 and allow it to engage The truck can no longer be driven The drive direction indicator will go...

Page 133: ...ruck if it has a defective steering system Steer the truck by turning the steering wheel 1 accordingly Turning the steering wheel in the direction of arrow A steers the truck in drive direction A Turning the steering wheel in the direction of arrow B steers the truck in drive direction B For turning radius information see Chap ter Technical data P 337 55048011501 EN 12 2015 121 ...

Page 134: ...tion there still is a risk of tipping Before using this function familiarise yourself with the change to the driving and steering characteristics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steering Do not turn off...

Page 135: ...eans that the load cannot be lifted above a preset height This function uses a sensor that is welded on at the factory at the required lift mast limit height Once attached the height cannot be easily changed Application If the ceiling of the building is lower than the maximum lift height of the truck this variant can prevent the lift mast from accidentally hitting the ceiling which can result in d...

Page 136: ...n and a load can be lifted to the truck s maximum lift height To switch the automatic lift cut out back on Press the F1 1 button again Lift mast vertical position variant Description If the truck is equipped with the lift mast vertical position comfort feature variant the driver can put down goods such as paper rolls vertically with precision and thus avoid damage when unloading The tilt cylinders...

Page 137: ...re consists of the following individual functions Display of the lift mast vertical position Automatic approach towards the lift mast vertical position Gentle running in to the end stops F1 F1 F2 F2 F1 F2 6210_003 092 1 2 4 5 3 The lift mast vertical position comfort feature is only available as a variant if the truck is equipped with one of the following operating devices Double mini lever 1 Trip...

Page 138: ...lt the lift mast forwards using the corre sponding operating device The lift mast stops automatically as soon as the prese lected setting is reached for the lift mast vertical position If the comfort feature is switched off the lift mast tilts forwards past the lift mast vertical position without stopping If the lift mast is tilted backwards it moves past the lift mast vertical position without st...

Page 139: ...wards and stops as soon as the vertical position is reached The arrow above the bar shown on the screen of the display and operating unit represents the lift mast vertical position Tilting the lift mast forwards beyond the vertical position Release the operating device for tilting and actuate again The lift mast is tilted beyond the vertical position up to the end stop The current mast tilt is sho...

Page 140: ...frequently the lift mast vertical position should be calibrated 6210_003 070_en_V2 1 2 3 Calibrating the lift mast vertical position Set the lift mast to the required position Press and hold the button 1 for the lift mast vertical position for at least five seconds The message VERTICAL POSITION will appear on the display Storing the mast position Press the drive program selection button 3 The curre...

Page 141: ...t or load may be higher than the fork carriage Note the heights of ceilings and entrances 6210_810 002 2 3 Hi Lo lift mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the max height 2 NOTE When lifting above the free lift the fork car riage always remains at the upper edge of the extending lift mast DANGER...

Page 142: ...uence may occur i e the inner lift mast may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for instance result from The hydraulic oil temperature being too low Blocking of the fork carriage in the inner lift mast Blocking of the free lift cylinder Blocking of the chain r...

Page 143: ...If the fork carriage rollers in the lift mast become blocked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on the lift mast see the chapter entitled Working at the front of the truck Lifting system operating devices The operation of the lifting syst...

Page 144: ...ands up from the driver s seat or exits the truck All hydraulic functions are disabled in this case Lift the load Lower the load Tilt the lift mast Auxiliary hydraulic functions To ensure that the hydraulics blocking function does not lock as well the operating device must be in the neutral position for the Lifting function Enabling the hydraulic blocking function The hydraulic blocking function m...

Page 145: ...n has been triggered If the truck hydraulics are disabled by the ex haust valve of the hydraulic blocking function either permanently or due to a technical fault it is possible to lower a raised load at the valve block See the chapter entitled Emergency lowering 55048011501 EN 12 2015 133 ...

Page 146: ...g system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift lower operating lever 1 in the direction of the arrow B To lower fork carriage Move the lift lower operating lever 1 in the direction of the arrow A Tilting the lift mast To tilt the lift mast forwards Move the tilt operating lever 2 in the direction of the arrow C To tilt the lift mast backwards...

Page 147: ...te the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the lift...

Page 148: ...the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the lift ma...

Page 149: ... from the driver s seat Tilting the lift mast To tilt the lift mast forwards Move the lift mast operating lever 1 in the direction of the arrow A To tilt the lift mast backwards Move the lift mast operating lever 1 in the direction of the arrow B Lifting lowering the fork carriage To lift fork carriage Move the lift lower operating lever 2 in the direction of arrow D To lower fork carriage Move th...

Page 150: ...egulations for handling loads Only operate the lifting system from the driver s seat 6210_003 089 1 A B Lifting lowering the fork carriage To lift the fork carriage Pull the joystick 4Plus 1 backwards B To lower the fork carriage Push the joystick 4Plus 1 forwards A 2 D C 6210_003 090 Tilting the lift mast To tilt the lift mast forwards Tilt the horizontal rocker button 2 to the left D To tilt the...

Page 151: ...ove the fork carriage to the left Push the joystick 4Plus 1 to the left E To move the fork carriage to the right Push the joystick 4Plus 1 to the right F NOTE The symbols on the joystick 4Plus indicate the direction of movement of the lift mast or the fork carriage 55048011501 EN 12 2015 139 ...

Page 152: ...handling loads Only operate the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Pull the lift lower operating lever 1 backwards To lower fork carriage Push the lift lower operating lever 1 forwards Tilting the lift mast To tilt the lift mast forwards Push the tilt operating lever 2 forwards To tilt the lift mast backwards Pull the tilt operating lever...

Page 153: ...he fork is a danger area Always wear protective gloves and safety footwear when changing the fork arms Ensure that no one stands in the danger area Do not pull on the fork arms The fork arms must always be carried by two people if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used ...

Page 154: ...iage on a pallet Push the fork arms onto the fork carriage from the outside towards the centre Pull the locking lever 1 upwards and push the fork arms into the required position Ensure that the locking lever snaps into place Fit and tighten the locking screw 2 DANGER There is a risk to life caused by a falling load or fork Tighten the locking screw after every fork replacement It is not permitted ...

Page 155: ...safety footwear WARNING There is a risk of tipping The weight and dimensions of the fork extension affect the stability of the truck The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance Observe load capacity see the Before picking up a load chapter NOTE If the truck is equipped with the load measu rement comfort feature a zero adjust...

Page 156: ...ion is on the fork arm Always secure the fork extension with a securing bolt Always secure the securing bolt with a linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork extension 1 Push the fork extension onto the fork arms until it is flush with the fork back Insert the securing bolts located behind the fork back fully into the fork extension Insert the ...

Page 157: ...alling Do not carry out reverse operation with the standard fork arms WARNING Risk of accident from slipping load Loads may slip on the fork arms 1 if there is no load support A fork extension variant cannot be secured against slipping Load pick up on the fork arms is not permitted The fork extension variant must not be used WARNING Risk of accident from the truck tipping over When driving the cen...

Page 158: ...t comfortfeature then a zeroadjustment of the load measurement is obligatory after the reversible fork arms have been changed see Chapter Zero adjustment of the load measurement variant P 5 101 Otherwise correct load measurement cannot be guaran teed 146 55048011501 EN 12 2015 ...

Page 159: ...nded 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 from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safety guard variant to pre...

Page 160: ...pplicable The position of the capacity rating plate can be found in the chapter entitled Identification points WARNING The figures show examples Only the capacity rating plates on the truck are valid The attachment of additional weights to increase load capacity is prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These values apply to compact and ho...

Page 161: ...ded Observe the special capacity rating plate infor mation shown on the truck and the attachment Load measurement variant Description Knowing the weight of the load to be trans ported gives the driver greater security If the truck is equipped with the load measure ment variant comfort feature the weight of the lifted load can be measured and shown in the display and operating unit Load measurement...

Page 162: ...loads CAUTION If the weight determined by a load measurement exceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce load immediately If necessary use another truck with sufficient load bearing capacity NOTE Accurate load measurement is only possible under the following conditions The hydraulic oil is at normal operating temperature The lo...

Page 163: ...ghlighted in black NOTE If the truck is equipped with mini levers or fingertip operation the F1 button can also be pressed as an alternative NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the load measurement will not be accurate To stop the lowering procedure quickly release the oper...

Page 164: ...ar apart and are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the load Loads are to be picked up and transported as close to the middle as possible DANGER Risk of accident from a falling load When transporting small items attach a load sa...

Page 165: ...its working equipment its load carrying equipment e g attachments or the load Also included are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all ...

Page 166: ... Only safely and carefully positioned loads may be transported 6210_001 007 Transport of swinging loads Contact your national regulatory authorities employer s liability insurance associations in Germany prior to transporting swinging loads National regulations may place restrictions on these operations Contact the relevant authorities DANGER Swinging loads can result in the following risks Impair...

Page 167: ...ing hanging loads suitable devices e g guy wires or hand rails are to be made available and used by guide persons DANGER Risk of accidents When transporting hanging loads never abruptly perform or end driving and load movements during transport Never drive on slopes with a hanging load Containers with fluids cannot be transported as hanging loads Picking up a load DANGER There is a risk to life cau...

Page 168: ...k 6210_800 006 Position the forks NOTE The tilt speed of the lift mast in this truck is significantly higher than for previous products in this series This is signalled by a warning message shown on the display and operating unit after the key switch has been switched on Set the lift mast to vertical Lift the fork carriage to the stacking height CAUTION Risk of component damage When inserting the f...

Page 169: ...ift the fork carriage until the load is resting entirely on the fork DANGER Risk of accident Beware of any people in the danger area CAUTION Risk of component damage Ensure that the roadway behind you is clear Reverse carefully and slowly until the load is clear of the rack Brake gently DANGER Due to the risk of tipping never tilt the lift mast with a raised load Lower the load before tilting the ...

Page 170: ...5 Operation Working with loads 5060_003 102 Lower the load while maintaining ground clearance 5060_003 101 Tilt the lift mast backwards The load can be transported 158 55048011501 EN 12 2015 ...

Page 171: ...ent Driving with a raised load and the lift mast tilted forward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards 6210_800 013 Drive slowly and carefully round corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the inform...

Page 172: ...ift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take parti cular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during lowering the load may fall When removing from stock move the truck far enough back ...

Page 173: ...a moderate speed NOTE The tilt speed of the lift mast in this truck is significantly higher than for previous products in this series This is signalled by a warning message shown on the display and operating unit after the key switch has been switched on 6210_800 016 Lower the load until it rests securely on the rack Look behind you Move the truck back until the fork arms can be lowered without tou...

Page 174: ...itted to put items into stock or to remove them from stock while on an ascending or descending slope The forklift truck should not be parked on a slope In case of emergency secure the truck with chocks 5060_003 071 Driving on lifts The driver is only allowed to use this truck on lifts with a sufficient load capacity and for which the operating company see Chap ter Definition of responsible persons P...

Page 175: ...h ing it off P 5 282 Determine the unit weights by reading the truck nameplate and if necessary the attachment variant nameplate and if necessary by weighing the load to be lifted Add the determined unit weights to obtain the actual total weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Net weight of attachment variant Weight of the load to be lifted 100 ...

Page 176: ...can support the load of the truck Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V 1 3 2...

Page 177: ...achment and the visibility from the driver s position with and without a load must be checked by a competent person If the visibility is deemed insufficient visual aids such as mirrors a camera monitor system etc must be used NOTE Please observe the definition of the following responsible person competent person CAUTION Attachments must be CE certified If the truck is not fitted with an attachment spe...

Page 178: ...re installation Never grab or climb on moving parts of the truck 7090_900 001 Hydraulic connection Before installing the attachment release the pressure from the hydraulic system CAUTION Risk of damage to components Open connections of plug connectors can become dirty The plug connectors can become stiff and dirt can enter the hydraulic system Once the attachment has been disassembled attach the p...

Page 179: ...alled by au thorised personnel in accordance with the information provided by the manufacturer and supplier of the attachments After each instal lation the attachment must be checked for correct function prior to initial commissioning NOTE The pressure release procedure is dependent on the operating devices for controlling the hydraulic functions see the chapter entitled Lifting system operating d...

Page 180: ... warning system variant NOTE Press the button for switching on the hazard warning system even if the truck is not equip ped with a hazard warning system Switching on the hazard warning system prevents the electrical system from being switched off even if the key switch is subsequently swit ched off Switch off the key switch Actuate the operating lever 1 for control ling the hydraulic functions rep...

Page 181: ...ve operating devices see the relevant sections in this chapter WARNING Use of attachments can give rise to additional hazards such as a change in the centre of gravity additional danger areas etc Attachments must only be used for their intended purpose as described in the relevant operating instructions Drivers must be taught how to operate the attachments Loads may only be picked up and transport...

Page 182: ...e pictograms on the operating devices NOTE All the attachments described fall into the category of equipment variants Please see the respective operating instructions for an exact description of the respective movements actions of the attachment fitted 170 55048011501 EN 12 2015 ...

Page 183: ...he direction of movement shown in the lower part of the pictogram 5060_003 166 2 3 6 4 7 5 8 Note the following attachment functions and pictograms 2 Move side shift frame or fork for wards backwards 3 Move sideshift to the left right 4 Adjust fork arms open close 5 Swivel lift mast or fork to the left right 6 Push off pull in load 7 Turn to the left right 8 Tip shovel over tip shovel back NOTE Th...

Page 184: ...om parts of the pictograms on the operating levers always show the function that is activated by that lever The upper part of the pictogram shows that the attachment is equipped with the 5th function The meanings are as follows Move operating lever forwards The attachment moves in the direction of movement shown in the centre part of the pictogram Move operating lever backwards The attachment move...

Page 185: ...ose 5 Push off pull in load 6 Turn to the left right 7 Tip shovel over tip shovel back 8 Swivel lift mast or fork to the left right NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if re...

Page 186: ...wing Move the attachments 1 cross lever in the direction of the arrow A The attachment moves in accordance with the pictogram in position A Move the attachments 1 cross lever in the direction of the arrow B The attachment moves in accordance with the pictogram in position B Move the attachments 1 cross lever in the direction of the arrow C The attachment moves in accordance with the pictogram in p...

Page 187: ...r fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted...

Page 188: ...5th hydraulic function via the cross lever The pictograms on the attachments cross lever show the respective functions that are activated by this lever This essentially involves the following Actuate the 5th function 1 function key and move the attachments 2 cross lever in the direction of arrow E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function...

Page 189: ...r fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted...

Page 190: ...ated by these levers This essentially involves the following Move the operating lever 1 towards A The attachment moves in accordance with the pictogram in position A Move the operating lever 1 towards B The attachment moves in accordance with the pictogram in position B Move the operating lever 2 towards C The attachment moves in accordance with the pictogram in position C Move the operating lever...

Page 191: ...r fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted...

Page 192: ...tion key 3 which then allows the 5th hydraulic function to be controlled with the operating lever 1 The pictograms on the operating levers show the respective functions that are activated by these levers The meanings are as follows Actuate the 5th function function key 3 and move operating lever 1 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th functio...

Page 193: ...rms close 3 Rotate to the left 4 Rotate to the right NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if required 55048011501 EN 12 2015 181 ...

Page 194: ...tion that is activated by these levers This essentially involves the following Move the operating lever 1 towards A The attachment moves in the direction shown in pictogram A Move the operating lever 1 towards B The attachment moves in the direction shown in pictogram B Move the operating lever 2 towards C The attachment moves in the direction shown in pictogram C Move the operating lever 2 toward...

Page 195: ...r fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted...

Page 196: ...y 5 which then allows the 5th hydraulic function to be controlled using the operating lever 3 The pictograms on the operating levers show the respective functions that are activated by these levers The meanings are as follows Actuate the 5th function function key 5 and move operating lever 3 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th function func...

Page 197: ...rms close 3 Rotate to the left 4 Rotate to the right NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if required 55048011501 EN 12 2015 185 ...

Page 198: ...ams Operating device Function of the attachment 1 Joystick 4Plus Move sideshift to the left right 2 Joystick 4Plus or slider Adjust fork arms open close 3 Slider Move reach frame or fork carriage forwards backwards 4 Joystick 4Plus or slider Rotate attachment left right 5 Slider Tip shovel over tip shovel back NOTE The pictograms on the joystick 4Plus are attached according to the attachments fitte...

Page 199: ...function 2 1 6210_003 086 For attachments that are controlled using the 5th hydraulic function the procedures for operation are as follows Press and hold shift key F 1 on the joystick 4Plus Simultaneously actuate the horizontal rocker switch 2 in the direction shown in the pictogram so that the attachment moves accordingly NOTE The pictograms on the joystick 4Plus are attached according to the att...

Page 200: ... the pictogram 6210_003 031 2 3 6 4 7 9 10 5 8 Note the following attachment functions and pictograms 2 Move side shift frame or forks forwards backwards 3 Move sideshift to the left to the right 4 Adjust fork arms open close 5 Swivel lift mast or forks to the left to the right 6 Release clamp load retainer 7 Push off pull in load 8 Open close clamps 9 Turn to the left to the right 10 Tip shovel o...

Page 201: ...the corresponding operating lever controls the 5th function The pictogram 3 behind the operating lever shows in the upper and lower parts the function that is activated with this lever The meanings are as follows Move operating lever forwards The attachment moves in the direction of movement shown in the upper part of the pictogram Move operating lever back The attachment moves in the direction of...

Page 202: ...d to the 3rd operating lever see adhesive label 6 F1 F1 F2 F2 6210_003 034 7 8 9 Press the function key 7 NOTE The arrow 8 under the function key indicates which operating lever is equipped with the 5th function The 5th function is switched to the 4th operating lever see adhesive label 9 NOTE The movement action of this 5th function can be found in the operating instructions of the fitted attachmen...

Page 203: ...d for the correct representation and changed if necessary Contact the authorised service centre if required Clamp locking mechanism variant This truck can be fitted with a clamp locking mechanism as a variant This prevents the clamp from opening unintentionally if the operating function is inadvertently triggered DANGER There is a risk of fatal injury from falling loads if the correct function of t...

Page 204: ... button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one second the clamp locking mechanism is automatically reactivated To open the clamp push the control lever 1 forwards again It is not necessary to release the clamp locking mechanism in order to...

Page 205: ...the clamp pull the control lever 1 back To operate clamping attachments see the section entitled Controlling attachments using the triple mini lever and the 5th function 6210_003 079 2 1 Quadruple mini lever To release the clamp locking mechanism push the operating lever 1 forwards The LED for button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for ...

Page 206: ...ng mechanism is released To open the clamp press and hold shift key F 3 and move the horizontal rocker button 1 to the right NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one second the clamp locking mechanism is automatically reactivated It is not necessary to release the clamp locking mechanism in order to close ...

Page 207: ... To operate the clamping attachments see the section entitled Controlling attach ments using the fingertip and the 5th func tion 1 2 3 7090_860 002 Taking up a load using attachments WARNING Risk of accidents Attachments may only be used for their intended purpose as described in the relevant operating instructions Drivers must be instructed in the handling of the attachments WARNING Risk of accide...

Page 208: ...rking spotlights The front working spotlights 4 are switched on Press button 7 for the rear working spot lights The rear working spotlights 5 are switched on NOTE The rear working spotlights symbol 6 lights up until the rear working spotlights are switched off again NOTE Depending on the configuration the rear working spotlights 5 only light up when the drive direction switch is set to reverse Pres...

Page 209: ... can also be switched on without the key switch being switched on Switching the rotating beacon on and off 5060_003 045_V2 2 1 Push the button 1 for switching on the rotating beacon The rotating beacon symbol 2 appears on the display The rotating beacon is switched on NOTE Pushing the button again switches the rotating beacon off again 55048011501 EN 12 2015 197 ...

Page 210: ...E The hazard warning system can also be switched on without the key switch being switched on Switching direction indicators on and off 5060_003 096 F1 F2 1 Mini lever version Switch on the direction indicators by moving the corresponding drive direction turn indicator cross lever 1 to the left or right The direction indicators and the correspond ing direction indicator lights 2 or 3 flash Switch of...

Page 211: ...ion Switch on the direction indicators by moving the corresponding turn indicator button 1 to the left or to the right The direction indicators and the correspond ing direction indicator lights 2 or 3 flash Turn off the direction indicators by pushing the other turn indicator button 55048011501 EN 12 2015 199 ...

Page 212: ...tch on the direction indicators by moving the turn indicator switch 1 to the left or to the right The direction indicators and the correspond ing direction indicator lights 2 or 3 flash Switch off the direction indicators by moving the turn indicator switch to the centre position 200 55048011501 EN 12 2015 ...

Page 213: ... great lift heights the lower working spotlight illuminates the working area directly in front of the truck Depending on the equipment the upper working spotlights can be switched on off automatically or manually Switching the upper working spotlights on off manually NOTE The upper working spotlights can be switched on off independently of the lower working spotlights For information on switching ...

Page 214: ...two seconds NOTE In these two seconds a maximum of two lifts can take place so that the working spotlights do not switch on each time a precise adjust ment is made If more lifts are carried out during this time the upper working spotlights will remain switched off NOTE The upper working spotlights are switched off automatically when the truck is driven for longer than one second and faster than 2 ...

Page 215: ...itch may be adjusted by trained personnel Inform the relevant service centre Operating the windscreen wiper washer 5060_003 013_V2 1 Push the button 1 to actuate the front windscreen wiper washer variant Every time the button is pressed the wiper interval increases Button 1 Operating stage Off 1st time On 2nd time Interval 3rd time Washer hold down the third time you press it 4th time Off FleetMan...

Page 216: ...his data can be electronically read out and evaluated For further informa tion contact your STILL service centre Driver restraint systems variants Different driver restraint systems are available as variants for this truck The description and operation for these systems can be found in the separate Driver restraint systems operating instructions 6210_003 107 2 1 Clipboard variant The clipboard 1 w...

Page 217: ...Overloading can lead to component damage on the truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the existing towed load corresponds to the rated capacity of the truck no load may be transported on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust it to correspond...

Page 218: ...is restricted to the towing of unserviceable trucks and in exceptional cases for shunting purposes It is not permitted to use it for trailer operation DANGER Never jack up or crane load the truck on the tow coupling The tow coupling is not designed for this and could be deformed or damaged The truck could fall off with potentially fatal consequences For jacking up and crane loading use only the de...

Page 219: ...e coupling pin and attach the security pin DANGER If the coupling pin is lost or destroyed during towing the trailer will become loose and uncontrollable This causes a risk of accident Use only original coupling pins that have been checked for good condition Ensure that the coupling pin is correctly inserted and secured Remove any items used to prevent the trailer from rolling away Tow or shunt th...

Page 220: ...ER The trailer coupling is not designed to support loads and could be deformed or damaged This could cause the supported load to fall with potentially fatal consequences The tow coupling should be subjected only to horizontal loads i e the tiller must be horizontal DANGER If you briefly leave the truck to couple or uncouple the trailer there is a risk to life caused by the truck rolling away and ru...

Page 221: ...hese instructions could result in damage to the coupling jaw or to the tow bar eye Ensure that the tow bar eye enters the coupling jaw centrally Slowly move the truck backwards DANGER If the coupling pin works loose during towing the trailer will become loose and uncontrollable This causes a risk of accident Ensure that the coupling pin is engaged cor rectly If it is not repeat the coupling proced...

Page 222: ...um distance to fixed installations when turning and cornering The permissible length of the trailer trains depends on the roadways to be driven and may need to be determined during the test drive It is the responsibility of the operating com pany to instruct the drivers regarding the permissible number of trailers and where required any additional speed reductions on individual sections of the rout...

Page 223: ... to the maintenance data table see Chapter Maintenance data table P 6 303 Operation CAUTION Changing from a cold inside temperature to a warm outside temperature may result in the formation of condensation water This water may freeze on re entering the cold store blocking moving parts of the truck It is essential that close attention is paid to the duration of deployment in the different temperatu...

Page 224: ...tteries in the cold store To compensate for the reduction in capacity at low temperatures it is advisable to use batteries with the maximum nominal capacity in the respective battery dimensions for the range Electric forklift trucks should not be parked for any longer than necessary in a cold area This also applies to unused batteries The charging station and the parking area for trucks and batter...

Page 225: ...s below 0 C as this could cause the systems and the water present in the hose lines to freeze On discharge the battery voltage is therefore generally lower at low temperatures and the final discharged voltage is reached earlier i e the battery s capacity is lower 55048011501 EN 12 2015 213 ...

Page 226: ...long the truck can be driven if the operating situation of the last 30 minutes is maintained 2 Drive program Displays the number of the selected drive program To change the drive program refer to the section entitled Setting the drive program The Blue Q icon appears when the Blue Q function is switched on refer to the section entitled Blue Q efficiency mode 3 Power rating The power rating indicator...

Page 227: ...splay must be avoided Cease work with the truck immediately Charge the batteries immediately NOTE To prevent deep discharge certain restric tions variant can be activated e g slow lifting Consult the authorised service centre on this matter Power trends indicator Symbol Energy consumption trend Significant increase 50 Increase up to 50 Slight increase up to 30 No change Slight decrease up to 30 Dec...

Page 228: ...n good time 7 Operating hours Displays the total operating hours completed by the truck The hour meter starts running as soon as the truck is driven or the working hydraulics are actuated 8 Total distance Displays the total distance driven in kilometres 9 Daily kilometres Displays the kilometres driven for the day NOTE Ask the authorised service centre about the speed driven indicator NOTE Have al...

Page 229: ...adjusted in the CONFIGU RATION menu Turn the key switch to position I Press the drive program button 1 and the menu change button 2 at the same time The display changes to the PASSWORD menu Press the return key 3 The display changes to the CONFIGURA TION menu The following settings are possible and can be found in the corresponding chapter Setting the date and time Resetting the daily kilometres a...

Page 230: ...Battery charging Drive program Hour meter Odometer Daily hour meter Daily odometer Speed Steering angle Load Time Hydraulic system Exh gas purifier Coolant temperature Fuel level Blue Q Power rating average Power rating trend Symbols for warning messages Description Symbol Parking brake Actuate seat switch Safety belt Battery acid level Neutral warning message 218 55048011501 EN 12 2015 ...

Page 231: ... For the auxiliary equipment the following symbols for the soft key functions are used on the left in the display Description Symbol Empty field No display General function key OFF General function key ON Rear working spotlight OFF Rear working spotlight ON Front working spotlight OFF Front working spotlight ON Windscreen heating OFF Windscreen heating ON Rear window heating OFF Rear window heating...

Page 232: ...sed on the left of the display Description Symbol Empty field No display ESC button to return to the main menu ENTER button to confirm OK button to confirm RES button to reset Button to return to the main menu Button to return to the previous edit field Scroll button to scroll up Scroll button to scroll down Scroll button to count up Scroll button to count down Status LEDs of the function keys for add...

Page 233: ...ad The available inputs and the positions of the keys are shown for inputting digits ESC and ENTER BQ_037 1 2 6 7 3 4 5 ESC Keys for the digits 1 to 7 and the ESC and ENTER keys for inputting the fleet manager password 1 2 6 7 3 4 5 8 9 0 BQ_038 Keys for digits 0 to 9 for inputting the driver PIN access code 55048011501 EN 12 2015 221 ...

Page 234: ... levels Confirm the time set by pressing the Return key 4 Use the arrow key 3 to exit the menu and return to the next higher level NOTE The date is set in a similar manner 8 9 0 6 7 4 3 5 7312_003 055_en_V4 1 2 3 4 Resetting the daily kilometres and daily operating hours The daily number of kilometres and daily operating hours displays can be reset to zero Switch to the CONFIGURATION menu see Chapt...

Page 235: ...essing Return key 4 The LANGUAGE menu appears Press drive program button 1 or menu change button 2 until the desired language appears in the display Confirm your selection by pressing the Return key 4 Use arrow key 3 to exit the menu and return to the next higher level Soft key button for operating various equipment variants There are two soft key columns available on the display operating unit Wit...

Page 236: ...ft key columns depend on the individual equipment of the truck Therefore the soft keys on your display operating unit may vary to those shown here Configuring Blue Q efficiency mode The following operating modes can be se lected to activate the Blue Q efficiency mode STANDARD Blue Q is turned off whenever the truck is commissioned The driver can use the Blue Q button to switch efficiency mode on and o...

Page 237: ...r the menu change button 2 until op tion BLUE Q CONFIGURATION appears Confirm your selection by pressing the Return key 4 The BLUE Q CONFIGURATION menu appears Press drive program button 1 or menu change button 2 until the desired effi ciency mode appears in the display Confirm the set efficiency mode with Return button 4 Use arrow key 3 to exit the menu and return to the next higher level 55048011501...

Page 238: ...up to approx 40 m lower speeds are reached than would be the case if the efficiency mode was not activated Blue Q has no influence on Maximum speed Climbing capability Traction Braking characteristics NOTE The Blue Q efficiency mode can be swit ched on and off in the STANDARD and FI XED FLEX operating modes If the FIXED operating mode is configured in the display operating unit the Blue Q button has n...

Page 239: ...ng X No shutdown for StVZO Road Traffic Licensing Regulations equipment Switching efficiency mode Blue Q on and off NOTE The Blue Q efficiency mode can be swit ched on and off in the STANDARD and FI XED FLEX operating modes If the FIXED operating mode is configured in the display operating unit the Blue Q button has no func tion and the Blue Q efficiency mode is swit ched on permanently For information...

Page 240: ... Q button 1 The Blue Q symbol 2 appears next to the drive programme symbol in the display and operating unit which means that the Blue Q efficiency mode is activated Pressing the Blue Q button once again turns the Blue Q efficiency mode off again 228 55048011501 EN 12 2015 ...

Page 241: ...ays appears repeatedly and for a certain period depending on the event In the case of successive events the respec tive messages are displayed one after another on the screen After a few seconds the screen will alternate between the last shown operating display and the message The frequency of alternation depends on the type of event If a message appears follow these operat ing instructions Once t...

Page 242: ...off switch is actuated An operating device is actuated Refer to the chapter entitled Checking the emergency off function SEAT SWITCH message The truck is equipped with a seat switch If the SEAT SWITCH message appears the driving functions and the working hydraulic are blocked The SEAT SWITCH message is triggered by the following situations The seat switch is not actuated while the accelerator peda...

Page 243: ...nd fasten the seat belt The forklift truck can be driven again without restriction 7312_003 067_en_V2 F1 F2 The seat switch is not actuated while the operating device for the working hydraulics is actuated An operating device for the working hydraulics is actuated even though no one is sitting in the driver s seat SEAT SWITCH appears on the display The working hydraulic functions cannot be execute...

Page 244: ... The forklift truck can again be operated without restriction 7312_003 064_en_V2 F1 F2 Exceeding the operating time NOTE The operating time is adjustable If the key switch is switched on the parking brake is released and the driver does not leave the seat until the set operating time is exceeded and if neither the operating devices for the working hydraulics nor the accelerator pedal are actuated ...

Page 245: ...onally will not drive at all Depending on the configuration selected the working hydraulics functions lift tilt are either available as normal slowed down or not available at all The SAFETY BELT message with the restric ted driving and lifting functions is triggered by the following circumstances Seat belt not worn and driver s seat occu pied The seat belt is continuously fastened and the driver s ...

Page 246: ...parked on a slope Do not leave the truck until the parking brake has been applied In emergencies secure the truck using wedges on the side facing downhill 7312_003 069_en_V3 If you park the truck without applying the parking brake and then vacate the driver s seat the APPLY HANDBRAKE message will appear in the display variant An optional signal tone sounds Apply the parking brake The APPLY HANDBRA...

Page 247: ...KS message appears in the display variant An optional signal tone sounds Lower the forks to the ground The message LOWER FORKS disappears 7312_003 072_en_V3 REFERENCE CYCLE message If the fork was lowered after the truck was switched off the control electronics do not know the position of the fork when the truck is restarted The truck will only travel at a reduced driving speed Depending on the po...

Page 248: ...t To drive again lower the fork to a maximum of 300 mm above the ground The truck can now be driven again with no speed limitation 8 9 0 6 7 4 3 5 7312_003 176_en SERVICE BRAKE message If the message SERVICE BRAKE appears in the display the brake fluid level must be checked Contact your service centre 236 55048011501 EN 12 2015 ...

Page 249: ...pe Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V 1 3 2 6210_001 016_V2 Determining the act...

Page 250: ...re chocking To ensure secure parking after chocking the fork carriage can be lowered as far as the chock Raise the fork carriage high enough so that the chocks can be inserted in front of the front wheels Secure the truck from rolling away by placing a wheel chock in front of each front wheel and behind the back wheel 1 Park the truck securely CAUTION Risk of component damage If you remove the bat...

Page 251: ...tach lashing straps 1 to both sides of the truck and lash the truck to the rear 5060_003 068 2 3 3 Sling lashing straps 2 around the rear of the truck within the chassis contour and lash the truck to the front DANGER The truck may slip if the lashing straps slip The truck must be lashed securely so that it cannot move during transportation Make sure that the lashing straps are tightened securely a...

Page 252: ... rigid connection has not been used during towing for the power transmission in two directions the truck may drive into the towing vehicle when the towing vehicle brakes For safety reasons only a tested tow bar may be used Use a tested tow bar Set down load and lower fork arms close to the ground CAUTION If the truck drive between the drive motor and the drive axle is not interrupted the drive may...

Page 253: ...draulics fail The selected towing speed must allow braking and control of the truck and towing vehicle at all times CAUTION If the truck is not steered while it is being towed it may veer out in an uncontrolled manner The truck being towed must also be steered by a driver The driver of the truck being towed must sit in the driver s seat and fasten the seat belt before towing Where possible activat...

Page 254: ...ow bar to the towing vehicle and to the eye bolt 1 of the truck Sit in the driver s seat in the truck to be towed and fasten the seat belt Where possible activate the restraint systems provided Release the parking brake Select a towing speed that allows the truck and towing vehicle to be effectively braked and controlled at all times Tow the truck After towing secure the truck from rolling away e ...

Page 255: ...sts may load trucks Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V 1 3 2 6210_001 016_...

Page 256: ...here is risk of being hit if the hoists and harnesses fail and cause the truck to fall with potentially fatal consequences Only use hoists and harness with sufficient load capacity for the actual total weight of the truck Only use the truck s designated lifting points Make sure that harnesses such as hooks shackles belts etc are only used in the indicated load direction The harnesses must not be da...

Page 257: ...cessary seek advice from STILL service Determine the truck s centre of gravity NOTE The centre of gravity is indicated by the symbol S in the operating instructions see the sec tion entitled Dimensions Chapter Techni cal data P 337 6210_003 046 10 9 Set the length of the harnesses so that the lifting eye 9 is vertically above the truck s centre of gravity This ensures that the truck hangs level wh...

Page 258: ...eople There is a risk to life Never walk or stand underneath suspended loads Do not allow the truck to bump into anything whilst it is being lifted or allow it to move in an uncontrolled way If necessary hold the truck using guide ropes Carefully lift the truck and take care when setting it down at the intended location 246 55048011501 EN 12 2015 ...

Page 259: ... switch is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency In an emergency all functions of the truck can be shut down Press the emer...

Page 260: ... instructions e g driving on unacceptably steep gradients or failing to adjust speed when cornering can cause the truck to tip over If the truck starts to tip over do not leave the truck under any circumstances This increases the danger of being hit by the truck Do not release your seat belt Never jump off the truck You must adhere to the rules of behaviour if the truck tips over Rules of behaviou...

Page 261: ...on and the mini lever version B Multiple lever version For the Joystick 4Plus version and the mini lever version A Using the hexagon socket wrench 2 turn the emergency lowering screw 5 on the valve block a maximum of 1 5 revolutions to loosen it For the multiple lever version B Using the hexagon socket wrench turn the emergency lowering screw 3 on the valve block 3 a maximum of 1 5 revolutions to ...

Page 262: ...urely store the hexagon socket wrench between the battery hood and the valve cover DANGER If the truck is operated with the hydraulic controller blocked there is an increased risk of accidents After the emergency lowering procedure have the malfunction rectified Notify the authorised service centre 250 55048011501 EN 12 2015 ...

Page 263: ...ructions of the manufacturer of the battery battery charger or truck The handling instructions for the battery and the operating instructions for the battery charger must be followed The following safety regulations must be observed when maintaining charging and changing the battery DANGER WARNING Risk of crushing shearing The battery is very heavy There is a risk of serious injury if any parts of...

Page 264: ...st be no flammable mate rials or spark forming operating ma terials within 2 m of either the truck when it is parked for charging or the battery charger When working with batteries take the following security precautions Keep away from open flames and do not smoke Always ensure adequate ventilation in the vicinity Disconnect the battery male connector before charging and only when the truck and batt...

Page 265: ...from trucks with an internal roller channel can be carried out with the following lifting accessories Lift truck including external roller channel variant The battery can be removed from trucks with a bridge variant using the following lifting accessories Crane NOTE The removal of batteries from trucks without their own devices must be carried out by the authorised service centre Battery weight an...

Page 266: ...uced at the battery male connector This can lead to corrosion at the contacts and can considerably shorten the service life of the contacts Switch off the key switch or battery charger be fore the battery male connector is disconnected or connected Only disconnect the battery male connector while under load in an emergency Opening and closing the battery hood CAUTION Risk of damage through compone...

Page 267: ...switch is switched on under load an arc will be produced This can lead to corrosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connector see the chapter entitled Disconnect...

Page 268: ...ose objects from the battery hood before opening Make sure that the battery hood is not being pushed down by strong winds or other persons Position the driver s seat as far back as it can go 5060_003 115 1 2 3 Push the locking lever 1 to the left Lift the battery hood 3 using the handle 2 and bring it forwards NOTE The battery hood can be raised to a max angle of approx 30 Closing the battery hood...

Page 269: ...nlocked battery hood may swing open towards the seat and driver injuring the driver Ensure that the battery hood is shut securely Drive the truck only when the battery hood is locked DANGER Risk to life from the battery sliding out If the battery hood is not locked and the truck tips over the battery can slide out of position and can fall on the driver Ensure that the battery hood is shut securely...

Page 270: ...o the opened position once the power supply is restored CAUTION Risk of component damage If you connect the battery male connector with the key switch switched on under load an arc will be produced This can lead to corrosion at the contacts which considerably shortens their service life Switch off the ignition switch before the battery male connector is disconnected frs_003 022 5 Connect the batte...

Page 271: ...attery door Opening the battery door NOTE The battery door is equipped with a spring mechanism and an end position latch so that it does not close automatically 1 5060_003 064_V3 Push the battery door release button 1 in the direction of the arrow and open the battery door forwards 55048011501 EN 12 2015 259 ...

Page 272: ...thing should come between the battery door and the edge of the chassis Carefully close the battery door Only close the battery door if the battery cable is not in the way WARNING Risk of accident due to the battery door opening An unlocked battery door may open if the truck decelerates sharply If the battery door opens while driving there is risk of damage from a collision Ensure that the battery ...

Page 273: ...n Ensure that the battery door is shut se curely Disconnecting the battery male connector CAUTION Risk of component damage If you remove the battery male connector while the key switch is switched on under load an arc will be produced This can lead to corrosion at the contacts which considerably shortens their service life Do not disconnect the battery male connector while the key switch is switch...

Page 274: ...mage Ensure that the battery cable does not come into contact with the battery door Close the battery door Battery replacement using a bridge Removing the battery DANGER WARNING If the truck is not parked on horizontal ground there is nothing to prevent the battery rolling away once the lock has been opened leading to a risk of crushing and shearing The truck must be parked on horizontal ground Pe...

Page 275: ...door may be damaged if it is struck by the battery Ensure that the battery door is fully open and secured during battery removal Park the truck securely Switch off the key switch Open the battery hood Open the battery door CAUTION Do not disconnect the battery male connector while the key switch is switched on Ensure that the key switch is switched off 1 5060_003 051 Disconnect the battery male co...

Page 276: ...rve decal information 11 for the indi vidual procedures for battery replacement shown on the inside of the battery door 5 6 2 3 4 5060_003 124_V3 Raise the bridge support 3 at the red web belt 2 until the lock 4 audibly engages Ensure that the battery stop 5 is clear of the edge of the battery tray 6 264 55048011501 EN 12 2015 ...

Page 277: ...o not attempt to keep hold of the battery if it rolls away 5060_003 126_V2 6 5 9 Carefully pull the battery tray 6 with the battery 9 completely out of the battery compartment to the battery stop 5 on the bridge NOTE The battery stop is mounted on a pull out piece and travels with the battery to the end stop of the pull out piece Transfer the battery using the crane see chapter Battery transport w...

Page 278: ...ttery then cannot be inserted Ensure that the bridge support stands vertically under the bridge Ensure that the battery has not been set down on the battery stops Ensure that the battery is resting right up against the battery stops 5060_003 147_V3 7 5 9 Using the crane carefully set down the battery 9 on to the bridge and push it up against the stops 5 and 7 Release the battery from the lifting g...

Page 279: ...nnector becoming damaged and a short circuit Only fold up the battery bridge when the entire battery cable is positioned on top of the battery NOTE To fold down the bridge support the lock must be released The lock is released with a two handed operation This protects the operator against injuries due to an incorrect sequence of operations WARNING The bridge support can be folded down During foldi...

Page 280: ...aged behind the battery tray 6 5060_003 155_V2 12 10 Always lay the battery cable 12 to the left of the cable guide 10 as shown in the diagram CAUTION The battery cable may be damaged by becoming trapped there is risk of short circuit due to crus hing If the battery cable 12 is laid to the right of the cable guide 10 the battery cable will become trapped between the battery bridge and the battery ...

Page 281: ... avoid short circuits batteries with open terminals or connectors should be covered with a rubber mat Attach battery 1 to suitable lifting gear 2 Observe the operating instructions for the lifting gear The lifting gear should be vertical when lifting so that no lateral pressure is applied to the tray Lift the battery from the roller channel Ensure that there is sufficient distance from the battery ...

Page 282: ...irectly in the battery s direction of travel or in the battery compartment Do not place objects or any parts of the body between the battery and the truck chassis Use only the handles that are provided and identified Park the truck securely Switch off the key switch Open the battery hood Open the battery door CAUTION Do not disconnect the battery male connector while the key switch is switched on E...

Page 283: ...the battery door CAUTION The battery door may be damaged if it is struck by the battery Ensure that the battery door is fully open and secured during battery removal CAUTION If the battery rolls out of the battery compartment when no external device is present this can lead to material damage Before removing the battery always position an external device such as an external roller channel see chap...

Page 284: ...ent Do not place objects or any parts of the body between the battery and the truck chassis Do not attempt to keep hold of the battery if it rolls away The battery is now freely accessible and can be pulled out of the battery compartment using an external device such as an external roller channel see chapter Replacing the battery using an external roller channel Activities after installation of th...

Page 285: ...ler channel for battery replacement NOTE Trucks with an integral roller channel allow the battery to be changed using a hand pallet truck which is equipped with an external roller channel DANGER Risk of crushing due to the hand pallet truck tipping over or rolling away The load capacity of the hand pallet truck must correspond to at least the battery weight see battery identification plate The hand...

Page 286: ...s shown for the deflector plates and the guide bolts can be found in the following table Battery type C A B 4 Pzs 1 1 1 5 Pzs 1 1 2 6 Pzs 2 2 3 7 Pzs 3 3 4 8 Pzs 4 4 5 Perform these activities before removing the battery see the chapter entitled Chang ing the battery using the internal roller chan nel 5060_003 151 5 6 7 Fully open the safety lever 7 by moving it in the direction of the arrow Positi...

Page 287: ...the truck s bottom plate 4 Apply the parking brake on the hand pallet truck to secure it against rolling away 5060_003 143 8 9 7 Carefully pull the battery 8 out of the battery compartment until it reaches the battery stop 9 on the external roller channel Fully apply the safety lever 7 by moving it in the direction of the arrow in front of the battery Lower the forks of the hand pallet truck until...

Page 288: ...ve to transport the battery over long distances Transport the battery to the intended storage space CAUTION If the battery support is not sufficiently strong it can be damaged or destroyed by the weight of the battery The battery must be stored on a suitable beam support or on suitable racking The battery must not be stored on a wooden beam or the like Set down the battery Installing the battery CA...

Page 289: ... 5060_003 152 5 6 7 8 Fully open the safety lever 7 by moving it in the direction of the arrow Carefully slide the battery 8 from the external roller channel 6 fully into the battery compartment Lower the forks of the hand pallet truck 5 until the guide bolt of the stop plate is completely clear of the slotted hole in the bottom plate Release the parking brake of the hand pallet truck and remove t...

Page 290: ...battery WARNING Battery acid is toxic and corrosive Observe the safety regulations in the Battery acid chapter NOTE Battery maintenance is carried out in accor dance with the battery manufacturer s opera ting instructions The operating instructions for the battery charger must also be followed Only theinstructions that camewith the battery charger are valid If any of these instructions are not ava...

Page 291: ...onnection or operation of the charging station or battery charger may result in damage to components Follow the operating instructions for the charging station or battery charger and for the battery CAUTION Possible damage to the male battery connector If the battery male connector is disconnected or connected while the ignition switch is switched on or the battery charger is under load an arc wil...

Page 292: ... instruc tions for your battery and the battery charger equalising charge CAUTION Risk of component damage If you disconnect the charging cable while the bat tery charger is switched on an arc will be produced This can lead to corrosion at the contacts which considerably shortens their service life Switch off the battery charger before the char ging cable is disconnected Start the battery charger ...

Page 293: ...Operation 5 Handling the battery 6210_600 001 Close the battery door When doing so ensure that no cable is crushed between the chassis and the battery door 55048011501 EN 12 2015 281 ...

Page 294: ...been applied DANGER There is a risk of fatal injury from a falling load or parts of the truck being lowered Lower the load fully before leaving the truck CAUTION Batteries may freeze If the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batteries The truck will then not be ready for operation At ...

Page 295: ...ter entitled General instructions for controlling attachments Turn the switch key to the left and remove it 6321_003 144 1 F1 F1 F2 F2 1 1 1 Press the emergency off switch 1 NOTE Switch keys FleetManager cards variant FleetManager transponder chips variant and the PIN code for access authorisation variant must not be handed over to other persons unless explicit instructions to this effect have bee...

Page 296: ...nd press the handle 2 down again Shutting down and storing the truck CAUTION Component damage due to incorrect storage In the event of incorrect storage or shutdown for more than two months the truck may suffer corro sion damage If the truck is parked in an ambient temperature of below 10 C for an extended pe riod the batteries cool down The electrolyte may freeze and damage the batteries Store th...

Page 297: ...lead to corrosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connector Check the battery condition acid level and acid density Service the battery NOTE Store only fully cha...

Page 298: ...ing after storage If the truck has been in storage for longer than six months it must be carefully checked before being recommissioned As in the annual inspection this check should also include all safety items for the truck Clean the truck thoroughly see chapter Cleaning Lubricate the joints and controls Check the battery condition acid level and acid density Check hydraulic oil for condensation ...

Page 299: ...Operation 5 Decommissioning NOTE For further information see the truck work shop manual or contact the authorised service centre 55048011501 EN 12 2015 287 ...

Page 300: ...re is a risk of injury due to falling when climbing onto the truck When climbing onto the truck you can get stuck or slip on components and fall Higher points on the truck should only be accessed using the appropriate equipment Adhere strictly to the following steps Use only the steps provided to climb onto the truck Use equipment such as stepladders or platforms to reach inaccessible areas Prepar...

Page 301: ... ignite in the vicinity of hot components e g drive units Adhere strictly to the following steps Regularly remove all deposits accumula tions of foreign materials in the vicinity of hot components DANGER Flammable fluids can be ignited by hot components on the truck causing a risk of fire Adhere strictly to the following steps Do not use flammable fluids for cleaning Note the manufacturer s guidelines...

Page 302: ...more often the truck is cleaned the more frequently it must be lubricated Cleaning the electrical system WARNING Danger of electric shocks due to residual capacity Never reach into the electrical system with your bare hands CAUTION Cleaning electrical system parts with water can damage the electrical system Cleaning electrical system parts with water is forbidden Do not remove covers etc Use only ...

Page 303: ...s such as benzine When using a steam jet do not use addi tional cleaning agents Remove any water in the chain links using compressed air immediately after cleaning Move the chain several times during this procedure Immediately after drying the chain spray it with chain spray Move the chain several times during this procedure For chain spray specifications see the Main tenance data table chapter ENV...

Page 304: ... and start up the truck in accordance with regulations CAUTION Danger of short circuits If any moisture has penetrated into the motors despite the precautionary measures taken this must first be dried with compressed air The truck must then be started up to prevent possible corrosion damage 292 55048011501 EN 12 2015 ...

Page 305: ...6 Maintenance ...

Page 306: ...onnel in accordance with the instructions from the manufacturers of the battery battery charger and truck The handling instructions for the battery and the operating instructions for the battery charger must be followed Maintenance work without special qualifications Simple maintenance work e g checking the hydraulic oil level may be carried out by untrained personnel A qualification like that of a ...

Page 307: ...als are defined for standard use Shorter maintenance intervals can be defined in consultation with the operating company depending on the application conditions of the truck The following factors may necessitate shorter maintenance intervals Contaminated poor quality roads Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Mul...

Page 308: ...6 Maintenance General maintenance information 296 55048011501 EN 12 2015 ...

Page 309: ...age Check the dual pedal variant for damage and function and lubricate Tyres and wheels Check tyres for wear and check the air pressure Check wheels for damage and check the tightening torques Power unit Drive unit Check that it is securely attached and check for leaks Gearbox oil Check oil level Steering Check the steering system for correct function and for leaks Check that the steering wheel is...

Page 310: ...he load chains for damage and wear adjust and lubricate Check the lift cylinder and connections for damage and leaks Check the guide pulleys for damage and wear Check the support rollers and chain rollers for damage and wear Check the play between the fork carriage stop and the run out barrier Check the tilt cylinder and connections for damage and leaks Check the fork carriage for damage and wear ...

Page 311: ...ce 6 General maintenance information At operating hours 1000 2000 4000 5000 7000 Carried out 8000 10000 11000 13000 14000 Check labelling to ensure it is complete Perform a test drive 55048011501 EN 12 2015 299 ...

Page 312: ...6 Maintenance General maintenance information 300 55048011501 EN 12 2015 ...

Page 313: ...s can be found in the spare parts list Only use spare parts as per the manufac turer s instructions The use of unapproved spare parts can result in an increased risk of accidents due to insufficient quality or incor rect assignment Anyone using unapproved spare parts shall assume unlimited liability in the event of damage or harm Quality and quantity of the required operating materials Only the ope...

Page 314: ...ot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part involved When topping up working materials use only clean containers 302 55048011501 EN 12 2015 ...

Page 315: ...ions Quantity System filling Distilled water As required Insulation resistance DIN 43539 VDE 0510 Min 500 V against ground Electrical system Unit Operating materials Specifications Quantity Insulation resistance DIN EN 1175 VDE 0117 Min 1000 V against ground Controls joints Unit Operating materials Specifications Quantity Grease DIN 51825 KPF2 N 20 penetration class 2 lithium saponified ID no 163488 A...

Page 316: ...id rubber tyres Wear limit To wear mark Steering axle drive axle Unit Operating materials Specifications Quantity Wheel nuts screws Torque wrench 195 Nm Wheel gear Gearbox oil ARAL Degol GS 220 Running axle Unit Operating materials Specifications Quantity Wheel nuts screws Torque wrench 195 Nm Brakes Brake fluid ATE DOT 4 SL 6 0 2 l Lift mast Unit Operating materials Specifications Quantity Lubricatio...

Page 317: ...Maintenance 6 General maintenance information Washer system Unit Operating materials Specifications Quantity System filling Screen wash Winter ID no 172566 As required 55048011501 EN 12 2015 305 ...

Page 318: ...nd secure the lift mast to prevent it tilting backwards unintentionally Observe the maximum lift height of the lift mast and compare the dimensions from the technical data with the dimensions of the hall into which the truck is to be driven These steps are taken to prevent a collision with the ceiling of the hall and to avoid any damage caused as a result Working on the hydraulic equipment The hyd...

Page 319: ...airs and when changing hydraulic and electrical compo nents These are listed in the appropriate sections Lifting and jacking up DANGER There is a risk to life if the truck tips over If not raised and jacked up properly the truck may tip over and fall off Only the hoists specified in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity Only have th...

Page 320: ...tre CAUTION Possibility of damage to the ceiling Note the maximum lift height of the lift mast Securing the lift mast against tilting backwards A hardwood beam with a cross section of 120 x 120 mm is required The length of the hardwood beam must approximately correspond to the width of the fork carriage b3 To avoid impact injuries the hardwood beam must not protrude beyond the outer contour of the...

Page 321: ...R Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technician to remove the lift mast Securing the lift mast against falling off DANGER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technician to secure the lift mast 55048011501 EN 12 2015 309 ...

Page 322: ...e pedal version Remove the right bottom plate 4 Chap ter Removing installing the bottom plate P 6 311 In the dual pedal version 3 5 1 2 3 4 5060_003 049_V2 Remove the right bottom plate 4 Chap ter Removing installing the bottom plate for dual pedal operation variant P 6 313 Unscrew the four screws 3 Lift up the valve cover 5 and remove Installing the valve cover Position the valve cover and attach...

Page 323: ...assis There is a risk of crushing When closing the bottom plate make sure nothing is between the bottom plate and the edge of the chassis NOTE The left bottom plate 1 has a recess which the operator can insert his fingers into to lift it The recess is underneath the rubber covering 4 Fold the rubber covering 4 forwards and reach into the recess 2 5060_003 057_V2 3 1 Lift up the bottom plate 1 Disco...

Page 324: ...is located underneath the bottom plate Lift the bottom plate 5 forwards and carefully guide it upwards over the brake pedal 6 Disconnect the connecting plug for the accelerator Remove the bottom plate Installing the right bottom plate Position the bottom plate Connect the connecting plug for the accel erator Lower the bottom plate carefully guiding it downwards over the brake pedal Close the botto...

Page 325: ...isk of crushing When closing the bottom plate make sure nothing is between the bottom plate and the edge of the chassis NOTE The accelerator pedals 3 and 5 are atta ched to the left bottom plate and are removed with it Due to the design the right bottom plate must always be removed first Lift the bottom plate 1 forwards and carefully guide it upwards over the brake pedal 2 and the forwards accelera...

Page 326: ...nce points Disconnect the connecting plug for the accelerator Remove the bottom plate Installing the left bottom plate Position the bottom plate Connect the connecting plug for the accel erator Close the bottom plate 314 55048011501 EN 12 2015 ...

Page 327: ...the truck tips over or is subjected to sharp deceleration the battery hood can open and the battery can fall out If the hood lock is deformed damaged or stiff inform STILL Service immediately and do not operate the truck Always check the hood lock after an accident Check the hood lock for secure function Pivot points must be greased and move easily NOTE The interval for greasing is influenced signi...

Page 328: ...belt is faulty it may tear or open during an accident and no longer keep the driver in the driver s seat The driver may therefore be hurled against the truck components or out of the truck Ensure operational reliability by continually testing Do not use a truck with a defective seat belt A defective belt must only be replaced by your service centre Only use genuine spare parts Do not make any chan...

Page 329: ...utton 4 is pressed The automatic blocking mechanism must be tested at least once a year Park the forklift truck on level ground Pull out the belt with a jerk The automatic blocking mechanism must block extension of the belt Tilt the seat at least 30 In order to do this open the battery hood fully see Chapter Opening and closing the battery hood P 5 254 Slowly extend the belt The automatic blocking...

Page 330: ...els and tyres WARNING Risk of accident Uneven wear decreases the stability of the truck and increases the braking distance Change worn or damaged tyres without delay WARNING Risk of tipping Tyre quality affects the stability of the truck If you wish to use a different type of tyre on the truck from the tyres approved by the truck manufacturer or tyres from a different manufacturer you must first ob...

Page 331: ... the manufacturer When changing wheels or tyres always ensure that this does not cause the truck to tilt to one side e g always change right and left wheels at the same time NOTE The wear of the tyres on an axle must be approximately the same Superelastic tyres and solid rubber tyres can be worn down to the wear mark 2 If necessary remove any foreign bodies 1 imbedded in the tyre tread 55048011501...

Page 332: ...c Note safety regulations for working with gearbox oil see Chapter Oils P 3 39 NOTE See the workshop manual for the filling quantity for gearbox oil as well as for the tightening torque of the oil filler plug 1 or ask the relevant service centre Turn the steering completely to the right in order to make the oil filling opening at the gearbox housing 2 accessible Park the truck securely see Chap ter P...

Page 333: ...CE BRAKE appears in the display operating unit the brake fluid level must be checked WARNING Risk of injury from becoming trapped in moving parts Observe the safety regulations for working at the front of the truck see Chapter Working at the front of the truck P 6 308 WARNING Brake fluid is hazardous to your health Observe the safety regulations for working with brake fluid see Chapter Brake fluid P 3...

Page 334: ...ording to the maintenance data table see Chapter Maintenance data table P 6 303 4 1 2 3 5060_003 163 Checking the brake fluid level sensor WARNING Risk of injury from becoming trapped in moving parts Observe the safety regulations for working at the front of the forklift truck see Chapter Working at the front of the truck P 6 308 WARNING Brake fluid is hazardous to your health Observe the safety reg...

Page 335: ...nscrew filler cap 2 Press brake fluid level sensor switch 3 The SERVICE BRAKE message must appear in the display If the message does not appear in the display inform the service centre When testing is complete screw the filler cap back on 55048011501 EN 12 2015 323 ...

Page 336: ...spilt battery acid immediately with plenty of water Have defective battery overhauled 6321_003 126 1 2 Open filler cap 1 and check the acid level For batteries with caged cell plugs the acid must reach the bottom of the cage for batteries without caged cell plugs it must cover the lead plates by about 10 15 mm Top up missing fluid with distilled water only The battery cell covers must be kept clean ...

Page 337: ...le the key switch is switched on under load an arc will be produced This can lead to corrosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency NOTE Depending on the equipment not all fuses will be present ...

Page 338: ...on of fuses 3 check that the cable connections are secure and check for oxidation residues Clean if necessary CAUTION Water in the electrical system can cause damage to components In order to protect the electrical system against ingress of water the cover must be closed Refit the cover after completion of the activities Close the cover of the control electronics Close the cover Close the battery h...

Page 339: ... lead to corrosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency DANGER Risk of fire Using the wrong fuses can result in lack of protection against short circuits Only use fuses with the prescribed nomina...

Page 340: ... replace it with a new fuse with the specified nominal current CAUTION Water in the electrical system can cause damage to components In order to protect the electrical system against ingress of water the cover must be closed Refit the cover after completion of the activities Close the cover of the control electronics Close the cover Close the battery hood Connect the battery male connector Carry out...

Page 341: ...l level must be within the lower mark 2 For lift masts over 2100 mm in height the oil level must be within the upper mark 3 The corresponding minimum marking must be exceeded 1 5060_003 065_V3 1 2 3 Unscrew breather filter with oil dipstick 1 Check the oil level NOTE The oil level must lie within the mark 2 or wi thin the mark 3 on the dipstick depending on the height of the lift mast The correspon...

Page 342: ...plied with Deviating national laws are to be taken into account Check pipe and hose connection screw joints for leaks traces of oil Hose lines must be changed if The outer layer has been breached or becomes brittle with tears They are leaking There are unnatural deformations e g bubble formation or buckling A fitting is detached from the hose A fitting is badly damaged or corroded Pipes must be chan...

Page 343: ...03 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again 6210_900 002 Maintenance for trucks used in cold stores On trucks used in cold stores variant check all rollers and chains in the lift mast for ease of movement once a week Maintaining the tow coupling NOTE Wear to moving parts can be significantly reduced by app...

Page 344: ...r eye 4 and the coupling pin 3 4 7321_003 093 Model RO 244 Grease via the lubricating nipple in ac cordance with the maintenance data ta ble see Chapter Maintenance data ta ble P 6 303 For couplings without a lubricating nipple unscrew the end cover 4 then open the coupling and grease it Grease the supporting surface for the tow bar eye 332 55048011501 EN 12 2015 ...

Page 345: ...e cables Checking accelerator pedal and brake pedal Check the accelerator pedal and brake pedal for damage and function Remove the bottom plate as necessary and lubricate the mechanism 7311_003 012 Checking the brake system for correct operation and leaks Perform a functional check of the brake system see Chapter Checking the brake system for correct function P 5 99 If you determine that the pedal...

Page 346: ...mechanism are securely positioned Perform visual inspection to verify that all screws are coated with retaining com pound 7094_810 004 Checking the lift cylinders and connections for leaks WARNING Risk of injury Observe safety regulations for working on the lift mast see the Working at the front of the truck chapter Check the hydraulic connections and lift cylinder for leaks visual inspection Have...

Page 347: ...l thickness CAUTION Worn fork arms should always be replaced in pairs Check the securing mechanism 3 for proper operation The locking screw 2 that prevents dislodg ing must be present 6210_842 003 1 Checking the reversible fork arms NOTE This check is only required for reversible fork arms variant Check the outside of the fork bend 1 for cracks Contact your service centre 55048011501 EN 12 2015 33...

Page 348: ...6 Maintenance 1000 hour maintenance Annual maintenance 336 55048011501 EN 12 2015 ...

Page 349: ...7 Technical data ...

Page 350: ...7 Technical data Dimensions Dimensions 1 Seat is adjustable 90 mm 2 Fork spacing is adjustable 338 55048011501 EN 12 2015 ...

Page 351: ...the truck is equipped with a different lift mast attachment or driver protection structure this value is only a guide value If necessary the centre of gravity S must be determined on an individual basis for each truck VDI datasheet RX50 10 and RX50 13 Characteristics Model RX50 10c RX50 10 RX50 13 Type number 5060 5061 5063 Manufacturer STILL GmbH STILL GmbH STILL GmbH Drive Electric Electric Elec...

Page 352: ...80 70 8 180 70 8 180 70 8 Rear tyre size 180 70 8 180 70 8 180 70 8 Number of front wheels x driven 2 2 2 Number of rear wheels x driven 1x 1x 1x Front track width b10 mm 840 840 840 Rear track width b11 mm Basic dimensions Model RX50 10c RX50 10 RX50 13 Type number 5060 5061 5063 Tilt of lift mast fork carriage forwards α degrees 3 3 3 Tilt of lift mast fork carriage backwards β degrees 5 5 5 Hei...

Page 353: ... carriage width b3 mm 980 980 980 Ground clearance with load under lift mast m1 mm 90 90 90 Ground clearance at centre of wheelbase m2 mm 90 90 90 Aisle width for pallet 1000 x 1200 crosswise Ast mm 2888 2942 3050 Aisle width for pallet 800 x 1200 longitudinal Ast mm 3010 3064 3172 Turning radius Wa mm 1229 1283 1391 Smallest pivot point distance b13 mm Performance data Model RX50 10c RX50 10 RX50...

Page 354: ...load s 5 1 5 1 5 3 Acceleration time without load s 4 7 4 7 4 8 Service brake Hydraulic Hydraulic Hydraulic Elec motor Model RX50 10c RX50 10 RX50 13 Type number 5060 5061 5063 Traction motor power rating at S2 60 min kW 4 9 4 9 4 9 Lift motor power rating at S3 15 kW 7 6 7 6 7 6 Battery in accordance with DIN 43531 35 36 A B C no DIN 43535 A DIN 43535 A DIN 43535 A Battery voltage U V 24 24 24 Ba...

Page 355: ...e number 5065 5066 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seated Seated Rated capacity load Q kg 1000 1000 Load centre of gravity distance c mm 500 500 Load distance x mm 335 335 Wheelbase y mm 1190 1190 Weight Model RX50 15 RX50 16 Type number 5065 5066 Net weight including battery kg 2826 2833 Axle load with front load kg 3679 3866 Axle load with rear load kg 647 56...

Page 356: ...st fork carriage backwards β degrees 5 5 Height with lift mast retracted h1 mm 2160 2160 Free lift h2 mm 150 150 Lift3 h3 mm 3230 3230 Height with lift mast extended h4 mm 3805 3805 Height to top of overhead guard cab h6 mm 2050 2050 Seat height in relation to SIP h7 mm 953 953 Coupling height h10 mm Total length l1 mm 2575 2580 Length including fork back l2 mm 1775 1780 Total width b1 mm 990 990 ...

Page 357: ...speed with load km h 12 0 12 0 Driving speed without load km h 12 5 12 5 Lifting speed with load m s 0 32 0 30 Lifting speed without load m s 0 54 0 54 Lowering speed with load m s 0 54 0 54 Lowering speed without load m s 0 60 0 60 Pulling force with load N 1280 1240 Pulling force without load N 1670 1670 Max pulling force without load N 3770 3470 Max pulling force without load N 7150 7150 Climbi...

Page 358: ...voltage U V 24 24 Battery capacity K5 Ah 920 920 Battery weight Kg 676 676 Energy consumption 60 VDI working cycles hour kWh h 4 8 4 9 Other Model RX50 15 RX50 16 Type number 5065 5066 Working pressure for attachments bar 230 230 Oil flow for attachments l min 30 30 Sound pressure level LpAZ driver s compartment 4 dB A 63 9 63 9 Human vibration acceleration according to EN 13059 m s2 0 7 0 7 Tow co...

Page 359: ...t and the seat suspen sion must be set to this driver s requirements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clearance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into account and in accordance with EN ISO 3411 In general from the...

Page 360: ...change the position of ballast weights Check the battery weight against the information on the nameplate Only use a battery tray that is closed at the bottom RX50 10 5060 Battery compartment dimensions in mm Battery designa tion Capac ity in Ah Weight in kg 5 Length Width Height Tray Ballast weight in kg 4 PzV 440 440 4 PzS 460 460 372 284 845 645 104 RX50 10 5061 Battery compartment dimensions in...

Page 361: ...S 750 750 6 CSM 750 750 524 392 106 78 7 PzV 700 700 7 PzS 805 805 7 PzS 875 875 7 CSM 875 875 600 446 845 645 107 RX50 15 5065 RX50 16 5066 Battery compartment dimensions in mm Battery designa tion Capac ity in Ah Weight in kg 5 Length Width Height Tray Ballast weight in kg 6 PzV 600 600 6 PzS 690 690 6 PzS 750 750 6 CSM 750 750 524 392 106 156 7 PzV 700 700 7 PzS 805 805 7 PzS 875 875 7 CSM 875 ...

Page 362: ...a Battery specifications Battery compartment dimensions in mm Battery designa tion Capac ity in Ah Weight in kg 5 Length Width Height Tray Ballast weight in kg 8 PzS 1000 1000 8 CSM 1000 1000 350 55048011501 EN 12 2015 ...

Page 363: ...tandard F13 30 A 3 CAN power port CPP 2 lighting F18 20 A 4 12 V voltage transformer supply F14 10 A 5 Enable hydraulics multi lever F19 10 A 6 Switch lock display and operating unit main control unit MCU diagnostic connector F11 10 A 7 Proportional technology F17 10 A 8 5th hydraulic function F16 10 A 9 Not assigned F15 10 A 55048011501 EN 12 2015 351 ...

Page 364: ... 10 Horn F12 10 A 11 Pre charging the converter F20 10 A 12 Traction motor main fuse 1 F01 355 A 13 Pump motor main fuse 2 F01 355 A NOTE Depending on the equipment not all fuses will be present in the truck 352 55048011501 EN 12 2015 ...

Page 365: ...a double mini lever 174 Controlling using multi lever operation 171 Controlling using the double mini lever and the 5th function 176 Controlling using the four way mini lever and the 5th function 184 Controlling using the three way mini lever and the 5th function 180 Controlling via the joystick 4Plus 186 Controlling with a quadruple mini lever 182 Controlling with a triple mini lever 178 Controll...

Page 366: ...the brake fluid level 321 Checking the function of the sensor 322 Brake system Checking for correct operation 333 Checking for leaks 333 C CE labelling 2 Changes to the truck 29 Changing the drive direction 115 Dual pedal version 118 Changing the fork arms 141 Changing the password 93 Checking accelerator pedal and brake pedal 333 Checking fork arms 335 Checking the battery hood lock 315 Checking t...

Page 367: ...e daily kilometres 222 Setting the date 222 Setting the language 223 Setting the time 222 Standard displays 214 Display symbols 217 Auxiliary equipment soft key functions 219 Error messages 219 Menu navigation soft key functions 220 Numeric keypad 221 Operating messages 218 Status LEDs 220 Warning messages 218 Disposal Battery 11 Components 11 Documentation scope 4 Double mini lever 57 Lifting low...

Page 368: ...s 330 Checking the oil level 329 I Identification points 64 Impermissible use 14 Information for carrying out mainte nance 294 Maintenance timeframe 295 Information symbols 5 Insulation testing 37 Insurance cover on company premises 29 Issue date of the operating instructions 5 J Jacking up 307 Joystick 4Plus 60 Fork carriage sideshift 139 Lifting lowering the fork carriage 138 Tilting the lift mas...

Page 369: ...sed in cold stores 331 Maintenance personnel for batteries 294 Maintenance work without special qualifications 294 Malfunctions during lifting mode 130 Measuring the battery s insulation resistance 38 Measuring the insulation resistance of the electrical system 38 Medical equipment 34 Message APPLY HANDBRAKE 234 EMERGENCY SWITCH 230 LOWER FORKS 235 REFERENCE CYCLE 235 SAFETY BELT 233 SEAT SWITCH 23...

Page 370: ...idual risks 17 Retrofitting 29 Reversible fork arm Checking 335 Reversible fork arms 145 Roadways 107 108 Rotating beacon 197 Rules for roadways and the working area 108 S Safety devices 307 Safety inspection 37 Safety regulations for maintenance General information 306 Safety devices 307 Set values 307 Working on the electrical equip ment 306 Working on the hydraulic equip ment 306 Safety regulati...

Page 371: ...wing 240 Proper use 14 Trailers Towing 210 Transport of swinging loads 154 Transporting 237 Transporting pallets 154 Triple mini lever Tilting the lift mast 136 Types of lift mast 128 Telescopic mast 129 Tyres Safety principles 33 U Unlocking the emergency off switch 82 Using batteries in the cold store 212 Using working platforms 16 V Valve cover Installing 310 Removing 310 Variants Access author...

Page 372: ...king the condition 71 Checking wheel fastenings 320 Servicing 318 Windscreen wiper washer 203 Working at the front of the truck 308 Working on the electrical equipment 306 Working on the hydraulic equipment 306 Working spotlights Automatically switching on off 202 Lift height controlled switching on off 202 Manually switching on off 201 Switching on and off 201 Z Zero adjustment of the load measur...

Page 373: ......

Page 374: ...STILL GmbH 55048011501 EN 12 2015 ...

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