Still FXV 14 N, Original Instructions Manual

Page 1: ...Pallet stacker FXV 14 N FXV 16 N Original instructions 1537 1538 2376 2377 11748011551 EN 02 2021 09 ...

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Page 3: ...of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany Tel 49 0 40 7339 0 Fax 49 0 40 7339 1622 Email info still de Website http www still de Preface I 11748011551 EN 02 2021 09 ...

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Page 5: ...ion of symbols used 9 Disposing of components and batteries 9 2 Safety Safety regulations 12 Safety regulations for handling consumables 13 Permissible consumables 13 Oils 13 Hydraulic fluid 14 Battery acid 14 Disposal of consumables 15 Emissions 16 Noise emission values 16 Vibration characteristics for vibrations to which the body is exposed 16 Residual dangers residual risks 17 Stability 17 Defi...

Page 6: ...ioning 36 Checking the emergency off switch 36 Checking the brakes 36 Checking the horn 37 Truck operating instructions 38 Stepping on off the truck 40 Operation of operator presence detection 41 Driver s compartment settings 43 Adjusting the seat 43 Adjusting the floor 43 Seat heater option 44 Using the display operating unit 45 Selection buttons 45 Display of the drive wheel position 45 Operatio...

Page 7: ...Handling a single load 73 Driving assistance system Dynamic Load Control 77 Description of the Dynamic Load Control DLC 77 The No Dynamic Load Control DLC display 78 Using Dynamic Load Control DLC version 1 79 Using Dynamic Load Control DLC version 3 81 Rules for using the Dynamic Load Control 84 Cold store usage optional 87 Parking the truck 89 Handling the battery 90 Battery type 90 Order pickin...

Page 8: ...mmended lubricants 110 Accessing the technical compartment 111 1000 hour maintenance plan 113 5000 hour maintenance plan 114 10 000 hour service plan 114 Chassis bodywork and fittings 115 Cleaning the truck 115 General information on battery maintenance 117 Checking the condition of the forks 118 Steering and wheels 119 Checking the condition of the wheels 119 Electrical equipment 120 Cleaning and...

Page 9: ...mast chains 125 Checking the protective screen 126 Storage and decommissioning 128 Storage of truck 128 Permanent Putting Out of Commission Destruction 129 6 Technical specifications FXV 14N 16N datasheet 132 FXV 14N 16N mast types 136 Table of contents VII 11748011551 EN 02 2021 09 ...

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Page 11: ...1 Introduction ...

Page 12: ...w the truck to be handled safely By complying with the specifications in these operating instructions the functionality and the approved features of the truck will be retained Get to know the technology understand it and use it safely these operating instructions pro vide the necessary information and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Ther...

Page 13: ... addi tion to the tow tractor can compromise safety thereby invalidating the EC declaration of con formity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities Copyright and property rights This manual and any excerpts thereof may not be reproduced translated or transmitted in any form to third parties without the express written permission o...

Page 14: ...pliance declaration STILL S A S The manufacturer declares that the truck com plies with the requirements of the EC direc tives valid at the time of marketing This is confirmed by the EC declaration of conformity and by the EC labelling on the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declarat...

Page 15: ...lar 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 Model Manufacturer Serial number Year of manufacture Unladen weight without battery in kg Maximum battery weight Minimum battery weight for a lithium ion battery the weight of the ballast con...

Page 16: ...et the description giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given i...

Page 17: ... or by scanning the QR code displayed to the side When the web page is open please type in the following password Spareparts24 On the next screen please enter your email address and truck serial number to receive the link by email Then download the spare parts list 2511 Introduction 1 Spare parts list 7 11748011551 EN 02 2021 09 ...

Page 18: ...le The capacity label specifies the maximum load that can be raised This limit must not be exceeded Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature in tropical and Nordic regions ranging from 10 C to 45 C Start capability from 10 C to 45 C Maximum start time of 20 seconds Use at up to 2000 metres above sea level Special use partly with special meas ...

Page 19: ...physical harm WARNING Compulsory procedure that must followed to avoid injury CAUTION Compulsory procedure that must be followed to avoid damage to and or destruction of equipment NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Disposing of components and batteries The truck is made up of different materials If components or batteries...

Page 20: ...Introduction 1 Disposing of components and batteries 10 11748011551 EN 02 2021 09 ...

Page 21: ...2 Safety ...

Page 22: ...allets or any other container Information concerning starting driving and braking Information concerning maintenance and repair Regular checks and technical inspections Recycling of lubricants oils and batteries Residual risks Care is recommended both for the user and the person in charge employer with regard to adhering to all safety rules concerning the use of material handling trucks When instr...

Page 23: ...Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation 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 when combined w...

Page 24: ...m plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the regulations Dispose of old hydraulic fluid according to reg ulations Battery acid WARNING Battery acid contains dissolved sulphuric acid This is toxic Avoid contact and consumption In case of injury seek medical advice immediately WARNING Battery ac...

Page 25: ...only be carried out in areas designated for this purpose Take care to minimise as far as pos sible any impact on the environment Any spillage of fluids such as hydraulic oil brake fluid or gear lubricant oil must be im mediately soaked up with an oil binding agent The regulations for disposal of used oil are applicable Any spillage of battery acid must be neutral ised immediately Safety 2 Safety r...

Page 26: ...termined according to EN 13059 using trucks with standard equipment according to the datasheet driving over test course with humps Specified characteristics for upper limb vi brations Vibration characteristics 2 5 m s2 NOTE The vibration characteristics for bodily vibra tions cannot be used to determine the actual load level of vibrations during operation This depends on the operating conditions s...

Page 27: ...the load being unsta ble or the load slipping etc Risk of fire and explosion due to batteries and electrical voltages Human error Disregarding safety regula tions It is important to adjust the speed of the truck depending on the load and ground conditions The stability of the truck has been tested to the latest standards These standards only take account of the static and dynamic tilting forces th...

Page 28: ...tion of industrial trucks in terms of health and safety Drivers This truck may only be driven by suitable per sons who are at least 18 years of age have been trained in driving have demonstrated their skills in driving and handling loads and have been specifically designated to drive the truck Specific knowledge of the truck is also necessary Driver rights duties and rules of behav iour The driver...

Page 29: ...is responsible 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 Safety 2 Definition of responsible persons 19 11748011551 EN 02 2021 09 ...

Page 30: ...til at least a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring that any defects are remedied immediately Contact your servi...

Page 31: ...3 Overviews ...

Page 32: ...n Control module Seat Lift cylinder Platform Drive wheel 1 2 3 4 5 6 7 Stabiliser wheel Operator presence pedal Battery compartment Forks Load wheels or bogies Mast Emergency off switch 8 9 10 11 12 13 14 Overviews 3 Overview 22 11748011551 EN 02 2021 09 ...

Page 33: ...General view of the technical compartment Pump motor unit Fan Horn Traction motor 1 2 3 4 Fuses Tank ES30 24 steering unit 5 6 7 Overviews 3 Overview 23 11748011551 EN 02 2021 09 ...

Page 34: ...ystick depending on option selected Emergency off switch Switch key or electronic key 1 2 3 Display Control button Steering Knob device Steering wheel Handle for stepping on and off the truck 4 5 6 7 Overviews 3 Operating and display devices 24 11748011551 EN 02 2021 09 ...

Page 35: ...L ELECTRON IC KEY SET TINGS 0 0 0 0 0 0 0 0 by default continuous red con tinuous green 3 Once the LEDs have gone out the electronic key automatically reverts to operating mode New operator code 0 4 5 6 7 8 red off green flash ing 2 code accepted Example of new opera tor code 45678 Allocating opera tor codes 2 5 4 3 2 1 red off green flash ing 2 code accepted 2 operator reference 10 options from 0...

Page 36: ...wer switches off auto matically after 10 mi nutes 600 seconds by default if the truck is not in use Setting the time delay of the auto matic switch off 3 6 0 red off green flash ing 2 value accepted Example automatically switches off after 1 mi nute 60 seconds if not in use Minimum setting 10 seconds maximum 3000 seconds Deactivating the automatic switch off 2 0 red off green flash ing 2 command a...

Page 37: ...Activity indicator light Error Code menu 1 2 3 4 5 6 7 8 Settings menu Load Management and Drive wheel position menu Status menu Display of the operating time of the truck Display of the battery charge Display of the date and time 9 10 11 12 13 14 For more information refer to chapter 4 Using the display operating unit Overviews 3 Operating and display devices 27 11748011551 EN 02 2021 09 ...

Page 38: ...ty inspection of the truck label Danger instructions label Consult operating instructions 1 2 3 4 Capacity label Never touch with hands label Mast safety label Slinging label Consult operating instructions Model label 5 6 7 8 9 Overviews 3 Markings 28 11748011551 EN 02 2021 09 ...

Page 39: ...number for all technical en quiries The serial number contains the following infor mation 1 Production location 2 Type 3 Year of production 4 Count number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Overviews 3 Markings 29 11748011551 EN 02 2021 09 ...

Page 40: ...Overviews 3 Markings 30 11748011551 EN 02 2021 09 ...

Page 41: ...4 Use ...

Page 42: ...ic steering offers driving precision and easier manoeuvring The truck is equipped with a 0 185 kW asyn chronous steering motor The steering is controlled with a steering wheel and a control module The drive unit is mounted on a turntable Steering is provided by an electric geared mo tor that positions the turntable The steering motor is controlled by a variable speed transmission It receives infor...

Page 43: ...exhaustive Electronic key Cold store 35 C Document holder Steering knob Joystick NOTE The operating instructions can be found in the document holder located on the technical compartment door Use 4 Technical description 33 11748011551 EN 02 2021 09 ...

Page 44: ...sion Ensure the visible area specified by the manufacturer is observed Attachment parts special equipment must be properly secured and function according to their operating instructions Damaged or missing stickers must be re placed in compliance with the marking posi tion table The guard grille must be intact and securely mounted The roller guide rails must be coated in a visible layer of grease T...

Page 45: ...tery compartment hood is closed and locked correctly Climb onto the truck using the handle Sit on the seat Press the operator presence pedal Release the emergency off switch 1 if it has been pressed Turn the key 2 For models equipped with an electronic key or the FleetManager op tion enter the PIN code The display 3 lights up The truck is ready for operation Use 4 Starting up 35 11748011551 EN 02 ...

Page 46: ...iliser wheels operate cor rectly This influences braking effectiveness Checking the brakes Braking by releasing the drive switch Drive the truck in direction 1 or 2 Release the drive switch The brake is activated until the truck stops completely Braking by reversing the drive direction Drive the truck in direction 1 or 2 Move the drive switch in the opposite direc tion The truck slows down and the...

Page 47: ...ocated on the rear side of the control module To check the operation of the horn proceed as follows Press the button 1 on the control module The horn sounds Use 4 Checks and actions prior to commissioning 37 11748011551 EN 02 2021 09 ...

Page 48: ...k could tip over when break ing or cornering The loads must be consistent with a maxi mum recommended height of 2 m For uses other than those shown above please consult the After Sales Service Centre It is important to use pallets that are in good condition Speed must be reduced when moving over obstacles to prevent the truck from becoming unbalanced and vibrations in the operator s arms The truck...

Page 49: ...a safe braking distance from vehicles or people in front of him The driver must avoid stopping suddenly making U turns too quickly and overtaking in dangerous areas with poor visibility CAUTION Risk of injury Before using a side access truck check that the bat tery is correctly locked Use 4 Truck operating instructions 39 11748011551 EN 02 2021 09 ...

Page 50: ...njury or impact from the edges of the truck The chassis is narrow Be careful not to hit yourself on the truck when stepping onto it CAUTION Risk of damaging the equipment Never pull on the steering wheel or control unit when climbing onto the truck Excessive force on the steering wheel or the control unit can damage it and cause a malfunction DANGER Risk of injury To avoid accidental start up do n...

Page 51: ... from the chair in the event of poor visi bility The truck then travels at 2 km h The forklift operator presence pedal must be kept depressed Before rising from the chair it is essential to slow down the truck to a very low pace and to check the working environment WARNING Risk of injury Do not rise from the chair when the truck is travelling at full speed NOTE Do not rise from the chair to slow d...

Page 52: ...ng of controls If the operator presence pedal is released when moving The truck brake is automatically activated The controls no longer work Use 4 Operation of operator presence detection 42 11748011551 EN 02 2021 09 ...

Page 53: ...low This operation also enables you to adjust the hardness of the seat Adjusting the floor The floor is fitted with a pressure based height adjustment system To adjust the floor height proceed as follows Sit on the seat Press the floor unlocking button 2 and hold it down for the duration of the opera tion Exert pressure on the floor 3 by pushing it with your legs to obtain a good driving posi tion...

Page 54: ...or Put the truck into service Press the LED button 1 to activate the heating The LED button 1 illuminates to indicate that the heater is in operation NOTE When the driver gets up or leaves the seat the heating stops in order to conserve battery power No visual information is shown on the display Check whether the LED button 1 is on Press the LED button 1 to reactivate the heater Use 4 Driver s com...

Page 55: ...ition The forklift operator can find out the position of the drive wheel by referring to the display Proceed as follows Press the left arrow or right arrow button to scroll through the menu Select the Wheel menu 2 Press the confirm button 1 The position of the drive wheel is then shown on the display 3 Operation of the display unit Operator presence For the truck to operate the operator must be de...

Page 56: ...t ing the operator s presence on the pedal 2 which flashes Press the operator presence pedal with your left foot The light indicating the operator s presence on the pedal 2 remains continuously illumi nated for two seconds and then goes out Use 4 Using the display operating unit 46 11748011551 EN 02 2021 09 ...

Page 57: ... and 4 icons flash and an audible beep sounds A warning message appears at the 4 icon and remains on until the battery is re charged 2 20 of charge remaining Three regular beeps sound lifting is restricted the 3 icon flashes and the 4 icon remains on with a new warning message Temperature settings and warning lights The temperature light 1 comes on in the event of overheating of the traction motor...

Page 58: ...he icon of the drive mode selected appears on the display Select the desired drive mode using the navigation keys Activity indicator The activity indicator light 1 flashes continu ously while the truck is in operation When the indicator is off the display unit is locked or frozen A warning is shown on the display Use 4 Using the display operating unit 48 11748011551 EN 02 2021 09 ...

Page 59: ...rast Adjustment of the brightness Select the desired option Error codes menu It is possible to access error messages that are disrupting the operation of the truck Select the Error messages menu 1 The operator can access the error codes If several codes are affecting the truck the oper ator can scroll through several successive dis plays The number of error messages is indicated at the bottom of t...

Page 60: ...ioned above additional data is available The Truck status menu 1 displays the truck menu The hourglass icon 2 indicates the operat ing time of the truck The clock icon 3 indicates the time and date Use 4 Using the display operating unit 50 11748011551 EN 02 2021 09 ...

Page 61: ...the dash board is prohibited The operator must be rest ing against the seat These trucks are designed to be used as a pallet stacker double pallet stacker and pallet truck Therefore Never sit on the dashboard to drive the truck The truck must not be used as a stepladder The truck is not designed to transport peo ple Operators must always stay within the truck clearance Stay in the safety area work...

Page 62: ...ware of the position of the drive wheel Slowly start the truck Check the position of the drive wheel on the display NOTE Always operate the drive switch slowly as the truck reacts immediately Abrupt starts brak ing or reversal of drive direction must be avoi ded at all costs The drive switch is located on the control unit NOTE Always keep hands and feet inside the driver s compartment while the tr...

Page 63: ...ally WARNING Restricted visibility During reverse travel visibility may be restricted Be very careful Make sure that the path behind is clear before travelling backwards Reversing the drive direction Push the drive switch in direction 1 or 2 Release the drive switch Operate it progressively in the opposite di rection until the required speed is reached Braking WARNING The quality of the floor surf...

Page 64: ...the following conditions is met The operator releases the operator pres ence pedal decelerates and then brakes The operator gets up from the seat decel erates and then brakes The drive switch is in the neutral position The power supply is cut off The operator presses the emergency off switch Horn The horn is positioned on the rear side of the control module It is used On routes where there is poor...

Page 65: ... selected on the screen the truck operates at its maximum perform ance Blue Q mode Selecting Blue Q mode allows you to slightly reduce the performance of the truck The travel speed of the truck is reduced 70 of maximum speed The speed of lifting and lowering the forks is reduced 90 of maximum speed This mode allows you to save battery Tortoise mode Selecting Tortoise mode allows you to reduce the ...

Page 66: ...on must be avoi ded at all costs Front of the joystick The front of the joystick is used to Move the truck forwards or backwards Raise or lower the forks Forward travel Push the joystick to the left 1 to travel for wards opposite fork direction Reverse travel Push the joystick to the right 2 to travel backwards fork direction Fork lifting Tilt the joystick downwards 4 Fork lowering Tilt the joysti...

Page 67: ... turning knob with caution The turning knob allows you to adjust the posi tion of the wheel There is no need to reposi tion it when driving if the trajectory is straight When the button is positioned in the centre at the zero point 1 the truck travels in a straight line Two stops one on the left 2 and one on the right 3 delimit the axis of rotation The oper ator adjusts the turning knob within thi...

Page 68: ... Move the turning knob to the left anti clock wise 2 to turn to the right Move the turning knob to the right clock wise 2 to turn to the left Use 4 Driving 58 11748011551 EN 02 2021 09 ...

Page 69: ... with great cau tion Never attempt a slope whose gradient is greater than that specified in the truck s da tasheet Make sure that the ground is clean and has a non slip surface and that the route is clear Travelling up slopes Always travel up slopes in reverse The load faces uphill Without a load we recommend that you go up a slope forwards Use 4 Driving 59 11748011551 EN 02 2021 09 ...

Page 70: ...e truck on a slope Never make a U turn or take shortcuts on a slope On a slope the operator must drive more slowly WARNING Risk of serious injury and or serious damage to equipment Driving on slopes steeper than 10 is prohibited due to braking capacity and stability The load being transported could tip over Starting on a slope Proceed as follows Move the drive switch in the required direc tion Rel...

Page 71: ...le with antenna The options available on the truck are Access control Access control and shock sensor Access control and GPRS module Access control shock sensor and GPRS module 1 GPRS General Packet Radio Service 2 GSM Global System for Mobile Communi cation Shock sensor This sensor allows you to record the shocks received by the truck If the truck receives a shock it is possible to configure a sp...

Page 72: ...nter key 3 to confirm The truck is now ready for use NOTE In the configuration the fleet manager can specify that the operator must enter a prelimi nary code when logging in The operator can then assess the state of the truck Commissioning a truck equipped with an RFID reading device Turn the switch key to start the truck Place the RFID transponder card or the RFID transponder 4 in front of the re...

Page 73: ...e enter the PIN code Lit continuously Red colour Flashes once Green colour A long acoustic signal sounds The operator has been granted ac cess authorisa tion But the peri od of validity has expired Use the interface to enter a new pe riod of validity The date of the truck is incorrect Update the date of the truck Flashes quickly Yellow colour Lit continuously Green colour Memory is 80 full Clear t...

Page 74: ... quickly Blue colour Off The truck is con nected via a Blue tooth link The op erating data is be ing read The reading process can take up to five minutes The truck is switched on but is not moving Wait for all of the rele vant data to be read As soon as the LEDs change to a different sta tus resume work Use 4 Operating the FleetManager option 64 11748011551 EN 02 2021 09 ...

Page 75: ...n a safe place Press the button 3 to log off Keep the but ton pressed in No LEDs light up A long acoustic signal sounds The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to sw...

Page 76: ... The LED 1 lights up for a second red col our The LED 2 is not lit A long acoustic signal sounds The LED 1 is no longer lit The LED 2 flash es slowly at two second intervals green col our No acoustic signal sounds The truck is disabled Turn the switch key to the off position to switch the truck off completely Use 4 Operating the FleetManager option 66 11748011551 EN 02 2021 09 ...

Page 77: ...s WARNING Take care not to trap hands or feet when operating the truck Grabbing a loading unit Watch out for the following elements the load must be well balanced and centred correctly between the fork arms the fork arms must be sufficiently slid un derneath the load to guarantee stability The load must not protrude too far over the fork arms nor should the fork arms protrude too far out from the ...

Page 78: ...me is only author ised when the safety preconditions are fulfilled by order of the monitoring agent The forklift operator must ensure that the load ing unit is properly packaged He must only move loading units that have been carefully prepared and that meet the safety require ments 0252_003 103 0252_003 104 Use 4 Transporting loads 68 11748011551 EN 02 2021 09 ...

Page 79: ...ks again before moving the truck The truck has two lift systems Main lift Lifting the fork arms Start the truck Push the fork lifting control 1 upwards A The fork arms are raised Lowering the fork arms Pull the fork lowering control 1 downwards B The fork arms are lowered When the lifting control 1 is released the forks stabilise at the required height NOTE The speed of lifting and lowering moveme...

Page 80: ... Lifting the load arms Pull the control 2 downwards D The load arms are raised Lowering the load arms Push the control 2 upwards C The load arms are lowered Use 4 Transporting loads 70 11748011551 EN 02 2021 09 ...

Page 81: ...XV 14 16 N capacity without initial lift FXV 14 N 1400 kg FXV 16 N 1600 kg FXV 14 16 N capacity with initial lift FXV 14 N 1400 kg FXV 16 N 1600 kg Usage in pallet truck mode 2000 kg at a height of 210 mm Reading the capacity plate Example using an FXV 16 N with initial lift fitted with a 4716 mm triplex mast 1 Maximum lift height 4802 mm 2 Maximum mast capacity 820 kg with a height of 4802 mm cen...

Page 82: ...n the lower position A detector 1 that senses when the position of the forks is 30 cm from the bottom part of the mast triggers an automatic slowing of the low ering action This detector prevents a violent impact at the end of travel Push the fork lowering control until the car riage is fully lowered The progressive shutoff device for the carriage prevents the buffer from being hit at the end of t...

Page 83: ... the fork arms Check that the load is not damaged CAUTION Risk of injury Safety shoes must be worn Transporting people is strictly prohibited Do not use the forks to lift a person DANGER Risk of tipping It is essential to slow down when approaching a cor ner or on wet ground CAUTION Arrangement of loads Do not touch nearby loads or loads positioned at the side or in front of the load being handled...

Page 84: ... make a U turn Reverse travel is used for setting down the load Adjust your speed as the position of the forklift operator is now less comfortable Do not drive with an unstable load If visibility is poor let someone guide you Raise the forks slightly in order to pass ob stacles Be careful of low passageways low door ways scaffolding pipes etc Check that the width of the load is not greater than th...

Page 85: ...to disengage the load from the stor age area Proceed as follows Drive the truck to the required location Lower the load arms completely Raise the forks clearly above the level where the load is to be placed Drive the truck forward into the rack Lower the load until the forks are free Withdraw the truck in a straight line Lower the forks again until they are several centimetres from the ground DANG...

Page 86: ... com pletely clear of the rack The forklift operator must re main vigilant and ensure that there are no obstacles preventing the lowering of the forks With the load on the forks lower the forks again until they reach the ground Lift the load arms to move the truck Before leaving the truck NOTE Always stop the truck on level ground away from traffic routes Proceed as follows Lower the forks to the ...

Page 87: ...ty CAUTION Risk of accident Despite this function the operator must remain vigi lant The safety guidelines must be observed This function enables you to manage the re sidual capacity of the truck On this truck three different types of DLC are available No DLC DLC 1 DLC 3 The No DLC and DLC 1 versions use the mast sensor between 300 mm and 1500 mm The DLC 3 version uses an ultrasonic height sensor ...

Page 88: ...ve the message does not appear on the display In a configura tion without DLC nothing is displayed It appears when the forks are lifted beyond 1500 millimetres Simply lower the forks again to restore the Dynamic Load Control function The initial lift must be in the lowered position to be able to raise the forks above 1500 mm If the initial lift is lifted the main lift is blocked at 1500 mm The fol...

Page 89: ...e screen load are provided for information only Due to the tolerance range the values cannot be used for precision operations The operator must visually check that the forks are at the correct height when handling loads in a rack Example of reading a display with the Dy namic Load Control DLC option version 1 The weight of the load on the forks 2 is not displayed The maximum authorised load is 140...

Page 90: ...on version 1 weight of the load significantly exceeded The weight of the load on the forks is 1600 kg 3 A tolerance of 50 kg applies The dis played weight takes this into account The maximum authorised load 1 on the forks is 1400 kg The measured weight exceeds the maximum weight Warning beeps sound and a red trian gle symbol 2 is shown on the display The measured weight 3 flashes The arrow points ...

Page 91: ...C option ver sion 3 shows height and load values Howev er this is only an aid to driving and the opera tor must remain vigilant under all circumstan ces WARNING There is a risk of striking a rack or a load The values displayed on the screen height and load are provided for information only Due to the toler ance range the values cannot be used for precision operations The operator must visually che...

Page 92: ...s is 1400 kg The maximum authorised height 1 is 3 3 m The lift height measured 4 is 3 2 m The measured weight is close to the maximum weight The lift height is close to the maximum authorised height A warning beep sounds once and a yellow triangle symbol 2 is shown on the display The measured weight and the measured height flash An arrow 5 indicates whether it is possible to continue raising or lo...

Page 93: ...tinue in order to free a load There is a similar display when the measured lift is greater than the authorised lift Example of reading a display with the Dy namic Load Control DLC option version 3 weight of the load significantly exceeded The weight of the load on the forks is 1600 kg 6 A tolerance of 50 kg applies The dis played weight takes this into account The maximum authorised load 3 on the ...

Page 94: ...ible in case of an accident WARNING Risk of loss of stability While driving the truck the operator must not listen to an MP3 player or any other device that could im pair awareness of his her working environment He she also must be very vigilant in case of loud am bient noise He she might not hear the warning beeps Rules for using the Dynamic Load Control WARNING There is a risk of striking a rack...

Page 95: ...t be low ered regularly If the forks remain in the raised position for more than four hours A beep sounds The Dynamic Load Control icon 3 appears on the display A yellow triangle symbol 1 appears on the display On the display the arrow 2 points down wards only The forks must be lowered immediately If the operator does not lower the forks imme diately the truck will only move at 4 km h and the lift...

Page 96: ...ocking the field between the two sensors The presence of an object may block it The sensors are clean After these checks the forklift operator must restart the truck If the error code L354 appears again after the restart please contact the After Sales Service Use 4 Driving assistance system Dynamic Load Control 86 11748011551 EN 02 2021 09 ...

Page 97: ...es between 30 C and 45 C Specific rules should be followed so as not to damage the truck and to avoid the occurrence of streaming see the following paragraph The truck is parked outside of the cold store Precautions for Use The difference in temperature between the cold store and the room temperature zone may result in the formation of condensation water This water can freeze when the truck goes b...

Page 98: ...d store could cause seri ous damage to the electrical and mechanical equipment seals hoses rubber and synthetic parts CAUTION Do not leave discharged or unused batteries in the cold store They could be permanently damaged Use 4 Cold store usage optional 88 11748011551 EN 02 2021 09 ...

Page 99: ...s sary secure the truck with wedges Stopping the truck Immobilise the truck Lower the forks Switch off the ignition key or electronic key Press the emergency off switch Restarting work Switch on the ignition again key or elec tronic key Press the operator presence pedal Pull the emergency off switch Use 4 Parking the truck 89 11748011551 EN 02 2021 09 ...

Page 100: ... picking Maintenance personnel The battery must be replaced by specially trained personnel Personnel must follow the manufacturer s instructions for the battery the charger and the truck It is also necessary to follow the battery main tenance instructions Fire protection measures WARNING Do not smoke or create a flame when handling batteries There must be no combustible material or tools that pro ...

Page 101: ...orks Switch off the ignition key or electronic key Press the emergency off switch Lift the hood 1 using the handle designed for this purpose Closing the battery hood To close the battery hood WARNING Risk of trapping fingers When closing the battery hood correctly position your fingers to avoid any risk of them being trapped Close the hood 1 Ensure that the battery hood is closed se curely CAUTION...

Page 102: ...all mounted connector WARNING Electrical risk Only unplug the battery connector from the battery charger when both the battery charger and truck are switched off NOTE Follow the instructions provided by the battery and battery charger manufacturers equalising charge WARNING Risk of damage short circuit or explosion Do not place any metallic objects or tools on the bat tery Smoking is prohibited WA...

Page 103: ...are generated during battery charg ing Make sure that the area is well ventilated Make sure that the battery hood remains open for the entire time the battery is charging Use 4 Handling the battery 93 11748011551 EN 02 2021 09 ...

Page 104: ...ecommend that you use a fixed roller frame or a truck with ex traction rollers fitted with rollers for easier handling of the battery To change the battery proceed as follows Immobilise the truck Lower the forks Switch off the ignition and remove the key Press in the emergency off switch Open the battery hood Unclip the hood from the fixed screw 1 Place it on the forks Disconnect the battery conne...

Page 105: ...truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment on level ground Operate and pull the locking handle 2 in the direction indicated by the arrow Use 4 Handling the battery 95 11748011551 EN 02 2021 09 ...

Page 106: ...lers or the roller frame Replace the battery Remove the dis charged battery and position a charged bat tery on the roller frame Position the truck with extraction rollers or the roller frame 4 in the upright position next to the battery compartment Use 4 Handling the battery 96 11748011551 EN 02 2021 09 ...

Page 107: ...from the rear side A of the battery Take care not to trap your fingers by pushing from the top or the side of the battery DANGER Risk of injury The battery is correctly positioned but is not yet locked Push it down to the end of the compart ment Use 4 Handling the battery 97 11748011551 EN 02 2021 09 ...

Page 108: ...ng bar should not in any circumstances be positioned under or on top of the stop It must be positioned against the stop Reconnect the battery connector Refit the battery hood Return the truck to service WARNING Risk of injury Before restarting the truck ensure that the battery is correctly installed Check that the battery is locked and that the battery hood is closed Use 4 Handling the battery 98 ...

Page 109: ...the technical compartment door Loosen the screw 1 using an 8 mm open ended spanner DANGER Danger of death Do not walk underneath raised loads Check that no one is in the danger area before man ually lowering the mast When the forks are fully lowered Loosen the screw 1 using an 8 mm open ended spanner Close the technical compartment door Use 4 Handling the truck in an emergency 99 11748011551 EN 02...

Page 110: ...the truck being towed Moving with no battery NOTE In the event of an electrical fault or no battery it is possible to unlock the brake manually CAUTION This procedure must be carried out by authorised personnel Unload the fork arms then disconnect the battery Remove the engine cover Two M5 X 35 screws 1 are required Screw the screws 1 to the brake 2 in the holes 3 The brake is then unlocked CAUTIO...

Page 111: ...re establish brake operation unscrew and remove the two screws 1 Refit the covers WARNING It is essential that the covers are correctly refitted be fore the machine is used 0252_003 110 3 2 Use 4 Handling the truck in an emergency 101 11748011551 EN 02 2021 09 ...

Page 112: ...ng instructions Shut off the truck and disconnect the bat tery connector Remove any items that could fall Protect all parts that come into contact with the lifting device Attach the lifting device to the sling ring 1 NOTE Do not sling the truck by the control module or the steering wheel Carefully lift the truck DANGER Risk of falling Make sure no one is under or near the truck when slinging the t...

Page 113: ... 3 As a safety precaution always insert a wood en chock WARNING Risk of truck falling Immobilise and chock the truck after lifting it Transporting the truck CAUTION Always switch off the ignition and disconnect the bat tery Never tie down or sling the truck by the control unit or other points not designed for this CAUTION Risk of damage to the truck Use a hoist and woven NON METALLIC slings with a...

Page 114: ...obilised so that no part is in contact with the wall of the lift cage A minimum safety distance of 100 mm from the walls of the lift must always be observed Anyone transported with the truck must only enter the lift after the truck has been correctly immobilised and they must exit the lift first Driving on loading bridges Before crossing a loading bridge the operator must make sure it is properly ...

Page 115: ...5 Maintenance ...

Page 116: ... the truck is used under harsh conditions extreme heat or cold large quantities of dust Grade and quantity of lubricants and other consumables Only lubricants and other consumables speci fied in these operating instructions are author ised for use in maintenance work Lubricants and other consumables required for truck maintenance are listed in the mainte nance specifications table Never mix differ...

Page 117: ...ow the manufacturer s in structions of the battery the battery charger and the truck It is essential to follow the battery mainte nance instructions and the battery charger op erating instructions Maintenance operations that do not require special training Simple maintenance operations such as checking the hydraulic fluid level or checking the battery electrolyte level can be carried out by person...

Page 118: ... personnel who have received detailed instructions who have been authorised to perform this work who have taken the necessary precaution ary measures Rings metal bracelets etc must be removed before carrying out any operations on electric components Remove the electric equipment which compri ses electric components such as the traction controller before carrying out any welding op erations This pr...

Page 119: ... oil 0 98 l Traction motor 3 kW 1F1 fuse Power 300 A quantity 1 Steering unit ES30 24 0 185 kW S1 3F1 fuse Power 40 A quantity 1 Pump motor 3 2 kW 1F1 fuse Power 300 A quantity 1 Control fuse 1F3 fuse Control 7 5 A quantity 1 Control fuse 1F4 fuse Control 5 A quantity 1 Battery Distilled water As required Joints Lithium soap grease As required Maintenance 5 Technical data for inspection and mainte...

Page 120: ... oil for the cold store version ISO L HM 32 as per ISO 6743 4 or ISO VG32 HLP as per DIN 51524 2 Transmission oil Recommended oil SAE 85W 90 API GL4 Aerosol can for chains Standard chain spray Grease for pinion gear and steering ring CAUTION Follow the maintenance and safety guidelines Multi purpose grease Lithium soap grease with EP agents and MoS 2KPF 2N 20 complying with the stand ard DIN 51825...

Page 121: ...hnical compartment Immobilise the truck Lower the forks Switch off the truck key or electronic key Press the emergency off switch Disconnect the battery connector Move the seat all the way forwards Remove the mounting screw 1 at the bot tom of the door Maintenance 5 Accessing the technical compartment 111 11748011551 EN 02 2021 09 ...

Page 122: ... 2 CAUTION Risk of trapping fingers Take care not to trap your fingers between the door and the chassis Be careful not to trap your fingers in the external hinges 3 Refit the mounting screw Reconnect the battery connector Return the truck to service Maintenance 5 Accessing the technical compartment 112 11748011551 EN 02 2021 09 ...

Page 123: ...gears Wheels Check the condition and tightness of the wheels Check the stabilisers Electrical equipment Clean the electric steering system and lifting motors Check the condition of the cables and the battery sockets and ensure that they are positioned correctly Check the electrical insulation between the chassis and the electric components Check the electrical insulation between the chassis and th...

Page 124: ...ntenance work Hydraulics Drain the hydraulic oil 10 000 hour service plan Depending on the application environmental conditions and driving style the following proce dures should be carried out every 10 000 hours Information Carry out all 1000 hour maintenance work Carry out all 5000 hour maintenance work Motor Drain the transmission gear oil Maintenance 5 5000 hour maintenance plan 114 1174801155...

Page 125: ... are sensitive to moisture par ticularly electric components must be protected when the truck is cleaned Follow the manufacturer s instructions when using the cleaning product Clean the truck with a non flammable clean ing product mixed with water a sponge and cloths Specifically clean the oil filler holes and sur rounding area as well as the lubricating nip ples before lubrication NOTE A frequent...

Page 126: ... of compressed air It is advisable to wear protection goggles and a mask Restart the truck in accordance with the in structions NOTE If despite taking precautions traces of mois ture remain in the motor dry it using com pressed air After having eliminated any traces of moisture the truck may be reactivated Do not do so before then to prevent any corro sion Maintenance 5 Chassis bodywork and fittin...

Page 127: ...ible charger Before charging ensure that the charger is suitable for the type of battery CAUTION Gel batteries are subject to specific charging mainte nance and treatment instructions A non compatible charger may result in a battery failure Observe the manufacturer s recommendations NOTE The discharge indicators used to check the battery must also be suitable for the type of battery Contact the re...

Page 128: ...hat the forks 1 show no signs of deformation splits heavy wear or cracks CAUTION Truck damage If the carriage is damaged have it changed by the After Sales Service Centre Maintenance 5 Chassis bodywork and fittings 118 11748011551 EN 02 2021 09 ...

Page 129: ... move any objects that may prevent them from turning or may obstruct them CAUTION Risk of damaging the wheels In order to avoid any risk of damaging the bearings and tyres of the wheels it is essential to remove any wires or plastic strips that may wind around the wheel hubs and bearings Maintenance 5 Steering and wheels 119 11748011551 EN 02 2021 09 ...

Page 130: ...ttery connector Open the technical compartment hood Blow the electrical components with com pressed air WARNING Use of compressed air It is advisable to wear protection goggles and a mask Check the condition of the cable harness connector pins Checking the battery acid level and electrolyte density NOTE Remove the battery from its compartment to check the water level Maintenance 5 Electrical equip...

Page 131: ...rinse away any spilled battery acid with plenty of water In case of injury seek medical advice immediate ly Always follow the safety information provided by the battery manufacturer Comply with the regulations in force Check the battery acid level and electrolyte density according to the battery manufactur er s recommendations The cell covers of the battery must be kept dry and clean Any spillage ...

Page 132: ...d output terminals are not sulphated presence of white salt Check the condition of the battery connec tor contacts and the presence of the keying pin CAUTION Risk of damaging the equipment The points mentioned above can cause serious inci dents In the event of an incident contact our After Sales Service Centre as quickly as possible Maintenance 5 Electrical equipment 122 11748011551 EN 02 2021 09 ...

Page 133: ...of friction wear Check the external pipes and hoses on the technical compartment Close the technical compartment door Return the truck to service CAUTION Risk of damaging the truck In the event of leakage please contact the After Sales Service Centre Checking the hydraulic oil level To check the hydraulic oil level proceed as follows Immobilise the truck Lower the forks Switch off the ignition and...

Page 134: ... necessary top up via the opening Refit the plug 1 afterwards CAUTION Risk of damage to hydraulic components Only use hydraulic oil that complies with the manu facturer s specifications see table of recommended lubricants Close the technical compartment door Reconnect the battery connector Return the truck to service Maintenance 5 Hydraulic systems 124 11748011551 EN 02 2021 09 ...

Page 135: ... lubricant CAUTION Risk of the equipment becoming worn or damaged Chains are safety components Use of cold cleaning agents chemical products acid or chlorinated prod ucts could destroy the chains NOTE Use of high pressure liquid cleaning devices is not advisable DANGER Danger of death and or risk of serious damage to equipment On trucks fitted with macrolon mast protection clean the translucent sc...

Page 136: ...After Sales Serv ice Centre Checking the protective screen It is important to check the condition of the mast protective screens and to check that the mountings are tightened Check that the protective screen 1 is cor rectly attached and in good condition un damaged Replace the protective screen if it is dam aged Adhere to the number of mountings defined by the manufacturer WARNING Risk of serious ...

Page 137: ...ectly attached Do not attach anything to the screen that could affect the visibility of the forks When cleaning the fork carriage side only clean the screen when the fork carriage is in the lowered posi tion Maintenance 5 Lift mast 127 11748011551 EN 02 2021 09 ...

Page 138: ... must not touch the ground in order to prevent ir reversible deformation of the tyres Cover the truck with a cotton cover to pro tect it from dust CAUTION We recommend that you do not use a plastic sheet as this encourages condensation to form Consult the service department for further measures to take if the truck must be stored for a longer period of time Recommissioning after storage If the tru...

Page 139: ...um iron etc Before scrapping the truck notify the com petent authorities of your country in writing After receiving the authorisation from the competent authorities remove any compo nents according to national standards NOTE The client is solely responsible for any irregu larities he has committed during or after the scrapping of the truck s components and the removal of components Maintenance 5 S...

Page 140: ...Maintenance 5 Storage and decommissioning 130 11748011551 EN 02 2021 09 ...

Page 141: ...6 Technical specifications ...

Page 142: ...FXV 14N 16N datasheet Technical specifications 6 FXV 14N 16N datasheet 132 11748011551 EN 02 2021 09 ...

Page 143: ... 1 1179 1920 1 2 3 Load per unladen axle drive side load side 10 kg 1050 530 1 971 528 1 WHEELS FXV 14N FXV 16N FXV 14Ni FXV 16Ni 3 1 Tyre polyurethane rubber drive side load side P P P P P P 3 2 Drive wheel dimensions width at the ground Ø x L mm Ø254 x L102 Ø254 x L102 3 3 Wheel dimensions load side Ø x L mm Ø85 x L85 bo gies Ø85 x L60 Ø85 x L85 bo gies Ø85 x L60 3 4 Additional wheels dimensions...

Page 144: ...0 780 4 2 5 Outside fork spread minimum maximum 5 mm b5 mm 560 560 4 2 6 Inside load arm spread b4 mm 255 255 4 3 2 Ground clearance at the centre of the wheelbase 2 mm m2 mm 30 20 4 3 3 Dimension of the b12 x L6 load mm 800 x 1200 800 x 1200 4 3 4 Aisle width with predetermined load Ast mm 2606 3 2606 3 4 3 5 Turning radius minimum 20 mm Initial lift raised lowered Wa mm 1783 1783 PERFORMANCE DAT...

Page 145: ... Li ion 410 Ah 23 410 6 5 Battery weight 10 kg 290 290 Battery weight with tray 10 4PzS SL Li ion 205 Ah 312 Battery weight with tray 10 4PzS SL Li ion 410 Ah 351 6 6 Energy consumption according to stand ardised VDI cycle kWh 1h 1 65 1 65 6 7 Turnover output according to VDI cycle t h 64 64 6 8 Energy consumption at turnover output kWh 1h 2 26 2 26 MISCELLANEOUS FXV 14N FXV 16N FXV 14Ni FXV 16Ni ...

Page 146: ... 3244 3744 4144 4644 h4 2364 2864 3364 3764 4264 4664 5164 Mast type Duplex 1844D 2344D 2844 3244D 3744D h1 1415 1665 1915 2115 2365 h1 h2 895 1145 1395 1595 1845 h3 1844 2344 2844 3244 3744 h4 2364 2864 3364 3764 4264 Mast type Triplex 4266T 4716T 5316T h1 1915 2065 2265 h1 h2 1395 1545 1745 h3 4266 4716 5316 h4 4786 5236 5836 Technical specifications 6 FXV 14N 16N mast types 136 11748011551 EN 0...

Page 147: ...g the chains 125 Cleaning the truck 115 Climatic conditions 8 cold store 87 Cold store usage 87 Consumables 13 Battery acid safety instructions 14 Disposal 15 Oil Safety Information 13 Safety information for handling hydraul ic fluid 14 Contact details I Copyright and property rights 3 D Defining directions 52 Description of the Dynamic Load Control DLC 77 Description of use 8 Destruction 129 Disp...

Page 148: ... In the event of error code L354 86 J Joystick function Front of the joystick 56 Rear of the joystick 57 L Lift control elements 69 Lifting Base lift 70 Main lift 69 Lifting the truck 103 Load handling safety rules 67 Location of markings 28 M Maintenance plan 106 1000 hours 113 5000 hours 114 Managing battery charging 47 Managing residual capacity 81 Mast 32 Multi purpose grease 110 N No Dynamic ...

Page 149: ...the truck 89 Symbols used 9 T Technical data for inspection and mainte nance 109 Technical description 32 Transmission oil 110 Transporting a load 74 Transporting the truck 103 Transporting the truck in the lift 104 Travelling down slopes 60 Travelling up slopes 59 Truck operating instructions 38 U Unauthorised use 9 Using Dynamic Load Control DLC ver sion 1 79 Using Dynamic Load Control DLC ver s...

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