Still RX60-35/600 Original Instructions Manual Download Page 351

Page: 351 / 470

Operation

Replacing and transporting the battery

6210_600-002

NOTE

The apertures in the ﬂap (arrowed) are ne-

cessary for forced ventilation and must not be

blocked.

Special notes for installing the

lithium-ion battery

With the exception of the following special

notes, lithium-ion batteries are replaced in the

same way as lead-acid batteries.
– Push down the lifting eyes before inserting

the battery into the battery compartment.

Make sure that the lifting eyes do not

protrude.

The lifting eyes may bend in the event of a

collision with the truck chassis.
– Install the lithium-ion battery with the display

facing the outside of the truck so that it can

be read when the battery door or battery

cover is open.

– Lay the battery cable on the battery. Make

sure that the cable does not come into

contact with the truck chassis during

installation.

171533 EN - 02/2019 - 19

337

Summary of Contents for RX60-35/600

Page 1: ...Original instructions Electric trucks RX60 35 600 RX60 40 RX60 40 600 RX60 45 RX60 45 600 RX60 50 RX60 50 600 6327 6328 6329 6330 6367 6368 6369 171533 EN 02 2019 19 ...

Page 2: ......

Page 3: ...nies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for the safe operation of industrial trucks Information on the use of industrial trucks Information on transport initial commis sioning and storage of industrial trucks Internet address ...

Page 4: ......

Page 5: ... Parking in temperatures below 10 C 14 Using working platforms 15 Information about the documentation 16 Documentation scope 16 Supplementary documentation 17 Issue date and topicality of the operating instructions 18 Copyright and trademark rights 18 Explanation of information symbols used 18 List of abbreviations 19 Deﬁnition of directions 21 Schematic views 21 Environmental considerations 23 Pa...

Page 6: ...iew of hazards and countermeasures 44 Danger to employees 47 Safety tests 48 Regular safety inspection of the truck 48 Insulation testing 48 Safety regulations for handling consumables 50 Permissible consumables 50 Oils 50 Hydraulic ﬂuid 51 Battery acid 52 Disposal of consumables 53 Emissions 54 3 Overviews General view 58 General view of driver s compartment 60 Shelves and cup holders 61 Operatin...

Page 7: ...function 95 Zero adjustment of the load measurement variant 95 Switching on 97 Switching on the key switch 97 Access authorisation with PIN code variant 99 Display operating unit 109 Indicators 109 Adjusting the displays 111 Symbols in the display 113 Setting the date or time 118 Resetting the daily kilometres and daily operating hours 118 Setting the language 119 Softkeys for operating various eq...

Page 8: ...ing the truck securely and switching it off 160 Wheel chock variant 161 Lifting 162 Lifting system variants 162 Types of lift mast 162 Lifting system operating devices 163 Multi lever lifting system 164 Controlling the lifting system using a double mini lever 165 Controlling the lifting system using a triple mini lever 166 Controlling the lifting system using a quadruple mini lever 167 Controlling...

Page 9: ...achments using a quadruple mini lever 221 Controlling attachments using the quadruple mini lever and the 5th function 223 Controlling attachments using the Joystick 4Plus 225 Controlling attachments with Joystick 4Plus and the 5th function 227 Controlling the attachments with ﬁngertip 229 Controlling attachments with ﬁngertip and the 5th function 230 Clamp locking mechanism variant 232 Taking up a...

Page 10: ...Drive speciﬁc messages 291 Procedure in emergencies 295 Emergency shutdown 295 Procedure if truck tips over 296 Emergency hammer 297 Emergency lowering 297 Emergency operation of the electric parking brake 299 Towing 300 Connecting and disconnecting the battery male connector 303 Connecting the battery male connector 303 Disconnecting the battery male connector 304 Handling the lead acid battery 3...

Page 11: ... pallet truck 338 Replacing the battery using a change frame variant 341 Replacing the battery with the hydraulic battery carrier 345 Transporting the lead acid battery by crane 353 Transporting the lithium ion battery by crane 354 Cleaning the truck 355 Cleaning the truck 355 Cleaning the electrical system 357 Clean load chains 357 Cleaning the windows 358 After cleaning 358 Transporting the truc...

Page 12: ...s seat 395 Maintaining wheels and tyres 396 Servicing the steering axle 398 Checking the battery 400 Checking the fuses 400 Replacing fuses 402 Checking the hydraulic oil level 404 Checking the hydraulic system for leak tightness 405 Lubricating the lift mast and roller track 406 Greasing the automatic tow coupling 406 Preserving operational readiness for cold store application 409 Maintaining the...

Page 13: ...26 VDI datasheet RX60 45 and RX60 45 600 430 VDI datasheet RX60 50 and RX60 50 600 434 Ergonomic dimensions 438 Information about the lead acid battery 439 Information about the lithium ion battery 441 Fuse assignment 442 Fuse assignment standard equipment 442 Fuse assignment equipment variants 443 171533 EN 02 2019 19 XI ...

Page 14: ......

Page 15: ...1 Foreword ...

Page 16: ... and the selected drive program to calculate the remaining available time until the battery has to be recharged and displays this information The truck supports all functions of FleetMan ager 4 0 variant Brake system The brake system of the truck is comprised of three different brakes Service brake Regenerative brake Mechanically actuated parking brake Electrically actuated parking brake variant T...

Page 17: ...r the purpose of damping pressure peaks in the hydraulic system Drive The STILL RX60 35 50 is driven via both front wheels by maintenance free three phase drives in the front axle with 80 volt technology Power is supplied by lead acid batteries or lithium ion batteries The batteries are located at the side of the truck to enable easy replacement In both cases the trucks can be supplied as a cold s...

Page 18: ... from ﬁve different drive programmes The display operating unit monitors the truck functions including each individual cell in the lithium ion battery General The truck described in these operating instruc tions corresponds to the applicable standards and safety regulations If the truck is to be operated on public roads it must conform to the existing national regula tions for the country in which...

Page 19: ...elling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is conﬁrmed by the issued EC declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addition to the truck can compromise safety thus invalidating the EC declaration of conformity The EC declaration of conformity must be carefully st...

Page 20: ...2113 Hamburg Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH 6 171533 EN 02 2019 19 ...

Page 21: ...Foreword 1 Your truck Accessories Key for key switch 2 pieces Key for cab variant Hexagon socket wrench for emergency lowering Battery replacement frame 171533 EN 02 2019 19 7 ...

Page 22: ...RIESERVICE DANGER 23 Regelmäßige Prüfung FEM 4 004 nach nationalen Vorschriften basierend auf den EG Richtlinien 95 63 EG 99 92 EG 2001 45 EG Die Prüfplakette ersetzt nicht das Prüfprotokoll Nächste Prüfung 56344391019 Mitglied der Fédération Européene de la Manutention STILL GmbH Hamburg 20xx Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn ...

Page 23: ...arning sign Danger due to shearing 14 Decal information Lifting gear attachment point 15 Decal information Lifting gear attachment point 16 Decal information Hydraulic oil tank 17 Decal information FEM audit 18 Manufacturer s label text 19 Manufacturer s label text 20 Decal information Ceiling sensor next to the display operating unit 21 Manufacturer s label text 22 Decal information Unlocking 23 ...

Page 24: ...y weight in kg 7 Ballast weight in kg 8 Address of manufacturer 9 Refer to the technical data listed in these operating instructions for more detailed information 10 CE labelling 11 Nominal drive power in kW 12 Battery voltage in V 13 Rated capacity in kg Nameplate The truck can be identiﬁed from the informa tion on the nameplate The information for the battery weights 5 6 and the ballast weight 7...

Page 25: ...e Capacity Energy Capacity equivalent Weight P N B P N SN Custumer order no Still order no Date Made in Germany Safety Advices for Lithium Ion Batteries Do not crush Do not heat or incinerate Do not short circuit Do not dismantle Do not immerse in any liquid it may vent or rupture 9 3 4 5 1 2 6 7 8 Nameplate of a lithium ion battery 1 Manufacturer 2 Technology 3 Transportation notes 4 General oper...

Page 26: ... 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 to prevent haz ards The maximum load to be lifted is speciﬁed on the capacity rating plate load diagram and must not be exceeded see also the chapter entitled Before picking up a load Proper use during t...

Page 27: ...rly dusty Stacking or unstacking is not permissible on inclined surfaces or ramps 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 public roads the truck must conform to the national regula tions for the country in which ...

Page 28: ...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 surroundings Depending on the application additional ﬁre protection must be provided on the truck If in doubt contact the relevant authorities NOTE Please observe the deﬁnition of the following responsible person operating co...

Page 29: ...orking platforms is regulated by na tional law The use of working platforms is only permitted by virtue of the jurisdiction in the country of use Observe national legislation Before using working platforms consult the national regulatory authorities 171533 EN 02 2019 19 15 ...

Page 30: ...mer requirements UPA are documented in separate operating instructions If you have any questions please contact your authorised service centre Enter the production number and year of manufacture from the nameplate in the space provided Production number Year of manufacture Please quote the production number in all technical enquiries Each truck comes with a set of operating instructions These inst...

Page 31: ...please contact the authorised service centre Supplementary documentation This industrial truck can be ﬁtted with un planned equipment UPA that deviates from the standard equipment and or the variants The UPA may be for example Special sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documentation This may be in the form of an insert...

Page 32: ...m cannot be asserted Please contact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts except with the express written approval of the manufacturer Explanation of information symbols used DANGER Indicates procedures that must be str...

Page 33: ... BGG Berufsgenossenschaftlicher Grundsatz German principles and test speciﬁcations for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations CE Communauté Européenne Conﬁrms conformity with product speciﬁc European directives CE mark CEE ...

Page 34: ...ork backs MAK Maximum workplace concentration Maximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identiﬁcation Number Personal identiﬁcation number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simpliﬁed assembly without...

Page 35: ...o the front Schematic views 6210_003 062 View of functions and operations This documentation explains the usually sequential chain of certain functions or oper ations Schematic diagrams of a counterbal ance truck are used to illustrate these proce dures NOTE These schematic diagrams are not represen tative of the structural state of the documented truck The diagrams are used solely for the purpose...

Page 36: ...erating statuses and values in the display of the display operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values can vary Information that is not relevant for descriptions is not shown 22 171533 EN 02 2019 19 ...

Page 37: ... properly after delivery of the truck Disposal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispo sing of batteries ENVIRONMENT N...

Page 38: ...1 Foreword Environmental considerations 24 171533 EN 02 2019 19 ...

Page 39: ...2 Safety ...

Page 40: ...neer or a person who fulﬁls the following requirements A completed vocational qualiﬁcation that demonstrably proves their professional expertise This proof should consist of a vocational qualiﬁcation or a similar document Professional experience indicating that the qualiﬁed person has gained practical experience of industrial trucks over a proven period during their career During this time this pe...

Page 41: ... trained in accordance with BGG General Employers Liability Insurance Association Act 925 Observe the national regulations for your country Driver rights duties and rules of be haviour The driver must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety helmet industrial goggles and glove...

Page 42: ...he aforementio ned substances are not permitted to perform work of any kind on or with the truck Prohibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key 28 171533 EN 02 2019 19 ...

Page 43: ...y premises In many cases company premises are restricted public trafﬁc areas NOTE The business liability insurance should be reviewed to ensure that in the event of any damage caused in restricted public trafﬁc areas there is insurance cover for the truck in respect of third parties 171533 EN 02 2019 19 29 ...

Page 44: ...f a conventional lead acid battery DANGER Risk of explosion Heating to over 80 C mechanical stress and incorrect use may cause the battery to explode Never heat the battery to over 80 C or expose it to naked ﬂames Do not subject the battery to excessive mechanical loads Do not climb on the battery Avoid impacts Do not open the battery Never short circuit the battery connectors Do not connect the b...

Page 45: ... The safety valve 2 opens when the battery is subjected to over pressure or it catches ﬁre All lithium ion batteries are essentially associ ated with the risk of a ﬁre starting of the battery exploding and of the battery causing chemical burns When used as intended no hazardous substances escape from the closed tray and contact with toxic substances will not occur There is a risk of contact only i...

Page 46: ...kforce must also be informed that trucks with lithium ion batteries are being used Hazard assessment In accordance with 3 of the German Ordi nance on Industrial Safety and Health Betr SichV the operating company is obliged to perform a separate hazard assessment in or der to assess the risks posed to the company by lithium ion batteries Observe the national regulations for the country in which the...

Page 47: ...ry outside the premises may require a special transport container Contact the authorised service centre for more information Changes and retroﬁtting If the truck will be used for work that is not listed in the directives or in these instructions convert or retroﬁt the truck for this purpose as required Any structural modiﬁcation can impair the handling and stability of the truck and can result in ...

Page 48: ...lt In addition the seat belt protects against the consequences of rear end collisions and falling off ramps Use the seat belt too 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 ...

Page 49: ...y must also fulﬁl the following prerequisites Design 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 requ...

Page 50: ...of load may only be mounted on the overhead guard if the structural design has been tested and the manufacturer has given approval Seek advice from the authorised service centre for the mounting of roof loads Warning regarding non original parts Original parts attachments and accessories are specially designed for this truck We speciﬁcally draw your attention to the fact that parts attachments and...

Page 51: ...ional headlights etc is only permitted with the manufacturer s written approval All electrical system interventions must be documented Even if they are removable roof panels may not be removed as they are designed to protect against small falling objects Tyres DANGER Risk to stability Failure to observe the following information and instructions can lead to a loss of stability The truck may tip ov...

Page 52: ... does not cause the truck to tilt to one side e g always replace right hand and left hand wheels at the same time Changes must only be made following consultation with the manufacturer If the type of tyre used on an axle is changed for example from superelastic tyres to pneu matic tyres the load diagram must be changed accordingly Contact the authorised service centre on this matter Medical equipm...

Page 53: ...ng tempe ratures over 80 C and heavy contamination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper installation of an accumulator results in an elevated risk of injury Before starting work on the accumulator it must be depressurised Contact the authorised service centre Length of the fork arms ...

Page 54: ...c principles for safe operation picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre 40 171533 EN 02 2019 19 ...

Page 55: ...ncident or breakdown etc WARNING All persons that are in the vicinity of the truck must be instructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regulati ons in these operating instructions 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 ...

Page 56: ...rect operation and losing stability can never be excluded The loss of stability can be avoided or min imised by the following actions Always secure the load against slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as centrally as possible with the truck and transport in ...

Page 57: ...isk time the truck is used in a manner that falls outside the scope of normal use and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci dents 171533 EN 02 2019 19 43 ...

Page 58: ... only for authorised persons O Truck not in a safe condition Recurrent testing and rectiﬁcation of defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when using working platforms Compliance with national regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability insurance associations Impaired visibili...

Page 59: ...nd labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note German...

Page 60: ...Industrial Safety and Health BetrSichV employers liability insurance association regulation 104 and the operating instructions O German Ordinance on Industrial Safety and Health BetrSichV and employers liability insurance association regulation 104 With driverless transport systems Roadway quality inadequate Clean clear driveways O German Ordinance on Industrial Safety and Health BetrSichV Load ca...

Page 61: ...he hazard assessment At tachments possess their own CE labelling and likewise are not included for that reason The operating company must however select the type and equipment of the trucks so as to com ply with the local provisions for deployment The result must be documented 6 Arb SchG In the case of truck applications involv ing similar hazard situations the results may be summarised This overv...

Page 62: ... The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service centre NOTE Observe the national regulations for your country I...

Page 63: ...nent Recommended test voltage Measurements Nominal voltage UBatt Test values 50 VDC 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω Battery 100 VDC Batt Batt Battery tray 80 volts 4000 Ω Test values for the entire truck Nominal voltage 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 ...

Page 64: ...le substances that are necessary for operation see Chapter Maintenance data table P 5 387 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 rins...

Page 65: ...d immediately with oil binding agents and disposed of according to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of according to the regulations Dispose of old oils according to the regula tions Hydraulic ﬂ...

Page 66: ...se appropriate personal protective equipment e g protective gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic ﬂuid is a water polluting substance Always store hydraulic ﬂuid in containers that comply with regulations Avoid spills Spilt hydraulic ﬂuid should be removed immediately with oil binding agents and disposed of according to the regulations Dispose ...

Page 67: ...llow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair maintenance and cleaning must be collected properly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas de...

Page 68: ...ent LpAZ Measurement uncertainty KpA 70 0 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted values for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 E...

Page 69: ...2 0 21 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than 2 5 m s2 There are therefore no measure ment guidelines for these measurements The individual vibration load on the driver over the course of a working day must be determined by the operating company in accordance with Directive 2002 44 EC at the ...

Page 70: ...is always sufﬁcient ventilation in working areas that are entirely or partially enclosed Keep away from open ﬂames and ﬂying sparks Do not smoke Observe the instructions in the chapter entitled Safety regulations when handling the battery Radiation According to the guide lines DIN EN 62471 2009 03 VDE 0837 471 2009 03 the STILL Safety Light variant is assigned to risk group 2 due to its photobiolo...

Page 71: ...3 Overviews ...

Page 72: ...eral view 5 6 7 8 9 1 2 3 4 6327_003 011_V2 1 Lift mast 2 Overhead guard 3 Driver s compartment 4 Traction electronics 5 Steering axle 6 Battery 7 Drive axle with traction motor 8 Fork arms 9 Fork carriage 58 171533 EN 02 2019 19 ...

Page 73: ...Overviews 3 General view 171533 EN 02 2019 19 59 ...

Page 74: ...3 Overviews General view of driver s compartment General view of driver s compartment 8 9 6 7 2 0 1 3 5 75 h 2 234 7 12 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6321_003 132_V3 60 171533 EN 02 2019 19 ...

Page 75: ...may differ from the equipment shown 7321_003 125 1 2 3 Shelves and cup holders WARNING Objects may fall into the footwell and obstruct the pedals which poses a risk of accident Objects to be stored must be of the correct size so that they cannot fall from the shelf 1 or out of the cup holder 2 Objects that fall into the footwell during travel as a result of steering or braking may slip between the...

Page 76: ... display digital 17 Not assigned 18 Rotating beacon display 19 Interior light display 20 Rear window heating display 21 Softkey for interior light rotating beacon 22 Softkey for rear window heating 23 Menu change button 24 Lighting button 25 Blue Q button 26 Rear window wiper button NOTE The Softkeys 5 21 22 and the correspon ding indicators 6 7 18 19 20 are assigned according to the auxiliary equ...

Page 77: ...y display The lithium ion battery display is located on the side of the battery tray In addition to the display operating unit the lithium ion battery display also shows the charging status and information relating to the lithium ion battery Note the information in the separate operat ing instructions for the lithium ion battery 171533 EN 02 2019 19 63 ...

Page 78: ...ferent versions of the operating devices are available for operating the truck s hydraulic and traction functions The truck can be equipped with the following operating devices Multiple lever Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip Mini console 64 171533 EN 02 2019 19 ...

Page 79: ...erating lever 3 Operating lever for attachment variant 4 Operating lever for attachments with 5th function variant 5 5th function function switch variant 6 Drive direction switch NOTE In the dual pedal version variant the truck is equipped with a signal horn button instead of the drive direction switch 171533 EN 02 2019 19 65 ...

Page 80: ...tion key F2 4 Drive direction turn indicator cross lever 5 Function key 5th function 6 Attachments cross lever 7 Emergency stop switch 8 Signal horn button NOTE Depending on the speciﬁcation various electric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre 66 171533 EN 02 2019 19 ...

Page 81: ...n turn indicator cross lever 5 Function key 5th function 6 Auxiliary hydraulics 1 operating lever 7 Auxiliary hydraulics 2 operating lever 8 Emergency stop switch 9 Signal horn button NOTE Depending on the speciﬁcation various electric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre 171533 EN 02 2019 19 67 ...

Page 82: ... Drive direction turn indicator cross lever 6 Function key 5th function 7 Auxiliary hydraulics 1 operating lever 8 Auxiliary hydraulics 2 operating lever 9 Emergency stop switch 10 Signal horn button NOTE Depending on the speciﬁcation various electric attachment parts can be controlled via function keys 3 and 4 Changes must only be made by the authorised service centre 68 171533 EN 02 2019 19 ...

Page 83: ... the basic hydraulic functions 3 Pictograms for the 5th hydraulic function and the clamp locking mechanism variant 4 Pictograms for the 3rd 4th hydraulic functions 5 LED for clamp locking mechanism variant 6 Slider for the 4th hydraulic function e g reach frame forwards backwards 7 Vertical rocker button for the drive direction 8 Shift key F 9 Signal horn button 171533 EN 02 2019 19 69 ...

Page 84: ...hand turn indicator button 6 Button for 5th function 7 Emergency stop switch 8 Attachments operating lever 9 Attachments operating lever 10 Tilt operating lever 11 Lift lower operating lever 12 Travel direction switch NOTE Depending on the speciﬁcation various electric attachment parts can be controlled via function keys 1 and 2 Changes must only be made by the authorised service centre 70 171533 ...

Page 85: ...ting devices and display elements 7311_003 056 1 2 1 Travel direction switch 2 Direction indicator switch Mini console The mini console is located on the steering column below the steering wheel 171533 EN 02 2019 19 71 ...

Page 86: ...3 Overviews Operating devices and display elements 72 171533 EN 02 2019 19 ...

Page 87: ...4 Operation ...

Page 88: ...t before daily use The components that must be checked and their check points 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 Da mage or other defects must be reported to the supervisor or the responsible ﬂeet manager immediately so that ...

Page 89: ...the same manufacturer are ﬁtted In the event of uneven tyre wear replace both tyres Observe the safety regulations in the section entitled Tyres Axle Make sure that no consumables are escaping from the axle Overhead guard guard grille variant Perform a visual inspection for integrity Check for secure mounting Steps Make sure they are clean free of ice not slippery Panes of glass variant Perform a ...

Page 90: ...nd intact legible Replace damaged or missing adhesive labels in accordance with the section entitled Labelling points Driver s seat seat belt Check the integrity and function Lighting warning units Check the integrity and function Antistatic belt 3 corona electrode 4 See the following illustration Perform a visual inspection for integrity Ensure cleanliness Make sure that the antistatic belt 3 is ...

Page 91: ... the truck WARNING Risk of injury when jumping out of the truck If your clothing or jewellery e g watch ring etc becomes stuck on a component while you are jumping out of the truck this can lead to serious injuries e g from falling loss of ﬁngers etc It is forbidden to jump out of the truck Do not jump out of the truck Do not wear jewellery at work Do not wear loose ﬁtting workwear CAUTION Compone...

Page 92: ...step 3 Climb out of the truck right foot ﬁrst Adjusting the MSG 65 MSG 75 driver s seat DANGER There is a risk of accident if the seat or seat backrest shifts suddenly which could cause the driver to move in an uncontrolled manner This may result in unintentional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the sea...

Page 93: ...the seat 7094_003 006 1 Moving the driver s seat Lift and hold the lever 1 Push the driver s seat into the desired position Release the lever Ensure that the driver s seat is securely engaged 7094_003 008 2 Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it Lift and hold the lever 2 Push the seat backrest into the desired position Release the lever Ensure that t...

Page 94: ... with electric air suspension that is activated using an electric switch instead of the lever 3 Fully extend the weight adjusting lever 3 Pump it up or down to set the driver s weight Return the weight adjusting lever to the central initial position before each new lift audible click Fully fold in the weight adjusting lever once adjustment is complete NOTE The driver s weight has been selected cor...

Page 95: ...port moves a convex support cushion into the upper or lower part of the backrest Turn the turning knob 5 up or down until the lumbar support is in the desired position 6321_003 040 6 Adjusting the backrest extension variant Adjust the backrest extension 6 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by jolting it upwards 17153...

Page 96: ... the truck tips over This risk of injury can be reduced through the combined use of the restraint system and the seat belt In addition the seat belt protects against the consequences of rear end collisions and falling off a ramp We therefore recommend that you also use the seat belt DANGER Only bracket doors variant or the driver s cab variant with closed ﬁxed doors constitute a driver restraint s...

Page 97: ...ure one person Have any malfunctions repaired by the authori sed service centre NOTE The buckle has a buckle switch variant In the event of an operating error or malfunction the message SAFETY BELT appears in the display and operating unit see the chapter entitled Display messages Pull the seat belt 3 out of the belt retractor without jerking and fasten closely around the body over the thighs NOTE...

Page 98: ...elt tongue slowly back to the retractor NOTE Do not allow the seat belt to retract too quickly The automatic blocking mechanism may be triggered if the belt tongue strikes the housing It will then no longer be possible to pull the seat belt out with the usual force Using increased force pull the seat belt around 10 15 mm out of the retractor to disengage the blocking mechanism Slowly allow the sea...

Page 99: ...f the truck or load 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 7331_342 001 3 1 2 Adjusting the length of the armrest Release the star grip handle 1 by turning it anti clockwise Shift the armrest 2 into the desired posi tion Tighten the star grip handle by turning it clockwise Check t...

Page 100: ...t the steering column only when the truck is at a standstill Ensure that the steering column is engaged Press down and hold the lever 2 for steering column adjustment Position the steering column 1 and release the lever When the steering column engages the lever snaps back to the initial position Gently push and pull on the steering column to make sure that the steering column is engaged 86 171533...

Page 101: ...ion 4 Checks and tasks before daily use Unlocking the emergency off switch 6321_003 145 F1 F1 F2 F2 1 IV I III II F1 F2 1 1 1 Pull out turn the emergency off switch 1 until it unlocks 171533 EN 02 2019 19 87 ...

Page 102: ... F1 F1 F2 F2 6210_003 095 1 1 1 1 1 Operating the signal horn Push the signal horn button 1 The signal horn sounds NOTE The signal horn is used to warn people against imminent danger or toannounce yourintention to overtake 88 171533 EN 02 2019 19 ...

Page 103: ... prevents the driver from being thrown from the truck if it tips over The driver s cab constitutes a driver restraint system only if the cab door is sturdy and closed Fabric co vered cabs 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 operation If the door is ...

Page 104: ...ency braking DANGER Risk of accident due to excessive speed Depending on the charge state of the battery rege nerative 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 opposite drive direction is selected the truck is braked using the electric brake To actuate th...

Page 105: ...on the incline If the truck rolls away despite 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 prevent it from rolling away Have the parking brake checked and repaired by the authorised service centre Checking the parking brake on a level surface WARNING Risk of accident from abrupt deceleration The ...

Page 106: ...ke The truck must decelerate and remain station ary 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 repaired by the authorised service centre NOTE Special features of the electrical parking brake The deceleration cannot be inﬂuen...

Page 107: ...defective steering system Operate steering wheel 1 The steering play while stationary must not be more than two ﬁnger widths NOTE If the truck is switched on with the steering wheel turned the maximum driving speed is limited Travel speed limitation is removed as soon as the steering wheel is moved out of a cornering position into the straight ahead position This requires a change in steering angl...

Page 108: ...e NOTE The mounting position of the emergency off switch can also be on the steering column in the multiple lever version II Drive the truck forwards slowly Push the emergency off switch 1 The truck will coast The display and operating unit shows the message EMERGENCY OFF SWITCH period ically Brake the truck to a standstill by actuating the brake pedal NOTE In trucks with an electric parking brake...

Page 109: ...as the end stop Tilt the lift mast forward The lift mast must tilt forwards and stop in the vertical position Release the operating device to tilt and actuate again The lift mast must tilt forwards fully and move gently as far as the end stop Zero adjustment of the load mea surement variant NOTE A zero adjustment must be carried out in order to guarantee the accuracy of the load measurement varian...

Page 110: ...he zero adjustment of the load measurement is switched on The symbol is displayed The message LOWER FORKS appears on the display NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the zero adjustment will not be accurate To stop the lowering procedure quickly release the operating device...

Page 111: ...ng Do not operate the truck if defects have been detected contact the authorised service centre NOTE When the truck is switched on the maximum driving speed is restricted The driving speed limitation is disabled as soon as the truck is steered out of cornering to drive in a straight line To do this rotate the steering wheel by approximately half a turn I 1 0 5060_003 029_V2 Insert switch key 1 int...

Page 112: ... is switched on the display shows the welcome screen in the set language until the truck controller has fully started up If the truck is ready for operation the standard displays are shown If the truck is equipped with the access authorisation with PIN code variant the display initially changes to the input menu for access authorisation 98 171533 EN 02 2019 19 ...

Page 113: ...ad in the form of driving or lifting operations Additional information may appear on the display If malfunctions occur refer to the informa tion in the chapter entitled Display mes sages Access authorisation with PIN code variant Description Trucks equipped with the Access authori sation with PIN code variant are protected against unauthorised use by a ﬁve digit driver PIN Up to ﬁfty different dri...

Page 114: ... the truck in order for the truck to be operated again Contact the authorised service centre on this matter The ﬁrst driver PIN is preset to 11111 at the factory All others are preset to 0xFFF but have no function as the highest valid driver PIN is 99999 Persons with the appropriate access authorisation e g ﬂeet managers can change the driver PINs in the corresponding menu NOTE When ﬁrst commissio...

Page 115: ...for the driver PIN 2 are not visible but are represented by circles instead If the driver PIN entered is correct the familiar screen appears with the standard display and all truck functions are available 8 9 6 7 4 2 0 1 3 5 BQ_023_en_V2 If an incorrect driver PIN is entered the message INVALID appears for a short time When the message goes out the driver PIN can be re entered 171533 EN 02 2019 19...

Page 116: ...ﬁned only by per sons with the appropriate access authorisa tion e g ﬂeet managers To set the driver PIN the ﬂeet manager must access the con ﬁguration menu The conﬁguration menu is password protected After entering the pass word the ﬂeet manager can conﬁgure general settings for the truck To change the pass word see the chapter entitled Changing the password Push the drive program selection butto...

Page 117: ...r digit password factory default 2777 using the buttons 1 Conﬁrm the input using Softkey 2 8 9 6 7 4 2 0 1 3 5 BQ_31_en 1 3 2 CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the ACCESS CODE menu Conﬁrm your selection using Soft key 2 171533 EN 02 2019 19 103 ...

Page 118: ... the CODE selection ﬁeld 2 contains the number 1 The ﬁrst of the ﬁfty driver PINs can now be deﬁned Use the drive program selection button 1 and the menu change button 4 to select the desired driver PIN 1 to 50 Conﬁrm your selection using Soft key 3 NEW CODE appears in the display Enter the desired driver PIN using the buttons or Softkeys 5 The digits entered do not appear in the display Instead t...

Page 119: ...tered the system will accept the new driver PIN once the last digit has been entered The display switches back to the ACCESS CODE menu Another driver PIN can be deﬁned here 8 9 6 7 4 2 0 1 3 5 BQ_023_en_V2 If the driver PIN entered in the CONFIRM sub menu does not match the driver PIN entered previously in the NEW CODE submenu the message INVALID will appear The message will then disappear after a...

Page 120: ... the ACCESS CODE menu The desired driver PIN must be re deﬁned Blue Q_029_V2 1 2 Changing the password It is recommended that you change the factory default password NOTE The password can only be changed when the parking brake is applied Push the drive program selection button 1 and the menu change button 2 at the same time 106 171533 EN 02 2019 19 ...

Page 121: ...Enter the current password using the buttons 1 Conﬁrm the input using Softkey 2 8 9 6 7 4 2 0 1 3 5 1 2 3 BQ_032_en CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the PASSWORD menu Conﬁrm your selection using Soft key 2 171533 EN 02 2019 19 107 ...

Page 122: ...e conﬁguration op tions for the ﬂeet manager are restricted to driver authorisations and cannot be reset independently The authorisations can only be reset by the autho rised service centre Enter the new desired password using the buttons 1 The digits entered are shown in plain text in the NEW CODE ﬁeld 4 Conﬁrm your selection using Soft key 3 In the NEW CODE ﬁeld appears brieﬂy The new password i...

Page 123: ...n be driven if the operating situation of the last 30 minutes is maintained 2 Drive program Displays the number of the selected drive program To change the drive program refer to the section entitled Setting the drive program The Blue Q icon appears when the Blue Q function is switched on refer to the section entitled Blue Q efﬁciency mode 3 Power rating The power rating indicator shows the averag...

Page 124: ...st be avoided Cease work with the truck immediately Charge the batteries immediately NOTE To prevent deep discharge certain restric tions variant can be activated e g slow lifting Consult the authorised service centre on this matter Power trends indicator Symbol Energy consumption trend Signiﬁcant increase 50 Increase up to 50 Slight increase up to 30 No change Slight decrease up to 30 Decrease up...

Page 125: ... hour meter starts running as soon as the truck is driven or the working hydraulics are actuated 8 Total distance Displays the total distance driven in kilometres 9 Daily kilometres Displays the kilometres driven for the day NOTE Ask the authorised service centre about the speed driven indicator NOTE Have all repair and maintenance work perfor med by an authorised service centre This is the only w...

Page 126: ...y switch to position I Blue Q_029_V2 1 2 Press the drive program button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC The display changes to the PASSWORD menu NOTE It may be necessary to enter a password in order to conﬁgure the displays This depends on the conﬁguration of the display operating unit For conﬁguration of the display operating ...

Page 127: ...s and daily operating hours Setting the language Conﬁgure Blue Q Symbols in the display Messages To show operating messages warning messages or error messages in the display text messages and symbols are used Symbols for operating messages Description Symbol Empty ﬁeld No display Please wait Service required Lift limitation Reference cycle Battery charging Drive program Hour meter Odometer Daily h...

Page 128: ...ating trend Symbols for warning messages Description Symbol Parking brake Actuate seat switch Safety belt Battery acid level Neutral warning message Are you sure Oil pressure Symbols for error messages Description Symbol Brake system malfunction Overheating of the engine Overheating Malfunction in the electrical system General malfunction 114 171533 EN 02 2019 19 ...

Page 129: ...tlight ON Front working spotlight OFF Front working spotlight ON Windscreen heating OFF Windscreen heating ON Rear window heating OFF Rear window heating ON Interior lighting OFF Interior lighting ON Roof wiper washer OFF Roof wiper washer ON Heater blower OFF Heater blower ON Rotating beacon OFF Rotating beacon ON Seat heater OFF Seat heater ON Signal horn OFF Signal horn ON Cruise control OFF Cr...

Page 130: ...ay for menu navigation and to acknowledge messages Description Symbol Empty ﬁeld No display Cancel input Conﬁrm input Conﬁrm information Reset Back by one menu level Back to the previous edit ﬁeld Scroll up Scroll down Count up Count down Status LEDs of the function keys for additional electrical installations The current switch status of a button is indi cated with LEDs next to the relevant funct...

Page 131: ...d Softkeys that can be used to enter numbers and to cancel or conﬁrm input values are shown in the display BQ_037 1 2 6 7 3 4 5 ESC Screen for entering the ﬂeet manager pass word 1 2 6 7 3 4 5 8 9 0 BQ_038 Screen for entering the driver PIN access code 171533 EN 02 2019 19 117 ...

Page 132: ...es in three levels Conﬁrm the set time using Softkey 4 Use the Softkey 3 to exit the menu and return to the next level up NOTE The date is set in a similar manner 8 9 0 6 7 4 3 5 7312_003 055_en_V4 1 2 3 4 Resetting the daily kilometres and daily operating hours The daily number of kilometres and daily operating hours displays can be reset to zero Switch to the CONFIGURATION menu see the chapter e...

Page 133: ...eatedly until the LANGUAGE option appears Conﬁrm your selection using the Soft key 4 The LANGUAGE menu appears Press drive program button 1 or menu change button 2 until the desired language appears in the display Conﬁrm your selection using the Soft key 4 Use the Softkey 3 to exit the menu and return to the next level up Softkeys for operating various equipment variants Additional functions can b...

Page 134: ...n three equipment variants that can be switched on and off using Softkeys In this case proceed as follows to switch between the two columns Brieﬂy press the Menu change button 1 The grey bar jumps to the left hand col umn These additional functions can now be switched on and off via the corresponding Softkeys 2 NOTE Press the Menu change button 1 for approx 1 second to switch between the individua...

Page 135: ...fﬁciency mode For moderate speeds of at least approx 7 km h acceleration is gentler Therefore on distances of up to approx 40 m lower speeds are reached than would be the case if the efﬁciency mode was not activated Blue Q has no inﬂuence on Maximum speed Climbing capability Traction Braking characteristics NOTE The Blue Q efﬁciency mode can be swit ched on and off in the STANDARD and FI XED FLEX ...

Page 136: ... working spotlights X X Forwards Top double working spotlight X X 3 km h Headlights X X Front wiper X X Backwards 3 km h Rear wiper X X Forwards Seat heater X Cab heating X NOTE On the version with StVZO German Road Trafﬁc Licensing Regulations equipment the Blue Q efﬁciency mode does not switch off the lighting devices headlights and working spotlights side lights rear lights and license plate la...

Page 137: ...cy mode The following operating modes can be se lected to activate the Blue Q efﬁciency mode STANDARD Blue Q is turned off whenever the truck is commissioned The driver can use the Blue Q button to switch efﬁciency mode on and off at any time while the truck is being operated FIXED Blue Q is switched on permanently when ever the truck is commissioned and during truck operation The driver cannot tu...

Page 138: ... 1 or the menu change button 2 until op tion BLUE Q CONFIGURATION appears Conﬁrm your selection with Softkey 4 The BLUE Q CONFIGURATION menu appears Press drive program button 1 or menu change button 2 until the desired efﬁ ciency mode appears in the display Conﬁrm the set efﬁciency mode using Softkey 4 Use the Softkey 3 to exit the menu and return to the next level up 124 171533 EN 02 2019 19 ...

Page 139: ...opping suddenly turning 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 colum...

Page 140: ... sure that the driving lane is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walking pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be...

Page 141: ... guidelines apply for areas outside of the EU The required aisle widths depend on the dimensions of the load The aisle widths for pallets are as follows Aisle width mm Model Type With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX60 35 600 6367 4208 4408 RX60 40 6367 4208 4408 RX60 40 600 6368 4208 4408 RX60 45 6328 4208 4408 RX60 45 600 6369 4218 4418 RX60 50 6329 4218 4418 RX60 50...

Page 142: ...ng on long ascending and descending gradients greater than 15 CAUTION Risk of component damage due to reduced ground clearance with a hydraulic battery carrier variant Trucks ﬁtted with a hydraulic battery carrier va riant have a reduced ground clearance and the permitted climbing capability is therefore reduced The ground clearance with standard tyres is redu ced to 70 5 mm The maximum wear limit...

Page 143: ...n the event that components protrude beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers The dimensions of the trucks are designed for this purpose However movable components may protrude beyond the truck contour and be damaged or torn off Examples of these components are An unfolded roof panel in the driver s cab Open cab...

Page 144: ...its representatives Trafﬁc routes must be free of obstacles The load may only be set down and stored in the designated locations The operating company and its representatives must ensure that unauthorised third parties do not enter the working area NOTE Please note the deﬁnition of operating com pany in the sense of responsible persons Hazard areas Hazard areas on the roadways must be marked by st...

Page 145: ... the driving dynamics The following drive programs are available Drive program 1 2 3 4 5 Speed km h 16 16 16 16 16 Acceleration forwards backwards 80 90 100 110 120 Deceleration forwards backwards 80 90 100 110 120 Reversing forwards backwards 80 90 100 110 120 Brake retardation electric brake booster 60 70 80 90 100 NOTE For trucks with sprint mode variant swit ching on sprint mode leads to a gen...

Page 146: ... quickly NOTE With sprint mode switched on the truck s energy consumption is higher The battery is therefore discharged more quickly Push button 1 Sprint mode is switched on the symbol has a dark background NOTE Sprint mode remains on until the seat is vacated or button 1 is pushed again 6311_003 026_V2 2 1 Switching off sprint mode Push button 1 Sprint mode is switched off the symbol has a light ...

Page 147: ...nd is then accelerated again in the opposite direction reversing The indicator for the selected drive direction forwards 1 or reverse 2 lights up on the display 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 pedal Brieﬂy select the dr...

Page 148: ... Chapter Selecting the drive direction P 4 133 For the forwards drive direction push the drive direction switch 1 downwards For the backwards drive direction push the drive direction switch upwards 5060_003 096 F1 F2 1 Actuating the drive direction switch mini lever version Push the cross lever 1 forwards to drive forward Pull the cross lever backwards to drive backward 134 171533 EN 02 2019 19 ...

Page 149: ...or the drive direction 1 upwards A For the reverse drive direction push the vertical rocker button for the drive direction 1 downwards B F1 F1 F2 F2 5060_003 097 1 Actuate the drive direction switch ﬁngertip version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction push the drive direction switch backwards 171533 EN 02 2019 19 135 ...

Page 150: ... s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter entitled Safety regulations when driving The driver s seat is equipped with a seat switch This checks whether the driver s seat is occupied If it is not occupied or in the case of malfunction of the seat switch the truck cannot be moved and all lift functions are locked out In such a case t...

Page 151: ...r pedal is released the truck decelerates NOTE The truck can brieﬂy be stopped on upward or downward gradients without actuating the parking brake electric brake The truck begins to creep downwards slowly DANGER Risk of accident due to brake failure The electric brake only functions while the key switch is switched on the emergency off switch has not been actuated and the parking brake is released...

Page 152: ...act your authorised service centre Starting drive mode dual pedal version variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit down on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter entitled Safety regulations when driving The driver s seat is equipped with a seat switch This checks whet...

Page 153: ... operating unit NOTE Depending on the equipment an acoustic signal variant may sound a warning during reverse travel the warning light variant may light up or the hazard warning system variant may ﬂash The truck will travel in the selected drive direc tion The speed is controlled by the accelera tor pedal position When the accelerator pedal is released the truck decelerates NOTE The truck can be s...

Page 154: ...om actuated accelerator pedal Actuate the accelerator pedal for the opposite direction The truck will travel in the selected drive direction NOTE In the event of an electrical fault with the accelerator the drive unit is shut down The electric brake service brake causes the truck to decelerate The truck cannot be driven again until the accelerator pedal has been released and then actuated again pr...

Page 155: ...by 50 and that the drive torque has decreased to 50 of the normal level a component failure may have occurred Bring the truck to a standstill using the brakes Use the parking brake if necessary to assist in this process Notify the authorised service centre Do not operate the truck again until the service brake has been repaired DANGER At speeds that are too high there is a danger that the truck co...

Page 156: ...ER There is a risk of being run over if the truck rolls away and therefore a danger to life The truck must not be parked on a slope In emergencies secure with wedges on the side facing downhill Only leave the truck when the parking brake is applied NOTE Once the parking brake is released the previously selected drive direction is retained and is shown on the drive direction indicator NOTE If you o...

Page 157: ...er possible The drive direction indicator 2 on the display and operating unit goes out 6210_494 002 Releasing the parking brake Pull the parking brake lever 1 down fully out of the middle position In the lower lever position pull out the lever knob and then guide the parking brake lever up fully NOTE The parking brake lever swivels to the upper position automatically by means of spring force and s...

Page 158: ...y male connector has been connectedandthekey switch is switched on The LED 2 lights up as soon as the truck is switched on Only the display operating unit indicates that the parking brake is applied Stop the truck As soon as the driver leaves the seat the seat switch is released and the parking brake is applied The LED 2 in the push button for the parking brake lights up continuously The electric ...

Page 159: ...e for the parking brake the parking brake is not always fully applied However under the following circumstances the parking brake is always fully applied The truck is stationary on a slope and can roll away easily The parking brake is automatically applied fully The driver wishes to fully apply parking brake and does so by pressing the push button for the parking brake The driver switches off the ...

Page 160: ...eleasing the electric parking brake after the truck has been switched on NOTE The LED 2 lights up as soon as the truck is switched on Only the display operating unit indicates that the parking brake is applied The parking brake cannot be released by pressing the accelerator pedal immediately after switching on the truck 6210_003 050_V4 2 1 Press the push button 1 to release the electric parking br...

Page 161: ... manually Press the push button 1 The parking brake will make a noise when it is applied and the LED 2 lights up continuously The parking brake is applied automatically 6311_003 031_en_V2 If the electric parking brake is applied the PARKING BRAKE ACTIVE message ap pears in the display for 5 seconds 171533 EN 02 2019 19 147 ...

Page 162: ...ng Actuation by the driver Press the push button 1 The truck is braked moderately Depending on the situation driving is possible again after the button has been released If the truck is at a standstill you will hear the parking brake engage and the LED 2 illuminates with a steady light Actuation triggered automatically Cause Effect When the driver leaves the driver s seat After a short wait the tr...

Page 163: ...rom being switched off when the parking brake is not applied The function is activated if the parking brake has been applied but has not been applied correctly as a result of a malfunction In both cases the function intervenes as follows The function intervenes as follows If the driver tries to switch off the truck when the parking brake is not applied or the parking brake is faulty the PARKING BR...

Page 164: ...t the truck from rolling away Have the parking brake repaired by an authori sed service centre NOTE If it is necessary to switch off a truck with a faulty parking brake the Switching off a truck with a faulty electrical parking brake section must be observed It is essential to secure the truck to prevent it from rolling away Malfunctions in the electric parking brake Before leaving the truck the d...

Page 165: ...ise at all It cannot be guaranteed that the parking brake has been applied properly Park the truck safely Notify the authorised service centre A warning signal is issued from signal horn or another acoustic warning unit in the truck It cannot be guaranteed that the parking brake has been applied properly Park the truck safely Notify the authorised service centre The truck rolls even though the par...

Page 166: ...to 5 km h The error message ﬂashes every 30 seconds for ﬁve seconds Try again to apply the parking brake via the push button 1 If this solution does not work park the truck safely and notify the authorised service centre Apply the parking brake manually See the chapter entitled Emergency operation of the electric parking brake Symbol Service required Display PARKING BRAKE Error number X6501 The LE...

Page 167: ...d Emergency operation of the electric parking brake Actuating a faulty electric parking brake 6210_003 050_V4 2 1 If the electric parking brake is faulty the LED 2 in the push button 1 will ﬂash and the message APPLY HANDBRAKE will appear on the display and operating unit A possible cause of the malfunction is that the parking brake cannot determine whether the truck is stationary or still in moti...

Page 168: ...e parking brake is applied NOTE The truck will brake more sharply if the push button 1 is pressed and held for a long period or if the push button is pressed multiple times Switching off the truck when the electric parking brake is faulty If the electric parking brake cannot be applied and the driver tries to switch off the truck the truck will not switch off at ﬁrst Instead the truck responds wit...

Page 169: ... leaves the truck a warning sound will be emitted and will stop only when the driver has resumed his her seat in the truck To switch off the truck despite the parking brake being faulty e g in order to tow the truck proceed as follows Switch off the key switch again The message APPLY HANDBRAKE will appear on the display and operating unit Press the ESC 3 soft key 171533 EN 02 2019 19 155 ...

Page 170: ...hing off the truck press the ESC 7 soft key If switching off the truck was continued the truck will now be switched off and the parking brake will not have been applied The truck can now be towed If the truck is not going to the towed the truck must be secured with wheel chocks to prevent it from rolling away DANGER Risk of fatal injury from the truck rolling away The truck is not secured against ...

Page 171: ...truck if it has a defective steering system Steer the truck by turning the steering wheel 1 accordingly Turning the steering wheel in the direction of arrow A steers the truck in drive direction A Turning the steering wheel in the direction of arrow B steers the truck in drive direction B For turning radius information see Chap ter Technical data P 419 171533 EN 02 2019 19 157 ...

Page 172: ...ction there still is a risk of tipping Before using this function familiarise yourself with the change to the driving and steering characteristics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steering Do not turn of...

Page 173: ...Operation 4 Driving 7321_003 052_en_V2 Reducing speed with a raised load variant This function variant reduces the speed of the truck with a raised load 171533 EN 02 2019 19 159 ...

Page 174: ... applied DANGER There is a risk 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 The electrolyte may freeze and damage the batteries The truck is then not ready for operation At ambient...

Page 175: ... transponder chips variant and the PIN code for access authorisation variant must not be handed over to other persons unless explicit instructions to this effect have been given 7321_003 039_V2 2 1 1 Wheel chock variant The wheel chock variant is used to prevent the truck from rolling away on a slope Lift handle 2 on the support mounting Remove wheel chock 1 from the support mounting Push the whee...

Page 176: ...h see Chapter Safety regulations when handing loads P 4 184 Types of lift mast One of the following lift masts may be installed in the truck 6210_810 001 1 Telescopic mast During lifting the lift mast rises over the outer lift cylinders bringing the fork carriage with it via the chains fork carriage rises twice as fast as the inner lift mast The top edge 1 of the inner lift mast can therefore be h...

Page 177: ...g devices The operation of the lifting system depends on the operating devices that are ﬁtted on the truck Possible equipment variants include Multiple lever Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck e g lift mast ...

Page 178: ...ng system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift lower operating lever 1 in the direction of the arrow B To lower fork carriage Move the lift lower operating lever 1 in the direction of the arrow A Tilting the lift mast To tilt the lift mast forwards Move the tilt operating lever 2 in the direction of the arrow C To tilt the lift mast backward...

Page 179: ...ate the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the lif...

Page 180: ... the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the lift m...

Page 181: ...m from the driver s seat Tilting the lift mast To tilt the lift mast forwards Move the lift mast operating lever 1 in the direction of the arrow A To tilt the lift mast backwards Move the lift mast operating lever 1 in the direction of the arrow B Lifting lowering the fork carriage To lift fork carriage Move the lift lower operating lever 2 in the direction of arrow D To lower fork carriage Move t...

Page 182: ...rrying devices etc can lead to serious injury or death and is therefore prohibited Observe the safety regulations for handling loads Only operate the lifting system from the driver s seat 6210_003 089 1 A B Lifting lowering the fork carriage To lift the fork carriage Pull the joystick 4Plus 1 backwards B To lower the fork carriage Push the joystick 4Plus 1 forwards A 168 171533 EN 02 2019 19 ...

Page 183: ...wards Tilt the horizontal rocker button 2 to the right D 1 6210_003 091 E F Fork carriage sideshift To move the fork carriage to the left Push the joystick 4Plus 1 to the left E To move the fork carriage to the right Push the joystick 4Plus 1 to the right F NOTE The symbols on the joystick 4Plus indicate the direction of movement of the lift mast or the fork carriage 171533 EN 02 2019 19 169 ...

Page 184: ... handling loads Only operate the lifting system from the driver s seat Lifting lowering the fork carriage To lift fork carriage Pull the lift lower operating lever 1 backwards To lower fork carriage Push the lift lower operating lever 1 forwards Tilting the lift mast To tilt the lift mast forwards Push the tilt operating lever 2 forwards To tilt the lift mast backwards Pull the tilt operating leve...

Page 185: ...ctive gloves and safety footwear when changing the fork arms Ensure that no one stands in the danger area Do not pull on the fork arms The fork arms must always be carried by two people if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used and should be dimensioned such that the fo...

Page 186: ...Place the fork arms on a pallet next to the fork carriage on the side chosen for installation Pull up the locking lever 1 and push the fork arms onto the fork carriage one after the other Place the fork arms in the required position and push down the locking lever Ensure that the locking lever snaps into place Screw in and tighten the locking screw 2 DANGER There is a risk of fatal injury from a f...

Page 187: ...ety footwear WARNING There is a risk of tipping The weight and dimensions of the fork extension affect the stability of the truck The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance The truck is equipped with a fork extension ex works the capacity rating plate is already adjusted accordingly Observe load capacity see the Before pick...

Page 188: ...sion is on the fork arm Always secure the fork extension with a securing bolt Always secure the securing bolt with a linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork extension 1 Push the fork extension onto the fork arms until it is ﬂush with the fork back Insert the securing bolts located behind the fork back fully into the fork extension Insert the...

Page 189: ...rk 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 higher 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 max of 600 mm above the ground NOTE If the truck is equipp...

Page 190: ...e Incorrect extension sequence DANGER Risk of accidents With triple masts variant an incorrect extension sequence may occur i e the inner lift mast may extend before the free lift has ﬁnished As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for instance result from The hydraulic oil temperature being too low The...

Page 191: ...le location If the fork carriage rollers in the lift mast become blocked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on lift masts see Chapter Working at the front of the truck P 5 374 Hydraulic blocking function The hydraulic blocking function en...

Page 192: ...riant means that the load cannot be lifted above a preset height This function uses a sensor that is welded on at the factory at the required lift mast limit height Once attached the height cannot be easily changed Application If the ceiling of the building is lower than the maximum lift height of the truck this variant can prevent the lift mast from accidentally hitting the ceiling which can resu...

Page 193: ... switch the automatic lift cut out back on Press Softkey 1 Automatic lift cut out is switched on The symbol is displayed Loads can be lifted only to the set lift height for the truck Lift mast vertical position variant Description If the truck is equipped with the lift mast vertical position comfort feature variant the driver can put down goods such as paper rolls vertically with precision and thu...

Page 194: ...ure consists of the following individual functions Display of the lift mast vertical position Automatic approach towards the lift mast vertical position Gentle running in to the end stops F1 F1 F2 F2 F1 F2 6210_003 092 1 2 4 5 3 The lift mast vertical position comfort feature is only available as a variant if the truck is equipped with one of the following operating devices Double mini lever 1 Tri...

Page 195: ...ilt the lift mast forwards using the corre sponding operating device The lift mast stops automatically as soon as the prese lected setting is reached for the lift mast vertical position If the comfort feature is switched off the lift mast tilts forwards past the lift mast vertical position without stopping If the lift mast is tilted backwards it moves past the lift mast vertical position without s...

Page 196: ...rwards and stops as soon as the vertical position is reached The arrow above the bar shown on the screen of the display and operating unit represents the lift mast vertical position Tilting the lift mast forwards beyond the vertical position Release the operating device for tilting and actuate again The lift mast is tilted beyond the vertical position up to the end stop The current mast tilt is sh...

Page 197: ...he vertical position has to be corrected frequently the lift mast vertical position should be calibrated 6210_003 070_en_V2 1 2 3 Calibrating the lift mast vertical position Set the lift mast to the required position Press and hold the button 1 for the lift mast vertical position for at least ﬁve seconds The message VERTICAL POSITION will appear on the display Storing the mast position Press the d...

Page 198: ...d loads or raised fork arms Never exceed the maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safety guard variant to preven...

Page 199: ...plicable The position of the capacity rating plate can be found in the chapter entitled Identiﬁcation points WARNING The ﬁgures show examples Only the capacity rating plates on the truck are valid The attachment of additional weights to increase load capacity is prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These values apply to compact and hom...

Page 200: ...ed Observe the special capacity rating plate infor mation shown on the truck and the attachment Load measurement variant Description Knowing the weight of the load to be trans ported gives the driver greater security If the truck is equipped with the load measure ment variant comfort feature the weight of the lifted load can be measured and shown in the display and operating unit Load measurement ...

Page 201: ...oads CAUTION If the weight determined by a load measurement exceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce load immediately If necessary use another truck with sufﬁcient load bearing capacity NOTE Accurate load measurement is only possible under the following conditions The hydraulic oil is at normal operating temperature The loa...

Page 202: ...OTE If the truck is equipped with mini levers or ﬁngertip operation the F1 button can also be pressed as an alternative NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the load measurement will not be accurate To stop the lowering procedure quickly release the operating device for low...

Page 203: ... and are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the load Loads are to be picked up and transported as close to the middle as possible DANGER Risk of accident from a falling load When transporting small items attach a load safety gua...

Page 204: ...ts working equipment its load carrying equipment e g attachments or the load Also included are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all p...

Page 205: ...nd carefully positioned loads may be transported 6210_001 007 Transporting suspended loads Before transporting suspended loads con sult the national regulatory authorities in Germany the employer s liability insurance associations National regulations may place restrictions on these operations Contact the relevant authorities DANGER Suspended loads that begin to swing can result in the following r...

Page 206: ... suspended loads and prevent the loads from swinging Take particular care to ensure that there is no one in the drive direction in the driving lane If despite this the load begins to swing ensure that no person is placed at risk DANGER Risk of accidents When transporting hanging loads never perform or end driving and load movements abruptly Never drive on slopes with a suspended load Transporting ...

Page 207: ...e speciﬁed aisle width is not reduced by protruding parts 6210_800 005 Approach the racking carefully brake gently and stop just in front of the racking 6210_800 006 Position the forks Set lift mast to vertical Lift the fork carriage to the stacking height CAUTION Component damage possible When inserting the fork into the racking ensure that the racking and load are not damaged 171533 EN 02 2019 1...

Page 208: ... middle 6210_800 008 Lift the fork carriage until the load is resting entirely on the forks DANGER Risk of accidents Beware of any people in the danger area Ensure that the roadway behind you is clear DANGER Never tilt the lift mast with a raised load due to the risk of tipping Lower the load before tilting the lift mast Move backwards carefully and slowly until the load is clear of the racking Br...

Page 209: ...Operation 4 Handling loads 5060_003 102 Lower the load while maintaining ground clearance 5060_003 101 Tilt the lift mast backwards The load can be transported 171533 EN 02 2019 19 195 ...

Page 210: ...nt Driving with a raised load and the lift mast tilted forward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards 6210_800 013 Drive slowly and carefully round corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the informa...

Page 211: ...g The truck may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take parti cular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from a falling load If the fork or the load remains suspended during lowering the load may fall When remov...

Page 212: ...wards the rack carefully 6210_800 016 Lower 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 198 171533 EN 02 2019 19 ...

Page 213: ... drive onto or along ascending and descending gradients at an angle Do not park the truck on ascending or descending 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 stability...

Page 214: ...se à vide Leergewicht max min kg kg kg kg kg kW V see Operating instructions voir Mode d emploi siehe Betriebsanleitung D 22113 Hamburg Berzeliusstr 10 1 3 2 Determining the actual total weight Park the truck securely see Chap ter Parking the truck securely and switch ing it off P 4 160 Determine the unit weights by reading the truck nameplate and if necessary the attachment variant nameplate and ...

Page 215: ...érie Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min kg kg kg kg kg kW V see Operating instructions voir Mode d emploi siehe Betriebsanleitung D 22113 Hamburg Berzeliusstr 10 1 3 2 Determining the total actual weigh...

Page 216: ...chment and the visibility from the driver s position with and without a load must be checked by a competent person If the visibility is deemed insufﬁcient visual aids such as mirrors a camera monitor system etc must be used In addition it is essential that the warnings below are observed CAUTION Attachments must be CE certiﬁed If the truck is not ﬁtted with an attachment speciﬁc residual load capa...

Page 217: ...tallation Never grab or climb on moving parts of the truck 7090_900 001 Hydraulic connection Before installing the attachment release the pressure from the hydraulic system CAUTION Risk of damage to components Open connections of plug connectors can become dirty The plug connectors can become stiff and dirt can enter the hydraulic system Once the attachment has been disassembled attach the protect...

Page 218: ...ing During the process described below the fork carriage or the lift mast can only be moved slightly Do not reach into or stand below the components of the load lift system Non clamping attachments are connected to the third hydraulic circuit via the plug connectors on the fork carriage and are controlled via the 5th hydraulic function Before ﬁtting attachments the pressure must be released from t...

Page 219: ...ck is not equip ped with a hazard warning system Switching on the hazard warning system prevents the electrical system from being switched off even if the key switch is subsequently swit ched off Switch off the key switch The message KEY SWITCH appears in the display Press and hold the horizontal rocker button for the 5th function 2 While holding down the button actuate the operating lever several...

Page 220: ...r of operating levers shown may differ from the truck s equipment WARNING Unintended movement of the lift mast presents a risk of injury The hydraulic pump is inactive If an operating device for the hydraulic functions is accidentally actuated it may still cause unintended movements of the lift mast Do not touch the operating devices 206 171533 EN 02 2019 19 ...

Page 221: ...revents the electrical system from being switched off even if the key switch is subsequently swit ched off Switch off the key switch The message KEY SWITCH appears in the display Actuate the operating lever 1 several times in the direction of the arrow until the end position is reached The hydraulic circuits of the ﬁrst four hydraulic functions are depressurised Press and hold the 5 Funktion 2 fun...

Page 222: ...erating devices see the relevant sections in this chapter WARNING Use of attachments can give rise to additional hazards such as a change in the centre of gravity additional danger areas etc Attachments must only be used for their intended purpose as described in the relevant operating instructions Drivers must be taught how to operate the attachments Loads may only be picked up and transported wi...

Page 223: ...tograms on the operating devices NOTE All the attachments described fall into the category of equipment variants Please see the respective operating instructions for an exact description of the respective movements actions of the attachment ﬁtted 171533 EN 02 2019 19 209 ...

Page 224: ...of the pictogram 7311_862 001 2 3 6 4 7 9 10 5 8 Note the following attachment functions and pictograms 2 Move side shift frame or fork for wards backwards 3 Move sideshift to the left right 4 Adjust fork arms open close 5 Swivel lift mast or fork to the left right 6 Release clamp load retainer 7 Push off pull in load 8 Open close clamps 9 Turn to the left right 10 Tip shovel over tip shovel back ...

Page 225: ...g functions The central and bottom parts of the pictograms on the operating levers always show the function that is activated by that lever The top part of the pictogram shows that the attachment is equipped with the 5th function This essentially involves the following Move the operating lever forwards The attachment moves in the direction of movement shown in the centre part of the pictogram Move...

Page 226: ...load retainer 6 Push off pull in load 7 Turn to the left right 8 Tip shovel over tip shovel back 9 Swivel lift mast or fork to the left right NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service ce...

Page 227: ...Move the attachments 1 cross lever in the direction of the arrow A The attachment moves in accordance with the pictogram in position A Move the attachments 1 cross lever in the direction of the arrow B The attachment moves in accordance with the pictogram in position B Move the attachments 1 cross lever in the direction of the arrow C The attachment moves in accordance with the pictogram in positi...

Page 228: ... to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the p...

Page 229: ... lever 2 show the respective functions that are activated by this lever This essentially involves the following Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow F The at...

Page 230: ...ack wards 5 Move sideshift to the left 6 Move sideshift to the right 7 Adjust fork arms open 8 Adjust fork arms close 9 Swivel lift mast or fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Rotate to the left 16 Rotate to the right 17 Tip shovel over 18 Tip shovel back 216 171533 EN 02 2019 19 ...

Page 231: ...y these levers This essentially involves the following Move the operating lever 1 towards A The attachment moves in accordance with the pictogram in position A Move the operating lever 1 towards B The attachment moves in accordance with the pictogram in position B Move the operating lever 2 towards C The attachment moves in accordance with the pictogram in position C Move the operating lever 2 tow...

Page 232: ... to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the p...

Page 233: ...e 5th hydraulic function can be controlled with the operating lever 1 by switching the functions using the function key 3 The pictograms on the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 3 and move operating lever 1 towards E The attachment moves in accordance with the pictogram in ...

Page 234: ...ose 3 Rotate to the left 4 Rotate to the right NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if required 220 171533 EN 02 2019 19 ...

Page 235: ...that is activated by these levers This essentially involves the following Move the operating lever 1 towards A The attachment moves in the direction shown in pictogram A Move the operating lever 1 towards B The attachment moves in the direction shown in pictogram B Move the operating lever 2 towards C The attachment moves in the direction shown in pictogram C Move the operating lever 2 towards D T...

Page 236: ... to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the p...

Page 237: ...ic function can be controlled with the operating lever 3 by switching the functions using the 5th function function key 5 The pictograms on the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 5 and move operating lever 3 towards E The attachment moves in accordance with the pictogram in ...

Page 238: ...ose 3 Rotate to the left 4 Rotate to the right NOTE The pictograms shown correspond to the attachments ﬁtted to this truck at the factory If an attachment with other functions is ﬁtted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if required 224 171533 EN 02 2019 19 ...

Page 239: ... on the adhesive labels re garding operation of the Joystick 4Plus 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 directions A or B as shown in the pictogram Move the slider 4 in the direction of the arrow C or D T...

Page 240: ... afﬁxed according to the attachment ﬁtted at the factory If an attachment with different functions is ﬁtted the authorised service centre must check that the pictograms bear the correct representation and must change them if necessary For actuation of the clamp locking mecha nism see the section entitled Clamp lock ing mechanism variant 226 171533 EN 02 2019 19 ...

Page 241: ...tion 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 attachment 1 Shift key F and Joystick 4Plus Adjust fork arms close open 2 Shift key F and rocker button Adjust fork backwards forwards 3 Shift key F and rocker button Swivel lif...

Page 242: ...ms are afﬁxed according to the attachment ﬁtted at the factory If an attachment with different functions is ﬁtted the authorised service centre must check that the pictograms bear the correct representation and must change them if necessary 228 171533 EN 02 2019 19 ...

Page 243: ...pictogram 6210_003 031 2 3 6 4 7 9 10 5 8 Note the following attachment functions and pictograms 2 Move side shift frame or forks forwards backwards 3 Move sideshift to the left to the right 4 Adjust fork arms open close 5 Swivel lift mast or forks to the left to the right 6 Release clamp load retainer 7 Push off pull in load 8 Open close clamps 9 Turn to the left to the right 10 Tip shovel over t...

Page 244: ...tch 2 to switch functions in which case the corresponding operating lever controls the 5th function The pictogram 3 behind the operating lever shows in the upper and lower parts the function that is activated with this lever The meanings are as follows Move operating lever forwards The attachment moves in the direction of movement shown in the upper part of the pictogram Move operating lever back ...

Page 245: ...function key indicates which operating lever is equipped with the 5th function The 5th function is switched to the 4th operating lever see adhesive label 9 NOTE The movement action of this 5th function can be found in the operating instructions of the ﬁtted attachment NOTE The pictograms are applied depending on the pre assembled attachment If an attachment with other functions is ﬁtted the pictog...

Page 246: ...h a clamp locking mechanism as a variant This clamp locking mechanism prevents the clamp from opening unintentionally if the operating function is inadvertently triggered DANGER There is a risk of fatal injury from falling loads if the correct function of the clamp locking mechanism is not guaranteed If other attachments are used on this truck in addi tion to the clamp make sure that the clamp loc...

Page 247: ...e clamp pull the operating lever 1 backwards F1 F2 6210_003 077 1 2 Double mini lever To release the clamp locking mechanism push the operating lever 1 forwards The LED for button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one second the clamp loc...

Page 248: ...king mechanism in order to close the clamp To close the clamp pull the operating lever 1 backwards 6210_003 079 2 1 Quadruple mini lever To release the clamp locking mechanism push the operating lever 1 forwards The LED for button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking m...

Page 249: ... button 1 to the left again within 1 second The LED 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one second the clamp locking mechanism is automatically reactivated It is not necessary to release the clamp locking mechanism in order to close the clamp ...

Page 250: ...lamp pull the operating lever 1 backwards 1 2 3 7090_860 002 Taking up a load using attachments WARNING Risk of accidents Attachments may only be used for their intended purpose as described in the relevant operating instructions Drivers must be instructed in the handling of the attachments WARNING Risk of accidents Loads may only be picked up and transported with attachments if they are securely ...

Page 251: ...he parking light To switch off the driving lights press the button 1 again The driving lights go out Working spotlights Blue Q_008_V3 1 To switch on the working spotlights front and rear press the button 1 The working spotlights light up To switch off the working spotlights press the button 1 again The working spotlights go out NOTE When the working spotlights are switched on in trucks with StVZO ...

Page 252: ...ed The rear working spotlight does not yet illuminate Set the drive direction to Reverse The rear working spotlight illuminates NOTE If the drive direction is set to Forwards the rear working spotlight goes out Switching the rotating beacon on and off 5060_003 045_V2 2 1 Press the Softkey 1 to switch on the rotating beacon The rotating beacon is switched on The symbol is displayed To switch off th...

Page 253: ...arning system press the button 1 again The hazard warning system goes out NOTE To switch on the hazard warning system without the key switch being switched on press and hold the button for three seconds Switching the turn indicators on and off Mini lever version 5060_003 096 F1 F2 1 Switch on the turn indicators by moving the cross lever of the drive direction turn indicator 1 to the left or to th...

Page 254: ...itch off the turn indicators by moving the cross lever to the centre position Fingertip version F1 F1 F2 F2 5060_003 100 1 Switch on the turn indicators by moving the corresponding turn indicator button 1 to the left or to the right Switch off the turn indicators by actuating the other turn indicator button 240 171533 EN 02 2019 19 ...

Page 255: ...indicators by moving the turn indicator switch 1 to the left or to the right 2 3 5060_003 012_V2 The turn indicators and the corresponding turn indicator displays 2 or 3 ﬂash Switch off the turn indicators by moving the turn indicator switch to the centre position 171533 EN 02 2019 19 241 ...

Page 256: ...tlight illuminates the working area directly in front of the truck Depending on the equipment the upper working spotlights can be switched on off automatically or manually Switching the upper working spotlights on off manually NOTE The upper working spotlights can be switched on off independently of the lower working spotlights For information about switching on the lower working spotlights see th...

Page 257: ...tomatically when the lift mast is lifted for a period of at least two seconds NOTE During these two seconds a maximum of two lifts can be executed to prevent the working spotlights from switching on each time a precise adjustment is made If more lifts are carried out during this time the upper working spotlights will remain switched off NOTE The upper working spotlights are switched off automatica...

Page 258: ...into the STILL SafetyLight The STILL SafetyLight is a visual warning unit designed to enable early detection of trucks in driving areas with low visibility such as drive lanes high racks as well as at blind junctions The STILL SafetyLight is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations The STILL SafetyLight projects one or more light blue light sp...

Page 259: ...me Interval 3rd time hold Washer 4th time Off 1 2 6327_003 008 Filling the washer system Open the ﬁller cap 1 of the washer system variant Fill the washer reservoir 2 with washer ﬂuid containing anti freeze according to the maintenance data table see Chap ter Maintenance data table P 5 387 CAUTION Components may become damaged due to the effects of frost Water expands when it freezes If there is n...

Page 260: ...nt in which an acceleration sensor is installed in the truck The acceleration sensor records data arising from rapid accelerations or decelerations of the truck e g in the event of an accident This data can be electronically read out and evaluated If you have any questions please contact your authorised service centre Driver restraint systems variants Different driver restraint systems are availab...

Page 261: ...tain that the ceiling sensor system is functioning correctly Despite the ceiling sensor system being installed the driver must also check the speed indicator on the display operating unit on a regular basis to ensure that he does not exceed the maximum speed permitted for the environment Entering a hall The ceiling detector system automatically detects whether the truck enters a hall The system th...

Page 262: ...a hall ceiling and reduce the maximum speed In rare cases it may occur that the ceiling sensor system does not recognize a ceiling and does not then reduce the speed This can happen if the signals from the ceiling sensor are insufﬁciently reﬂected due to the ceiling geometry for example if there are large window areas at a 45 angle In these cases the sensitivity and the range of the ceiling sensor...

Page 263: ... the underside of the assembly baseplate on the overhead guard loosen the four nuts 1 on the sensor Carefully remove the sensor 2 Using the supplied key 2 open the sensor housing to gain access to the DIP switches 171533 EN 02 2019 19 249 ...

Page 264: ... the manufacturer They must not be changed Factory settings of the manufacturer do not change 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 m 4 5 Sensitivity 0 0 Very high 0 1 High 1 0 Medium 1 1 Low The sensor has different beam angles de...

Page 265: ... table Sensitivity Range Beam angle 2 m 22 5 4 m 22 5 8 m 20 16 m 15 Low 1 24 m 5 2 m 35 4 m 30 8 m 25 16 m 22 5 Medium 2 24 m 10 Sensitivity Range Beam angle 2 m 42 4 m 33 8 m 22 5 16 m 20 High 3 24 m 15 2 m 45 4 m 43 8 m 30 16 m 22 5 Very high 4 24 m 18 171533 EN 02 2019 19 251 ...

Page 266: ...t 2 3 4 1 2 3 4 Representation of the beam angle depending on the sensitivity of the sensor that has been set from 1 low to 4 very high Additional labelling Adhesive label next to the display operating unit 252 171533 EN 02 2019 19 ...

Page 267: ...ged position Opening the cab door from the outside 6321_003 061_V3 4 5 2 1 3 Insert the key in the door lock 5 unlock and remove the key Pull the door handle 4 and release the door lock Open the cab door 3 by pulling outwards Opening the cab door from the inside Take hold of the handlebar 2 and latch 1 Press the latch in and push the cab door outwards 171533 EN 02 2019 19 253 ...

Page 268: ...dow Press the handle 3 together and slide the rear side window 2 forwards Opening the front side window The front side window 1 can be opened in the same way as the rear side window 6321_003 141_V2 3 1 2 Closing the side windows WARNING There is a risk of crushing between the window frame and side window from the side windows slipping inadvertently during travel Make sure that the handle engages s...

Page 269: ...312_003 013 7 8 Operating the interior lighting 6311_003 013_V2 2 1 Switch the interior lighting 7 on or off using the switch 8 or button 1 The interior lighting symbol 2 appears in the display 171533 EN 02 2019 19 255 ...

Page 270: ...003 015 1 2 Radio variant The radio 1 and the loudspeakers 2 are an equipment variant If the truck is equipped with a radio and loudspeakers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the radio WARNING The driver s attention is adversely affected by operating the radio or listening to excessive volume while driving...

Page 271: ... the desired blower position The blower is in operation and runs at the speed level selected by the blower switch 1 DANGER The heating system overheats if the hot air cannot escape from it There is a risk of ﬁre The heating system may only be switched on if the blower is running and the heating system is not covered by objects such as a jacket or cover Always switch the blower on ﬁrst Do not switc...

Page 272: ...level 1 Set heating system to medium 75 Set heating level switch 2 to level 2 Set heating system to high 100 Set heating level switch 2 to level 3 Turn off the heating system and blower DANGER The heating system overheats if the hot air cannot escape from it There is a risk of ﬁre The blower may only be turned off if the heating system is turned off Always turn the heating system off ﬁrst Only tur...

Page 273: ...ach between the roof window and the overhead guard Do not reach in to touch components as they are being closed The push up roof window 1 is an equipment variant To unlock and open the roof window rotate the handle 2 in an anti clockwise direction and use it to push the roof window upwards The roof window is held in the open position by means of gas springs 3 To close and lock the roof window pull...

Page 274: ...4 Operation Cab 6210_003 107 2 1 Clipboard variant The clipboard 1 with reading lamp 2 is an equipment variant 260 171533 EN 02 2019 19 ...

Page 275: ... Overloading can lead to component damage on the truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the existing towed load corresponds to the rated capacity of the truck no load may be transported on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust it to correspon...

Page 276: ...ting time If the truck is to be used for towing on a more regular basis the manufacturer should be consulted Coupling pin in the counterweight Coupling the trailer DANGER If you brieﬂy leave the truck to couple or uncouple the trailer there is a risk to life caused by the truck rolling away and running you over Apply the parking brake Lower the forks to the ground Switch off the key switch and rem...

Page 277: ...curing bush are lost or destroyed during towing the trailer will work loose and become uncontrollable This causes a risk of accident Use only original coupling pins that have been checked carefully Ensure that the coupling pin is correctly inserted and secured Insert the coupling pin into the counter weight press downwards against the spring pressure and turn 90 the coupling pin is locked in this ...

Page 278: ...etween the truck and trailer DANGER Never jack up the truck on the tow coupling or use it for crane lifting The tow coupling is not designed for this and could be deformed or damaged This could cause the truck to fall with potentially fatal consequences Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER The tow coupling is not design...

Page 279: ...due to its overhang The tow coupling can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow coupling test the tow coupling for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufﬁcient room In the case of a collision test the tow coupling for damage Replace tow coupling if damaged if necessary ...

Page 280: ...r a tow bar eye in accordance with DIN 74054 bore diameter 40 mm Take measures to prevent the trailer from rolling away e g use wheel chocks 1 Adjust the tow bar eye of the tiller so that it is at the centre of the towing jaws 3 7321_003 064 2 Pull out the safety handle 3 Push the hand lever 2 upwards DANGER Persons may become trapped between the truck and trailer When hooking up ensure that no on...

Page 281: ...RO 243 by hand DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for example a tow rope is to be secured in the tow coupling use only a suitable device to close the tow coupling e g assembly lever Use a suitable device e g assembly lever to push the coupling pin up The coupling pin is released from the latch and the tow coupling then closes automatically 3...

Page 282: ...R People can become trapped between the truck and trailer When hooking up ensure that no one is between the truck and trailer CAUTION When being coupled the tow bar eye must engage in the middle of the coupling jaw Failure to follow these instructions could result in damage to the coupling jaw or to the tow bar eye Ensure that the tow bar eye enters the coupling jaw centrally Move the truck back s...

Page 283: ... Remove any items used to prevent the trailer from rolling away Tow the trailer Closing model RO 244 A by hand DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for example a tow rope is to be secured in the tow coupling only actuate the tow coupling via the closing lever 1 Press the closing lever 1 downwards as far as it will go The tow coupling is closed...

Page 284: ...nd lever 5 upwards The tow coupling is opened DANGER People can become trapped between the truck and trailer When hooking up ensure that no one is between the truck and trailer Slowly move the truck back DANGER If thecoupling pin drops out during towing thetrailer will work loose and can no longer be controlled There is a risk of accident A protruding safety handle means that the tow bar eye has n...

Page 285: ...O 841 is intended for a tow bar eye in accordance with DIN 74054 bore diameter 40 mm Take measures to prevent the trailer from rolling away e g use wheel chocks Push the hand lever 7 upwards until it snaps into place DANGER People may be trapped between truck and trailer When hooking up ensure that no one is between the truck and trailer CAUTION When being coupled the tow bar eye must engage in th...

Page 286: ...y drive the truck forwards until the tow bar eye and towing jaws are disconnected Close the tow coupling 7090_900 011 Towing trailers Drivers who are towing a trailer for the ﬁrst time must practise driving with a trailer in a suitable area When passing through narrow road areas entrances gates etc observe the dimen sions of the trailer and load When towing multiple trailers ensure a sufﬁcient min...

Page 287: ...Operation 4 Trailer operation NOTE Please observe the deﬁnition of the following responsible persons operating company and driver 171533 EN 02 2019 19 273 ...

Page 288: ...d outdoor use to 25 C brieﬂy up to 40 C Operation CAUTION Changing from a cold internal temperature to a warm outside temperature may result in the formation of condensation water This water may freeze on re entry to the cold store blocking moving parts of the truck It is essential that close attention is paid to the duration of deployment in the different temperature ranges for both types of appl...

Page 289: ...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 respective battery dimensions for the truck series Electric trucks must not be parked in a cold area for any longer than necessary This also applies to unused batteries The charging st...

Page 290: ... 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 meaning the capacity of the battery is lower 276 171533 EN 02 2019 19 ...

Page 291: ...time according to the event In the case of successive events the respec tive messages are displayed one after another on the display After a few seconds the display will alternate between the last shown operating display and the message The frequency of alternation depends on the type of event If a message appears follow these operat ing instructions Once the event is remedied the message will dis...

Page 292: ...horised service centre ACCELERATOR A3811 Accelerator conﬁguration is invalid The truck cannot be driven Notify the authorised service centre BRAKE SENSOR A3016 A3017 Sensor fault truck can only be driven at emergency mode speed Notify the authorised service centre CONFIGURATION A2111 A3801 A3812 Parameterisation error drive unit and hydraulic drive not functioning Notify the authorised service cen...

Page 293: ...draulic drive function Notify the authorised service centre POWER SUPPLY A2242 Transmitter power supply short circuit The truck cannot be driven Notify the authorised service centre SURVEILLANCE A2801 A2802 A2808 A2809 A2810 A2815 Drive unit not functioning Release accelerator pedal If this error occurs sporadically it can be tolerated If the operational capacity is impaired notify the authorised ...

Page 294: ...y the authorised service centre BATTERY CHANGER A5931 Plausibility error from the potentiometer for the hydraulic battery carrier Notify the authorised service centre CONTROL UNIT A3305 CIO not functioning Notify the authorised service centre PARKING BRAKE OIL PRES SURE A3043 The oil pressure in the parking brake is too low the drive unit is locked Notify the authorised service centre PARKING BRAK...

Page 295: ...sappear and the hydraulic function will be available again If required the authorised service centre can disable monitoring of the hydraulic functions A4680 Implausible pressure request to the hydraulic pump Switch the truck off and then on again using the key switch If the error message persists notify the authorised service centre SERVICE REQUIRED S5950 The lithium ion battery requires servicing...

Page 296: ...ed service centre Park the truck securely for checking by the authorised service centre If multi disc brakes in the drive wheel units are blocked tow the truck APPLY HANDBRAKE message DANGER Risk of fatal injury from being run over if the truck rolls away Parking the truck without the parking brake applied is dangerous and is not permitted The truck must not be parked on a slope Only leave the tru...

Page 297: ...NSOR message If the BRAKE SENSOR message appears in the display the maximum driving speed will be reduced The brake sensor in the brake pedal must be checked Notify the authorised service centre CODE DENIED message If the message CODE DENIED appears on the display the driver PIN has been entered incorrectly three times The input is then locked for ﬁve minutes before another attempt can be made Ent...

Page 298: ...ng brake has been released by pressing the button Release the parking brake by pressing the button PARKING BRAKE APPLY HAND BRAKE message If the message PARKING BRAKE APPLY HANDBRAKE appears on the display the electric parking brake is faulty Release the parking brake by pressing the button LOWER FORKS message DANGER There is a risk of fatal injury from a falling load or parts of the truck being l...

Page 299: ...rs on the display after the welcome screen the tilting speed of the lift mast on this truck is signiﬁcantly higher than on previous trucks in this family EMERGENCY SWITCH message WARNING No electric braking assistance is available when the emergency off switch is actuated Actuating the emergency off switch will disconnect the drives from the power supply To brake actuate the service brake The truc...

Page 300: ...ll only travel at a reduced driving speed Depending on the position of the fork the message REFERENCE CYCLE variant may appear in the display To align the position with the control electronics the fork must be raised Switch on the key switch The truck will only travel at a reduced driving speed The message REFERENCE CYCLE may appear in the display Raise the fork The message REFERENCE CYCLE goes ou...

Page 301: ... will not drive at all Depending on the conﬁguration selected the working hydraulics functions lifting tilting are either available as normal slowed down or not available at all The SAFETY BELT message with the restric ted driving and lifting functions is triggered by the following circumstances Seat belt not worn and driver s seat occu pied The seat belt is constantly fastened but the driver s se...

Page 302: ... message The truck is equipped with a seat switch If the SEAT SWITCH message appears the driving functions and the working hydraulics are blocked The SEAT SWITCH message is triggered by the following situations The seat switch is not actuated while the accelerator pedal or steering wheel is actuated The seat switch is not actuated while the operating device for the working hydraulics is actuated T...

Page 303: ... s seat and fasten the seat belt The truck can be driven again without restric tions 7325_003 054_en_V2 F1 F2 The seat switch is not actuated while the operating device for the working hydraulics is actuated An operating device for the working hydraulics is actuated even though no one is sitting in the driver s seat The message SEAT SWITCH appears on the display The working hydraulics functions ca...

Page 304: ... NOTE The operating time is adjustable If the key switch is switched on the parking brake is released and the driver does not leave the seat before the set operating time is exceeded and if neither the operating devices for the working hydraulics nor the accelerator pedal are actuated during this time SEAT SWITCHappears on the display The truck will not move Depending on the conﬁguration the worki...

Page 305: ...essage NOT VALID appears on the display an incorrect driver PIN has been entered when entering the access code Once the message goes out enter the driver PIN again Drive speciﬁc messages Message PARKING BRAKE OIL PRESSURE If the following message appears in the display when the accelerator pedal is actuated PARKING BRAKE OIL PRESSURE the service brake of the truck is not yet ready for use The driv...

Page 306: ...age CLOSE THE DOOR variant appears in the display the battery door is not shut correctly The truck will not move Close the battery door LEVER message If an operating device is actuated continuously for a long period the Lever message is displayed with the error code A4601 4604 If you continue to move the operating device the affected hydraulic function is switched off The message disappears as soo...

Page 307: ... determined by physics cannot be altered the increased safety provided by this function must not be misused in order to take safety risks If the fork is raised above a certain height the following happens 6210_003 054 en_V3 Lifting the load at a standstill The key switch is switched on The driver sits on the seat with the belt fastened The load is lifted The display brieﬂy shows the ﬂashing messag...

Page 308: ...ad during a stacking unstacking operation and lift the load while travelling the ﬂashing message LIFT HEIGHT appears brieﬂy in the display The truck will travel slowly or will be braked Lower the fork load to just above the ground The truck can now be driven again with no speed limitation 294 171533 EN 02 2019 19 ...

Page 309: ...he key switch is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the key switch before 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 Press the ...

Page 310: ...ps over the driver could fall out and slide under the truck with potentially fatal conse quences 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 cornering can cause the truck to tip over If the truck starts to tip over do not leave the truck under any circumstances This in...

Page 311: ...ace and cause damage to skin and eyes through cuts When a pane of glass is smashed the face should be turned away and covered with the crook of the free arm Protect the face when smashing a pane of glass Pull the emergency hammer out of its support 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 l...

Page 312: ...h turn the emergency lowering screw 2 on the valve block 5 a maximum of 1 5 revolutions to loosen it For the multiple lever version B Using the hexagon socket wrench 1 turn the emergency lowering screw 4 on the valve block 3 a maximum of 1 5 revolutions to loosen it WARNING The load is lowered The lowering speed is regulated by unscrewing the emergency lowering screw Note the following list For bo...

Page 313: ...051_V3 Emergency operation of the electric parking brake WARNING The truck can roll away when the parking brake is released Emergency operation of the parking brake can be initiated only when the fork is lowered and the truck is switched off In emergency operation or during transport without a battery the electric parking brake can be operated manually via the hand wheel Lower the forks to the gro...

Page 314: ...d the cover to its normal position 6 0 3 6 B a 0 2 6 5060_003 070 Towing DANGER The brake system on the towing vehicle may fail There is a risk of accident If the brake system of the towing vehicle is not adequately sized the vehicle may not brake safely or the brakes may fail The towing vehicle must be able to absorb the pulling and braking forces from the unbraked towed load total actual weight ...

Page 315: ...owing vehicle may only be manoeuvred and the tow bar may only be attached using a second person as a guide This ensures that the driver of the towing vehicle and the mechanic attaching the tow bar are aware of possible risks Only manoeuvre with a guide CAUTION Steering is stiff There is no power steering if the hydraulics fail The selected towing speed must allow the truck and towing vehicle to be...

Page 316: ... Secure the tow bar to the tow coupling of the towing vehicle and the truck Sit in the driver s seat in the truck to be towed and fasten the safety belt Where possible activate the restraint systems provided Release the parking brake Select a towing speed that allows the truck and towing vehicle to be effectively braked and controlled at all times Tow the truck After towing secure the truck from r...

Page 317: ...he service life of the contacts Do not connect the battery male connector with the key switch switched on Make sure that the key switch is switched off before connecting the battery male connector Ensure that the battery male connector 1 and the plug connection are dry clean and free of foreign objects Insert the battery male connector 1 fully into the plug connection on the truck CAUTION There is...

Page 318: ...ry male connector with the key switch switched on in an emergency Open the battery cover 1 5060_003 051 Disconnect the battery male connector 1 by pulling in the direction of the arrow at the plug connection Place the battery male connector on the battery CAUTION There is a risk of short circuit if the cables are damaged Position the battery cable on the battery in such a way that it cannot be cru...

Page 319: ...ntenance personnel Batteries may only be charged maintained or replaced by properly trained personnel in accordance with the instructions from the manufacturers of the battery battery charger and truck Follow the handling instructions for the battery and the operating instructions for the battery charger WARNING Risk of crushing shearing The battery is very heavy There is a risk of serious injury ...

Page 320: ...There must be no ﬂammable materials or spark forming operating materials within 2 m of either the truck when it is parked for charging or the battery charger When working with batteries take the following safety precautions Keep away from open ﬂames and do not smoke Ensure that work areas are adequately ventilated Disconnect the battery male connector before charging and only when the truck and ba...

Page 321: ...main within the weight range speci ﬁed on the nameplate Do not remove or change the position of ballast weights Note the battery weight Performing battery maintenance The cell covers of the battery must be kept dry and clean Terminals and cable shoes must be clean lightly coated with battery grease and screwed on tightly Neutralise any spilt battery acid immedi ately Observe the safety regulations...

Page 322: ...or is disconnected or connected while the key switch is switched on or while the battery charger is under load an arc or a transition spark will be produced at the battery male connector This can lead to erosion at the contacts and can considerably shorten the service life of the contacts Switch off the key switch or the battery charger before the battery male connector is disconnec ted or connect...

Page 323: ...d Only theinstructions thatcame withthe battery charger are valid If any of these instructions are not available please request them from the dealer The battery maintenance is composed of the following sections Checking the battery con dition acid level and acid density Checking the battery charge status Charging the bat tery and Equalising charge to prevent a deep discharge of the battery togethe...

Page 324: ...acid leaks Have defective batteries repaired by the authorised service centre 6321_003 126 1 2 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 only Clean the battery cell...

Page 325: ...eep discharge of the battery Cease work with the truck immediately Charge the batteries immediately Do not leave batteries in a discharged or partly discharged state Apply the parking brake Switch on the key switch Read the charge state 1 from the display Charge a discharged or partly discharged battery NOTE The battery charge display shows the avai lable battery capacity as a segmented bar graph ...

Page 326: ...isconnected or connected NOTE Battery maintenance is carried out in accor dance with the battery manufacturer s opera ting instructions The operating instructions for the battery charger must also be followed Only theinstructions that camewith the battery charger are valid If any of these instructions are missing please request them from the dealer To read the battery charging state see the sectio...

Page 327: ...e cab variant 6321_003 127 3 Attach the battery male connector 3 to the battery charger connector NOTE Follow the information in the operating instruc tions for your battery and the battery charger equalising charge Start the battery charger The ventilation gaps between the cover and chassis must not be blocked DANGER Risk of explosion The battery cover must be kept open during charging to ensure ...

Page 328: ...ose the battery cover completely When doing so ensure that no cables are crushed between the chassis and the cover The battery cover must be locked otherwise the CLOSE THE DOOR error message will appear in the display and the truck will not drive Charging the battery with the battery charging ﬂap DANGER Risk of explosion Observe the safety regulations when handling the battery see the chapter enti...

Page 329: ...pop out Turn the release buttons 1 The release buttons 1 unlock the battery charging ﬂap 2 Open the battery charging ﬂap 2 fully 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 Sw...

Page 330: ...ions for handling battery acid see the chapter entitled Battery acid Rinse away spilt battery acid immediately using plenty of water Before charging check the battery cable and the charging cable for damage and have the cables replaced by the authorised service centre if necessary CAUTION Damage to the connection assembly is possible If the charging cable is connected while the battery charger is ...

Page 331: ... the ﬂap and chassis must not be blocked After charging Switch off the battery charger CAUTION Damage to the connection assembly is possible If you pull out the charging cable while the battery charger is switched on an arc will be produced This can lead to erosion at the contacts which con siderably shortens the service life of the contacts Switch off the battery charger before you discon nect th...

Page 332: ...tery cover 6210_600 001 Close the battery cover completely When doing so ensure that no cables are crushed between the chassis and the cover Equalising charging to preserve the battery capacity Equalising charges ensure that unevenly charged battery cells are evenly charged again This preserves the service life of the battery and the battery capacity An equalising charge should be carried out in a...

Page 333: ... charge takes up to 2 hours Please refer to the operating instruc tions from the manufacturer of the battery charger Ending the equalising charge The equalising charge ends automatically If the battery is required during this process you can interrupt the equalising charge by pushing the stop button on the battery charger Please refer to the operating instruc tions from the manufacturer of the bat...

Page 334: ...4 Operation Handling the lead acid battery Insert the battery male connector fully into the plug connection on the truck 320 171533 EN 02 2019 19 ...

Page 335: ...of contact with the skin Thoroughly wash the skin with soap and water Eye irritation can occur in the event of contact with the eyes Immediately rinse eyes thoroughly with water 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...

Page 336: ...in accor dance with the directions in these operating instructions When charging and maintaining the battery observe the manufacturer s maintenance instructions for the battery and battery charger Fire protection measures DANGER There is a risk of damage short circuiting and explosion Do not place any metal objects or tools on the battery Keep away from naked ﬂames and donot smoke DANGER Increased...

Page 337: ...remove or change the position of ballast weights Observe the battery weight General safety regulations for lithium ion batteries The following safety regulations generally apply to operating lithium ion batteries Comply with the speciﬁcations stated in the safety data sheets of the battery manufacturer Protect the battery against mechanical damage to prevent internal short circuits If batteries ha...

Page 338: ...ector 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 eyes Have bent lifting eyes replaced by the authorised service centre NOTE When switching to lithium ion batteries have the truck electronics adapt...

Page 339: ...limatise in a warmer area Temperature 60 C allow the truck to cool down LITHIUM BATTERY RESTRICTION The truck performance is gradually reduced The truck goes into emergency operation Switch off the truck and then switch it on again If the error occurs frequently notify your authorised service centre LITHIUM BATTERY ERROR The battery has an error and reports it to the truck control unit The truck s...

Page 340: ...ht 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 negative impact on the service life of the battery After twelve months check the charging state of the b...

Page 341: ...teries no mixed storage Maintain a safety margin of at least 2 5 m to other goods To avoid a deep discharge observe the speciﬁcations of the battery manufacturer regarding the maximum permissible stor age period If you have any questions please contact your authorised service centre 171533 EN 02 2019 19 327 ...

Page 342: ...ttery NOTE The battery charge display shows the avai lable battery capacity as a segmented bar graph in 10 increments Approx every 10 seconds the display switches between the battery charge and the remaining period Meaning of the bar graph on the display The remaining two bars ﬂash The charge state is 30 The battery must be recharged soon No bars are displayed The charge state is 15 Charge the bat...

Page 343: ...ts The charge state LEDs can light up green and red A charge state of 0 to 20 is indicated by a red bar If this bar ﬂashes the charge state is 2 The truck can no longer be moved A charge state of 20 to 30 is indicated by yellow bars A charge state of 30 to 100 is indicated by green bars When charging the charge state LEDs 3 light up green as a chase light Service LED The service LED 1 lights up re...

Page 344: ...vent deep discharge of the lithium ion battery performance limitations are imposed once the charge state of the battery is 10 If the charge state drops below 15 drive to the charging station and charge the battery WARNING There is no electric brake assistance when the battery is switched off The drives are de energised when the battery is automatically switched off The truck will not be held on a ...

Page 345: ... different manufac turers please contact your authorised service centre NOTE To prevent deep discharge of the lithium ion battery performance limitations are imposed once the charge state of the battery drops to a certain level The battery must be charged before the charge state drops below 15 To read the battery charge state see the section entitled Checking the battery charge status Park the tru...

Page 346: ...ng The battery has no memory effect Therefore it can be charged in any charge state without the capacity of the battery being impaired At ambient temperatures below 0 C the charging process will take much longer Observe the information in the operating instructions for the battery and the battery charger After charging The battery charger will stop automatically Disconnect the battery male connect...

Page 347: ... battery CAUTION Risk of components being damaged by the lifting accessory and battery rolling away The lifting accessory and battery may roll away in an uncontrolled manner if the battery is not removed on a level smooth ﬂoor with sufﬁcient load bearing capacity Follow the operating instructions for the lifting accessories used Always remove the battery on a level smooth ﬂoor with sufﬁcient load ...

Page 348: ...y may be damaged by a deep discharge When changing to TENSOR batteries the maximum speed of the truck must be limited to 17 km h for technical reasons Contact the authorised service centre in this situation Only use lithium ion batteries that have been approved by STILL with this truck 6327_600 010 1 Opening closing the battery cover Opening the battery cover CAUTION The outside mirror 1 is in the...

Page 349: ...y close the battery cover if there are no parts of the body in the way WARNING When closing the battery cover there is a risk of trapping the battery cable If the cable is crushed or sheared off there is a risk of short circuit When closing the battery cover nothing should come between the battery cover and the edge of the chassis Close the battery cover carefully Only close the battery cover if t...

Page 350: ...h potentially fatal consequences Ensure that the battery safety catch 5 is locked as far as it will go NOTE If the battery safety catch 5 is difﬁcult to move use the coupling pin 4 to help Allow the battery cover lock to snap into place 6327_600 005_V4 6 The battery cover interlock must snap into place properly or the built in sensor 6 will generate the error message CLOSE THE DOOR on the display ...

Page 351: ...id batteries Push down the lifting eyes before inserting the battery into the battery compartment Make sure that the lifting eyes do not protrude The lifting eyes may bend in the event of a collision with the truck chassis Install the lithium ion battery with the display facing the outside of the truck so that it can be read when the battery door or battery cover is open Lay the battery cable on t...

Page 352: ...aration Park the truck safely Open the battery cover CAUTION Risk of component damage If you remove the battery male connector when the key switch is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Only disconnect the battery male connec...

Page 353: ... or between the battery and the forklift truck when removing and inserting the battery with the forklift truck or lift truck WARNING Risk of accident The load capacity of the truck in use must at least match the battery weight see battery identiﬁcation plate 6210_606 011 A B Before picking up the battery the fork arms must be adjusted to match the opening in the chassis A Push the fork arms togeth...

Page 354: ...distances Carefully remove the battery from the truck 6321_003 002 Set the battery down on a stable base so that it is secure Position the battery against the stops on the base Pick up the new battery and transport it 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 Carefully in...

Page 355: ...c tion battery only onto a ﬁrm surface with sufﬁcient load bearing capacity Do not place the battery change frame with the traction battery onto a soft surface or in a rack The battery change frame variant features an advantageous design that allows a truck or pallet stacker to pick up the battery quickly The battery along with the change frame can be set down and charged The change frame ﬁts betw...

Page 356: ... on the battery in such a way that it cannot be crushed when removing or inserting the battery or when closing the battery cover Check the connection cable for damage Ensure that the battery cable does not come into contact with the battery cover WARNING Risk of crushing shearing Personnel must not stand directly next to the battery or between the battery and the truck when removing and inserting ...

Page 357: ...ently mark the centre of the battery 1 e g using a strip of adhesive tape Picking up the battery CAUTION Risk of component damage Move the change frame under the battery only up to the edge of the stop 6321_003 086 2 Fold the battery safety catches 2 to the side 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...

Page 358: ...on the base Move the change frame out from under the battery Pick up the new battery using the change frame and transport the new 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 Carefully insert the battery into the battery compartment Once the battery is positioned cor...

Page 359: ...er Ensure that the battery cable does not come into contact with the battery cover Close the battery cover Replacing the battery with the hydraulic battery carrier Preconditions The following prerequisites apply when replacing a battery with the hydraulic battery carrier The extension area must be free of obsta cles The ground must be clean even and offer sufﬁcient load capacity NOTE If a battery ...

Page 360: ...the battery male connector If the battery male connector is connected while the key switch is on under load a jump spark will be produced This jump spark can damage the contacts and considerably shorten the service life of the contacts Do not connect the battery male connector with the key switch switched on Make sure that the key switch is switched off before connecting the battery male connector...

Page 361: ...ttery safety catches WARNING Risk of crushing shearing When extending the battery carrier there must be no personnel in the extension area There is a risk of crushing and shearing when the battery carrier extends The battery male connector must remain in reach as an emergency off mechanism Place beside the counterweight and outside the extension area 171533 EN 02 2019 19 347 ...

Page 362: ...y cable is not dam aged when the carriage is extended NOTE If the movement of the carriage is restricted by obstacles release the push button The carriage can only be retracted If the push button is actuated continuously the drive switches off after 50 seconds WARNING Risk of crushing Never reach under the battery to remove obstacles Retract the battery again and remove the obstacle NOTE If the mo...

Page 363: ...on except in an emergency Switch off the key switch Disconnect the battery male connector and place it on the battery Hook the battery on to suitable lifting gear Observe the operating instructions for the lifting gear 6327_003 046 Lift the battery sideways out of the truck Ensure that there is sufﬁcient distance from the battery cover CAUTION Risk of component damage Do not allow slack lifting ge...

Page 364: ...th the key switch switched on Make sure that the key switch is switched off before connecting the battery male connector Ensure that the battery male connector and the plug connection are dry clean and free of foreign objects Connect the battery male connector Switch on the key switch WARNING Risk of injury Personnel must stand beside the counterweight and outside the retraction area CAUTION Risk ...

Page 365: ...utton NOTE If the movement of the carriage is restricted by obstacles release the push button WARNING Risk of crushing Never reach under the battery to remove obstacles Extend the carriage again Lift the battery again using the crane swivel the battery to the side and remove the obstacle CAUTION Risk of damage If the drive system overheats the battery carrier is switched off automatically After a ...

Page 366: ...ated Allow the truck to cool down for one hour 5910 5930 5931 Notify the authorised service centre Message Cause Remedy BATTERY CHANGER The battery support is not fully retracted Press the Retract battery push button until the support is fully retracted If this operation is not successful notify the authorised service centre CLOSE THE DOOR The battery cover is not closed correctly Close the batter...

Page 367: ...rms in size and load capacity To avoid short circuits cover batteries with open terminals or connectors with a rubber mat Observe the operating instructions for the lifting gear Attach the battery 1 to suitable lifting gear 2 Lift the battery carefully and ensure that it hangs straight on the lifting gear The lifting gear must be vertical when lifting so that no lateral pressure is applied to the ...

Page 368: ...battery 1 is equipped with four extendable lifting eyes The battery may only be transported by crane using a lifting gear and bridge piece 2 that are suitable in terms in size and load capacity Pull out the two lifting eyes 1 on each side and tilt them towards each other The lifting eyes are locked in this position Observe the operating instructions for the lifting gear Attach the lifting gear to ...

Page 369: ...not use any ﬂammable cleaning materials CAUTION Risk of ﬁre due to ﬂammable materi als 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 conta...

Page 370: ...irectly with water Use only high pressure cleaners with a maximum output power of up to 50 bar and 85 C If a high pressure cleaner is used maintain a distance of at least 20 cm between the nozzle and the object being cleaned Do not aim the cleaning jet directly at adhesive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot components Use o...

Page 371: ...ly dry cleaning materials in accordance with the manufactu rer s speciﬁcations Clean the electrical system parts with a metal free brush and blow the dust off with low pressure compressed air 6327_003 016 Clean load chains WARNING Risk of accident Load chains are safety elements The use of cold cleaning solvents chemical clea ners or ﬂuids that are corrosive or contain acid or chlorine can damage ...

Page 372: ...windows Any panes of glass e g cab windows vari ant must always be kept clean and free of ice This is the only means of guaranteeing good visibility CAUTION Do not damage the rear window heater inside Take great care when cleaning the rear window 1 and do not use any objects with sharp edges Clean the windows NOTE Cleaning can be done using a commercially available glass cleaner After cleaning CAU...

Page 373: ...grease to all uncoated moving parts Grease the truck Lubricate the joints and controls Lubricate the battery cover interlock Check that the battery male connector is dry before you connect the battery male connector NOTE The more often the truck is cleaned the more frequently the truck must be lubricated 171533 EN 02 2019 19 359 ...

Page 374: ...o No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min kg kg kg kg kg kW V see Operating instructions voir Mode d emploi siehe Betriebsanleitung D 22113 Hamburg Berzeliusstr 10 1 3 2 Determining the actual to...

Page 375: ... by placing a wheel chock in front of each front wheel and behind each back wheel 1 Park the truck securely CAUTION Risk of component damage If you remove the battery male connector when the key switch is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens their service life Switch off the key switch before the battery male connector ...

Page 376: ...traps 1 to the coupling pin 2 or loop around the coupling pin and lash the truck to the side DANGER Shifting of the load caused by the lashing straps slipping The truck must be lashed securely so that it cannot move during transportation Make sure that the lashing straps are tightened securely and that the pads cannot slip off Crane loading Crane loading is only intended for transporting the compl...

Page 377: ...Berzeliusstr 10 1 3 2 Determining the loading weight Park the truck securely see chapter Park ing the truck securely Determine the unit weights by reading them off the truck nameplate and if necessary the attachment variant nameplate Add the determined unit weights to obtain the loading weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Attachment net weigh...

Page 378: ... determined loading weight Only use the truck s designated lifting points Make sure that harnesses such as hooks shackles belts etc are only used in the indicated load direction The harnesses must not be damaged by truck parts NOTE The attachment points are indicated by a hook symbol 4 6321_003 069 Loop the lifting straps around the main traverse 4 on the outer mast of the lift mast 364 171533 EN ...

Page 379: ...gs level when lifting it Connect the lifting straps to the lifting eye and insert the safety device 7 CAUTION Incorrectly ﬁtted harnesses may damage attach ment parts Pressure from the harnesses can damage or destroy attachment parts when the truck is lifted If attachment parts are in the way e g lighting rear window trademark emblem etc these must be removed before loading Secure harnesses in suc...

Page 380: ...t storage Improper storage or decommissioning for a period of more than two months can result in corrosion damage to the truck If the truck is parked in an am bient temperature of below 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batteries Store the truck in a dry clean frost free and well ventilated environment Implement the following measure...

Page 381: ...n the chapter entitled 1000 hour maintenance annual maintenance Lubricate the battery interlock and the battery cover see the section entitled Checking the battery interlock and battery cover in the chapter entitled Remaining ready for operation CAUTION Risk of component damage If you remove the battery male connector with the key switch switched on under load an arc will be produced This can caus...

Page 382: ...n of condensation water Cover with vapour permeable material e g cotton Cover the truck to protect it from dust If the truck is to be shut down for even longer periods contact the authorised service centre to ﬁnd out about additional measures Returning to service after decommis sioning If the truck has been decommissioned for longer than six months it must be carefully checked before being re comm...

Page 383: ... condensation water Change the hydraulic oil if neces sary Carry out the checks and tasks that are to be performed before the ﬁrst commissioning Perform visual inspections and function checking The following points must be checked in particular Drive control steering Brakes service brake parking brake Lifting system lifting accessories load chains mounting NOTE For further information see the work...

Page 384: ...4 Operation Decommissioning 370 171533 EN 02 2019 19 ...

Page 385: ...5 Maintenance ...

Page 386: ...and secure the lift mast to prevent it tilting backwards unintentionally Observe the maximum lift height of the lift mast and compare the dimensions from the technical data with the dimensions of the hall into which the truck is to be driven These steps are taken to prevent a collision with the ceiling of the hall and to avoid any damage caused as a result Working on the hydraulic equipment The hy...

Page 387: ...pairs and when changing hydraulic and electrical compo nents These are listed in the appropriate sections Lifting and jacking up DANGER There is a risk to life if the truck tips over If not raised and jacked up properly the truck may tip over and fall off Only the hoists speciﬁed in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity Only have t...

Page 388: ...ntre CAUTION Possibility of damage to the ceiling Note the maximum lift height of the lift mast Securing the lift mast against tilting backwards A hardwood beam with a cross section of 120 x 120 mm is required The length of the hardwood beam must approximately correspond to the width of the fork carriage b3 To avoid impact injuries the hardwood beam must not protrude beyond the outer contour of th...

Page 389: ...ER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technician to remove the lift mast Securing the lift mast against falling off DANGER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technician to secure the lift mast 171533 EN 02 2019 19 375 ...

Page 390: ...nel who have received appropriate training in accordance with the instructions from the manufacturers of the battery battery charger and truck Follow the handling instructions for the battery and the operating instructions for the battery charger Maintenance work without special qualiﬁcations Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel...

Page 391: ...vals are deﬁned for standard use Shorter maintenance intervals can be deﬁned in consultation with the operating company depending on the application conditions of the truck The following factors may necessitate shorter maintenance intervals Contaminated poor quality roads Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Mu...

Page 392: ...5 Maintenance General maintenance information 378 171533 EN 02 2019 19 ...

Page 393: ...ecessary Check wheels for damage and check the tightening torques Power unit Drive axle Check mounting check for leaks and clean cooling ﬁns Drive wheel unit and multi disc brake Check the oil level Change the gearbox oil once after the ﬁrst 1000 hours Steering Check steering system for correct function and for leaks Check that the steering wheel is ﬁrmly attached and check the turning handle for ...

Page 394: ...eck the battery lock for damage Variant Hydraulic battery carrier Check all moving parts for wear and oil or lubri cate Observe the special maintenance schedule Variant Hydraulic battery carrier Check the oil level and check for leaks Hydraulics Check hydraulic system for condition correct function and leaks Check the hydraulics blocking function ISO valve Check oil level Lift mast Check mast bear...

Page 395: ...k the condition of the antistatic belt or antistatic electrode Check heating system for damage observe manufacturer s maintenance instructi ons Check attachments for wear and damage observe manufacturer s maintenance instructions Check trailer coupling for wear and damage observe manufacturer s maintenance instructions General Read out error numbers and delete list Reset maintenance interval Check...

Page 396: ...5 Maintenance General maintenance information 382 171533 EN 02 2019 19 ...

Page 397: ...lace the accumulator Ordering spare parts and wearing parts Spare parts are provided by our spare parts service department The information required for ordering parts can be found in the spare parts list Only use spare parts as per the manufac turer s instructions The use of unapproved spare parts can result in an increased risk of accidents due to insufﬁcient quality or incor rect assignment Anyo...

Page 398: ...cts the lubricity If a change between different manufacturers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work ﬁlter changes or any work on the hydraulic system carefully clean the area around the part involved When topping up working materials use only clean containers 384 171533 EN 02 2019 19 ...

Page 399: ...nformation Lubrication plan Code1 Lubrication point A Four lubricating nipples on each side of the steering axle for the axle stub bearing and track rod bearings B Sliding surfaces on the lift mast C Load chains 171533 EN 02 2019 19 385 ...

Page 400: ... The 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 main tenance points on variant trucks see the relevant chapter and or instructions provided by the manufacturer 386 171533 EN 02 2019 19 ...

Page 401: ...ode Unit Operating materials Speciﬁcations Quantity Insulation resistance DIN EN 1175 VDE 0117 For further information refer to the workshop manual for the truck in question Controls joints Code Unit Operating materials Speciﬁcations Quantity High pressure grease ID no 0147873 As required Lubrication Oil SAE 80 MIL L2105 API GL4 As required Hydraulic system Code Unit Operating materials Speciﬁcati...

Page 402: ...als Speciﬁcations Quantity A Axle stub bearing spherical bearing High pressure grease ID no 0147873 As required Wheel nuts screws Torque wrench 195 Nm Wheel hub fastening Torque wrench 300 Nm Axle stub nut Torque wrench 310 Nm Drive axle Code Unit Operating materials Speciﬁcations Quantity Wheel nuts screws Torque wrench 600 Nm Wheel gear Mineral oil ARAL HGS FLUID ID no 127830 Lift mast Code Unit...

Page 403: ...ls Speciﬁcations Quantity C Lubrication High load chain spray Fully synthetic Temperature range 35 C to 250 C ID no 0156428 As required Washer system Code Unit Operating materials Speciﬁcations Quantity System contents Washer ﬂuid Winter ID no 172566 As required 171533 EN 02 2019 19 389 ...

Page 404: ... 2 Remove the heating system panelling 3 If the cover 6 is in place remove it by lifting it with your ﬁnger Unscrew the four screws 5 5 5 6 4 Lift up the valve cover 4 and remove it Fitting the valve cover Reﬁt the valve cover 4 Reﬁt the cover 6 Reﬁt the heating system panelling 3 Opening the fuse box To access the fuse box and other components in the electronic control unit you need to remove the...

Page 405: ...rews 2 but do not remove them completely The cover sheet is held in place by clamps at the sides Unscrew two screws 3 Remove the cover sheet 1 To ﬁt the cover sheet slide it into the clamps at the sides Tighten all screws 4 5 5 Opening the fuse box Unscrew the screws 5 The screw at the side can be accessed through the open battery door or battery cover Remove the fuse box cover 4 To ﬁt the cover s...

Page 406: ... fall out when the truck is tilted or during sharp deceleration If the battery falls out there is a danger of being crushed If the interlock is deformed damaged or difﬁcult to move inform STILL Service immediately Do not operate the truck Check that the interlocks function correctly Interlocks must be greased and move easily Always check the interlock after an accident NOTE The interval for greasi...

Page 407: ...ot deformed or damaged 6321_003 136 2 3 Check that the battery cover lock 3 moves easily and that it is not deformed or dam aged Check that the rest plate 2 of the battery cover lock is seated correctly and that it is not deformed or damaged Grease the lock mechanisms Close the battery cover again 171533 EN 02 2019 19 393 ...

Page 408: ...y have a defective belt replaced by your service centre Only use genuine spare parts Do not make any changes to the belt NOTE Carry out the following checks on a regular basis monthly In the case of signiﬁcant strain a daily check is necessary Checking the seat belt 6327_342 009 1 2 3 Pull out the belt 3 completely and check for wear The belt must not be frayed or cut The stitching must not be loo...

Page 409: ...k extension of the belt Cleaning the seat belt Clean the seat belt as necessary but without using chemical cleaning materials a brush will sufﬁce Replacement after an accident As a rule the seat belt must be changed after an accident 6327_342 010 Checking the driver s seat WARNING Risk of injury After an accident check the driver s seat with attached restraining belt and fastening Check the contro...

Page 410: ...anufacturer you must ﬁrst obtain approval from the truck manufacturer WARNING Risk to stability When using pneumatic tyres or solid rubber tyres rim wheel parts must never be changed and rim wheel parts from different manufacturers must not be mixed 6311_003 004 Checking the condition and wear of the tyres WARNING Tyre quality affects the stability and handling of the truck Changes can only be mad...

Page 411: ...wear of the tyres on an axle must be approximately the same Super elastic tyres and solid rubber tyres can be worn down to the wear mark 2 6210_460 004 3 Checking wheel fastenings Check wheel fastening nuts 3 and bolts for secure positioning and retighten as necessary Observe the torques see the maintenance data table 171533 EN 02 2019 19 397 ...

Page 412: ...xle bearing 1 and tie rod joint 2 for play and wear Check the steering cylinder 3 for leaktight ness traces of oil NOTE In the case of excessive play or wear have your service centre change the relevant parts Lubricating the steering axle ENVIRONMENT NOTE Dispose of old grease and contaminated devices in accordance with the national regulations for the country in which the truck is being used 398 ...

Page 413: ... Switch on the truck Actuate the steering Park the truck securely again Repeat the lubrication procedure NOTE Please note the more often the truck is cleaned the more frequently it must be lubricated Checking the lines for leaks Retighten leaky connections NOTE Have faulty lines replaced by your authorised service centre After repairs force out any trapped air by turning the steering wheel from st...

Page 414: ...ecking the battery For information on checking the battery see the chapter entitled Checking the battery condition acid level and acid density Checking the fuses DANGER Hazard from electrical current Take care when handling residual capacity may be present Before starting the following mainten ance work Park the truck securely Disconnect the battery male connector 400 171533 EN 02 2019 19 ...

Page 415: ...cts which considerably shortens their service life Switch off the key switch before the battery male connector is disconnected Do not disconnect the battery male connector while the key switch is switched on except in an emergency 1 Fuses for standard equipment and equipment variants are located in the rear part of the control electronics 1 Open the cover Remove the cover from the control electron...

Page 416: ... speciﬁcation not all fuses will be present in the truck CAUTION Water in the electrical system can cause damage to components In order to protect the electrical system against ingress of water the cover must be closed Reﬁt the cover after these tasks have been completed Connect the battery male connector Carry out a functional test Replacing fuses DANGER Hazard from electrical current Take care w...

Page 417: ...es can result in short circuits Only use fuses with the prescribed nominal current NOTE Depending on the equipment not all fuses will be present in the truck 1 Fuses for standard equipment and equipment variants are located in the rear part of the control electronics 1 Open the cover Remove the cover from the control electron ics Replace the blown fuse see the section entitled Fuse assignment CAUT...

Page 418: ... Hydraulic oils are hazardous to your health and are under pressure during operation Note the safety regulations in the Hydraulic ﬂuid chapter CAUTION Risk of damage to components Remove connector for drive unit 1 2 6210_700 002 Unscrew breather ﬁlter 1 Check the oil level on the oil dipstick The oil level must be between the markings 2 If the oil level is too low pour hydraulic oil of the correct...

Page 419: ...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 regulations for the country of use Check pipe and hose connection screw joints for leaks traces of oil Replace hose lines if they display the following abnormalities Outer layer has...

Page 420: ... data table P 5 387 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 Greasing the automatic tow coupling NOTE Wear to moving parts can be signiﬁcantly reduced by appropriate servicing and regular lubrication of the coupling Avoid over greasing NOTE Close the coupling before cleaning with a high pressure cleaner A...

Page 421: ...itable tool For journeys with a rigid drawbar trailer lubricate the underside of the tow bar eye and the supporting surface on the coupling 7321_003 092 Determine the wear on the coupling pin The diameter of the spherical part must not be less than 36 5 mm Model RO 244 A Open coupling Wartung_Rockinger 244 A 1 Grease using the lubricating nipple 1 in accordance with the maintenance data table see ...

Page 422: ...tenance data table see Chapter Maintenance data table P 5 387 Grease the supporting surface for the tow bar eye 7321_003 095 Model RO 841 Lubricate via the points provided for this purpose lubricating nipple opened cou pling in accordance with the maintenance data table see Chapter Maintenance data table P 5 387 Grease the supporting surface for the tow bar eye 408 171533 EN 02 2019 19 ...

Page 423: ...onal readiness for cold store application On trucks for cold store application vari ant check all rollers and chains in the lift mast for ease of movement once a week 6321_003 091 1 2 Maintaining the heater Loosen the ﬁxing screw 1 and remove the cover 2 171533 EN 02 2019 19 409 ...

Page 424: ...readiness 6321_003 092 3 Check the ﬁlter mat 3 for soiling If the ﬁlter mat is grey in colour replace it NOTE Change the ﬁlter mat at least every 2 months 6321_003 093 4 Clean the fresh air inlet 4 of dust and dirt 410 171533 EN 02 2019 19 ...

Page 425: ...dised connections and replace brittle cables 6327_003 045 1 Checking the hydraulic oil level of the hydraulic battery carrier WARNING Hydraulic oils are hazardous to your health and are under pressure during operation Note safety regulations for working with hydrau lic oils see Chapter Hydraulic ﬂuid P 2 51 Checking the hydraulic oil level Park the forklift truck on level ground Remove the battery...

Page 426: ...the battery holder plate Retract the hydraulic battery carrier Withdraw sealing plug 1 through the opening in the mounting plate The oil level must lie between 65 and 70 mm when measured from the base of the container If the oil level is below the required level top up the hydraulic oil via the ﬁller neck according to the maintenance data table see Chapter Maintenance data ta ble P 5 387 NOTE Use ...

Page 427: ...d contaminated lubricant residues Lubricate the slide elements and guide rails 2 and 3 in accordance with the mainte nance data table see Chapter Mainte nance data table P 5 387 Reinstall the battery Oiling the catch rails WARNING Risk of injury If the battery carrier is not at a sufﬁciently safety distance from mechanical components when it is actuated hands or feet may be crushed Actuating beyon...

Page 428: ...support rollers must be swung out fully and locked in position after lubrication NOTE The catch rails of the support rollers are loca ted beneath the battery carrier If necessary use a mirror to gain a better view Park the forklift truck on level ground 6210_003 007 Remove the battery see Replacing the battery with the hydraulic battery carrier Place the battery next to the truck so that the batte...

Page 429: ... the support rollers are swung all the way out and are locked in position If the support rollers are fully swung out and locked reinstall the battery If the support rollers do not swing out correctly or are not in the locked position inform your authorised service centre 6327_003 016 Checking the lift cylinders and connections for leaks WARNING Risk of injury Observe safety regulations for working...

Page 430: ...e original thickness CAUTION Worn fork arms should always be replaced in pairs Check the securing mechanism 3 for proper operation The locking screw 2 that prevents dislodg ing must be present 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 416 171533 EN 02 2019 19 ...

Page 431: ...e Check that the support and springs of the double pedal mechanism are securely positioned Check that all screws are sealed with locking varnish Checking the battery changeover frame The screw joints and welded seams of the battery changeover frame must be subjected to a visual inspection 171533 EN 02 2019 19 417 ...

Page 432: ...5 Maintenance 1000 hour maintenance yearly maintenance 418 171533 EN 02 2019 19 ...

Page 433: ...6 Technical data ...

Page 434: ...l data Dimensions Dimensions 1 Seat is adjustable 90 mm 2 Fork spacing is adjustable NOTE Measurements h1 h3 h4 h6 and b1 are customer speciﬁc and can be taken from the order conﬁrmation 420 171533 EN 02 2019 19 ...

Page 435: ... 985 5 mm RX60 50 6329 1023 mm RX60 50 600 6330 1023 mm NOTE The speciﬁed centre of gravity S relates to trucks with standard equipment If for example the truck is equipped with a different lift mast attachment or driver protection structure this value is only a guide value If necessary the centre of gravity S must be determined on an individual basis for each truck 171533 EN 02 2019 19 421 ...

Page 436: ...er 6367 Manufacturer STILL GmbH Drive Electric Operation Seat Rated capacity load Q kg 3500 Load centre of gravity distance c mm 600 Load distance x mm 525 Wheelbase y mm 2021 Weights Model RX60 35 600 Type number 6367 Net weight kg 6495 Front axle load laden kg 8748 Rear axle load laden kg 1247 Front axle load unladen kg 3300 Rear axle load unladen kg 3195 Wheels chassis frame Model RX60 35 600 T...

Page 437: ... h3 mm 2980 Height with lift mast extended h4 mm 3762 Height above overhead guard cab h6 mm 2322 Seat height in relation to SIP h7 mm 1251 Coupling height h10 mm 546 421 Overall length l1 mm 4086 Length including fork back l2 mm 2886 Overall width b1 mm 1256 Fork arm thickness s mm 50 Fork arm width e mm 120 Fork arm length l mm 1000 Fork carriage Standard class form ISO 2328 III A Fork carriage w...

Page 438: ...ad m s 0 55 Lowering speed with load m s 0 55 Lowering speed without load m s 0 46 Pulling force with load kg 3850 Pulling force without load kg 4390 Max tractive force with load kg 16000 Max tractive force without load kg 16140 Climbing capability with load 11 9 Climbing capability without load 17 0 Max climbing capability with load 16 9 Max climbing capability without load 26 8 Acceleration time...

Page 439: ...el RX60 35 600 Type number 6367 Traction motor power rating at S2 60 min kW 15 Lift motor power rating at 15 ED kW 25 Battery Standard circuit DIN 43536 A Battery voltage U V 80 Battery capacity K5 K5 Ah 840 930 Battery weight kg 2178 Energy consumption 60 VDI working cycles hour kWh h 9 7 Other Model RX60 35 600 Type number 6367 Working pressure for attachments bar 250 Oil ﬂow for attachments l m...

Page 440: ...LL GmbH Drive Electric Electric Operation Seat Seat Rated capacity load Q kg 4000 4000 Load centre of gravity distance c mm 500 600 Load distance x mm 525 525 Wheelbase y mm 2021 2021 Weights Model RX60 40 RX60 40 600 Type number 6327 6368 Net weight kg 6477 6810 Front axle load laden kg 9296 9587 Rear axle load laden kg 1181 1223 Front axle load unladen kg 3286 3361 Rear axle load unladen kg 3209...

Page 441: ...m 2980 2980 Height with lift mast extended h4 mm 3762 3987 Height above overhead guard cab h6 mm 2322 2320 Seat height in relation to SIP h7 mm 1251 1249 Coupling height h10 mm 546 422 546 423 Overall length l1 mm 3886 4086 Length including fork back l2 mm 2886 2886 Overall width b1 mm 1256 1399 Fork arm thickness s mm 50 50 Fork arm width e mm 120 120 Fork arm length l mm 1000 1200 Fork carriage ...

Page 442: ...s 0 55 0 46 Lowering speed with load m s 0 55 0 55 Lowering speed without load m s 0 47 0 48 Pulling force with load kg 3770 3700 Pulling force without load kg 4390 4470 Max tractive force with load kg 15940 15900 Max tractive force without load kg 16140 16150 Climbing capability with load 11 3 10 6 Climbing capability without load 17 0 16 8 Max climbing capability with load 15 5 15 5 Max climbing...

Page 443: ...27 6368 Traction motor power rating at S2 60 min kW 15 15 Lift motor power rating at 15 ED kW 25 25 Battery Standard circuit DIN 43536 A DIN 43536 A Battery voltage U V 80 80 Battery capacity K5 K5 Ah 840 930 840 930 Battery weight kg 2178 2178 Energy consumption 60 VDI working cycles hour kWh h 10 2 10 3 Other Model RX60 40 RX60 40 600 Type number 6327 6368 Working pressure for attachments bar 25...

Page 444: ...L GmbH Drive Electric Electric Operation Seat Seat Rated capacity load Q kg 4500 4500 Load centre of gravity distance c mm 500 600 Load distance x mm 525 535 Wheelbase y mm 2021 2021 Weights Model RX60 45 RX60 45 600 Type number 6328 6369 Net weight kg 6793 7145 Front axle load laden kg 10112 10441 Rear axle load laden kg 1184 1204 Front axle load unladen kg 3329 3413 Rear axle load unladen kg 346...

Page 445: ...m 2980 2980 Height with lift mast extended h4 mm 3987 3987 Height above overhead guard cab h6 mm 2320 2320 Seat height in relation to SIP h7 mm 1249 1249 Coupling height h10 mm 546 424 546 425 Overall length l1 mm 3886 4096 Length including fork back l2 mm 2886 2896 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 ...

Page 446: ... s 0 47 0 48 Lowering speed with load m s 0 55 0 55 Lowering speed without load m s 0 49 0 50 Pulling force with load kg 3620 3610 Pulling force without load kg 4470 4400 Max tractive force with load kg 15830 15750 Max tractive force without load kg 16150 16090 Climbing capability with load 9 5 9 2 Climbing capability without load 16 8 15 8 Max climbing capability with load 14 3 14 3 Max climbing ...

Page 447: ...28 6369 Traction motor power rating at S2 60 min kW 15 15 Lift motor power rating at 15 ED kW 25 25 Battery Standard circuit DIN 43536 A DIN 43536 A Battery voltage U V 80 80 Battery capacity K5 K5 Ah 840 930 840 930 Battery weight kg 2178 2178 Energy consumption 60 VDI working cycles hour kWh h 10 8 11 1 Other Model RX60 45 RX60 45 600 Type number 6328 6369 Working pressure for attachments bar 25...

Page 448: ...L GmbH Drive Electric Electric Operation Seat Seat Rated capacity load Q kg 4990 4990 Load centre of gravity distance c mm 500 600 Load distance x mm 535 535 Wheelbase y mm 2021 2088 Weights Model RX60 50 RX60 50 600 Type number 6329 6330 Net weight kg 7121 7711 Front axle load laden kg 10917 11547 Rear axle load laden kg 1194 1154 Front axle load unladen kg 3372 3845 Rear axle load unladen kg 374...

Page 449: ...m 2980 2780 Height with lift mast extended h4 mm 3987 3935 Height above overhead guard cab h6 mm 2320 2320 Seat height in relation to SIP h7 mm 1249 1249 Coupling height h10 mm 546 426 546 427 Overall length l1 mm 3896 4163 Length including fork back l2 mm 2896 2963 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 1000 1200 Fork carriage ...

Page 450: ... s 0 46 0 44 Lowering speed with load m s 0 55 0 55 Lowering speed without load m s 0 51 0 52 Pulling force with load kg 3600 3600 Pulling force without load kg 4400 4400 Max tractive force with load kg 15670 15670 Max tractive force without load kg 16090 16090 Climbing capability with load 8 8 7 4 Climbing capability without load 15 8 13 7 Max climbing capability with load 13 2 12 6 Max climbing ...

Page 451: ...9 6330 Traction motor power rating at S2 60 min kW 15 15 Lift motor power rating at 15 ED kW 25 25 Battery Standard circuit DIN 43536 A DIN 43536 A Battery voltage U V 80 80 Battery capacity K5 K5 Ah 840 930 840 930 Battery weight kg 2178 2178 Energy consumption 60 VDI working cycles hour kWh h 11 5 12 1 Other Model RX60 50 RX60 50 600 Type number 6329 6330 Working pressure for attachments bar 250...

Page 452: ...at and the seat suspen sion must be set to this driver s requirements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clearance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into account and in accordance with EN ISO 3411 In general from th...

Page 453: ... change the position of ballast weights Check the battery weight against the information on the nameplate Only use a battery tray that is closed at the bottom NOTE Battery speciﬁcations according to DIN 43535 cells in accordance with DIN EN 60254 2 80 V circuit A The battery weight can be found on the nameplate of the battery RX60 40 6327 RX60 45 6328 RX60 50 6329 RX60 50 600 6330 RX60 35 600 6367...

Page 454: ... Width Height Tray 6 PzV 720 720 6 PzW 840 HAWKER wf 200plus 840 6 PzS 840 840 6 PzS 930 930 6 CSM 960 960 1028 999 784 236 NOTE When converting to TENSOR batteries the maximum speed of the truck must be limited to 17 km h for technical reasons Contact the authorised service centre regarding this matter 440 171533 EN 02 2019 19 ...

Page 455: ...teries with a nominal voltage of 90 V can be used Use batteries that meet DIN standards Check the battery weight against the information on the nameplate Only use a battery tray 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 GGS Li Ion 90 V BG7...

Page 456: ... A 5 Option board solenoid valve on the attachment F23 10 A 6 CPP RPP roof F26 25 A 7 CPP RPP seat F27 25 A 8 MMS option board F29 15 A 9 CPP RPP front F28 10 A 10 Proportional technology F25 10 A 11 U4 voltage converter F15 10 A Solenoid valve on attachment F15 10 A 12 U1 voltage converter F14 15 A U1 U2 voltage converter F14 30 A 48 V working spotlight F14 15 A 13 SU MCU F11 10 A 14 Horn F12 10 ...

Page 457: ...ignment 8 9 0 6 7 4 2 1 3 5 F1 F2 7312_003 042 75 h 2 234 7 12 15 1 2 3 Fuse assignment equipment vari ants 1 5th hydraulic function 24 48 V F1 10 A 2 Variant e g MMS F3 10 A 3 Variant e g light F2 10 A 171533 EN 02 2019 19 443 ...

Page 458: ...6 Technical data Fuse assignment 444 171533 EN 02 2019 19 ...

Page 459: ...the double mini lever and the 5th function 215 Controlling using the joystick 4Plus 225 Controlling using the quadruple mini lever and the 5th function 223 Controlling using the triple mini lever and the 5th function 219 Controlling with a quadruple mini lever 221 Controlling with a triple mini lever 217 Controlling with ﬁngertip 229 Controlling with ﬁngertip and 5th function 230 General controlli...

Page 460: ...ssword 106 Charging the lithium ion battery 331 Checking fork arms 416 Checking the cable connections 411 Checking the charge state of the lead acid battery 311 Checking the charge state of the lithium ion battery 328 Checking the double pedal 417 Checking the driver s seat 395 Checking the emergency off function 94 Checking the lift cylinders and connections for leaks 415 Checking wheel fastening...

Page 461: ...lometres 118 Setting the date 118 Setting the language 119 Setting the time 118 Standard displays 109 Display symbols 113 Auxiliary equipment softkey functions 115 Error messages 114 Menu navigation softkey functions 116 Numeric keypad 117 Operating messages 113 Status LEDs 116 Warning messages 114 Display operating unit Standard display elements 99 Disposal Battery 23 Components 23 Documentation ...

Page 462: ...t Equipment variants 443 Standard equipment 442 Fuse box Closing 391 Opening 391 Fuses Checking 400 Replacing 402 G General 4 General view 58 Driver s compartment 60 H Handling gas springs and accumulators 39 Hazard areas 130 Hazard assessment 32 Hazard warning system 239 Hazards and countermeasures 44 Heating system 257 Hydraulic battery carrier Checking the oil level 411 Lubricating the slide el...

Page 463: ... with the ﬁngertip console 170 Multi lever 164 Operating devices 163 Lighting STILL SafetyLight 244 Switching on and off 237 List of abbreviations 19 Lithium ion batteries Battery weight and dimensions 323 Changing the battery type 334 Charging 331 Checking the charge state 328 Danger areas 31 Declaring the use of 32 Display 63 Display messages 325 Driver qualiﬁcation 32 Fire protection measures 3...

Page 464: ...263 Medical equipment 38 Message PARKING BRAKE OIL PRES SURE 291 VERTICAL POSITION 286 ACCELERATOR 283 APPLY HANDBRAKE 282 ARE YOU SURE 288 BRAKE SENSOR 283 CLOSE THE DOOR 292 CODE DENIED 283 EMERGENCY SWITCH 285 LEVER 292 LIFT HEIGHT 292 LITHIUM BATTERY ERROR 325 LITHIUM BATTERY RESTRIC TION 325 LITHIUM BATTERY TEMPERA TURE 325 LOWER FORKS 284 MOT GEN TEMP 291 NOT VALID 291 OVERHEATING 290 292 PA...

Page 465: ...ccessories 7 P Packaging 23 Parking brake 142 Electric parking brake 144 Mechanical parking brake 142 Parking the truck securely 160 Permissible lithium ion batteries 32 Personnel qualiﬁcations 376 Picking up loads 189 Place of use 13 Procedure if truck tips over 296 Procedure in the event of a ﬁre when using lithium ion batteries 32 Product speciﬁc dangers of lithium ion batteries 31 Production n...

Page 466: ...king on the lift mast 374 Safety regulations for working with lithium ion batteries 323 Safety regulations when driving 125 Safety regulations when handing loads 184 Schematic views 21 Scope of the documentation UPA solutions 17 Seat belt 82 Checking 394 Cleaning 395 Fastening 83 Fastening on a steep slope 84 Maintaining 394 Malfunction due to cold 84 Releasing 84 Replacement after an accident 395...

Page 467: ...ms 15 V Valve cover Installing 390 Removing 390 Variant Ceiling sensor 247 Variants Access authorisation with PIN code 99 Automatic lift cut out 178 Clamp locking mechanism 232 Clipboard 260 FleetManager 246 Fork extension 173 Heating system 257 Lift mast vertical position 179 Lifting systems 162 Load measurement 186 Push up roof window 259 Radio 256 Reducing speed with a raised load 159 Reversibl...

Page 468: ...truck 374 Working on the electrical equipment 372 Working on the hydraulic equipment 372 Working spotlight for reverse travel Switching on and off 238 Working spotlights Automatically switching on off 243 Lift height controlled switching on off 243 Manually switching on off 242 Switching on and off 237 242 Z Zero adjustment of the load measure ment 95 454 171533 EN 02 2019 19 ...

Page 469: ......

Page 470: ...STILL GmbH 171533 EN 02 2019 19 ...

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