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Still RX60 25-35, Original Instructions Manual

The Still RX60 25-35 Original Instructions Manual is essential for efficiently operating this powerful forklift. Download this comprehensive manual for free from our website, providing you with valuable guidance and instructions for a smooth and safe handling experience. Get your hands on this user manual at manualshive.com now!

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Lighting. . . . . . . . . . . . . . . . . . . . . . . . . .  152

Changing the light bulb. . . . . . . . . . . .  450
Meaning of the symbols. . . . . . . . . . .  152
STILL SafetyLight. . . . . . . . . . . . . . . .  159
Warning zone light. . . . . . . . . . . . . . .  160

List of abbreviations. . . . . . . . . . . . . . . . . .  32
Load

Driving. . . . . . . . . . . . . . . . . . . . . . . .  242
Picking up. . . . . . . . . . . . . . . . . . . . . .  238
Setting down. . . . . . . . . . . . . . . . . . . .  247

Load-dependant assistance systems

Dynamic Load Control 1. . . . . . . . . . .  259
Dynamic Load Control 2. . . . . . . . . . .  260
Load measurement. . . . . . . . . . . . . . .  262
Overload detection. . . . . . . . . . . . . . .  258
Precision load measurement. . . . . . .  265
Tare function. . . . . . . . . . . . . . . . . . . .  267
Total load. . . . . . . . . . . . . . . . . . . . . .  269

Load capacity. . . . . . . . . . . . . . . . . . . . . .  233
Load chains

Cleaning. . . . . . . . . . . . . . . . . . . . . . .  418

Load measurement. . . . . . . . . . . . . . . . .  262

Calibrating. . . . . . . . . . . . . . . . . . . . .  263

Load programs

Selecting 1 to 3. . . . . . . . . . . . . . . . . .  220

Lubricating the joints and controls. . . . . .  451

M

Main display. . . . . . . . . . . . . . . . . . . . . . .  119
Maintenance

General information. . . . . . . . . . . . . .  434
Safety regulations. . . . . . . . . . . . . . . .  430

Maintenance data table. . . . . . . . . . . . . .  447

Battery. . . . . . . . . . . . . . . . . . . . . . . .  447
Brake system. . . . . . . . . . . . . . . . . . .  447
Controls/joints. . . . . . . . . . . . . . . . . . .  447
Drive axle. . . . . . . . . . . . . . . . . . . . . .  448
Electrical system. . . . . . . . . . . . . . . . .  447
Flame proof enclosure. . . . . . . . . . . .  449
General lubrication points. . . . . . . . . .  447
Hydraulic system. . . . . . . . . . . . . . . .  448
Lift mast. . . . . . . . . . . . . . . . . . . . . . .  448
Load chains. . . . . . . . . . . . . . . . . . . .  449
Steering axle. . . . . . . . . . . . . . . . . . . .  448
Tyres. . . . . . . . . . . . . . . . . . . . . . . . . .  448
Washer system. . . . . . . . . . . . . . . . . .  449

Maintenance personnel for batteries. . . .  435
Maintenance work without special qualifi-

cations. . . . . . . . . . . . . . . . . . . . . . . . . .  435

Malfunctions during lifting mode. . . . . . .  229
Malfunctions in the parking brake. . . . . .  186
Manual tow coupling

Coupling. . . . . . . . . . . . . . . . . . . . . . .  344
Uncoupling. . . . . . . . . . . . . . . . . . . . .  345

Mast tilt angle display. . . . . . . . . . . . . . .  252
Medical equipment. . . . . . . . . . . . . . . . . . .  47
Messages

About operation. . . . . . . . . . . . . . . . .  358
About the truck. . . . . . . . . . . . . . . . . .  365
Introduction. . . . . . . . . . . . . . . . . . . . .  358

Misuse of safety systems. . . . . . . . . . . . . .  45
Multi-lever

Lifting/lowering the fork carriage. . . . .  208
Tilting the lift mast. . . . . . . . . . . . . . . .  209

N

Nameplate. . . . . . . . . . . . . . . . . . . . . . . . .  13
Nameplate of the battery. . . . . . . . . . . . . .  16
Nameplate of the pressure-tight housing. .  14
Neutral position. . . . . . . . . . . . . . . . . . . .  174

O

Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  62
Opening/closing the cab door. . . . . . . . .  333
Opening/closing the side window. . . . . .  334
Operating

Display-operating unit. . . . . . . . . . . . .  122

Operating company. . . . . . . . . . . . . . . . . .  38
Operating devices and display elements. .  76
Operating devices for hydraulic and driving

functions

Double mini-lever. . . . . . . . . . . . . . . . .  82
Fingertip. . . . . . . . . . . . . . . . . . . . . . . .  88
Joystick 4Plus. . . . . . . . . . . . . . . . . . . .  89
Multi-lever operation. . . . . . . . . . . . . . .  81
Quadruple mini-lever. . . . . . . . . . . . . .  86
Triple mini-lever. . . . . . . . . . . . . . . . . .  84

Operating materials

Quality and quantity. . . . . . . . . . . . . .  445

Operating procedures. . . . . . . . . . . . . . . .  34
Operating the pneumatic signal horn. . . .  102
Operating the signal horn. . . . . . . . . . . .  101

Index

 

 497

56378011526 EN - 03/2021  -  01

Summary of Contents for RX60 25-35

Page 1: ...Electric truck RX60 25 35 Cat 3GD For use in potentially explosive areas Original instructions 6301 6302 6304 6305 6307 6308 6309 56378011526 EN 03 2021 01 ...

Page 2: ......

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

Page 4: ...rtlist still eu into a web browser or by scanning the QR code shown to the side On the web page enter the following pass word Spareparts24 On the next screen enter your email address and truck serial number to receive an email with the link and download the spare parts list 2511 Preface II 56378011526 EN 03 2021 01 ...

Page 5: ...ormation on explosion protection 19 Commissioning 21 Proper use 22 Proper use during towing 23 Improper use 23 Place of use 25 Parking in temperatures below 10 C 27 Using working platforms 27 Information about the documentation 29 Scope of the documentation 29 Supplementary documentation 30 Issue date and topicality of the operating instructions 31 Copyright and trademark rights 31 Explanation of ...

Page 6: ...s springs and accumulators 48 Length of the fork arms 48 Residual risk 50 Residual dangers residual risks 50 Special risks associated with using the truck and attachments 52 Overview of hazards and countermeasures 54 Danger to employees 56 Safety tests 58 Carrying out regular inspections on the truck 58 Explosion protection checks 59 Testing the electrical system 60 Insulation testing 60 Safety re...

Page 7: ...usting the driver s seat and armrest 97 Adjusting the steering column 97 Switching on the battery isolating switch 98 Adjusting the swivelling display operating unit 98 Unlock the emergency off switch 100 Checking the emergency off function 100 Operating the signal horn 101 Operating the pneumatic signal horn 101 Using the driver s cab 102 Checking the brake oil level 103 Checking the brake system...

Page 8: ...ming driver profiles 147 Deleting driver profiles 150 Lighting 152 Meaning of the symbols 152 Driving lights 153 Working spotlights 153 Working spotlight for reverse travel variant 155 Turn indicators 155 Hazard warning system 157 Rotating beacon 158 STILL SafetyLight variant 159 Warning zone light variant 160 Efficiency and drive modes 161 Blue Q variant 161 Switching Blue Q on and off 163 Config...

Page 9: ...94 Cruise control variant 196 Parking 201 Parking the truck securely and switching it off 201 Wheel chock variant 204 Lifting 205 Lifting system variants 205 Lift mast versions 205 Operating devices for the lifting system 206 Controlling the lifting system using multi lever operation 208 Controlling the lifting system using a double mini lever 210 Controlling the lifting system using a triple mini...

Page 10: ...ement variant 265 Tare function 267 Total load variant 269 Depressurising the hydraulic system 272 Need to depressurise the hydraulic system 272 Wizard for depressurising the hydraulic system 273 Depressurising the hydraulic system using multi lever operation 275 Depressurising the hydraulic system using multi lever operation and the 5th and 6th function 276 Depressurising the hydraulic system usi...

Page 11: ...d the 5th function 310 Controlling attachments using a quadruple mini lever 312 Controlling attachments using the quadruple mini lever and the 5th function 314 Controlling attachments using the Fingertip 315 Controlling attachments using the Fingertip and the 5th function 317 Controlling attachments using the Joystick 4Plus 319 Controlling attachments using the Joystick 4Plus and the 5th function ...

Page 12: ...374 Towing 376 Connecting and disconnecting the battery male connector 380 Connecting the battery male connector 380 Disconnect the battery male connector 382 Handling the lead acid battery 384 Safety regulations for handling the battery 384 Maintaining the battery 389 Checking the battery condition acid level and acid density 390 Checking the battery charge status 392 Charging the lead acid batte...

Page 13: ... equipment 431 Safety devices 431 Set values 431 Lifting and jacking up 432 Working at the front of the truck 432 General maintenance information 434 Personnel qualifications 434 Maintenance of the explosion protection components 435 Information for carrying out maintenance 436 Maintenance by the operating company Explosion protection components 150 hours monthly 438 Maintenance by the authorised ...

Page 14: ...ting the lift mast and roller track 466 Preserving operational readiness for cold store application 466 1000 hour maintenance annual maintenance 467 Other work that must be carried out 467 Checking the lift cylinders and connections for leaks 467 Checking the fork arms 467 Checking the reversible fork arms 469 Checking the double pedal 470 Checking the battery changeover frame 470 6 Technical data...

Page 15: ...1 Foreword ...

Page 16: ...ing devices for drive functions and hydraulic functions The driving condition information and all messages are issued via a large colour display The display operating unit uses the current battery charge state and the selected drive programme to calculate the re maining available time until the battery has to be recharged and displays this information It also supports all FleetManager 4 x function...

Page 17: ...es that the truck remains securely in place when parked Hydraulic system The steering system the lift cylinders and the tilt cylinders in the lift mast are supplied with power via a hydraulic pump operated by an electric motor The proportional valve technology provides particularly sensitive movements and safe handling of the load The hydraulic functions can be parameterised individually by the au...

Page 18: ...ating devices enable precise operation and smooth control of the lifting speed thanks to directly controlled valves and proportional valve technology The acceleration behaviour and braking be haviour can be selected individually using dif ferent drive programmes For drive mode the truck features either sin gle pedal or dual pedal operation The truck is accelerated and braked regenerative braking v...

Page 19: ...tions pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Therefore Before commissioning the truck read the operating instructions and follow the instruc tions Always follow all of the safety information contained in the operating instructions and on the truck CE labelling The manufacturer uses CE labelling to indi cat...

Page 20: ...on protection notice The explosion protection notice indicates that the manufacturer complies with the explosion protection licensing regulations 6036_001 001 Foreword 1 Your truck 6 56378011526 EN 03 2021 01 ...

Page 21: ...declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH Foreword 1 Your truck 7 56378011526 EN 03 2021 01 ...

Page 22: ... switch not for trucks with the Switch on via push button variant Two keys for the cab variant A hexagon socket wrench for emergency lowering in the compartment A battery change frame Foreword 1 Your truck 8 56378011526 EN 03 2021 01 ...

Page 23: ...Foreword 1 Your truck 9 56378011526 EN 03 2021 01 ...

Page 24: ...Labelling points II 11 12 13 14 CAT 2G 6301_901 001 10 15 15 12 14 15 11 13 15 Foreword 1 Your truck 10 56378011526 EN 03 2021 01 ...

Page 25: ...l information Lifting gear fixing point Decal information Tyre filling pressure 1 2 3 4 5 6 7 Warning sign Dangerous electrical voltage Decal information Load measurement Warning sign Cable cross section Decal information Explosion protection mark and equipment category Decal information ELECTRICALLY CON DUCTIVE antistatic paint Decal information ANTISTATIC CHECKED on the backrest of the driver s ...

Page 26: ...Year 20 T cable C Ex tb CABLE ENTRIES SEE INSTRUCTIONS USE SCREWS QUALITY 8 8 OR BETTER DO NOT OPEN WHEN ENERGIZED DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE PRESENT IIIC T II 2 1 GD C Db IP66 16 18 19 19 27 24 23 33 22 21 20 30 37 34 25 28 29 25 32 31 34 16 17 18 26 17 20 21 22 23 24 25 33 35 34 28 30 37 29 32 26 27 31 35 36 Foreword 1 Your truck 12 56378011526 EN 03 2021 01 ...

Page 27: ...otential equalisation point on all discharge points such as tyres antistatic belts and corona electrodes Decal information Explosion protection check Decal information on non conductive com ponents Non conductive parts risk of electrostatic charge only clean using a damp cloth Decal information Identification of the flame proof enclosure depending on the truck equipment Warning sign Open only in a...

Page 28: ... Production number NOTE The production number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequential number 5060_901 020_V2 0044 S r l I 20812 LIMBIATE MB Via Marconi 31 CBH 5 II 573714 3 CEC 14 ATEX 043X T amb 20...

Page 29: ...ation This label includes information on the weight and load distribution of the truck in kg 1 Tare weight 2 Total permissible weight 3 Permitted front axle load 4 Permitted rear axle load 5 Payload Foreword 1 Your truck 15 56378011526 EN 03 2021 01 ...

Page 30: ...ELLERZELLEN CONSTRUCTORELEMENTOS N DISERIE SERIALN 20812 LIMBIATE MB ACCUMULATORETIPO BATTERYTYPE ACCUMULATEURTYPE BATTERIETYP BATERIATIPO CAPACITÀ CAPACITY CAPACITÉ KAPAZITÄT CAPACIDAD TENSIONENOMINALE NOMINALVOLTAGE TENSIONNOMINAL NENNSPANNUNG TENSIONNOMINAL N DISERIE SERIENN N DELFABRICANTE N ELEMENTI N CELLS N ELEMENTS N ZELLEN N ELEMENTOS PESOINORDNEDIMARCIA RUNNINGWEIGHT POIDSENORDREDEMARCHE...

Page 31: ...the battery supplier If the truck is equipped with an explosion protected battery from another manufacturer the authorised service centre will provide assistance in de coding the nameplate of the battery Foreword 1 Your truck 17 56378011526 EN 03 2021 01 ...

Page 32: ...ring and reading out the truck control unit Only the authorised service centre may operate the diagnostic interface The di agnostic interface is identified by the decal in formation see illustration IRP 0017 01 C AN BU S 6219_901 019 Foreword 1 Your truck 18 56378011526 EN 03 2021 01 ...

Page 33: ...ary inform the safety officer Examples of this work are Battery replacement and battery charging Maintenance and repair Settings and safety checks Conversion and retrofitting Transportation and loading Areas with explosive atmospheres are divided into zones Equipment is divided into equip ment groups and equipment categories The equipment category determines the zones in which the explosion protec...

Page 34: ...ive atmosphere in the form of a flammable dust cloud Equipment is divided into groups I II and III Division of equipment Group Description I Mining equipment subterranean endangered by exposure to pit gas dust II Equipment in all other areas with gas explosion protection and dust explo sion protection outside of mining III Equipment in all other areas with dust explosion protection outside of mini...

Page 35: ... 2 Depending on the zone classification the operating and display elements on the trucks may be enclosed in a special housing Gases and vapours are divi ded into temperature classes T1 to T6 and permissible equipment surface temperatures are defined Temperature classes Temperature class Ignition temperature range Maximum surface temperature T1 450 C 450 C T2 300 C to 450 C 300 C T3 200 C to 300 C ...

Page 36: ... of explosion for which it is ap proved in accordance with the attached EC declaration of conformity and type approval NOTE For explanations of the various areas see the chapter entitled Basic information on explo sion protection If the truck is to be used for purposes other than those specified in the operating instruc tions the approval of the manufacturer and if applicable the relevant regulato...

Page 37: ...used by improper use Use for purposes other than those described in these operating instructions is prohibited NOTE Please note the definition of the following re sponsible persons operating company and driver DANGER There is a risk of fatal injury from falling off the truck while it is moving It is prohibited to carry passengers on the truck DANGER Risk of tipping over or tilting of the forklift ...

Page 38: ... in mining underground Areas of the equipment group III i e for use in potentially explosive dust atmospheres Areas of zone 0 and 20 Areas of zones for which the truck is not specifically approved for use as listed in the data on the nameplate Areas with temperature classes in which the truck is not specifically approved for use as listed in the data on the nameplate For towing trailers in potenti...

Page 39: ...ing without conductive flooring The truck must only be operated in potentially explo sive areas that are fitted with conductive flooring Avoid electrostatic charges NOTE More information concerning the requirements for conductive or dissipative floorings can be found in the guidelines relating to electrostatic hazards CLC TR 60079 32 1 The truck is approved in accordance with Di rective 2014 34 EU...

Page 40: ...ration due to gases steam mist or dusts Trucks approved for zone 1 are automatically also approved for zone 2 Trucks approved for zone 21 are automatically also approved for zone 22 Compare the permissible temperature classes for the potentially explosive areas with the specification on the nameplate See also the section entitled Basic informa tion on explosion protection Operation on public roads...

Page 41: ...e relevant authorities NOTE Please observe the definition of the following responsible person operating company Parking in temperatures below 10 C 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 is then not ready for opera tion At ambient tem...

Page 42: ...heck the area of application by com paring with nameplate information on the working platform If the area of application is not clear ask a safety official WARNING The use of working platforms is regulated by national law The use of working platforms is only permitted by virtue of the jurisdiction in the country of use Observe national legislation Before using working platforms consult the na tion...

Page 43: ...ter the production number year of manufacture and the Miretti job number from the nameplate Production number Year of manufacture Miretti Job number Please quote the production number in all technical enquiries Specify the Miretti job number for any spare parts orders Each truck comes with a set of operating in structions These instructions must be stored carefully and must be available to the dri...

Page 44: ...sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documentation This may be in the form of an insert or separate operating instructions The original operating instructions for this in dustrial truck are valid for the operation of standard equipment and variants without re striction The operational and safety informa tion in the origi...

Page 45: ...made accessible to third parties including as excerpts except with the ex press written approval of the manufacturer Explanation of signal terms used The signal terms Danger Warning Caution Note and Environmental note and the symbol are used in these instructions as haz ard warnings or for unusual information that requires special identification DANGER Risk of explosion There is a risk of explosio...

Page 46: ...on of the EU working equipment directive BG Berufsgenossenschaft German insurance company for the com pany and employees BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident...

Page 47: ...tment LSP Load centre of gravity Distance of the centre of gravity of the load from the front face of the fork backs MAK Maximum workplace concentration Maximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment...

Page 48: ... load is to the front Schematic views View of functions and operating proce dures At many points in this documentation the mostly sequential operation of certain func tions or operating procedures is explained Schematic diagrams of a counterbalance truck are used to illustrate these procedures NOTE These schematic views are not representative of the structural state of the documented truck The vie...

Page 49: ...display of the display and operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values may vary 12 6 h 10 35 6219_003 021_V3 Foreword 1 Information about the documentation 35 56378011526 EN 03 2021 01 ...

Page 50: ...osal of components and batter ies The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man...

Page 51: ...2 Safety ...

Page 52: ...pany must provide training to its personnel regarding the special features of potentially explosive areas The operating company must provide training to its personnel at regular intervals regarding working with forklift trucks in potentially explo sive areas The operating company must have the exper tise required by law to guarantee explosion protection for equipment and operating materi als The o...

Page 53: ... the test in question or of carrying out similar tests Moreover this person must be aware of the latest techno logical developments regarding the industri al truck being tested and the risks being as sessed Sufficient knowledge in the field of industrial trucks that have been converted for use in potentially explosive areas A qualification certificate in accordance with standard DIN EN 60079 17 20...

Page 54: ...th the BGG General Employers Liability In surance Association Act 925 their training meets the training requirements under 3 of the Health and Safety at Work Act and 9 of the German Ordinance on Industrial Safety and Health Observe the national regulations for the country in which the truck is being used Rights obligations and codes of con duct DANGER Risk of accident due to consuming intoxicants ...

Page 55: ... footwear while working in potentially explosive areas The requirements for antistatic clothing are defined in the following standards Shoes EN ISO 20344 Personal protective equip ment Test procedure for shoes in the cur rent version Protection suit including gloves EN 1149 5 protection suit Electrostatic properties Part 5 Material performance and design requirements Prohibition of use by unauthor...

Page 56: ...t is not lis ted in the directives or in these instructions the truck must be converted or retrofitted by the authorised service centre as required Any structural modification can impair the handling and stability of the truck and can result in ac cidents Any modifications that adversely affect the stability the load capacity or the all round visi bility of the truck require written approval from ...

Page 57: ... drill any holes in the battery hood NOTE Welding operations are forbidden The operating company is only permitted to make modifications to the truck independently if the manufacturer goes into liquidation and the company is not taken over by another le gal person The operating company must also fulfil the fol lowing prerequisites Design documents test documents and as sembly instructions associat...

Page 58: ...y falling loads or the truck tipping over may result in buckling of the modified overhead guard and no pro tection for the driver Do not perform welding on the overhead guard Do not perform drilling on the overhead guard CAUTION Heavy roof loads damage the overhead guard To ensure the stability of the overhead guard at all times a roof load may only be mounted on the over head guard if the structu...

Page 59: ...be reported to the supervisor or responsible fleet manager immediately so that they can have the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g co...

Page 60: ...n marking tyres are identified by the safety information Observe the explosion protection regula tions Ensure that permissible tyres are used Check the presence and condition of the antistatic belts corona electrode If in doubt speak to the safety officer NOTE Electrically conductive tyres are required on both axles DANGER Risk to stability Failure to observe the following information and in struc...

Page 61: ...anufacturer must be ob tained beforehand NOTE Check with the authorised service centre be fore changing over to a different tyre size When changing wheels or tyres ensure that the truck is not tilting Always change wheels on the right and left e g at the same time Changes must only be made following consul tation with the manufacturer If the type of tyre used on an axle is changed for example from...

Page 62: ...t under pressure If required the authorised service centre will de pressurise the gas spring in accordance with the reg ulations before removal Gas springs must be dep ressurised before recycling Avoid damage lateral forces buckling tempera tures over 80 C and heavy contamination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators...

Page 63: ...k arms may move for wards and fall If the fork arms are too long they can catch on loading units behind the load that is to be picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre Safety 2 Basic principles for safe operation 49 56378011526 EN 03 2021 01 ...

Page 64: ...cannot be exclu ded even when the truck is used for its inten ded purpose and all instructions are observed A residual risk cannot be excluded even be yond the narrow limits of the danger area that the truck itself represents Persons in this area around the truck must exercise a heightened degree of awareness so that they can react immediately in the event of any malfunction incident or breakdown ...

Page 65: ...tervals The manufacturer shall not be liable for acci dents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or due to negli gence Stability The stability of the truck has been tested to the latest technological standards and is guar anteed provided that the truck is used properly and according to its intended purpose These st...

Page 66: ...ve areas with attachments that do not com ply with explosion protection regulations can lead to explosions in the surround ing atmosphere Only operate attachments that comply with the explosion protection regula tions Check the area of application by com paring with nameplate information on the attachments If the area of application is not clear ask a safety officer Approval from the manufacturer ...

Page 67: ...Safety 2 Residual risk 53 56378011526 EN 03 2021 01 ...

Page 68: ...rised persons O Truck not safe for op eration Periodic inspection and rectification of de fects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due t...

Page 69: ... O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Safety and Health BetrSichV DG...

Page 70: ...ds in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the German Ordinance on Indus trial Safety and Health BetrSichV and labour protection law ArbSchG the operating com pany must determine and assess hazards dur ing operation and establish the labour protec tion measures required for employees B...

Page 71: ... This overview see chapter Overview of hazards and counter measures provides help on complying with this regulation The overview specifies the main hazards that are the most frequent cause of accidents in the event of non compli ance If other major operational hazards are involved they must also be taken into consid eration The conditions of use for trucks are broadly similar in many plants so the...

Page 72: ... must be created The results of the inspection must be retained at least until a fur ther two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the authorised service centre to perform regular testing on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operating company is responsibl...

Page 73: ...son see also Definition of re sponsible persons Competent person How ever as a manufacturer STILL recommends that this test is carried out annually If the truck is subject to harsh application conditions the interval between tests must be shortened Create a test log The results of the inspection must be retained at least until a further two in spections have been carried out The inspection date is...

Page 74: ...ope of the checks is described in the workshop manual A test log book is to be kept if requested by the responsible authority Only a competent person may perform sys tem testing Observe the national regulations for the country in which the truck is being used Insulation testing The insulation of the truck must have sufficient insulation resistance For this reason insula tion testing in accordance ...

Page 75: ...es Battery 50 VDC Batt Batt Battery tray 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω 100 VDC 80 volts 4000 Ω Test values for the entire truck Nominal volt age Test voltage Test values for new trucks Minimum values over the duration of the service life 24 volts 50 VDC Min 50 kΩ 24 kΩ 48 volts 100 VDC Min 100 kΩ 48 kΩ 80 volts 100 VDC Min 200 kΩ 80 kΩ Safety 2 Safety tests 61 56378011526 EN 03 2021 01 ...

Page 76: ...he permissible con sumables can be found in the maintenance data table Oils DANGER Oils are flammable Follow the statutory regulations Do not allow oils to come into contact with hot engine parts No smoking fires or naked flames DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse thoroughly for...

Page 77: ...rding to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of ac cording to the regulations Dispose of old oils according to the regula tions Hydraulic fluid WARNING These fluids are pressurised during op erati...

Page 78: ...ve gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers that comply with regulations Avoid spills Spilt hydraulic fluid should be removed im mediately with oil binding agents and dis posed of according to the regulations Dispose of old hydraulic fluid according to the regulations ...

Page 79: ...f used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair main tenance and cleaning must be collected prop erly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas designated for the pur pose Care must be taken to minimis...

Page 80: ...uncer tainty KpA 70 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted val ues for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal nois...

Page 81: ...surements The personal vibration load on the driver over a working day must be determined by the op erating company at the actual place of use in accordance with Directive 2002 44 EC in or der to consider all additional influences such as driving route intensity of use etc NOTE Please observe the definition of the following responsible person operating company Battery DANGER Risk of explosion due ...

Page 82: ...performed on the truck in potentially explosive areas Charge batteries only outside of po tentially explosive areas Radiation In accordance with the guidelines DIN EN 62471 2009 03 VDE 0837 471 2009 03 the STILL Safety Light and the warning zone light variant are assigned to risk group 2 medium risk due to their photobiological hazard potential Safety 2 Emissions 68 56378011526 EN 03 2021 01 ...

Page 83: ...3 Overviews ...

Page 84: ...Overview 6301_003 020 Overviews 3 Overview 70 56378011526 EN 03 2021 01 ...

Page 85: ...xle with traction motors Front lighting Fork arms 1 2 3 4 5 6 7 Fork carriage Lift cylinder Rear lighting Battery door Steering axle Towing device Counterweight 8 9 10 11 12 13 14 NOTE The truck equipment may differ from the equipment shown Overviews 3 Overview 71 56378011526 EN 03 2021 01 ...

Page 86: ...Driver s compartment 6301_901 003 8 10 11 12 13 14 15 16 17 18 Overviews 3 Driver s compartment 72 56378011526 EN 03 2021 01 ...

Page 87: ... s seat Accelerator pedal Brake pedal Bottom plate Pneumatic signal horn Steering column adjustment lever Reset button Explosion protection warning lights 10 11 12 13 14 15 16 17 18 On category 2 explosion protected trucks the plastic parts are coated with a special antistat ic paint that prevents the build up of an elec trostatic charge The coated areas are identi fied with the decal information ...

Page 88: ...Shelves 6219_901 015_V3 Overviews 3 Shelves 74 56378011526 EN 03 2021 01 ...

Page 89: ...ry Only store objects that fit on the shelves 1 2 Make sure that objects cannot fall from the shelves 1 2 when the truck sets off is steered or braked The truck is equipped with a compartment 2 for the operating instructions and the hexagon socket wrench for emergency lowering The safety officer must decide whether the operat ing instructions and the hexagon socket wrench may be carried in potenti...

Page 90: ...dynam ics display Right hand favourites bar 1 2 3 4 5 6 7 8 Lift height restriction Automatic mast vertical positioning Menu button Scrolling buttons Right turn indicator display Back button Main display button Driving speed or parking brake Left turn indicator display Reverse drive direction indicator Forward drive direction indicator Display for direction of movement of the truck Brightness sens...

Page 91: ...operating instructions entitled STILL Easy Control display operat ing unit The display operating unit is attached to the armrest except in trucks equipped with multi lever operation If the truck is equipped with multi lever operation the display operating unit is swivel mounted on the right A pillar For information on swivelling the display op erating unit see the section entitled Adjust ing the s...

Page 92: ... The explosion protection light insulation warning is not present in category 3 trucks See the section on Behaviour when the ex plosion protection warning lights are illumi nated in the Display messages chapter Battery isolating switch The battery isolating switch 1 is located on the right next to the storage compartment It switches the electrical system into a de ener gised state Use this switch ...

Page 93: ...lating switch can be secured in the OFF position by using a lead seal or a padlock to prevent the switch from being actu ated without authorisation 1 6219_901 018 1 6219_901 006 Overviews 3 Operating devices and display elements 79 56378011526 EN 03 2021 01 ...

Page 94: ...truck be driven out of the potentially explosive area The Reset button 1 is located to the left of the steering column If the truck has switched off automatically this key allows the truck to be manoeuvred out of the danger zone Only the safety officer may decide whether the truck can be removed from the potentially ex plosive area See also the Automatic emer gency shutdown section in the chapter ...

Page 95: ... Operating lever for attachments variant Function key for the 5th or 6th function variants Signal horn button 6 7 8 NOTE In the dual pedal version variant the drive direction switch 1 is used exclusively to acti vate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version Overviews 3 Operating devices and display elements 81 56378011...

Page 96: ...ss lever Attachments Function key for the 5th function Signal horn button 1 2 3 4 F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 Overviews 3 Operating devices and display elements 82 56378011526 EN 03 2021 01 ...

Page 97: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 5 Overviews 3 Operating devices and display elements 83 56378011526 EN 03 2021 01 ...

Page 98: ...g lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 Signal horn button F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 8 Overviews 3 Operating devices and display elements 84 56378011526 EN 03 2021 01 ...

Page 99: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 6 Overviews 3 Operating devices and display elements 85 56378011526 EN 03 2021 01 ...

Page 100: ...operating lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 5 Signal horn button F1 function key Lift lower operating lever Display field for the hydraulic functions 6 7 8 9 Overviews 3 Operating devices and display elements 86 56378011526 EN 03 2021 01 ...

Page 101: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 7 Overviews 3 Operating devices and display elements 87 56378011526 EN 03 2021 01 ...

Page 102: ...wer operating lever Tilt operating lever F1 function key LED for F1 7 8 9 10 11 NOTE In the dual pedal version variant the drive direction switch 7 is used exclusively to activate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 10 Overviews 3 ...

Page 103: ... the 4th hydraulic function Vertical rocker button for the drive direction Shift key F Signal horn button 5 6 7 8 9 NOTE In the dual pedal version variant the verti cal drive direction rocker button 7 is used exclusively to activate the cruise con trol function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign diff...

Page 104: ...uck stops in a danger area the drive direction selection lever on the travel direction selector and indicator module can be used for emergency driving Refer to the section entitled Emergency driv ing via the drive direction switch drive direction selection lever in the chapter entitled Proce dure in emergencies Drive direction selection lever Turn indicator switch 1 2 Overviews 3 Operating devices...

Page 105: ...4 Operating ...

Page 106: ...e truck or the attachment variant during the following inspections the truck must not be used until it has been properly repaired Damage or other defects must be reported to the supervisor or the responsible fleet manag er immediately so that repairs by the author ised service centre can be arranged Ensure that the truck is safe for operation each day before it is used Component Course of action F...

Page 107: ...erve the safety regulations in the section enti tled Tyres Axle Make sure that no consumables are escaping from the axle Check that the temperature sensors and wiring on the traction motor pump motor are in good condi tion and are securely attached The electric cables and line inlets must be free from damage The total damage to the antistatic paintwork and seat covering must amount to no more than...

Page 108: ...ty and to ensure that it is working correctly Check that the linchpin is present and working cor rectly chain rope split pin Labelling adhesive label Check that labels are present and intact legible Replace damaged or missing adhesive labels in ac cordance with the section entitled Labelling points Driver s seat seat belt Check the integrity and function Display operating unit assistance systems C...

Page 109: ... do not operate the truck in potentially explo sive areas Notify the authorised service centre Climbing into and out of the truck WARNING Risk of injury when climbing into and out of the truck due to slipping striking parts of the truck or becom ing stuck If the footwell cover is very dirty or smeared with oil there is a risk of slipping There is also a risk of hit ting your head on the post of th...

Page 110: ...s specifically designed for the purpose of climbing into and out of the truck To assist with climbing into and out of the truck use the step 1 use the footwell 2 as a step and use the handle 4 for support The post of the overhead guard 3 can also be used for support Always climb into the truck facing forwards Grip the handle 4 with your left hand and do not let go Place your left foot on the step ...

Page 111: ...one of the checks and tasks that must be per formed before daily use The truck can only be operated safely when the seat position is cor rect Refer to the following chapter entitled Driv er s seat Adjusting the steering column Pull up and hold the lever 2 for steering column adjustment Position the steering column 1 then push the lever down again and allow the steering column to engage DANGER Risk...

Page 112: ...Adjusting the swivelling display op erating unit If the truck is equipped with multi lever opera tion the display operating unit is swivel moun ted on the right A pillar The display operating unit can be swivelled from the neutral position to 15 to the left right up and down The unit cannot rotate around its own axis 1 6219_901 018 1 6219_901 006 Operating 4 Checks and tasks before daily use 98 56...

Page 113: ... socket head screws 2 as re quired Hold the display operating unit 1 in place Adjust the display operating unit 1 so that it can be read without glare Tighten the socket head screws 2 as re quired NOTE If the angle of the display operating unit changes during driving tighten the socket head screws This makes the display operat ing unit more secure in the support mounting 1 2 2 6219_003 235 Operati...

Page 114: ... the truck forwards slowly Push the emergency off switch 1 The truck will coast to a stop The message Emergency off active appears on the display operating unit Stop the truck by actuating the brake pedal NOTE In trucks with an electric parking brake the electric parking brake will be applied as soon as the truck comes to a stop Turn the emergency off switch 1 clockwise until it pops out The truck...

Page 115: ...gnal horn is used to warn people against imminent danger or to announce your intention to overtake Press the signal horn button 1 The signal horn sounds 1 1 1 Operating 4 Checks and tasks before daily use 101 56378011526 EN 03 2021 01 ...

Page 116: ...sing a special antistat ic paint This paint prevents the parts from building up an electrostatic charge Otherwise static discharge may occur resulting in explosions in the surrounding atmosphere in potentially explosive areas The non conductive parts of the cab variant must also be covered with anti static materials or coated with antistatic paint Only drive into potentially explosive areas if the...

Page 117: ...ant with doors made of plastic or canvas do not constitute a driver restraint system and offer no protection from the consequences of the truck tipping over Close the cab door before use If the door is open or has been removed use a comparably secure restraint system We recommend that you always use the seat belt Checking the brake oil level A brake oil reservoir is located under the cover of the ...

Page 118: ...brake oil If the brake oil level is lower than it should be or has visibly dropped contact the au thorised service centre In this case do not use the truck The authorised service centre must rectify the cause of the reduced brake oil 6331_003 004 1 2 Operating 4 Checks and tasks before daily use 104 56378011526 EN 03 2021 01 ...

Page 119: ...Operating 4 Checks and tasks before daily use 105 56378011526 EN 03 2021 01 ...

Page 120: ...e speed Depending on the charge state of the battery regen erative braking may be insufficient when driving downhill meaning that the maximum permissible speed of the truck is exceeded Press the brake pedal 1 If the driving speed is restricted or if the oppo site drive direction is selected the truck is braked using the electric brake To actuate this release the accelerator pedal 2 The truck must ...

Page 121: ...e the parking brake being applied stop the truck using the service brake In an emergency secure the truck with wedges on the downhill facing side to pre vent it from rolling away Have the parking brake checked and re paired by the authorised service centre Checking the parking brake on a level surface WARNING Risk of accident from abrupt deceleration The truck will decelerate abruptly if the parki...

Page 122: ... re paired by the authorised service centre NOTE Special features of the electric parking brake The deceleration cannot be influenced The electric parking brake is applied moder ately until the truck comes to a stop The emergency off switch must be unlocked to release the electrical parking brake Warming up the hydraulic oil at cold ambient temperatures If the truck has been exposed to low ambient...

Page 123: ...until the warm up phase is complete 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 steer ing system Operate the steering wheel 1 The steer ing play while stationary must not be more than two finger widths 6219_003 312 1 Operating 4 Checks and task...

Page 124: ...l operating devices can be actuated safely Ensure that the seat and the seat backrest are se curely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the driver s head and the lower edge of the roofing sheet must be at least 40 mm NOTE Observe any separate operating instructions for the s...

Page 125: ... not apply pressure to the seat backrest when adjusting the seat backrest Raise the lever 2 and hold it in position Push the seat backrest into the required po sition Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structure of the truck 7094_003 006 1 7094_003 008 2 Operating 4 Driver s seat 111 563780...

Page 126: ... the lever 3 Fold out the weight adjusting lever 3 Pump the lever up or down to set the driv er s weight Return the weight adjusting lever to the ini tial central position each time before raising it again a click can be heard when this po sition is reached Retract the weight adjusting lever once the adjustment is complete NOTE The correct driver s weight has been selected when the arrow 4 is in t...

Page 127: ...rt of the backrest Turn the turning knob 6 up or down until the lumbar support is in the required posi tion Adjusting the backrest extension var iant Adjust the backrest extension 7 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by firmly pushing it upwards 6321_003 039_V3 6 6321_003 040_V3 7 Operating 4 Driver s seat 113 563780...

Page 128: ...t In addition the seat belt protects against the consequences of rear end collisions and falling off a lorry ramp Recommendation When operating the truck on a lorry ramp fasten the seat belt in addition to using the driv er s cab the bracket door or the re straining bracket DANGER Only bracket doors restraining brackets and the driver s cab variants with closed fixed doors con stitute driver restr...

Page 129: ...The message Close seat belt appears on the display operating unit The truck will not drive at speeds faster than 4 km h The hydraulic functions are blocked NOTE One variant prevents the truck from being driv en at all if the seatbelt is not fastened The message Close seat belt appears on the display Pull the seat belt 3 smoothly out of the belt retractor and place over the thighs close to the body...

Page 130: ...l if the cab door is open The mes sage Close cab door appears in the display Special feature for trucks with HSR re straint systems variant If the bracket is not closed the message Close restraint system appears in the display Fastening on a steep slope The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient It is no longer possible to pull ...

Page 131: ...around 10 to 15 mm out of the retractor to disengage the blocking mechanism Slowly allow the seat belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold If the buckle or belt retractor are frozen thaw the buckle or the belt retractor and dry the parts This prevents the parts from refreezing CAUTION The seat belt may be damaged by heat Do not subjec...

Page 132: ...s can be actuated safely Ensure that the armrest is securely tightened Adjusting the length of the armrest Release the star grip handle 1 by turning to the left Shift the armrest 2 into the desired posi tion Tighten the star grip handle by turning to the right Check that the armrest is firmly attached Adjusting the height of the armrest Release the hand wheel 3 by turning to the left Shift the arm...

Page 133: ... code variant the display initially changes to the input menu for access authorisation Once the truck is ready for operation the main screen is shown on the display Main screen 1 Selected drive programme with driving dynamics display 2 Load information variants 3 Status bar battery charge operating hours time 4 Selected load dynamics programme with dynamics bar 5 Right turn indicator display 6 Dri...

Page 134: ...uthorisation with PIN code variants In place of the key switch the truck has a push button 1 that is used to switch the truck on and off To switch on the truck press the push but ton 1 or sit on the driver s seat A mes sage on the display operating unit asks the operator to place the FleetManager card in position or to enter the PIN code Authorisation via the FleetManager card or the PIN code must...

Page 135: ...but ton 1 and hold for 1 second NOTE For the variant with Access authorisation with PIN code see the relevant section FleetManager see the original operating instructions for FleetManager Operating 4 Switching on 121 56378011526 EN 03 2021 01 ...

Page 136: ...using the control and enter keys 5 8 and the soft keys 4 10 The display 2 shows informa tion about the current driving programme load programme and the configuration of the fa vourites bars 1 3 The brightness sensor 9 automatically adjusts the brightness of the dis play based on the truck s surroundings Operating 4 Display operating unit 122 56378011526 EN 03 2021 01 ...

Page 137: ...his button clears input entered in the settings menus This button switches between upper case and lower case for alphanumeric entries Back button 7 When the back button is pressed the display switches to the next menu level up This button cancels input entered in the settings menus Main display button 9 Pressing the main display button at any menu level takes you directly back to the main display ...

Page 138: ... is ready for use If the input was incorrect enter the PIN code again NOTE The authorised service centre can configure access authorisation so that the PIN code has to be re entered each time after someone leaves the truck When the driver s seat is occupied again the message Log in appears The display then changes to the Access authorisation in put menu Changing the PIN codes The fleet manager can...

Page 139: ...t can be con figured by the users themselves Access to these settings is protected by a fleet manager password Three options are available for the Access authorisation for the fleet manager variant 1 No fleet manager password Access to the configuration menus is not enabled If access is required at a later Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Change...

Page 140: ...ssword is noted on the order confirmation and on the truck invoice NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is re leased prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the softkey The first menu level appears Press the Access authorisa tion softkey...

Page 141: ...rect is dis played If this happens enter the password again NOTE While the Access authorisation for the fleet manager is activated Fleet manager is displayed in an orange bar at the bottom of the screen When the users switches to the main display the access authorisation expires again Changing the fleet manager password Activate the Access authorisation for the fleet manager Enter password 6219_00...

Page 142: ...s auth menu appears Press the Change password ac cess auth softkey Follow the instructions on the display Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Version list 6219_003 275_en Operating 4 Display operating unit 128 56378011526 EN 03 2021 01 ...

Page 143: ...t been compiled the only question stored by default is Truck ready for operation The authorised service centre can then restrict the truck functions in the event of a negative test result There are fixed responses No response Speed limitation Restriction of hydraulics to 33 In addition the fleet manager has the follow ing options The fleet manager can view the results of all checks via the History...

Page 144: ...st such as the functional test of the lighting NOTE The main display symbol appears only when it is required for the test To access the main display press the main display button or the softkey The main display contains the message To complete Pre Shift Check press This means that the Pre Shift Check is still ac tive and the truck functions are restricted To acknowledge the message press the softk...

Page 145: ...ns active shows that truck functions are restricted As long as the truck functions are restricted no further Pre Shift Check is re quested at the start of a new shift The check is only requested again after the fleet manager has reset the restrictions All questions The authorised service centre can use this question catalogue to put together the Pre Shift Check during commissioning Are the fork ar...

Page 146: ... brake work properly Does the service brake work properly Does the steering work properly Does the emergency off work Is the condition of the battery obviously not OK Are all decal information and adhesive labels present and legi ble Is the load backrest undamaged Does the accelerator pedal work properly Is the engine compartment dirty or does it contain foreign ob jects Are the lift mast or the f...

Page 147: ...nsciously by the driver This means that there is no rou tine aspect Activate the Access authorisation for the fleet manager Press the Service softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 133 56378011526 EN 03 ...

Page 148: ...tion To access the main display press the main display button Displaying the history The fleet manager can display a Pre Shift Check history Activate the Access authorisation for the fleet manager Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Random sequence Fixed sequence 6219_003 273_en Operating 4 Pre Shift Check 134 56378011526 EN 03 2021 0...

Page 149: ...ll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 135 56378011526 EN 03 2021 01 ...

Page 150: ...ager can define up to three shifts and their start times The Pre Shift Check is then always requested at this time NOTE If the truck is equipped with FleetManager the shifts are defined on the FleetManager inter face See the relevant operating instructions Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Pre Shift Check results 27 09 19 15 11 nicht ok Funktioni...

Page 151: ...rvice softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 137 56378011526 EN 03 2021 01 ...

Page 152: ...time The orange activation bar indicates which shifts are activated To edit a shift press the corresponding soft key Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operating 4 Pre Shift Check 138 56378011526 EN 03 2021 01 ...

Page 153: ... requested from this shift start time The display returns to the previous menu To deactivate a certain shift start select the relevant shift Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate Save Cancel 6219_003 272_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operating 4 Pre Shift Check 139 56378011526 EN 03 2021 01 ...

Page 154: ... main display button Resetting the truck restrictions If truck functions are restricted due to checks with a bad result the fleet manager can reset these restrictions The fleet manager can also do this if a problem on the truck has been rec tified Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate S...

Page 155: ...ift Check menu appears Press the Reset restriction softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Operating 4 Pre Shift Check 141 56378011526 EN 03 2021 01 ...

Page 156: ...The display returns to the previous menu To cancel press the softkey The truck functions remain restricted The dis play returns to the previous menu To access the main display press the main display button 6219_003 274_en Fleet manager Reset the truck restrictions The entry remains in the history Operating 4 Pre Shift Check 142 56378011526 EN 03 2021 01 ...

Page 157: ...r profile Selected drive programme 1 to 3 Load dynamics Efficiency and drive modes Blue Q sprint mode If a driver without an existing driver profile logs in using the Access authorisation with PIN code or FleetManager variants a driver pro file is generated This driver profile corre sponds to the settings when the truck was de livered If the truck is not equipped with these variants drivers must s...

Page 158: ...g brake is applied If the parking brake is re leased prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the Settings softkey Press the Driver profiles soft key Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Operating 4 Driver profiles 144 56378011526 EN 03 2021 01 ...

Page 159: ...oth the fleet manager and the driver can cre ate up to ten driver profiles NOTE If the truck is equipped with the Access au thorisation with PIN code or FleetManager variants the driver profile is generated auto matically when logging in for the first time Apply the parking brake Press the button Press the Settings softkey Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Oper...

Page 160: ...on NOTE Unoccupied storage locations that do not con tain a driver profile are indicated by Availa ble storage position Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operating 4 Driver profiles 146 56378011526 EN 03 2021 01 ...

Page 161: ...then be available the next time that the driver logs in Renaming driver profiles Driver profiles can be renamed Drivers can only rename their own driver profile The fleet manager has access authorisation to rename all driver profiles Renaming by the driver Apply the parking brake Press the button Press the Settings softkey Press the Truck settings softkey Enter driver name Clear Driver name Horst ...

Page 162: ... press the button Renaming by the fleet manager Activate the Access authorisation for the fleet manager Press the Truck settings softkey Rename driver profiles Driving programme 6219_003 298_en Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Operating 4 Driver profiles 148 56378011526 EN 03 2021 01 ...

Page 163: ... softkey Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Operating 4 Driver profiles 149 56378011526 EN 03 2021 01 ...

Page 164: ...Activate the Access authorisation for the fleet manager Press the Truck settings softkey Press the Manage driver profiles softkey Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Operating 4 Driver profiles 150 56378011526 EN 03 2021 01...

Page 165: ...he driver profile to be deleted The driver profile is deleted Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operating 4 Driver profiles 151 56378011526 EN 03 2021 01 ...

Page 166: ...e selected When one of the lighting devices is switched on the activation bar next to the relevant sym bol lights up orange NOTE If the truck is equipped with the StVZO Ger man Road Traffic Licensing Regulations var iant the hazard warning system works even when the truck is switched off 1 This function is not available if the truck is equipped with the StVZO German Road Traffic Licensing Regulati...

Page 167: ...nt variant and a licence plate lamp then this also lights up To switch off the driving light 2 press the Softkey again The driving light and licence plate lamp go out To switch off the parking light 1 push the Softkey again The front side lights and the tail lights go out If the truck does not have StVZO German Road Traffic Licensing Regulations equip ment variant then the parking light and driv i...

Page 168: ...ions variant the parking light is al so switched on when the working spotlights are switched on The licence plate lamp if present is also switched on when the forward facing working spotlights are switched on Working spotlights on the roof and the side of the lift mast The roof spotlights light up the working area when the fork carriage is raised To switch on the roof spotlights 5 push the associa...

Page 169: ...ss the softkey The activation bar next to the symbol lights up The working spotlight does not yet light up Set the drive direction to Reverse The working spotlight for reverse travel lights up If the drive direction is set to Forward the working spotlight goes out Turn indicators The turn indicators are switched on and off via the travel direction selector and indicator mod ule Operating 4 Lightin...

Page 170: ...is play 2 or 3 on the display operating unit flash To switch off the turn indicators push the lever 1 back to the centre position All turn indicators and the turn indicator dis plays on the display operating unit stop flash ing 6219_003 098 2 71 m 7 1 6 t 2 3 6219_003 301 432 h 08 20 Operating 4 Lighting 156 56378011526 EN 03 2021 01 ...

Page 171: ...n All direction indicators and the turn indicator displays on the display operating unit stop flashing Specific features of the StVZO German Road Traffic Licensing Regulations variant For the StVZO German Road Traffic Licens ing Regulations variant the hazard warning system cannot be switched on and off via the display operating unit It is switched on and off using the hazard warning button on the...

Page 172: ...and the turn indicator displays on the display operating unit stop flashing Rotating beacon To switch on the rotating beacon push the associated Softkey on the display operating unit The rotating beacon is switched on To switch off the rotating beacon push the Softkey again The rotating beacon goes out 2 71 m 7 1 6 t 2 3 6219_003 301 432 h 08 20 Operating 4 Lighting 158 56378011526 EN 03 2021 01 ...

Page 173: ...ots in front of or behind the truck and thus warns others about the approaching truck Several light spots are projected as a chase light The chase light indicates the location of the truck with its direction of travel Depending on the configuration of the truck the STILL SafetyLight automatically switches itself on when the truck is moving This means that during reverse travel variant for exam ple...

Page 174: ...ntitled Handling loads The warning zone light switches on and off again together with the truck If the truck has StVZO German Road Traffic Licensing Regulations equipment the warn ing zone light can be switched on and off via the display operating unit To do so push the softkey NOTE If the truck is to be operated on public roads the warning zone light must be switched off Before using the truck ma...

Page 175: ...40 m lower speeds are reached than would be the case if the efficiency mode was not activated As in STILL Classic mode the maximum speed is 20 km h has no influence on Maximum speed Climbing capability Pulling force Braking characteristics Effects on additional consumers The following table shows the specific conditions that cause certain auxiliary devices to shutdown when Blue Q is activated The ...

Page 176: ...at switch Truck is stationary Drive direction Screen heating X No shut off for StVZO German Road Traffic Licensing Regulations equipment variant Operating 4 Efficiency and drive modes 162 56378011526 EN 03 2021 01 ...

Page 177: ...mode is switched on To switch off Blue Q efficiency mode push the associated softkey again The Blue Q symbol disappears and Blue Q ef ficiency mode is switched off NOTE The fleet manager can also use his access authorisation to activate Blue Q efficiency mode permanently See the next section Operating 4 Efficiency and drive modes 163 56378011526 EN 03 2021 01 ...

Page 178: ...tkey The orange activation bar appears next to the pushed softkey The main display button takes you to the main display STILL Classic and sprint mode The drive modes affect the handling of the truck Two different drive modes are available 1 STILL Classic This mode is active after the truck has been switched on This mode is the de fault setting and provides a balance be tween hydraulic functions an...

Page 179: ... level the truck will consume more energy As a result the battery is discharged faster and the traction drives and energy supply may become too hot The battery voltage and the temperature of the traction drives and energy supply are moni tored continuously If the voltage becomes too low or if the temperature becomes too high sprint mode is deactivated automatically If the truck is automatically sw...

Page 180: ... quickly and overtaking at dangerous or blind spots must be avoided Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden during driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Adjusting the steering column Releasing the seat be...

Page 181: ...ne is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walk ing pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be used for ob serving the...

Page 182: ...e the EU The required aisle widths depend on the di mensions of the load The aisle widths for pallets are as follows Model Type Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX60 25 6301 3700 3890 RX60 25 600 6302 3705 3895 RX60 25L 600 6304 3905 4116 RX60 30 6305 3742 3940 RX60 30L 6307 3940 4124 RX60 30L 600 6308 3941 4141 RX60 35 6309 3941 4141 Applies to telesc...

Page 183: ...le can be used only to com pare the performance of forklift trucks in the same category The specified values in no way represent the normal daily operating con ditions It is permitted to drive the truck on the following ascending and descending gradients Model Type Maximum gradient With load PP HP Without load PP HP RX60 25 6301 23 5 17 1 29 5 26 6 RX60 25 600 6302 22 6 16 5 27 4 27 4 RX60 25L 600...

Page 184: ...ese obstacles with as few bumps as possible Take note of the load capacity of manhole covers drain covers etc There must be sufficient distance between the highest points of the truck or the load and the fixed elements of the surrounding area The height is based on the overall height of the lift mast and the dimensions of the load see the chapter entitled Technical data Rules for roadways and the ...

Page 185: ...rive programme selected the greater the driving dynamics The drive programme is selected using the display operating unit under the Drive menu item Press the softkey to select the de sired drive programme If the drive programmes are saved as a fa vourite on a softkey press the Drive pro gramme softkey until the number of the desired drive programme is shown on the display The number of dynamic bar...

Page 186: ...te on a softkey press the Drive pro gramme Softkey until the letter of the desired drive programme is shown on the display Configuring drive programmes A and B The drive programmes can be configured by the driver NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is re leased prematurely the settings menu will cl...

Page 187: ...ation Determines the electrical brake retardation when the accelerator pedal is released in five stages 1 indicates the lowest deceleration and 5 indicates the greatest deceleration To select a higher level press the appropri ate plus softkey To select a lower level press the appropri ate minus softkey To save the setting press the Confirm softkey The settings are saved To cancel the setting press...

Page 188: ... The truck is then decelerated and accelerated again in the op posite direction reversing The indicator for the selected drive direction forwards 1 or backwards 2 lights up on the display operating unit Neutral position If leaving the truck for a prolonged period the neutral position must be selected in order to avoid the truck suddenly moving off due to an inadvertent actuation of the accelerator...

Page 189: ...ion selection lever in the chapter entitled Procedure in emergen cies Actuating the drive direction switch with the mini lever version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction pull the drive direction switch 1 backwards NOTE If the drive direction switch 1 is defective and the truck stops in a danger area the drive di rection sel...

Page 190: ...indicator module variant can be used for emergency driving Refer to the sec tion entitled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergen cies Actuating the vertical rocker button for the drive direction Joy stick 4Plus version For the forward drive direction push the vertical rocker button for the drive direc tion 1 upw...

Page 191: ... enti tled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergencies Starting drive mode DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations whe...

Page 192: ...travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the accelerator pedal is released NOTE The truck is also held in place on ascending or descending gradients even if the electric park ing brake is not engaged DANGER Risk of accident due to brake failure The regenerative brake only functions if the truck is switched on the emer...

Page 193: ...e truck still cannot be operated park the truck securely and con tact the authorised service centre Starting drive mode dual pedal ver sion variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations when driving The...

Page 194: ...rds 1 or reverse 2 lights up on the display operating unit NOTE Depending on the equipment the following variants of warning units for reverse travel may be present An acoustic signal will be heard The STILL SafetyLight lights up The hazard warning system flashes The truck travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the ...

Page 195: ...drive the truck again by releasing the accelerator pedal and then actuating the accelerator pedal again If the truck still cannot be operated park the truck securely and con tact the authorised service centre Operating the service brake The regenerative brake converts the accelera tion energy of the truck into electrical energy When the accelerator pedal is released the truck decelerates Electrica...

Page 196: ...s with the square of the speed Adapt the driving and braking style to suit the weather conditions and the level of contamination on the roadway Always choose a driving speed that will provide a sufficient stopping distance NOTE If the parking brake is actuated while the truck is in motion the truck may decelerate with a jerk Actuating the electric parking brake DANGER There is a risk of fatal inju...

Page 197: ...e The parking brake was applied by pressing the push button Pressing the push button is the only way to release the parking brake Releasing the electric parking brake af ter the truck has been switched on Press the push button 1 to release the parking brake The truck is held in place by the traction mo tor Manually actuating the electric parking brake when the truck is stationary Applying the park...

Page 198: ...s applied The truck is switched off The electric parking brake is immediately ap plied with an audible sound The LED 2 will light up briefly with a steady light until the control units switch off The emergency off switch is actuated The electric parking brake is immediately ap plied with an audible sound The LED 2 lights up with a steady light If the electric parking brake has applied auto matical...

Page 199: ...al times The electric parking brake cannot be released by actuating the accelerator pedal WARNING Risk of accident The truck may decelerate abruptly Fasten the seat belt Automatically triggered actuation when the truck is in motion Cause Effect The driver s seat is vacated The truck is braked in accordance with the se lected drive programme Once the truck has come to a standstill the electric park...

Page 200: ...he truck accelerates sharply even though the accelerator pedal has not been actuated The parking brake is immediately applied with an audible sound The LED 2 lights up with a steady light The symbol appears in the display Malfunctions in the electric parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Do not leave the...

Page 201: ...parking brake when the truck is stationary There are two ways to apply the parking brake Press and hold the push button 1 for at least five seconds and then release the push button or Press the push button 1 several times in succession so that the push button is actu ated for a total of five seconds The parking brake is applied with an audible sound After the push button is released the parking br...

Page 202: ...d Activation and intervention by the Safe parking function Cause Effect The driver s seat is vacated The electric park ing brake cannot be applied or previously could not be applied The following message appears in the display Parking brake cannot be applied To confirm press the softkey A warning signal sounds when the driver s seat is vacated Sitting in the driver s seat silences the warning sign...

Page 203: ...actuation mechanism se cure the truck with wedges to prevent it from rolling Have the parking brake repaired by an au thorised service centre Message Parking brake cannot be applied If the truck control unit detects a malfunction in the parking brake the truck cannot be switch ed off The message Parking brake can not be applied appears on the display operating unit The LED 2 on the push button 1 f...

Page 204: ... parking brake cannot be applied auto matically or via the push button apply the parking brake via the emergency actuation process Refer to the section entitled Emergency actuation of the parking brake in the chapter Procedure in emergencies If the parking brake cannot be applied via the emergency actuation process secure the truck with wedges so that the truck can not roll away Have the parking b...

Page 205: ... the truck by turning the steering wheel 1 accordingly Turning the steering wheel to the left L steers the truck to the left L Turning the steering wheel to the right R steers the truck to the right R The arrow 2 displays the direction in which the truck is moving For information on the turning radius see the Technical data 1 L L R L R R 6219_003 109 2 Operating 4 Driving 191 56378011526 EN 03 202...

Page 206: ... Before using this function familiarise yourself with the change to the driving and steering characteris tics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steer ing Do not turn off the key switch while driving Actua...

Page 207: ... the cab door is opened while the truck is in motion the truck brakes automatically Keep the cab door closed when driving With the cab equipment variant the truck has a cab door monitoring function via a sen sor The signal from this sensor is linked with the signal from the buckle switch in the control electronics of the truck If the cab door is not closed and the seat belt is not fastened the dri...

Page 208: ... first menu level appears Press the Drive softkey The Drive menu appears Press the Speed limitation softkey The activation bar appears next to the symbol The speed limitation is switched on To switch off the speed limitation press the softkey again Configuring the speed limitation NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If...

Page 209: ...be used to set the maximum truck speed when speed limitation is active To adjust the maximum speed press the Enter max speed softkey The Speed restriction menu opens Using the softkeys set a maximum speed between 2 km h and 20 km h The maximum speed is dependent on the truck equipment and may be restricted by a factory setting To save press the button The maximum speed is entered To clear press th...

Page 210: ...he hydraulic functions When the cruise control function is activated the driver can save the speed when driving forwards at a speed of at least 6 0 km h by pressing a button and can continue driving without actuating the accelerator pedal The pictogram 3 for operating the cruise control function is located on the operating de vice for the hydraulic functions Putting the cruise control function on ...

Page 211: ...control symbol 1 goes out Activating cruise control WARNING Risk of accident from failing to adjust speed Driving at excessive speeds can cause accidents e g the truck could tip over when cornering Adjust speed along the entire distance being trav elled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise con trol function ...

Page 212: ...for for wards travel NOTE In the dual pedal version variant the drive direction switch 2 is used exclusively to acti vate and deactivate the cruise control function variant 2 F 2 2 2 3 3 3 3 Operating 4 Driving 198 56378011526 EN 03 2021 01 ...

Page 213: ...tiva ted at any time when the accelerator pedal is depressed by pressing the drive direction switch for forwards travel again When the cruise control function is deactiva ted the symbol 1 is greyed out NOTE The easiest way to deactivate the cruise con trol function is to touch the accelerator pedal The following actions deactivate the cruise control function Actuating the foot brake Actuating the ...

Page 214: ... the truck is initially braked via the drive unit The following message appear on the display Release the accelerator pedal The truck will continue to drive only when the accelerator pedal is released and then actu ated again If these conditions have changed again the speed that was initially saved is set again NOTE If the truck is configured with automatic func tions to reduce the driving speed a...

Page 215: ...ents are being lowered Lower the load fully before leaving the truck CAUTION Batteries may freeze If the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down For lead acid batteries the electrolyte can freeze and damage the batteries The truck is then not ready for operation At ambient temperatures of below 10 C only park the truck for short p...

Page 216: ...ps of the fork arms rest on the ground If attachments variant are fitted retract the working cylinders see the chapter entitled General instructions for controlling attach ments Turn the switch key to position 0 and re move the key Operating 4 Parking 202 56378011526 EN 03 2021 01 ...

Page 217: ... In the push button ignition variant press the button 1 Depending on the truck version Push the battery isolating switch 1 OR 1 6219_901 018 Operating 4 Parking 203 56378011526 EN 03 2021 01 ...

Page 218: ...hock variant is used to prevent the truck from rolling away on a slope It is lo cated on the rear post of the overhead guard Pull the support bracket 1 away from wheel chock and hold the support bracket in position Grasp the wheel chock 2 and pull it up wards and out of the support mounting 3 Push the wheel chock under a front axle wheel on the side facing the descending gradient After use insert ...

Page 219: ...when handing loads Page 232 Lift mast versions DANGER Risk of accident due to collision of the lift mast or load with low ceilings or entrances Note that the inner lift mast or load may be higher than the fork carriage Observe the heights of ceilings and entrances One of the following lift masts may be attach ed to the truck Telescopic lift mast When lifting the lift mast rises above the outer lif...

Page 220: ...st Triple mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the maximum height 2 Operating devices for the lifting sys tem The method of operating the lifting system de pends on the operating devices included in the truck s equipment Possible equipment variants include Multi lever Double mini lever Triple m...

Page 221: ...due to delayed response from the truck If the lifting movements are configured to use low dy namics the lifting system responds after a delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control...

Page 222: ...fferent configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 1 The adhesive label with the corresponding pictogram 4 is located on the operating lever The tilting movement of the lift mast is contro...

Page 223: ...direction of the arrow C To tilt the lift mast backwards Move the tilting operating lever 2 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 209 56378011526 EN 03 2021 01 ...

Page 224: ...aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic functions 1 or 2 is affixed at the designated po...

Page 225: ...he lift mast 360 lever 4 in the di rection of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 211 56378011526 EN 03 2021 01 ...

Page 226: ...drivers aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic functions 1 or 2 is affixed at the desig...

Page 227: ...he lift mast 360 lever 4 in the di rection of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 213 56378011526 EN 03 2021 01 ...

Page 228: ... all drivers aware of the fact that a different configuration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 3 The adhesive label bearing the corresponding pictograms 1 is affixed at the designated point 6 ...

Page 229: ...the lift mast operating lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast operating lever 4 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 215 56378011526 EN 03 2021 01 ...

Page 230: ...iguration has been config ured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 4 The adhesive label with the corresponding pictogram 3 is located on the operating lever The tilting movement of the lift mast is control led using ...

Page 231: ...e safety regulations for handling loads Operate the lifting system from the driver s seat only WARNING Risk of accident as a result of an operating error These operating instructions describe how to operate the lifting system in the factory configuration If the authorised service centre has configured a dif ferent configuration the newly applied pictograms must be observed to ensure safe operation...

Page 232: ...ork carriage To lift the fork carriage Pull the Joystick 4Plus 1 backwards B To lower the fork carriage Push the Joystick 4Plus 1 forwards A Tilting the lift mast To tilt the lift mast forwards Tilt the horizontal rocker button 3 to the left C To tilt the lift mast backwards Tilt the horizontal rocker button 3 to the right D F 6219_003 167_V3 1 2 A B F 6219_003 165_V3 D C 3 4 Operating 4 Lifting 2...

Page 233: ...oes not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 1 2 assistance systems Work with particular attention and care The authorised service centre can reduce the dynamics of the hydraulic movements to adapt the hydraulic movements to the application re quirements The hydra...

Page 234: ...ement only decelerates slow ly The fork carriage therefore continues to run for some time before the movement comes to a standstill Selecting load programs 1 to 3 The truck has three load programs for the dif ferent lifting behaviours of the fork carriage and the lift mast The higher the number of the load program selected the greater the load dynamics Differences between the load programs Load pr...

Page 235: ...er to the section entitled Warming up the hydraulic oil at cold ambient tempera tures in the chapter entitled Operation Checks and tasks before daily use Fork wear protection variant The fork wear protection variant ensures that the fork arms do not touch the ground The fork arms are protected against wear and the building floor is protected against damage The lift cylinders have in built fixed st...

Page 236: ...explosive areas only fork arms that comply with explosion protec tion regulations may be used These fork arms are specially coated to prevent sparks forming when coming in to contact with the load or floor The coating does not extend to the area in side the fork bends so that it is possible to check for cracks Fit only fork arms that correspond to explosion protection regulations Check that the cl...

Page 237: ...fork arms The fork arms must always be carried by two peo ple if necessary use a hoist NOTE It is advisable to use a transport pallet to sup port the fork arms when they are being instal led or removed The pallet size depends on the size of fork arms in use It should be large enough that the fork arms do not protrude af ter being placed on the pallet This means the fork arms can be safely placed d...

Page 238: ...ge Push the fork arms onto the fork carriage from the outside towards the centre Pull the locking lever 1 upwards and push the fork arms into the required position En sure that the locking lever snaps into place Fit and tighten the locking screw 2 DANGER There is a risk of fatal injury from a falling load or fork It is not permitted to drive or to transport loads with out the locking screw in plac...

Page 239: ...ng when coming in to contact with the load or floor The coating does not extend to the area in side the fork bends so that it is possible to check for cracks Fit only fork arms that correspond to explosion protection regulations Check that the cladding is complete Do not use fork arms with worn clad ding DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park...

Page 240: ... of fatal injury from falling load At least 60 of the length of the fork extension must lie on the fork arm No more than 40 of the length of the fork extension may overhang the end of the fork arms In addition the fork extension must be se cured against slipping from the fork arm If the fork extension 1 is not secured with a secur ing bolt 2 and linch pin 3 the load may fall along with the fork ex...

Page 241: ...bolt fully into the fork ex tension Insert the linch pin into the securing bolt and secure Operation with reversible fork arms variant DANGER Risk of explosion Working on a truck within potentially ex plosive areas can lead to explosions in the surrounding atmosphere No work must be performed on the truck in potentially explosive areas Do not perform any work on trucks in potentially explosive are...

Page 242: ...n reverse operation using reversible fork arms 1 WARNING Risk of accident from slipping load Loads may slip on the reversible fork arms if there is no load support A fork extension variant cannot be secured against slipping Do not use a fork extension variant WARNING Risk of accident from the truck tipping over When driving the centre of gravity of the load 2 must not be more than 600 mm above the...

Page 243: ... of accidents In the case of Hi Lo lift masts variant and triplex lift masts variant an incorrect extension sequence may occur i e the inner lift mast may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for in stance result from The hydraulic oil temperature being too low...

Page 244: ... the lift mast be come blocked due to contamination lift the fork carriage until the chains are under ten sion again Remove the contamination be fore resuming work WARNING Risk of injury Observe the safety regulations for working on the lift mast see the chapter entitled Working at the front of the truck Hydraulic blocking function The hydraulic blocking function ensures that all the functions of ...

Page 245: ...NOTE Only the emergency steering function remains available Operating 4 Lifting 231 56378011526 EN 03 2021 01 ...

Page 246: ...e maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver Use ...

Page 247: ...crease the load capacity is prohibited DANGER Risk of fatal injury from the truck losing stability Never exceed the maximum loads shown These val ues apply to compact and homogeneous loads If these values are exceeded the stability and rigidity of the fork arms and lift mast cannot be guaranteed Improper or incorrect operation or the placement of persons to increase load capacity is prohibited 660...

Page 248: ...rma tion shown on the truck and the attachment Picking up loads To make sure that the load is securely suppor ted it must be ensured that the fork arms are sufficiently far apart and are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the lo...

Page 249: ...d centre of gravity must be midway be tween the fork arms Only actuate the fork prong positioner var iant when the fork is not carrying a load Danger area The danger area is the area in which people are at risk due to the movements of the truck its working equipment its load carrying equip ment e g attachments or the load Also in cluded are the areas where loads could fall or working equipment cou...

Page 250: ...orised par ties DANGER Danger of death from falling loads Never walk or stand underneath sus pended loads Transporting pallets As a rule loads e g pallets must be trans ported individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the technical requirements have been met The driver must ensure proper condition of the load Only safely ...

Page 251: ... of stability and cause the truck to tip over When transporting suspended loads observe the following instructions Instructions for transporting suspended loads Swinging loads must be prevented by using the proper driving speed and driving style careful steering braking Hanging loads must be hooked on to the truck in such a way that the harness cannot shift or release unintentionally and cannot be...

Page 252: ...e Transportation of swinging loads is not permitted Do not transport swinging loads Picking up a load DANGER There is a risk to life from a falling load or from truck components being lowered Never walk or stand underneath suspended loads or raised fork arms Never exceed the maximum load values specified on the capacity rating plate Otherwise stability cannot be guaranteed Only store pallets that ...

Page 253: ...rack Position the forks Set the lift mast to vertical Lift the fork carriage to the stacking height CAUTION Risk of component damage When the fork is inserted into the rack take care not to damage the rack or the load Operating 4 Handling loads 239 56378011526 EN 03 2021 01 ...

Page 254: ...l the load is resting entirely on the fork DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear DANGER Due to the risk of tipping never tilt the lift mast with a raised load Lower the load before tilting the lift mast Reverse carefully and slowly until the load is clear of the rack Brake gently Operating 4 Handling loads 240 56378011526 EN 03 ...

Page 255: ... Lower the load while maintaining ground clearance Tilt the lift mast backwards The load can be transported Operating 4 Handling loads 241 56378011526 EN 03 2021 01 ...

Page 256: ...d and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards Drive slowly and carefully around corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating ...

Page 257: ... to perform tasks such as emptying containers of bulk material The shake function moves the fork carriage quickly up and down via the Lifting function This function may only be used for a limited load and must not be used with a full nominal load Maximum permissible load for the shake function Maximum 30 of the nominal load If an at tachment is being used its weight must be subtracted from this va...

Page 258: ...o start the shaking If the two seconds elapse without the shake function being used the shake function is deactivated again WARNING The shake function remains active for two seconds following activation If the driver simply wants to lift or lower the load dur ing this time note that the fork carriage may move significantly more jerkily with the load than in normal operation If the two seconds elap...

Page 259: ... four times Then continue to move the component in the same way Double mini lever Move the 360 lever 2 back and forth be tween positions A and B four times Then continue to move the component in the same way 6210_003 089 1 A B Operating 4 Handling loads 245 56378011526 EN 03 2021 01 ...

Page 260: ...e same way Quadruple mini lever Move the operating lever 4 back and forth between positions A and B four times Then continue to move the component in the same way Fingertip Move the operating lever 5 back and forth four times Then continue to move the com ponent in the same way Operating 4 Handling loads 246 56378011526 EN 03 2021 01 ...

Page 261: ...ards take particu lar care to ensure that the truck does not tip for wards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during low ering the load may fall When removing from stock move the truck far enough back so that the load and the fork can be lowered freely Drive up to the stack with the load lowered in accordance with re...

Page 262: ...es special dangers Always follow the instructions below On ascending and descending gradients the load must be carried facing uphill It is only permitted to drive on ascending and descending gradients that are marked as traffic routes and that can be used safe ly Ensure that the ground to be traversed is clean and provides a good grip Do not turn on ascending and descending gradients Do not drive ...

Page 263: ...ace loads into stock and remove loads from stock on a horizontal plane Driving on lifts The driver may only use this truck on lifts with a sufficient load capacity and for which the op erating company has been granted authorisa tion refer to the section entitled Definition of responsible persons DANGER There is a risk of fatal injury from being crushed or run over by the truck There must not be an...

Page 264: ...total actual 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 kg allowance for driver Total actual weight Drive the truck into the lift with the forks fac ing forwards Make sure not to touch the shaft walls Park the truck securely in the lift and switch it off to prevent uncontrolled mov...

Page 265: ...cient load ca pacity e g lorry bridge Ensure that the lorry onto which you will be driving is secured to prevent it from shifting and that it can support the load of the truck Determining the total actual weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the nameplate on the attachment variant and or by weighing the load to be lifted Add toge...

Page 266: ...llid ing with racks or other objects Before using the automatic mast vertical position ing assistance system position the truck at a suf ficient distance from racks and other objects The automatic mast vertical positioning as sistance system can be used to set down the goods so that the goods are exactly vertical e g paper rolls This prevents damage when setting down the load Automatic mast verti ...

Page 267: ...tical positioning function Push the automatic mast vertical position ing softkey The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast stops in the vertical position NOTE The lift mast also stops in the vertical position if it is tilted forwards by 3 from a backward tilt NOTE The automatic mast vertical positioning must be...

Page 268: ...ion proceed as fol lows Push the automatic mast vertical position ing softkey The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast must stop in the vertical position The automatic mast vertical positioning can be used If the lift mast does not stop in the vertical position do not use the assistance system In this case con...

Page 269: ...Once the automatic mast vertical positioning assistance system has been calibrated a pal let can be stored horizontally in a rack when the truck is standing on a HGV ramp for ex ample Lift the fork carriage slightly Apply the parking brake Attach a tilt angle template with a spirit level to the outer lift mast Bring the lift mast to the vertical position ac cording to the spirit level Press the bu...

Page 270: ...keys until the Cal ibration menu appears Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Operating 4 Tilt angle dependent assistance systems 256 56378011526 EN 03 2021 01 ...

Page 271: ...alibration has been completed suc cessfully the message Successful cal ibration appears Switch the truck off and on again The calibration is now complete NOTE If the message A6701 Fault Monitor ing of assistance system ap pears during the calibration perform the cali bration again Fleet manager Load measurement Lift mast tilting 6219_003 278_en Operating 4 Tilt angle dependent assistance systems 2...

Page 272: ...igher than the nominal load The overload detection restricts the hydraulic functions as follows If the rated capacity or the maximum load set by the authorised service centre is ex ceeded the lifting speed is reduced If the rated capacity or the set maximum load are exceeded by more than 10 the Lifting function is disabled NOTE Please note the following special considera tions If the load pressure...

Page 273: ...ics of the hydraulic move ments section in the chapter entitled Lifting Dynamic Load Control 1 improves the han dling of the load This function protects the truck and the load from abrupt movements Dynamic Load Control 1 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria Lift height Load weight Load movements which could lead to critical conditi...

Page 274: ...mics the lifting system responds after a delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately instead it takes approx one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 2 Work with particular attention and care Observe the Dynamics of the hydraulic move ments section in the chapter ent...

Page 275: ...mitation again Re lease the accelerator pedal for a short period to do this The bar display on the display of the display operating unit is part of the load information It is part of the Dynamic Load Control 2 The number and colour of the bars indicates to what extent the determined load weight and load centre of gravity affect the stability of the truck The bar display is divided into three secti...

Page 276: ...oad measurement variant Knowing the weight of the load to be transpor ted gives the driver greater security If the truck is equipped with the load measurement assistance system the weight of the lifted load is measured and displayed in the display op erating unit 1 The measuring accuracy is 5 of the rated capacity Observe the following safety information DANGER Risk of accident from a falling load...

Page 277: ...obviously incor rect If t is displayed permanently this means that the function is calibrated incorrect ly load 0 kg See the section entitled Calibrating the load measurement Calibrating the load measurement If the truck is equipped with the load meas urement assistance system then this assis tance system must be calibrated The load measurement is calibrated using a wizard on the display operating...

Page 278: ...for the fleet manager Press the Service softkey Press the scroll keys until the Cal ibration menu appears Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Operating 4 Load dependant assistance systems 264 56378011526 EN 03 2021 01 ...

Page 279: ...tion again Precision load measurement var iant This assistance system is available only if the truck is equipped with the load measurement variant The Precision load measurement variant al lows the weight of the load being picked up to be measured and displayed on the display op erating unit accurate to within 1 of the rated capacity of the truck NOTE If the load is to be measured exclusive of the...

Page 280: ...wly lowering the fork carriage increases the measurement accuracy in trucks with multi lever operation The value is calculated The Calc ongo ing message appears 0 0 0 70 m 1 5 t t 6219_003 222 1 0 0 0 70 m 1 5 t 6219_003 223_V3_en Lower fork slightly Operating 4 Load dependant assistance systems 266 56378011526 EN 03 2021 01 ...

Page 281: ...on should not factor in the weight of a load container the tare function must be run It is then possible to determine the net weight of the raised load NOTE During the following process the fork carriage must be lowered slightly When doing so the fork must not touch the ground as otherwise the result will be inaccurate Set the lift mast to vertical Pick up the empty load container such as a crate ...

Page 282: ... dis played The Precision load measurement can be performed To clear the tare weight press the tare softkey again WARNING Risk of accident due to incorrect load specification If the requirements for the precision load measure ment function change the tare function must be run again for example if a precision load measurement needs to be performed without a crate Otherwise the new precision load me...

Page 283: ... up the load and call up the load menu 2 Measure the load 3 Add subtract the load WARNING Risk to stability If the weight determined by a load measurement ex ceeds the permissible residual load capacity of the truck the truck cannot be operated safely Do not lift the load higher than 800 mm Set down and reduce the load immediately If necessary use another truck with sufficient load bearing capacit...

Page 284: ...d here using Press the softkey The Total load menu storage space ap pears This menu provides the following functions Tare Precision load measurement Add a load Subtract a load Delete load summation Measuring the load Press the Precision load measure ment Softkey Measure the load 0 00 0 00 0 00 t 0 00 t Operating 4 Load dependant assistance systems 270 56378011526 EN 03 2021 01 ...

Page 285: ...To subtract the current load press the Softkey The current load is subtracted from the sum The load is saved automatically NOTE If for instance this load was added to the wrong total load it is also possible to perform a subtraction with the previously measured and added load Delete total load To delete the total load press the soft key The Clear total load message is displayed To delete press the...

Page 286: ... persons The specifications provided by the manufacturer and supplier of the attach ments must be observed during installation of the attachments Before changing attachments the hydraulic system must be depressurised This is done using a wizard on the display operating unit If the truck has a 5th hydraulic function or 6th hydraulic function the hydraulic circuits of these functions must also be de...

Page 287: ...es access authorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is released prematurely the settings menu will close Set the load down if necessary Apply the parking brake Starting the wizard Press the button Press the Settings Softkey Activate the Access authorisation for the fleet ma...

Page 288: ... menu appears Push the Relieve hydraulics soft key The following message appears Caution the lift mast may move To confirm push the softkey Press the softkey to exit the wizard Operating 4 Depressurising the hydraulic system 274 56378011526 EN 03 2021 01 ...

Page 289: ...e function for relieving the hy draulics becomes inactive Depressurising the hydraulic sys tem using multi lever operation Start the wizard for depressurising the hy draulic system Depressurising the hydraulic circuits for the basic functions The basic functions include the first four hy draulic functions The basic functions are con trolled via the first two hydraulic circuits The basic functions ...

Page 290: ...ions In this case press the button 1 and hold it down Push the operating lever 2 once in the di rection of the arrow until the end position is reached Release the button 1 The hydraulic circuits of the sideshift and fork adjustment are now depressurised The plug connectors on the lift mast are depressurised Completing the depressurisation To complete the depressurisation observe the section entitl...

Page 291: ...ng lever 4 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Press the button 2 and hold it down Push the operating lever 3 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 6th hydraulic func tion is depre...

Page 292: ...justment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the cross lever 1 for controlling the additional functions once in the direction of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To complete...

Page 293: ...ctuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the cross lever 1 once in the direc tion of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Completi...

Page 294: ...t Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To compl...

Page 295: ...tuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Compl...

Page 296: ... Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To comple...

Page 297: ...Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the di rection of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Com...

Page 298: ...k adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisati...

Page 299: ...elevant pictogram for the 5th function Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Push the operating levers 1 or 4 once in the direction of the arrow until the end posi tion is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func t...

Page 300: ... functions The additional features include features such as the sideshift and fork adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Push the Joystick 4Plus 1 once in the direc tion of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurise...

Page 301: ...nction Press and hold shift key F 1 Push the Joystick 4Plus 3 once in the di rection of the arrow until the end position is reached Push the horizontal rocker button 2 once in the direction of the arrow The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Release shift key F 1 Completing the depressurisation To complete the de...

Page 302: ...ed Clamp locking mechanism variant in the chapter entitled Attachments Exiting the wizard After the hydraulics have been depressur ised press the softkey to confirm The wizard for depressurising the hydraulics is switched off The truck is ready for operation Operating 4 Depressurising the hydraulic system 288 56378011526 EN 03 2021 01 ...

Page 303: ...ttachments If the area of application is not clear ask the safety officer If the truck is equipped with an integrated at tachment variant at the factory the specifica tions in the STILL operating instructions for in tegrated attachments must be observed If attachments are fitted at the place of use the specifications in the operating instructions from the attachment manufacturer must be ob served ...

Page 304: ...ver grab or climb on moving parts of the truck WARNING Risk of accident due to incorrect labelling The use of attachments can cause accidents if the labelling is incorrect or missing If the truck is not fitted with an attachment specific residual load capacity rating plate and the operating devices are not marked with the relevant pictograms the truck must not be used Use only CE certified attachm...

Page 305: ...ment has been disassembled seal the plug connectors using the protective caps Mounting attachments Only competent persons are permitted to mount and connect the energy supply to the attachment Observe the information provided by the manufacturer and supplier or sub supplier of the attachment when doing so After each installation the function of the at tachment must be tested prior to initial com m...

Page 306: ... of the manufacturer and suppli er of the attachment Observe the residual load capacity rating plate see the chapter entitled Picking up a load using attachments Operating 4 Attachments 292 56378011526 EN 03 2021 01 ...

Page 307: ... included in the truck s equipment Possible equipment variants include Multi lever Multi lever with a 5th or 6th function var iant Double mini lever Double mini lever with a 5th function var iant Triple mini lever Triple mini lever with a 5th function variant Quadruple mini lever Quadruple mini lever with a 5th function variant Fingertip Fingertip with a 5th function variant Joystick 4Plus Joystic...

Page 308: ...ibed below The directions of movement can be seen in the pictograms on the operating devices All the attachments described fall into the category of equipment variants An exact description of the respective movements or actions of the at tachment fitted can be found in the relevant operating instructions With fleet manager access authorisation var iant the fleet manager can adjust the speed of the...

Page 309: ...s fed from the auxiliary hydraulics 2 2 and is implemented by an additional connec tion for a switch valve that is not shown here NOTE If one switch valve is used the auxiliary hy draulic functions 1 3 and 2 4 that are sup plied by this switch valve cannot be operated simultaneously The switch valve supplies ei ther auxiliary hydraulics 1 3 or 2 4 Adjusting the hydraulic speed for at tachments If ...

Page 310: ...ion for the fleet manager Push the Auxiliary hydraulics Softkey This menu lists all the available hydraulic axles for attachments Refer to the operating instructions of the at tachment to determine which hydraulic axle is occupied by the attachment The authorised service centre will help you de termine the axles Setting the revolution speed Push the softkey for the hydraulic axle to be configured ...

Page 311: ...nus softkey To save the setting press the Confirm softkey The settings are saved To cancel the setting press the Can cel softkey The settings return to the most recently set value Locking the flow rate You can also lock the hydraulic oil flow rate in full To do this push the Deactivate auxiliary hydraulics softkey The hydraulic oil flow rate for this hydraulic axle is locked Setting the return flo...

Page 312: ...e from a falling load If other attachments in addition to the clamp are used on this truck the clamp locking mechanism must be reassigned to the corresponding operating device ev ery time the clamp is reassembled Make sure that the authorised service centre reas signs the function of the clamp locking mechanism to the corresponding operating device Make sure that the additional clamp locking mech ...

Page 313: ... See the section concerning the relevant op erating device Operating 4 Attachments 299 56378011526 EN 03 2021 01 ...

Page 314: ...in the upper part of the pic togram Move the operating lever backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Note the following attachment functions and pictograms Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adju...

Page 315: ...ns is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism NOTE For technical reasons no clamp locking mech anism is available for the multi lever operating device Operating 4 Attachments 301 56378011526 EN 03 2021 01 ...

Page 316: ...c togram Move the operating lever 3 4 backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Press and hold the switch 1 The additional function of the attachment is activated and can be controlled as the 5th function with the operating lever 4 NOTE The movement action of the 5th function can be found in the operating instructions of the at tachment t...

Page 317: ... to the right Tip shovel over Tip shovel back Swivel the fork to the left Swivel the fork to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary If the at tachment is known the re...

Page 318: ...this lever The pictograms are arranged according to the direction of movement of the attach ments cross lever 1 The following applies Move the attachments cross lever 1 in the direction of arrow A B C or D The attachment moves accordingly in the di rections A B C or D as shown in the pictogram Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or f...

Page 319: ...chanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er 2 forwards again It is not nece...

Page 320: ...l becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 2 The pictograms on the attachments cross lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 3 The LED for the 5th function lights up Move the attachments cros...

Page 321: ...nction Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service cen...

Page 322: ...spective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment func...

Page 323: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 324: ...dhesive label becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 3 The pictograms on the operating lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating le...

Page 325: ...hment function Auxiliary hydraulics 5th function Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the co...

Page 326: ...espective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment fun...

Page 327: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 328: ...sentially involves the following Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating lever 1 in the direc tion E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram Example using the pictograms for configura tion 1 If the operating lever 1 is moved in the direc tion of the arrow E the sideshift moves to th...

Page 329: ...ating lever 2 and the adhesive label 4 for the op erating lever 1 are affixed at the designated points If the adhesive labels become illegible or are missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive labels 3 4 The pictograms on the operating levers show the respective functions that are activated by these levers The following...

Page 330: ... au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism To release the clamp locking mechanism push the operating lever 2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for...

Page 331: ...sing please contact your authorised service centre The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Move the operating lever 4 or 6 in the di rection of the arrow E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram NOTE The place where the adhesive label bearing the pictograms 1 or 5 is affixed s...

Page 332: ...NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Operating 4 Attachments 318 56378011526 EN 03 2021 01 ...

Page 333: ...show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus The following applies Move the Joystick 4Plus 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the slider 4 in the direction of the ar row C or D The attachment moves accordingly in the di rections C or D as show...

Page 334: ...ush the slider 1 to the left The clamp locking mechanism is released The LED for the clamp release 2 lights up and remains lit while the clamp locking mech anism is released To open the clamp push the slider 1 to the left again NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is...

Page 335: ... on the adhesive label regard ing operation of the Joystick 4Plus show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus Note the following attachment functions and pictograms Operating device Function of the at tachment 1 Shift key F and Joystick 4Plus Adjust fork arms close open 2 Shift key F and horizontal rocker button Adjust fork back wards...

Page 336: ...ments must only be deployed for their inten ded use as described in the relevant operating in structions Drivers must be taught how to operate the attach ments WARNING Risk of accident Loads may only be picked up and transported with attachments if the loads are securely grasped and at tached Where necessary loads must also be se cured against slipping rolling falling over swinging or tipping over...

Page 337: ...The acceleration sensor records data arising from rapid accelerations or decelerations of the truck e g in the event of an accident This da ta can be electronically read out and evalu ated If you have any questions please contact your authorised service centre Driver restraint systems variants Different driver restraint systems are available as variants for this truck The description and operation...

Page 338: ...own with an orange back ground To activate the Washer operating stage press and hold the softkey The Washer operating stage is activated The symbol 4 is displayed for as long as the softkey is pressed Once the window is clean release the soft key The previous operating stage is reactivated To switch this operating stage off press the softkey repeatedly until the symbol 1 ap pears again on the disp...

Page 339: ...ss the softkey repeatedly until the symbol 1 ap pears again on the display Roof panel wiper and washer To activate the On operating stage press the corresponding softkey 9 The On operating stage is activated The symbol 11 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 10 is shown with an orange background To activate the Washer operating stage press a...

Page 340: ...isk of frost use fluid that is suitable for winter use Close the filler cap Operate the screen washer system until washer fluid is discharged from the spray nozzles Operating the rear window heating DANGER Risk of explosion Operating the rear window heating sys tem within potentially explosive areas classified as zones 1 and 21 can lead to explosions in the surrounding atmos phere Rear window heat...

Page 341: ...of observing the speed limits on company prem ises Depending on the system setting the ceiling sensor can detect overhead structures above the truck at a height of 2 m to 24 m above the sensor If the truck is equipped with a ceiling sensor this assistance system is listed in the Assis tance systems menu in the display operating unit Operating the ceiling sensor system The drivers must be instructe...

Page 342: ... accel erator briefly and then operate the accelera tor again Switching on the truck in a hall If the truck is switched on inside a hall the ceiling sensor system detects the hall ceil ing and reduces the driving speed to the maximum speed that is set for halls Possible limitations for object recogni tion If the truck moves under larger overhead structures outdoors e g a pedestrian bridge the ceil...

Page 343: ...to loosen it Disconnect the electrical connec tion assembly by pulling out the plug On the underside of the assembly base plate on the overhead guard hold four nuts 3 in place Unscrew four socket head screws 2 The key 5 is secured with a nut under the as sembly baseplate Carefully remove the ceiling sensor 1 Deckensensor_Anbau 1 4 2 3 5 Deckensensor_Einstellschlüssel_V2 Operating 4 Auxiliary equip...

Page 344: ...rewdriver CAUTION The settings for DIP switches 6 to 8 are the factory settings of the manufacturer Do not change the factory settings of the manufac turer Factory settings of the manufacturer DIP switch 6 7 8 1 1 0 The possible settings for DIP switches 1 to 5 are shown in the following tables DIP switch 1 2 3 Range 0 0 0 2 m 0 0 1 3 m 0 1 0 4 m 0 1 1 6 m 1 0 0 8 m 1 0 1 12 m 1 1 0 16 m 1 1 1 24 ...

Page 345: ...nsor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following ta ble Sensitivity Range Beam angle Low 1 2 m 22 5 4 m 22 5 8 m 20 16 m 15 24 m 5 Medium 2 2 m 35 4 m 30 8 m 25 16 m 22 5 24 m 10 2 3 4 1 2 3 4 Operating 4 Auxiliary equipment 331 56378011526 EN 03 2021 01 ...

Page 346: ... 8 m 22 5 16 m 20 24 m 15 Very high 4 2 m 45 4 m 43 8 m 30 16 m 22 5 24 m 18 After the adjustment refit the cover Refit the ceiling sensor and connect it Check that it is working correctly Operating 4 Auxiliary equipment 332 56378011526 EN 03 2021 01 ...

Page 347: ... CAUTION Risk of component damage If the cab door opens while driving there is risk of damage from a collision The cab door must be latched securely in the en gaged position The truck has a cab door sensor that is used to monitor the closing of the cab door If the seat belt is not fastened and the cab door is not closed the driving speed is limited to 4 km h The message Close cab door or seat belt...

Page 348: ...lose it Opening and closing the side win dow WARNING There is a risk of crushing between the window frame and side window due to the side windows slip ping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the front side window Squeeze the handle 3 Slide the front side window 1 backwards Opening the rear side window The rear side window 2...

Page 349: ... If the truck is equipped with a ra dio and loudspeakers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the ra dio WARNING The driver s attention is adversely affected by operat ing the radio or listening to it at excessive volumes while driving or handling loads Risk of accident Do not operate the radio when driving o...

Page 350: ... of fire due to overheating The heating system can overheat if the hot air cannot escape from it The heating system may only be switch ed on if the blower is running and the heating system is not covered by objects such as a jacket or cover Always switch the blower on first Do not switch the heating system on until the blower is switched on Move any objects away from the heating system or air dist...

Page 351: ...red position Selecting blower settings To select a lower fan output turn the fan control knob 2 anticlockwise To select a high blower output turn the fan control knob 2 clockwise Setting heating levels To set a lower heater power turn the heat ing level control knob 1 anticlockwise To set a higher heater power turn the heat ing level control knob 1 clockwise Setting the air vent control knob To di...

Page 352: ...lways supplied with air It is not necessary to adjust the heating system using the operating devi ces To open the air distributor push the inden tation 1 on the disc The discs open Grasp the discs to align the air flow The discs can be adjusted to the desired an gle The air distributor can be rotated Press down again to close the discs Changing fuses DANGER Risk of fire as a result of short circui...

Page 353: ...shed up to and locked in three positions Pushed up at the front Pushed up at the rear Completely pushed up Two handles 2 5 and two locking bolts 3 4 are located on the right hand side for this pur pose To push up and close the roof window stop the truck and apply the parking brake Pushing up and closing the roof window at the front To push up the roof window pull out the locking bolt 4 with your r...

Page 354: ...f window pull out the locking bolt 3 with your left hand and keep hold of the locking bolt Use your right hand to take hold of the han dle 2 on the roof window 1 and push up wards until the locking bolt 3 engages The roof window 1 is held in the pushed up position To close the roof window pull out the lock ing bolt 3 with your left hand and keep hold of the locking bolt Use your right hand to take...

Page 355: ...ront 4 To adjust the sun visor 2 grasp it and move it to the desired position To move the sun blind 4 up and down grasp the tab 3 and move the sun blind If necessary fully unroll the sun blind for the roof 1 and attach the ends 5 in the ex tended position To roll up slowly roll the blind 1 back up Operating 4 Cab 341 56378011526 EN 03 2021 01 ...

Page 356: ... in the surrounding atmosphere within potential ly explosive areas Only use trailers tow couplings and coupling pins that meet explosion protection regulations Check the area of application by re ferring to the information on the nameplates of the trailers and tow couplings If the area of application is not clear ask the safety officer Operating 4 Trailer operation 342 56378011526 EN 03 2021 01 ...

Page 357: ...st not exceed the rated capacity If the towed load present corresponds to the rated capacity of the truck it is not permitted to transport a load on the fork at the same time The load can be distrib uted between the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe the permissible rigidity value of the tow coupling CAUTION Risk of damage to...

Page 358: ...nterweight Coupling the trailer DANGER There is a risk of fatal injury if the truck rolls away If you briefly leave the truck to couple or uncouple it there is a risk of fatal injury from being run over if the truck rolls away Apply the parking brake Lower the fork to the ground Switch off the truck Remove the switch key or block access to the truck Take measures to prevent the trailer from rollin...

Page 359: ...nents If the coupling pin or securing bush are lost or de stroyed during towing the trailer will work loose and become uncontrollable Only use original coupling pins that have been checked Ensure that the coupling pin is correctly inserted and secured Insert the coupling pin into the counter weight press the pin downwards against the spring pressure and rotate the pin by 90 The coupling pin is loc...

Page 360: ...tween the truck and the trailer DANGER Never jack up the truck on the tow coupling or use it for crane lifting The tow coupling is not designed for this and could be deformed or damaged This could cause the truck to fall with potentially fatal consequences Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER The tow coupling is not des...

Page 361: ...ng can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow cou pling check the tow coupling for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufficient room In the case of a collision check the tow coupling for damage Replace tow coupling if damaged if necessary contact the authorised service...

Page 362: ... a tow bar eye in accordance with DIN 74054 bore diameter 40 mm or DIN 8454 bore diameter 35 mm Take measures to prevent the trailer from rolling away e g using wedges Adjust the tow bar eye of the tiller so that it is at the centre of the towing jaws Push the hand lever 2 upwards until it snaps into place The tow coupling is opened CAUTION When being coupled the tow bar eye must engage in the mid...

Page 363: ... control pin does not protrude out of its guide Remove any items used to prevent the trail er from rolling away Tow the trailer Closing the coupling DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for exam ple a tow rope is to be secured in the tow coupling only actuate the tow coupling via the closing lever 1 Press the closing lever 1 downwards as far a...

Page 364: ...railers ensure a suf ficient minimum distance to fixed installa tions when turning and cornering The permissible length of the trailer trains de pends on the roadways to be driven and may need to be determined during the test drive It is the responsibility of the operating compa ny to instruct the drivers regarding the permis sible number of trailers and where required any additional speed reducti...

Page 365: ...nguished by two dif ferent temperature ranges 1 Constant use in the temperature range down to 5 C short term use at temper atures down to 10 C Operation possible with standard equip ment and standard hydraulic oil 2 Alternating between indoor use down to 32 C and outdoor use up to 25 C briefly up to 40 C Operation possible only with cold store equipment and low temperature hydraulic oil NOTE When ...

Page 366: ...e temperature may result in the formation of condensation water This water may freeze on re en try to the cold store blocking moving parts of the truck It is essential that close attention is paid to the dura tion of deployment in the different temperature rang es for both types of application Before being used in the cold store the truck must be dry and warmed up The truck must not leave the cold...

Page 367: ...tside the cold store CAUTION Risk of component damage The lead acid batteries must not be left in the cold store overnight without power uptake or charging Charge the battery outside the cold store and operate the truck using a replacement battery Using batteries in the cold store To compensate for the reduction in capacity at low temperatures it is advisable to use lead acid batteries with the ma...

Page 368: ...th the battery acid so that it does not freeze Water top up systems must not be used at temperatures below 0 C as this could cause the systems and the water present in the hose lines to freeze The battery voltage when discharged is thus generally lower at low temperatures The final discharged voltage is reached earlier i e the capacity is lower Operating 4 Cold store application 354 56378011526 EN...

Page 369: ...Operating 4 Cold store application 355 56378011526 EN 03 2021 01 ...

Page 370: ...explosion protection warning lights 1 2 illuminates The hydraulic functions of the truck are switched off as soon as the explosion protection warning light 3 illuminates The driving functions of the truck are switched off as soon as the explosion protection warning light 4 il luminates Stop the truck safely This section describes the actions required when an explosion protection warning light is f...

Page 371: ...ximum surface temperature of the pump motor has been reached No hydraulic functions are available Set down the load Actuate the reset button and drive the truck out of the potentially explosive area Safely bring the truck to a standstill Allow the overheated motor to cool down If one of the warning lights 1 3 remains il luminated after the motor has cooled down notify the authorised service centre...

Page 372: ... messages about operation and messages about the truck If a message about operation appears the display operating unit will prompt you to perform an action A mes sage about the truck means that the truck con trol unit has detected a fault The following types of message may appear individually or in combination A graphic symbol The message A code consisting of a letter and a four digit number The m...

Page 373: ...rent causes The battery is defective The wrong battery is connected Contact the authorised service centre Check battery acid lev el The acid level of the lead acid battery is too low Check the acid level of the battery Correct if necessary V6965 Battery temperature high The charging process has been automatically terminated due to the battery temperature being too high This message about the on bo...

Page 374: ...orking The electrolyte circulation pump is not working The charging process is continued without elec trolyte circulation Intermediate charging can cause damage to the battery Cancel the charging process Contact the authorised service centre Development mode ac tive This message is not displayed during normal operation Contact the authorised service centre Drive unit blocked This message follows e...

Page 375: ... Switch the truck off and on again If the message continues to appear please contact the authorised service centre V7074 V7051 Mains voltage error This message about the on board charger is triggered by different causes The fuse for the power supply has been trig gered There is a defect in the power supply There is a power failure Re establish the power supply When the power supply has been re est...

Page 376: ...ng brake by pressing the but ton Parking brake Mainte nance required The truck control unit detects that the electric parking brake needs servicing Secure the truck with wedges so that the truck does not roll away Contact your authorised service centre Lower forks This message appears e g for precision load measurement variant Lower the fork carriage Lift height restriction active The lift height ...

Page 377: ... that is too low this message appears Observe the previous message Emerg direct via drive direction lever The drive direction switch on the hydraulic oper ating device has failed Emergency driving is possible to do so Move the drive direction selection lever on the travel direction selector and indicator module to the desired direction of travel and hold the drive direction selection lever in posi...

Page 378: ...on the truck Shock event detected If the truck control unit detects a very strong ac celeration or deceleration e g in the event of an accident this message appears Service required If the maintenance interval has been reached this message appears Contact the authorised service centre Service mode active This message is not displayed during normal operation Contact the authorised service centre Cl...

Page 379: ...control unit detects an excessive battery temperature this message appears Allow the truck to cool down Working mode active This message is not displayed during normal operation Contact the authorised service centre Access expired If the truck is equipped with this variant this message might appear See the associated instructions Access denied Access expires in 1 month Access expires in 1 day If t...

Page 380: ... and reflector Lift height sensor measurement error A5934 Re insert charging plug Error on the charging connector detection Disconnect the connection assembly and re connect it A5961 Battery overtempera ture Overtemperature of the lithium battery Switch off the truck and leave it to cool down A5962 Battery too cold Insufficient lithium battery temperature Move the truck to a warmer environment A59...

Page 381: ... Switch off the truck before the battery male con nectors are disconnected Do not disconnect the battery male connectors while the truck is switched on except in an emer gency All functions of the truck can be shut down in an emergency Press the emergency off switch 1 or turn the battery isolating switch 2 to OFF In drive mode pressing the emergency off switch 1 or turning the battery isolating sw...

Page 382: ...rgency shutdown DANGER Risk of explosion During operation the current tempera tures wear values and insulation values of various components are monitored by sensors If dangerous limit values are detected the truck controller automatically shuts down the drive units This automatic emergency shutdown indicates a serious malfunction Remove the truck from the potentially explosive area The cause of th...

Page 383: ...ately moved out of a danger area despite the auto matic emergency shutdown having been trig gered To do this push and hold the reset button 1 and simultaneously actuate the acceler ator pedal The truck will move in the preselected drive di rection Drive the truck out of the danger area Notify the authorised service centre NOTE Only push the reset button without consulting the safety officer in the...

Page 384: ...k You must adhere to the rules of behaviour if the truck tips over Rules of behaviour if truck tips over Hold onto the steering wheel with your hands Brace your feet in the footwell Bend your upper body over the steering wheel Bend your body against the direction of the fall Emergency hammer The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazard ous situation fo...

Page 385: ...conditions the emergency driv ing function can be used to remove the truck from a hazardous area As the truck can only be moved to a limited extent this poses a risk of an accident This function is possible in the following situa tions The drive direction switch on the operating device for the hydraulic functions has failed The message Emerg direct via drive direction lever ap pears The drive dire...

Page 386: ... the hydraulic controller fails whilst a load is raised emergency lowering can be performed An emergency lowering screw designed for this purpose is located on the valve block DANGER There is a risk to life from falling loads or from truck components being low ered Do not walk beneath the raised load Adhere to the steps detailed below Remove the lower lid 1 on the right hand side of the footwell p...

Page 387: ...g the emergency lowering screw slightly The load lowers slowly Unscrewing the emergency lowering screw further The load lowers quickly After lowering Re tighten the emergency lowering screw Return the hexagon socket wrench to the support mounting in the compartment Refit the lid DANGER If the truck is operated while the hydraulic controller is blocked there is an increased risk of accidents After ...

Page 388: ... emergency actuation mechanism The emergency release of the electric parking brake must be actuated under the following conditions The parking brake is not functioning proper ly The parking brake is not being supplied with power e g defective battery The truck is being transported without a bat tery NOTE If the parking brake is released via the emer gency actuation mechanism it is possible to driv...

Page 389: ...nd hold on to the emergency ac tuation mechanism 2 Release the brake pedal Let go of the emergency actuation mechanism 2 Once two grooves are visible see arrow the parking brake is released Apply parking brake Fully depress the brake pedal The emergency actuation mechanism 2 re turns to its initial position Release the brake pedal Once only one groove is visible see arrow the parking brake is appl...

Page 390: ...l Risk of accident If the brake system of the towing vehicle is not ade quately sized the vehicle may not brake safely or the brakes may fail The towing vehicle must be able to absorb the pulling and braking forces from the un braked towed load total actual weight of the truck Check the pulling and braking forces of the towing vehicle DANGER The truck could drive into the towing vehicle when the t...

Page 391: ...he steering will be stiff Select a towing speed that allows the truck and towing vehicle to be braked and controlled effec tively at all times WARNING Risk of accident due to unguided truck If the towed truck is not steered the truck may veer out in an uncontrolled manner The truck being towed must also be steered by a driver The driver of the truck being towed must sit in the driver s seat and fa...

Page 392: ...brake Switch off the truck Disconnect the battery male connector Check the pulling and braking forces of the towing vehicle With the help of a guide move the towing vehicle to the truck Secure the tow bar to the tow coupling on the towing vehicle and the truck Sit in the driver s seat in the truck being towed Fasten the seat belt Use the available restraint systems Manually release the parking bra...

Page 393: ...ng brake to apply by actuating the brake pedal Make sure that the emergency actuation mechanism returns to the initial position or only one groove is visible If the status of the emergency actuation mechanism is unclear secure the truck af ter towing using wedges so that the truck cannot roll away Remove the tow bar Operating 4 Procedure in emergencies 379 56378011526 EN 03 2021 01 ...

Page 394: ...he key switch is switched on under load a jump spark will be produced This jump spark can damage the contacts and considerably shorten the service life of the contacts Switch off the key switch before the battery male connectors are connected NOTE The battery male connectors are non inter changeable The battery connectors are routed through different grooves Incorrect connection is not possible Th...

Page 395: ...pted Power assisted steering and re generative braking will fail Always secure the battery male connectors NOTE The truck is not approved for use in potentially explosive areas if the battery male connectors are unsecured If necessary connect the potential equalisa tion connector 4 to the battery tray The potential equalisation point is identified by the decal information CAUTION There is a risk o...

Page 396: ...ode which considerably shortens the service life of the contacts Switch off the key switch before the battery male connectors are disconnected Do not disconnect the battery male connectors while the key switch is switched on except in an emergency NOTE The battery male connectors are non inter changeable The battery connectors are routed through different grooves Incorrect connection is not possib...

Page 397: ...en closing the battery door the battery door may collide with the battery male connectors The battery male connectors can be damaged as a result If this occurs the authorised service centre must replace the battery male connectors Until the battery male connectors are replaced it is prohibited to use the truck in potentially explosive areas Ensure that the battery door does not collide with the ba...

Page 398: ...se of the truck Only use explosion protected batter ies of the same type in accordance with the Battery specifications sec tion Batteries may be checked only by a competent person Observe the explosion protection reg ulations Compare the permissible operating areas of the truck and battery as lis ted on the respective nameplates DANGER Risk of explosion When handling or charging batteries in poten...

Page 399: ...so apply to trucks with a battery cover They apply 1 1 Parking the truck securely If work is being performed on the battery park the truck outside the potentially explo sive areas The following points must be satisfied for the truck to be used The battery male connectors must be con nected and secured The battery door must be closed Maintenance personnel Batteries may only be charged maintained or...

Page 400: ... maintenance in structions for the battery and the battery charger Fire protection measures DANGER Risk of explosion due to flammable gases During charging the battery releases a mixture of oxygen and hydrogen This gas mixture oxyhydrogen is explosive and must not be ignited There must be no flammable materials or spark forming operating materials within 2 m of either the truck when it is parked f...

Page 401: ... plate Check the load capacity of the lifting accessory Remove the battery on suitable ground Battery weight and dimensions DANGER Risk of tipping due to change in battery weight The battery weight and dimensions affect the stability of the truck When replacing the battery the weight ratios must not be changed The battery weight must remain within the weight range specified on the nameplate Do not...

Page 402: ... con nected while the truck is switched on or while the battery charger is under load an electrical arc or a transition spark will be produced at the battery male connector This can lead to erosion at the contacts and can considerably shorten the service life of the contacts Switch off the truck or the battery charger before disconnecting or connecting the battery male con nector Do not disconnect...

Page 403: ...ions The operating instructions for the battery charger must also be followed Only the instructions that came with the battery charger are valid If any of these instructions are missing request the relevant instructions from the dealer The battery maintenance information is com posed of the following sections Checking the status acid level and acid density of the bat tery Checking the battery char...

Page 404: ...ty protection of the battery male connectors must be checked Observe the information in the operating instruc tions for the battery Ensure that the battery tray is closed correctly all the way round Ensure that a tray lid is present for category 2 ver sions Only use batteries and plug connectors that are approved for potentially explosive areas and for the truck The safety officer will allocate a ...

Page 405: ...ean the battery cell covers and dry if nec essary Remove any oxidation residue on the bat tery terminals then coat the terminals with acid free grease At regular intervals have the battery termi nal clips 2 tightened by the authorised service centre in accordance with the bat tery manufacturer s instructions Check the acid density with an acidimeter After charging the acid density must be be tween...

Page 406: ...ged state Apply the parking brake Switch on the truck Read the charge status on the display of the display operating unit Charge a discharged or partly discharged battery Meaning of the colours in the display 1 Green The battery is sufficiently charged 2 Yellow Charge the battery soon 3 Red Stop working Charge the battery imme diately The battery is at risk of deep dis charge Charging the lead aci...

Page 407: ...ion due to old batteries Old and inadequately maintained batteries can cause excessive gas emissions and excessive heating dur ing charging The increased production of explosive gas can lead to an explosion If an increased build up of heat or a sulphurous odour is detected stop the charging process im mediately Provide good ventilation Inform the authorised service centre so that it can determine ...

Page 408: ...ctor while the truck is switched on except in an emer gency Park the truck securely Ensure that work areas are adequately ven tilated Make sure that the external ventilation gaps on the truck are unobstructed and are not blocked Fully open any protective structures e g fabric covered cab Open the battery door completely If the truck is equipped with an electric bat tery carrier variant fully exten...

Page 409: ...tart the battery charger NOTE Observe the information in the operating in structions for the battery and the battery charger DANGER Risk of explosion To ensure adequate ventilation the bat tery door must be locked in the charging position using the support bracket during the charging process Operating 4 Handling the lead acid battery 395 56378011526 EN 03 2021 01 ...

Page 410: ...attery charger Swing the support bracket 1 back into po sition and lock it into the support mount ing 2 on the battery door Open the battery door Lock the battery door in the open position Disconnect the battery male connector from the plug for the battery charger Connect the battery male connector DANGER Risk of explosion Do not disconnect the plug and socket until the truck and battery charger a...

Page 411: ...the service life of the battery and the battery capacity An equalising charge should be carried out in accordance with the battery manufacturer s in structions several times a month after the nor mal charging process NOTE Depending on the battery charger used the equalising charge may not begin until 24 hours have elapsed A period when no shifts are running such as the weekend is therefore ideal f...

Page 412: ...the battery charger Please refer to the operating instructions from the manufacturer of the battery charg er CAUTION Damage to the connection assembly is possible If you disconnect the charging cable while the battery charger is switched on an arc will be produced This can lead to erosion at the contacts which considera bly shortens the service life of the contacts Switch off the battery charger b...

Page 413: ...apacity lifting accessories and the battery can roll away in an uncontrolled manner Follow the operating instructions for the lifting ac cessories used Always remove the battery on a level smooth floor with sufficient load capacity Batteries can be removed with a truck and with a lift truck equipped with a battery change frame The load capacity of the lifting accessory used must at least match the...

Page 414: ... to TENSOR batteries the authorised service centre must limit the maxi mum speed of the truck to 17 km h for techni cal reasons Setting the new battery capacity and the new battery type Stop the truck Actuate the parking brake Press the button Press the Settings softkey The first menu level appears Activate the Access authorisation for the fleet manager The Settings menu opens on the display Press...

Page 415: ...Perform ance variant the components have a higher current draw CAUTION Risk of overheating of the battery cable Due to the higher current draw the wire cross sec tion of the battery cable must be at least 70 mm2 Ensure that all batteries in use have a battery ca ble with a wire cross section of at least 70 mm2 NOTE If different batteries are used in alternating battery operation always ensure that...

Page 416: ...oor Grasp the door handle 1 on the battery door Open the battery door by pulling it backwards The hinge of the battery door holds the battery door in the open position Operating 4 Replacing and transporting the battery 402 56378011526 EN 03 2021 01 ...

Page 417: ...n closing the battery door limbs could become trapped There is a risk of crushing When closing the battery door nothing should come between the battery door and the edge of the chassis Carefully close the battery door Only close the battery door if there are no parts of the body in the way WARNING When closing the battery door the bat tery cable could become trapped There is risk of short circuit ...

Page 418: ... locked NOTE The apertures in the door are necessary for forced ventilation and must not be blocked If the battery door is fully open grasp the battery door by its handle and open it slight ly further This will release the latch in the hinge Close the battery door by hand until it en gages in the lock The battery door must be locked in place The truck is equipped with a door contact switch for the...

Page 419: ...han the length of the chas sis opening B max 850 mm It is useful to mark this measurement B measured from the fork tips on the fork arms Removing the battery Park the truck securely and switch it off Open the battery door CAUTION Possibility of damaging the battery male connectors If the battery male connectors are disconnected while the key switch is switched on under load an arc will be produced...

Page 420: ...n the battery locks 1 NOTE If the battery locks cannot be opened by hand the coupling pin 2 from the counterweight can be used as a lever extension Carefully drive the truck under the battery Carefully lift the battery until it maintains a sufficient distance from the seating and from the chassis above Position the fork arms horizontally CAUTION Risk of damage If the battery knocks against the cha...

Page 421: ...stalling the battery Pick up the battery and transport it to the truck Carefully insert the battery into the battery compartment When doing so ensure that Before inserting the battery position the battery cables on the battery in such a way that the cables will not be trapped when the battery is inserted The lifting accessory is at a right angle to the truck The gaps are maintained for the entire ...

Page 422: ...nected while the key switch is switched on under load a jump spark will be produced This can cause the contacts to erode which considerably shortens the service life of the contacts Do not connect the battery male connectors with the key switch switched on Make sure that the key switch is switched off be fore connecting the battery male connectors Make sure that the battery male connectors and the...

Page 423: ...ace with sufficient load bear ing capacity Do not place the battery change frame with the bat tery on a soft surface or in a rack The battery change frame variant features an advantageous design that allows a truck or pallet stacker to pick up the battery quickly The battery remains on the change frame for charging and storage The change frame fits between the battery holding fixtures in the bat t...

Page 424: ... Switch off the key switch before the battery male connectors are disconnected Disconnect the battery male connector WARNING Risk of crushing shearing No one must stand directly next to the battery or between the battery and the truck when removing and inserting the battery CAUTION Risk of damage Position the battery cable on the bat tery in such a way that the cable can not be crushed either when...

Page 425: ...ry is positioned centrally on the change frame The battery must be positioned centrally on the change frame in order for the change frame to be moved into the truck and to reduce the risk of the battery tipping over when being moved If multiple batteries are used it is advisable to permanently mark the centre of the battery 1 e g using a strip of adhesive tape CAUTION Risk of component damage Move...

Page 426: ...sure that the change frame 2 does not protrude beyond the bat tery Set down the battery on a stable base so that it is secure and position the battery against the stops on the base Installing the battery Remove the change frame Pick up a charged battery using the change frame and transport the battery to the truck Position the battery cable on the battery so that it will not become trapped when th...

Page 427: ...ark will be produced This can cause the contacts to erode which considerably shortens the service life of the contacts Do not connect the battery male connectors with the key switch switched on Make sure that the key switch is switched off be fore connecting the battery male connectors Ensure that the battery male connectors and the plug connections are dry clean and free of foreign objects Connec...

Page 428: ...with open terminals or connectors with a rubber mat Observe the operating instructions for the lifting gear Attach the battery 1 to suitable lifting gear 2 Lift the battery carefully and ensure that it hangs straight on the lifting gear The lifting gear must be vertical when lifting so that no lateral pressure is applied to the tray Set the battery down carefully Remove the lifting gear after the ...

Page 429: ...here can penetrate the housing during operation in at risk areas this can cause an explosion which can in turn spread to the surrounding environment Do not open pressure tight housings CAUTION If water penetrates the electrical system there is a risk of a short circuit occurring The flame proof enclosures have a nar row gap that could allow water to pene trate Do not use high pressure cleaning equ...

Page 430: ...ose to climb onto the truck Use equipment such as stepladders or platforms to reach inaccessible areas CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck bef...

Page 431: ...ctly at adhe sive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot com ponents Use only non flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials Clean plastics only with cleaning materials intended for plastics Observe the manufacturer s guidelines for working with cleaning materials Cle...

Page 432: ...al system parts with a metal free brush and blow the dust off with low pressure compressed air Cleaning load chains WARNING Risk of accident Load chains are safety elements The use of cold chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden Observe the manufacturer s guidelines for working with cleaning materials Place a collection vess...

Page 433: ...an environ mentally friendly manner Follow the statutory regulations Cleaning the windows Any glass for example cab windows variant must always be kept clean and free of ice This is the only means of guaranteeing good visibility CAUTION Do not damage the rear window heater inside 1 Clean the rear window very carefully Do not use sharp objects Clean the windows with a soft cloth and commercial wind...

Page 434: ...tion before connecting them Use compressed air to remove any foreign objects that may be lodged in the battery male connector and the plug connection Carefully dry the truck e g using com pressed air Lubricate the joints and actuators Lubricate the truck according to the lubrica tion plan NOTE The more often the truck is cleaned the more frequently the truck must be lubricated Operating 4 Cleaning...

Page 435: ...nents can be permanently deformed or damaged due to overload ing Determine the actual total weight of the truck Only load the truck if the load capacities of the means of transport the ramps and the loading bridges are greater than the actual total weight of the truck Determining the total actual weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necess...

Page 436: ... in front of each front wheel and behind each back wheel CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the key switch is on under load an arc will be pro duced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the key switch before disconnecting the battery male connector...

Page 437: ... or foam underneath the lifting points Lashing at the front There are two ways to connect the harness to the front of the truck A Looping around the fork carriage If the fork carriage is attached the har ness must be attached to the truck here To do this loop the harness around the fork carriage as shown Lash the truck at an angle towards the rear B Looping around the mudguard If no fork carriage ...

Page 438: ...ding Crane loading is only intended for transporting the complete truck including the lift mast for its initial commissioning This may be per formed only by the authorised service centre with the harnesses expressly provided and ap proved for this purpose Do not load the truck by crane Operating 4 Transporting the truck 424 56378011526 EN 03 2021 01 ...

Page 439: ...mosphere in potentially explosive areas The entire explosion protected system must be checked before re commission ing Have the explosion protection equip ment inspected by the authorised service centre before re commission ing Decommissioning and storing the truck CAUTION Damage to components due to incorrect storage Improper storage or decommissioning for a period of more than two months can res...

Page 440: ... actuators CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the truck is switched on under load an electric arc will be produced This can lead to erosion of the con tacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male...

Page 441: ... truck to protect it from dust If the truck needs to be shut down for even longer periods contact the authorised serv ice centre to find out about additional cour ses of action Use after storage or decommission ing If the truck has been decommissioned for lon ger than six months it must be checked care fully before being used again As with the an nual safety inspection this inspection must al so i...

Page 442: ...ections and func tional checks The following points in particular must be checked Drive Controller Steering Brakes service brake parking brake Lifting system lifting accessories load chains mounting NOTE For further information see the workshop manual for the truck or contact the authorised service centre Operating 4 Decommissioning 428 56378011526 EN 03 2021 01 ...

Page 443: ...5 Maintenance ...

Page 444: ... disconnection with screws To prevent loss of the screws screw the screws back in place after disconnecting the battery male connector Ensure that the truck cannot move uninten tionally or start up inadvertently If necessary have the truck jacked up by the authorised service centre Components specifically for explosion protec tion are attached on the underside of the truck If these components are ...

Page 445: ...competent person Any interference with the electrical equipment of the truck is forbidden For work on the electrical equipment contact the authorised service centre Safety devices After maintenance and repair work all safety devices must be reinstalled and tested for op erational reliability Set values The device dependent set values must be ob served when making repairs and when chang ing hydraul...

Page 446: ...oists is described in the truck s workshop manual Working at the front of the truck DANGER Risk of accident due to an unsecured lift mast If the lift mast or fork carriage is raised no work may be performed on the lift mast or at the front of the truck unless the appropriate safety measures are put in place When securing only use chains with sufficient load bearing capacity Contact the authorised ...

Page 447: ...rised service centre to re move the lift mast Securing the lift mast against falling off DANGER Risk of accident This work must only be performed by an authorised service technician To secure the lift mast against falling contact the authorised service centre Maintenance 5 Safety regulations for maintenance 433 56378011526 EN 03 2021 01 ...

Page 448: ...explosive areas Only perform truck maintenance or repairs outside potentially explosive areas Only qualified and authorised personnel are allowed to perform maintenance work Regu lar safety checks and checks after unusual in cidents must be performed by a competent person See also the section entitled Competent person for explosion protection checks in the chapter entitled Definition of responsi b...

Page 449: ...entre Maintenance work without special quali fications Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel A qualification of the type held by a competent person is not required to carry out this work The required tasks are de scribed in the chapter entitled Preserving op erational readiness Maintenance of the explosion pro tection components ...

Page 450: ... the correct maxi mum gap at the closure line of pressure tight housings verification of the lack of excessive wear and axial play of brake linings and brakes in compliance with structural design safety and of the correct positioning of the temper ature sensor and the brake lining wear sen sor after repair depending on the series verification of the minimum thickness of 1 mm for the fork arm cladd...

Page 451: ...tremely high or low ambient tempera tures and extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components Service menu The date when the truck requires maintenance is stored in the Service menu NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If th...

Page 452: ... 900 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000 3150 3300 3450 3600 3750 3900 4050 4200 4350 4500 4650 4800 4950 5100 5250 5400 5550 5700 5850 6000 6150 6300 6450 6600 6750 6900 7050 7200 7350 7500 7650 7800 7950 8100 8250 8400 8550 8700 8850 10000 Carried out Electrical system Check the mounting and condition of the electric cables of explosion protection components Che...

Page 453: ...ittings Check the driver s seat Check the antistatic paint coat Lift mast Check the fork arms Check lubricate the lift mast bearings Check the fork arm adjustment Maintenance by the authorised service centre Explosion protection compo nents 1000 hours yearly At operating hours 1000 2000 3000 4000 5000 6000 7000 9000 10000 Carried out Note Perform all 150 hour maintenance tasks Perform periodic tes...

Page 454: ...e sensor are working correctly and check for dam age Check the battery lock for damage Variant Check the oil level of the hydraulic battery carrier and check for leak tight ness Check all moving parts for wear and lubricate them Tyres and wheels Check tyres for wear and check the air pressure if necessary Check the wheels for damage and check the tightening torques Drive axle Check the mounting of...

Page 455: ... working correctly Check the lighting and indicator lights Cooling system converter drive axle and hydraulics Check that the fans and the air ducts are working correctly and check for damage Clean the fans and the air ducts Clean the cooling fins in the cooling section Battery and accessories Check the lead acid battery for damage and check the acid density observe the manufacturer s maintenance i...

Page 456: ...ck the play between the fork carriage stop and the run out barrier Check the tilt cylinders and connections for damage and for leaks Check the fork carriage for damage and for wear Check the fork arm interlock for damage and check that it is working correctly Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Special equipment ...

Page 457: ...2000 4000 5000 7000 8000 10000 11000 13000 14000 Carried out Reset the maintenance interval Check that the labelling is complete Perform a test drive Maintenance 5 General maintenance information 443 56378011526 EN 03 2021 01 ...

Page 458: ...riginal parts are installed on the truck it is no longer approved for use in potentially explosive areas Spare parts are provided by our spare parts service department The information required for ordering parts can be found in the spare parts list Only use spare parts as per the manufactur er s instructions The use of unapproved spare parts may result in an increased risk of acci dents due to ins...

Page 459: ...data table Oil and grease types of a different quality must not be mixed This negatively affects the lu bricity If a change between different manufac turers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part in volved When topping up working materials use only clean containe...

Page 460: ... on each of the two lift mast bearings 1The respective lubricant specification can be found in the Maintenance data table section be low under this Code This lubrication plan describes the series production truck with standard equipment For mainte nance points on variant trucks see the relevant chapter and or instructions provided by the man ufacturer Maintenance 5 General maintenance information ...

Page 461: ... resistance DIN 43539 VDE 0510 For further informa tion refer to the workshop manual for the truck in question Brake system Code Unit Operating materials Specifications Dimension System filling Mineral oil brake fluid Shell Spirax S4 ATF HDX Up to the neck of the brake oil reservoir Electrical system Code Unit Operating materials Specifications Dimension Insulation resistance DIN EN 1175 VDE 0117 ...

Page 462: ... depth Air pressure see in formation on truck Min tread depth 1 6 mm Steering axle Code Unit Operating materials Specifications Dimension A Axle stub bearing spherical bearing Multi purpose grease DIN 51825 KPF2 As required Wheel screws Torque wrench For further informa tion refer to the workshop manual for the truck in question Drive axle Code Unit Operating materials Specifications Dimension Whe...

Page 463: ...gh load chain spray Fully synthetic Temperature range 35 C to 250 C ID no 0156428 As required Washer system Code Unit Operating materials Specifications Dimension System filling Screen wash Winter ID no 172566 As required Flame proof enclosure Code Unit Operating materials Specifications Dimension Gap Feeler gauge 0 05 mm Cover screws Torque wrench M5 M6 M8 M10 2 5 to 5 Nm 5 to 10 Nm 10 to 20 Nm 2...

Page 464: ...the truck is designed to enable it to enter approved zones Other light bulbs increase sur face temperatures Use in potentially explosive areas is prohibited if other light bulbs are employed Light bulbs must only be changed by an author ised service centre Maintenance 5 Preserving operational readiness 450 56378011526 EN 03 2021 01 ...

Page 465: ... being crushed to death If the interlock is deformed damaged or difficult to move inform the authorised service centre imme diately Do not operate the truck Check that the interlocks function correctly The interlocks must be greased and must move easily Always check the interlock after an accident NOTE The interval for greasing is influenced signifi cantly by the application conditions and the env...

Page 466: ...ulty it may tear or open during an accident and no longer keep the driver in the driver s seat The driver may therefore be hurled against the truck components or out of the truck Ensure operational reliability by continually test ing Do not use a truck with a defective seat belt Only have a defective belt replaced by your serv ice centre Only use genuine spare parts Do not make any changes to the ...

Page 467: ...g mechanism must be tested at least once a year Park the forklift truck on level ground Pull out the belt with a jerk The automatic blocking mechanism must block extension of the belt Tilt the seat at least 30 if necessary re move the seat Slowly extend the belt The automatic blocking mechanism must block extension of the belt Cleaning the seat belt Clean the seat belt as necessary but with out us...

Page 468: ...ent mechanism for correct operation Check the condition of the seat e g wear on the upholstery and the secure fastening to the hood The driver s seat of the truck has anti static characteristics Driver s seats with anti static characteristics are identified on the backrest with decal in formation ANTISTATIC CHECKED The surface resistance must be less than or equal to 1 GΩ 109 Ω at a test voltage o...

Page 469: ...mosphere in potentially explosive areas Have any damage repaired by your authorised service centre Check the paint layer on the plastic parts for damage and abrasion The antistatic paint is applied to the following plastic parts Panelling Consoles Steering column panelling Document holders Compartments The protected areas are identified with the decal information ELECTRICALLY CON DUCTIVE Non coate...

Page 470: ...s Category of the truck Maximum permissi ble damaged area IIA 100 cm2 IIB IIB H2 20 cm2 IIB C2H2 IIB H2 C2H2 Please contact your authorised service cen tre for repair or advice if you have any questions Servicing the heating system or air conditioning Replacing the filter mat Loosen the screw 1 Remove the cover 2 2 1 Maintenance 5 Preserving operational readiness 456 56378011526 EN 03 2021 01 ...

Page 471: ...eaning the fresh air inlet The fresh air inlet must be cleaned if the filter mat Is damaged Is incorrectly seated in the filter frame Has not been replaced every two months Remove the filter mat Loosen the screws 1 on the filter frame 2 Remove the filter frame 2 1 1 2 Maintenance 5 Preserving operational readiness 457 56378011526 EN 03 2021 01 ...

Page 472: ... Remove any dust and dirt from the fresh air inlet 1 beneath the filter mat carrier 1 Maintenance 5 Preserving operational readiness 458 56378011526 EN 03 2021 01 ...

Page 473: ...changing wheels or tyres ensure that this does not cause the truck to tilt to one side e g al ways replace right hand and left hand wheels at the same time WARNING Risk of accident due to the use of non approved wheels The quality of the tyres and of the rims affects the stability of the truck Changes must only be made fol lowing consultation with the manufacturer Rim parts must never be changed a...

Page 474: ...crews 3 of the drive axle and the wheel fastening nuts of the steering axle are securely in place and re tighten as necessary Note the tightening torques specified in the workshop manual Servicing the steering axle Park the truck securely Check if any of the joints of the steering axle have been knocked out Check the steering axle for bent parts Lubricating the steering axle ENVIRONMENT NOTE Dispo...

Page 475: ...ase to escape from the joints Switch the truck on Actuate the steering Park the truck safely again Repeat the lubrication procedure NOTE Please note The more often the truck is cleaned the more frequently it must be lubri cated Checking the battery For information on checking the battery see the chapter entitled Checking the battery condition acid level and acid density Maintenance 5 Preserving op...

Page 476: ... current High voltages are present in the fuse box There is a risk of electric shock Do not open the fuse box The fuses must be replaced only by the authorised service centre Checking the hydraulic system for leak tightness WARNING Hydraulic oil is hazardous to health Hydraulic oil under pressure can escape from leaking pipes and lines and cause injuries Wear suitable protective gloves pro tection...

Page 477: ...of Germany observe the national regula tions for the country of use Check pipe and hose connection screw joints for leaks traces of oil Replace hose lines if they display the following abnormalities Outer layer has been damaged or is brittle or cracked Leaking Deformation e g with blisters or kinks A fitting has come loose A fitting is badly damaged or corroded Replace pipes if they display the fo...

Page 478: ...on under load an arc will be pro duced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the key switch before disconnecting the battery male connector Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connectors Turn the bayonet catches on the bottom pla...

Page 479: ...quantity Marking Overall height mm Oil filling quantity l Telescopic lift mast NiHo lift mast Triple mast 2 5 t 3 0 t 3 5 t 2 5 t 3 0 t 3 5 t 2 5 t 3 0 t 3 5 t 1 3175 2775 3025 2475 2225 38 5 2 2825 3175 3075 3225 2525 3225 2275 3025 2575 45 3 3075 3225 2625 3225 50 CAUTION Risk of damage If the hydraulic oil level is too low the steering is re stricted and the pump may be damaged If the oil level...

Page 480: ...ce data table Page 447 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Preserving operational readiness for cold store application On trucks for cold store application var iant check all rollers and chains in the lift mast for ease of movement once a week 1 6210_800 020 6210_900 002 Maintenance 5 Preserving oper...

Page 481: ...e centre Checking the fork arms DANGER Risk of explosion If fork arms are used that do not corre spond to the explosion protection regula tions this can lead to spark formation resulting in explosions in the surrounding atmosphere Only use fork arms that are approved for use in potentially explosive areas according to the nameplate of the truck If the cladding is worn do not operate the truck in p...

Page 482: ...service cen tre Perform a visual inspection of the fork arms 1 Check the cladding 2 4 for wear It must satisfy the minimum thickness of 1 mm Check the fork bends 3 for cracks Compare the Miretti job number on the fork arm heads 5 with the data on the name plate of the truck Ensure that only fork arms that comply with explosion protection regulations are fitted Thickness and material of the claddin...

Page 483: ...not fall out Repairing the fork arms DANGER Risk of explosion due to improper re pair Damaged or worn cladding may be only repaired by the manufacturer or by a specialist welder All straightening work hot and cold on deformed fork arms is forbidden Contact the authorised service centre Checking the reversible fork arms NOTE This check is only required for reversible fork arms variant Check the out...

Page 484: ...securely posi tioned Check that all screws are sealed with lock ing varnish Checking the battery changeover frame The screw joints and welded seams of the battery changeover frame must be subjec ted to a visual inspection 6327_003 026 Maintenance 5 1000 hour maintenance annual maintenance 470 56378011526 EN 03 2021 01 ...

Page 485: ...6 Technical data ...

Page 486: ...ements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clear ance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into ac count and in accordance with EN ISO 3411 In general from the seat position the operator has sufficient space to reach th...

Page 487: ... l2 y x Q c h 4 h 3 s m 1 m 2 h 7 h 6 h 1 h 10 h 2 l α β e b 3 b 1 b 2 10 b 1 b 11 6301_003 039 1 Seat is adjustable 90 mm 1 Fork spacing is adjustable 2 Technical data 6 Dimensions 473 56378011526 EN 03 2021 01 ...

Page 488: ...NOTE Measurements h1 h3 h4 h6 and b1 are cus tomised and can be taken from the order con firmation Technical data 6 Dimensions 474 56378011526 EN 03 2021 01 ...

Page 489: ... 600 Load distance x mm 455 460 460 Wheelbase y mm 1645 1645 1797 Weights Model RX60 25 RX60 25 600 RX60 25L 600 Type number 6301 6302 6304 Net weight including battery kg 4599 4821 5019 Front axle load laden kg 6317 6421 6478 Rear axle load laden kg 782 900 1041 Front axle load unladen kg 2370 2315 2508 Rear axle load unladen kg 2229 2506 2511 Wheels chassis frame Model RX60 25 RX60 25 600 RX60 2...

Page 490: ... 2135 2225 2135 2225 2135 Seat height in relation to SIP h7 mm 1235 1235 1235 Coupling height h10 mm 484 484 484 Overall length l1 mm 3413 3618 3770 Length including fork back l2 mm 2413 2418 2570 Overall width b1 mm 1200 1200 1200 Fork arm thickness s mm 40 45 45 Fork arm width e mm 100 100 100 Fork arm length l mm 1000 1200 1200 Fork carriage Standard class form ISO 2328 II A ISO 2328 II A ISO 2...

Page 491: ...oad m s 0 66 0 60 0 66 0 60 0 66 0 60 Lowering speed with load m s 0 50 0 50 0 50 Lowering speed without load m s 0 45 0 45 0 45 Pulling force Plus performance2 Standard performance 3 with load N 10800 8140 10760 8016 10720 7985 Pulling force Plus performance2 Standard performance 3 without load N 10760 8100 10670 8110 10690 8110 Max pulling force Plus perform ance2 Standard performance 3 with loa...

Page 492: ...5 5 5 0 5 6 Service brake Hydraulically actuated mul ti disc brake Hydraulically actuated mul ti disc brake Hydraulically actuated multi disc brake Gradients The values specified in the Performance da ta table as the maximum climbing capability can be used only to compare the performance of forklift trucks in the same category The specified values in no way represent the nor mal daily operating co...

Page 493: ...nce kWh h 6 0 6 0 6 2 6 2 6 3 6 3 Other Model RX60 25 RX60 25 60 0 RX60 25L 600 Type number 6301 6302 6304 Handling performance Plus per formance1 Standard performance t h 176 169 176 169 176 169 Energy consumption for handling performance Plus performance1 Standard performance kWh h 7 1 6 6 7 2 6 8 7 4 6 9 Working pressure for attachments bar 250 250 250 Oil flow for attachments l min 55 55 55 So...

Page 494: ...00 Load centre of gravity c mm 500 500 600 Load distance x mm 468 468 468 Wheelbase y mm 1652 1797 1797 Weights Model RX60 30 RX60 35 RX60 30L 60 0 Type number 6305 6307 6308 Net weight including battery kg 5040 5063 5308 Front axle load laden kg 7163 7257 7419 Rear axle load laden kg 877 806 889 Front axle load unladen kg 2411 2646 2641 Rear axle load unladen kg 2629 2417 2667 Wheels chassis fram...

Page 495: ...m 160 160 160 Lift2 h3 mm 3066 3066 3066 Height above overhead guard low variant h6 mm 2225 2135 2225 2135 2225 2135 Seat height in relation to SIP h7 mm 1235 1235 1235 Coupling height h10 mm 484 484 484 Overall length l1 mm 3433 3578 3778 Length including fork back l2 mm 2433 2578 2578 Overall width b1 mm 1200 1200 1300 Fork arm thickness s mm 50 50 50 Fork arm width e mm 100 100 100 Fork arm len...

Page 496: ...8 18 21 Lifting speed Plus performance2 Standard performance with load m s 0 57 0 49 0 57 0 49 0 57 0 49 Lifting speed Plus performance2 Standard performance without load m s 0 57 0 51 0 57 0 51 0 57 0 51 Lowering speed with load m s 0 50 0 50 0 50 Lowering speed without load m s 0 43 0 43 0 43 Pulling force Plus performance2 Standard performance 3 with load N 10430 7740 10490 7737 10400 7695 Pull...

Page 497: ... 6 6 5 7 6 3 Acceleration time over 15 m Plus performance1 Standard perform ance without load s 5 0 5 6 5 0 5 6 5 0 5 4 Service brake Hydraulically actuated mul ti disc brake Hydraulically actuated multi disc brake Hydraulically actuated multi disc brake Gradients The values specified in the Performance da ta table as the maximum climbing capability can be used only to compare the performance of f...

Page 498: ...nce kWh h 6 6 6 5 6 6 6 6 6 7 6 7 Other Model RX60 30 RX60 35 RX60 30L 60 0 Type number 6305 6307 6308 Handling performance Plus per formance1 Standard performance t h 228 222 228 222 228 222 Energy consumption for handling performance Plus performance1 Standard performance kWh h 7 8 7 3 7 8 7 3 8 0 7 5 Working pressure for attachments bar 250 250 250 Oil flow for attachments l min 55 55 55 Sound ...

Page 499: ... centre of gravity c mm 500 Load distance x mm 468 Wheelbase y mm 1797 Weights Model RX60 35L Type number 6309 Net weight including battery kg 5500 Front axle load laden kg 8042 Rear axle load laden kg 958 Front axle load unladen kg 2662 Rear axle load unladen kg 2838 Wheels chassis frame Model RX60 35L Type number 6309 Tyres SE Tyre size front 315 45 12 Tyre size rear 180 70 8 18x7 8 Number of fr...

Page 500: ...Overall width b1 mm 1300 Fork arm thickness s mm 50 Fork arm width e mm 100 Fork arm length l mm 1000 Fork carriage Standard class form ISO 2328 III A Fork carriage width b3 mm 1150 Ground clearance with load below lift mast m1 mm 115 Ground clearance at the middle of the wheelbase m2 mm 126 Aisle width for pallet 1000 x 1200 crosswise3 Ast mm 3941 Aisle width for pallet 800 x 1200 lengthwise3 Ast...

Page 501: ...s performance1 Standard per formance 2 with load 17 8 12 9 Climbing capability Plus performance1 Standard per formance 2 without load 28 2 21 9 Max climbing capability Plus performance1 Stand ard performance 2 with load 24 2 20 6 Max climbing capability Plus performance1 Stand ard performance 2 without load 28 2 28 2 Acceleration time over 15 m Plus performance1 Standard performance with load s 5 ...

Page 502: ...Ah 700 775 Battery weight kg 1863 Energy consumption in accordance with EN 16796 Plus performance1 Standard performance kWh h 7 1 7 1 Other Model RX60 35L Type number 6309 Handling performance Plus performance1 Standard performance t h 258 245 Energy consumption for handling performance Plus performance1 Standard performance kWh h 8 6 8 0 Working pressure for attachments bar 250 Oil flow for attac...

Page 503: ...s in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given in Article 2 Scope Item 1 b Technical data 6 Eco design requirements for electric mo...

Page 504: ...late The location of ballast weights must not be changed The bottom of the battery tray must be closed Do not 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 bot tom NOTE The batteries for this truck are designed for the special area of application If a battery is to be exchanged or replaced use ...

Page 505: ...0 5TCSM 840 840 NOTE To convert to TENSOR batteries contact the authorised service centre Battery requirements for use in poten tially explosive areas Batteries for use in potentially explosive areas are designed and specifically tested in respect of the zones and temperature ranges in which they are to be used The permitted area of use is permanently and clearly indicated on the nameplate of the ...

Page 506: ...quired explosion protection regula tions The information on the auxiliary hydraulics dif fers depending on the truck Take this into consideration when selecting the attachment Multi lever operation Proportional valve technology Maximum system pressure Pmax 280 bar 280 bar Maximum volume flow rate Qmax 50 l min 45 l min Trigger of the switch valve 12 V 2 A 12 V 2 A Technical data 6 Information on t...

Page 507: ...n and the 5th function 302 Controlling with multi lever operation and the 6th function 302 Controlling with the fingertip 315 Controlling with the fingertip and the 5th function 317 General controlling 293 Information on the auxiliary hydraulics 492 Load capacity 291 Mounting 291 Picking up a load 322 Safety information 290 Special risks 52 Automatic emergency shutdown 368 Automatic mast vertical ...

Page 508: ...e truck 95 Climbing out of the truck 95 Clipboard 339 Cold store application 351 Batteries 353 Operation 351 Types of application 351 Commissioning 21 Competent person 39 Condition of the roadways 170 Consumables 62 Disposal 65 Safety information for handling battery acid 64 Safety information for handling oils 62 Safety information for hydraulic fluid 63 Contact details I Copyright and trademark ...

Page 509: ...ctric parking brake Symbols in the display operating unit 183 Electrostatic charge Safety information 97 Emergencies Actuating the reset button 368 Emergency actuation of the parking brake 374 Truck tipping over 370 Using the emergency hammer 370 Emergency drive direction 371 Emergency driving 371 Emergency hammer 370 Emergency lowering 372 Emergency shutdown 367 Automatic 368 Emissions 66 Battery...

Page 510: ...ressurise 272 Special feature for clamping attach ments 287 Wizard for depressurising 273 I Improper use 23 Information about the documentation 29 Information for carrying out maintenance 435 436 Maintenance timeframe 437 Next maintenance interval 437 Information on the auxiliary hydraulics 492 Insulation testing 60 Drive battery test values 61 Test values for the truck 61 Insurance cover on compa...

Page 511: ...m 449 Maintenance personnel for batteries 435 Maintenance work without special qualifi cations 435 Malfunctions during lifting mode 229 Malfunctions in the parking brake 186 Manual tow coupling Coupling 344 Uncoupling 345 Mast tilt angle display 252 Medical equipment 47 Messages About operation 358 About the truck 365 Introduction 358 Misuse of safety systems 45 Multi lever Lifting lowering the fo...

Page 512: ...tion of use by unauthorised persons 41 Proper use 22 Push up roof window 339 Q Quadruple mini lever Lifting lowering the fork carriage 214 Tilting the lift mast 215 R Radio 335 Rear window heating Switching on and off 326 Reducing speed when turning 192 Regular inspections 58 Replacing the battery General information 399 High Performance variant 401 Using a change frame 409 Using a truck 405 Reset...

Page 513: ...s 74 Shock recognition 323 Shutting down and restarting Safety information 425 Signal terms 31 Spare parts 444 Spare parts list II Special risks 52 Speed limitation Configuring 194 Switching on and off 194 Speed reduction when the cab door is open 193 Sprint mode Automatic switch off 165 Switching on and off 165 Stability 51 Starting drive mode 177 Dual pedal version 179 Steering 191 Steering axle...

Page 514: ...323 Fork extension 225 Fork wear protection 221 Heating system 336 Interior lighting 335 Lifting systems 205 Load measurement 262 NiHo lift mast 206 Overload detection 258 Pre Shift Check 129 Precision load measurement 265 Push up roof window 339 Radio 335 Reversible fork arms 227 Shake function 243 Shock recognition 323 Speed limitation 194 Speed reduction when the fork carriage is raised 193 Sun...

Page 515: ...eather conditions 460 Windscreen wipers and washers Switching on and off 323 Winter tyres 460 Working at the front of the truck 432 Working on the electrical equipment 431 Working on the hydraulic equipment 431 Working spotlight for reverse travel Switching on and off 155 Working spotlights Switching on and off 154 Y Your truck 2 Index 501 56378011526 EN 03 2021 01 ...

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Page 518: ...STILL GmbH 56378011526 EN 03 2021 01 ...

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