Still RX70-20/600 Original Instructions Manual Download

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LPG trucks

RX70-20/600

RX70-25

RX70-25/600

RX70-30

RX70-30/600

RX70-35

Original instructions

7400 7401 7402 7403 7404 7405

573

8011501 EN - 10/2020 - 04

Summary of Contents for RX70-20/600

Page 1: ...LPG trucks RX70 20 600 RX70 25 RX70 25 600 RX70 30 RX70 30 600 RX70 35 Original instructions 7400 7401 7402 7403 7404 7405 57378011501 EN 10 2020 04 ...

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

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Page 5: ...cumentation 17 Issue date and topicality of the operating instructions 18 Copyright and trademark rights 18 Explanation of information symbols used 18 Definition of directions 19 Schematic views 19 List of abbreviations 20 Environmental considerations 22 Packaging 22 Disposal of components and batteries 22 2 Safety Definition of responsible persons 24 Operating company 24 Specialist 24 Drivers 25 ...

Page 6: ...pections on the LPG system 42 Regularly checking the level of harmful substances in the exhaust gas 43 Insulation testing 44 Safety regulations for handling consumables 45 Permissible consumables 45 Oils 46 Hydraulic fluid 47 Battery acid 48 LPG 49 Coolant and cooling fluid 52 Brake fluid 52 Disposal of consumables 54 Emissions 55 3 Overviews Overview 60 Driver s compartment 61 Shelves and cup hol...

Page 7: ...dinal horizontal suspension variant 94 Seat belt 95 Pre Shift Check 98 Description of the Pre Shift Check variant 98 Process 99 All questions 100 Defining the question sequence 102 Displaying the history 103 Defining the shift start 105 Resetting the truck restrictions 109 Driver profiles 112 Driver profiles variant 112 Selecting driver profiles 112 Creating driver profiles 114 Renaming driver pro...

Page 8: ... programmes A and B 155 Selecting the drive direction 157 Actuating the drive direction switch with the mini lever version 158 Actuating the vertical rocker button for the drive direction Joystick 4Plus version 158 Actuating the drive direction switch with the Fingertip version 158 Actuating the drive direction switch mini console version 159 Starting drive mode 159 Starting drive mode dual pedal ...

Page 9: ...1 Fork extension variant 204 Operation with reversible fork arms variant 206 Handling loads 208 Safety regulations when handing loads 208 Before taking up load 209 Load measurement variant 211 Picking up loads 212 Danger area 212 Transporting pallets 213 Transporting suspended loads 214 Picking up a load 215 Transporting loads 218 Setting down loads 219 Shake function variant 221 Driving on lifts ...

Page 10: ...and windscreen washers variant 259 Filling the washer system 261 FleetManager variant 261 Shock recognition variant 261 Driver restraint systems variants 262 Ceiling sensor variant 262 Cab 268 Opening the cab door 268 Closing the cab door 269 Opening the side windows 270 Closing the side windows 270 Turning the interior lighting on or off variant 271 Operating the rear window heating 271 Radio var...

Page 11: ...1 Towing 322 Transporting the truck 325 Transporting 325 Crane loading 327 Short term operation 331 Decommissioning 332 Shutting down and storing the truck 332 Returning to service after decommissioning 333 5 Maintenance Safety regulations for maintenance 336 General information 336 Working on the hydraulic equipment 336 Working on the electrical equipment 335 Working on the ignition system 337 Wo...

Page 12: ...3 Cleaning the radiator checking for leaks 364 Check the cooling fluid level 364 Topping up the cooling fluid and checking the coolant concentration 365 Replacing the air filter cartridges 367 Lubricating the joints and controls 369 Maintaining the seat belt 370 Checking the driver s seat 372 Checking the door latch 372 Maintaining wheels and tyres 372 Maintaining the battery 375 Replacing fuses 3...

Page 13: ...ecking the LPG tank variant 389 6 Technical data Dimensions 392 VDI datasheet for RX70 20 600 and RX70 25 394 VDI datasheet for RX70 25 600 and RX70 30 398 VDI datasheet for RX70 30 600 and RX70 35 402 Ergonomic dimensions 406 Fuse assignment 407 Table of contents XI 57368011501 EN 10 2020 04 ...

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Page 15: ...1 Foreword ...

Page 16: ... 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 regen erative brake of the electric traction motor takes effect The regenerative brake converts the acceleration energy o...

Page 17: ...in the lift line due to uneven ground for example Drive concept The internal combustion engine drives an electric three phase generator The generated current is routed to two maintenance free electrical 11 7 kW three phase AC traction motors which drive the truck using the two front wheels Electronic revolution control gen tly provides high torque for both forwards and backwards travel The compone...

Page 18: ...ruck features either sin gle pedal or dual pedal operation The accel erator pedal is used to accelerate and brake electric brake the truck In emergency situa tions or when carrying heavy loads the driver can also brake the truck using the service brake by pressing the brake pedal In dual pedal operation the truck has one pedal for the Forwards drive direction and one pedal for the Reverse drive di...

Page 19: ...ng the truck read the operating instructions and follow the instruc tions Always follow all of the safety information contained in the operating instructions and on the truck CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is confirmed by the issued EC declaration of conformity The CE labell...

Page 20: ...perating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH Accessories Key for key switch two pieces Key for cab variant Hexagon socket wrench for emergency low ering Foreword 1 Your truck 6 57368011501 EN 10 2020 04 ...

Page 21: ...Foreword 1 Your truck 7 57368011501 EN 10 2020 04 ...

Page 22: ...DANGER 6 4 DANGER DANGER 3 10 bar 2 2 2 3 7 9 10 8 9 WA L 10 11 11 7 8 98 1 Decal information Check head clearance Decal information Tyre filling pressure 1 2 Decal information Emergency operation of the parking brake 3 Foreword 1 Your truck 8 57368011501 EN 10 2020 04 ...

Page 23: ...al information Nameplate Decal information StVZO German Road Traffic Licensing Regulations information variant 5 6 7 8 Decal information Sound power level Decal information Load capacity Attach ment Decal information Load capacity Basic ta ble 9 10 11 Foreword 1 Your truck 9 57368011501 EN 10 2020 04 ...

Page 24: ...Labelling points on the right of the truck 5 3 1 7 10 bar 4 DANGER DANGER 6 DANGER 20xx 10 11 9 8 1 2 3 4 6 7 8 5 11 10 9 Foreword 1 Your truck 10 57368011501 EN 10 2020 04 ...

Page 25: ... information for the battery weights 5 6 and the ballast weight 7 only applies to elec tric forklift trucks Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instruc...

Page 26: ...ation 2 Model 3 Year of manufacture 4 Sequential number StVZO Road Traffic Licensing Reg ulations information This label includes information on the weight and load distribution of the truck 7090_921 004 xx xxxx x xxxxx 1 2 3 4 7094_003 098 1 2 3 4 5 Tare weight in kg Permitted total weight in kg Permitted front axle weight in kg Permitted rear axle weight in kg Payload in kg 1 2 3 4 5 Foreword 1 ...

Page 27: ...ter entitled Before picking up a load Proper use during towing This truck is suitable for the occasional towing of trailers and is equipped with a towing de vice 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 ob...

Page 28: ...being used The ground must have an adequate load ca pacity concrete asphalt and a rough surface Routes working areas and aisle widths must conform to the specifications in these operat ing instructions see chapter entitled Routes Driving on upward and downward gradients is permitted provided the specified data and specifications are observed see chapter enti tled Routes The truck is suitable for u...

Page 29: ...her poisonous gases There is a risk of fatal injury Only operate the truck in areas that are well venti lated Using working platforms WARNING The use of working platforms is regulated by national law The use of working platforms is only permitted by virtue of the jurisdiction in the country of use Observe national legislation Before using working platforms consult the na tional regulatory authorit...

Page 30: ...ants available at the time of printing Special versions to meet customer require ments UPA are documented in separate op erating instructions If you have any questions contact your au thorised service centre Enter the production number and year of man ufacture from the nameplate in the space pro vided Production number Year of manufacture Please quote the production number in all technical enquiri...

Page 31: ...rovements or if you have found any errors please contact the authorised service centre Supplementary documentation This industrial truck can be fitted with unplan ned equipment UPA that deviates from the standard equipment and or the variants The UPA may be for example Special sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documen...

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

Page 33: ...ew of functions and operating proce dures At many points in this documentation the mostly sequential operation of certain func tions or operating procedures is explained Schematic diagrams of a counterbalance truck are used to illustrate these procedures NOTE These schematic views are not representative of the construction of the documented truck The views are used solely for the purpose of clarif...

Page 34: ...G Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations CE Communauté Européenne Confirms conformity with product specific European directives CE labelling...

Page 35: ...imum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without loose rim parts StVZO Straßenverkehrs Zulassu...

Page 36: ...osal of components and batter ies The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man...

Page 37: ...2 Safety ...

Page 38: ...ication that demonstrably proves their professional ex pertise This proof should consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven pe riod during their career During this time this person has become familiar with a wide range of symptoms that require checks to...

Page 39: ... be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety hel met industrial goggles and gloves that is ap propriate for the conditions the job and the load to be lifted Solid footwear should be worn to ensure safe driving and braking The driver must be familiar with the operating instruction...

Page 40: ...e for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety 2 Definition of responsible persons 26 57368011501 EN 10 2020 04 ...

Page 41: ... and stability of the truck and can result in accidents Any modifications that adversely affect the stability the load capacity or the circumferen tial view of the truck require written approval from the manufacturer The following components may only be modi fied with prior written approval from the manu facturer Brakes Steering Operating devices Safety systems Equipment variants Attachments The t...

Page 42: ...trucks The design office must comply with the standards and directives valid at the time that modifica tions are made Decal information with the following data must be permanently affixed to the truck so that it is clearly visible Type of modification Date of modification Name and address of the company that car ried out the modification Changes to the overhead guard and roof loads DANGER In the e...

Page 43: ...on of the truck is also no longer permitted Warning regarding non original parts Original parts attachments and accessories are specially designed for this truck We spe cifically draw your attention to the fact that parts attachments and accessories supplied by other companies have not been tested and approved by STILL CAUTION Installation and or use of such products may there fore have a negative...

Page 44: ...manufacturer s written appro val All electrical system interventions must be documented Even if they are removable roof panels may not be removed as they are designed to pro tect against small falling objects Tyres DANGER Risk to stability Failure to observe the following information and in structions can lead to a loss of stability The truck may tip over risk of accident The following factors can...

Page 45: ...g always replace right hand and left hand wheels at the same time Changes must only be made following consultation with the manufacturer If the type of tyre used on an axle is changed for example from superelastic tyres to pneu matic tyres the load diagram must be changed accordingly Contact the authorised service centre on this matter Medical equipment WARNING Electromagnetic interference may occ...

Page 46: ...must be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper in stallation of an accumulator results in an elevated risk of injury Before starting work on the accumulator it must be depressurised Contact the authorised service centre Length of the fork arms DANGER Risk of accident due to the incorrect selection of fork arms The fork arms m...

Page 47: ... For help with selecting the correct fork arms contact the authorised service centre Safety 2 Basic principles for safe operation 33 57368011501 EN 10 2020 04 ...

Page 48: ...nstructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regula tions in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Falling tripping etc wh...

Page 49: ...st slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as cen trally as possible with the truck and trans port in this position Avoid turning and diagonally driving across slopes or gradients Never have the load facing downhill when travelling on slopes or gradients Pick up...

Page 50: ...the truck correctly and without the risk of acci dents Safety 2 Residual risk 36 57368011501 EN 10 2020 04 ...

Page 51: ...Safety 2 Residual risk 37 57368011501 EN 10 2020 04 ...

Page 52: ...rised persons O Truck not safe for op eration Periodic inspection and rectification of de fects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due t...

Page 53: ... O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Safety and Health BetrSichV DG...

Page 54: ...ds in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the German Ordinance on Indus trial Safety and Health BetrSichV and labour protection law ArbSchG the operating com pany must determine and assess hazards dur ing operation and establish the labour protec tion measures required for employees B...

Page 55: ... This overview see chapter Overview of hazards and counter measures provides help on complying with this regulation The overview specifies the main hazards that are the most frequent cause of accidents in the event of non compli ance If other major operational hazards are involved they must also be taken into consid eration The conditions of use for trucks are broadly similar in many plants so the...

Page 56: ...ions have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service centre NOTE Observe the national regu...

Page 57: ...nt in accordance with BGG 936 observe the applicable national regulations The results must be retained until the next inspection The inspection documents must be available for viewing by the authori ties at any time The type and scope of tests may differ accord ing to the country Any differing legal provi sions in the respective country of operation must be observed when using trucks with an LPG s...

Page 58: ...he truck insulation must have sufficient insu lation resistance For this reason insulation testing in accordance with DIN EN 1175 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...

Page 59: ...with a propane concentration of max 95 LPG with a butane concentration of max 80 and a propane concentration of at least 20 The LPG quality must comply with the require ments of DIN 51622 as a minimum In the best case scenario the LPG complies with the requirements of EN 589 automotive gas Condition of the LPG cylinders DANGER Risk of explosion LPG cylinders must not protrude beyond the edges of t...

Page 60: ...o not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly wh...

Page 61: ...not allow the fluids to come into contact with hot engine parts WARNING These fluids are pressurised during op eration of the truck and are hazardous to your health Do not allow the fluids to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the skin is particularly dangerous if these fluids escape at high pressure due to leaks in the hydraulic system In c...

Page 62: ...edical advice immediately WARNING Battery acid contains dissolved sulphuric acid This is corrosive When working with battery acid use appropriate PSA rubber gloves apron protection goggles When working with battery acid nev er wear a watch or jewellery Do not allow any acid to get onto clothing or skin or into the eyes If this does happen rinse immediately with plenty of clean water In case of inj...

Page 63: ...r or more NOTE In these operating instructions liquid gases are called LPG DANGER Risk of explosion LPG immediately be comes gaseous when it escapes meaning that a hazardous explosive at mosphere is created immediately Use only anti static treated tools that do not produce sparks Anti static clothing and footwear are recommended DANGER Risk of fire No open flames stoves storm lanterns activities p...

Page 64: ...ithout liquid traps ventilation shafts and light wells or combustible material Safe use of LPG trucks The LPG system must be checked for damage and leaks at least once a year by a person qualified in LPG systems see the chapter en titled Carrying out regular safety inspections on the LPG system A person qualified in LPG systems should be hired immediately to carry out testing if you are unsure of ...

Page 65: ... installations Not in specially marked escape routes Not in garages Not in work rooms NOTE Please also observe the section entitled Gen eral requirements for pressurised gas contain ers Operating pressurised gas containers in the technical regulations for pressurised gas containers TRG 380 and 404 in addition to the relevant national guidelines Electric hand lamps used in these rooms must be equip...

Page 66: ...rs bottles or oth er containers Observe the national regulations for the country of use ENVIRONMENT NOTE Soak up any spilt coolant or cooling fluid im mediately 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 ac cordance with the national regulations for the country of use Brake fluid WARNING...

Page 67: ...d is flammable Do not allow brake fluid to come into contact with hot motor parts Smoking fires and naked flames are prohibited CAUTION Brake fluid has strong dissolving and colour chang ing properties Immediately rinse off any brake fluid that has splashed on paint clothing and shoes with plenty of water ENVIRONMENT NOTE Brake fluid is a water pollutant Always store brake fluid in containers com ...

Page 68: ...ng used Work must only be carried out in areas designated for the pur pose Care must be taken to minimise any en vironmental pollution Soak up any spilt fluids such as hydraulic oil brake fluid or gearbox oil using an oil binding agent Neutralise any spilt battery acid immediate ly Always observe national regulations con cerning the disposal of used oil Safety 2 Safety regulations for handling con...

Page 69: ...uncer tainty KpA 77 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted val ues for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal nois...

Page 70: ... 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 s2 There are therefore no meas urement guidelines for these measurements The personal vibration load on the driver over a working day must be determined by the op erating company at the actual place of use in accordance with Directive 2002 44 ...

Page 71: ...an in ternal combustion engine in entirely or partially enclosed working areas Always ensure that there is sufficient ventilation available 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 direct body contact can cause burns to the skin and materi als that are too close can be burned or singed Do not gr...

Page 72: ...Safety 2 Emissions 58 57368011501 EN 10 2020 04 ...

Page 73: ...3 Overviews ...

Page 74: ...r s compartment Starter battery LPG cylinder LPG tank variant Towing device Steering axle Drive axle 1 2 3 4 5 6 7 8 9 Fork arms Fork carriage Hydraulic connection for an attachment Front lighting variant Lift mast Front working spotlight variant Overhead guard Exhaust pipe 10 11 12 13 14 15 16 17 Overviews 3 Overview 60 57368011501 EN 10 2020 04 ...

Page 75: ... Display control unit STILL Easy Control Operating devices Compartment and storage location for oper ating instructions 1 2 3 4 5 6 7 8 Cup holder Driver s seat Accelerator pedal Brake pedal Steering column adjustment lever Parking brake 9 10 11 12 13 14 Overviews 3 Driver s compartment 61 57368011501 EN 10 2020 04 ...

Page 76: ...the footwell and slide between the pedals 3 As a re sult the pedals may get stuck This could prevent braking Stow away objects and check that objects are se cure Make sure that stored objects cannot fall from the shelf 1 when the truck sets off is steered or braked Bottles of max 1 5 l may be stored in the cup holder 2 1 2 3 7400 003 003 Overviews 3 Shelves and cup holders 62 57368011501 EN 10 202...

Page 77: ...n Scrolling buttons Right turn indicator display Back button Main display button Driving speed or parking brake Left turn indicator display Reverse drive direction indicator Forward drive direction indicator Display for direction of movement of the truck Brightness sensor 10 11 12 13 14 15 16 17 18 19 20 21 The STILL Easy Control is a display operat ing unit that serves as an operating device for ...

Page 78: ...put a label over the brightness sen sor 21 or cover it with anything This sensor allows the display to adapt to the current light conditions Operating devices for hydraulic and driving functions Different versions of the operating devices are available for operating the truck s hydraulic functions and drive functions The truck can be equipped with the following operating devices Double mini lever ...

Page 79: ...ss lever Attachments Function key for the 5th function Signal horn button 1 2 3 4 F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 Overviews 3 Operating devices and display elements 65 57368011501 EN 10 2020 04 ...

Page 80: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 5 Overviews 3 Operating devices and display elements 66 57368011501 EN 10 2020 04 ...

Page 81: ...g lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 Signal horn button F1 function key Lift mast 360 lever Display field for the hydraulic functions 5 6 7 8 Overviews 3 Operating devices and display elements 67 57368011501 EN 10 2020 04 ...

Page 82: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 6 Overviews 3 Operating devices and display elements 68 57368011501 EN 10 2020 04 ...

Page 83: ...operating lever Auxiliary hydraulics 2 operating lever Function key for the 5th function 1 2 3 4 5 Signal horn button F1 function key Lift lower operating lever Display field for the hydraulic functions 6 7 8 9 Overviews 3 Operating devices and display elements 69 57368011501 EN 10 2020 04 ...

Page 84: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 7 Overviews 3 Operating devices and display elements 70 57368011501 EN 10 2020 04 ...

Page 85: ...c function and for the clamp locking mechanism variant Pictograms for the 3rd 4th hydraulic func tion 1 2 3 4 LED for the clamp locking mechanism var iant Slider for the 4th hydraulic function e g side shift frame forwards backwards Vertical rocker button for the drive direction Shift key F Signal horn button 5 6 7 8 9 Overviews 3 Operating devices and display elements 71 57368011501 EN 10 2020 04...

Page 86: ...wer operating lever Tilt operating lever F1 function key LED for F1 7 8 9 10 11 NOTE In the dual pedal version variant the drive direction switch 7 is used exclusively to activate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 10 Overviews 3 ...

Page 87: ...uck stops in a danger area the drive direction selection lever on the travel direction selector and indicator module can be used for emergency driving Refer to the section entitled Emergency driv ing via the drive direction switch drive direction selection lever in the chapter entitled Proce dure in emergencies Drive direction selection lever Turn indicator switch 1 2 Overviews 3 Operating devices...

Page 88: ...Overviews 3 Operating devices and display elements 74 57368011501 EN 10 2020 04 ...

Page 89: ...4 Operation ...

Page 90: ... other defects are identified on the truck or the attachment variant the truck must not be used until it has been properly repaired Ensure that the truck is safe for operation each day before it is used Component Course of action Fork arms general lifting accessories Perform a visual inspection to check for deformation and wear e g to check if they are bent broken or feature significant wear Check...

Page 91: ...Coupling pin tow coupling variant Perform a visual inspection for deformation and wear for example bent torn broken Check the securing bush in the counterweight for integrity and to ensure that it is working correctly Check that the linchpin is present and working cor rectly chain rope split pin Labelling adhesive label Check for presence integrity and legibility Replace damaged or missing adhesiv...

Page 92: ...lace both tyres Observe the safety regulations in the section enti tled Tyres Axle Make sure that no consumables are escaping from the axle Engine Check the engine oil level Top up if necessary Check the coolant level Top up if necessary Do not use the truck if there is any damage or defects Contact the authorised service centre Operation 4 Checks and tasks before daily use 78 57368011501 EN 10 20...

Page 93: ...ping off the truck If your clothing or jewellery e g watch ring etc be comes 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 off the truck Do not jump off the truck Do not wear jewellery at work Do not wear loose fitting workwear CAUTION Components may become damaged through incor rect use Tr...

Page 94: ...ndle 1 with your left hand and hold on Put your left foot on the step 4 Enter the truck with your right foot first and sit down on the driver s seat 3 Always climb out of the truck backwards Grip the handle 1 with your left hand and hold on Stand up from the driver s seat and place your left foot on the step 4 Climb out of the truck right foot first 7321_003 126_V2 1 2 3 4 5 Operation 4 Checks and...

Page 95: ... signal horn button 1 The signal horn sounds NOTE The signal horn is used to warn people against imminent danger or to announce your intention to overtake 1 1 1 Operation 4 Checks and tasks before daily use 81 57368011501 EN 10 2020 04 ...

Page 96: ... is open or has been removed use a comparably secure restraint system We recommend that you always use the seat belt Checking the condition of the wheels and tyres WARNING Risk of accident With uneven wear or incorrect air pressure the stability of the truck decreases and the braking distance increases Change worn or damaged tyres without delay WARNING Risk of tipping Tyre quality affects the stab...

Page 97: ... indicated on the adhesive labels 2 must be observed NOTE Observe the safety principles outlined in the chapter entitled Tyres Checking the brake system for cor rect function DANGER Risk of accident due to failure of the brake system If the brake system fails the truck will be insufficient ly braked or will not be braked at all Do not operate the truck with a defective brake system 1 Operation 4 C...

Page 98: ... is not applied Do not exit the truck during the follow ing check Stop the truck on a steep gradient e g a ramp and actuate the parking brake The parking brake must hold the truck on the incline If the truck rolls back despite the parking brake being applied Secure the truck using the service brake Secure the truck with chocks so that the truck does not roll away Contact the authorised service cen...

Page 99: ...obstructed Accelerate the truck to walking speed Use the key switch to switch off the engine Apply the parking brake The truck must decelerate and remain station ary If the truck only coasts and does not deceler ate or decelerates only slightly Secure the truck using the service brake Secure the truck with chocks so that the truck does not roll away Have the parking brake checked and re paired by ...

Page 100: ...paired by the authorised service centre Checking the steering system for correct function DANGER If the hydraulics fail there is a risk of accident as the steering characteristics have changed Do not operate the truck if it has a defective steer ing system Operate steering wheel 1 The steering play while stationary must not be more than two finger widths NOTE If the truck is switched on with the s...

Page 101: ...utomatic mast vertical positioning function proceed as fol lows Push the automatic mast vertical position ing softkey The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast must stop in the vertical position The automatic mast vertical positioning can be used If the lift mast does not stop in the vertical position do not us...

Page 102: ...t all operating devices can be actuated safely Make sure that the seat and the seat backrest are 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 WARNING Optimum seat cushioning is better for your back and protects y...

Page 103: ... is occupied it can be difficult to release the seat backrest Release the seat backrest Lift the lever 2 and hold the lever in posi tion Push the seat backrest into the desired po sition Release the lever Make sure that the seat backrest is engag ed NOTE The backwards tilt angle of the seat backrest can be restricted by means of the truck s structure 7094_003 006 1 7094_003 008 2 Operation 4 Drive...

Page 104: ... s seat Fully fold out the weight adjusting lever 3 Pump the lever up or down to set the driv er s weight After each stroke move the weight adjust ing lever back to the centre position until the weight adjusting lever audibly engages Fully fold in the weight adjusting lever once the adjustment is complete NOTE The correct driver s weight has been selected when the arrow 4 is in the centre position...

Page 105: ... re quired position turn the turning knob 5 up or down Adjusting the backrest extension var iant The backrest extension 6 is in the seat back rest and is height adjustable To move the backrest extension into the re quired position pull up or push in the back rest extension To remove the backrest extension tug the backrest extension up past the end stop and out 6321_003 039 5 6321_003 040 6 Operati...

Page 106: ...eat position is unstable Swivel the driver s seat only while the truck is sta tionary The driver s seat designed to swivel to the right makes it easier to look back during re verse travel without having to rotate the upper body too much To swivel the seat to the right for reverse trav el Sit in the driver s seat Pull the lever 8 back and hold it in posi tion Swivel the driver s seat to the right u...

Page 107: ...ck or load to move in an uncontrolled fashion Do not adjust the armrest while driving Adjust the armrest so that all operating devices can be actuated safely Ensure that the armrest is securely tightened Adjusting the length of the armrest Release the star grip handle 1 by turning to the left Shift the armrest 2 into the desired posi tion Tighten the star grip handle by turning to the right Check ...

Page 108: ...e driver s seat again release the lever 1 Gently slide the seat back and forth to lock the seat in place Blocking the longitudinal horizontal sus pension To block the longitudinal horizontal suspen sion push down the locking lever 2 on the left hand side of the driver s seat A CAUTION Suspension comfort reduced If the longitudinal horizontal suspension is blocked the suspension comfort is signific...

Page 109: ... fixed doors constitute a driver restraint system Plastic doors weather protection do not constitute a restraint system If the doors are open or have been removed you must use an alternative suitable restraint system e g a seat belt Fastening the seat belt DANGER Risk to life when driving without a seat belt If the truck tips over or crashes into an obstacle and the driver is not wearing the seat ...

Page 110: ... against the seat backrest The auto matic blocking mechanism permits sufficient freedom of movement on the seat Click the belt tongue 2 into the buckle 1 Check the tension of the seat belt The belt should fit closely around your body Fastening on a steep slope The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient It is no longer possible t...

Page 111: ... the seat belt around 10 15 mm out of the retractor to dis engage the blocking mechanism Slowly allow the seat belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold weather condi tions If the buckle or belt retractor is frozen thaw them out and dry them thoroughly to pre vent recurrence CAUTION The seat belt may be damaged by heat Do not subject t...

Page 112: ...ompiled only the question Truck ready for operation is stored in the factory settings The authorised service centre can then restrict the truck functions in the event of a negative test result There are fixed responses No response Speed limitation Restriction of hydraulics to 33 In addition the fleet manager has the follow ing options The fleet manager can view the results of all checks via the Hi...

Page 113: ...st such as the functional test of the lighting NOTE The main display symbol appears only when it is required for the test To access the main display press the main display button or the softkey The main display contains the message To complete Pre Shift Check press This means that the Pre Shift Check is still ac tive and the truck functions are restricted To acknowledge the message press the softk...

Page 114: ...ons active shows that truck functions are restricted As long as the truck functions are restricted no further Pre Shift Check is re quested at the start of a new shift The check is only requested again after the fleet manager has reset the restrictions All questions The authorised service centre can use this question catalogue to put together the Pre Shift Check during commissioning Are the fork a...

Page 115: ... brake work properly Does the service brake work properly Does the steering work properly Does the emergency off work Is the condition of the battery obviously not OK Are all decal information and adhesive labels present and legi ble Is the load backrest undamaged Does the accelerator pedal work properly Is the engine compartment dirty or does it contain foreign ob jects Are the lift mast or the f...

Page 116: ...nsciously by the driver This means that there is no rou tine aspect Activate the Access authorisation for the fleet manager Press the Service softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre Shift Check 102 57368011501 EN 10 ...

Page 117: ...tion To access the main display press the main display button Displaying the history The fleet manager can display a Pre Shift Check history Activate the Access authorisation for the fleet manager Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Random sequence Fixed sequence 6219_003 273_en Operation 4 Pre Shift Check 103 57368011501 EN 10 2020 0...

Page 118: ...ll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre Shift Check 104 57368011501 EN 10 2020 04 ...

Page 119: ...ager can define up to three shifts and their start times The Pre Shift Check is then always requested at this time NOTE If the truck is equipped with FleetManager the shifts are defined on the FleetManager inter face See the relevant operating instructions Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Pre Shift Check results 27 09 19 15 11 nicht ok Funktioni...

Page 120: ...rvice softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operation 4 Pre Shift Check 106 57368011501 EN 10 2020 04 ...

Page 121: ...time The orange activation bar indicates which shifts are activated To edit a shift press the corresponding soft key Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operation 4 Pre Shift Check 107 57368011501 EN 10 2020 04 ...

Page 122: ... requested from this shift start time The display returns to the previous menu To deactivate a certain shift start select the relevant shift Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate Save Cancel 6219_003 272_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operation 4 Pre Shift Check 108 57368011501 EN 10 2020 04 ...

Page 123: ... main display button Resetting the truck restrictions If truck functions are restricted due to checks with a bad result the fleet manager can reset these restrictions The fleet manager can also do this if a problem on the truck has been rec tified Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate S...

Page 124: ...heck menu appears Press the Reset vehicle restrictions soft key Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Operation 4 Pre Shift Check 110 57368011501 EN 10 2020 04 ...

Page 125: ...The display returns to the previous menu To cancel press the softkey The truck functions remain restricted The dis play returns to the previous menu To access the main display press the main display button 6219_003 274_en Fleet manager Reset the truck restrictions The entry remains in the history Operation 4 Pre Shift Check 111 57368011501 EN 10 2020 04 ...

Page 126: ...r profile Selected drive programme 1 to 3 Load dynamics Efficiency and drive modes Blue Q sprint mode If a driver without an existing driver profile logs in using the Access authorisation with PIN code or FleetManager variants a driver pro file is generated This driver profile corre sponds to the settings when the truck was de livered If the truck is not equipped with these variants drivers must s...

Page 127: ... brake is applied If the parking brake is re leased prematurely the settings menu will close Stop the truck Actuate the parking brake Press the button Press the Settings softkey Press the Driver profiles soft key Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Operation 4 Driver profiles 113 57368011501 EN 10 2020 04 ...

Page 128: ...oth the fleet manager and the driver can cre ate up to ten driver profiles NOTE If the truck is equipped with the Access au thorisation with PIN code or FleetManager variants the driver profile is generated auto matically when logging in for the first time Apply the parking brake Press the button Press the Settings softkey Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Oper...

Page 129: ...on NOTE Unoccupied storage locations that do not con tain a driver profile are indicated by Availa ble storage position Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operation 4 Driver profiles 115 57368011501 EN 10 2020 04 ...

Page 130: ...then be available the next time that the driver logs in Renaming driver profiles Driver profiles can be renamed Drivers can only rename their own driver profile The fleet manager has access authorisation to rename all driver profiles Renaming by the driver Apply the parking brake Press the button Press the Settings softkey Press the Truck settings softkey Enter driver name Clear Driver name Horst ...

Page 131: ... press the button Renaming by the fleet manager Activate the Access authorisation for the fleet manager Press the Truck settings softkey Rename driver profiles Driving programme 6219_003 298_en Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Operation 4 Driver profiles 117 57368011501 EN 10 2020 04 ...

Page 132: ... softkey Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Operation 4 Driver profiles 118 57368011501 EN 10 2020 04 ...

Page 133: ...Activate the Access authorisation for the fleet manager Press the Truck settings softkey Press the Manage driver profiles softkey Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Operation 4 Driver profiles 119 57368011501 EN 10 2020 04...

Page 134: ...he driver profile to be deleted The driver profile is deleted Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operation 4 Driver profiles 120 57368011501 EN 10 2020 04 ...

Page 135: ...nt tem perature The preheating time is at least 2 hours Engine preheating can be safely used continu ously Temperature control prevents the cool ant temperature from exceeding 58 C Engine preheating CAUTION Overheating can damage the heating element Contaminants such as dirt ice air or radiator sealing compound or insufficient coolant in the cooling sys tem can cause the heating element to overhea...

Page 136: ... engine Opening the LPG cylinder valve DANGER There is a risk of explosion if LPG es capes Escaping LPG may explode when ex posed to ignition sources and cause se rious accidents Do not smoke or use a naked flame lighter Do not start the engine Close the cylinder valve Notify your authorised service centre LPG cylinders should be opened in well ventilated spaces away from openings in the ground DA...

Page 137: ...LPG cylinder valve for a double cylinder holder DANGER There is a risk of explosion if LPG es capes Escaping LPG may explode when ex posed to ignition sources and cause se rious accidents Do not smoke or use a naked flame lighter Do not start the engine Close the cylinder valve Notify your authorised service centre LPG cylinders should be opened in well ventilated spaces away from openings in the ...

Page 138: ... the upper gas cylinder 1 push the lever 2 down Open the cylinder valve 3 of the upper gas cylinder by slowly turning the star grip han dle anti clockwise Check the cylinder valve 4 of the lower gas cylinder The valve must be closed If necessary close the valve of the lower gas cylinder by turning it clockwise 1 2 4 3 Operation 4 Switching on and starting 124 57368011501 EN 10 2020 04 ...

Page 139: ...ther the hose and con nection screw joints have iced over Opening the shut off valve of an LPG tank variant DANGER There is a risk of explosion if LPG es capes Escaping LPG may explode when ex posed to ignition sources and cause se rious accidents Do not smoke or use a naked flame lighter Do not start the engine Close the shut off valve Notify your authorised service centre Only open the shut off ...

Page 140: ...valve anti clockwise Check whether it smells of gas Check whether the hose 1 is securely con nected to the LPG tank Check to see whether the hose and con nection screw joints have iced over The fill level display 4 on the LPG container displays how much LPG is available 7314_003 010 2 1 7314_003 057 4 50 60 70 80 85 90 10 20 30 40 95 5 Inhalt Operation 4 Switching on and starting 126 57368011501 E...

Page 141: ...e input menu for access authorisation Once the truck is ready for operation the main screen is shown on the display Main screen 1 Selected drive programme with driving dynamics display 2 Load information variants 3 Status bar1 fuel level operating hours time 4 Selected load dynamics programme with dynamics bar 5 Right turn indicator display 6 Driving speed or parking brake 7 Left turn indicator di...

Page 142: ...d on the Ac cess authorisation input menu ap pears All hydraulic functions and drive functions of the truck are blocked In the StVZO German Road Traffic Licensing Regulations variant the function of the hazard warning system variant is guaranteed To activate the blocked functions use the softkeys to enter the PIN code To confirm push the button If the input was correct the display changes to the m...

Page 143: ...ant Activate the Access authorisation for the fleet manager Press the Service softkey Press the scroll keys until the Change PIN codes menu appears Press the Change PIN codes softkey Follow the instructions on the display Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Change PIN codes 6219_003 276_en Operation 4 Switching on and starting 129 57368011501 EN 10...

Page 144: ...the section entitled Changing the fleet manager password NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is re leased prematurely the settings menu will close Stop the truck Actuate the parking brake Press the button Press the Settings softkey The first menu level appears Press the Access authorisa tion softke...

Page 145: ...incorrect the message Password incorrect is dis played If this happens enter the password again NOTE While the Access authorisation for the fleet manager is activated Fleet manager is displayed in an orange bar at the bottom of the screen When the users switches to the main display the access authorisation expires again Changing the fleet manager password Activate the Access authorisation for the ...

Page 146: ... en closed spaces The engine consumes oxygen and emits carbon dioxide carbon monoxide and other poisonous gases Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure that there is sufficient ventilation available Fleet manager Calibration Relieve hydraulics Shock sensor Change password access aut...

Page 147: ...0 seconds stop the starting procedure to protect the start er battery then repeat after one minute CAUTION Risk of engine damage If an error message appears on the display after the engine has been started the engine lubrication may be insufficient Insufficient lubrication may cause en gine damage Stop the engine immediately Check the engine oil level and top up if necessary If the message continu...

Page 148: ...NOTE If the engine does not start due to a dis charged battery charge the battery or jump start the engine Operation 4 Switching on and starting 134 57368011501 EN 10 2020 04 ...

Page 149: ...e selected When one of the lighting devices is switched on the activation bar next to the relevant sym bol lights up orange NOTE If the truck is equipped with the StVZO Ger man Road Traffic Licensing Regulations var iant the hazard warning system works even when the truck is switched off 1 This function is not available if the truck is equipped with the StVZO German Road Traffic Licensing Regulati...

Page 150: ...nt variant and a licence plate lamp then this also lights up To switch off the driving light 2 press the Softkey again The driving light and licence plate lamp go out To switch off the parking light 1 push the Softkey again The front side lights and the tail lights go out If the truck does not have StVZO German Road Traffic Licensing Regulations equip ment variant then the parking light and driv i...

Page 151: ...ions variant the parking light is al so switched on when the working spotlights are switched on The licence plate lamp if present is also switched on when the forward facing working spotlights are switched on Working spotlights on the roof and the side of the lift mast The roof spotlights light up the working area when the fork carriage is raised To switch on the roof spotlights 5 push the associa...

Page 152: ...ss the softkey The activation bar next to the symbol lights up The working spotlight does not yet light up Set the drive direction to Reverse The working spotlight for reverse travel lights up If the drive direction is set to Forward the working spotlight goes out Turn indicators The turn indicators are switched on and off via the travel direction selector and indicator mod ule Operation 4 Lightin...

Page 153: ...is play 2 or 3 on the display operating unit flash To switch off the turn indicators push the lever 1 back to the centre position All turn indicators and the turn indicator dis plays on the display operating unit stop flash ing 6219_003 098 2 71 m 7 1 6 t 2 3 6219_003 301 432 h 08 20 Operation 4 Lighting 139 57368011501 EN 10 2020 04 ...

Page 154: ...an Road Traffic Licensing Regulations variant For the StVZO German Road Traffic Licens ing Regulations variant the hazard warning system cannot be switched on and off via the display operating unit It is switched on and off using the hazard warning button on the steer ing column The hazard warning system in this variant works even when the truck is switched off To switch on the hazard warning syst...

Page 155: ... beacon To switch off this lighting equipment push the StVZO softkey The orange activation bar lights up next to the softkey To switch on this lighting equipment push the StVZO softkey again The orange activation bar goes out NOTE This function is configured for the German StVZO ex works Outside of Germany observe the national regulations for the country of use The authorised service centre can am...

Page 156: ...n a support on the overhead guard such that it is not affected by jolts and vibrations Depending on the version the STILL Safety Light projects one or more light blue light spots in front of or behind the truck and thus warns others about the approaching truck Several light spots are projected as a chase light The chase light indicates the location of the truck with its direction of travel Dependi...

Page 157: ... To do so push the Softkey NOTE If the truck is to be operated on public roads the STILL SafetyLight must be switched off Operation 4 Lighting 143 57368011501 EN 10 2020 04 ...

Page 158: ... approx 7 km h accel eration is gentler Therefore on distances of up to approx 40 m lower speeds are reached than would be the case if the efficiency mode was not activated The maximum speed is 18 km h compared to a maximum speed of 21 km h in the mode STILL Classic To reduce fuel consumption and noise vol ume Blue Q lowers the number of revolutions of the internal combustion engine in drive mode ...

Page 159: ...y mode is switched on To switch off Blue Q efficiency mode push the associated softkey again The Blue Q symbol disappears and Blue Q ef ficiency mode is switched off NOTE The fleet manager can also use his access authorisation to activate Blue Q efficiency mode permanently See the next section Operation 4 Blue Q efficiency mode 145 57368011501 EN 10 2020 04 ...

Page 160: ...sumers Condition Seat switch not actu ated Truck stopped Truck is in motion Front working spot lights X X Backwards 3 km h Rear working spot lights X X Forwards Top double working spotlight X X 3 km h Headlights X X Front wiper X X Backwards 3 km h Rear wiper X X Forwards Seat heater X Cab heating X NOTE On the version with StVZO German Road Traffic Licensing Regulations equipment the Blue Q effic...

Page 161: ... heat up more quickly Switching sprint mode on and off To switch on sprint mode push the associ ated Softkey The sprint mode symbol 2 appears on the display of the display operating unit Sprint mode is switched on To switch off the mode push the Softkey again The symbol disappears and the mode is switched off The truck is then back in STILL Classic mode Automatic switch off for sprint mode If the ...

Page 162: ...int mode can then only be switched on again if the following conditions are met The temperatures of the drive units and the energy supply are not too high The truck has been restarted Operation 4 Blue Q efficiency mode 148 57368011501 EN 10 2020 04 ...

Page 163: ... quickly and overtaking at dangerous or blind spots must be avoided Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden during driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Adjusting the steering column Releasing the seat be...

Page 164: ...ne is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walk ing pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be used for ob serving the...

Page 165: ... are Model Type Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX70 20 600 7400 3963 4163 RX70 25 7401 3963 4163 RX70 25 600 7402 4047 4247 RX70 30 7403 4060 4260 RX70 30 600 7404 4127 4352 RX70 35 7405 4127 4327 The truck must be used only on roadways that do not have excessively sharp curves exces sively steep gradients or excessively narrow or low entrances Drivi...

Page 166: ... 15 If you have any questions contact your authorised service centre The ascending and descending slopes must not exceed the above gradient A rough road surface is non slip and increases tyre grip Even transitions of the road surface to the gra dient prevent impact with the ground This helps to avoid damage to the load the truck and the road surface Warning about components that pro trude beyond t...

Page 167: ...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 Only routes approved by the operating compa ny or its representative may be driven on The roadways must be free of obstacles The load must only be set down and stored in the des ignated locations The operating company and its representative ...

Page 168: ...ng unit under the Drive menu item Press the Softkey to select the desired drive programme If the drive programmes are saved as a fa vourite on a Softkey press the Drive pro gramme Softkey until the number of the desired drive programme is shown on the display The number of dynamic bar segments indi cates the driving dynamics of the selected drive programme One bar slower acceleration and decelera ...

Page 169: ...te on a softkey press the Drive pro gramme Softkey until the letter of the desired drive programme is shown on the display Configuring drive programmes A and B The drive programmes can be configured by the driver NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is re leased prematurely the settings menu will cl...

Page 170: ...y and 5 indi cates the greatest agility Deceleration Determines the deceleration using five lev els 1 indicates the lowest deceleration and 5 indicates the greatest deceleration To select a higher level press the appropri ate plus Softkey To select a lower level press the appropri ate minus Softkey To save the setting press the confirm Softkey The settings are saved To cancel the setting press the...

Page 171: ... The truck is then decelerated and accelerated again in the op posite direction reversing The indicator for the selected drive direction forwards 1 or backwards 2 lights up on the display operating unit Neutral position If leaving the truck for a prolonged period the neutral position must be selected in order to avoid the truck suddenly moving off due to an inadvertent actuation of the accelerator...

Page 172: ...tor module variant can be used for emergency driving Refer to the sec tion entitled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergen cies Actuating the vertical rocker button for the drive direction Joy stick 4Plus version For the forward drive direction push the vertical rocker button for the drive direc tion 1 upwards A...

Page 173: ...riving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergen cies Actuating the drive direction switch mini console version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction push the drive direction switch to the rear NOTE Alternatively the drive direction can also be selected using th...

Page 174: ...s seat is shown on the display of the display operating unit Sit on the driver s seat Fasten the seat belt Lift the fork carriage until the necessary ground clearance is achieved Tilt the lift mast backwards Release the parking brake Select the desired drive direction The indicator for the selected drive direction forwards 1 or backwards 2 lights up on the display operating unit NOTE Depending on ...

Page 175: ...e accelerator pedal Select the desired drive direction Press the accelerator pedal The truck will travel in the selected drive direc tion NOTE The drive direction can also be changed dur ing travel Your foot can remain on the accel erator pedal while you do so The truck is then decelerated and accelerated again in the op posite direction reversing NOTE If an electrical fault occurs in the accelera...

Page 176: ...malfunc tioning the truck cannot be moved and all lift ing functions are locked In these situations the message Sit in the driver s seat is shown on the display of the display operating unit Sit on the driver s seat Fasten the seat belt Lift the fork carriage until the necessary ground clearance is achieved Tilt the lift mast backwards Release the parking brake Press the right accelerator pedal 1 ...

Page 177: ...OTE The truck is also held in place on ascending or descending gradients even if the electric park ing brake is not engaged DANGER Risk of accident due to brake failure The regenerative brake functions only while the truck is switched on and the parking brake is released Use the brake pedal if the regenerative brake mal functions Engage the parking brake before leaving the truck Changing the drive...

Page 178: ...l only the regenerative braking takes effect As the pedal is depressed further the service brake is also activated and acts on the drive wheels DANGER Risk of accident If the service brake fails the truck cannot brake suffi ciently Bring the truck to a standstill by applying the park ing brake Do not operate the truck again until the service brake has been repaired DANGER Risk of tipping and risk ...

Page 179: ...al Actuating the electric parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Do not leave the truck until the park ing brake has been applied In an emergency secure the truck with wedges on the downhill facing side to prevent it from rolling away This truck is equipped with an electric parking brake The parking brake...

Page 180: ...motor keeps the truck at a stand still Manually actuating the electric parking brake when the truck is stationary Applying the parking brake manually Press the push button 1 The electric parking brake will make a noise when it is applied and the LED 2 lights up continuously The symbol appears in the display Releasing the parking brake manually Sit on the driver s seat Press the push button 1 The e...

Page 181: ...s released The LED 2 goes out NOTE If the symbol appears in the display the truck cannot be driven until the electric parking brake has been released by pressing the push button 1 The symbol may appear if the park ing brake was not applied as a result of re leasing the accelerator pedal or vacating the driver s seat Actuation of the electric parking brake when the truck is in motion Manual actuati...

Page 182: ...lied with an audible sound The LED 2 lights up The symbol appears in the display The key switch is switched off The truck will coast to a stop Once the truck has come to a standstill the electric parking brake is applied with an audible sound The LED 2 lights up The symbol appears in the display until the control units switch off The truck accelerates sharply even though the driver s seat has been...

Page 183: ...e Apply parking brake via button message appears on the display operating unit The LED 1 on the push button 2 flashes A warning signal sounds NOTE If it becomes necessary to switch off a truck with a faulty parking brake always secure the truck to prevent it from rolling A possible cause of the malfunction is that the parking brake cannot determine whether the truck is stationary or still in motio...

Page 184: ... parking brake is applied NOTE The truck brakes more strongly if the push button 1 is pressed and held down for longer or pressed several times Safe parking function This function monitors the braking effect after the truck is parked If a sensor is fitted on the lift mast variant it also checks whether the fork carriage is lowered This function alerts the driver with an audible warning signal if T...

Page 185: ...press the Soft key Secure the truck to prevent it from rolling Secure the truck with wedges so that the truck does not roll away To confirm the message press the Soft key It is now possible to switch off the truck DANGER Risk of fatal injury from being run over if the truck rolls away Park the truck securely if the parking brake is faulty Secure the industrial truck to prevent it from rolling away...

Page 186: ...sed via the emer gency actuation mechanism it is possible to drive the truck at a low speed The truck can be moved out of the hazard ous situation or to the repair location Driving with a faulty parking brake requires the driver to be especially vigilant If the parking brake cannot be applied auto matically or via the push button apply the parking brake via the emergency actuation process Refer to...

Page 187: ...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 Chapter Technical data Page 391 A A B A B B 5060_003 007 1 Operation 4 Driving 173 57368011501 EN 10 2020 04 ...

Page 188: ...nding gradients at an angle Do not park the truck on ascending or de scending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and sta bility values Before driving on ascending a...

Page 189: ...re set re sponse time has elapsed the engine automat ic shut off function variant automatically switches off the internal combustion engine The message CUTOUT MODE appears in the display Conditions that apply simultaneously The truck is stationary The driver s seat is not occupied Energy intensive consumers are switched off e g the air conditioning Response time The response time is set between 30...

Page 190: ...responses are possible Press softkey The engine does not start the message disap pears Press softkey The engine starts the message disappears To change the response time contact the authorised service centre Engine stalls because the evapora tor has iced over NOTE Gas cools significantly upon evaporation If the evaporator is not warmed sufficiently by the coolant circulation in the engine it may i...

Page 191: ...k again Make sure that there are no people or objects in the area behind the exhaust Close the valve on the gas cylinder Disconnect the plug 1 from the gas shut off valve The gas shut off valve is closed The gas flow to the evaporator is blocked Attempt to start the engine again using the key switch If the engine starts leave it run ning until it stalls again due to the lack of gas Once the engine...

Page 192: ...rks Never thaw frozen system components by means of a naked flame or smoulder ing objects Carefully follow the instruc tions below DANGER Risk of explosion Escaping gas can ignite when it comes into contact with the heating coil in heating devices such as a hot air gun During de icing tasks the heat source must not exceed 50 C Do not deliver the warm air straight from a heating device However it i...

Page 193: ...e control function is activated the speed can be saved when driving forwards at a speed of at least 6 0 km h by pressing a button and the truck can continue driving with out the accelerator pedal being actuated The pictogram for operating the cruise con trol function is located on the operating device for the hydraulic functions Putting the cruise control function on standby In order for the cruis...

Page 194: ...l sym bol goes out Activating cruise control function WARNING Risk of accident from failing to adjust speed Driving at excessive speeds can cause accidents e g the truck could tip over when cornering Adjust speed along the entire distance being trav elled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise con trol functio...

Page 195: ...ating cruise control Deactivating the cruise control function means that the speed is again controlled by the accel erator pedal The cruise control function re mains on standby The function can be activa ted at any time when the accelerator pedal is depressed by pressing the drive direction switch for forwards travel again When the cruise control function is deactiva ted the symbol is greyed out N...

Page 196: ... detects abnormalities e g a voltage drop If the accelerator pedal is actuated in these circumstances the truck is initially braked via the drive unit The following message appears on the display Release the accelera tor pedal To continue driving release the accelerator pedal and actuate it again If these circumstances have changed again the speed that was initially saved is set again NOTE If the ...

Page 197: ...lects on the ground where it may form hazardous explosive mixtures of gas and air Do not park the truck near pits cel lars stairwells heating systems or other heat sources Do not park the truck below ground level Protect gas cylinders from heat Observe the safety regulations for working with LPG Apply the parking brake Lower the fork to the ground Tilt the lift mast forwards until the tips of the ...

Page 198: ...isplay and operating unit The truck can still be operated but your authorised service cen tre must be notified of the error immediately The error message is shown on the display and operating unit until the error has been rec tified by the authorised service centre NOTE Switch keys FleetManager cards variant FleetManager transponder chips variant and the PIN code for access authorisation variant m...

Page 199: ...lope 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 sup port mounting and press the handle 2 down again 7 7314_003 016 7321_003 039_V2 2 1 1 Operation 4 Parking 185 57368011501 EN 10 2020 04 ...

Page 200: ...h racks or other objects Before using the automatic mast vertical position ing assistance system position the truck at a suf ficient distance from racks and other objects The automatic mast vertical positioning as sistance system can be used to set down the goods so that the goods are exactly vertical e g paper rolls This prevents damage when setting down the load Automatic mast verti cal position...

Page 201: ...ymbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast stops in the vertical position NOTE The lift mast also stops in the vertical position if it is tilted forwards by 3 from a backward tilt NOTE The automatic mast vertical positioning must be calibrated in order to ensure accuracy at all times The access authorisation for the ...

Page 202: ... mast or load may be higher than the fork carriage Note the heights of ceilings and entrances Hi Lo lift mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the max height 2 NOTE When lifting above the free lift the fork car riage always remains at the upper edge of the extending lift mast DANGER Risk of acci...

Page 203: ... may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for in stance result from The hydraulic oil temperature being too low Blocking of the fork carriage in the inner lift mast Blocking of the free lift cylinder Blocking of the chain roller on the free lift cylinder If the...

Page 204: ... lift the fork carriage until the chains are under ten sion again Remove the contamination be fore resuming work WARNING Risk of injury Observe the safety regulations for working on the lift mast see the chapter entitled Working at the front of the truck Hydraulic blocking function The hydraulic blocking function ensures that all the functions of the working hydraulics are disabled whenever the se...

Page 205: ...The method of operating the lifting system de pends 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 The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck e g lift mast sideshifts ...

Page 206: ...gnated point 4 If the adhesive label becomes illegible or is missing please contact your authorised service centre Observe the pictograms on the adhesive la bels 1 and 2 The pictograms are arranged according to the direction of movement of the lift mast 360 lever 3 NOTE The truck is configured at the factory in ac cordance with the adhesive label 1 The fol lowing steps for moving the fork carriage...

Page 207: ...o tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 193 57368011501 EN 10 2020 04 ...

Page 208: ...ed point 4 If the adhesive label becomes illegible or is missing please contact your authorised service centre Observe the pictograms on the adhesive la bels 1 and 2 The pictograms are arranged according to the direction of movement of the lift mast 360 lever 3 NOTE The truck is configured at the factory in ac cordance with the adhesive label 1 The fol lowing steps for moving the fork carriage and...

Page 209: ...o tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operation 4 Lifting 195 57368011501 EN 10 2020 04 ...

Page 210: ...ed point 6 The ad hesive label 2 is attached at the designated point 5 The truck is configured at the factory in accordance with the adhesive label 1 Observe the pictograms on the adhesive la bels 1 and 2 The pictograms are arranged according to the direction of movement of the operating lev er 3 or 4 Lifting lowering the fork carriage To lift the fork carriage Move the lifting lowering operating ...

Page 211: ...t sideshifts working equip ment load carrying devices etc can lead to seri ous injury or death and is therefore prohibited Observe the safety regulations for handling loads Only operate the lifting system from the driver s seat 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 6210_003 ...

Page 212: ... mast forwards Tilt the horizontal rocker button 2 to the left C To tilt the lift mast backwards Tilt the horizontal rocker button 2 to the right D 6210_003 090 D C 2 7312_003 022_V2 D C B A Operation 4 Lifting 198 57368011501 EN 10 2020 04 ...

Page 213: ...k 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 fork carriage 1 6210_003 091 E F Operation 4 Lifting 199 57368011501 EN 10 2020 04 ...

Page 214: ...s for the hydraulic functions 2 3 are affixed on the operating levers Observe the pictograms on the adhesive la bels 2 and 3 The pictograms are arranged according to the direction of movement of the operating lev er 1 or 2 Lifting lowering the fork carriage To lift the fork carriage Move the lifting lowering operating lev er 1 in the direction of the arrow A To lower the fork carriage Move the lif...

Page 215: ...e forks into a pallet more comfortable Mechanical version Fixed stops in the lift cylinder prevent the fork arms from hitting the ground No symbol ap pears in the display operating unit This version cannot be adjusted NOTE The mechanical fork wear protection must be continually adjusted as the wear on the front tyres increases For help with this call the au thorised service centre Changing the for...

Page 216: ...The fork arms must always be carried by two peo ple if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used and should be dimen sioned such that the fork arms do not pro trude after being placed on the pallet This means the fork arms can be safely placed down and transported Both for...

Page 217: ... un screwed on the side chosen for installation Place the fork arms on a pallet next to the fork carriage on the side chosen for installa tion Pull up the locking lever 1 and push the fork arms onto the fork carriage one after the other Place the fork arms in the required position and push down the locking lever Ensure that the locking lever snaps into place Screw in and tighten the locking screw ...

Page 218: ...ts on sharp edges or burrs Always wear protective gloves and safety foot wear WARNING There is a risk of tipping The weight and dimensions of the fork extension af fect 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 alre...

Page 219: ... 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 ex tension 1 Push the fork extension onto the fork arms until it is flush with the fork back Insert the securing bolts located behind the fork back fully into the fork extension Insert the linch pin into the securing bolt and secure...

Page 220: ...nnot 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 equipped with the load meas u...

Page 221: ...d and tilted in the same manner Only work in reverse operation using rever sible 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 enti tled Transporting suspended loads 6341_862 001...

Page 222: ...e maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver Use ...

Page 223: ...ttachment of additional weights to in crease load capacity is prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These val ues apply to compact and homogenous loads Other wise the stability as well as the rigidity of the fork arms and lift mast cannot be guaranteed Improper or incorrect operation or the placement of persons to increase load capacity...

Page 224: ...ruck losing stability The permissible load of the attachments variant and the reduced lifting capacity of the combination of truck and attachment must not be exceeded Observe the special capacity rating plate informa tion shown on the truck and the attachment 5051_003 007 3 5230 500 2 880 K g 1 Operation 4 Handling loads 210 57368011501 EN 10 2020 04 ...

Page 225: ...eeding the residual load capacity If the weight determined by a load measurement ex ceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce the load immediately If necessary use another truck with sufficient load bearing capacity NOTE The load measurement must be calibrated in order to ensure accuracy at all times The ac cess authorisation ...

Page 226: ... a load safety guard variant to prevent the load from falling on the driver A closed roof covering variant should also be used Removable roof panels may not be removed Adjusting the fork Lift the locking lever 1 and move the fork arms to the desired position Allow the locking lever to snap back into place The load centre of gravity must be midway be tween the fork arms Only actuate the fork prong ...

Page 227: ...rea despite warnings Cease work with the truck immediately Secure the truck against use by unauthorised par ties DANGER Danger of death from falling loads Never walk or stand underneath sus pended loads Transporting pallets As a rule loads e g pallets must be trans ported individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the tech...

Page 228: ...and cause the truck to tip over When transporting suspended loads observe the following instructions Instructions for transporting suspended loads Swinging loads must be prevented by using the proper driving speed and driving style careful steering braking Hanging loads must be hooked on to the truck in such a way that the harness cannot shift or release unintentionally and cannot be damaged When ...

Page 229: ... or raised fork arms Never exceed the maximum load values specified on the capacity rating plate Otherwise stability cannot be guaranteed Only store pallets that do not exceed the specified maximum size Damaged loading equipment and incorrectly formed loads must not be stored Attach or secure the load to the lifting ac cessory so that the load cannot move or fall Store the load so that the specifi...

Page 230: ...t the rack and load do not become dam aged when inserting the fork into the rack Insert the fork as far under the load as pos sible Stop the truck as soon as the fork back is resting on the load The load centre of gravity must be midway between the fork arms 6210_800 006 6210_800 007 Operation 4 Handling loads 216 57368011501 EN 10 2020 04 ...

Page 231: ...way behind you is clear DANGER Due to the risk of tipping never tilt the lift mast with a raised load Lower the load before tilting the lift mast Reverse carefully and slowly until the load is clear of the rack Brake gently Lower the load while maintaining ground clearance 6210_800 008 5060_003 102 Operation 4 Handling loads 217 57368011501 EN 10 2020 04 ...

Page 232: ...ess stable it be comes The truck can tip over or the load can fall increasing the risk of accident Driving with a raised load and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards 5060_003 101 6210_800 011 Operation 4 Handling loads 218 57368011501 EN 10 202...

Page 233: ...cident due to changed moment of tilt The load centre of gravity and the moment of tilt move due to tilting the lift mast forwards with a raised load or due to the load slipping 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 particu lar care to ensure that the truck does not t...

Page 234: ... mast to vertical Lift the load to the stacking height Drive the truck towards the rack carefully 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 li...

Page 235: ...at tachment is being used its weight must be subtracted from this value NOTE The weight of an attachment can be seen on its nameplate Operation To activate the shake function Move the corresponding operating device for the Lifting function over the zero posi tion four times in quick succession The fork carriage moves as normal The shake function is active after the fourth time the operating device...

Page 236: ...f the two seconds elapse without the shake function being used the fork carriage can be moved normally again with the load The following section shows how the shake function is activated via the standard assign ment for lifting lowering using the different variants of the operating devices If the lifting lowering function is assigned differently on the operating device the shake function is ac tiv...

Page 237: ...ple mini lever Move the 360 lever 3 back and forth be tween positions A and B four times Then continue to move the component in the same way Quadruple mini lever Move the operating lever 4 back and forth between positions A and B four times Then continue to move the component in the same way Operation 4 Handling loads 223 57368011501 EN 10 2020 04 ...

Page 238: ...r which the operating company has been granted authori sation DANGER There is a risk to life if you are crushed or run over by the truck There must be no personnel already in the lift when the truck is driven into the lift Personnel are only permitted to enter the lift once the truck is secure and must exit the lift before the truck is driven out 5060_003 071 Operation 4 Handling loads 224 5736801...

Page 239: ...eer off the loading bridge towards the edge This may cause the truck to crash The lorry driver and the truck driver must agree on the lorry s departure time Before driving across a loading bridge ensure that it is properly attached and secured and has a sufficient load capacity lorry bridge etc Drive slowly and with care on the loading bridge Ensure that the vehicle onto which you will be driving ...

Page 240: ...net weight variant Weight of the load to be lifted 100 kg allowance for driver Actual total weight 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 voi...

Page 241: ...rom the driv er s position with and without a load must be checked by a competent person If the visibili ty is deemed insufficient visual aids such as mirrors a camera monitor system etc must be used In addition it is essential that the warnings be low are observed CAUTION Attachments must be CE certified If the truck is not fitted with an attachment specific residual load ca pacity rating plate a...

Page 242: ...limb on moving parts of the truck 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 at tach the protective caps to the plug connectors Mount...

Page 243: ...ork car riage or the lift mast can only be moved slightly Do not reach into or stand below the components of the load lift system NOTE The internal combustion engine must be switched off in order to depressurise the sys tem Insert the switch key into the key switch and turn it to the I position The valves are supplied with power and the hydraulic system is depressurised Depressurising the hydrauli...

Page 244: ...perated The hydraulic circuits for the 5th hydraulic functions are actuated via the corresponding buttons on the operating devices Function key for the 5th function with mini lever control and Fingertip operation Shift key F with Joystick 4Plus operation hereinafter referred to as the button Press and hold the button 1 for the operat ing devices Again actuate the operating levers for con trolling ...

Page 245: ...ocking mechanism Push the operating device once in the Open direction Push the operating device once in the Close direction Completing the depressurisation After the hydraulics have been depressur ised press the Softkey to confirm Switch off the truck Install the attachment Switch on the truck The function for depressurising the hydraulics is inactive The truck is ready for operation Check and ens...

Page 246: ... additional haz ards such as a change in the centre of gravity addi tional danger areas etc Attachments must only be deployed for their inten ded use as described in the relevant operating in structions 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 at tached Where necessary loads must also be...

Page 247: ...ructions for the attachment In the menu for the available hydraulic axles for attachments the designation Hydraulic axle specifies the connection of the corre sponding auxiliary hydraulics See also the section entitled Adjusting the hydraulic speed for attachments in this chapter Attachment example for an attachment for ad justment of the fork arms 1 Auxiliary hydraulics 1 2 Auxiliary hydraulics 2...

Page 248: ...uctions for the attachment The authorised service centre will help to make the correct adjustments The Information on the auxiliary hydraulics differs depending on the truck Take this into consideration when selecting the attachment NOTE The adjustment procedure requires access authorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the...

Page 249: ...n the speed The return flow automatically adjusts to the set supply flow When the orange activation bar next to the Synchronise auxiliary hydraul ics softkey lights up synchronisation takes place automatically The return flow is shown only dimly on the display To adjust the speed push the Plus or Minus softkey To save the setting press the Confirm softkey The settings are saved To cancel the setti...

Page 250: ...this push the Synchronise auxiliary hydraulics softkey The return flow is displayed in addition to the supply flow at full brightness To adjust the speed push the Plus or Minus softkey To save the setting press the Confirm softkey The settings are saved To cancel the setting press the Can cel softkey The settings return to the most recently set value Fleet manager Forwards Auxiliary hydraulics 2 3...

Page 251: ...this lever The pictograms are arranged according to the direction of movement of the attach ments cross lever 1 The following applies Move the attachments cross lever 1 in the direction of arrow A B C or D The attachment moves accordingly in the di rections A B C or D as shown in the pictogram Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or f...

Page 252: ...chanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er 2 forwards again It is not nece...

Page 253: ...l becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 2 The pictograms on the attachments cross lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 3 The LED for the 5th function lights up Move the attachments cros...

Page 254: ...nction Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service cen...

Page 255: ...spective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment func...

Page 256: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 257: ...dhesive label becomes illegible or is missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive label 3 The pictograms on the operating lever show the respective functions that are activated by this lever The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating le...

Page 258: ...hment function Auxiliary hydraulics 5th function Move the sideshift to the left Move sideshift to the right Adjust fork arms open Adjust fork arms close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the co...

Page 259: ...espective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment fun...

Page 260: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 261: ...sentially involves the following Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Move the operating lever 1 in the direc tion E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram Example using the pictograms for configura tion 1 If the operating lever 1 is moved in the direc tion of the arrow E the sideshift moves to th...

Page 262: ...ctograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Operation 4 Attachments 248 57368011501 EN 10 2020 04 ...

Page 263: ...t 1 Joystick 4Plus Move sideshift to the left right 2 Joystick 4Plus or slider Adjust fork arms open close 3 Slider Move side shift frame or fork carriage for wards backwards 4 Joystick 4Plus or slider Rotate attachment left right 5 Slider Tip shovel over tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is ...

Page 264: ...ydraulic function the procedures for op eration are as follows Press and hold shift key F 1 on the Joy stick 4Plus Simultaneously actuate the horizontal rock er button 2 in the direction shown in the pictogram The attachment moves in the selected direc tion NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au ...

Page 265: ...unctions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment function Move ...

Page 266: ...ds The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er 2 forwar...

Page 267: ...tion 2 The LED for the 5th function 3 lights up Move the operating lever 4 or 6 in the di rection of the arrow E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram NOTE The place where the adhesive label bearing the pictograms 1 or 5 is affixed shows which operating lever is intended to operate the 5th function The pictograms show the functions that are activ...

Page 268: ...ng function is inadvertently triggered DANGER If the correct function of the clamp locking mecha nism is not guaranteed there is a risk to life from a falling load If other attachments are used on this truck in addition to the clamp make sure that the function of the clamp locking mechanism is reassigned to the corre sponding operating device every time the clamp is refitted See the section entitl...

Page 269: ... close the clamp To close the clamp pull the operating lev er 2 backwards Triple mini lever To release the clamp locking mechanism push the operating lever 2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the ...

Page 270: ...ose the clamp To close the clamp pull the operating lev er 2 backwards Fingertip To release the clamp locking mechanism push the operating lever 2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locki...

Page 271: ... to the right again Taking up a load using attachments WARNING Risk of accidents Attachments may only be used for their intended pur pose as described in the relevant operating instruc tions Drivers must be instructed in the handling of the at tachments WARNING Risk of accidents Loads may only be picked up and transported with attachments if they are securely attached Where necessary loads should ...

Page 272: ... Load capacity Q kg 1 Lift height h mm 2 Load distance C mm 3 Operation 4 Attachments 258 57368011501 EN 10 2020 04 ...

Page 273: ...3 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 2 is shown with an orange back ground To activate the Washer operating stage press and hold the softkey The Washer operating stage is activated The symbol 4 is displayed for as long as the softkey is pressed Once the window is clean release the soft key The previous operating stage is reactivated To swi...

Page 274: ...ss the softkey repeatedly until the symbol 1 ap pears again on the display Roof panel wiper and washer To activate the On operating stage press the corresponding softkey 9 The On operating stage is activated The symbol 11 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 10 is shown with an orange background To activate the Washer operating stage press a...

Page 275: ...t Operate washer system until washer fluid is discharged from the spray nozzles FleetManager variant FleetManager is an equipment variant and can be fitted to the truck in different versions The description and operation information can be found in the separate operating instructions for the corresponding FleetManager versions Shock recognition variant The shock recognition is an equipment variant...

Page 276: ... equipped with a ceiling sensor this assistance system is listed in the Assis tance systems menu in the display operating unit Operating the ceiling sensor system The drivers must be instructed on the use of the ceiling sensor system by the operating company When the driver enters a hall for the first time after starting work they must be certain that the ceiling sensor system is working correctly...

Page 277: ...ossible limitations for object recogni tion If the truck moves under larger overhead structures outdoors e g a pedestrian bridge the ceiling sensor system may inter pret this overhead structure to be a hall ceil ing and reduce the maximum speed In rare cases it may occur that the ceiling sensor system does not recognize a ceiling and does not then reduce the speed This can happen if the signals fr...

Page 278: ...ling sensor 1 The sensor is adjusted using DIP switches 6 To access the DIP switches open the cover on the underside of the sensor housing with the key 5 During this process the two tabs of the key 5 fit into the recesses of the cover Using the DIP switches 1 to 5 6 adjust the range and the sensitivity of the sensor The DIP switches can be adjusted using a small screwdriver Deckensensor_Anbau 1 4 ...

Page 279: ...ettings of the manufacturer DIP switch 6 7 8 1 1 0 The possible settings for DIP switches 1 to 5 are shown in the following tables DIP switch 1 2 3 Range 0 0 0 2 m 0 0 1 3 m 0 1 0 4 m 0 1 1 6 m 1 0 0 8 m 1 0 1 12 m 1 1 0 16 m 1 1 1 24 m 4 5 Sensitivity 0 0 Very high 0 1 High 1 0 Medium 1 1 Low Operation 4 Auxiliary equipment 265 57368011501 EN 10 2020 04 ...

Page 280: ...nsor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following ta ble Sensitivity Range Beam angle Low 1 2 m 22 5 4 m 22 5 8 m 20 16 m 15 24 m 5 Medium 2 2 m 35 4 m 30 8 m 25 16 m 22 5 24 m 10 2 3 4 1 2 3 4 Operation 4 Auxiliary equipment 266 57368011501 EN 10 2020 04 ...

Page 281: ... 8 m 22 5 16 m 20 24 m 15 Very high 4 2 m 45 4 m 43 8 m 30 16 m 22 5 24 m 18 After the adjustment refit the cover Refit the ceiling sensor and connect it Check that it is working correctly Operation 4 Auxiliary equipment 267 57368011501 EN 10 2020 04 ...

Page 282: ...osition Opening the cab door from the outside Insert the key in the door lock 1 unlock the door and remove the key To release the door pull on the door handle 2 and open the cab door 3 outwards Opening the cab door from the inside Turn the rotary handle 4 on the handle 5 and push the cab door outwards 7300_003 003 5 2 1 3 4 Operation 4 Cab 268 57368011501 EN 10 2020 04 ...

Page 283: ... door while pulling the door handle 2 otherwise the locking mecha nism in the lock will not function Use the door handle only to open the cab door Closing the cab door from the inside Take hold of the handle 5 Pull the cab door inwards until the door lock engages Make sure that the cab door is fully closed NOTE Do not turn the rotary handle 4 when closing the door or when the cab door is closed Do...

Page 284: ...ar Make sure that the handle engages in the stop slot 3 Closing the side windows WARNING There is a risk of crushing between the window frame and side window due to the side windows slip ping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Closing the rear side window Press the handle 2 together and pull the rear side window 1 to the rear Make ...

Page 285: ... window heating To switch on the rear window heating push the associated Softkey on the display oper ating unit The rear window heating is switched on To switch off the rear window heating push the Softkey again The rear window heating is switched off NOTE The screen heating will switch off automatical ly after approx 10 minutes 1 Operation 4 Cab 271 57368011501 EN 10 2020 04 ...

Page 286: ...driving or when handling loads Keep the radio at a volume that allows you to hear warning signals The radio 1 and the loudspeakers 2 are an equipment variant If the truck is equipped with a radio and loudspeakers they are integrated into the roof lining The description and information relating to the operation of this equipment can be found in the separate operating instructions for the ra dio 1 2...

Page 287: ...function Go to the Bluetooth settings Select the relevant device with the name of the radio Enter the code 1234 The symbols A2DP 4 HFP 5 and Blue tooth 6 appear on the radio display The smartphone is paired with the radio Unpairing a smartphone Select mode A2DP 4 on the radio using the SRC button 1 Press and hold the 6D button 2 for 2 seconds The symbols A2DP 4 HFP 5 and Blue tooth 6 will disappea...

Page 288: ...Outgoing calls Regardless of the mode Radio AUX A2DP dial the number on the smartphone and make the call The acoustic signals are automatically broad cast via the radio speaker End the call using the smartphone or by pressing the button depicting a red hand set 2 NOTE The telephone number can also be selected via the radio refer to the original operating in structions for the radio 7300_003 020 VO...

Page 289: ...ere is a risk of poisoning if heavily polluted surrounding air is aspirated in to the closed cab Do not operate the heating system in the vicinity of storage areas or similar areas in which fuel vapours or fine dust e g coal wood or grain dust can build up DANGER Risk of explosion due to heat The heat can cause gases to expand considerably or to ignite Do not expose spray cans or gas car tridges t...

Page 290: ...of burns if it is touched Do not touch the heating system housing during operation Only touch the switches provided Operating devices of the heating sys tem The operating devices of the heating system include 1 Heating level control knob 2 Fan control knob 3 Air vent control knob Switching on the blower and heating system Turn the fan control knob 2 to the desired blower position The blower runs a...

Page 291: ...ow to the footwell turn the air vent control knob 3 in an anticlockwise direction to position To direct the air flow to the windscreen turn the air vent control knob 3 in a clockwise direction to position The centre position directs the air flow to the footwell and the windscreen Switching off the heating system and blower Turn the heating level control knob 1 in an anticlockwise direction until i...

Page 292: ... short circuits Use only fuses with the prescribed nominal current Air conditioning variant The air conditioning dries the air in the cab to prevent the glass panes misting up The tem perature of the air that is blown out is based on the heating level that has been set The de frost function can be used to de ice the wind screen quickly The operating devices of the air conditioning include 1 Heatin...

Page 293: ...b 3 clockwise to the position Open the air distributors and direct them onto the windscreen Switch on the air conditioning Push the defrost switch 4 The LED on the switch lights up green The air conditioning operates at full power The high est heating level is selected This feature op erates for a limited period only To save ener gy it switches itself off automatically Press the defrost switch 4 a...

Page 294: ...ow pull the roof window downwards using the handle and rotate the handle in a clockwise direc tion 12 V socket A 12 V socket 1 is fitted to the right of the driver s seat for connecting an external electri cal consumer CAUTION Risk of short circuit The nominal current of the connected consumer must not exceed 10 A Before connecting check the nominal current of the device in question Lift up the du...

Page 295: ...me dirty and dusty if no plug is inserted or the dust guard cover is not closed Over time this can lead to problems with the electrical connection Push the dust guard cover all the way down after using the socket Operation 4 Cab 281 57368011501 EN 10 2020 04 ...

Page 296: ...e truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the existing towed load corresponds to the rated capacity of the truck no load may be transported on the fork at the same time The load can be distributed be tween the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe the permissib...

Page 297: ...s to be used for towing on a more regu lar basis the manufacturer should be consul ted Coupling pin in the counterweight Coupling the trailer DANGER If you leave the truck briefly to couple or uncouple the trailer there is a risk of fatal injury from the truck rolling away Apply the parking brake Lower the fork to the ground Switch off the key switch and remove the key Take measures to prevent the...

Page 298: ...checked 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 rotate by 90 the coupling pin is locked in this position Remove any items used to prevent the trail er from rolling away Uncoupling the trailer Take measures to prevent the trailer from rolling away e g using wheel chocks Push the co...

Page 299: ...stroyed This could cause the supported load to fall with poten tially fatal consequences The tow coupling should be subjected only to hori zontal 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 the forks to the ground Switch off...

Page 300: ...wheel steering the side slew ing angle of the tiller may not be adequate The cou pling 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 the tiller in the tow cou pling i...

Page 301: ...must engage in the middle of the coupling jaw Failure to follow these instructions could result in damage to the cou pling 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 the coupling pin drops out during towing the trail er will work loose and can no longer be controlled There is a risk of accident A protruding safety ha...

Page 302: ...mbly 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 automatical ly 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 eye and towing jaws...

Page 303: ...en 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 cou pling jaw or to the tow bar eye Ensure that the tow bar eye enters the coupling jaw centrally Move the truck back slowly until the tow bar eye is i...

Page 304: ...the trail er 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 exam ple a tow rope is to be secured in the tow coupling only actuate the tow coupling via the closing lever 1 Press the closing lever 1 downwards as far as it will go The tow coupling is closed Uncoupling model RO 244 A Take ...

Page 305: ...le 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 the coupling pin drops out during towing the trail er 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 not been coupled correctly The trailer must not be towe...

Page 306: ...m eter 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 the middle of the coupling jaw Failure to follow these instructions could ...

Page 307: ...he tow bar eye and towing jaws are disconnected Close the tow coupling 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 suf ficient minimum distance to fixed installa tions when t...

Page 308: ...NOTE Please observe the definition of the following responsible persons operating company and driver Operation 4 Trailer operation 294 57368011501 EN 10 2020 04 ...

Page 309: ... A mes sage about the truck means that the truck con trol unit has detected a fault The following types of message may appear individually or in combination A graphic symbol The message A code consisting of a letter and a four digit number The message is displayed until either the cause has been corrected or the message has been acknowledged In the case of successive events the respec tive message...

Page 310: ...tion speed with the access authorisa tion Development mode active This message is not displayed during normal opera tion Contact the authorised service centre Drive unit blocked This message follows earlier messages e g over temperature It is not possible to drive the truck Wait until the message disappears If necessary switch the truck off and on again If the message continues to appear please co...

Page 311: ...echni cal fault Apply the parking brake according to the section entitled Malfunctions in the electric parking brake Secure the truck with wedges so that it cannot roll away Apply parking brake via but ton The electric parking brake is not applying automati cally Apply the parking brake by pressing the button Release parking brake via button The electric parking brake cannot be released auto matic...

Page 312: ...ired direc tion Drive the truck to a safe area and park it safely Contact the authorised service centre Parameter calibration This message is not displayed during normal opera tion Contact the authorised service centre Seatbelt sequence If the configured sequence for applying the restraint systems is not observed this message appears Fasten the seat belt Close restraint system If for example the t...

Page 313: ...is too high this message appears Sprint mode is no longer availa ble Observe the previous message Foot switch If the truck is equipped with a foot switch and a truck function is called up when the foot switch is not actu ated this message appears Actuate the foot switch Overload With the overload protection variant this message appears if an excessive load is picked up Set down the load Factory mo...

Page 314: ...chment is fitted this message can be ignored If there is an attachment fitted contact the au thorised service centre A2801 Monitoring Process monitoring proc 1 A2802 Monitoring Process monitoring proc 2 A2803 Monitoring Process monitoring proc 3 A2804 Monitoring Process monitoring proc 4 A2805 Monitoring Process monitoring proc 5 A2806 Monitoring Process monitoring proc 6 A2807 Monitoring Process ...

Page 315: ...rive unit Drive unit overtemperature collective fault Switch off the truck and leave it to cool down A5091 Overtemp Hydraulic drive Hydraulic drive overtemperature collective fault Switch off the truck and leave it to cool down A5632 Check the engine oil lev el Engine oil level too high too low The driving speed is reduced Check the engine oil level and if necessary drain or refill the engine oil ...

Page 316: ... are ap proved Only change LPG cylinders in well ventilated spaces away from open ings in the ground Observe the safety regulations for working with LPG DANGER Risk of explosion from spark discharge Striking tools must not be used to aid opening and closing DANGER Open flames red hot objects etc may cause explosions Frozen system parts must be thawed out using only hot water hot sandbags or simila...

Page 317: ...valves must be opened slowly Leaking gas cylinders must not be reused Taking all precautions into account leaking gas cylinders must immediately be emptied outside by blowing and marked as leaking If damaged gas cylinders are supplied the provider or a representative service station attendant etc must be immediately notified of the damage present where possible in writing Even if no accident occur...

Page 318: ... the connection screw joint of the cylin der shut off valve points vertically down wards Secure the gas cylinder properly in the cyl inder holder Open the cylinder valve 1 by slowly turn ing the star grip handle anti clockwise Check whether the hose or connection screw joints have iced over DANGER There is a risk of explosion if LPG es capes Do not start the engine if there is a leak age gas smell...

Page 319: ...es Observe the na tional regulations in the relevant country Switch off the engine Do not smoke or use a naked flame lighter Ensure that permissible LPG cylin ders are used Only change LPG cylinders in well ventilated spaces away from open ings in the ground Thaw frozen system parts with hot water hot sandbags or similar DANGER Risk of explosion from spark discharge Do not use a striking tool when...

Page 320: ...he full gas cylinder When installing the gas cylinder make sure that the connection screw joint of the cylin der shut off valve points vertically down wards Insert the upper part of the cylinder holder Fit the hook to the holder and swivel the handle of the tensioning device downwards Securely grip the connection nipple using the handhold and screw on the union nut Open the cylinder valve by slowl...

Page 321: ...osion during thawing of gas system Gas can ignite and explode when ex posed to excessive heat naked flames glowing objects and objects that produce sparks Frozen system components must only be thawed using warm air warm water warm sand bags or similar The temperature of the applied heat must not exceed 50 C Do not apply warm air directly using a heating device e g a hot air blower The gas can igni...

Page 322: ...d accessories for gas in the liquid phase and in the LPG container must not be exposed to an impermissible level of heat Explosions involving a gas cylinder or an LPG system must always be reported im mediately in Germany to the employers li ability insurance association and the re sponsible industrial inspectorate Store damaged components until the investigation has been completed Replace removab...

Page 323: ...ION It is possible to underfill or overfill the LPG tank Only fill the LPG tank until the tank valve switches itself off Do not fill according to the fill level indicator 4 Release the actuating lever for the pistol type nozzle immediately after the tank valve has switched off and stop the filling process Switch off the pump motor and close the main shut off valve of the filling station Carefully ...

Page 324: ...certain circumstances Take the following measures immedi ately Action in the event of irregularities Stop filling the tank immediately If possible remove the pistol type nozzle and screw on the locking cap In the event of faults in the gas system do not operate the truck until the fault is re solved Contact your supervisor the fleet manager or the authorised service centre Operation 4 Refuelling 3...

Page 325: ...components Do not use any flammable cleaning materials CAUTION Risk of fire due to flammable materials Deposits and solids can be ignited by hot components e g drive units Remove deposits and solids CAUTION If water penetrates the electrical system there is a risk of short circuit The engine must be switched off during washing Do not use water to clean the area around the cen tral electrical syste...

Page 326: ...he nozzle and the object being cleaned Do not aim the cleaning jet directly at adhe sive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot com ponents Use only non flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials Clean plastics only with cleaning materials intended for plastics Observ...

Page 327: ...ids that are corrosive or contain acid or chlorine can damage the chains and is forbidden Observe the manufacturer s guidelines for working with cleaning materials Place a collection vessel under the lift mast Clean with paraffin derivatives such as benzine When using a steam jet do not use addi tional cleaning agents Remove any water in the chain links using compressed air immediately after clean...

Page 328: ... great care when cleaning the rear window and do not use any objects with sharp edges Clean the windows using a commercially available glass cleaner After washing Carefully dry the truck e g with com pressed air Sit on the driver s seat and start up the truck in accordance with regulations CAUTION Risk of short circuit If any moisture has penetrated into the engine de spite the precautionary measu...

Page 329: ...off the truck You must adhere to the rules of behaviour if the truck tips over Rules of behaviour if truck tips over Hold onto the steering wheel with your hands Brace your feet in the footwell Bend your upper body over the steering wheel Bend your body against the direction of the fall Emergency hammer The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazard ous ...

Page 330: ... one of the two metal tips on the head of the emergency hammer hit the pane of glass with force until it breaks Emergency lowering If the hydraulic controller fails whilst a load is raised emergency lowering can be performed An emergency lowering screw designed for this purpose is located on the valve block DANGER There is a risk to life from falling loads or from truck components being low ered D...

Page 331: ...gulates the lowering speed Observe the list of points below The following applies Tightening torque Max 2 5 Nm Unscrewing the emergency lowering screw slightly The load is lowered slowly Unscrewing the emergency lowering screw further The load is lowered quickly After lowering Re tighten the emergency lowering screw Return the hexagon socket wrench to the support mounting in the compartment Refit ...

Page 332: ...oll ing away Lower the fork to the ground Switch off the key switch The electric parking brake can be released and applied via an emergency actuation mechanism The emergency operation of the electric park ing brake is required under the following con ditions The parking brake is not functioning proper ly No power supply to the parking brake e g if the starter battery is discharged or re moved NOTE...

Page 333: ... ac tuation mechanism 2 Release the brake pedal Let go of the emergency actuation mechanism 2 Once two grooves are visible see arrow the parking brake is released Apply parking brake Fully depress the brake pedal The emergency actuation mechanism 2 re turns to its initial position Release the brake pedal Once only one groove is visible see arrow the parking brake is applied If the status of the pa...

Page 334: ... battery terminal clip Proceed as follows to quickly disconnect the battery Unscrew star grip screws 1 to the left and right of the rear cover and fold the cover 2 back Pull the negative terminal battery terminal clip upward Lift the battery terminal clip off the negative terminal of the battery and place it to the side 7321_003 062 1 2 7311_003 068 Operation 4 Procedure in emergencies 320 5736801...

Page 335: ...erminals are connected to the negative cable both bodies are also conductively connected to one another If the positive cable touch es one of the two bodies as further cables are con nected a short circuit can occur Ensure that the correct order is followed when connecting and disconnecting the jump leads Remove covering from the back see Chapter Removing and attaching the rear cover Page 358 Leav...

Page 336: ...attery Disconnect the positive cable from the posi tive terminal on the current giving battery NOTE Leave the engine to run because the battery is not yet sufficiently charged Replace the covering at the back Towing DANGER Risk of accident due to failure of the brake system of the towing vehicle If the brake system of the towing vehicle is not ade quately sized the vehicle may not brake safely or ...

Page 337: ... the me chanic attaching the tow bar about the risks When you fit the tow bar always use a second person to guide the towing vehicle manoeuvres Manoeuvre with a second person as a guide CAUTION Steering is stiff There is no power steering if the hy draulics fail Select a slow towing speed to ensure that the truck and the towing vehicle can be braked and controlled effectively at all times CAUTION ...

Page 338: ...ar to the tow coupling on the towing vehicle and on the truck Sit in the driver s seat of the truck being towed and fasten the seat belt Where possible activate the restraint sys tems provided Release the parking brake Select a slow towing speed Tow the truck After towing secure the truck so that it can not roll away e g by applying the parking brake or by using wedges Remove the tow bar Operation...

Page 339: ...ruck safely Determine the unit weights by reading the truck nameplate and if necessary the at tachment nameplate variant Add together the determined unit weights to obtain the total actual weight of the truck Net weight 1 Ballast weight variant 2 Net weight of attachment variant 100 kg allowance for driver Total actual weight Type Modèle Typ Serial no No de série Serien Nr year année Baujahr Rated...

Page 340: ... driven has been sufficiently secured against moving Maintain a safety distance from edges loading bridges ramps working platforms etc Drive slowly and carefully onto the transport vehi cle Wedging the wheels Use two wedges to secure each of the front and rear wheels against sliding or rolling away Lashing down CAUTION Harnesses can rub against the seating and cause damage Place a slip resistant m...

Page 341: ...sses 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 condi tions that require frequent loading or that are not presented here please contact the manu facturer with regard to special equipment var iants Trucks may only be laden by persons wi...

Page 342: ... or similar protective devices if necessa ry DANGER There is a risk of being hit if the hoists and har nesses fail and cause the truck to fall Danger to life Only use hoists and harnesses with adequate load capacity for the determined loading weight Only use the truck s designated lifting points Make sure that harnesses such as hooks shack les belts etc are only used in the indicated load directio...

Page 343: ...ints are indicated by a hook sym bol Loop the lifting straps around the tow bolt 4 in the tow bar eye of the towing device Secure the tow bolt Determine the truck s centre of gravity see Chapter Dimensions Page 392 3 7321_003 012 7311_003 060 4 Operation 4 Transporting the truck 329 57368011501 EN 10 2020 04 ...

Page 344: ...e damaged Secure harnesses so that they are not touching any attachment parts If applicable the LPG cylinder or LPG tank should be disassembled by trained personnel Check that harnesses cannot collide with attachment parts Loading the truck DANGER If the raised truck swings in an uncon trolled fashion it may crush people There is a risk to life Never walk or stand underneath sus pended loads Do no...

Page 345: ...er This causes the engine to come to a halt The evaporator can ice over as a result of Frequent operation for short periods High engine loads at low ambient tempera tures NOTE Avoid short term operation and high motor loads in low ambient temperature wherever possible If necessary run the engine until the operating temperature is reached If the engine stalls suddenly and does not start again check...

Page 346: ... that all the wheels are clear of the ground This prevents permanent defor mation of the tyres CAUTION Danger of damage from corrosion due to condensa tion on the truck Many plastic films and synthetic materials are water tight Condensation water on the truck cannot es cape through these covers Do not use plastic film as this facilitates the forma tion of condensation water NOTE Store only fully c...

Page 347: ...ur permeable ma terials such as cotton in order to protect against dust If the truck is to be shut down for even lon ger periods contact your authorised service centre to find out about additional meas ures Returning to service after decom missioning DANGER Risk of explosion If the truck has been parked in an en closed space for an extended period of time there is a risk of explosive gases forming...

Page 348: ...htness using leak spray Check the screw joints of the LPG system for tightness Have the same checks and tasks carried out by the authorised service centre that were carried out before initial commission ing Carry out the checks and tasks that are to be performed before daily use Recommission the truck During commissioning the following points must be checked in particular Leak tightness and functi...

Page 349: ...5 Maintenance ...

Page 350: ... truck jacked up by the authorised service centre Have the raised fork carriage or the exten ded 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 the maximum lift height of the lift mast and compare...

Page 351: ... serv ice centre Working on the ignition system To prevent personal injury and or destruction of the ignition system please observe the fol lowing Only connect and disconnect ignition sys tem 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 actually started e g for a compression pressure test disc...

Page 352: ...s the manufacturers installation instructions must be observed The cylinder and main shut off valves must be closed when doing so The condition of the electrical system of trucks running on LPG must be kept under constant surveillance Sparks may cause explosions if system parts containing gas are leaking After a truck running on LPG has been shut down for a long period of time the storage room mus...

Page 353: ... 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 au thorised service centre must be informed that this is to take place Safe handling of the truck and the corresponding hoists is described in the tr...

Page 354: ...is recommended Obtain the dimensions b1 and b3 from the corresponding VDI datasheet 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 technician to re move the lift mast Securing the lift mast against falling off...

Page 355: ...without special quali fications Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel A qualification such as those held by a competent person is not re quired to carry out this work The required tasks are described in the chapter entitled Remaining ready for operation Information for carrying out mainte nance This section contains all informati...

Page 356: ...ls 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 information in these operat ing instructions takes precedence over th...

Page 357: ...ng correctly and lubricate Tyres and wheels Check tyres for wear and check the air pressure if necessary Check the wheels for damage and check the tightening torques Internal combustion engine Check the condition of the internal combustion engine visual inspection Check the V belt Change the engine oil and replace the oil filter Replace the air filter main cartridge Check the cooling system for le...

Page 358: ...y handle for damage Check the mounting of the steering axle and check the steering axle for leak tight ness Grease all lubricating nipples on the steering axle Check the steering stop Brake system Check the condition of all mechanical brake parts and check that they are working correctly Check the actuation distance of the brake pedal and adjust if necessary Check the filling level in the brake re...

Page 359: ...nd connections for damage and for leak tightness Check the guide pulleys for damage and for wear Check the support rollers and chain rollers for damage and for wear Check the play between the fork carriage stop and the run out barrier Check the tilt cylinders and connections for damage and for leaks Check the fork carriage for damage and for wear Check the fork arm interlock for damage and check t...

Page 360: ...rer s main tenance instructions Check the trailer coupling for wear and for damage observe the manufacturer s maintenance instructions General Read out the error numbers and clear the list Reset the maintenance interval Check that the labelling is complete Perform a test drive Maintenance 5 General maintenance information 346 57368011501 EN 10 2020 04 ...

Page 361: ...Change the actuation oil for the foot brake Hydraulics Change the hydraulic oil Replace the return line filter and the breather filter Replace the high pressure filter 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 manufactur er s i...

Page 362: ...f a different quality must not be mixed This negatively affects the lu bricity If a change between different manufac turers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part in volved When topping up working materials use only clean containers Maintenance 5 General maintena...

Page 363: ...point A Four lubricating nipples on each side of the steering axle for the axle stub bearing and track rod arm B Sliding surfaces on the lift mast C Load chains Maintenance 5 General maintenance information 349 57368011501 EN 10 2020 04 ...

Page 364: ...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 Maintenance 5 General maintenance information 350 57368011501 EN 10 2020 04 ...

Page 365: ...er information refer to the work shop manual for the truck in question Electrical system Code Unit Operating materials Specifications Dimension Insulation resistance For further information refer to the work shop manual for the truck in question Hydraulic system Code Unit Operating materials Specifications Dimension System filling Hydraulic oil HVLP 68 DIN 51524 Part 3 Max 58 l Hydraulic oil for t...

Page 366: ...sion Wheel nuts screws Torque wrench For further informa tion refer to the workshop manual for the truck in question Wheel gear Mineral oil FUCHS TITAN GEAR HYP LD SAE 80W 90 API GL 5 Brake Mineral oil ARAL HGS FLUID 127830 Lift mast Code Unit Operating materials Specifications Dimension B Lubrication Multi purpose grease DIN 51825 KPF2 As required Stop Play Min 2 mm Screws for the lift mast beari...

Page 367: ...nder Code Unit Operating materials Specifications Dimension System filling LPG DIN 51622 EN 589 11 kg Brake system Code Unit Operating materials Specifications Dimension System filling Brake fluid ARAL HGS FLUID 127830 0 25 l Engine Code Unit Operating materials Specifications Dimension System filling Engine oil API CI4 SAE10 W40 Low ash With filter change 8 6 l Air filter Filter cartridge and saf...

Page 368: ...t hand cab door is open On forklift trucks equipped with a cab var iant open the right hand cab door Remove all loose objects from the right hand shelf Move the steering column 1 as far for wards as possible and secure see section entitled Adjusting the steering column Slide the driver s seat 2 all the way for ward see section entitled Adjusting the MSG 65 MSG 75 driver s seat On trucks equipped w...

Page 369: ... in the open position When additional load is present for example heavy objects strong wind or other persons the bonnet can lower suddenly Cold weather and ageing can also reduce the perform ance of the gas spring and cause the bonnet to low er If the force of the gas spring is deteriorating re place the gas spring If the gas spring has a position lock variant make sure that the latch is engaged T...

Page 370: ...essed Exerting force when closing the bonnet will damage the gas spring or bonnet sus pension Before closing the bonnet make sure that the gas spring is equipped with a prop variant For gas springs with props variant release the latch 1 before closing the bonnet Releasing the prop latch variant Press the latch 1 at the marking PRESS and lower the bonnet slightly Release the latch Closing the bonne...

Page 371: ...driver s seat Adjust the steering column 1 see section entitled Adjusting the steering column On forklift trucks equipped with a cab var iant close the right hand cab door 7311_120 001 1 2 Maintenance 5 Providing access to maintenance points 357 57368011501 EN 10 2020 04 ...

Page 372: ... place to one side after removal Removing the cover Unscrew the star grip screws 1 on the right and left Fold back the cover 2 Lift up and remove the cover Attaching the cover Fit the cover 2 from above Fold the cover forwards Securely tighten the star grip screws 1 on the right and left 7321_003 062 1 2 7321_003 062 1 2 Maintenance 5 Providing access to maintenance points 358 57368011501 EN 10 20...

Page 373: ...rt their fingers in order to lift it The recess is beneath the rubber mat NOTE The accelerator pedal is attached to the bot tom plate and is removed with the bottom plate The connecting plug for the accelerator is located underneath the bottom plate Open the bonnet Remove the rubber mat Grasp the recess in the bottom plate 1 Raise the bottom plate slightly Pull out the bottom plate under the brake...

Page 374: ... 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 Set down the bottom plate upright in the footwell Connect the connection assembly to the ac celerator pedal Position the bottom plate at the front Carefully guide the bottom plate down and close Insert the rubber mat Close the bonnet 7311_003 0...

Page 375: ...centre Have the LPG system checked for leakages using leak spray Have the screw joints of the LPG system checked for tightness Check the condition and tension of the V ribbed belt 1 NOTE If the V ribbed belt is damaged have it re placed by the authorised service centre 7311_003 026 1 Maintenance 5 Maintenance after the first 50 operating hours 361 57368011501 EN 10 2020 04 ...

Page 376: ...o the lower mark unscrew the filler cap 2 and top up the oil Do not top up beyond the upper mark Observe the information regarding the quantity and specification of the motor oil in the chapter entitled Maintenance data ta ble Insert the oil dipstick as far as it will go Screw the filler cap back on tightly Close the bonnet NOTE Remove spilt oil immediately using oil binding agent and dispose of t...

Page 377: ...screen wash can freeze at temperatures below freezing and damage the washer system Always use screen wash that contains anti freeze Open the bonnet Open the filler cap 1 on the screen wash reservoir Fill the screen wash reservoir with screen wash and anti freeze in accordance with the maintenance data table Close the filler cap Close the bonnet Operate the washer system until washer flu id is disc...

Page 378: ...k the cooling fluid level WARNING Risk of scalding due to hot cooling fluid The cooling system is pressurised Cooling fluid may escape if the cooling fluid tank 5 is opened while the engine is hot Switch off the engine and allow it to cool down be fore opening the filler cap 1 WARNING Coolant and cooling fluid can pose a hazard to health and the environment Observe the safety regulations set out i...

Page 379: ...e tank cap 1 is screwed on and is tightly sealed Check the leak tightness of the cooling sys tem see the section entitled Cleaning the radiator checking for leaks Replace the rear cover Topping up the cooling fluid and checking the coolant concentration WARNING Risk of scalding due to hot cooling fluid The cooling system is pressurised Cooling fluid may escape if the cooling fluid tank 5 is opened...

Page 380: ...e at least 40 even if frost protection is not needed in warmer climates If greater frost protection is required for climatic rea sons the percentage of coolant additive can be in creased to up to 60 The percentage of coolant must not exceed 60 otherwise the frost protection is reduced In addition the cooling effect is also reduced Only use clean softened water for the water per centage Frost prote...

Page 381: ...he cooling sys tem see the section entitled Cleaning the radiator checking for leaks Replace the rear cover Replacing the air filter cartridges NOTE The air filter cartridges must be replaced if the Change the air filter message ap pears on the display operating unit or at least every 3000 hours or every two years Open the bonnet Release the three clamps 1 on the air filter housing and remove the ...

Page 382: ...he housing so that no dirt enters the intake system Wipe out the air filter housing using a damp cloth Remove the safety cartridge 4 check for contamination and replace the safety car tridge if necessary Refit the safety cartridge Insert a new filter cartridge 3 3 7321_003 076 4 7321_003 077 Maintenance 5 Preserving operational readiness 368 57368011501 EN 10 2020 04 ...

Page 383: ...ng to the maintenance data table see Chapter Maintenance data table Page 351 Driver s seat guide Lubricate bonnet hinges at the lubricating nipple Control linkage for valves In the cab lubricate door hinges at the lubri cating nipple variant Lubricate shafts and joints in dual pedal op eration variant 7321_003 078 7 7 7 6 5 Maintenance 5 Preserving operational readiness 369 57368011501 EN 10 2020 ...

Page 384: ...ctive seat belts replaced by your authorised service centre Only use genuine spare parts Do not make any changes to the seat belt NOTE The checks below must be carried out on a regular basis monthly In the case of signifi cant strain a daily check is necessary Checking the seat belt Pull out the seat belt 3 completely and check for fraying The seat belt must not be frayed or cut The stitching must...

Page 385: ...atic blocking mechanism must block extension of the belt Tilt the seat at least 30 to do this tilt the bonnet Slowly pull out the seat belt The automatic blocking mechanism must block extension of the belt Cleaning the seat belt Clean the seat belt if it is dirty but without using chemical cleaning materials a brush will suffice Replacement after an accident The seat belt must always be replaced b...

Page 386: ... wear Check the lock mechanism for easy opera tion Maintaining wheels and tyres WARNING Risk of accident Uneven wear reduces the stability of the truck and in creases the braking distance The level of wear ex hibited by tyres on the same axle must be approxi mately the same Worn or damaged tyres left or right must be re placed immediately When changing wheels or tyres ensure that this does not cau...

Page 387: ...roval from the truck manufacturer be fore using a different type of tyre or a different tyre manufacturer Checking the condition and wear of the tyres Superelastic tyres variant Check the remaining distance between the tyre tread and the wear mark 60 J Superelastic tyres variant can be worn down to the wear mark 60 J Remove any foreign bodies embedded in the tyre 6 0 J 6 0 J Maintenance 5 Preservi...

Page 388: ...ressure NOTE The correct air pressure for pneumatic tyres variant is determined by the type of tyre used The air pressure measured must corre spond to the manufacturer s information See the air pressure values stated on the adhesive label 1 on the truck Check the air pressure of all four tyres and compare with the air pressure values stated on the adhesive labels Add or release air as required if ...

Page 389: ...ery NOTE Battery servicing is carried out in accordance with the battery manufacturer s operating manual WARNING Risk of short circuit and explosion Do not place any metal objects or tools on the battery Keep away from naked flames and fire Smoking is forbidden Checking the battery charge state Remove the rear cover 7300_003 018 1 Maintenance 5 Preserving operational readiness 375 57368011501 EN 1...

Page 390: ...ging the battery WARNING The electrolyte diluted sulphuric acid is poisonous and corrosive Observe the safety regulations for handling battery acid Observe the safety information from the battery manufacturer With batteries that are not maintenance free check the level of the battery acid The battery acid must come up to the lower edge of the insert in the battery housing or 5 mm above the upper e...

Page 391: ... listed acid densities refer to an acid temperature of 27 C Charge state Battery charge Acid density kg l Full 100 approx 1 28 Normal 75 approx 1 21 Weak 50 approx 1 16 Discharged 25 approx 1 13 Deep dis charged 0 10 1 06 NOTE Temperature fluctuations can cause the meas urement results to change In the event of a difference in temperature of 35 C the values deviate from each other by approx 0 05 k...

Page 392: ...e the cover Replace the defective fuse with 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 per sists or if the fuse is still defective notify your authorised service centre Checking the hydraulic system for leak tightness WARNING Hydraulic oil is hazardous to health Hydrauli...

Page 393: ...r has been damaged or is brittle or cracked Leaking Deformation e g with blisters or kinks A fitting has come loose A fitting is badly damaged or corroded Replace pipes if they display the following ab normalities Abrasion Deformation and bending Leaking Lubricating the lift mast and roller track Remove dirt and lubricant residue from the roller track Lubricate the roller tracks 1 of the outside m...

Page 394: ... hand lever 2 upwards Grease using the lubricating nipple 1 in ac cordance with the maintenance data table see Chapter Maintenance data table Page 351 Close the coupling by raising the coupling pin with a suitable tool For journeys with a rigid drawbar trailer lu bricate the underside of the tow bar eye and the supporting surface on the coupling Determine the wear on the coupling pin The diameter ...

Page 395: ...pporting surface 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 da ta table Page 351 Grease the supporting surface for the tow bar eye Wartung_Rockinger 244 A 1 7321_003 094 Maintenance 5 Preserving operational readiness 381 57368011501 EN 10 2020 04 ...

Page 396: ...serve the safety regulations for working with hydraulic oils see Chapter Hydraulic fluid Page 47 Park the truck securely see Chapter Parking the truck securely and switching it off Page 183 Open the bonnet see Chapter Opening the bonnet Page 354 Unscrew the breather filter with the oil dip stick 1 in an anti clockwise direction and remove The breather filter with the dipstick is located on the lef...

Page 397: ...g specification see Chapter Mainte nance data table Page 351 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 any spilled oil Dispose of these substances in an environmentally friend ly manner 7094_700 002 1 2 Maintenance 5 Preserving operational readiness 383 ...

Page 398: ...Maintenance 5 Preserving operational readiness 384 57368011501 EN 10 2020 04 ...

Page 399: ...ecure fit and leaks Changing the LPG filter DANGER There is a risk of explosion if LPG es capes Note safety regulations for working with LPG Chapter LPG Page 49 Switch off the engine For trucks with LPG cylinders close the cyl inder valve 1 For trucks with an LPG tank variant close the shut off valve 2 Open the bonnet see Chapter Opening the bonnet Page 354 1 7311_003 036 7325_003 012 2 Maintenanc...

Page 400: ... that the sealing ring is properly seated in the recess of the filter insert and that the filter is correctly installed Check the seals 7 for damage and change if necessary Screw filter housing back on Open the cylinder valve 1 or the shut off valve 2 Check all connections for leakages using leak spray Close the bonnet 7325_003 013 4 3 7081_003 038 3 4 5 6 7 7 Maintenance 5 1000 hour maintenance y...

Page 401: ... and excessive wear No cracks or deformations must be visible on the fork arms in the area around the fork bend Wear must not amount to more than 10 of the original thickness Check that the locking screws 2 are present and securely attached Replace any worn or deformed fork arms Check the condition and correct operation of the fork latch Move the locking lever 3 into a vertical po sition It must b...

Page 402: ...versible fork arms NOTE This check is only required for reversible fork arms variant Check the outside of the fork bend 1 for cracks Contact your service centre Maintenance 5 1000 hour maintenance yearly maintenance 388 57368011501 EN 10 2020 04 ...

Page 403: ...ection intervals The testing must be conducted only by an approved in spection body and by a competent person In Germany testing is conducted by TÜV for ex ample Have the LPG tank tested by an approved inspection body and by a competent per son Observe the national regulations for the country in which the truck is being used 7311_003 043 Maintenance 5 10 year maintenance 389 57368011501 EN 10 2020...

Page 404: ...Maintenance 5 10 year maintenance 390 57368011501 EN 10 2020 04 ...

Page 405: ...6 Technical data ...

Page 406: ...Dimensions 7306_003 002 Steering column is adjustable 80 mm Seat is adjustable 90 mm Fork spacing is adjustable Technical data 6 Dimensions 392 57368011501 EN 10 2020 04 ...

Page 407: ...954 RX70 30 7403 1003 RX70 30 600 7404 1003 RX70 35 7405 1068 NOTE The specified centre of gravity S relates to trucks with standard equipment If for exam ple the truck is equipped with a different lift mast attachment or driver protection struc ture this value is only a guide value If neces sary the centre of gravity S must be deter mined on an individual basis for each truck Technical data 6 Dim...

Page 408: ...eat Load capacity load Q kg 2000 2500 Load centre of gravity c mm 600 500 Load distance x mm 459 459 Wheelbase y mm 1760 1760 Weights Model RX70 20 600 RX70 25 Type number 7400 7401 Net weight kg 3834 3834 Front axle load laden kg 4993 5652 Rear axle load laden kg 841 682 Front axle load unladen kg 1790 1790 Rear axle load unladen kg 2044 2044 Wheels chassis frame Model RX70 20 600 RX70 25 Type nu...

Page 409: ... 1074 1074 Coupling height h10 mm 340 455 340 455 Overall length l1 mm 3605 3605 Length including fork back l2 mm 2605 2605 Overall width b1 mm 1192 1192 Fork arm thickness s mm 40 40 Fork arm width e mm 100 100 Fork arm length l mm 1000 1000 Fork carriage in acc with ISO 2328 class form II A II A Fork carriage width b3 mm 1150 1150 Ground clearance with load below lift mast m1 mm 125 125 Ground c...

Page 410: ...Climbing capability without load 26 26 Acceleration time with load s 5 1 5 1 Acceleration time without load s 4 5 4 5 Service brake Electr hydr Electr hydr CAUTION To use the truck safely with or without a load the maximum permitted ascending or descending gradi ent for travel is 15 If you have any questions contact your authorised service centre Engine Model RX70 20 600 RX70 25 Type number 7400 7...

Page 411: ...or attachments bar 250 250 Oil flow for attachments l min 30 30 Capacity of fuel tank l kg 11 11 Sound pressure level LpAZ driver s com partment 2 dB A 77 77 Sound power level LwAZ working cycle dB A 97 97 Human vibration acceleration in accord ance with EN 13059 m s2 0 58 0 58 Tow coupling DIN type model Bolt Bolt 1 With Blue Q energy saving programme 2 Without cab Values are different with a cab...

Page 412: ...eat Load capacity load Q kg 2500 3000 Load centre of gravity c mm 600 500 Load distance x mm 464 469 Wheelbase y mm 1820 1820 Weights Model RX70 25 600 RX70 30 Type number 7402 7403 Net weight kg 4135 4168 Front axle load laden kg 5788 6462 Rear axle load laden kg 847 706 Front axle load unladen kg 1827 1865 Rear axle load unladen kg 2308 2303 Wheels chassis frame Model RX70 25 600 RX70 30 Type nu...

Page 413: ...1074 1074 Coupling height h10 mm 340 455 340 455 Overall length l1 mm 3705 3705 Length including fork back l2 mm 2705 2705 Overall width b1 mm 1192 1192 Fork arm thickness s mm 45 50 Fork arm width e mm 100 100 Fork arm length l mm 1000 1000 Fork carriage in acc with ISO 2328 class form II A III A Fork carriage width b3 mm 1150 1150 Ground clearance with load below lift mast m1 mm 125 125 Ground c...

Page 414: ...limbing capability without load 24 24 Acceleration time with load s 5 1 5 1 Acceleration time without load s 4 5 4 5 Service brake Electr hydr Electr hydr CAUTION To use the truck safely with or without a load the maximum permitted ascending or descending gradi ent for travel is 15 If you have any questions contact your authorised service centre Engine Model RX70 25 600 RX70 30 Type number 7402 74...

Page 415: ...or attachments bar 250 250 Oil flow for attachments l min 30 30 Capacity of fuel tank l kg 11 11 Sound pressure level LpAZ driver s com partment 2 dB A 77 77 Sound power level LwAZ working cycle dB A 97 97 Human vibration acceleration in accord ance with EN 13059 m s2 0 58 0 58 Tow coupling DIN type model Bolt Bolt 1 With Blue Q energy saving programme 2 Without cab Values are different with a cab...

Page 416: ...at Load capacity load Q kg 3000 3500 Load centre of gravity c mm 600 500 Load distance x mm 469 469 Wheelbase y mm 1820 1820 Weights Model RX70 30 600 RX70 35 Type number 7404 7405 Net weight kg 4460 4460 Front axle load laden kg 6652 7253 Rear axle load laden kg 808 707 Front axle load unladen kg 1890 1890 Rear axle load unladen kg 2570 2570 Wheels chassis frame Model RX70 30 600 RX70 35 Type num...

Page 417: ...1074 1074 Coupling height h10 mm 340 455 340 455 Overall length l1 mm 3770 3770 Length including fork back l2 mm 2770 2770 Overall width b1 mm 1224 1224 Fork arm thickness s mm 50 50 Fork arm width e mm 100 100 Fork arm length l mm 1000 1000 Fork carriage in acc with ISO 2328 class form III A III A Fork carriage width b3 mm 1150 1150 Ground clearance with load below lift mast m1 mm 125 125 Ground ...

Page 418: ...Climbing capability without load 20 20 Acceleration time with load s 5 4 5 4 Acceleration time without load s 4 8 4 8 Service brake Electr hydr Electr hydr CAUTION To use the truck safely with or without a load the maximum permitted ascending or descending gradi ent for travel is 15 If you have any questions contact your authorised service centre Engine Model RX70 30 600 RX70 35 Type number 7404 7...

Page 419: ...or attachments bar 250 250 Oil flow for attachments l min 30 30 Capacity of fuel tank l kg 11 11 Sound pressure level LpAZ driver s com partment 2 dB A 77 77 Sound power level LwAZ working cycle dB A 97 97 Human vibration acceleration in accord ance with EN 13059 m s2 0 58 0 58 Tow coupling DIN type model Bolt Bolt 1 With Blue Q energy saving programme 2 Without cab Values are different with a cab...

Page 420: ...ements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clear ance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into ac count and in accordance with EN ISO 3411 In general from the seat position the operator has sufficient space to reach th...

Page 421: ... engine oil 10 A 1F08 1F09 1F10 1F11 1F12 1F15 1F16 1F17 1F18 1F19 1F21 ECU K01 ECU K03 ECU K05 15 A Signal horn 10 A CAN power port 1 CPP 1 roof top 30 A CAN power port 5 CPP 5 roof bottom 20 A CAN power port 3 CPP 3 driver s seat wiper 30 A Electric parking brake 30 A SAE 12 V socket 10 A Starter motor terminal 50 30 A Relay for glow plug monitor 10 A Air conditioning condenser 20 A Air conditio...

Page 422: ...eft of the fuse box on the starter battery NOTE Depending on the equipment not all fuses will be present in the truck 7300_003 009 9F06 9F36 Sheathed element heater plug only on diesel trucks 25 A 12 V socket 10 A 9F06 9F36 Technical data 6 Fuse assignment 408 57368011501 EN 10 2020 04 ...

Page 423: ... 250 Controlling with the fingertip 251 Controlling with the fingertip and the 5th function 253 Depressurising the connections 229 General controlling 232 Mounting 228 Special risks 35 Taking up a load 257 Automatic mast vertical positioning Checking for correct function 87 Operation 186 Automatic tow coupling 285 Coupling RO 243 287 Coupling RO 244 A 289 Coupling RO 245 291 Coupling RO 841 292 Un...

Page 424: ...for handling battery acid 48 Safety information for handling oils 46 Safety information for hydraulic fluid 47 Safety precautions for LPG 49 Contact details I Coolant 365 Coolant and cooling fluid 52 Cooling fluid Topping up 365 Copyright and trademark rights 18 Crane loading 327 Cruise control 179 Cup holders 62 D Damage 30 Danger area 212 Danger to employees 40 De icing the evaporator 176 Declar...

Page 425: ...ift mast 200 Fitting attachments 227 FleetManager 261 Shock recognition 261 Foreword 0 Fork arms Length 32 Fork extension 204 Fork wear protection 201 Function checking 76 Fuse assignment 407 G Gas spring with prop variant Releasing the latch 356 General 4 H Handling gas springs and accumulators 32 Handling loads 208 Hazardous areas 153 Hazards and countermeasures 38 Hazard warning system Switchin...

Page 426: ...ing 307 Opening the shut off valve 125 Lubricating the joints and controls 369 M Main display 127 Maintenance 0 10 year 389 1000 hour 385 After the first 50 operating hours 361 General information 341 Yearly 385 Maintenance data table 351 Air conditioning 353 Battery 351 Brake system 353 Controls joints 351 Cooling system 353 Drive axle 352 Electrical system 351 Engine 353 General lubrication poin...

Page 427: ...the truck is stationary 166 Emergency operation 318 Malfunctions 169 Parking the vehicle safely 170 Parking the truck securely 183 Personnel qualifications 341 Picking up loads 212 Place of use 14 Pre Shift Check All questions 100 Description 98 History 103 Process 99 Question sequence 102 Shift start 105 Truck restrictions 109 Procedure if truck tips over 315 Production number 12 Prohibition of u...

Page 428: ... Shake function 221 Double mini lever 223 Fingertip switch 224 Joystick 4Plus 222 Quadruple mini lever 223 Triple mini lever 223 Shelves 62 Shock recognition 261 Short term operation 331 Shutting down the truck 332 Side windows closing 270 Side windows opening 270 Special risks 35 Sprint mode Automatic switch off 147 Switching on and off 147 Stability 35 Starting drive mode 159 Dual pedal version ...

Page 429: ...ke function 221 Shock recognition 261 Speed reduction when the fork carriage is raised 175 Travel direction selector and indicator module 73 Triplex lift mast 189 Wheel chock 185 Windscreen wipers and washers 259 Zero braking 165 VDI datasheet RX70 20 600 394 RX70 25 394 RX70 25 600 398 RX70 30 398 RX70 30 600 402 RX70 35 402 View of functions and operating proce dures 19 View of operating procedu...

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