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Still RX70-16, Original Instructions Manual

The "Still RX70-16" is a robust and efficient forklift designed for handling heavy loads. Get the most out of this powerful machine by using the Original Instructions Manual. Download it for free at manualshive.com to gain valuable insights and maximize your productivity.

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5

Maintenance

General maintenance information

General maintenance information

Personnel qualifications

Only qualified and authorised personnel

are allowed to perform maintenance work.

The annual testing must be carried out by

a qualified person. The examination and

assessment of the qualified person must

be unaffected by operational and economic

conditions and must be conducted solely

from a safety perspective. They must have

sufficient knowledge and experience to

be able to assess the condition of a forklift

truck and the effectiveness of the protective

equipment in accordance with technical

conventions and the principles for testing

forklift trucks.

Maintenance work without special

qualifications

Simple maintenance work, e.g. checking

the hydraulic oil level, may be carried out by

untrained personnel. A qualification, like that

of a specialist, is not required to carry out this

work. The required operations are described

in sufficient detail in the corresponding places

in these operating instructions.

Information for carrying out mainte-

nance

This section contains all information required

to determine when the truck needs mainte-

nance. Carry out maintenance work within the

time limits according to the hour meter and

using the following maintenance check lists.

This is the only way to ensure that the truck

remains ready for operation and provides op-

timal performance and service life. It is also a

precondition for any warranty claims.

304

174749 EN - 03/2017

Summary of Contents for RX70-16

Page 1: ...Original instructions Diesel truck RX70 16 RX70 18 RX70 20 7311 7312 7313 174749 EN 03 2017 ...

Page 2: ......

Page 3: ...ce g Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de 174749 EN 03 2017 I ...

Page 4: ......

Page 5: ...5 Documentation scope 15 Supplementary documentation 16 Issue date and topicality of the operating instructions 17 Copyright and trademark rights 17 Explanation of information symbols used 17 List of abbreviations 18 Definition of directions 20 Schematic views 20 Environmental considerations 22 Packaging 22 Disposal of components and batteries 22 2 Safety Definition of responsible persons 24 Operati...

Page 6: ... of the truck 42 Checking the diesel engine emissions 42 Trucks with particle filters 43 Insulation testing 44 Safety regulations when handling consumables 45 Permissible consumables 45 Oils 45 Hydraulic fluid 46 Battery acid 47 Diesel fuel 48 Coolant and cooling fluid 50 Disposal of consumables 50 Emissions 52 3 Overviews General view 56 Driver s compartment 57 Operating and display elements 58 Disp...

Page 7: ... Checking the emergency off function 101 Zero adjustment of the load measurement variant 102 Checking the vertical lift mast position variant for correct function 104 Operation of the display operating unit 105 Displays 105 Adjusting the displays 106 Symbols in the display 106 Setting the date or time 111 Resetting the daily kilometres and daily operating hours 111 Setting the language 112 Soft ke...

Page 8: ...Lifting 143 Lifting system variants 143 Automatic lift cut out variant 143 Lift mast vertical position variant 144 Types of lift mast 148 Malfunctions during lifting mode 150 Hydraulic blocking function 151 Lifting system operating devices 152 Controlling the lifting system using a double mini lever 153 Controlling the lifting system using a triple mini lever 154 Controlling the lifting system usi...

Page 9: ...g the joystick 4Plus and the 5th function 201 Controlling the attachments with the fingertip 202 Controlling attachments with the fingertip and 5th function 203 Clamp locking mechanism variant 205 Taking up a load using attachments 208 Auxiliary equipment 209 Switching the lighting on and off 209 Switching the rotating beacon on and off 210 Switching the hazard warning system on and off 210 Switchin...

Page 10: ...pecifications 269 Topping up the diesel fuel 273 Cleaning 275 Cleaning the truck 275 Cleaning the electrical system 277 Cleaning load chains 278 Cleaning the windows 278 After washing 279 Behaviour in emergencies 279 Emergency shutdown 279 Procedure if truck tips over 281 Emergency hammer 282 Emergency lowering 282 Emergency operation of the electric parking brake 284 Disconnecting the battery 285 ...

Page 11: ...314 Providing access to maintenance points 317 Opening the bonnet 317 Closing the bonnet 317 Installing and removing the bottom plate 318 Maintenance after first 50 operating hours 320 Maintenance during the break in period 320 Remaining ready for operation 321 Cleaning the radiator checking for leaks 321 Topping up the cooling fluid and checking the coolant concentration 321 Changing the air filter ...

Page 12: ...343 Checking the exhaust gas system 343 Changing the fuel filter 344 Changing the fuel filter for Eberspächer particle filters 345 Checking the lift cylinders and connections for leaks 345 Checking the fork arms 346 Checking the reversible fork arms 346 6 Technical data Dimensions 348 VDI datasheet for RX70 16 RX70 18 and RX70 20 350 Ergonomic dimensions 354 Fuse assignment 356 X 174749 EN 03 2017 ...

Page 13: ...1 Foreword ...

Page 14: ... use Brake system The brake system of the truck is comprised of three different brakes Service brake Regenerative brake Parking brake The service brake is based on a wear free oil immersed multi disc brake This multi disc brake is used as the service brake for heavy braking or emergency braking with the brake pedal In the normal working mode the regenerative brake of the electric traction motor ta...

Page 15: ...accumulator is also available in the lifting circuit for the purpose of dampening pressure peaks in the hydraulic system Drive concept The internal combustion engine drives an electric generator The generated current is directed to an electric traction motor which drives the truck An electronic speed controller gently provides high torque for both forwards and backwards travel The components for t...

Page 16: ...e truck is assisted by the agile steering axle 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 it is being used The driving permit must be obtained from the appropriate office The trucks have been fit...

Page 17: ...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 stored and made available to the responsible authorities 174749 EN 03 2017 5 ...

Page 18: ... 22113 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 174749 EN 03 2017 ...

Page 19: ...Foreword 1 Your truck Accessories overview Key for key switch 2 pieces Key for cab variant Hexagon socket wrench for emergency lowering 174749 EN 03 2017 7 ...

Page 20: ... la Manutention STILL GmbH Hamburg 7314_003 017_V11 xx xxxx x xxxxx 1 2 3 4 Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe B...

Page 21: ...gear attachment point 13 Decal information Parking brake released 14 Decal information Parking brake applied 15 Warning sign Danger due to shearing Danger due to high fluid pressure 16 Warning sign Do not stand underneath the fork Do not stand on the fork 17 Decal information Sound power level 18 Decal information Caution Read the operating instructions Fasten the seat belt Apply the parking brake ...

Page 22: ... 6 7 8 9 10 11 12 6210_921 003_V2 1 Type 2 Production number 3 Year of manufacture 4 Tare weight in kg 5 Max permissible battery weight in kg for electric forklift trucks only 6 Min permissible battery weight in kg for electric forklift trucks only 7 Ballast weight in kg for electric forklift trucks only 8 Refer to the technical data listed in these operating instructions for more detailed informa...

Page 23: ...ion 2 Model 3 Year of manufacture 4 Sequential number 7094_003 098 1 2 3 4 5 1 Tare weight in kg 2 Permitted total weight in kg 3 Permitted front axle weight in kg 4 Permitted rear axle weight in kg 5 Payload in kg StVZO Road Traffic Licensing Regulations information This label includes information on the weight and load distribution of the truck Use of truck Proper usage The truck described in the...

Page 24: ...wing of trailers and is equipped with a towing device for this purpose This occasional towing may not exceed 2 of the daily operating time If the truck is to be used for towing on a more regular basis the manufacturer should be consulted The regulations regarding trailer operation must be observed see chapter Trailer operation Impermissible use The operating company or driver and not the manufactu...

Page 25: ... the country in which it is being used The ground must have an adequate load capacity concrete asphalt and a rough surface Routes working areas and aisle widths must conform to the specifications in these operating instructions see the chapter entitled Routes Driving on upward and downward gradients is permitted provided the specified data and specifications are observed see the chapter entitled Rout...

Page 26: ...atment systems e g catalytic converters particle filters or comparable systems can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure sufficient ventilation Using working platforms WARNING ...

Page 27: ... 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 instructions must be stored carefully and must be available to the driver and operating company at a...

Page 28: ...ay include the following for example Special sensors Special attachments Towing devices Customer specific attachments In this case the industrial truck has additional documentation This may be in the form of an insert or separate operating instructions The original operating instructions for this industrial truck are valid for the operation of standard equipment and variants without restriction The...

Page 29: ...g 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 strictly adhered to in order to prevent the risk of fatalities WARNING Indicates procedures that mu...

Page 30: ...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 Commission on the Rules for the Approval of the Electrical Equipment International commission on the rules ...

Page 31: ...ntrations 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 loose rim parts StVZO Straßenverkehrs Zulassungs Ordnung German regulation...

Page 32: ...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 33: ...rating 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 174749 EN 03 2017 21 ...

Page 34: ...f 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 ...

Page 35: ...2 Safety ...

Page 36: ...ineer 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 p...

Page 37: ...n 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 glov...

Page 38: ...the 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 26 174749 EN 03 2017 ...

Page 39: ...y change to its structural state can affect the handling and stability of the truck which in turn can lead to accidents You should therefore contact your service centre beforehand Changes that will adversely affect stability load capacity and safety systems among other things must not be made without the manufacturer s approval The truck may only be converted with written approval from the manufac...

Page 40: ...rhead guard is prohibited with a lift height greater than 1800 mm For lift heights of 1800 mm and greater only use trucks with on overhead guard In the event that the manufacturer goes into liquidation and the company is not taken over by another legal person the operating company can make changes to the truck To do so the operating company must fulfil the following prerequisites Construction docum...

Page 41: ...f the modified overhead guard and no protection for the driver Do not perform welding on the overhead guard Do not perform drilling on the overhead guard CAUTION Heavy roof loads damage the overhead guard To ensure the stability of the overhead guard at all times a roof load may only be mounted on the overhead guard if the structural design has been tested and the manufacturer has given approval Se...

Page 42: ...sponsible fleet manager immediately so that they can have the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g connecting a radio additional headlight...

Page 43: ...y use wheels and tyres approved by the manufacturer Only use high quality products Wheels and tyres approved by the manu facturer can be found on the spare parts list If other wheels or tyres are to be used au thorisation from the manufacturer must be obtained beforehand Contact the authorised service centre on this matter When changing wheels or tyres always ensure that this does not cause the tr...

Page 44: ...tions on the truck can be supported by gas springs Gas springs are complex components that are subject to high internal pressures up to 300 bar They may under no circumstances be opened unless instructed to do so and may be installed only when not under pressure If required the authorised service centre will depressurise the gas spring in accordance with the regulations before removal Gas springs ...

Page 45: ...up In addition be aware that the load centre of gravity may shift as a result of dynamic forces such as braking A load that is otherwise resting safely on the fork arms may move forwards and fall If the fork arms are too long they can catch on loading units behind the load that is to be picked up These other loading units then fall over when the load is raised For help with selecting the correct f...

Page 46: ...incident 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 47: ...rrect 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 48: ...risk time the truck is used in a manner that falls outside the scope of normal use and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci dents 36 174749 EN 03 2017 ...

Page 49: ...Safety 2 Residual risk 174749 EN 03 2017 37 ...

Page 50: ...y 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 visibil...

Page 51: ...and labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note Germa...

Page 52: ...n 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 ...

Page 53: ...the 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 over...

Page 54: ...e inspection must be retained until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay C...

Page 55: ...xhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure sufficient ventilation The operating company must ensure that the following requirements are met Usage must be reported to the responsible occup...

Page 56: ...75 and DIN 43539 VDE 0117 and VDE 0510 must be conducted at least once every year NOTE Contact your service centre to arrange for an insulation test Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage test voltage 500 V Ensure that all voltage sources have been disconnected from the circuit to be tested Measure the insulation resistance with a suitable measuri...

Page 57: ...ible substances that are necessary for operation see Chapter Maintenance data table P 5 314 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 ri...

Page 58: ...ved 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...

Page 59: ... use 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 Dispos...

Page 60: ...ediately rinse away spilt battery acid with plenty of water Follow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Diesel fuel WARNING Diesel fuel is combustible Observe statutory regulations Do not allow diesel fuel to come into contact with hot engine components Do not smoke WARNING Diesel fuel is toxic Avoid contact and swallowing ...

Page 61: ...iately change soaked clothing and shoes WARNING Risk of slipping due to spilled diesel fuel particularly in combination with water Immediately collect spilled diesel fuel using an oil binding agent and dispose of it in accordance with regulations ENVIRONMENT NOTE Diesel fuel is a water polluting substance Always store in regulation containers Avoid spilling diesel fuel Immediately collect spilled ...

Page 62: ...s Observe the national regulations for the country of use ENVIRONMENT NOTE Soak up any spilt coolant or cooling fluid immediately using an oil binding agent and dispose of it in accordance with the national regulations for the country of use Dispose of old coolant or cooling fluid in accordance with the national regulations for the country of use Disposal of consumables ENVIRONMENT NOTE Materials th...

Page 63: ...Safety 2 Safety regulations when handling consumables Neutralise any spilt battery acid immedi ately Always observe national regulations con cerning the disposal of used oil 174749 EN 03 2017 51 ...

Page 64: ...nt LpAZ Measurement uncertainty KpA 74 0 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted values for operating conditions 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 ...

Page 65: ...ty 0 71 m s2 0 177 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or on the operating devices in the truck is less than 2 5 m s 2 There are therefore no mea surement guidelines for these measurements The personal vibration load on the driver over a working day must be determined by the operating company at the actual place of use in accordance wit...

Page 66: ...th hazard and risk of poisoning when operating the truck Observe the national regulations for the country of use when using trucks with an internal com bustion engine in entirely or partially enclosed working areas Always ensure sufficient ventilation Heat DANGER Risk of burns due to hot exhaust gases Exhaust gases or components that carry exhaust gases e g exhaust pipes can become so hot that dire...

Page 67: ...3 Overviews ...

Page 68: ... General view 7312_003 172_V2 1 2 3 4 5 6 7 8 9 10 1 Lift mast 2 Overhead guard 3 Driver s compartment 4 Fuel tank 5 Towing device 6 Steering axle 7 Drive axle 8 Fork arms 9 Fork carriage 10 Lift cylinders 56 174749 EN 03 2017 ...

Page 69: ... 4 Display and operating unit 5 Document holder 6 Operating devices for hydraulic and traction functions 7 Compartment variant 8 Cup holder for max 0 5 l bottles 9 Driver s seat 10 Compartment and storage location for operating instructions 11 Accelerator pedal 12 Brake pedal 13 Steering column adjustment lever NOTE The truck equipment may differ from the equipment shown 174749 EN 03 2017 57 ...

Page 70: ...ndicator 15 Operating hours display 16 Time display digital 17 Particle filter display 18 Rotating beacon display 19 Interior lighting display 20 Rear window heating display 21 Interior lighting rotating beacon button 22 Rear window heating particle filter regener ation button 23 Menu change button 24 Lighting button 25 Blue Q button 26 Rear window wiper button NOTE Buttons 5 21 22 and the accompany...

Page 71: ...r hydraulic and driving functions Different 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 Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip switch Mini console 174749 EN 03 2017 59 ...

Page 72: ... key F1 3 Function key F2 4 Drive direction turn indicator cross lever 5 Function key 5th function 6 Attachments cross lever 7 Signal horn button NOTE Depending on the equipment various electric attachmentparts canbe controlled viafunction keys 2 and 3 Changes must only be made by the STILL service centre 60 174749 EN 03 2017 ...

Page 73: ... Drive direction turn indicator cross lever 5 Function key 5th function 6 Auxiliary hydraulics 1 operating lever 7 Auxiliary hydraulics 2 operating lever 8 Signal horn button NOTE Depending on the equipment various electric attachmentpartscanbecontrolledvia function keys 2 and 3 Changes must only be made by the STILL service centre 174749 EN 03 2017 61 ...

Page 74: ...ction key F2 5 Drive direction turn indicator cross lever 6 Function key 5th function 7 Auxiliary hydraulics 1 operating lever 8 Auxiliary hydraulics 2 operating lever 9 Signal horn button NOTE Depending on the equipment various electric attachmentparts canbe controlled viafunction keys 3 and 4 Changes must only be made by the STILL service centre 62 174749 EN 03 2017 ...

Page 75: ...e 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 174749 EN 03 2017 63 ...

Page 76: ...utton 5 Right turn indicator button 6 Function key 5th function 7 Attachments operating lever 8 Attachments operating lever 9 Tilt operating lever 10 Lift lower operating lever 11 Drive direction switch NOTE Depending on the equipment various electric attachmentparts canbe controlled viafunction keys 1 and 2 Changes must only be made by the STILL service centre 64 174749 EN 03 2017 ...

Page 77: ... Operating 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 174749 EN 03 2017 65 ...

Page 78: ...3 Overviews Operating and display elements 66 174749 EN 03 2017 ...

Page 79: ...4 Operation ...

Page 80: ...g the following inspections the truck may not be used until it has been properly repaired Do not remove or deactivate safety systems or switches Do not change any predefined set values Do not use the truck until it has been properly repaired WARNING There is a risk of falling when working on high parts of the truck Use only the steps provided on the truck Do not stand on truck components or use the...

Page 81: ...ing and shifting Roller tracks 2 Make sure that there is a film of grease Load chains Perform a visual inspection to ensure that the chains are intact and have adequate and even tension Load lift system Attachments variant Ensure correct mounting in accordance with the operating instructions of the manufacturer Perform a visual inspection to ensure the attachments are intact and not leaking Perform...

Page 82: ...tegrity and deformation Check that the lock is in good condition and is working correctly Check the close function Close Coupling pin tow coupling variant Perform a visual inspection for defor mation and wear for example bent torn broken Check the securing bush in the counterweight for integrity and that it is working correctly Check that the linchpin is present and working correctly chain rope sp...

Page 83: ...es are escaping from the axle Do not use the truck if there is any damage or defects Contact your authorised service centre 7312_003 080 1 Checking the cooling fluid level The cooling fluid level is monitored by a sensor As soon as the message COOLANT LE VEL appears on the display proceed as fol lows WARNING Risk of scalding due to hot cooling fluid The cooling system is pressurised Opening the cooli...

Page 84: ... oil level NOTE The truck should be parked on as level ground as is possible while this check is carried out Open the bonnet see Chapter Opening the bonnet P 5 317 Pull out the oil dipstick 1 and wipe it Insert the oil dipstick to the stop and pull out again Make sure that the insertion marks 2 are aligned when inserting The oil level must be between the marks arrows If the oil level is only up to...

Page 85: ...ip on the truck WARNING Risk of injury when jumping out of the truck If your clothing or jewellery e g watch ring etc become 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 Com...

Page 86: ...driver s seat and place your left foot on the step 4 Climb out of the truck right foot first 0 7 8 5 3 1 6 5 12890 15 23 F1 F2 7314_003 050 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 fa...

Page 87: ...hat all operating devices can be actuated safely Ensure that the seat and seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the head and the lower edge of the roofing sheet must be at least 40 mm NOTE If there are separate operating instructions for the seat they ...

Page 88: ...ver s seat is securely engaged 7094_003 008 2 Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it Lift and hold the lever 2 Push the seat backrest into the desired position Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structural condition of the truck 76 174749 EN 0...

Page 89: ...pped 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...

Page 90: ... support 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 7...

Page 91: ...ng the switch Adjusting the armrest DANGER There is a risk of accident if the armrest lowers sud denly causing the driver to move in an uncontrolled manner This can result in unintentional actuation of the steering or the operating devices and thus cause uncontrolled movements of the truck or load Do not adjust the armrest while driving Adjust the armrest so that all operating devices can be actua...

Page 92: ...rest 2 into the desired posi tion Tighten the hand wheel by turning it clock wise Check that the armrest is firmly attached 6210_424 001 1 2 Adjusting the steering column Press down the steering column adjustment lever 2 Position the steering column 1 and pull the lever up again DANGER Risk of accidents Ensure that the steering column is secure The steering column must click into place Never adjust...

Page 93: ...ntil it unlatches Switching on the key switch WARNING Before switching on the key switch all tests prior to start up must be performed without detecting any defects Perform the tests prior to commissioning Do not operate the truck if defects have been detected Notify the authorised service centre 174749 EN 03 2017 81 ...

Page 94: ...fore daily use 7090_001 002 0 I 1 Insert the switch key 1 into the key switch and turn to position I 7312_003 085 This initiates a self test All lamps in the drive direction and turn indicator displays light up briefly 82 174749 EN 03 2017 ...

Page 95: ...nd operating unit 1 Fuel level Shows the fuel level in the fuel tank as a percentage 2 Drive programme Displays the current drive programme numerically 1 5 The drive programme can be changed see the chapter entitled Setting the drive programme 3 Operating hours Displays the total operating hours completed by the truck The hour meter operates as soon as the engine is started 4 Time Displays the cur...

Page 96: ...on the input menu for the driver PIN appears on the display and operating unit screen All of the truck s functions driving hydraulics additional electrical installations and the display and operating unit displays are blocked The function of the hazard warning system variant is guaranteed Enter the five digit driver PIN possible entries from 00000 to 99999 to enable the blocked functions Once the c...

Page 97: ...red in the truck control unit These are still available if the display and operating unit has been changed The authorised service centre can use a diagnostic device to read out the driver PIN and if necessary restore the factory default driver PIN ACCESS CODE input menu The driver enters the five digit driver PIN 00000 to 99999 in this input menu The driver PIN is entered using the buttons 1 The di...

Page 98: ... is entered the message INVALID appears for a short time When the message goes out the driver PIN can be re entered 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three invalid entry attempts the mes sage CODE DENIED appears The input is then locked for five minutes before another attempt can be made 86 174749 EN 03 2017 ...

Page 99: ...guration menu is password protected After entering the password the fleet manager can configure general settings for the truck To change the password see the chapter entitled Changing the password Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the four digit password ...

Page 100: ...n_V3 1 3 4 2 Selecting the driver PIN In the ACCESS CODE menu there are fifty possible driver PINs to choose from The digit sequences can be set or changed in the NEW CODE submenu Once the ACCESS CODE menu has been ac cessed the CODE selection field 2 contains the number 1 The first of the fifty driver PINs can now be defined Use the drive program selection button 1 and the menu change button 4 to sele...

Page 101: ...1 3 5 7 8 1 2 6 7 3 4 5 8 9 0 BQ_026_en CONFIRM appears in the display The CONFIRM submenu is used to confirm the new driver PIN Enter the new driver PIN for a second time in the CONFIRM field 8 using the buttons 7 If the entry matches the new driver PIN previously entered the system will accept the new driver PIN once the last digit has been entered The display switches back to the ACCESS CODE menu...

Page 102: ...e NEW CODE submenu the message INVALID will appear The message will then disappear after a short time The new driver PIN can be entered in the CONFIRM submenu for further confirma tion 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three incorrect entries the CODE DE NIED message appears The display switches back to the ACCESS CODE menu The desired driver PIN must be re defined 90 174749 EN 03 2017 ...

Page 103: ...E 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 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the current password using the buttons 1 Confirm the entry by pressing the ENTER button 2 174749 EN 03 2017 91 ...

Page 104: ...e menu change button 3 to select the PASSWORD menu Confirm your selection by pressing the ENTER button 2 8 9 6 7 4 2 0 1 3 5 1 3 4 BQ_033_en 2 1 PASSWORD PASSWORD LEVEL appears in the display Use the drive program selection button 1 and the menu change button 4 to select the desired PASSWORD LEVEL 2 Confirm your selection by pressing the ENTER button 3 92 174749 EN 03 2017 ...

Page 105: ...ntly 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 by pressing the ENTER button 3 In the NEW CODE field appears briefly The new password is confirmed To correct the new password push the ESC button 2 The display switches back to PASS WORD ...

Page 106: ...intention to overtake Seat belt DANGER Even when using an approved restraint system there is some residual risk that the driver might be injured if 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 t...

Page 107: ...n obstacle There is a risk of fatal injury Fasten the seat belt before every trip Do not twist the seat belt when fastening it Only use the seat belt to secure one person Have any malfunctions repaired by the authori sed service centre NOTE The buckle has a buckle switch variant In the event of an operating error or malfunction the message SAFETY BELT appears in the display and operating unit see ...

Page 108: ...the belt 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 th...

Page 109: ...ruck tips over a restraint system must be in place and must be used The restraint system 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 co...

Page 110: ... NOx components contained in the exhaust gas Modern exhaust gas treatment systems e g catalytic converters particle filters or comparable systems can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas A...

Page 111: ...he engine has started If the engine does not start after 20 seconds stop the starting procedure and repeat after one minute CAUTION Risk of engine damage If the OIL PRESSURE message appears on the display after starting the motor there may be in sufficient engine lubrication Insufficient lubrication may cause engine damage Stop the engine immediately Check the engine oil level and top up the engine ...

Page 112: ...see Driving chapter Press the brake pedal 1 firmly The truck must decelerate noticeably 6210_342 005 Checking the parking brake DANGER If the truck rolls away there is a risk of being run over 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 Check the function o...

Page 113: ...aximum 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 angle of about half a revolution Checking the emergency off function NOTE Only diesel trucks with a particle filter system variant or a joystick 4Plus variant have an emergency off switch WARNING No ...

Page 114: ...ternal self test and is then ready for operation again 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 variant at all times Zero adjustment is required as part of daily commissioning after changing the fork arms after fitting or changing attachments NOTE Accurate zero adjustment is only possible i...

Page 115: ...ast four seconds the zero adjustment 2 symbol will appear in the display NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the zero adjustment will not be accurate To stop the lowering procedure quickly release the operating device for lowering so that it jumps into the zero position Lo...

Page 116: ...function key 1 to switch on the comfort feature lift mast vertical position Function display 2 must appear in the display Tilt the lift mast backwards The lift mast must tilt back fully and move gently as far as the end stop Tilt the lift mast forward The lift mast must tilt forwards and stop in the vertical position Release the operating device to tilt and actuate again The lift mast must tilt fo...

Page 117: ...as soon as the engine is started 4 Time Displays the current time digitally in hours and minutes The time can be adjusted see the chapter entitled Setting the time 7312_003 185 990h 0 0km 0 0km T 1 2h T 6 7 5 8 9 Additional indicators 5 Menu change button When the menu change button is pressed the following additional indi cators appear 6 Service in indicator Displays the remaining time in hours u...

Page 118: ... the key switch to position I Press the drive program button 1 and the menu change button 2 at the same time The display changes to the PASSWORD menu Press the return key 3 The display changes to the CONFIGURA TION menu The following settings are possible and can be found in the corresponding chapter Setting the date and time Resetting the daily kilometres and daily operating hours Setting the lan...

Page 119: ...ometer Daily hour meter Daily odometer Speed Steering angle Load Time Hydraulic system Exh gas purifier Coolant temperature Fuel level Blue Q Power rating average Power rating trend Symbols for warning messages Description Symbol Parking brake Actuate seat switch Safety belt Battery acid level Neutral warning message Are you sure Oil pressure 174749 EN 03 2017 107 ...

Page 120: ... soft key functions are used on the left in the display Description Symbol Empty field No display General function key OFF General function key ON Rear working spotlight OFF Rear working spotlight ON Front working spotlight OFF Front working spotlight ON Windscreen heating OFF Windscreen heating ON Rear window heating OFF Rear window heating ON Interior lighting OFF Interior lighting ON Roof wiper ...

Page 121: ... display ESC button to return to the main menu ENTER button to confirm OK button to confirm RES button to reset Button to return to the main menu Button to return to the previous edit field Scroll button to scroll up Scroll button to scroll down Scroll button to count up Scroll button to count down Status LEDs of the function keys for additional electrical installations The current switch status of a...

Page 122: ...d the positions of the keys are shown for inputting digits ESC and ENTER BQ_037 1 2 6 7 3 4 5 ESC Keys for the digits 1 to 7 and the ESC and ENTER keys for inputting the fleet manager password 1 2 6 7 3 4 5 8 9 0 BQ_038 Keys for digits 0 to 9 for inputting the driver PIN access code 110 174749 EN 03 2017 ...

Page 123: ...ee levels Confirm the time set by pressing the Return key 4 Use the arrow key 3 to exit the menu and return to the next higher level NOTE The date is set in a similar manner 8 9 0 6 7 4 3 5 7312_003 055_en_V4 1 2 3 4 Resetting the daily kilometres and daily operating hours The daily number of kilometres and daily operating hours displays can be reset to zero Switch to the CONFIGURATION menu see Cha...

Page 124: ...pressing Return key 4 The LANGUAGE menu appears Press drive program button 1 or menu change button 2 until the desired language appears in the display Confirm your selection by pressing the Return key 4 Use arrow key 3 to exit the menu and return to the next higher level Soft key button for operating various equipment variants There are two soft key columns available on the display operating unit W...

Page 125: ...soft key columns depend on the individual equipment of the truck Therefore the soft keys on your display operating unit may vary to those shown here Configuring Blue Q efficiency mode The following operating modes can be se lected to activate the Blue Q efficiency mode STANDARD Blue Q is turned off whenever the truck is commissioned The driver can use the Blue Q button to switch efficiency mode on and...

Page 126: ... or the menu change button 2 until op tion BLUE Q CONFIGURATION appears Confirm your selection by pressing the Return key 4 The BLUE Q CONFIGURATION menu appears Press drive program button 1 or menu change button 2 until the desired effi ciency mode appears in the display Confirm the set efficiency mode with Return button 4 Use arrow key 3 to exit the menu and return to the next higher level 114 17474...

Page 127: ...e if the efficiency mode was not activated Blue Q has no influence on Maximum speed Climbing capability Traction Braking characteristics NOTE The Blue Q efficiency mode can be swit ched on and off in the STANDARD and FI XED FLEX operating modes If the FIXED operating mode is configured in the display operating unit the Blue Q button has no func tion and the Blue Q efficiency mode is swit ched on perman...

Page 128: ... STANDARD and FI XED FLEX operating modes If the FIXED operating mode is configured in the display operating unit the Blue Q button has no func tion and the Blue Q efficiency mode is swit ched on permanently For information on configuring the Blue Q operating modes see chapter Configuring Blue Q efficiency mode 2 6210_003 065_V3 1 2 Press the Blue Q button 1 The Blue Q symbol 2 appears next to the driv...

Page 129: ...topping 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 colu...

Page 130: ...e 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 b...

Page 131: ... 654 EEC mini mum safety and health requirements for the workplace must be observed The respective national guidelines apply for areas outside of the EU The required aisle widths depend on the dimensions of the load For pallets these are Aisle width mm Model Type With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise 7311 RX70 16 7314 3523 3727 7312 RX70 18 7315 3557 3762 7313 RX70 20 731...

Page 132: ... and descending gradients Maximum gradient Model Type With load There is no load on the truck 7311 RX70 16 7314 27 0 7312 RX70 18 7315 7313 RX70 20 7316 26 0 28 0 The upwards and downwards gradients must not exceed the maximum gradients above and must feature a rough surface The top and bottom of the gradient must feature smooth and gradual transitions to prevent the load from falling to the groun...

Page 133: ... and the fixed elements of the surrounding area The height is based on the overall height of the lift mast and the dimensions of the load see the chapter entitled Technical data Rules for roadways and the working area It is only permitted to drive on routes autho rised for traffic by the operating company or its representatives Traffic routes must be free of obstacles The load may only be set down an...

Page 134: ...ration forwards backwards 50 100 120 140 160 Deceleration forwards backwards 50 100 120 140 160 Reversing forwards backwards 50 100 120 140 160 Brake retardation electric brake booster 60 70 80 90 100 5060_003 082 1 2 Selecting the drive direction The desired drive direction of the truck must be selected using the drive direction switch before attempting to drive The method of actuating the drive ...

Page 135: ...tor pedal is inadvertently pressed Briefly select the drive direction switch for the direction opposite to the current direction The drive direction indicator on the display and operating unit goes out NOTE When the seat is vacated the drive direction switch is set to Neutral To drive the drive direction switch must be actuated again 5060_003 096 F1 F2 1 Actuating the drive direction switch mini le...

Page 136: ...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 7325_003 031 1 Actuating 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 124 174749 EN 03 2017 ...

Page 137: ...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 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 lifting functions are lo...

Page 138: ...edal 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 downhill 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 variant has not been actuated and the parking brake is rele...

Page 139: ...our 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 whether the driver s...

Page 140: ... and 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 ...

Page 141: ...foot from actuated accelerator pedal Actuate the accelerator pedal for the other 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 electrical brake service brake causes the truck to decelerate The truck cannot be driven again until the accelerator pedal has been released and then actuated ag...

Page 142: ...ring the truck to a standstill by applying the parking brake Do not operate the truck again until the service brake has been repaired DANGER Risk of tipping and risk of slipping The braking distance of the truck depends on the weather conditions and the level of contamination on the roadway The braking distance increases with the square of the speed There is a danger that the truck could slip or o...

Page 143: ...e depends on which parking brake the truck is fitted with Possible equipment variants are as follows Mechanical parking brake see Chap ter Actuating the mechanical parking brake P 4 131 Electric parking brake see Chapter Ac tuating the electric parking brake P 4 133 Actuating the mechanical parking brake DANGER There is a risk of being run over if the truck rolls away and therefore a danger to life...

Page 144: ...i cally The parking brake is engaged and the wheels are blocked Driving is no longer 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 brak...

Page 145: ...onsible for parking the truck safely The safety information about safe parking applies DANGER There is a risk of being run over if the truck rolls away and therefore a danger to life The truck should not be parked on a slope In emergencies secure with wedges on the side facing downhill Only leave the truck if the parking brake is applied NOTE To electrically activate the parking brake the battery ...

Page 146: ...ate with a steady light When the accelerator pedal is released After a short waiting period the parking brake will audibly engage and the LED 2 will illuminate with a steady light The truck is held on a gradient by the traction motor until the parking brake is applied When the key switch is turned off The parking brake will audibly engage immediately and the LED 2 will illuminate briefly with a ste...

Page 147: ...wn on the driver s seat Press push button 1 The parking brake will audibly release and the LED 2 will go out Releasing the parking brake by starting to drive NOTE The electric parking brake can be released by starting to drive only if the electric parking brake is applied automatically by releasing the accelerator pedal or vacating the driver s seat Sit down on the driver s seat Select the drive d...

Page 148: ...en applied by the accelerator pedal being released or the driver s seat being vacated then it is not possible to drive the truck until the parking brake has been released by pressing the button The RELEASE PARKING BRAKE message appears in the display 136 174749 EN 03 2017 ...

Page 149: ... is at a standstill the parking brake audibly engages and the LED 2 illuminates with a steady light When the key switch is turned off The truck will roll to a stop If the truck is at a standstill the parking brake audibly engages and the LED 2 illuminates with a steady light until the control units switch off If the emergency off switch variant is actuated following the emergency off function The ...

Page 150: ... 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 VDI datasheet for RX70 16 RX70 18 and RX70 20 P 6 350 138 174749 EN 03 2017 ...

Page 151: ...rive 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 v...

Page 152: ...ge CUTOUT MODE appears in the display Conditions that apply simultaneously The truck is stationary The parking brake is applied The driver s seat is not occupied Particle filter regeneration is not in progress There are no consumers switched on that require a significant amount of energy such as the air conditioning The waiting time only starts when all condi tions apply simultaneously If one of the...

Page 153: ...Apply the parking brake Lower the fork carriage to the ground Tilt the lift mast forwards until the tips of the fork arms rest on the ground If attachments variant are fitted retract the working cylinders see the chapter entitled General instructions for controlling attachments Take your foot off the accelerator pedal and allow the engine to continue idling for a short while Turn the switch key to ...

Page 154: ... from rolling away on a slope Lift handle 2 on the support mounting Remove wheel chock 1 from the support mounting Push the wheel chock under a front axle wheel on the side facing the downhill slope NOTE After use return the wheel chock to the support mounting and press the handle 2 down again 142 174749 EN 03 2017 ...

Page 155: ... 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 result in...

Page 156: ...ridden and a load can be lifted to the truck s maximum lift height To switch the automatic lift cut out back on Press the F1 1 button again Lift mast vertical position variant Description If the truck is equipped with the lift mast vertical position comfort feature variant the driver can put down goods such as paper rolls vertically with precision and thus avoid damage when unloading The tilt cyli...

Page 157: ...ture 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 7314_003 059 2 1 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 Tr...

Page 158: ...Tilt 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 ...

Page 159: ...forwards 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 ...

Page 160: ...ed frequently the lift mast vertical position should be calibrated 6210_003 070_en_V2 1 2 3 Calibrating the lift mast vertical position Set the lift mast to the required position Press and hold the button 1 for the lift mast vertical position for at least five seconds The message VERTICAL POSITION will appear on the display Storing the mast position Press the drive program selector button 3 The cur...

Page 161: ...ast or load may be higher than the fork carriage Note the heights of ceilings and entrances 6210_810 002 2 3 Hi Lo lift mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the max height 2 NOTE When lifting above the free lift the fork car riage always remains at the upper edge of the extending lift mast DANG...

Page 162: ...equence may occur i e the inner lift mast may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for instance result from The hydraulic oil temperature being too low Blocking of the fork carriage in the inner lift mast Blocking of the free lift cylinder Blocking of the chain...

Page 163: ...cked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on the lift mast see the chapter entitled Working at the front of the truck Hydraulic blocking function The hydraulic blocking function ensures that all the functions of the working hydraulics are d...

Page 164: ... operating devices The method of operating the lifting system depends on the operating devices included in the truck s equipment Possible equipment variants include Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip switch The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck ...

Page 165: ... lifting system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower the 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 t...

Page 166: ...fting system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower the 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 ...

Page 167: ...om the driver s seat only Tilting the lift mast To tilt the lift mast forwards Move the lift mast operating lever 1 in the direction of arrow A To tilt the lift mast backwards Move the lift mast operating lever 1 in the direction of arrow B Lifting lowering the fork carriage To lift the fork carriage Move the lift lower operating lever 2 in the direction of arrow D To lower the fork carriage Move ...

Page 168: ...carrying 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 156 174749 EN 03 2017 ...

Page 169: ...kwards 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 174749 EN 03 2017 157 ...

Page 170: ...ing loads Operate the lifting system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Pull the lift lower operating lever 1 backwards To lower the 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 le...

Page 171: ... the fork is a danger area Always wear protective gloves and safety footwear when changing the fork arms Ensure that no one stands in the danger area Do not pull on the fork arms The fork arms must always be carried by two people if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size use...

Page 172: ...rriage on a pallet Push the fork arms onto the fork carriage from the outside towards the centre Pull the locking lever 1 upwards and push the fork arms into the required position Ensure that the locking lever snaps into place Fit and tighten the locking screw 2 DANGER There is a risk to life caused by a falling load or fork Tighten the locking screw after every fork replacement It is not permitte...

Page 173: ... 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 picking up a load chapter NOTE If...

Page 174: ...nsion 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 th...

Page 175: ...ork 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 equip...

Page 176: ...reversible fork arms The mast is lifted and tilted in the same manner Only work in reverse operation using reversible fork arms Do not use a fork extension variant If the load measurement comfort feature is available perform a zero adjustment of the load measurement To drive raise the load centre of gravity 2 to a max of 600 mm above the ground Observe the information in the section entitled Trans...

Page 177: ...spended 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 ...

Page 178: ...f applicable 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...

Page 179: ...eeded 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 measureme...

Page 180: ...p loads CAUTION If the weight determined by a load measurement exceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce load immediately If necessary use another truck with sufficient load bearing capacity NOTE Accurate load measurement is only possible under the following conditions The hydraulic oil is at normal operating temperature The ...

Page 181: ...highlighted in black NOTE If the truck is equipped with mini levers or fingertip operation the F1 button can also be pressed as an alternative NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the load measurement will not be accurate To stop the lowering procedure quickly release the op...

Page 182: ...ficiently far apart and are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the 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...

Page 183: ...ck its working equipment its load carrying equipment e g attachments or the load Also included are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of a...

Page 184: ...ly and 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 followi...

Page 185: ...uide 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 Transport...

Page 186: ...t the 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 174 174749 EN 0...

Page 187: ...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 CAUTION Component damage possible Ensure that the roadway behind you is clear Move backwards carefully and slowly until the load is clear of the racking Brake gently DANGER Never tilt the lift mast with a raised load due to the risk of tipping Lower the lo...

Page 188: ...4 Operation Working with loads 5060_003 102 Lower the load while maintaining ground clearance 5060_003 101 Tilt the lift mast backwards The load can be transported 176 174749 EN 03 2017 ...

Page 189: ...cident 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 inf...

Page 190: ...pping 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 r...

Page 191: ...k towards 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 174749 EN 03 2017 179 ...

Page 192: ...Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V 1 2 7321_003 011_V2 Determining the actual total weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the attachment variant nameplate and if necessary by ...

Page 193: ...ype Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V 1 2 7321_003 011_V2 Determining the actu...

Page 194: ...tachment 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 ca...

Page 195: ...nstallation 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 prote...

Page 196: ...au thorised personnel in accordance with the information provided by the manufacturer and supplier of the attachments After each instal lation the attachment must be checked for correct function prior to initial commissioning NOTE The pressure release procedure is dependent on the operating devices for controlling the hydraulic functions see the section entitled Lifting system operating devices NO...

Page 197: ...003 184 Actuate the operating lever 1 for control ling the hydraulic functions repeatedly in the direction of the arrow as far as the end position The valves open and the hydraulic system is depressurised Switch off the key switch 174749 EN 03 2017 185 ...

Page 198: ...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 with attachments if the loads are securely grasped and attached Wher...

Page 199: ...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 174749 EN 03 2017 187 ...

Page 200: ... 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 posit...

Page 201: ...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 pi...

Page 202: ...cross 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 T...

Page 203: ...r fork back 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 174749 EN 03 2017 191 ...

Page 204: ...ith 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 towards D The attachment moves in accordance with the pictogram in position D NOTE The pictograms are attached depending on the pre...

Page 205: ...s 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 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back 174749 ...

Page 206: ...tograms 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 position E Actuate the 5th function function key 3 and move operating lever 1 towards F The attachment moves in accordance with t...

Page 207: ...ion 4 Attachments 5060_003 122 3 4 1 2 Note the following attachment functions and pictograms 1 Adjust fork arms open 2 Adjust fork arms close 3 Rotate to the left 4 Rotate to the right 174749 EN 03 2017 195 ...

Page 208: ...ves 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 The attachment moves in the direction shown in pictogram D NOTE The pictograms are attached depending on the pre assembled attach...

Page 209: ...s 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 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back 174749 ...

Page 210: ...ctograms 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 position E Actuate the 5th function function key 5 and move operating lever 3 towards F The attachment moves in accordance with ...

Page 211: ...ion 4 Attachments 5060_003 122 3 4 1 2 Note the following attachment functions and pictograms 1 Adjust fork arms open 2 Adjust fork arms close 3 Rotate to the left 4 Rotate to the right 174749 EN 03 2017 199 ...

Page 212: ...Operating device Function of the attachment 1 Joystick 4Plus Move sideshift to the left right 2 Joystick 4Plus or slider Adjust fork arms open close 3 Slider Move reach frame or fork carriage forwards backwards 4 Joystick 4Plus or slider Rotate attachment left right 5 Slider Tip shovel over tip shovel back NOTE The pictograms on the joystick 4Plus are attached according to the attachments fitted to...

Page 213: ...r attachments that are controlled using the 5th hydraulic function the procedures for operation are as follows Press and hold shift key F 1 on the joystick 4Plus Simultaneously actuate the horizontal rocker button 2 in the direction shown in the pictogram The attachment moves in the selected direc tion NOTE The pictograms are attached depending on the pre assembled attachment If an attachment with...

Page 214: ... the lower part of the pictogram NOTE The pictograms are attached depending on the pre assembled attachment 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 6210_003 031 2 3 6 4 7 9 10 5 8 Note the following attachment functions and pictograms 2 Move side shift fra...

Page 215: ...tch functions in which case the corresponding operating lever controls the 5th function The upper and lower parts of the pictogram 3 behind the operating lever show the function that is activated with this lever This essentially involves the following Move the operating lever forwards The attachment moves in the direction of movement shown in the upper part of the pictogram Move the operating leve...

Page 216: ...ion key indicates which operating lever is equipped with the 5th function The 5th function is switched to the 4th operating lever see sticker 9 NOTE The movement action of this 5th function can be found in the operating instructions of the fitted attachment NOTE The pictograms are attached depending on the pre assembled attachment If an attachment with other functions is fitted the pictograms must b...

Page 217: ...n be fitted with a clamp locking mechanism as a variant This prevents the clamp from opening unintentionally if the operating function is inadvertently triggered DANGER There is a risk of fatal injury from falling loads if the correct function of 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 locking mecha...

Page 218: ... without releasing the clamp locking mechanism To close the clamp pull the cross lever 1 backwards 7325_003 048 1 2 Triple 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 mech...

Page 219: ...3 2 6210_003 097 Joystick 4Plus To release the clamp locking mechanism press and hold shift key F 3 and move the horizontal rocker button 1 to the right Keep shift key F 3 pressed and move the horizontal rocker button 1 back to the neutral position The LED 2 lights up as long as the clamp locking mechanism is released To open the clamp press and hold shift key F 3 and move the horizontal rocker bu...

Page 220: ...ll 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 attache...

Page 221: ...ffic Licensing Regulations equipment the licence plate lamp also lights up To switch on the headlights press the button 1 again The headlights light up in addition to the 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 ligh...

Page 222: ...OTE Pushing the button again switches the rotating beacon off again 5060_003 011_V2 1 2 Switching the hazard warning system on and off Push the button 1 to switch on the hazard warning system All direction indicators and indicator lights 2 flash NOTE Pushing the button again switches the hazard warning system off again NOTE The hazard warning system can also be switched on without the key switch be...

Page 223: ... direction indicators by moving the corresponding drive direction turn indicator cross lever 1 to the left or right 2 3 5060_003 012_V2 The direction indicators and the correspon ding direction indicator lights 2 or 3 flash Switch off the direction indicators by moving the cross lever to the centre position 174749 EN 03 2017 211 ...

Page 224: ...on indicators by moving the corresponding turn indicator button 1 to the left or to the right 2 3 5060_003 012_V2 The direction indicators and the correspon ding direction indicator lights 2 or 3 flash Turn off the direction indicators by pushing the other turn indicator button 212 174749 EN 03 2017 ...

Page 225: ...dicators by moving the turn indicator switch 1 to the left or to the right 2 3 5060_003 012_V2 The direction indicators and the correspon ding turn indicator displays 2 or 3 flash Switch off the direction indicators by moving the turn indicator switch to the centre position 174749 EN 03 2017 213 ...

Page 226: ...orking spotlight illuminates the working area directly in front of the truck Depending on the equipment the upper working spotlights can be switched on off automatically or manually Switching the upper working spotlights on off manually NOTE The upper working spotlights can be switched on off independently of the lower working spotlights For information on switching the lower working spotlights on...

Page 227: ...aximum of two lifts can take place so that the working spotlights do not switch on each time a precise adjust ment is made If more lifts are carried out during this time the upper working spotlights will remain switched off NOTE The upper working spotlights are switched off automatically when the truck is driven for longer than one second and faster than 2 1 km h Lift height controlled switching o...

Page 228: ...fetyLight variant The STILL SafetyLight is a visual warning unit 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 It projects one or more light blue light spots approximately 5 meters in front o...

Page 229: ...er cap 1 of the washer system variant Fill the washer reservoir with washer fluid containing anti freeze according to the maintenance data table see Chap ter Maintenance data table P 5 314 CAUTION Components may become damaged due to the effects of frost Water expands when it freezes If there is no anti freeze in the washer system variant the system may become damaged due to the accumulation of ice...

Page 230: ...n 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 Cruise control variant Using the cruise control function the driver can save the speed in forwards travel when it is 6 0 km h by pressing a button and continue driving without actuating the accelerator pedal NOTE The cruise control function canno...

Page 231: ...dent from failing to adjust speed Driving at excessive speeds can cause accidents e g the truck could tip over when cornering Adjust speed along the entire distance being travelled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise control function and the dangers associated with it Start drive mode Accelerate the truck t...

Page 232: ...n the display and operating unit 8 9 0 6 7 4 3 5 2 7312_003 150 The current speed is saved The forwards drive direction indicator 2 flashes The cruise control symbol on the display and operating unit is shown in black Remove your foot from the accelerator pedal The truck continues to drive at the selected speed until the cruise control function is switched off again 220 174749 EN 03 2017 ...

Page 233: ...elerator pedal can be used to switch off the cruise control function depending on which function type is programmed Type 1 Even slightly depressing the accelerator pedal switches off the cruise control func tion Type 2 To switch off the cruise control function the accelerator pedal must be depressed at least as far as it was when saving the speed Switch off cruise control 8 9 0 6 7 4 3 5 2 7312_00...

Page 234: ...raint systems variants Different driver restraint systems are available as variants for this truck The description and operation for these systems can be found in the separate Driver restraint systems operating instructions 222 174749 EN 03 2017 ...

Page 235: ...rely engaged in the detent position Opening the cab door from the outside Insert the key in the door lock 1 unlock and remove the key again Pull the door handle 2 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 4 and latch 5 Press the latch in and push the cab door outwards 174749 EN 03 2017 223 ...

Page 236: ...lock engages Make sure that the cab door is fully closed 7314_003 040 4 5 2 1 3 Opening the side windows WARNING There is risk of crushing between the window frame and side window caused by the side windows slipping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the rear side window Press the handle 2 together and slide the rear side w...

Page 237: ... Make sure that the handle engages securely in the corresponding stop slot Closing the rear side window Press the handle 2 together and pull the rear side window 1 to the rear Make sure that the handle engages in the stop slot 3 Closing the front side window Press the handle 4 together and slide the front side window 5 forwards Make sure that the handle engages in the stop slot 3 174749 EN 03 2017...

Page 238: ... 7312_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 226 174749 EN 03 2017 ...

Page 239: ... 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 or handling loads There is a risk of acc...

Page 240: ...034 To switch on the blower turn on the blower switch 1 The blower runs at the speed level set at the switch Switching on the heating system DANGER Risk of fire Do not cover the heater DANGER Risk of burns Do not touch housing during opera tion NOTE Only switch on the heating system when the blower is running To switch on the heating system turn on the heating switch 2 The heating system is in oper...

Page 241: ...k of crushing When closing the roof window do not reach 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 ...

Page 242: ...4 Operation Cab 6210_003 107 2 1 Clipboard variant The clipboard 1 with reading lamp 2 is an equipment variant 230 174749 EN 03 2017 ...

Page 243: ...e 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 correspo...

Page 244: ...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 remove the key 1 7090_900 ...

Page 245: ...s 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 position Remove any items used to prevent the trailer from rolling away Uncoupling the trailer Take measures to prevent the trailer from rolling away e g use wheel...

Page 246: ...oads and could become deformed or destroyed This could cause the supported load to fall with poten tially fatal consequences The tow coupling should be subjected only to horizontal loads i e the tiller must be horizontal DANGER If you briefly leave the truck to couple or uncouple the trailer there is a risk to life caused by the truck rolling away and running you over Apply the parking brake Lower ...

Page 247: ...ye or tiller Due to the truck s rear wheel steering the side slewing angle of the tiller may not be adequate The coupling or the tiller may be damaged The tow bar eye of the tiller must fit the tow coupling in terms of shape and size Ensure that the tow bar eye and tiller fit correctly Avoid sharp cornering Exercise care when travelling and manoeuvring in reverse WARNING Risk of component damage if ...

Page 248: ...N 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 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 o...

Page 249: ...sembly 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 7321_003 064 2 Uncoupling model RO 243 Take measures to prevent the trailer from rolling away e g use wheel chocks Pull out the safety handle 3 Push the hand lever 2 upwards Slowly drive the truck forwards until the tow bar e...

Page 250: ...ER 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 ...

Page 251: ...e 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 close...

Page 252: ...and 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 ...

Page 253: ...RO 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 t...

Page 254: ...ly 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 mi...

Page 255: ...Operation 4 Trailer operation NOTE Please observe the definition of the following responsible persons operating company and driver 174749 EN 03 2017 243 ...

Page 256: ... 1 also lights up Messages are always shown repeatedly and for a certain period of 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 f...

Page 257: ...dal do not match truck cannot be driven Notify your authorised service centre ACCELERATOR A3811 Accelerator configuration is invalid truck cannot be driven Notify your authorised service centre BRAKE SENSOR A3016 A3017 Sensor fault truck can only be driven at emergency mode speed Notify your authorised service centre BRAKE SENSOR A3035 Brake fluid level too low or switch defective truck can only be ...

Page 258: ...raulic drive function Notify your authorised service centre AUX2 A3117 A3118 Sensor fault no or limited hydraulic drive function Notify your authorised service centre VERTICAL MAST A3130 A3131 A3132 No hydraulic function Turn off vertical lift mast position Notify your authorised service centre VERTICAL MAST ERROR A3135 No hydraulic function Turn off vertical lift mast position Notify your authori...

Page 259: ...ce centre AIR FILTER A5651 Depending on the design of the air filter replace the filter insert or the filter cartridges If this does not resolve the problem contact your authorised service centre CONTROL UNIT A3305 CIO not functioning Notify your authorised service centre EXHAUST GAS PURIFIER A5791 No regeneration and no intermediate glow Notify your authorised service centre EXHAUST GAS PURIFIER A57...

Page 260: ...s on the side facing downhill NOTE The truck is equipped with a negative spring operated brake Switching off the truck will block the multi disc brakes in the drive wheel units after a few minutes However the truck can still roll until the drive wheel units are blocked For this reason the parking brake must always be applied before you leave the truck If you park the truck without applying the par...

Page 261: ...splay the truck will remain stationary The accelerator must be checked Notify the authorised service centre SWITCH OFF TRUCK message If the message SWITCH OFF THE TRUCK appears on the display the switching off of the truck is verified Press the corresponding softkey on the display and operating unit to switch off the truck or cancel the operation PARKING BRAKE ACTIVE message If the electric parking...

Page 262: ...e safety risks Lower the load fully before leaving the truck 7312_003 071_en_V2 The fork is not lowered If the fork is above the height sensor the key switch is turned off and the seat vacated the LOWER FORKS message appears in the display variant An optional signal tone sounds Lower the fork to the ground The message LOWER FORKS disappears STEERING message If the STEERING message appears in the d...

Page 263: ...VERTICAL POSITION appears on the display calibration of the vertical lift mast position has been activated Save the mast position or cancel the calibration 7312_003 072_en_V3 REFERENCE CYCLE message If the fork was lowered after the truck was switched off the control electronics do not know the position of the fork when the truck is restarted The truck will only travel at a reduced driving speed D...

Page 264: ...ng used incorrectly the truck will only drive slowly or optionally 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 ...

Page 265: ...H 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 ...

Page 266: ...r 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 c...

Page 267: ...ed 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 wor...

Page 268: ... impaired notify your authorised service centre NOT VALID message If the message 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 NOTE Some of the following messages are equip ment specific and may not appear on the display and operating unit of every truck The followin...

Page 269: ...article filter system must be repaired by the authorised service centre To avoid damage take the truck out of operation until it is repaired Notify the authorised service centre CUTOUT MODE message When automatic shut off is activated the message CUTOUT MODE appears on the display see the section entitled Automatic shut off of the internal combustion engine variant Sit on the driver s seat The mess...

Page 270: ...UALITY message This truck is equipped with a sensor that measures the quality of the exhaust gas cleaned using AdBlue If the quality of the exhaust gas deteriorates the ADBLUE QUALITY message appears on the display and operating unit If the exhaust gas quality deteriorates further the driving speed is limited to 5 km h Maintain the quality of the AdBlue see the section entitled Maintenance data ta...

Page 271: ...an error The truck remains operational However the fuel consumption increases marginally Contact the authorised service centre in order to rectify the error HYDRAULIC PUMP message If the HYDRAULIC PUMP message appears on the display there was an error in the hydraulic pump volume control The engine can be overloaded and stall as a result of the overload This causes the assisted steering and regene...

Page 272: ... Cleaning the radiator checking for leaks EMPTY message If the message EMPTY flashes on the display the gas supply is almost exhausted Change the LPG cylinder or fill the LPG tank ALTERNATOR message If the ALTERNATOR message appears in the display this means that the alternator is no longer charging the starter battery This may have the following causes Drive belt loose or damaged The electrics to o...

Page 273: ...n the display the filter insert or the filter cartridge must be replaced Replace the filter insert or the filter cartridge OIL PRESSURE message CAUTION Risk of engine damage If the OIL PRESSURE message appears in the display the engine s oil pressure is too low Stop the engine immediately The message can have different causes The engine has overheated Insufficient oil The oil is insufficiently viscous E...

Page 274: ...s required urgently Perform parked regeneration Until parked regeneration has been carried out the maximum speed of the truck is re duced to 2 km h The lifting speed is restricted PARK REG ERROR message If the message PARK REG ERROR appears on the display parked regeneration was interrupted by applying the parking brake or by a malfunction in the internal combustion engine Apply the parking brake ...

Page 275: ...he truck cannot be switched off 6210_003 050_V4 2 1 Possible malfunctions Error indication Effect Remedy LED 2 in the push button 1 flashes Parking brake malfunction It cannot be guaranteed that the parking brake has been applied properly It may still be possible to actuate the parking brake by pressing the push button 1 Park the truck safely Notify the authorised service centre LED 2 in push butto...

Page 276: ...he parking brake fails to release The drive unit is locked The error message flashes every 30 seconds for five seconds Try again to release the parking brake via the push button 1 If this solution does not work park the truck safely and notify the service centre If the truck needs to be moved because it is in the way release the parking brake manually See the chapter entitled Emergency operation of ...

Page 277: ...ror number X6510 Malfunction in the parking brake The drive unit remains active as long as the contactor is closed Creep mode is possible once the parking brake has been released 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 ...

Page 278: ...e parking brake will make a noise when it is released If the malfunction in the parking brake persists it will not be possible to release the parking brake Actuating a faulty parking brake when the truck is in motion Press push button The 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 multi...

Page 279: ...the display and operating unit If the driver now 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 174749 EN 0...

Page 280: ...SC 3 soft key The message SWITCH OFF TRUCK will appear on the display and operating unit To continue switching off the truck press the soft key 4 To abort the process for switching off the truck press the ESC 5 soft key 268 174749 EN 03 2017 ...

Page 281: ...olling away be cause the parking brake is not applied Use wheel chocks to prevent the truck from rolling away Notify the authorised service centre so that it can repair the parking brake Refuelling Diesel fuel Specifications CAUTION Risk of component damage if non approved fuels are used Use only approved fuels with the following specifi cations If non approved fuels are used compliance with the spe...

Page 282: ...l regula tions The following are not permitted Admixtures of petroleum kerosene or additional fluidity additives Distillate fuels for marine engines Jet fuels Biodiesel fuels US fuels in line with the ASTM D 975 1 D S500 or ASTM D 975 2 D S500 stan dards If necessary query with the authorised service centre Ensure compliance with parameters including the following limit values in accordance with EN...

Page 283: ...th a sulphur content of 1 0 m m are also not permissible due to high corrosion and a significant lifetime reduction of the engine Winter operation with diesel fuel CAUTION Adding petrol can lead to malfunctions in the fuel injection system Do not add petrol Do not add petroleum kerosene or additional fluidity additives If necessary query with the authorised service centre During winter operation spe...

Page 284: ...ifferently in individual countries Light fuel oils and non road fuels are suitable for the engine as long as compliance with the limit values of EN 590 is ensured Use only sulphur free diesel fuels in accor dance with manufacturer specifications The operating company is obligated to check the permissibility of the fuel used in accordance with national regulations 272 174749 EN 03 2017 ...

Page 285: ...re filling up When refuelling smoking or the use of an open flame is strictly forbidden Legal regulations relating to the handling of diesel fuel must be observed Note safety regulations for working with diesel fuel see Chapter Die sel fuel P 2 48 CAUTION The truck may only be operated with diesel fuel according to DIN EN 590 otherwise there is a risk of engine damage Use of fuel additives supportin...

Page 286: ...4 Operation Refuelling 7312_003 001_V2 2 Top up with clean diesel fuel for the maxi mum filling quantity see Chapter Main tenance data table P 5 314 274 174749 EN 03 2017 ...

Page 287: ...a risk of short circuit Adhere strictly to the following steps Before cleaning switch the electrical system off so that there is no voltage Do not spray drive units and electrical components or their covers directly with water CAUTION Failure to follow these instructions could result in damaged components The engine must be switched off during washing Water should not be used for cleaning the area...

Page 288: ...ustible materials in the engine compartment DANGER Flammable fluids can be ignited by hot components on the truck causing a risk of fire Adhere strictly to the following steps Do not use flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials CAUTION Abrasive cleaning materials can damage compo nent surfaces Using abrasive cleaning materials that are uns...

Page 289: ...ften the truck is cleaned the more frequently it must be lubricated 7071_003 091 Cleaning the electrical system CAUTION Cleaning electrical system parts with water can damage the electrical system Cleaning electrical system parts with water is forbidden Use dry cleaning materials in ac cordance with the manufacturer s specifications Do not remove covers etc Clean the electrical system parts with a ...

Page 290: ...veral times during this procedure Immediately after drying the chain spray it with chain spray Move the chain several times during this procedure For chain spray specifications see the Main tenance data table chapter ENVIRONMENT NOTE Dispose of any fluid that has been spilled or collected in the collection vessel in an environmentally friendly manner Follow the statutory regulations Cleaning the win...

Page 291: ...nergise the drive unit The truck will not be held on a slope by the electric brake Use the emergency off switch only there is a risk of fire or to carry out a functional test To brake actuate the service brake WARNING There is no power steering when the emergency off switch is actuated The truck is equipped with a hydraulic power stee ring system When the emergency off switch is actuated the hydrau...

Page 292: ... speed when the accelerator pedal is released according to the drive program selected The truck will coast The electric brake does not function during the first part of brake pedal travel To brake the truck using the mechanical brake the brake pedal must be pushed down further The truck can only be held on a slope using the mechanical brake not the electric brake No power steering effect Steering f...

Page 293: ...ure if truck tips over DANGER If the truck tips 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 le...

Page 294: ...mer WARNING When glass is smashed there is a risk of injury caused by glass splinters When the cab glass is smashed splinters of glass can shoot into the face 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 supp...

Page 295: ...egulated by unscrewing the emergency lowering screw Note the following list Remember the following Tightening torque max 2 5 Nm When unscrewed a little The load lowers slowly When unscrewed a lot The load lowers quickly NOTE The valve block is located under the bottom plate A hexagon socket wrench 1 is moun ted on the valve block support The hexagon socket wrench must remain in the truck at all ti...

Page 296: ...er blocked there is an increased risk of accidents After the emergency lowering procedure have the malfunction rectified Notify the authorised service centre 3 6210_003 051_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 swi...

Page 297: ...arkedly and the truck is held securely The effort required is not great To release the parking brake rotate the hand wheel anticlockwise a maximum of 5 revolutions until the hand wheel can be turned easily After manual operation the hand wheel is to be returned to its latch position and the cover to its normal position Disconnecting the battery The negative battery terminal is fitted with a quickly...

Page 298: ... 1 Jump starting DANGER Risk of explosion due to spark discharge If the electrical system on the truck is switched on or a live cable touches a metal part of the truck this can cause a spark discharge Any escaping gas may explode as a result If the truck has not been used for a long period of time and before starting work ensure that the closed room is well ventilated before operating the truck Th...

Page 299: ...leads Connect the positive cable 2 to the positive terminal on the discharged battery Connect the positive cable to the positive terminal on the current giving battery Connect the negative cable 1 to the negative terminal on the current giving battery Connect the negative cable to negative terminal on the discharged battery CAUTION The vibrations produced when the engine is started can cause the j...

Page 300: ...s from the unbraked towed load total actual weight of the truck Check the pulling and braking force of the towing vehicle DANGER The truck could drive into the towing vehicle when the towing vehicle brakes There is a risk of acci dent If a rigid connection has not been used during towing for the power transmission in two directions the truck may drive into the towing vehicle when the towing vehicl...

Page 301: ...icle and the truck CAUTION Steering is tight There is no power steering if the hydraulics fail The selected towing speed must allow braking and control of the truck and towing vehicle at all times CAUTION If the truck is not steered while it is being towed it may veer out uncontrollably The truck to be towed must also be steered by a driver The driver of the truck to be towed must sit in the drive...

Page 302: ...following weights Tare weight truck Ballast weight truck Net weight attachment 100 kg allowance for driver Actual total weight Maintain a safe distance from edges loading bridges ramps working platforms etc Steering movements can cause the tail end to veer off the loading bridge towards the edge This may cause the truck to crash Park the truck securely see Chap ter Parking the truck securely and s...

Page 303: ...Setting chocks Secure both the front and rear wheels with two chocks apiece to prevent the truck from sliding or rolling away Lashing 6321_003 104 1 Attach lashing straps 1 to both sides of the truck and lash the truck to the rear 174749 EN 03 2017 291 ...

Page 304: ...ff 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 complete truck including the lift mast for its initial commissioning For application conditions that require frequent loading or that are not presented here plea...

Page 305: ...allast weight variant 2 Attachment net weight variant Loading weight 3 7321_003 012 Hooking on the lifting straps CAUTION Harnesses may damage the truck s paintwork Harnesses can damage paintwork by chafing and pressing on the surface of the truck Hard or sharp edged harnesses such as wires or chains can quickly damage the surface Use textile harnesses e g lifting straps with edge protectors or sim...

Page 306: ...ruck hangs level when lifted Connect the lifting straps to the lifting eye and insert the safety device 5 CAUTION Incorrectly fitted harnesses may damage attach ment parts Pressure from the harnesses can damage or destroy attachment parts when the truck is lifted Take particular care to ensure that the fuel system is not damaged or destroyed In some circumstances diesel fuel may leak from the damag...

Page 307: ...d fashion it may crush people There is a risk to life Never walk or stand underneath suspended loads Do not allow the truck to bump into anything whilst it is being lifted or allow it to move in an uncontrolled way If necessary hold the truck using guide ropes Carefully lift the truck and set it down at the intended location Shutdown Shutting down and storing the truck CAUTION Component damage due...

Page 308: ...n water NOTE Store only fully charged batteries Measures before shutdown Store the truck in a dry clean frost free and well ventilated environment Clean the truck thoroughly see the chapter entitled Cleaning Lift fork carriage to full extent several times Tilt the lift mast forwards and backwards several times and if fitted move attachment repeatedly To relieve the strain on the load chains lower t...

Page 309: ...orage for longer than six months it must be carefully checked before being put back into service As in the annual inspection this check should also include all safety items for the truck Clean the truck thoroughly Oil joints and controls Check battery condition and acid density recharge if necessary Restore engine to normal condition accord ing to regulations of engine manufacturer Check hydraulic...

Page 310: ...4 Operation Shutdown 298 174749 EN 03 2017 ...

Page 311: ...5 Maintenance ...

Page 312: ...onally or start up inadvertently If required have the truck jacked up by the authorised service centre Have the raised fork carriage or the ex tended lift mast secured against accidental lowering by the authorised service centre Insert an appropriately sized wooden beam as an abutment between the lift mast and the cab and secure the lift mast to prevent it tilting backwards unintentionally Observe...

Page 313: ... etc is only permitted with approval from the authorised service centre Working on the ignition system To prevent personal injury and or destruction of the ignition system please observe the following Only connect and disconnect ignition system lines including high voltage lines and measuring device lines with the ignition switched off If the engine is to be operated at starting speed but not actu...

Page 314: ...ested for the necessary safety and load capacity Only have the truck raised and jacked up by the authorised service centre Only jack the truck up at the points specified in the workshop manual The truck must be raised and jacked up for various types of maintenance work The authorised service centre must be informed that this is to take place Safe handling of the truck and the corresponding hoists i...

Page 315: ...ximum length matching the total width b1 of the truck is recommended Obtain the dimensions b1 and b3 from the corresponding VDI datasheet 1 2 3 6210_001 030_V3 Clamp the hardwood beam 1 between the driver protection structure 2 and the lift mast 3 Removing the lift mast DANGER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service te...

Page 316: ...esting forklift trucks Maintenance work without special qualifications Simple maintenance work e g checking the hydraulic oil level may be carried out by untrained personnel A qualification like that of a specialist is not required to carry out this work The required operations are described in sufficient detail in the corresponding places in these operating instructions Information for carrying out ...

Page 317: ...ck 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 Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components CAUTION Risk of component damage Any deviating technical in...

Page 318: ...5 Maintenance General maintenance information 306 174749 EN 03 2017 ...

Page 319: ...ls Check tyres for wear and check the air pressure Check wheels for damage and check the tightening torques Power unit Drive axle Check the screw joints check for leaks and clean the cooling fins Gearbox oil Check oil level Internal combustion engine Check the condition of the internal combustion engine visual inspection Change engine oil and oil filter Check toothed belt spur gears and V belt LPG R...

Page 320: ...or leaks Check that the steering wheel is securely attached and check the turning handle for damage Steering axle Check that the steering axle is securely attached check for leaks and apply grease Check the steering stop Brake Check the condition of all mechanical brake parts and check for correct function Perform brake test Electrical system Check all power cable connections Check the switches tr...

Page 321: ...ork carriage for damage and wear Check the fork arm interlock for damage and correct function Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Special equipment Check the heating system for damage clean the air filter and replace as required observe the manufacturer s maintenance instructions Check the attachments for wear and...

Page 322: ...5 Maintenance General maintenance information 310 174749 EN 03 2017 ...

Page 323: ... years LPG system Change all the hoses on the LPG system Hydraulics Change the hydraulic oil Replace the return line filter breather filter and high pressure filter variant 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...

Page 324: ...n the maintenance data table Oil and grease types of a different quality must not be mixed This negatively affects 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 ...

Page 325: ...the lift mast C Load chains D One lubricating nipple on each of the two lift mast bearings 1 See the following chapter Maintenance data table under this Code for the respective lubricant specificationThis lubrication plan describes the series production truck with standard equipment For maintenance points on variant trucks see the relevant chap ter and or instructions provided by the manufacturer 1...

Page 326: ...ID no 0147873 As required Battery Code Unit Operating material Specification Quantity System contents Distilled water As required Insulation resistance For further information refer to the work shop manual for the truck in question Electrical system Code Unit Operating material Specification Quantity Insulation resistance For further information refer to the work shop manual for the truck in questio...

Page 327: ... For further information refer to the workshop manual for the truck in question A Axle stub bearings track rod bearings Grease Aralub 4320 DIN 51825 KPF2N20 ID no 0148659 Fill with grease until a small amount of fresh grease escapes Drive axle Code Unit Operating material Specification Quantity Wheel nuts screws Torque wrench For further information refer to the workshop manual for the truck in que...

Page 328: ... C ID no 0156428 As required Cooling system Code Unit Operating material Specification Quantity System contents Corrosion inhibitor and cooling system protecting agent water G12 plus TL VW 774 F Approx 9 l Fuel tank Code Unit Operating material Specification Quantity System contents Diesel fuel EN 590 DIN 51628 ASTM D975 NATO F 54 non road fuels light fuel oils EN 590 quality Approx 58 l Engine Code...

Page 329: ...teering column P 4 80 Slide the driver s seat 2 all the way for wards see Chapter Adjusting the MSG 65 MSG 75 driver s seat P 4 75 For trucks with a rear window variant fold the seat backrest forwards see Chap ter Adjusting the MSG 65 MSG 75 driver s seat P 4 75 Remove all protruding ob jects from the shelf 7300_003 007_V2 4 Firmly insert a narrow screwdriver into the slot 4 of the bonnet release ...

Page 330: ...bottom plate CAUTION Risk of short circuit if cables are damaged Check the connection cables for damage When removing and reinstalling the bottom plate make sure that the connecting cables are not damaged NOTE The accelerator pedal is attached to the bottom plate and is removed with the bottom plate The connecting plug for the accelerator is located underneath the bottom plate Open the bonnet Remo...

Page 331: ...isk of crushing between the bottom plate and the frame edge If limbs or objects are between the bottom plate and frame edge when the bottom plate is closed they can be crushed Make sure that when you close the bottom plate there is nothing between the bottom plate and the frame edge Position the bottom plate at the front Connect the connection assembly to the accelerator pedal Carefully guide the ...

Page 332: ...after first 50 operating hours Maintenance during the break in period 7311_003 026 1 Check status and tension of V ribbed belt 1 see Chapter Checking theribbed V belt P 5 343 Check exhaust system see Chap ter Checking the exhaust gas system P 5 343 320 174749 EN 03 2017 ...

Page 333: ...ling fluid level is low this indicates a leak in the cooling system Check whether the leakage has been eliminated If not notify the authorised service centre Close the bonnet Topping up the cooling fluid and checking the coolant concentration CAUTION Risk of engine damage If the cooling fluid level is low this indicates a leak in the cooling system Check the cooling system for leaks see the chapter e...

Page 334: ...protection is required for climatic rea sons the percentage of coolant can be increased to up to 60 The percentage of coolant must not exceed 60 otherwise the frost protection is reduced In addi tion the cooling effect is also reduced Only use clean softened water for the water per centage Frost protection up to C Water percentage Coolant percentage 25 60 40 30 55 45 35 50 50 40 40 60 For details ...

Page 335: ...ing the air filter insert NOTE The air filter insert must be changed if the AIR FILTER message appears on the display and operating unit or at least every 3000 hours or every two years Open the bonnet see the chapter entitled Opening the bonnet 7312_003 146 1 Loosen the clamps 1 on the air filter housing 174749 EN 03 2017 323 ...

Page 336: ...is tilted downwards slightly CAUTION Risk of damage from contamination When taking out the filter insert block the intake opening 6 using a lint free cloth NOTE It is recommended that you change the filter insert instead of cleaning it Frequent cleaning can result in damage to the filter insert Such damage poses the risk of dust getting into the engine 324 174749 EN 03 2017 ...

Page 337: ...n angle and install in the truck using a swivel movement Ensure that the sealing lip 5 of the filter insert is seated correctly in the housing Allow the clamps 1 on the air filter housing to engage Close the bonnet 7094_121 002 1 Draining water from the fuel filter WARNING Consumables are toxic Observe safety regulations when handling Diesel fuel see Chap ter Diesel fuel P 2 48 Open the bonnet see Ch...

Page 338: ...rs the EXH GAS PURIFIER mes sage appears in the display and operating unit The particle filter must be regenerated The operating device is integrated into the display and operating unit NOTE The buttons 1 and the corresponding sym bols are assigned according to the auxiliary equipment installed The assignment shown here is an example and can deviate on the actual truck NOTE If particulate filter reg...

Page 339: ...g space DANGER Risk of fire The parking space must not be in an area containing hazardous materials or in a hall because hot combustion gases are produced from the exhaust pipe during regeneration NOTE Combustion may cause bad odours if fuel containing sulphur was used for operating the engine NOTE It is not possible to start the engine during regeneration The regeneration must be started manually ...

Page 340: ...Once the regeneration process has started switch the key switch to position 0 NOTE If the ignition is not turned off this can lead to the starter battery discharging after regenera tion is complete if the truck is not put back into service straight away After approx 25 minutes the regenera tion is complete The EXH GAS PURI FIER PLEASE WAIT message disappears The filter is free of soot again If the ...

Page 341: ...ised service centre Notify the authorised service centre Lubricating the joints and controls Oil or grease other bearing points and joints according to the maintenance data table see Chapter Maintenance data table P 5 314 Driver s seat guide Lubricate bonnet hinges at the lubricating nipple Control linkage for valves In the cab lubricate door hinges at the lubricating nipple variant Lubricate shaf...

Page 342: ...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 343: ...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 344: ...truck If you wish to use a different type of tyre on the truck from the tyres approved by the truck manufacturer or tyres from a different manufacturer you must first obtain approval 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 Checking a...

Page 345: ... same time NOTE The wear of the tyres on an axle must be approximately the same The tread depth 1 for pneumatic tyres must be at least 1 6 mm at every point on the tread Super elastic tyres variant can be worn down to the wear mark 3 Check the tread depth on all four tyres Check distance between the tyre tread and the wear mark Remove any foreign bodies imbedded in the tyre tread Checking wheel fa...

Page 346: ...03 040 1 With maintenance free batteries check the charge status at the inspection window 1 Green The battery is optimally charged Black The battery charge status is no longer optimal The battery should be recharged After recharging the indicator changes back to green Transparent light coloured The charge status is no longer adequate for reliable starting It is necessary to change the battery Char...

Page 347: ...Full Normal 1 13 1 28 Tropics 1 08 1 23 WARNING Risk of explosion Charging releases gases that are explosive While charging the surfaces of the battery cells must be free to ensure sufficient ventilation The charging area must be properly ventilated Keep bonnet open during charging avoid spark formationnear the battery Charge discharged batteries immediately until they are fully charged again The c...

Page 348: ...one that is rated for the nominal current according to Fuse assignment Close the cover to secure the fuse box Install the back covers Perform a function check If the error persists or if the fuse is still defective notify your authorised service centre Checking the hydraulic oil level CAUTION Hydraulic oils are hazardous to your health and are under pressure during operation Note safety regulation...

Page 349: ...hapter Maintenance data table P 5 314 into the filler neck until it reaches the upper marking as a maximum NOTE Use a funnel Screw in the breather filter with oil dipstick Close bonnet again ENVIRONMENT NOTE Carefully collect up any spilled oil and dispose of it in an environmentally friendly manner Checking the hydraulic system for leaks WARNING Hydraulic oil under pressure can escape from leaking ...

Page 350: ...ion or buckling A fitting is detached from the hose A fitting is badly damaged or corroded Pipes must be changed if There is abrasion with the loss of material There are unnatural deformations and detectable bending stress They are leaking 1 6210_800 020 Lubricating the lift mast and roller track Remove dirt and lubricant residue from the roller track Lubricate the roller tracks 1 of the outside mid...

Page 351: ...7321_003 091 2 1 Model RO 243 Pull out the safety handle 3 Push the hand lever 2 upwards Grease using the lubricating nipple 1 in accordance with the maintenance data table see Chapter Maintenance data table P 5 314 Close the coupling by raising the coupling pin with a suitable tool For journeys with a rigid drawbar trailer lubricate the underside of the tow bar eye and the supporting surface on t...

Page 352: ...r Maintenance data table P 5 314 Grease coupling pin tow bar eye and its supporting surface 7321_003 094 Model RO 245 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 5 314 Grease the supporting surface for the tow bar eye 340 174749 EN 03 2017 ...

Page 353: ...data table P 5 314 Grease the supporting surface for the tow bar eye 7314_003 036 1 1 1 2 3 Changing the heating system fresh air filter Open the cab door to the right Loosen the mounting screws 1 and remove the cover 2 Check the filter mat 3 for contamination If the filter mat is grey in colour replace it NOTE Change the filter mat at least every 2 months Clean the fresh air inlet by removing dust an...

Page 354: ...5 Maintenance Remaining ready for operation 342 174749 EN 03 2017 ...

Page 355: ...event failure or functional problems Crank the engine by hand while checking the ribbed V belt 1 for the following Substructure cracks initial cracks core breaks crosswise cracks Layer separation top layer tension mem bers Blowout of the substructure Fraying of the tension members Edge wear material removal frayed edges edge hardening surface cracks Checking the exhaust gas system Inspect the exha...

Page 356: ...uitable collection vessel beneath the fuel filter 1 Unscrew the fuel filter 1 ENVIRONMENT NOTE Dispose of fuel filter and the diesel fuel in accordance with applicable regulations NOTE A second fuel filter variant may be installed Both filters must be replaced Wet the sealing surface of the new fuel filter with diesel fuel and tighten the filter by hand Start the engine see Chapter Starting the engine P ...

Page 357: ...at the fuel filter 2 Change the fuel filter 2 and retighten the two clips 1 7094_810 004 Checking the lift cylinders and connections for leaks WARNING Risk of injury Observe safety regulations for working on the lift mast see the Working at the front of the truck chapter Check the hydraulic connections and lift cylinder for leaks visual inspection Have leaking screw joints or leaking hy draulic cyli...

Page 358: ...Check the fork latch 3 for correct opera tion Check that the locking screw 2 is secured and cannot fall out of the fork arms Replace any worn or deformed fork arms CAUTION Fork arms must not be uneven Always replace both fork arms 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 ...

Page 359: ...6 Technical data ...

Page 360: ...6 Technical data Dimensions Dimensions 1 Seat is adjustable 90 mm 2 Fork spacing is adjustable 348 174749 EN 03 2017 ...

Page 361: ...ont axle RX70 16 791 mm RX70 18 828 mm RX70 20 837 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 174749 EN 03 2017 349 ...

Page 362: ...el Diesel Diesel Operation Seated Seated Seated Load capacity load Q kg 1600 1800 2000 Load centre of gravity distance c mm 500 500 500 Load distance X mm 395 395 405 Wheelbase Y mm 1450 1487 1526 Weights Model RX70 16 RX70 18 RX70 20 Type number 7311 7312 7313 Net weight kg 2706 2856 3059 Axle load with front load kg 3817 4149 4568 Axle load with rear load kg 489 507 491 Axle load without front l...

Page 363: ...t mast retracted h1 mm 2160 2160 2160 Free lift h2 mm 150 150 150 Lift height h3 mm 3230 3230 3150 Height with lift mast extended h4 mm 3873 3873 3725 Height to top of overhead guard h6 mm 2117 2117 2117 Seat height h7 mm 1015 1015 1015 Coupling height h10 mm 474 474 474 Total length l1 mm 2975 3012 3061 Length including fork back l2 mm 2175 2212 2261 Total width b1 mm 1099 1099 1138 Fork arm thic...

Page 364: ...wering speed with load m s 0 59 0 59 0 59 Lowering speed without load m s 0 59 0 59 0 59 Pulling force with load N 13 000 13 000 13 000 Pulling force without load N 6700 6700 6700 Climbing capability1 with load 27 26 26 Climbing capability without load 28 28 28 Acceleration time with load s 4 9 5 0 5 1 Acceleration time without load s 4 6 4 7 4 7 Service brake electr hydr electr hydr electr hydr C...

Page 365: ...0 4 1900 Fuel consumption2 in accordance with the VDI cycle l h 1 9 2 0 2 2 Other Model RX70 16 RX70 18 RX70 20 Type number 7311 7312 7313 Traction controller type Stilltronic Stilltronic Stilltronic Working pressure for attachments bar 230 230 230 Oil volume for attachments l min 30 30 30 Capacity of fuel tank l 58 58 58 Noise level LpAZ driver s compart ment 3 dB A 74 74 74 Tow coupling DIN type...

Page 366: ...seat 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 ...

Page 367: ...Technical data 6 Ergonomic dimensions 174749 EN 03 2017 355 ...

Page 368: ...options servo hydraulics 10 A 1F17 Time delay relay terminal 15 10 A 1F18 12 V options servo hydraulics 10 A 1F19 12 V engine control unit ECU 10 A 1F21 Engine control unit components 15 A 1F22 Engine control unit components 15 A 4F01 Signal horn 10 A 9F03 12 V Option Board 15 A 9F04 Starter terminal 50 30 A 9F6 Engine glow plug relay diesel trucks only 50 A NOTE Depending on the specification not ...

Page 369: ...ntrolling using the joystick 4Plus and the 5th function 201 Controlling using the quadruple mini lever and the 5th function 198 Controlling using the triple mini lever and the 5th function 194 Controlling via the joystick 4Plus 200 Controlling with a quadruple mini lever 196 Controlling with a triple mini lever 192 Controlling with the fingertip 202 Controlling with the fingertip and 5th function 20...

Page 370: ...al system 277 Cleaning the truck 275 Cleaning the windows 278 Climbing into the truck 73 Climbing out of the truck 73 Clipboard 230 Closing the bonnet 317 Closing the cab door 224 Closing the side windows 225 Condition of the roadways 121 Consumables 45 Coolant and cooling fluid safety information 50 Disposal 50 Safety information for diesel fuel 48 Safety information for handling battery acid 47 S...

Page 371: ...carriage 153 Tilting the lift mast 153 Driver rights duties and rules of behaviour 25 Driver s cab Use 97 Drivers 25 Driveways 119 Driving Ascending gradients 139 Descending gradients 139 Driving lights Switching on and off 209 Driving on lifts 180 Driving on loading bridges 181 E Eberspächer particle filters Changing the fuel filter 345 Regeneration 326 EC declaration of conformity in accordance wi...

Page 372: ... Overview 8 Impermissible use 12 Information for carrying out mainte nance 304 Maintenance timeframe 305 Information symbols 17 Insulation testing 44 Insurance cover on company premises 27 Interior lighting 226 Issue date of the operating instructions 17 J Jacking up 302 Joystick 4Plus 63 Fork carriage sideshift 157 Lifting lowering the fork carriage 156 Tilting the lift mast 157 Jump starting 286...

Page 373: ...ft mast 315 Load chains 316 Steering axle 315 Tyres 315 Washer system 316 Maintenance during the break in period 320 Maintenance work without special qualifications 304 Malfunctions during lifting mode 150 Malfunctions in the electric parking brake 263 Measuring the insulation resistance of the electrical system 44 Medical equipment 32 Message VERTICAL POSITION 251 ACCELERATOR 249 ADBLUE FILLING LE...

Page 374: ...ng the bonnet 317 Opening the cab door 223 Opening the side windows 224 Operating company 24 Operating devices for hydraulic and driving functions 59 Operating materials Quality and quantity 312 Operating procedures 20 Operating the service brake 130 Operating the signal horn 94 Ordering spare parts and wearing parts 311 Overall view Driver s compartment 57 Overhead guard Drilling 29 Roof loads 29...

Page 375: ...ip ment 300 Working on the ignition system 301 Safety regulations for working on the lift mast 302 Safety regulations when driving 117 Safety regulations when handing loads 165 Schematic views 20 Scope of the documentation UPA solutions 16 Seat belt 94 Checking 330 Cleaning 331 Fastening 95 Fastening on a steep slope 96 Maintaining 330 Malfunction due to cold 96 Releasing 96 Replacement after an a...

Page 376: ...ternal combustion engine 140 Clamp locking mechanism 205 Clipboard 230 Cruise control 218 Emergency off switch 80 FleetManager 217 Fork extension 161 Hi Lo lift mast 149 Lift mast vertical position 144 Lifting systems 143 Load measurement 167 Push up roof window 229 Radio 227 Reducing speed with a raised load 140 Reversible fork arms 163 Shock recognition 218 Triplex lift mast 150 Wheel chock 142 ...

Page 377: ...ing at the front of the truck 302 Working on the electrical equipment 301 Working on the hydraulic equipment 300 Working on the ignition system 301 Working spotlights Automatically switching on off 215 Lift height controlled switching on off 215 Manually switching on off 214 Switching on and off 209 214 Z Zero adjustment of the load measure ment 102 174749 EN 03 2017 365 ...

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