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Still RX60 35-50, Original Instructions Manual

The "Still RX60 35-50" Original Instructions Manual, essential for operating and maintaining your equipment, is available for free download. Visit manualshive.com to access this comprehensive manual and ensure optimal functionality and performance of your Still RX60 35-50, featuring detailed instructions and guidelines.

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P

Packaging. . . . . . . . . . . . . . . . . . . . . . . . .  28
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . .  199
Parking brake

Actuation. . . . . . . . . . . . . . . . . . . . . . .  181
Actuation when the truck is in motion.  183
Actuation when the truck is stationary.  182
Emergency actuation mechanism. . .  409
Malfunctions. . . . . . . . . . . . . . . . . . . .  185
Parking the vehicle safely. . . . . . . . . .  186

Parking the truck securely. . . . . . . . . . . .  199
Permissible lithium-ion batteries. . . . . . . .  34
Personnel qualifications. . . . . . . . . . . . . .  507
Picking up loads. . . . . . . . . . . . . . . . . . . .  231
Place of use. . . . . . . . . . . . . . . . . . . . . . . .  18
Pre-Shift Check

All questions. . . . . . . . . . . . . . . . . . . .  128
Description. . . . . . . . . . . . . . . . . . . . .  126
History. . . . . . . . . . . . . . . . . . . . . . . .  131
Process. . . . . . . . . . . . . . . . . . . . . . . .  127
Question sequence. . . . . . . . . . . . . . .  129
Shift start. . . . . . . . . . . . . . . . . . . . . .  133
Truck restrictions. . . . . . . . . . . . . . . .  137

Precision load measurement. . . . . . . . . .  286
Procedure if truck tips over. . . . . . . . . . .  405
Procedure in emergencies. . . . . . . . . . . .  404
Procedure in the event of a fire when using

lithium-ion batteries. . . . . . . . . . . . . . . . .  34

Product-specific dangers of lithium-ion bat-

teries. . . . . . . . . . . . . . . . . . . . . . . . . . . .  36

Prohibition of use by unauthorised persons. 32

Q

Quadruple mini-lever

Lifting/lowering the fork carriage. . . . .  211
Tilting the lift mast. . . . . . . . . . . . . . . .  212

R

Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . .  376
Rear window heating

Switching on and off. . . . . . . . . . . . . .  349

Reducing speed when turning. . . . . . . . .  190
Regular inspections. . . . . . . . . . . . . . . . . .  52
Regulations for storing lithium-ion batter-

ies. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  458

Replacing the battery

General information. . . . . . . . . . . . . .  466
High Performance variant. . . . . . . . . .  466
Lithium-ion battery. . . . . . . . . . . . . . .  471
Using a change frame. . . . . . . . . . . .  476
Using an electric battery carrier. . . . .  482
Using a truck. . . . . . . . . . . . . . . . . . . .  471

Residual dangers. . . . . . . . . . . . . . . . . . . .  45
Residual risk. . . . . . . . . . . . . . . . . . . . . . .  45
Residual risks. . . . . . . . . . . . . . . . . . . . . .  45
Retrofitting. . . . . . . . . . . . . . . . . . . . . . . . .  37
Retrofitting lighting equipment. . . . . . . . .  149
Reversible fork arms. . . . . . . . . . . . . . . .  223

Checking. . . . . . . . . . . . . . . . . . . . . . .  538

Roadways. . . . . . . . . . . . . . . . . . . .  166, 168

Aisle widths. . . . . . . . . . . . . . . . . . . . .  166
Descending gradients. . . . . . . . . . . . .  167
Gradients. . . . . . . . . . . . . . . . . . . . . .  167

Rotating beacon

Switching on and off. . . . . . . . . . . . . .  156

Rules for roadways and the working area.  168

S

Safety devices. . . . . . . . . . . . . . . . . . . . .  505
Safety inspection. . . . . . . . . . . . . . . . . . . .  52
Safety regulations for handling consuma-

bles. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  54

Safety regulations for handling lithium-ion

batteries. . . . . . . . . . . . . . . . . . . . . . . .  454

Battery weight and dimensions. . . . . .  456
Fire protection measures. . . . . . . . . .  455
Maintenance personnel. . . . . . . . . . .  454

Safety regulations for handling the bat-

tery. . . . . . . . . . . . . . . . . . . . . . . . . . . .  439

Battery weight and dimensions. . . . . .  441
Damage to cables and battery male

connectors. . . . . . . . . . . . . . . . . . . .  442

Fire protection measures. . . . . . . . . .  440
Maintenance personnel. . . . . . . . . . .  439
Performing battery maintenance. . . .  442

Safety regulations for maintenance

General information. . . . . . . . . . . . . .  504
Safety devices. . . . . . . . . . . . . . . . . .  505
Set values. . . . . . . . . . . . . . . . . . . . . .  505
Working on the electrical equipment.  504
Working on the hydraulic equipment.  504

Index

 

 575

56388011501 EN - 05/2022  -  08

Summary of Contents for RX60 35-50

Page 1: ...Electric truck RX60 35 50 RX60 35 50 Li Ion Original instructions 6331 6332 6333 6334 6335 6336 6337 56388011501 EN 05 2022 08 ...

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 56388011501 EN 05 2022 08 ...

Page 5: ...lace of use 18 Parking in temperatures below 10 C 20 Using working platforms 20 Information about the documentation 21 Scope of the documentation 21 Supplementary documentation 22 Issue date and topicality of the operating instructions 23 Copyright and trademark rights 23 Explanation of information symbols used 23 List of abbreviations 24 Definition of directions 26 Schematic views 26 Environmenta...

Page 6: ...5 Special risks associated with using the truck and attachments 46 Overview of hazards and countermeasures 48 Danger to employees 50 Safety tests 52 Carrying out regular inspections on the truck 52 Insulation testing 52 Safety regulations for handling consumables 54 Permissible consumables 54 Oils 54 Hydraulic fluid 55 Battery acid 56 Disposal of consumables 57 Emissions 58 3 Overviews Overview 62...

Page 7: ...ke system for correct function 94 Warming up the hydraulic oil at cold ambient temperatures 96 Checking the steering system for correct function 97 Function checking of the automatic mast vertical positioning function variant 98 Driver s seat 99 Adjusting the MSG 65 and MSG 75 driver s seat 99 Adjusting the MGS 95 driver s seat 105 Seat belt 111 Adjusting the armrest 114 Switching on 116 Switching...

Page 8: ...hing Blue Q on and off 161 Configuring Blue Q 162 STILL Classic and sprint mode 162 Driving 164 Safety regulations when driving 164 Roadways 166 Selecting drive programmes 1 to 3 169 Selecting drive programme A or B 169 Configuring drive programmes A and B 170 Selecting the drive direction 172 Actuating the drive direction switch with the multiple lever version 173 Actuating the drive direction sw...

Page 9: ...m using a quadruple mini lever 211 Controlling the lifting system using the Fingertip 211 Controlling the lifting system using the Joystick 4Plus 214 Dynamics of the hydraulic movements 216 Selecting load programs 1 to 3 217 Fork wear protection variant 218 Changing the fork arms 219 Fork extension variant 221 Operation with reversible fork arms variant 223 Malfunctions during lifting mode 224 Hyd...

Page 10: ...2 variant 277 Load measurement variant 283 Calibrating the load measurement 284 Precision load measurement variant 286 Tare function variant 288 Total load variant 290 Zeroing the assistance systems 293 Zeroing process 293 Depressurising the hydraulic system 296 Need to depressurise the hydraulic system 296 Wizard for depressurising the hydraulic system 297 Depressurising the hydraulic system usin...

Page 11: ... lever 331 Controlling attachments using the triple mini lever and the 5th function 333 Controlling attachments using a quadruple mini lever 335 Controlling attachments using the quadruple mini lever and the 5th function 337 Controlling attachments using the Fingertip 338 Controlling attachments using the Fingertip and the 5th function 340 Controlling attachments using the Joystick 4Plus 342 Contr...

Page 12: ...ection selection lever 406 Emergency lowering 407 Emergency actuation of the electric parking brake 409 Towing 411 Charging quick access 414 Charging quick access in the counterweight variant 414 On board charger 419 General information about the on board charger variant 419 Changing the battery type used 420 Configuring the on board charger 421 Charging the battery 425 Compatible batteries 435 Pe...

Page 13: ...atteries 468 Opening and closing the battery door 468 Special notes for installing the lithium ion battery 471 Replacing the battery using a truck 471 Replacing the battery using a change frame variant 476 Replacing the battery using an electric battery carrier variant 482 Transporting the lead acid battery by crane 487 Transporting the lithium ion battery by crane 488 Cleaning the truck 490 Clean...

Page 14: ...t belt 523 Checking the driver s seat 525 Servicing the heating system or air conditioning 525 Servicing wheels and tyres 528 Servicing the steering axle 530 Checking the battery 531 Adjusting the warning zone light 531 Replacing the fuses 532 Checking the hydraulic system for leak tightness 532 Check the hydraulic oil level 534 Lubricating the lift mast and roller track 536 Preserving operational...

Page 15: ...DI data sheet RX60 50 Plus Li Ion and RX60 50 Plus 600 Li Ion 560 Eco design requirements for electric motors and variable speed drives 564 Information about the lead acid battery 565 Battery specifications for X Line lithium ion batteries 566 Information on the auxiliary hydraulics 566 Table of contents XIII 56388011501 EN 05 2022 08 ...

Page 16: ......

Page 17: ...1 Foreword ...

Page 18: ...ndition 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 remaining available time until the battery has to be recharged and displays this time It also supports all FleetManager 4 x functions Assistance systems The STILL RX60 35 50 can be equipped with assistance syst...

Page 19: ...n energy of the truck into elec trical energy This causes the truck to decel erate as soon as the accelerator pedal is re leased If the foot is completely removed from the accelerator pedal the truck brakes until it comes to a standstill A parking brake ensures that the truck remains securely in place when parked Hydraulic system The steering system the lift cylinders and the tilt cylinders in the...

Page 20: ... High Performance variant provides a higher level of performance Steering The kickback free hydraulic rear wheel steer ing with Curve Speed Control CSC ensures driving stability when cornering allowing the truck to achieve a small turning circle and ne gotiate narrow aisle widths Operating The multi lever the Fingertip mini lever and the Joystick 4Plus are available as operating devices for the hy...

Page 21: ...ula tions for the country in which it is being used The driving permit must be obtained from the appropriate office The truck has been fitted with state of the art technology Following these operating instruc tions will allow the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained ...

Page 22: ...an Union EU UKCA in the United Kingdom UK EAC in the Eurasian Economic Union The conformity marking is applied to the nameplate A declaration of conformity is is sued for the EU and UK markets An unauthorised structural change or addition to the industrial truck can compromise safety thus invalidating the declaration of conformity conformity symbols Foreword 1 Your truck 6 56388011501 EN 05 2022 0...

Page 23: ... 1 For the markets of the European Union the EU candidate countries the EFTA States and Switzerland 2 For the United Kingdom market The declaration of conformity document is supplied with the industrial truck The declara tion shown explains the conformity with the provisions of the EC Machinery Directive and the Supply of Machinery Safety Regulation 2008 2008 No 1597 An unauthorised structural cha...

Page 24: ... variant Two keys for the storage box containing the charging cable for the on board charger variant A hexagon socket wrench for emergency lowering in the compartment A battery change frame A battery change frame not for trucks with the electric battery carrier variant Foreword 1 Your truck 8 56388011501 EN 05 2022 08 ...

Page 25: ...Foreword 1 Your truck 9 56388011501 EN 05 2022 08 ...

Page 26: ...Labelling points 6301_003 018_V3 Foreword 1 Your truck 10 56388011501 EN 05 2022 08 ...

Page 27: ...the oper ating instructions Warning sign Risk of short circuit due to shearing 1 2 3 Warning sign Cleaning electrical system parts with water is forbidden Warning sign Danger due to shearing Decal information Lifting gear fixing point Decal information Tyre filling pressure Warning sign Dangerous electrical voltage Decal information Load measurement Warning sign Cable cross section Decal informati...

Page 28: ...geprüft gemäß DIN VDE 0701 0702 VDE Prüfung 0009386994 Foreword 1 Your truck 12 56388011501 EN 05 2022 08 ...

Page 29: ...ecal information StVZO German Road Traffic Licensing Regulations information Nameplate with CE labelling Decal information Battery service Decal information Regular testing Decal information VDE test Warning sign Ventilator 21 22 23 24 25 26 27 28 29 30 Nameplate Variant 1 Industrial trucks built up to 12 2021 1 Model 2 Serial number 3 Year of manufacture 4 Tare weight in kilograms 5 Maximum permi...

Page 30: ...power 10 Battery voltage only for electric trucks 11 Rated capacity NOTE It is possible for there to be multiple con formity markings on the nameplate The EAC mark may also be located in the immediate vicinity of the nameplate Serial number The serial number is used to identify the truck The serial number is shown on the nameplate Quote the serial number for all technical ques tions The serial num...

Page 31: ...matrix code for the authorised serv ice centre 6 CE labelling 7 Safety information 8 Data technical data 9 Address of manufacturer STILL Gmbh Berzeliusstraße 10 22113 Hamburg Rechargeable Lithium Ion Battery Produced by BMZ GmbH IEC 13IMP46 174 133 14 Nominal voltage Capacity Energy Capacity equivalent Weight P N B P N SN Custumer order no Still order no Date Made in Germany Safety Advices for Lit...

Page 32: ...Technology 3 Transportation notes 4 General operating notes 5 CE labelling 6 Data matrix code for the authorised serv ice centre 7 UKCA labelling 8 Safety information 9 Data technical data 10 Address of manufacturer Foreword 1 Your truck 16 56388011501 EN 05 2022 08 ...

Page 33: ...perat ing instructions If the truck is to be used for purposes other than those specified in the operating instruc tions the approval of the manufacturer and if applicable the relevant regulatory authorities must be obtained beforehand in order to pre vent hazards The maximum load to be lifted is specified on the capacity rating plate load diagram and must not be exceeded see the section entitled ...

Page 34: ...re is a risk of explosion in areas that cause corrosion or in areas that are particularly dus ty Stacking or unstacking on inclined surfaces or ramps is not permitted Place of use The truck can be used both outside and in buildings Operation on public roads is only permitted if the StVZO German Road Traffic Licensing Regulations equipment variant is installed If the truck is to be operated on publ...

Page 35: ...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 temperatures of below 10 C only park the truck for short periods of time The operating company must ensure suitable fire protection for the relevant application in the truck s surrou...

Page 36: ...e operating temperature is reached The truck is then not ready for operation At ambient temperatures of below 10 C only park the truck for short periods of time Pay attention to the equipped battery and the cor responding operating instructions Using working platforms WARNING The use of working platforms is regulated by national law The use of working platforms is only permitted by virtue of the j...

Page 37: ...rial number and year of manufacture from the nameplate in the space provided Serial number Year of manufacture Please quote the serial number in all technical enquiries Each truck comes with a set of operating in structions These instructions must be stored carefully and must be available to the driver and operating company at all times The stor age location is specified in the section entitled Ov...

Page 38: ...l attachment A special towing device Customised attachments When fitted with a CO the industrial truck is provided with additional documentation This may take 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 ti...

Page 39: ...rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts except with the express written approval of the manufacturer Explanation of information sym bols used DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities WARNING Indicates procedures that must be strictly adhered to in order to p...

Page 40: ...Berufsgenossenschaftliche Vorschrift German accident prevention regulations CE Communauté Européenne Confirms conformity with product specific European directives CE labelling CEE Commission on the Rules for the Approval of the Electrical Equipment International commission on the rules for the approval of electrical equipment DC Direct Current Direct current DFÜ Datenfernübertragung Remote data tr...

Page 41: ...n number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without loose rim parts StVZO Straßenverkehrs Zulassungs Ordnung German regulations for approval of vehi cles on public roads TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli cable in the Federal Republic of Germany UKCA Unite...

Page 42: ...ints 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 views are used solely for the purpose of clarifying procedures 6210_001 031 4 2 3 1 Foreword 1 ...

Page 43: ...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 27 56388011501 EN 05 2022 08 ...

Page 44: ...osal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man ...

Page 45: ...2 Safety ...

Page 46: ...ication that demonstrably proves their professional ex pertise This proof should consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven period during their career During this time this person has become familiar with a wide range of symptoms that require checks to ...

Page 47: ... be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety hel met industrial goggles and gloves that is ap propriate for the conditions the job and the load to be lifted Solid footwear should be worn to ensure safe driving and braking The driver must be familiar with the operating instruction...

Page 48: ...e for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety 2 Definition of responsible persons 32 56388011501 EN 05 2022 08 ...

Page 49: ...apply for the operating company and drivers when this truck is equipped with a lithium ion battery variant in place of a conventional lead acid battery DANGER Risk of explosion Heating to over 80 C mechanical stress and incorrect use may lead to the battery exploding Never heat the battery to over 80 C or ex pose it to naked flames Do not subject the battery to excessive me chanical loads Do not c...

Page 50: ...risks posed to the company by lithium ion batteries Observe the national regulations for the country in which the truck is being used Driver qualification In addition to the prerequisites set out in the chapter entitled Definition of responsible per sons in the section entitled Driver please observe the following The driver must be instructed in how to op erate the lithium ion battery This truck m...

Page 51: ...provided by the battery manufacturer regarding the proce dure in the event of a fire Water can be used to cool down an incipient fire Transport In certain circumstances transporting the lith ium ion battery outside the premises may re quire a special transport container Contact the authorised service centre for more information Safety 2 Basic principles for safe operation 35 56388011501 EN 05 2022...

Page 52: ...that can heat up to over 100 C during operation It can take several hours for the brake resistor to cool down to a temperature at which it poses no risk Do not touch the hot area 1 WARNING Risk of injury If the safety valve 2 trips there is a risk of injury Exit the area around the battery immediately re treating to a minimum distance of 5 m Safety 2 Basic principles for safe operation 36 56388011...

Page 53: ...hanical thermal electrical that leads to activation of the safety valve 2 or to the housing cracking As a result the electrolyte fluid may leak out the electrode material may react with moisture water or battery discharge a fire or an explosion can occur depending on the surrounding circum stances Touching live components can cause an elec tric shock which can have thermal or paralys ing effects T...

Page 54: ...he manufacturer Contact the authorised service centre be fore converting or retrofitting the truck Only the authorised service centre is permitted to perform welding work on the truck DANGER Risk of explosion from additional bores in the battery hood Explosive gases can escape and can lead to potentially fatal injuries if they explode Sealing bores with plugs is not sufficient to prevent gas from ...

Page 55: ...esign documents test documents and assembly instructions associated with the modification must be permanently archived and remain accessible at all times The capacity rating plate the decal informa tion the hazard warnings and the operating instructions must be checked to ensure that they are consistent with the modifications and must be amended if required Modifications must be designed checked a...

Page 56: ...d if the structural design has been tested and the manufacturer has given approval Seek advice from the authorised service centre for the mounting of roof loads Warning regarding non original parts Original parts attachments and accessories are specially designed for this truck We spe cifically draw your attention to the fact that parts attachments and accessories supplied by other companies have ...

Page 57: ...manufacturer s written appro val All electrical system interventions must be documented Even if they are removable roof panels may not be removed as they are designed to pro tect against small falling objects Tyres DANGER Risk to stability Failure to observe the following information and in structions can lead to a loss of stability The truck may tip over risk of accident The following factors can...

Page 58: ... g always replace right hand and left hand wheels at the same time Changes must only be made following consultation with the manufacturer If the type of tyre used on an axle is changed for example from superelastic tyres to pneumatic tyres the load diagram must be changed accordingly Contact the authorised service centre on this matter Medical equipment WARNING Electromagnetic interference may occ...

Page 59: ...ust be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper in stallation of an accumulator results in an elevated risk of injury Before starting work on the accumulator it must be depressurised Contact the authorised service centre Length of the fork arms DANGER Risk of accident due to the incorrect selection of fork arms The fork arms mu...

Page 60: ... For help with selecting the correct fork arms contact the authorised service centre Safety 2 Basic principles for safe operation 44 56388011501 EN 05 2022 08 ...

Page 61: ...structed regarding these risks that arise through use of the truck In addition we draw attention to the safety regula tions in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Falling tripping etc whe...

Page 62: ...inst slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as cen trally as possible with the truck and trans port in this position Avoid turning and diagonally driving across slopes or gradients Never have the load facing downhill when travelling on slopes or gradients Pick ...

Page 63: ...use the truck correctly and without the risk of accidents Safety 2 Residual risk 47 56388011501 EN 05 2022 08 ...

Page 64: ...ised 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 to...

Page 65: ... the operating in structions 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 Sa...

Page 66: ...e on Industrial Safety and Health BetrSichV No person detection when placing goods 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 In dustrial Safety and Health BetrSichV and labour protection law ArbSchG the operat ing company must determine and assess haz ards during ...

Page 67: ...ment must be documented 6 ArbSchG In the case of truck applications involving similar hazard situations the results may be summarised Refer to the chapter entitled Overview of haz ards and countermeasures which provides advice on complying with this regulation The overview specifies the primary hazards that in the event of non compliance are the most frequent causes of accidents If other major haz...

Page 68: ...e authorised service centre to perform regular testing on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operating company is responsible for en suring that any defects are remedied without delay Notify your authorised service centre NOTE In addition observe the national regulations for the country of use Insulation testing The insulation of th...

Page 69: ...tage Measurements Nominal volt age UBatt Test values 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 Sa...

Page 70: ...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 71: ...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 72: ...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 73: ...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 that pur pose Care must be taken to minimi...

Page 74: ...e 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 noise pollution If necessary these noi...

Page 75: ...mplitude of the hand and arm vibrations on the steering wheel or on the operating devices in the truck is less than 2 5 m s2 There are therefore no meas urement guidelines for these measurements 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 additi...

Page 76: ...warning zone light variant are assigned to risk group 2 medium risk due to their photobiological hazard potential The Laser Smartfork assistance system var iant is assigned to laser class 1M DANGER Risk of injury Looking into the laser beam can damage the eyes laser radiation laser class 1M If there is a possibility that people are at risk switch off the laser immediately Never look directly into ...

Page 77: ...3 Overviews ...

Page 78: ...Overview 6301_003 020 Overviews 3 Overview 62 56388011501 EN 05 2022 08 ...

Page 79: ...nt Drive axle 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 63 56388011501 EN 05 2022 08 ...

Page 80: ...Driver s compartment 15 Overviews 3 Driver s compartment 64 56388011501 EN 05 2022 08 ...

Page 81: ...caused by blocked pedals Objects may fall into the footwell during travel as a result of steering or braking They can slip between and under the pedals 2 They then block the ped als It may then not be possible to brake the truck when necessary Only store objects that fit on the shelves 1 3 Bottles with a maximum size of 1 5 litres may be stored in the cup holder 3 Make sure that objects cannot fal...

Page 82: ...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 sensor 9 10 11 12 13 14 15 16 17 18 19 20 21 STILL Easy Control is a third generation di...

Page 83: ...y operating unit is attached to the armrest except in trucks equipped with mul ti lever operation If the truck is equipped with multi lever operation the display operat ing 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 swivelling display operating unit in the chapter entitled Checks and tasks be fore d...

Page 84: ...ve the chapter entitled Display ele ments in the STILL Lithium ion batteries operating instructions Emergency off switch The emergency off switch 1 is situated on the right hand side of the steering column It disconnects the drives from the power supply Do not use this switch to park the truck safely 1 2 3 Service LED red Temperature LED yellow red Charging state LEDs red green 1 2 3 Overviews 3 O...

Page 85: ... 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 69 56388011...

Page 86: ...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 70 56388011501 EN 05 2022 08 ...

Page 87: ...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 71 56388011501 EN 05 2022 08 ...

Page 88: ...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 72 56388011501 EN 05 2022 08 ...

Page 89: ...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 73 56388011501 EN 05 2022 08 ...

Page 90: ...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 74 56388011501 EN 05 2022 08 ...

Page 91: ...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 75 56388011501 EN 05 2022 08 ...

Page 92: ...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 93: ... 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 ver tical 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 94: ...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 95: ...4 Operating ...

Page 96: ...checking are listed in the following table If damage or other defects are identified on the truck or the attachment variant during the following inspections the truck must not be used until it has been properly repaired Dam age or other defects must be reported to the supervisor or the responsible fleet manager immediately so that repairs by the authorised service centre can be arranged Ensure tha...

Page 97: ...rve the safety regulations in the section enti tled Tyres Axle Make sure that no consumables are escaping from the axle Service brake Check the filling level in the brake fluid reservoir Overhead guard guard grille variant Visually inspect for sound condition Check for secure mounting Steps Make sure they are clean free of ice not slippery Panes of glass variant Visually inspect for sound conditio...

Page 98: ...egrity 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 syste...

Page 99: ...ll cover is very dirty or smeared with oil there is a risk of slipping There is also a risk of hitting your head on the post of the overhead guard or of your clothes becoming stuck when climbing out of the truck Ensure that the footwell cover is not slippery Do not jump into or out of the truck Ensure that you have a secure grip on the truck WARNING Risk of injury when jumping out of the truck If ...

Page 100: ...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 1 Climb into the truck with your right foot and sit down on the driver s seat 5 Next place your left foot into the foot well 2 Always climb out of the truck backwards Grip the handle 4 with y...

Page 101: ...tc be comes stuck on a component while you are jumping into or out of the truck this can lead to serious inju ries from falling loss of fingers etc It is forbidden to jump out of the truck Do not jump out of the truck Do not wear jewellery at work Do not wear loose fitting workwear CAUTION Components may become damaged through incor rect use Truck components such as the driver s seat steer ing whe...

Page 102: ...here relevant Always climb out of the truck backwards If the truck has a driver s cab open the driv er s door Grip the handle 2 with your left hand and do not let go Stand up from the driver s seat and place your left foot on the top step 6 Grip the handle 4 with your right hand and do not let go Place your right foot on the bottom step 5 Place your left foot on the ground and climb down from the ...

Page 103: ...ar 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 To change the resistance for adjusting the dis play operating unit there are two socket head screws 2 on the support for the display op erating unit The hexagon socket wrench for emergency lowering can be used to loosen or tighten the socket head s...

Page 104: ... listed in the display operating unit To display the assistance systems perform the following steps Apply the parking brake Press the button Press the Softkey Press the Truck information softkey Press the Assistance systems soft key Check the function of the assistance sys tems stated in the list before daily use See the respective sections NOTE The fleet manager can configure some assis tance sys...

Page 105: ...Unlock the emergency off switch Turn the emergency off switch 1 clockwise until it pops out Operating 4 Checks and tasks before daily use 89 56388011501 EN 05 2022 08 ...

Page 106: ...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 90 56388011501 EN 05 2022 08 ...

Page 107: ...off switch 1 The truck will coast to a stop The message Emergency off ac tive 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 performs internal self testing It is then re...

Page 108: ...s variant 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 cov er ...

Page 109: ... 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 93 56388011501 EN 05 2022 08 ...

Page 110: ...e speed Depending on the charge state of the battery re generative 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 op posite drive direction is selected the truck is braked using the electric brake To actuate this release the accelerator pedal 2 The truck must ...

Page 111: ...ite 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 par...

Page 112: ... brake unlock the emergency off switch If the truck only coasts and does not decel erate or decelerates only slightly stop the truck using the service brake Secure the truck with chocks so that the truck does not roll away Have the parking brake checked and re paired by the authorised service centre Warming up the hydraulic oil at cold ambient temperatures If the truck has been exposed to low ambi...

Page 113: ...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 114: ...e function of the automatic mast vertical positioning function proceed as fol lows Press the 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 ...

Page 115: ...so that all operating devices can be actuated safely Ensure that the seat and the seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the driver s head and the lower edge of the roofing sheet must be at least 40 mm NOTE Observe any separate operating instructions ...

Page 116: ... 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 100 563880...

Page 117: ... ini tial central position each time before raising it again a click can be heard when this position 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 the centre position in the inspection window Once the minimum or maximum weight setting is reached the seat will not move any further even when you...

Page 118: ...orizontal sus pension move the locking lever 5 to the right B NOTE If the longitudinal horizontal suspension is blocked the suspension comfort is significant ly lower Impacts are much more noticeable Adjusting the lumbar support variant NOTE The lumbar support can be adjusted to suit the contours of the individual driver s spine Adjusting the lumbar support moves a convex support cushion into the ...

Page 119: ...he backrest extension move it past the end stop by firmly pushing it upwards Switching the seat heater variant on and off NOTE The seat heater only works when the driver is sitting on the driver s seat Switch the seat heater 8 on or off using the switch 6321_003 040_V3 7 6321_003 041_V3 8 Operating 4 Driver s seat 103 56388011501 EN 05 2022 08 ...

Page 120: ...iver s seat To swivel the driver s seat pull the lever 9 back and hold it in position Swivel the driver s seat to the right until it reaches the stop Move the lever 9 forwards again Make sure that the driver s seat is securely engaged Swivelling the driver s seat to the right is inten ded only for reverse travel The driver s seat must be swivelled back into place for forward travel To swivel the s...

Page 121: ...perating devices can be actuated safely Ensure that the seat and the seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the 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 seat ...

Page 122: ... 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 1 6301_003 150 2 6301_003 151 Operating 4 Driver s seat 106 563880...

Page 123: ... individual driver s weight must be set when the truck is stationary and the driver s seat is occupied Remain seated during this process To adjust to the driver s weight move the pushed in lever 4 up or down until the desired setting is reached To adjust the seat height pull the lever 4 out and move it up or down until the desired setting is reached 3 6301_003 152 4 6301_003 153 Operating 4 Driver...

Page 124: ... sion move the locking lever 5 forwards NOTE When the longitudinal horizontal suspension is locked the suspension comfort is significantly lower Impacts are much more noticeable Adjusting the lumbar support variant The lumbar support can be adjusted to suit the contours of the individual driver s spine Adjusting the lumbar support moves a convex support cushion into the upper or lower part of the ...

Page 125: ... To remove the backrest extension move it past the end stop by firmly pushing it upwards Switching the seat heater variant on and off NOTE The seat heater only works when the driver is sitting on the driver s seat Switch the seat heater 8 on or off using the switch 7 6301_003 156 8 6301_003 157 Operating 4 Driver s seat 109 56388011501 EN 05 2022 08 ...

Page 126: ...ng pressure from the front or rear seat base it tilts into the desired position Adjusting the seat depth The seat depth of the seat base can be adjus ted individually To adjust the seat angle pull the handle 10 upwards To achieve the desired position simultaneous ly slide the seat base forwards or backwards 9 6301_003 158 10 6301_003 159 Operating 4 Driver s seat 110 56388011501 EN 05 2022 08 ...

Page 127: ... the driver s cab variants with closed fixed doors constitute driver restraint systems Plastic doors weather protection do not constitute a restraint system If the doors are open or have been removed you must use an alternative suitable restraint system e g a seat belt Fastening the seat belt DANGER Mortal danger when driving without wearing a seat belt If the seat belt is not fastened and the tru...

Page 128: ... your back is resting on the seat backrest The automat ic blocking mechanism permits sufficient free dom of movement on the seat Click the belt tongue 2 into the buckle 1 Check the tension of the seat belt The belt must fit closely around your body Special feature for trucks with a cab variant If the truck is equipped with a cab variant it will have a cab door sensor If the seat belt is not fasten...

Page 129: ...asing the seat belt Push the red button 4 on the buckle 1 Slowly guide the belt tongue back to the retractor by hand NOTE Slowly allow the seat belt to retract The auto matic blocking mechanism may be triggered if the belt tongue strikes the housing It will then no longer be possible to pull the seat belt out with the usual force Using increased force pull the seat belt around 10 to 15 mm out of t...

Page 130: ...tional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the armrest while driving Adjust the armrest so that all operating devices 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 d...

Page 131: ... Tighten the hand wheel by turning to the right Check that the armrest is firmly attached Operating 4 Driver s seat 115 56388011501 EN 05 2022 08 ...

Page 132: ...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 Driv...

Page 133: ...thorisation 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 134: ...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 118 56388011501 EN 05 2022 08 ...

Page 135: ...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 119 56388011501 EN 05 2022 08 ...

Page 136: ...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 8 Pressing the main display button at any menu level takes you directly back to the main display ...

Page 137: ... 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 138: ...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 139: ...sword is noted on the order confirmation and on the truck invoice NOTE Access to the settings menu is only availa ble if the truck is at a standstill and the park ing brake is applied If the parking brake is released 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 140: ...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 141: ...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 125 56388011501 EN 05 2022 08 ...

Page 142: ...question stored by default is Truck ready for opera tion If the question is answered with No an entry is made in the history No restrictions in truck function for this scenario are stored by default The authorised service centre can replace this question with a question from the question catalogue In addition the fleet manager has the follow ing options The fleet manager can view the results of al...

Page 143: ...Check is still active and the truck functions are restricted To acknowledge the message press the softkey Switch on and check the function to be tes ted e g lighting Press the back button to go back to the Pre Shift Check Answer the question based on the result of the function check The next question appears NOTE If no questions regarding the Pre Shift Check have been compiled the question Truck r...

Page 144: ...eck during commissioning Are the fork arms damaged e g bent or cracked Are the fork arms securely mounted and the locking devices un damaged Are the roller tracks on the lift mast and lift chassis suffi ciently greased Are the load chains damaged Are the load chains sufficiently tensioned and loaded equally Are all attachments securely mounted and undamaged Are they in working order Are operating ...

Page 145: ...e the lift mast or the fork carriage obviously damaged Do the working hydraulics work properly according to the label ling Are the mirrors dirty or damaged Is the gas tank or its mounting obviously damaged Can unusual noises be heard when the industrial truck is used Is there any other obvious damage to the truck Does the washer system work Is the bonnet undamaged and securely closed If no Pre Shi...

Page 146: ...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 130 56388011501 EN 05 2022 08 ...

Page 147: ...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 131 56388011501 EN 05 2022 0...

Page 148: ...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 132 56388011501 EN 05 2022 08 ...

Page 149: ...ays requested 24 hours after the last check was performed The fleet manager can define up to three shifts and their start times The Pre Shift Check is then always requested at this time Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Pre Shift Check results 27 09 19 15 11 nicht ok Funktioniert die Feststellbremse einwandfrei 27 09 19 15 06 nicht ok Sind die Ga...

Page 150: ...ructions 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 134 56388011501 EN 05 2022 08 ...

Page 151: ...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 135 56388011501 EN 05 2022 08 ...

Page 152: ... requested from this shift start time The display reverts 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 136 56388011501 EN 05 2022 08 ...

Page 153: ...in 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 previously detected problem has been rectified Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivat...

Page 154: ...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 138 56388011501 EN 05 2022 08 ...

Page 155: ...The display reverts to the previous menu To cancel press the softkey The truck functions remain restricted The dis play reverts 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 139 56388011501 EN 05 2022 08 ...

Page 156: ...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 profile is generated This driver profile corre sponds to the settings when the truck was delivered If the truck is not equipped with these variants drivers must selec...

Page 157: ... ing brake is applied If the parking brake is released prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the 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 141 56388011501 EN 05 2022 08 ...

Page 158: ...les Both 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 softkey Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operatin...

Page 159: ...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 143 56388011501 EN 05 2022 08 ...

Page 160: ...will 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 softkey Press the Truck settings softkey Enter driver name Clear Driver name Horst abc ...

Page 161: ... 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 145 56388011501 EN 05 2022 08 ...

Page 162: ...s 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 146 56388011501 EN 05 2022 08 ...

Page 163: ...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 147 56388011501 EN 05 2022 08...

Page 164: ...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 148 56388011501 EN 05 2022 08 ...

Page 165: ...of working spotlights Only the symbols of the lighting devices that are installed in the truck can be 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 func...

Page 166: ...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 167: ...tions variant the parking light is also 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 168: ...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 module Operating 4 Lighting...

Page 169: ...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 153 56388011501 EN 05 2022 08 ...

Page 170: ...or 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 steer ing column The hazard warning system in ...

Page 171: ...his softkey is used to switch off all light ing devices that are not permitted on roads subject to German traffic regulations StVO This relates to the following variants of lighting equipment STILL SafetyLight and STILL Safety Light 4Plus Warning zone light and warning zone light plus Working spotlight Rotating beacon To switch this lighting equipment off press the softkey The orange activation ba...

Page 172: ... The rotating beacon is switched on To switch off the rotating beacon push the Softkey again The rotating beacon goes out STILL SafetyLight and STILL SafetyLight 4Plus var iants WARNING Danger of damage to eyes from look ing into the STILL SafetyLight and STILL SafetyLight 4Plus Do not look into the STILL SafetyLight or STILL SafetyLight 4Plus STILL SafetyLight and STILL SafetyLight 4Plus are visu...

Page 173: ...ant for exam ple it can be used as an additional light for the working spotlight for reverse travel The STILL SafetyLight or the STILL Safety Light 4Plus can also be switched on and off on the display operating unit To do so press the softkey NOTE If the truck is to be operated on public roads the STILL SafetyLight and the STILL Safety Light 4Plus must be switched off Warning zone light and warnin...

Page 174: ...off again together with the truck If the truck has StVZO German Road Traffic Licensing Regulations equipment the warn ing zone light plus can be switched on and off via the display operating unit To do so press 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 make sure that the warning zone light is working and has b...

Page 175: ... 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 Blue Q has no influence on Maximum speed Climbing capability Pulling force Braking characteristics Effects on additional consumers The following table shows conditions that cause certain additional consumers to shut down when Blue Q is activated The additi...

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 160 56388011501 EN 05 2022 08 ...

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 161 56388011501 EN 05 2022 08 ...

Page 178: ...ftkey 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 default setting and provides a bal ance between hydraulic functions an...

Page 179: ...l 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 under voltage does not apply to lithium ion batteries or overheating occurs sprint mode is automatically deactiva ted If the truck is automatical...

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: ...areas outside 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 35 600 6331 4265 4465 RX60 40 6332 4265 4465 RX60 40 600 6333 4265 4465 RX60 45 6334 4265 4465 RX60 45 600 6335 4275 4475 RX60 50 6336 4275 4370 RX60 50 600 6337 4475 4570 With...

Page 183: ... truck on the following ascending and descending gradients Model Type Maximum gradient With a load Without a load RX60 35 600 6331 12 4 20 3 RX60 40 6332 11 6 19 7 RX60 40 600 6333 11 18 8 RX60 45 6334 10 5 18 8 RX60 45 600 6335 9 6 16 3 RX60 50 6336 9 2 16 3 RX60 50 600 6337 8 9 15 5 The ascending and descending gradients must not exceed the gradients listed above and must have a rough surface Th...

Page 184: ...ixed elements of the surrounding area The height is based on the overall height of the lift mast and the dimensions of the load Rules for roadways and the working area It is only permitted to drive on routes author ised for traffic by the operating company or its representatives Traffic routes must be free from obstacles The load must only be set down and stored in the designated locations The ope...

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

Page 186: ... a favourite on a softkey press the soft key until the letter of the desired drive pro gramme 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 availa ble if the truck is at a standstill and the park ing brake is applied If the parking brake is released prematurely the settings menu will close ...

Page 187: ...ity and 5 indi cates the greatest agility Braking Determines the electrical brake retardation when the accelerator pedal is released in five stages 1 indicates the lowest delay and 5 indicates the greatest delay To select a higher stage press the soft key To select a lower stage press the soft key To save the setting press the softkey The settings are saved To cancel the setting press the softkey ...

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 ver sion 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 direction sel...

Page 190: ...ndicator 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 but ton 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 parking brake is not engaged DANGER Risk of accident due to brake failure The regenerative brake only functions if the truck is switched on the emerg...

Page 193: ...he truck still cannot be operated park the truck securely and con tact the authorised service centre Starting drive mode dual pedal version 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: ...ards 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: ... electrical fault has been corrected it will be possible to 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 a...

Page 196: ...e the truck When braking with the service brake it may be necessary to use the parking brake to assist the braking process Notify the authorised service centre Do not operate the truck again until the service brake has been repaired DANGER At speeds that are too high there is a danger that the truck could slip or overturn The braking distance of the truck depends on the weather conditions and the ...

Page 197: ...esponsible for parking the truck safely The safety information about parking the truck safely applies NOTE The electric parking brake can be actuated or released only if the battery male connector has been connected and the truck is switched on If the parking brake is applied this is indica ted by a symbol in the display operating unit instead of the driving speed Symbols for the parking brake in ...

Page 198: ... out The driving speed display is replaced by the symbol Automatic actuation of the electric park ing brake when the truck is stationary The electric parking brake is applied automati cally when the truck is stationary in the follow ing situations Automatically triggered actuation when the truck is stationary Cause Effect The driver s seat is vacated The electric parking brake will make a noise wh...

Page 199: ...ke will make a noise when it is released The LED 2 goes out NOTE If the symbol appears in the display the truck cannot be driven until the electric parking brake has been released by pressing the push button 1 This is the case if the parking brake has been applied manually Actuation of the electric parking brake when the truck is in motion Manual actuation when the truck is in motion Press the pus...

Page 200: ...p Once the truck has come to a standstill the electric parking brake is applied with an audible sound The LED 2 lights up with a steady light The symbol appears in the display until the con trol units switch off The emergency off switch is actuated The truck will coast to a stop Once the truck has come to a standstill the electric parking brake is applied with an audible sound The LED 2 lights up ...

Page 201: ...The Apply parking brake via button message appears on the display operating unit The LED 1 on the push button 2 flashes A warning signal sounds NOTE If it becomes necessary to switch off a truck with a faulty parking brake always secure the truck to prevent it from rolling A possible cause of the malfunction is that the parking brake cannot determine whether the truck is stationary or still in mot...

Page 202: ...he parking brake is applied NOTE The truck brakes more strongly if the push button 1 is pressed and held down for longer or pressed several times Safe parking function This function monitors the braking effect after the truck is parked If a sensor is fitted on the lift mast variant it also checks whether the fork carriage is lowered This function alerts the driver with an audible warning signal if...

Page 203: ...ss the softkey Secure truck against rolling away Secure the truck with wedges so that the truck does not roll away To confirm press the softkey It is now possible to switch off the truck DANGER Risk of fatal injury from being run over if the truck rolls away Park the truck securely if the parking brake is faulty Secure the industrial truck to prevent it from rolling away To do this strictly adhere...

Page 204: ...ed via the emer gency actuation mechanism it is possible to drive the truck at a low speed The truck can be moved out of the hazard ous situation or to the repair location Driving with a faulty parking brake requires the driver to be especially vigilant If the parking brake cannot be applied au tomatically or via the push button apply the parking brake via the emergency actua tion process Refer to...

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 189 56388011501 EN 05 202...

Page 206: ...g 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 steering Do not turn off the key switch while driving Actua...

Page 207: ...nics of the truck If the cab door is not closed and the seat belt is not fastened the driving speed is limited to 4 km h The message Close cab door or seat belt appears in the display If the cab door is opened while the truck is in motion the truck brakes automatically to a speed of 4 km h The message Close cab door appears in the display If the seat belt is released with the cab door closed no me...

Page 208: ...appears next to the symbol The speed restriction is switched on To switch off the speed restriction press the softkey again Configuring the speed restriction NOTE Access to the settings menu is available on ly if the truck is at a standstill and the park ing brake is applied If the parking brake is released prematurely the settings menu will close Access is only granted when the pass word is enter...

Page 209: ... 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 the scroll button The entry is deleted To cancel press the back button The display...

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: ... the cruise control function 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 and the dangers associa...

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 196 56388011501 EN 05 2022 08 ...

Page 213: ...tion can be acti vated 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 ...

Page 214: ...ces 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 spee...

Page 215: ...to life caused by a falling load or if truck components 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 tempera...

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 200 56388011501 EN 05 2022 08 ...

Page 217: ... 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 the wheel ch...

Page 218: ...s when handing loads Page 227 Lift mast versions DANGER Risk of accident if the lift mast or the load collides 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 out er lift...

Page 219: ...luded in the truck s equipment Possible equipment variants include Multi lever Double mini lever Triple mini lever Quadruple mini lever Fingertip Joystick 4Plus For clarity the movements of the lifting system are referred to by the letters A B C D in this subchapter A Lower the fork carriage B Lift the fork carriage C Tilting the lift mast forwards D Tilting the lift mast backwards See the relevan...

Page 220: ...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 NOTE If several hydraulic functions are used at the same time these functions can influence each other For example if the fork carriage is raised and an attachment is operated at the same time this may change the li...

Page 221: ...fferent configuration has been con figured 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 con tr...

Page 222: ...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 206 56388011501 EN 05 2022 08 ...

Page 223: ...ust make all drivers aware of the fact that a different configuration has been con figured 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 func tions 1 or 2 is affixe...

Page 224: ... of the arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast 360 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 208 56388011501 EN 05 2022 08 ...

Page 225: ... drivers aware of the fact that a different configuration has been con figured 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 desi...

Page 226: ...he lift mast 360 lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast 360 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 210 56388011501 EN 05 2022 08 ...

Page 227: ...e all drivers aware of the fact that a different configuration has been con figured 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 228: ...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 212 56388011501 EN 05 2022 08 ...

Page 229: ...iguration has been con figured 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 con trolled using ...

Page 230: ...ds 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 The operating company must make all ...

Page 231: ... 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 215 56388011501 EN 05 2022 08 ...

Page 232: ...es 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 hydrau...

Page 233: ...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 234: ... complete Refer 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 There are two types of fork ...

Page 235: ...DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Apply the parking brake Change the fork extension in a cordoned off safe location on a level surface WARNING There is a risk of injury when changing the fork arms the weight of the fork arms could cause them to fall on your legs feet or knees The space to the left and right of the...

Page 236: ...rriage until the lower edges of the fork arms are approx 3 cm higher than the height of the pallet Actuate the parking brake and make sure it is applied securely Turn the switch key to the left and pull it out Undo the locking screw 2 on the right or left Pull the locking lever 1 upwards and push the fork arms outwards onto the pallet Installing Position the fork arms on a pallet to the left or ri...

Page 237: ...ge the fork extension in a cordoned off safe location on a level surface WARNING There is a risk of injury There is a risk of crushing due to the weight of the fork extension There is a risk of cutting on sharp edges or burrs Wear protective gloves and safety shoes WARNING There is a risk of tipping The weight and dimensions of the fork extension af fect the stability of the truck The permissible ...

Page 238: ...th the fork extension Push the fork extension all the way to the back of the fork Make sure that 60 of the length of the fork ex tension is on the fork arm Always secure the fork extension with the secur ing bolt Always secure the securing bolt with the linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork ex tension 1 Push the fork extension onto the for...

Page 239: ... 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 ground The truck may tip forwards when driving or braking Only drive with a load centre of gravity up to a ma...

Page 240: ...s With triple masts variant an incorrect extension se quence may occur i e the inner lift mast may extend before the free lift has finished As a result the over all 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 The fork carriage becoming blocked in the inner lift ...

Page 241: ...lift mast become blocked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on lift masts see Chapter Working at the front of the truck Page 506 Hydraulic blocking function The hydraulic blocking function ensures that all the functions of the working hyd...

Page 242: ...NOTE Only the emergency steering function remains available Operating 4 Lifting 226 56388011501 EN 05 2022 08 ...

Page 243: ...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 a closed roof covering variant in addition Capacity rating plate The load capacity indicated for the truck on the capacity rating plate must not be excee ded The...

Page 244: ...tation of the capaci ty rating plate Only the capacity rating plates on the truck are valid The figures show examples Only observe the capacity rating plate on the truck DANGER Risk of fatal injury from the truck losing stability If the permissible loading of the attachments variant and the reduced load capacity of the truck and at tachment combination is exceeded there is a risk of loss of stabil...

Page 245: ... the attachment If an attachment is attached a second capacity rating plate is fitted the residual load capacity rating plate This plate shows the load capacity taking the attachment into account In the case of inte grated attachments only a basic capacity rat ing plate is created as the integrated devices cannot be easily removed from the truck The example values used here are marked in black To ...

Page 246: ...ifted higher than 5880 mm The load capacity specified for certain nominal lifts applies up to this nominal lift If the lift value of the first line is exceeded the load capacity from the second line applies up to the lift of the second line Residual load capacity rating plate for built in devices and attachments NOTE The residual load capacity rating plate for at tachments is read according to the...

Page 247: ...city rating plate applies to the maximum possible sideshift The driver is responsible for complying with the load capacity and sideshift information on the residual load capacity rating plate If in doubt use the load capacity for the maximum possi ble sideshift Special capacity rating plate for off cen tre loads If unbalanced loads are regularly transported a special capacity rating plate for off ...

Page 248: ...ariant should also be used Removable roof panels may not be removed Adjusting the fork Lift the locking lever 1 and move the fork arms to the desired position Allow the locking lever to snap back into place The load centre of gravity must be midway between the fork arms Only actuate the fork prong positioner var iant when the fork is not carrying a load Danger area The danger area is the area in w...

Page 249: ... immediately Secure the truck against use by unauthorised 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 mu...

Page 250: ...at begin to swing can result in the following risks Follow the Instructions for transporting suspen ded loads Risks due to suspended loads Impaired braking characteristics and steer ing movement Tipping over the front axle Tipping the truck at right angles to the drive direction Risk of crushing of accompanying persons Reduced visibility DANGER Loss of stability Slipping or swinging suspended load...

Page 251: ...Never drive on slopes with a suspended load Transporting containers holding fluids as hanging loads is not permitted 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 gu...

Page 252: ...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 236 56388011501 EN 05 2022 08 ...

Page 253: ...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 237 56388011501 EN 05 ...

Page 254: ... Lower the load while maintaining ground clearance Tilt the lift mast backwards The load can be transported Operating 4 Handling loads 238 56388011501 EN 05 2022 08 ...

Page 255: ... conditions can be evaluated by de termining the size of the area that is not visi ble A If the area that is not visible exceeds 1085 mm EN16842 2 A3 the visibility conditions are inadequate Procedure Sit down on the driver s seat and adopt the seat position Determine the area that is not visible A using the load height C and the length of the route D 4000 mm This area that is not visible A must n...

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 attachment is being used its weight must be subtracted from this val...

Page 258: ...orously and frequently the operating device is moved the more in tense the shaking is NOTE Once the function has been activated the driver has two seconds to start the shaking If 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 t...

Page 259: ...t perform the shake function close to the lift height of a lift limit Cancel the lift limit by pressing the F button See the note below NOTE The lift limit can be cancelled by pressing the F button See also the section entitled Inter mediate lift cut out variant For this option contact the authorised service centre The following section shows how the shake function is activated via the standard as...

Page 260: ...ple mini lever Move the 360 lever 3 back and forth between positions A and B four times Then continue to move the component in the 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 Operating 4 Handling loads 244 56388011501 EN 05 2022 08 ...

Page 261: ...may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take partic ular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during low ering the load may fall When removing from stoc...

Page 262: ...wer the load until it rests securely on the rack DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear Move the truck back until the fork arms can be lowered without touching the stack Lower the fork while maintaining ground clearance Tilt the lift mast backwards and drive away Operating 4 Handling loads 246 56388011501 EN 05 2022 08 ...

Page 263: ... descending gradients at an angle Do not park the truck on ascending or de scending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and sta bility values Before driving on ascen...

Page 264: ...ight Park the truck securely and switch it off 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 together the determined individual weights to obtain the total weight of the truck Net weight 1 Max permissible battery weight 2 Ballast weight variant 3 Net weight of attachment variant Weight...

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: ...of the lift mast and a reflector 1 on the fork carriage NOTE The LED sensor unit and reflector are adjus ted at the factory Follow up adjustments are carried out by the authorised service centre The LED lift height sensor constantly emits a light signal that is reflected by the reflector The truck control unit calculates the current lift height based on the travel time of the light signal NOTE Alt...

Page 267: ... display The message Clean lift height sensor appears in the display Clean the sensor glass 2 and the reflec tor 1 using a soft cloth and water Also clean the dust protection cover 3 if necessary A small amount of cleaning agent can be add ed to the water CAUTION Component damage caused by incorrect cleaning The sensor glass and the reflector can be damaged as a result of incorrect cleaning proced...

Page 268: ...in the display operating unit If the malfunction no longer exists or has been rectified the system is automatically available again Truck functions that are dependent on the lift height are restricted in the event of a malfunc tion in the height measurement system Mal functions must therefore be rectified immedi ately Contamination The driver can resolve a temporary interrup tion of the light sign...

Page 269: ...t value The following assistance systems can contin ue to be operated but with the restrictions of emergency operation Intermediate lift cut out Release the lifting operating device so that it can return to the zero position The fork carriage can then continue lifting at a reduced speed Lift mast end stop damping Release the lifting operating device so that it can return to the zero position WARNI...

Page 270: ...tre must adjust this value The system works across the entire lift range from ground level up to the maximum lift height When properly configured the measurement inaccuracy is as follows Repeatability 5 mm Maximum measure ment inaccuracy 45 mm NOTE If the prerequisites on the truck have changed e g the tyres are worn the value displayed for the lift height may differ more from reality In this case...

Page 271: ... in this section NOTE Check the lift heights set here before use via the Intermediate lift cut out menu NOTE The fleet manager can use his access author isation to set the lift heights at which the in termediate lift cut out takes effect If no fleet manager access is enabled the authorised service centre must set the desired lift heights The intermediate lift cut out is always active when the truc...

Page 272: ...ight If the fork carriage is lowered to below the configured lift height for the intermediate lift cut out the intermediate lift cut out function is switched on again WARNING Risk of accident due to unintentional switch off of the intermediate lift cut out If the truck is also equipped with the intermediate lift cut out variant and the shake function is performed close to an intermediate lift cut ...

Page 273: ...riod Continue lifting within one second as other wise the function will intervene again If the function intervenes again the black symbol will reappear Switching off the intermediate lift cut out Press the button The first menu level appears Press the softkey Press the softkey The orange coloured activation bar next to the softkey goes out The symbol disappears from the main dis play The function ...

Page 274: ...ift cut out softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 258 56388011501 EN 05 2022 08 ...

Page 275: ...button The menu closes The storage locations are displayed An orange activation bar indicates that the intermediate lift cut out 1 is activated Fleet manager Intermediate lift cut out 2 Intermediate lift cut out 3 End lift cut out Intermediate lift cut out 1 6219_003 315_en Fleet manager Enter desired height Clear Intermediate lift cut out 1 6 892 Activate Save Cancel 6219_003 316_en m Operating 4...

Page 276: ...d on telescopic lift masts and triple masts This protects the load against jerking movements Lift mast end stop damping var iant This assistance system in conjunction with the optical height measuring system ensures that the fork carriage reaches the lifting stops gently This prevents the lifting movement from stopping abruptly If the truck is equipped with the automatic mast vertical positioning ...

Page 277: ... Switching off the end lift cut out Stop the truck Apply the parking brake Press the button The first menu level appears Press the softkey Press the softkey The symbol goes out The end lift cut out is switched off To switch the end lift cut out on again press the softkey again NOTE The maximum lift height cannot be modified by the driver It can be changed either by the authorised service centre or...

Page 278: ...ift cut out softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 262 56388011501 EN 05 2022 08 ...

Page 279: ...oses An orange activation bar indicates that the End lift cut out is activated Fleet manager Intermediate lift cut out 2 Intermediate lift cut out 3 End lift cut out Intermediate lift cut out 1 6219_003 315_en Fleet manager Enter desired height Clear Intermediate lift cut out 1 6 892 Activate Save Cancel 6219_003 316_en m Operating 4 Lift height dependent assistance systems 263 56388011501 EN 05 2...

Page 280: ... the truck NOTE This lift height can be changed up to 500 mm either by the authorised service centre or with the Access authorisation for the fleet manag er via the display operating unit Configuration by the fleet manager Entering the lift height Activate the Access authorisation for the fleet manager Press the button Press the softkey Fleet manager Enter desired height Clear Intermediate lift cu...

Page 281: ...striction for lift softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 265 56388011501 EN 05 2022 08 ...

Page 282: ... menu closes Entering the speed restriction The maximum speed can be defined just like the lift height Activate the Access authorisation for the fleet manager Press the button Press the softkey Fleet manager Speed restriction Lift height 6219_003 321_en Fleet manager Enter desired height Clear Speed reduction when the fork carriage is raised Lift height Save Cancel 6219_003 322_en_V2 Operating 4 L...

Page 283: ...striction for lift softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 267 56388011501 EN 05 2022 08 ...

Page 284: ...r the speed using softkeys 0 to 9 To save press the button The menu closes Fleet manager Speed restriction Lift height 6219_003 321_en Enter maximum speed 2 20km h km h 10 Speed restriction 6219_003 193_en Operating 4 Lift height dependent assistance systems 268 56388011501 EN 05 2022 08 ...

Page 285: ...tive when the truck is switched on The fork wear protection symbol appears in the display Only the authorised service centre may deactivate the function If the symbol is grey the assistance system is switched on If the symbol is black the assistance system is taking effect The fork carriage does not lower to a level that is higher than the set level Lowering to the ground NOTE The fork wear protec...

Page 286: ... section entitled Zeroing the assis tance systems Configuration by the fleet manager The height of the fork wear protection can be configured for example for retraction into pal lets with a different height or uneven ground Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck settings softkey Operating 4 Lift height dependent assistance systems...

Page 287: ...utton The menu closes Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Fleet manager Enter desired height Clear Fork wear protection 0 120 Save Cancel 6219_003 320_en m Operating 4 Lift height dependent assistance systems 271 56388011501 EN 05 2022 08 ...

Page 288: ...vertical position ing variant CAUTION Risk of damage to property due to the lift mast collid 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 ver ti...

Page 289: ...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 calibrated in order to ensure accuracy at all times The access authorisation for...

Page 290: ...ift 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 contact your authorised service centre Calibrating the automatic mast vertical positioning The automatic mast vertical positioning is cali brated using a wizard on the display operating unit NOTE The wi...

Page 291: ...anding 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 according to the spirit level Press the button Press the Softkey Activate the Access authorisation for the fleet manager Press the Service softkey 80 90 80 7 0 6 0 7 0 6 0 Operating 4 Tilt angl...

Page 292: ...en completed successfully the message Calibration successful 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 Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Fleet manager ...

Page 293: ...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 294: ... Press the softkey Press the Truck settings softkey Press the Overload detection soft key Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Load dependant assistance systems 278 56388011501 EN 05 2022 08 ...

Page 295: ...ting movements are configured to use low dynamics 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 1 Work with particular attention and care Observe the Dynamics of the hy...

Page 296: ...educed to 5 km h at a lift height of 2 1 m and higher or in the second lifting stage NOTE When the fork carriage has been lowered be low the lift heights mentioned above the driver can deactivate the speed restriction again Re lease the accelerator pedal for a short period to do this If a sensor belonging to Dynamic Load Con trol 1 fails the level of intervention from the function is increased to ...

Page 297: ...ol 2 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria Lift height Load weight Load centre of gravity Dynamic Load Control 2 intervenes in the fol lowing operating situations With a telescopic lift mast The fork carriage is at least 2 1 m off the ground With a triple lift mast or NiHo lift mast The fork carriage is in the second lifting stage T...

Page 298: ...en segments A Grey area The dynamics of the lifting movements and tilting movements are not noticeably reduced B Yellow area If a load that is close to the nominal load is picked up the display moves into the yellow area The dynamics of the lifting movements and tilting movements are noticeably re duced Handle the load with the appropriate level of care C Red area When the combination of load weig...

Page 299: ...he rated capacity Observe the following safety information DANGER Risk of accident from a falling load The load may fall if the load centre of gravity has not been taken into account or the load has not been picked up securely Pick up the load securely see the chapter entitled Picking up loads WARNING Risk of accident as a result of exceeding the residual load capacity If the weight determined by ...

Page 300: ...ction entitled Zeroing the assis tance systems Calibrating the load measure ment 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 unit NOTE The calibration procedure requires access au thorisation for the fleet manager Access to the settings menu is only a...

Page 301: ...rvice 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 285 56388011501 EN 05 2022 08 ...

Page 302: ...bration again Precision load measurement variant 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 3 of the rated capacity of the truck NOTE If the load is to be measured exclusive of t...

Page 303: ...he fork carriage increases the measurement accuracy in trucks with mul ti 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 287 56388011501 EN 05 2022 08 ...

Page 304: ...ad measurement function 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 conta...

Page 305: ...is played The Precision load measurement can be performed To clear the tare weight press the soft key 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 measurem...

Page 306: ... 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 307: ... is explained here using Press the softkey The menu for storage location appears This menu provides the following functions Tare Precision load measurement Add load Subtract load Delete total load Measure load Press the softkey Measure the load 0 00 0 00 0 00 t 0 00 t Operating 4 Load dependant assistance systems 291 56388011501 EN 05 2022 08 ...

Page 308: ...ract 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 clear press the softkey...

Page 309: ...lacing a worn pair of tyres if the front and rear tyres are worn to different levels If the front and rear tyres show different levels of wear Electrical fork wear protection When changing fork arms NOTE The zeroing for the load measurement assis tance system is shown here as an example Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck setti...

Page 310: ...ocesses for zeroing the other assis tance systems are almost identical Fleet manager Change PIN codes Manage driver profiles On board charger Zeroing Auxiliary hydraulics 6219_003 323_en Fleet manager Lift height Tilt angle Fork wear protection Load weight 6219_003 324_en Operating 4 Zeroing the assistance systems 294 56388011501 EN 05 2022 08 ...

Page 311: ...ollowed the messages Zeroing successful or Zeroing failed are displayed If zeroing failed try again If zeroing fails repeatedly contact your au thorised service centre Fleet manager Lower forks Load weight 6219_003 325_en Operating 4 Zeroing the assistance systems 295 56388011501 EN 05 2022 08 ...

Page 312: ... 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 313: ...quires 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 softkey Activate the Access authorisation for the fleet manager...

Page 314: ...menu appears Push the Relieve hydraulics soft key The following message appears Caution the lift mast may move To confirm press the softkey Press the softkey to exit the wizard Operating 4 Depressurising the hydraulic system 298 56388011501 EN 05 2022 08 ...

Page 315: ...ssure has built up in the hydraulic system again the function for relieving the hy draulics becomes inactive Depressurising the hydraulic system using multi lever opera tion 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 th...

Page 316: ...r 2 can be assigned the sideshift and the fork adjustment functions In this case press the button 1 and hold it down Push the operating lever 2 once in the direction 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 depressurisati...

Page 317: ...d hold it down Push the operating lever 4 once in the direction 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 direction of the arrow until the end position is reached The hydraulic circuit of the 6th...

Page 318: ...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 direc tion of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To complet...

Page 319: ...Actuate 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 Complet...

Page 320: ...nt 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 comp...

Page 321: ...ctuate 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 direction 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 322: ...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 323: ...2 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 direction 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 Co...

Page 324: ...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 325: ... relevant 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 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 ...

Page 326: ... 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 di rection of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurise...

Page 327: ...unction 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 d...

Page 328: ...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 312 56388011501 EN 05 2022 08 ...

Page 329: ...ent person If the visibili ty is deemed insufficient visual aids must be used such as mirrors a camera a monitor system etc Observe the following warning notices DANGER Risk of fatal injury from falling load If attachments that hold the load by clamping it or exerting pressure on it do not have a second method of operating the function lock the load can work loose and fall off Ensure that the seco...

Page 330: ... specific residual load capacity rating plate to be fitted to the truck Arrange for the operating devices to be re label led Arrange for the authorised service centre to adjust the hydraulic system to the requirements of the attachment e g adjust the pump motor speed NOTE If the required labelling is not provided with the attachment contact the authorised service centre promptly Alternating operat...

Page 331: ...urer and supplier or sub supplier of the attachment when doing so NOTE Please observe the definition of the following responsible person competent person Switch off the truck Install the attachment Switch on the truck Check and ensure that all functions of the installed attachment are working properly Load capacity with attachment The permissible load capacity of the attach ment and the permissibl...

Page 332: ...p with a 5th function variant Joystick 4Plus Joystick 4Plus with a 5th function variant To control attachments see the sections re lating to the respective operating devices in this chapter WARNING Use of attachments can give rise to additional haz ards such as a change in the centre of gravity addi tional danger areas etc Attachments must only be deployed for their inten ded use as described in t...

Page 333: ...tion var iant the fleet manager can adjust the speed of the auxiliary hydraulics for attachments See also the section entitled Adjusting the hydraulic speed for attachments in this chapter Attachment example for the connection of the auxiliary hy draulics NOTE The authorised service centre will tell you which attachments can be used with this truck The connection of attachments to the auxiliary hy...

Page 334: ...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 attachments If different attachments are mounted the fleet manager can adjust the hydraulic speed for attachments and thus the flow rate of h...

Page 335: ...or the fleet manager Press the Auxiliary hy draulics 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 determine the axles Setting the revolution speed Push the softkey for the hydraulic axle to be configured Flee...

Page 336: ...e revolution speed press the or softkey To save the setting press the softkey The settings are saved To cancel the setting press the 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 so press the softkey The hydraulic oil flow for this hydraulic axle is locked Setting the return flow rate separately Dependin...

Page 337: ...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 anism f...

Page 338: ... See the section concerning the relevant op erating device Operating 4 Attachments 322 56388011501 EN 05 2022 08 ...

Page 339: ...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 340: ...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 324 56388011501 EN 05 2022 08 ...

Page 341: ...pictogram 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 attachment t...

Page 342: ...e 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 attachment is known the re...

Page 343: ...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 344: ...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 345: ...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 346: ...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 347: ...pective 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 funct...

Page 348: ...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 349: ...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 350: ...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 351: ...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 352: ...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 353: ...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 354: ...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 355: ... 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 356: ...ible or are missing 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 direction 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 ...

Page 357: ... 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 Operating 4 Attachments 341 56388011501 EN 05 2022 08 ...

Page 358: ...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 arrow C or D The attachment moves accordingly in the di rections C or D as shown...

Page 359: ...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 360: ... 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 361: ...hments 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 attached Where necessary loads must also be se cured against slipping rolling falling over swinging or tipping over...

Page 362: ... g in the event of an accident This data can be electronically read out and evalu ated If you have any questions please contact your authorised service centre Driver restraint systems var iants Different driver restraint systems are available as variants for this truck The description and operation for these systems can be found in the separate Driver restraint systems operat ing instructions Actu...

Page 363: ... off press the softkey repeatedly until the symbol 1 ap pears again on the display The activation bar next to the symbol goes out Rear window wiper and washer To activate the On operating stage press the corresponding softkey 5 The On operating stage is activated The symbol 7 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 6 is shown with an orange bac...

Page 364: ...as long as the softkey is pressed Once the window is clean release the soft key The previous operating stage is reactivated To switch off the speed limitation press the softkey again Filling the washer system Open the filler cap 1 of the washer sys tem Fill the washer reservoir 2 with washer flu id as described in the Maintenance data table CAUTION Damage due to the effects of frost When water fre...

Page 365: ...n assistance system that automatically re duces the driving speed of the truck within halls However this assistance system does not release the driver from the responsibility 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 ...

Page 366: ... to the maximum speed permitted for outdoor areas the speed limitation must still be unlocked To do this release the accelerator briefly and then operate the ac celerator 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 fo...

Page 367: ...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 assembly baseplate Carefully remove the ceiling sensor 1 Deckensensor_Anbau 1 4 2 3 5 Deckensensor_Einstellschlüssel_V2 Operating 4 Auxiliary equipm...

Page 368: ...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 369: ...nsor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following table 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 353 56388011501 EN 05 2022 08 ...

Page 370: ... 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 354 56388011501 EN 05 2022 08 ...

Page 371: ...d camera Rear camera 1 2 3 Left hand camera Monitor 4 5 The camera system consists of four cameras and a monitor for the camera images It pro vides a 360 circumferential view and supports the driver in handling the truck The camera Operating 4 Optical assistance systems 355 56388011501 EN 05 2022 08 ...

Page 372: ...due to improper use The camera system must only be used for its inten ded purpose as set out and described in these oper ating instructions Any other use is improper use and therefore not permitted CAUTION Possible component damage The camera inputs are live No moisture or conduc tive objects may enter the inputs CAUTION The camera system is an aid to the driver However the driver is always respon...

Page 373: ...NOTE The monitor is fitted with a cover to protect it from operating errors The components of the camera system must not be opened Only the authorised service centre may in stall and maintain the camera system Monitoring area of the camera Front camera Right hand camera Rear camera Left hand camera 1 2 3 4 Monitor Front field of vision Right hand field of vision Left hand field of vision 5 6 7 8 O...

Page 374: ...ith one hand Move the monitor to the desired position and hold it Display of camera images in all driving situa tions The monitor shows the images from all four fields of vision simultaneously in all driving sit uations NOTE If another monitor display is desired contact your authorised service centre For example other possible settings are Increasing the rear field of vision for reverse travel Inc...

Page 375: ...left hand sides In the rear camera image the rear part of the counterweight must be visible Cleaning Clean the camera lenses with compressed air or use a small amount of glass cleaner to moisten the lenses Then carefully wipe away with a lint free cloth Do not use an aggressive cleaning agent or solvents Do not use high pressure cleaning equip ment Carefully wipe the monitor with a lint free cloth...

Page 376: ...the lift mast 3 Monitor 4 Rear view camera on the overhead guard These cameras can only be ordered individu ally or in the following combinations Front view camera in the lift mast rear view camera on the overhead guard Camera on the right hand fork arm rear view camera on the overhead guard Operating 4 Optical assistance systems 360 56388011501 EN 05 2022 08 ...

Page 377: ... due to improper use The camera system must only be used for its inten ded purpose as set out and described in these oper ating instructions Any other use is improper use and therefore not permitted CAUTION Possible component damage The camera inputs are live No moisture or conduc tive objects may enter the inputs CAUTION The camera system is an aid to the driver However the driver is always respo...

Page 378: ...and A pil lar via a double joint To adjust the desired position of the monitor proceed as follows Turn the wing screw 1 anti clockwise to loosen it Hold the monitor with one hand Move the monitor to the desired position and hold it Re tighten the wing screw 1 by turning it clockwise Depending on the cameras installed on the truck different images are transmitted to the monitor Camera Monitor image...

Page 379: ...ion from backwards to for wards To change the default settings of the moni tor images contact the authorised service centre Information about the cameras Rear view camera The camera angle is chosen in such a way that the counterweight is always visible and thus the immediate surroundings of the truck STILL recommends not changing this setting The image is displayed the correct way round just like ...

Page 380: ... daily operation check that the cam era lens is uncovered clean and undam aged CAUTION Possible risk of injury or component damage If one fork arm is damaged or worn always replace both fork arms If there is damage or wear on one fork arm it can be assumed that the counterpart also has or will have corresponding damage or wear CAUTION Risk of damage to components Do not expose the fork arms to lat...

Page 381: ...em is an optical lift height positioning support e g for placing a load on a shelf A laser 1 in the tip of the right hand fork arm projects a horizon tal line onto the shelf directly in front of the fork arm This allows the driver to estimate the height on the racking at which the fork arms are located The system therefore assists driv ers when placing loads into stock and remov ing loads from sto...

Page 382: ...ions Any other use is improper use and therefore not permitted CAUTION Possible risk of injury or component damage If one fork arm is damaged or worn always replace both fork arms If there is damage or wear on one fork arm it can be assumed that the counterpart also has or will have corresponding damage or wear CAUTION Risk of damage to components Do not expose the fork arms to lateral forces Do n...

Page 383: ...correctly before starting work Check that the lens of the laser is uncov ered clean and undamaged If necessary clean the lens see the chapter entitled Cleaning Using Laser Smartfork CAUTION Risk of damage due to miscalculation of the lift height The Laser Smartfork is an assistance system that helps the driver to place loads into stock and remove loads from stock at significant lift heights The dr...

Page 384: ...imes or switch off speed contact the authorised service centre Depending on the variant switch on the laser Manual Press the button on the display operating unit and access the Load sub menu Then press the soft key You can also set this softkey as a fa vourite on the first level of the display oper ating unit See the chapter entitled Config uring favourites in the separate operating instructions f...

Page 385: ... rack Switch on the laser and lift the fork to the height of the reference object The laser line must run exactly parallel to the reference object If the line is not parallel proceed as follows Loosen the four grub screws 1 on the cov er plate 2 and carefully remove the cover plate Loosen the grub screw 3 that prevents the laser from rotating by turning the grub screw anti clockwise Carefully rota...

Page 386: ...fork tip only when the laser is switched off Clean the lens with a lint free cloth or cotton swab If necessary moisten the swab with a commercially available glass cleaner Do not use an aggressive cleaning agent or solvents Do not use high pressure cleaning equip ment Frequency of cleaning The lens must be cleaned when necessary and at least once every three months Operating 4 Optical assistance s...

Page 387: ...e door and remove the key Pull the handle 4 Unlock the door lock Open the cab door 3 by pulling it out wards Opening the cab door from the inside Take hold of the handle 2 and the latch 1 Push in the latch Push the cab door out wards Closing the cab door from the outside Take hold of the door by the door han dle 4 Close the cab door by pushing Closing the cab door from the inside Take hold of the ...

Page 388: ...ivelled up to the counterweight and locked there It is in tended for driving with the door open in high outside temperatures The door is split into two and hinged by two sets of hinges The front door section 6 can be opened 180 and locked in place To do this the front door sec tion 6 must be unlocked from the rear door section 2 which remains closed when the door is opened 180 How to open and clos...

Page 389: ...close it Opening the front door section 180 Move the locking handle 9 into a horizon tal position The front door section 6 is unlocked from the rear door section 2 Take hold of the handle 5 and the latch 4 Push in the latch Push the front door sec tion 6 outwards and swivel it 180 The front door section 6 locks with its secur ing cam 1 in the lock 3 of the rear door section 2 6301_003 163 9 6301_0...

Page 390: ...ch press the knob 10 in firmly Take hold of the handle 5 Pull the front door section inwards and close it Move the locking handle 9 into a vertical position The cab door sections are locked 6301_003 165 10 6301_003 164 9 Operating 4 Cab 374 56388011501 EN 05 2022 08 ...

Page 391: ...rds Opening the rear side window The rear side window 2 can be opened in the same way as the front side window Closing the front side window Slide the front side window 1 forwards us ing the handle 3 until it snaps into place Closing the rear side window The rear side window 2 can be closed in the same way as the front side window Turning the interior lighting on or off variant To turn the interio...

Page 392: ...t Do not operate the radio when driving or when handling loads Adjust the radio volume so that you can still hear warning signals Heating system variant DANGER There is a risk of poisoning if heavily polluted surrounding air is aspirated in to the closed cab Do not operate the heating system in the vicinity of storage areas or similar areas in which fuel vapours or fine dust e g coal wood or grain...

Page 393: ... of burns if it is touched Do not touch the heating system housing during operation Only touch the switches provided Operating devices of the heating sys tem The operating devices of the heating system include 1 Heating level control knob 2 Fan control knob 3 Air vent control knob Switching on the blower and heating system Turn the fan control knob 2 to the desired blower position The blower runs ...

Page 394: ...ow to the footwell turn the air vent control knob 3 in an anticlockwise direction to position To direct the air flow to the windscreen turn the air vent control knob 3 in a clockwise direction to position The centre position directs the air flow to the footwell and the windscreen Switching off the heating system and blower Turn the heating level control knob 1 in an anticlockwise direction until i...

Page 395: ...in short circuits Use only fuses with the prescribed nominal current Air conditioning variant The air conditioning dries the air in the cab to prevent the glass panes misting up The temperature of the air that is blown out is based on the heating level that has been set The defrost function can be used to de ice the windscreen quickly The operating devices of the air conditioning include 1 Heating...

Page 396: ...3 anti clock wise to the position Open the air distribu tors and direct them onto the windscreen Switch on the air conditioning Push the defrost switch 4 The LED on the switch lights up red The air conditioning operates at full power The highest heating level is selected This feature operates for a limited period only To save energy it switches itself off automatically Press the defrost switch 4 a...

Page 397: ...front 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 extended position To roll up slowly roll the blind 1 back up Operating 4 Cab 381 56388011501 EN 05 2022 08 ...

Page 398: ...e truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the existing towed load corresponds to the rated capaci ty of the truck no load may be transported on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe the permissib...

Page 399: ...basis the manufacturer should be consul ted Coupling pin in the counter weight 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 ...

Page 400: ...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 401: ...y fall over Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER Risk of fatal injury from detaching trailers The tow coupling is not designed for support loads and could be deformed or destroyed The supported load or the trailers could come loose The tow coupling should be subjected only to hori zontal loads i e the tiller must be hor...

Page 402: ...coupling can damage the racking or the tow coupling itself when manoeuvring If a collision with the tow coupling oc curs the tow coupling must be checked 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 Have a damaged tow coupling replaced by the authorised servic...

Page 403: ...for 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 towing eye of the tiller so that it is in the middle of the towing jaws Push the hand lever 2 upwards until it en gages The tow coupling is opened CAUTION When being coupled the tow bar eye must engage in the middle of...

Page 404: ... m and then move it back slightly On the coupling pin check again that the control pin does not protrude out of its guide Remove any items used to prevent the trail er from rolling away Tow the trailer Model RO 244 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 actuat...

Page 405: ...iller so that it is in the middle of the towing jaws Push the hand lever 5 upwards The tow coupling is opened DANGER People can become trapped between the truck and trailer When coupling ensure that there are no persons present between the truck and the trailer Slowly move the truck backwards DANGER Risk of accident due to open coupling pin A protruding safety handle means that the tow bar eye has...

Page 406: ...rances gates etc observe the dimen sions of the trailer and load When towing multiple trailers 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 regard...

Page 407: ...nguished by two different 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 c...

Page 408: ...de 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 col...

Page 409: ...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 maximum nominal capacity in the respect...

Page 410: ...ot 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 394 56388011501 EN 05 2022 08 ...

Page 411: ...sage is displayed until either the cause has been corrected or the message has been acknowledged In the case of successive events the respec tive messages are displayed one after another on the display Messages about operation If messages about operation appear on the display operating unit an action must be per formed Code Shown on display Cause action Log in The access authorisation variant is p...

Page 412: ...ated due to the battery temperature be ing too high This message about the on board charger is triggered by different causes The truck was heavily used before charging and the battery has become very hot The ambient temperature is too high and the battery cannot cool down The charging profile is configured incorrectly Allow the battery to cool down Allow the battery temperature symbol on the displ...

Page 413: ...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 earlier messages e g overtemperature It is not p...

Page 414: ...m ion battery Switch the truck off and on again If the message continues to appear please contact the authorised service centre Fault Battery The truck control unit detects an error in the lithium ion battery 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 tr...

Page 415: ...o matically Apply the parking brake by pressing the but ton Release parking brake via button The electric parking brake cannot be released automatically Release the parking brake by pressing the button 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 auth...

Page 416: ...f switch is unlocked Unlock the emergency off switch Emergency operation If the truck experiences a power reduction for example due to a battery charge state 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 ...

Page 417: ...f the hazard warning system variant is switch ed on when the truck is switched off the dis play operating unit remains active Then when a truck function is called up this message ap pears Switch on the truck Shock event detected If the truck control unit detects a very strong acceleration or deceleration e g in the event of an accident this message appears Service required If the maintenance inter...

Page 418: ...rotection variant this mes sage appears if an excessive load is picked up Set down the load Overtemp Drive unit The drive units are protected against overtem perature If the temperature at the drive units is too high this message appears Acceleration and maximum speed are reduced Allow the truck to cool down Overtemperature bat tery If the truck control unit detects an excessive battery temperatur...

Page 419: ...witch does not open Stand up from the driver s seat and sit down again A3035 Fault Brake fluid Brake fluid switch A3143 Check lift height sensor 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 of...

Page 420: ...hile the key switch is 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 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 In an emergency all functions of the truck can be shut down...

Page 421: ...s There is a risk to life Failure to comply with the limits specified in these operating instructions e g driving on unacceptably steep gradients or failing to adjust speed when cor nering can cause the truck to tip over If the truck starts to tip over do not leave the truck under any circumstances This increases the danger of being hit by the truck Do not release your seat belt Never jump off the...

Page 422: ...he face when smashing a pane of glass Pull the emergency hammer out of its sup port mounting at the handle Using one of the two metal tips on the head of the emergency hammer hit the pane of glass with force until it breaks Emergency driving via the drive direction switch drive direction selection lever Under certain conditions the emergency driv ing function can be used to remove the truck from a...

Page 423: ...sired drive di rection Press the accelerator pedal Drive the truck to a safe area and park the truck safely If the error occurs frequently contact the authorised service centre Emergency lowering If 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 ...

Page 424: ... revolutions to loosen it WARNING The load is lowered Unscrewing the emergency lowering screw regulates the lowering speed Observe the list of points below The following applies Tightening torque Max 2 5 Nm Unscrewing the emergency lowering screw slightly The load is lowered slowly Unscrewing the emergency lowering screw further The load is lowered quickly After lowering 6301_003 036 1 6219_003 26...

Page 425: ...he truck can roll away when the park ing brake is released In an emergency secure the truck with wedges on the downhill facing side to prevent it from rolling away Manually release the parking brake only when the truck is at a standstill with the fork lowered The electric parking brake can be released and applied via an emergency actuation mechanism The emergency release of the electric parking br...

Page 426: ...Pull the emergency actuation mechanism 2 with a maximum of 50 N To release the mechanism fully depress the brake pedal and hold it down Remove and 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 ac...

Page 427: ... into the towing vehicle when the tow ing vehicle brakes For safety reasons only a tested tow bar may be used Use a tested tow bar CAUTION If the truck drive between the drive motor and the drive axle is not interrupted the drive may be dam aged Set the drive direction switch to the neutral posi tion CAUTION Potential for damage to the battery male connector If the battery male connector is discon...

Page 428: ... at all times WARNING Risk of accident if the truck is not steered If the truck is not steered while it is being towed 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 fasten the seat belt before towing Use the available restraint systems Procedure Set down the load and lowe...

Page 429: ...rolled at all times Tow the truck NOTE If the service brake is actuated very strongly the parking brake may apply In this case manually release the parking brake Once the towing procedure is complete al low the parking 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 emerg...

Page 430: ...i um ion battery chapter Observe and follow the safety information below Safety information DANGER Risk of explosion due to flammable gases During charging the lead acid batteries release a mixture of oxygen and hydro gen oxyhydrogen gas This gas mixture is explosive and must not be ignited There must be no flammable materi als or spark forming operating materials within 2 m of either the truck wh...

Page 431: ...d as this will result in excessive wear and pose a fire hazard If the mains plug needs be pulled out before the end of the charging process cancel the charging process at the battery charger first DANGER Risk of explosion from connecting and disconnecting connection assemblies Even when the truck and the battery charger are switched off oxyhydrogen gas in the vicinity can explode if connec tion as...

Page 432: ...d off 4 Lithium ion battery with truck switched on Opening the lid Gently press in the lid 2 and release it The lid 2 is partially opened by a spring Then open the lid 2 completely by hand and hold it The lid 2 is secured against unintentional opening by a spring Closing the lid When the charging cable is disconnected from the charging quick access 1 the lid 2 closes automatically by spring pull N...

Page 433: ...ing cable from the charging quick access 1 3 Lithium ion battery with truck switch ed off Connect the charging cable to the charging quick access 1 Battery charging takes place The display operating unit shows the charging state dis play 3 When the charging process is complete disconnect the charging cable from the charging quick access 1 4 Lithium ion battery with truck switch ed on Connect the c...

Page 434: ... error The charging quick ac cess 1 may not recognise the charging ca ble In this case disconnect the charging cable from the charging quick access and re es tablish the connection If the charging process is running the charg ing state display 3 is animated in green If the charging process is not running the charging state display 3 flashes in grey 7 3 kW 10 48 88 6219_003 337 3 Operating 4 Chargi...

Page 435: ...mA Protective conductor NOTE All messages for the on board charger are lis ted in the section entitled Messages about operation in the Display messages chapter Conditions for the operation of the on board charger The on board charger must only be used to charge batteries that are located in the same truck as the charger and are connected to the truck The housing of the on board charger must not be...

Page 436: ...r has not been configured for the battery type used and for example an excessively high battery capacity has been set this may result in excessive heating and significant gas emissions Oxyhydrogen gas and sulphur compounds form as a result Observe the following conditions which may mean that a reconfiguration of the battery charger is required The battery charger must be configured for the battery...

Page 437: ... the battery type used Fleet manager access authorisation variant allows the fleet manag er to do this NOTE The configuration process requires access au thorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the parking brake is ap plied If the parking brake is released prema turely the settings menu will close Apply the parking brake Pr...

Page 438: ...teristic curves are displayed The orange activation bar displays the current selection Push the softkey that corresponds to the selection The display reverts to the On board charger menu Charging start time Press the Charging start time soft key Fleet manager Charging start time Charging current limitation Maintenance charge Charging characteristic curve 6219_003 285_en Fleet manager Standard Fast...

Page 439: ...e charging plug is plugged in outside the specified charging start time a charging state indicator 2 appears in grey Battery charging does not take place The time remaining 1 until the specified charging start time is displayed in the top left The softkey allows you to start charging directly To do so press the 3 softkey Fleet manager Enter time to start charging Clear 00 Charging start time 00 Ac...

Page 440: ...ts Press the Charging current limi tation softkey Charging current limitation menu Enter the charging current as a percent age 1 using softkeys 0 to9 The charging current is displayed under the input window in amperes 2 To save press the button The display reverts to the On board charger menu Maintenance charge If the truck remains stationary over a pro longed period and maintenance charge is 6219...

Page 441: ...ixture is explo sive and must not be ignited There must be no flammable materi als or spark forming operating materials within 2 m of either the truck when it is parked for charging or the battery charg er When working with batteries take the following safety precautions Keep away from open flames and do not smoke Ensure that work areas are adequately ven tilated Disconnect the battery male connec...

Page 442: ...the relevant socket DANGER Risk of fire due to overheated connec tion assembly Do not pull out the mains plug under load as this will result in excessive wear and pose a fire hazard If the mains plug needs be pulled out before the end of the charging process cancel the charging process manually first see the section entitled Stopping the charging process man ually DANGER Risk of explosion due to s...

Page 443: ... and discon necting connection assemblies Even when the truck and the battery charger are switched off oxyhydrogen gas in the vicinity can explode if connec tion assemblies are connected or dis connected Sufficiently ventilate the battery com partment of the truck and the charg ing area CAUTION Possible component damage Make sure that the charging cable does not cross any traffic routes Do not rou...

Page 444: ...ies may be charged intermediately as often as required with no restriction to the bat tery life Park the truck securely on a flat surface near a suitable CEE 16 A socket and switch off the truck Take the supplied charging cable out of the storage container Open the cover 2 of the charger socket 1 on the truck 6301_003 041 1 2 Operating 4 On board charger 428 56388011501 EN 05 2022 08 ...

Page 445: ...it If the charging state display 6 does not ap pear or the LED 5 lights up permanently in red there is a fault It is possible that the charger socket 1 does not recognise the truck plug 3 In this case pull out the truck plug 3 and plug it in again If the charging process is running the charg ing state display 6 is animated in green If the charging process is not running the charging state display ...

Page 446: ...active Yellow Battery voltage detection start phase Yellow Recharging phase active lead acid battery Yellow Battery almost fully charged lithium ion battery residual charging with reduced current Yellow green Battery fully charged Green Trickle charging only for lead acid batteries Green Deep discharge start possible press push button for 2 s Red Malfunction e g mains supply or battery faulty inte...

Page 447: ... the LED tail lights on the truck The individual LEDs in the tail lights begin to flash go out and flash again one after anoth er running from one side to the other side This light signal is displayed over the entire duration of the charging process Up to a charging state of 50 only the LEDs in the left tail light begin to flash The fewer LEDs that flash the lower the charging state As soon as the...

Page 448: ...or the truck plug at the same time Pull the truck plug out of the charger socket Pull the charging cable out of the CEE 16 A socket and attach the protective cap Place the charging cable in the storage con tainer on the counterweight Close the cover of the charger socket It is possible to stop the charging process manually at any time See the following sec tion entitled Stopping the charging proce...

Page 449: ...p and con figure this pump in the battery charger Using an electrolyte circulation pump reduces the charging time of a lead acid battery and enables intermediate charging If the truck is equipped with an electrolyte circulation pump a battery designed for elec trolyte circulation must always be used The pump can be damaged without the counter pressure from the battery The charger detects an error ...

Page 450: ... Before the charging process is started manually you must there fore measure all cell voltages in the battery and compare them for any irregularities If one cell voltage is significantly smaller than the others the battery is probably defective The charging process must not be started In addition the filling quantity of the acid in the cells must be checked and if necessary re filled according to ...

Page 451: ... can cause overloading as well as excessive gas emissions and overheating of the battery Only use intact batteries approved by STILL CAUTION Risk of damage to components If batteries other than those listed here are used it is not possible to guarantee that the batteries will not incur damage and will charge correctly Use only the batteries listed here In addition to proprietary STILL lithium ion ...

Page 452: ... TAB Exide 3 Gel batteries are charged solely in accord ance with the standard characteristic curve IUIa If in doubt contact the authorised service centre Performance data Input Mains voltage 400 V AC Network frequency 45 to 65 Hz Maximum power consumption 10 7 kW Maximum current draw 15 5 A Output Maximum output power 10 kW Maximum charging current 120 A1 Output voltage 40 108 V DC Nominal voltag...

Page 453: ...lug connection 1 are dry clean and free of foreign objects Insert the battery male connector 2 fully into the plug connection 1 on the truck The orange latch 3 must engage CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery door Ensure that the battery cable does not come into contact with the battery door NOTE The appearance ...

Page 454: ...or 2 unlocks Pull out the battery male connector 2 from the plug connection 1 on the truck and set it down safely CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery door Ensure that the battery cable does not come into contact with the battery door NOTE The appearance of a lithium ion battery differs from this illustration Th...

Page 455: ... or battery charg er and for the battery Observe the following safety regulations when maintaining charging and changing the battery Maintenance personnel Batteries must only be charged maintained and replaced by properly trained personnel in accordance with the instructions compiled by the manufacturers of the battery battery charger and industrial truck The handling instructions for the battery ...

Page 456: ...ing and maintaining the battery observe the manufacturer s maintenance in structions for the battery and the battery charger Fire protection measures DANGER Risk of explosion if the battery is not extended If the truck is equipped with an electric battery carrier variant the following applies The battery carrier reduces the space between the battery and the battery hood During charging lead acid b...

Page 457: ...ly disconnect when the industrial truck and battery charger are switched off The battery door must remain open during charging Expose the surfaces of the battery cells Do not place any metal objects on the bat tery Fully open any protective structures e g fabric covered cab Have fire extinguishing equipment ready Battery weight and dimensions DANGER Risk of tipping due to change in battery weight ...

Page 458: ...attery cable does not come into contact with the battery door CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected or con nected while the key switch is switched on or while the battery charger is under load an arc or a tran sition spark will be produced at the battery male connector This can lead to erosion at the contacts and can considerably s...

Page 459: ...ce with the battery manufacturer s operating instructions 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 a...

Page 460: ...the au thorised service centre Open filler cap 1 and check the acid level For batteries with caged cell plugs the liquid must reach the bottom of the cage For batteries without caged cell plugs the liquid must reach a height of approx 10 to 15 mm above the lead plates Top up missing fluid with distilled water on ly Clean the battery cell cover and dry if nec essary Remove any oxidation residues on...

Page 461: ...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 Calibrating the batte...

Page 462: ...n the display operating unit Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck settings softkey Press the Battery softkey Battery Driving programme 6219_003 327_en Operating 4 Handling the lead acid battery 446 56388011501 EN 05 2022 08 ...

Page 463: ... in the cab variant DANGER Risk of explosion if the battery is not extended If the truck is equipped with an electric battery carrier variant the following applies The battery carrier reduces the space between the battery and the battery hood During charging lead acid batteries generate explosive oxyhydrogen gas Sufficient quantities of this gas must be removed from the truck This gas can only be ...

Page 464: ... of the battery DANGER There is a risk of damage short circuiting and ex plosions Do not place any metal objects or tools on the battery Keep away from naked flames Do not smoke WARNING Battery acid is toxic and corrosive Observe the safety regulations in the chapter enti tled Battery acid CAUTION Risk of damage to the battery charger Incorrect connection or incorrect opera tion of the charging st...

Page 465: ...ully 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 extend the battery out of the truck See the section entitled Replacing the battery using an electric bat tery carrier variant in this chapter Disconnect the battery male connector Do not place any metal objects or tools on the battery ...

Page 466: ...attery 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 450 56388011501 EN 05 2022 08 ...

Page 467: ...y charger Swing the support bracket 1 back into position 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 to the truck DANGER Risk of explosion Only disconnect the connection assem blies when the truck and batter...

Page 468: ...battery capacity An equalising charge should be carried out in accordance with the battery manufacturer s instructions several times a month after the normal 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 for performing the equalising charge Observ...

Page 469: ...perating 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 before you discon nect the charging cable ...

Page 470: ...in with soap and water Eye irritation can occur in the event of contact with the eyes Immediately rinse eyes thoroughly with wa ter for 15 minutes then consult a doctor Maintenance personnel The lithium ion battery is virtually mainte nance free and can be charged by the driver If you have any questions please contact your authorised service centre The handling instruction for the battery and the ...

Page 471: ...taining the battery observe the manufacturer s maintenance in structions for the battery and battery charg er Fire protection measures DANGER There is a risk of damage short circuiting and ex plosion Do not place any metal objects or tools on the battery Keep away from naked flames and do not smoke DANGER Increased risk of fire Damaged lithium ion batteries pose an increased fire hazard In the eve...

Page 472: ...afety regulations for lithium ion batteries The following safety regulations generally ap ply to operating lithium ion batteries Comply with the specifications stated in the safety data sheets of the battery manufac turer Protect the battery against mechanical damage to prevent internal short circuits If batteries have even the slightest external damage dispose of them in accordance with national ...

Page 473: ...ifting eyes If bent lifting eyes are straightened they lose their rigidity The lifting eyes are then no longer able to support the weight of the battery The battery may fall Do not straighten bent lifting eyes Have bent lifting eyes replaced by the authorised service centre NOTE When switching to lithium ion batteries have the truck electronics adapted by the author ised service centre Operating 4...

Page 474: ... load capacity of the stor age area refer to the manufacturer s speci fications regarding battery weight To protect batteries against moisture do not store them directly on the floor Due to the fire risk store batteries outside buildings Store in a cool dry and well ventilated area Never subject the battery to temperatures below 35 C and above 80 C Long term storage below 10 C or above 50 C has a ...

Page 475: ...n batteries separately from other types of batteries no mixed storage Maintain a safety margin of at least 2 5 m from other goods To avoid a deep discharge observe the specifications of the battery manufacturer regarding the maximum permissible storage period If you have any questions contact your au thorised service centre Operating 4 Handling the lithium ion battery 459 56388011501 EN 05 2022 08...

Page 476: ...harge Reading from the battery indicator The battery indicator is located on the side of the battery tray Like the display operating unit the battery indicator shows the charge state of the lithium ion battery Warnings are issued only on this battery indicator If you have any questions contact your au thorised service centre Charge state LEDs When the battery is connected to the truck and the truc...

Page 477: ...e temperature falls into the normal range Colour of LED Cause Consequence Flashing yellow Slightly increased temperature 60 C Power reduction Solid yellow Increased temperature 65 C Shut off Flashing red Greatly increased temperature 70 C Shut off Solid red Greatly increased temperature 75 C Shut off Procedure if a lithium ion battery has a low charge state WARNING Risk of component damage or dest...

Page 478: ...r may result in damage to components Follow the operating instructions for the charging station or battery charger and for the battery CAUTION Risk of component damage Using battery male connectors and battery charger plugs from different manufacturers can result in dam age They are not designed to be used together Use battery male connectors and battery charger connectors from the same manufactur...

Page 479: ...ry male connector to the plug on the battery charger Start the battery charger The charging process starts automatically The display signals the charging process by illuminating the LEDS as a chase light The battery charger will indicate when the bat tery is fully charged Only disconnect the bat tery from the charger if no current is flowing The battery has no memory effect Therefore it can be cha...

Page 480: ...upport bracket 1 into the support mount ing 2 on the battery door After charging The battery charger will switch off automatical ly Open the battery door Lock the battery door in the open position Disconnect the battery male connector from the plug for the battery charger Insert the battery male connector fully into the plug connection on the truck CAUTION There is a risk of short circuit if the c...

Page 481: ...attery door The truck is equipped with a door contact switch for the battery door If the battery door is not fully closed the message Close battery door appears on the display of the display operating unit The truck will not move Operating 4 Handling the lithium ion battery 465 56388011501 EN 05 2022 08 ...

Page 482: ...ity of the lifting accessory used must at least match the battery weight see the battery nameplate Wire cross section of the battery cable on the High Performance variant If the truck is fitted with the High 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...

Page 483: ...ting unit Use only lithium ion batteries that have been approved by STILL for use with this truck Setting the new battery capacity and the new battery type Stop the truck Apply the parking brake Press the button Press the softkey The first menu level appears Activate the Access authorisation for the fleet manager Press the Truck settings softkey Press the Battery softkey Press the Battery type sof...

Page 484: ...rics so that they will work with the lithium ion batteries This includes The cable harness The battery male connector and the plug connection Adjusting the display operating unit Use only lithium ion batteries that have been approved by STILL for use with this truck Opening and closing the battery door Opening the battery door Grasp the door handle 1 on the battery door Open the battery door by pu...

Page 485: ...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 486: ... 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 487: ... that the cable does not come into con tact with the truck chassis during installa tion Replacing the battery using a truck Preparing WARNING Risk of accident The load capacity of the truck in use must at least match the battery weight see the battery name plate Observe the nameplates of the battery and of the change frame Before picking up the battery the fork arms must be adjusted to match the o...

Page 488: ...y 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 it cannot be crushed either when removing or in serting the battery or when closing the battery door Open the battery locks 1 NOTE If the battery locks cannot be opened by hand the coupling pin 2 from the counterweig...

Page 489: ...to the intended stor age space CAUTION Risk of damage The battery must be stored on a suitable beam sup port or on suitable racking The battery must not be stored on a wooden beam or any similar object Set down the battery Installing the battery Pick up the battery and transport it to the truck CAUTION Risk of component damage If the lifting eyes protrude from the lithium ion battery variant they ...

Page 490: ...the battery is inserted to a suffi cient depth the display on the lithium ion battery var iant points towards the battery door DANGER Risk of crushing or shearing While inserting the battery avoid putting your hands between the battery and the chassis CAUTION Risk of damage Position the battery cables on the bat tery in such a way that they cannot be crushed either when removing or inserting the b...

Page 491: ...ith the key switch switched on Make sure that the key switch is switched off be fore connecting the battery male connector Ensure that the battery male connector and the plug connection are dry clean and free of foreign objects Close the battery locks NOTE The battery door will close only when the bat tery is locked Insert the battery male connector fully into the plug connection on the truck Clos...

Page 492: ...llet 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 tery compartment of the truck Once the bat tery has been set down on its holding fixtures the change frame is moved back out of the truck Removing the battery Park the truck securely Open the battery door CAUTION Risk of ...

Page 493: ...ving or in serting the battery or when closing the battery door Open 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 Ensure that the maximum load capacity of the change frame is not exceeded The maximum load capacity of the change frame is specified on the identification plate Before picking up the ch...

Page 494: ...e g using a strip of adhesive tape CAUTION Risk of component damage Move the change frame under the battery only up to the edge of the stop Carefully move the change frame under the battery Carefully lift the battery up and out of the truck Pay attention to the distance to the chassis Slowly remove the battery from the battery compartment Transporting and setting down the bat tery WARNING Risk of ...

Page 495: ...k 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 the battery is inserted Position the battery at a right angle to the truck CAUTION Risk of component damage If the lifting eyes protrude from the lithium ion battery variant they will strike the truck chassis and bend Before insertin...

Page 496: ...en the bat tery is locked CAUTION Risk of component damage If the battery male connector is connected when the key switch is switched on under load a jump spark will be produced This can lead to erosion at the contacts 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...

Page 497: ... Insert the battery male connector fully into the plug connection on the truck Close the battery door Operating 4 Replacing and transporting the battery 481 56388011501 EN 05 2022 08 ...

Page 498: ...nge specified on the nameplate The location of ballast weights must not be changed Prerequisites WARNING Risk of injury when extending the battery The battery is extended out into the marked area 1 People must not stand in this area The area 1 extends over the width of the battery compartment and the extension range of the battery carrier Only stand in the operator s position 2 The following prere...

Page 499: ... switch is located next to the operating device for extending and retract ing the battery carrier on the counterweight In the event of an emergency actuate the emergency off switch M or disconnect the battery male connector G Ejecting the battery A Apply the parking brake B Make sure that there is no load on the driver s seat Open the battery door WARNING Risk of injury Open the battery door until...

Page 500: ...s unlocked This also applies to the emergency off switch on the driver s compartment E Push and release the extension button Push the extension button again and hold down the button C 6301_003 137 D 6301_003 140 E 6301_003 138 Operating 4 Replacing and transporting the battery 484 56388011501 EN 05 2022 08 ...

Page 501: ...attery fully Place a rubber mat on any batteries that have exposed terminals or connectors to prevent short circuits H Remove the battery from the carrier us ing suitable lifting gear For more informa tion see the section entitled Transporting the battery by crane Ensure that the truck is parked at a suffi cient distance from any obstacles to prevent damaging the truck when lifting the battery usi...

Page 502: ...on under load a transition spark will be produced This transition spark can damage the contacts and considerably shorten the service life of the contacts Ensure that the truck is switched off J Connect the battery male connector to the plug connection on the truck K Push and release the retraction button Push the retraction button again and hold down the button I 6301_003 147 J 6301_003 145 K 6301...

Page 503: ...E If the truck is equipped with the FleetManag er variant and this feature is to be used the driver must authenticate themself Otherwise the truck will switch off after a certain period of time Transporting the lead acid bat tery by crane DANGER There is risk of fatal injury from being struck by falling loads Never walk or stand underneath sus pended loads The tray for the lead acid battery 1 is e...

Page 504: ...he lithium ion bat tery by crane DANGER There is risk of fatal injury from being struck by falling loads Never walk or stand underneath sus pended loads WARNING Risk of accident due to weakened lifting eyes If bent lifting eyes are straightened they lose their rigidity The lifting eyes are then no longer able to support the weight of the battery The battery may fall Do not straighten bent lifting ...

Page 505: ... lifting eyes 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 battery has been set down Lift up and release the lift ing eyes to lower them Operating 4 Replacing and transporting the battery 489 563880115...

Page 506: ...materials CAUTION Risk of fire due to flammable materials Deposits and solids can be ignited by hot components e g drive units Remove deposits and solids CAUTION Risk of damage to the battery male connector when disconnecting If the battery male connector is disconnected while the key switch is switched on under load an arc will be produced The arc can damage the contacts and considerably shorten ...

Page 507: ...display operating unit could become cloudy Strictly adhere to the following steps Park the truck securely Switch off the key switch Disconnect the battery male connector Do not spray electric motors and other elec trical components or their covers directly with water Use only high pressure cleaners with a maximum output power of up to 60 bar and 85 C If a high pressure cleaner is used maintain a d...

Page 508: ...r can damage the electrical system Cleaning electrical system parts with wa ter is forbidden Do not remove covers etc Only use dry cleaning materials ac cording to the specifications in the section Cleaning the truck CAUTION Possible component damage due to compressed air If components are cleaned with compressed air the air must have a maximum pressure of 0 15 bar This prevents liquids or small s...

Page 509: ...do not use addi tional cleaning agents Remove any water in the chain links using compressed air immediately after cleaning Move the chain several times during this procedure Immediately after drying the chain spray it with chain spray Move the chain several times during this procedure For chain spray specifications see the Main tenance data table chapter ENVIRONMENT NOTE Dispose of any fluid that ...

Page 510: ...to the battery male con nector and plug connection can lead to an electrical short circuit Use compressed air to dry the battery male con nector and the plug connection 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 L...

Page 511: ... the load capacity of the means of transport ramps and loading bridges is greater than the total actual weight of the truck Determining the total actual weight Park the truck safely Determine the unit weights by reading the truck nameplate and if necessary the at tachment nameplate variant Add together the determined unit weights to obtain the total actual weight of the truck Net weight 1 Maximum ...

Page 512: ...1 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 produced 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 513: ... 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 514: ...ing Crane loading is only intended for transport ing 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 498 56388011501 EN 05 2022 08 ...

Page 515: ...ement the following measures before decom missioning Measures to be implemented before de commissioning Clean the truck thoroughly see the chapter entitled Cleaning the truck Lift the fork carriage to the stop several times Tilt the lift mast forwards and backwards several times and if fitted move the attach ment repeatedly To relieve the strain on the load chains lower the fork onto a suitable su...

Page 516: ...l contacts with a suitable contact spray CAUTION Tyre deformation as a result of continuous loading on one side Have the truck raised and jacked up by the author ised service centre so that all wheels are off the ground This prevents permanent deformation of the tyres Only have the truck raised and jacked up by the authorised service centre CAUTION Risk of corrosion damage due to condensation on t...

Page 517: ...heck the hydraulic oil for condensation water Change the hydraulic oil if necessa ry Arrange for the authorised service centre to perform the same inspections and tasks that were carried out before initial commis sioning The explosion protection inspection must be performed by the authorised service centre Perform the visual inspections and func tional checks The following points in particular mus...

Page 518: ...Operating 4 Decommissioning 502 56388011501 EN 05 2022 08 ...

Page 519: ...5 Maintenance ...

Page 520: ...he lift mast to prevent it tilting backwards unintentionally Observe the maximum lift height of the lift mast and compare the dimensions from the technical data with the dimensions of the hall into which the truck is to be driven These steps are taken to prevent a collision with the ceiling of the hall and to avoid any damage caused as a result Working on the hydraulic equip ment The hydraulic sys...

Page 521: ...when changing hydraulic and electrical components These are listed in the appropriate sections Lifting and jacking up DANGER There is a risk to life if the truck tips over If not raised and jacked up properly the truck may tip over and fall off Only the hoists specified in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity Only have the truck r...

Page 522: ...he lift mast against tilting backwards DANGER Risk of accident This work must only be performed by an authorised service technician To secure the lift mast against tilting back contact the authorised service centre Removing the lift mast DANGER Risk of accident This work must only be performed by an authorised service technician Commission the authorised service centre to re move the lift mast Sec...

Page 523: ... who have received ap propriate training in accordance with the in structions from the manufacturers of the bat tery battery charger and truck Follow the handling instructions for the bat tery and the operating instructions for the battery charger Maintenance work without special quali fications Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained person...

Page 524: ...tors may necessitate shorter maintenance intervals Dirty poor quality roadways Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures 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 Servic...

Page 525: ...ounter for maintenance and safety checks NOTE The maintenance interval can also be config ured in the status line Setting up and adjusting the due date counter for maintenance and safety checks On delivery from the factory the display oper ating unit indicates to the driver the number of operating hours until the standard mainte nance intervals of 1000 h and 3000 h are due The display also shows t...

Page 526: ...ger can define the corresponding due dates with his access authorisation To do this proceed as follows Activate the Access authorisation for the fleet manager Press the Service softkey Press the Maintenance interval softkey Press the softkey for the testing whose due date is to be set e g Safety check Fleet manager 2120 h 04 02 22 880 h 3000 h interval Latest date 1000 h interval Safety check h Em...

Page 527: ...t up addi tional due date counters for individual mainte nance intervals e g for an attachment The fleet manager can use his access authorisa tion to configure these due date counters The process is then the same as for the due date counters created ex works Fleet manager Enter date Clear Safety check 30 05 2022 Activate Save Cancel 6219_003 334_en Maintenance 5 General maintenance information 511...

Page 528: ...door and the sensor are working correctly and check for damage Check the battery lock for damage Variant Check the oil level of the hydraulic battery carrier and check for leak tightness 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 mo...

Page 529: ... 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 530: ...damage and for wear Check 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 attach...

Page 531: ...0 10000 11000 13000 14000 Carried out Read out the error numbers and clear the list Reset the maintenance interval Check that the labelling is complete Perform a test drive Maintenance 5 General maintenance information 515 56388011501 EN 05 2022 08 ...

Page 532: ...tion 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 can result in an increased risk of acci dents due to insufficient quality or incorrect assignment Anyone using unapproved spare parts shall assume unlimited liability in the event of damage or harm Quality and quantity of the re quired...

Page 533: ...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 containers Maintenance 5 General maintenance information 517 56388011501 EN 05 2022 08 ...

Page 534: ...e on each of the two lift mast bearings 1The respective lubricant specification can be found in the Maintenance data table section below 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 manufacturer Maintenance 5 General maintenance information 5...

Page 535: ...irax 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 For further informa tion refer to the workshop manual for the truck in question Controls joints Code Unit Operating materials Specifications Dimension Lubrication High pressure grease ID no 0147873 As required Oil SAE 80 MIL L...

Page 536: ... 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 Wheel screws Torque wrench For further informa tion refer to the workshop manual...

Page 537: ...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 Air conditioning normal cab Code Unit Operating materials Specifications Dimension System filling Refrigerant R134a Filling quantity 1107 g System filling Compressor oil POE RL68H 120 ml Air conditioning raised cab...

Page 538: ...re is a danger of 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 condi...

Page 539: ...lty 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 b...

Page 540: ...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 541: ...tion of the seat e g wear on the upholstery and secure fastening to the hood WARNING Risk of injury Have the seat repaired by the service centre if you identify any damage during the checks Servicing the heating system or air conditioning Replacing the filter mat Loosen the screw 1 Remove the cover 2 6327_342 010 2 1 Maintenance 5 Preserving operational readiness 525 56388011501 EN 05 2022 08 ...

Page 542: ...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 526 56388011501 EN 05 2022 08 ...

Page 543: ... Remove any dust and dirt from the fresh air inlet 1 beneath the filter mat carrier 1 Maintenance 5 Preserving operational readiness 527 56388011501 EN 05 2022 08 ...

Page 544: ...ers must not be mixed If you wish to use a type of tyre or tyre manufac turer that has not been approved by STILL obtain approval from STILL prior to use Do not change rim parts and do not mix rim parts from different manufacturers Checking the condition and wear of the tyres Superelastic tyres Remove any foreign bodies embedded in the tyres 1 The level of wear exhibited by tyres on the same axle ...

Page 545: ...ove any foreign bodies embedded in the tyres Checking the air pressure NOTE The correct air pressure for pneumatic tyres variant is determined by the type of tyre used The air pressure measured must corre spond to the manufacturer s information Observe the air pressure value on the ad hesive label on the truck see the labelling points Check the air pressure of all four tyres and compare with the a...

Page 546: ...s Lubricating the steering axle ENVIRONMENT NOTE Dispose of old grease and contaminated de vices in accordance with the national regula tions for the country in which the truck is being used The joints of the steering axle each have four lubricating nipples per side Apply grease to the lubricating nipples for the steering axle in accordance with the maintenance data table until old grease begins t...

Page 547: ...tly 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 Adjusting the warning zone light Switch on the truck Make sure that the parking brake is applied Loosen the nuts 2 to adjust each head light Adjust the headlight 1 The distance from the light bar to the truck must be between 70 ...

Page 548: ...lic hoses for more than two years Do not use hydraulic hoses for more than six years if they are subject to normal wear Do not use hydraulic hoses for more than two years if they are subject to a high level of wear Comply with the specifications of DGUV 113 020 in Germany Outside of Germany observe the national regula tions for the country of use Check pipe and hose connection screw joints for lea...

Page 549: ...Replace pipes if they display the following ab normalities Abrasion Deformation and bending Leaking Maintenance 5 Preserving operational readiness 533 56388011501 EN 05 2022 08 ...

Page 550: ...d while the key switch is 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 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 connector Fold up the floor ...

Page 551: ...ple mast 3 5 t LSP 600 4 5 t 5 0 t 3 5 t LSP 600 4 0 t 4 5 t 5 0 t 1 3250 2850 2350 42 2 3050 to 3250 2500 to 3000 2600 50 3 3200 2800 to 3200 58 CAUTION Risk of damage If the hydraulic oil level is too low the steering is restricted and the pump may be damaged If the oil level is too low do not use the truck and contact the authorised service centre Screw in the breather filter and the dipstick i...

Page 552: ...ce data table Page 519 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 readi ness 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 ope...

Page 553: ...onnections for leaks WARNING Risk of injury Observe safety regulations for working on the lift mast see the Working at the front of the truck chapter Check hydraulic connections and lift cylin ders for leaks visual inspection Have leaking screw joints or leaking hy draulic cylinders repaired by the authorised service centre 7094_810 004 Maintenance 5 1000 hour maintenance annual maintenance 537 56...

Page 554: ...rms in pairs Check that the fork latch 3 is functioning correctly Make sure that the locking screw 2 is present and cannot fall out Checking the reversible fork arms NOTE This check is only required for reversible fork arms variant Check the outside of the fork bend 1 for cracks Contact your service centre 2 1 3 Maintenance 5 1000 hour maintenance annual maintenance 538 56388011501 EN 05 2022 08 ...

Page 555: ...ecurely posi tioned Check that all screws are sealed with lock ing varnish Checking the battery change over 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 539 56388011501 EN 05 2022 08 ...

Page 556: ...Maintenance 5 1000 hour maintenance annual maintenance 540 56388011501 EN 05 2022 08 ...

Page 557: ...6 Technical data ...

Page 558: ...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 559: ...ons h h 10 h 7 h 6 h 1 h 3 h 4 s l2 x y l c Q h 2 m 1 m 2 b 11 b 1 6331_003 007 b 3 b 10 e 2 1 Seat is adjustable 90 mm 1 Fork spacing is adjustable 2 Technical data 6 Dimensions 543 56388011501 EN 05 2022 08 ...

Page 560: ...NOTE Measurements h1 h3 h4 h6 and b1 are cus tomised and can be taken from the order con firmation Technical data 6 Dimensions 544 56388011501 EN 05 2022 08 ...

Page 561: ...ion Seat Load capacity load Q kg 3500 Load centre of gravity c mm 600 Load distance x mm 515 Wheelbase y mm 2046 Weights Model RX60 35 Plus 600 Li Ion Type number 6331 Net weight including battery kg 6310 Front axle load laden kg 8747 Rear axle load laden kg 1063 Front axle load unladen kg 3322 Rear axle load unladen kg 2988 Wheels chassis frame Model RX60 35 Plus 600 Li Ion Type number 6331 Tyres...

Page 562: ...762 Height above overhead guard low variant h6 mm 2336 2241 Seat height in relation to SIP low variant h7 mm 1345 Coupling height h10 mm 540 415 Overall length l1 mm 4101 Length including fork back l2 mm 2901 Overall width b1 mm 1320 Fork arm thickness s mm 50 Fork arm width e mm 120 Fork arm length l mm 1200 Fork carriage Standard class form ISO 2328 III A Fork carriage width b3 mm 1200 Ground cl...

Page 563: ...e with load kg 7280 Pulling force without load kg 7750 Max pulling force with load Plus3 Standard Perform ance 4 kg 2720 19170 Max pulling force without load Plus3 Standard Per formance 4 kg 22460 19040 Climbing capability with load 12 4 Climbing capability without load 20 3 Max climbing capability with load Plus3 Standard Performance 4 22 1 15 9 Max climbing capability without load Plus3 Standard...

Page 564: ... or descending gradient per mitted for travel is 15 If you have any questions contact your authorised service centre Electric motor Model RX60 35 Plus 600 Li Ion Type number 6331 Traction motor power rating S2 60 min kW 2x11 Lift motor power rating S3 at 15 ED kW 25 Battery Standard circuit DIN 43536 A Battery voltage U V 80 Battery capacity K5 Ah 840 930 Battery weight kg 2178 Energy consumption ...

Page 565: ... flow for attachments l 50 Sound pressure level LpAZ driver s compartment 1 dB A 66 Human vibration acceleration according to EN 13059 m s2 0 42 Tow coupling type Bolt 1 Without cab Values are different with a cab Technical data 6 VDI datasheet RX60 35 Plus 600 Li Ion 549 56388011501 EN 05 2022 08 ...

Page 566: ...kg 4000 4000 Load centre of gravity c mm 500 600 Load distance x mm 515 515 Wheelbase y mm 2046 2046 Weights Model RX60 40 RX60 40 600 Type number 6332 6333 Net weight including battery kg 6310 6582 Front axle load laden kg 9326 9512 Rear axle load laden kg 984 1070 Front axle load unladen kg 3322 3312 Rear axle load unladen kg 2988 3270 Wheels chassis frame Model RX60 40 RX60 40 600 Type number 6...

Page 567: ...g height h10 mm 540 415 540 415 Overall length l1 mm 4101 4101 Length including fork back l2 mm 2901 2901 Overall width b1 mm 1320 1399 Fork arm thickness s mm 50 50 Fork arm width e mm 120 120 Fork arm length l mm 1200 1200 Fork carriage Standard class form ISO 2328 III A ISO 2328 III A Fork carriage width b3 mm 1200 1200 Ground clearance with load below lift mast m1 mm 129 127 Ground clearance a...

Page 568: ...19150 22730 19170 Max Tractive force without load plus3 standard performance 4 kg 22460 19040 22690 19230 Climbing capability with load 11 6 11 Climbing capability without load 19 7 18 8 Max Climbing ability with load plus3 standard performance 4 21 8 15 5 21 6 15 3 Max Climbing ability without load plus3 standard performance 4 28 5 28 5 28 4 28 4 Acceleration time 15 m with load plus3 standard pe...

Page 569: ... 2x11 Lift motor power rating at 15 ED kW 25 25 Battery Standard cir cuit DIN 43536 A DIN 43536 A Battery voltage U V 80 80 Battery capacity K5 Ah 840 930 840 930 Battery weight kg 2178 2178 Energy consumption in accordance with EN 16796 Plus performance1 Standard performance kWh h 9 8 9 8 10 1 9 9 Handling performance Plus perform ance1 Standard performance t h 272 248 272 248 Energy consumption ...

Page 570: ...driver s com partment 1 dB A 66 66 Human vibration acceleration according to EN 13059 m s2 0 42 0 42 Hitch Art Bolt Bolt 1 Without cab Values are different with a cab Technical data 6 VDI data sheet RX60 40 Plus Li Ion and RX60 40 Plus 600 Li Ion 554 56388011501 EN 05 2022 08 ...

Page 571: ... Q kg 4500 4500 Load centre of gravity c mm 500 600 Load distance x mm 515 525 Wheelbase y mm 2046 2046 Weights Model RX60 45 Li Ion RX60 45 Plus 600 Li Ion Type number 6334 6335 Net weight including battery kg 6582 7164 Front axle load laden kg 10067 10453 Rear axle load laden kg 1015 1211 Front axle load unladen kg 3312 3457 Rear axle load unladen kg 3270 3707 Wheels chassis frame Model RX60 45 ...

Page 572: ...eight above overhead guard low variant h6 mm 2333 2243 2333 2243 Seat height in relation to SIP low variant h7 mm 1343 1342 Coupling height h10 mm 540 415 540 415 Overall length l1 mm 4101 4111 Length including fork back l2 mm 2901 2911 Overall width b1 mm 1399 1399 Fork arm thickness s mm 50 60 Fork arm width e mm 120 130 Fork arm length l mm 1200 1200 Fork carriage Standard class form ISO 2328 I...

Page 573: ...ce with load kg 7030 6960 Pulling force without load kg 7650 7520 Max Tractive force with load plus3 stand ard performance 4 kg 22720 19150 22630 19050 Max Tractive force without load plus3 standard performance 4 kg 22690 19230 22660 19190 Climbing capability with load 10 5 9 6 Climbing capability without load 18 8 16 3 Max Climbing ability with load plus3 standard performance 4 21 3 15 21 14 6 Ma...

Page 574: ... without a load the maximum ascending or descending gradient per mitted for travel is 15 If you have any questions contact your authorised service centre Electric motor Model RX60 45 Li Ion RX60 45 Plus 600 Li Ion Type number 6334 6335 Traction motor power rating at S2 60 min kW 2x11 2x11 Lift motor power rating at 15 ED kW 25 25 Battery Standard cir cuit DIN 43536 A DIN 43536 A Battery voltage U ...

Page 575: ...Model RX60 45 Li Ion RX60 45 Plus 600 Li Ion Type number 6334 6335 Working pressure for attachments bar 250 250 Oil flow for attachments l 50 50 Sound pressure level LpAZ driver s com partment 2 dB A 66 66 Human vibration acceleration according to EN 13059 m s2 0 42 0 42 Hitch Art Bolt Bolt 1 High performance variant 2 Without cab Values are different with a cab Technical data 6 VDI data sheet RX6...

Page 576: ... Q kg 4990 4990 Load centre of gravity c mm 500 600 Load distance x mm 525 525 Wheelbase y mm 2046 2120 Weights Model RX60 50 Li Ion RX60 50 Plus 600 Li Ion Type number 6336 6337 Net weight including battery kg 7164 7768 Front axle load laden kg 10971 11475 Rear axle load laden kg 1183 1283 Front axle load unladen kg 3457 3814 Rear axle load unladen kg 3707 3954 Wheels chassis frame Model RX60 50 ...

Page 577: ...Height above overhead guard low variant h6 mm 2333 2243 2348 2253 Seat height in relation to SIP low variant h7 mm 1342 1351 Coupling height h10 mm 540 415 560 435 Overall length l1 mm 4111 4220 Length including fork back l2 mm 2911 3020 Overall width b1 mm 1399 1399 Fork arm thickness s mm 60 60 Fork arm width e mm 130 130 Fork arm length l mm 1200 1200 Fork carriage Standard class form ISO 2328 ...

Page 578: ...with load kg 6800 6750 Pulling force without load kg 7490 7430 Max Tractive force with load plus3 stand ard performance 4 kg 22620 19030 22590 19000 Max Tractive force without load plus3 standard performance 4 kg 22660 19190 22560 19090 Climbing capability with load 9 2 8 9 Climbing capability without load 16 3 15 5 Max Climbing ability with load plus3 standard performance 4 20 7 14 2 20 4 13 8 Ma...

Page 579: ...r without a load the maximum ascending or descending gradient per mitted for travel is 15 If you have any questions contact your authorised service centre Electric motor Model RX60 50 Li Ion RX60 50 Plus 600 Li Ion Type number 6336 6337 Traction motor power rating at S2 60 min kW 2x11 2x11 Lift motor power rating at 15 ED kW 25 25 Battery Standard cir cuit DIN 43536 A DIN 43536 A Battery voltage U...

Page 580: ...equirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation EU 2019 1781 because these motors do not meet the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Motors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles...

Page 581: ... nameplate Only use a battery tray that is closed at the bot tom NOTE Battery specifications according to DIN 43536 cells in accordance with DIN EN 60254 2 80 V circuit A The battery weight can be found on the nameplate of the battery Lead acid batteries Battery designa tion Capacity Ah Tray Weight ballast weight kg Battery compartment di mensions mm Circuit Length Width Height 5PzS 700 700 235 23...

Page 582: ...ay that is closed at the bottom The battery weight can be found on the nameplate of the battery For more information please refer to the nameplate and the operating instructions for the lithium ion battery X Line Li Ion 80 V BG 7 42 3 kWh and 74 0 kWh Battery group 7 5 Battery group 7 6 Nominal voltage V 88 08 88 08 Nominal capacity Ah 480 840 Nominal energy kWh 42 3 74 0 Length mm 1028 1028 Width...

Page 583: ...ve 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 the auxiliary hydraulics 567 56388011501 EN 05 2022 08 ...

Page 584: ...Technical data 6 Information on the auxiliary hydraulics 568 56388011501 EN 05 2022 08 ...

Page 585: ...lever and the 5th function 333 Controlling with multi lever operation and the 5th function 325 Controlling with multi lever operation and the 6th function 325 Controlling with the fingertip 338 Controlling with the fingertip and the 5th function 340 General controlling 316 Information on the auxiliary hydraulics 566 Load capacity 315 Mounting 315 Picking up a load 345 Safety information 313 Specia...

Page 586: ...he fin gertip 339 Releasing the mechanism with the joy stick 4Plus 343 Cleaning 490 Cleaning the electrical system 492 Cleaning the truck 490 Cleaning the windows 494 Clean the truck After cleaning 494 Climbing into the truck 83 Climbing in when the driver s compartment is raised 85 Climbing out of the truck 83 Climbing out when the driver s compart ment is raised 85 Clipboard 380 Cold store appli...

Page 587: ...of conformity in accordance with the Machinery Directive 7 Efficiency and drive modes 159 Electrical fork wear protection 269 Electric parking brake Symbols in the display operating unit 181 Emergencies Emergency actuation of the parking brake 409 Truck tipping over 405 Using the emergency hammer 406 Emergency drive direction 406 Emergency driving 406 Emergency hammer 406 Emergency lowering 407 Em...

Page 588: ...n about the documentation 21 Information for carrying out maintenance 507 Maintenance timeframe 508 Next maintenance interval 508 Information on the auxiliary hydraulics 566 Information symbols 23 Insulation testing 52 Drive battery test values 53 Test values for the truck 53 Insurance cover on company premises 33 Intended use 17 Interior lighting 375 Issue date of the operating instructions 23 J ...

Page 589: ... Load Determining visibility conditions when driving with a load 239 Driving 240 Picking up 235 Setting down 245 Load dependant assistance systems Load measurement 283 Overload detection 277 Precision load measurement 286 Total load 290 Load dependent assistance systems Dynamic Load Control 2 280 Tare function 288 Load chains Cleaning 493 Load measurement 283 Calibrating 284 Load programs Selectin...

Page 590: ...lift mast 206 N Nameplate 13 Nameplate of a lithium ion battery 15 Neutral position 172 O Oils 54 On board charger Changing the battery type 420 Charging characteristic curve 422 Charging current limitation 424 Charging start time 422 Charging the battery 425 Compatible batteries 435 Configuring 421 General 419 Maintenance charge 424 Performance data 436 Opening closing the 180 cab door 372 Openin...

Page 591: ... lithium ion batter ies 458 Replacing the battery General information 466 High Performance variant 466 Lithium ion battery 471 Using a change frame 476 Using an electric battery carrier 482 Using a truck 471 Residual dangers 45 Residual risk 45 Residual risks 45 Retrofitting 37 Retrofitting lighting equipment 149 Reversible fork arms 223 Checking 538 Roadways 166 168 Aisle widths 166 Descending gr...

Page 592: ...ed restriction Configuring 192 Switching on and off 192 Sprint mode Automatic switch off 163 Switching on and off 163 Stability 46 Starting drive mode 175 Dual pedal version 177 Steering 189 Steering axle Lubricating 530 Servicing 530 Steering system Checking for correct function 97 Storing the truck 499 StVZO Road Traffic Licensing Regula tions information 15 Sun blind 381 Sun visor 381 Switching...

Page 593: ...t height display 254 Lifting systems 202 Lift mast end stop damping 260 Lift transition damping 260 Load measurement 283 Mast tilt angle display 272 Modular camera system 360 On board charger 419 Optical lift height measuring system 250 Overload detection 277 Pre Shift Check 126 Precision load measurement 286 Radio 376 Reversible fork arms 223 Shake function 241 Shock recognition 346 Speed reducti...

Page 594: ...eel fastenings 530 Servicing 528 Usage in winter weather conditions 528 Windscreen wipers and washers Switching on and off 346 Winter tyres 528 Working at the front of the truck 506 Working on the electrical equipment 504 Working on the hydraulic equipment 504 Working spotlight for reverse travel Switching on and off 152 Working spotlights Switching on and off 151 Y Your truck 2 Z Zeroing the assi...

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Page 596: ...STILL GmbH 56388011501 EN 05 2022 08 ...

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