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Still RX20 14-20, Original Instructions Manual

Get the most out of your Still RX20 14-20 with the Original Instructions Manual. This comprehensive manual is available for free download on our website, allowing you to easily access important information and optimize your product's performance. Simply visit 88.208.23.73:8080 to download your manual today.

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Driver profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   131
Driver profiles (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   131
Selecting driver profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   131
Creating driver profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   133
Renaming driver profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   135
Deleting driver profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   138
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   140
Retrofitting lighting equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   140
Meaning of the symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   140
Driving lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   141
Working spotlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   141
Working spotlight for reverse travel (variant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   143
Turn indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   143
Hazard warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   145
StVZO equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   146
Rotating beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   147
STILL SafetyLight® and STILL SafetyLight 4Plus® (variants) . . . . . . . . . . . . . . . . . . . .   147
Warning zone light and warning zone light plus (variants) . . . . . . . . . . . . . . . . . . . . . . .   148
Efficiency and drive modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   150
Blue-Q (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   150
Switching Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   152
Configuring Blue-Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   153
STILL Classic and sprint mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   153
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   155
Safety regulations when driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   155
Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   157
Selecting drive programmes 1 to 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   161
Selecting drive programme A or B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   161
Configuring drive programmes A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   162
Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   164
Actuating the drive direction switch with the multiple-lever version. . . . . . . . . . . . . . . . .   165
Actuating the drive direction switch with the mini-lever version. . . . . . . . . . . . . . . . . . . .   165
Actuating the drive direction switch with the Fingertip version . . . . . . . . . . . . . . . . . . . .   165
Actuating the vertical rocker button for the "drive direction" with the

Joystick 4Plus version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   166
Actuating the drive direction selection lever with the travel direction selector and

indicator module version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   167
Starting drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   167
Starting drive mode, dual pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   169
Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   171
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   172
Applying the mechanical parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   173

Table of contents

 

 VI

56368011501 EN - 04/2022  -  13

Summary of Contents for RX20 14-20

Page 1: ...Electric truck RX20 14 20 RX20 14 20 Li Ion Original instructions 6219 6220 6221 6222 6223 6224 6225 6226 6227 6228 6229 6230 6231 56368011501 EN 04 2022 13 ...

Page 2: ......

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

Page 4: ...rtlist still eu into a web browser or by scanning the QR code shown to the side On the web page enter the following pass word Spareparts24 On the next screen enter your email address and truck serial number to receive an email with the link and download the spare parts list 2511 Preface II 56368011501 EN 04 2022 13 ...

Page 5: ...8 Place of use 18 Parking in temperatures below 10 C 20 Using working platforms 20 Information about the documentation 21 Scope of the documentation 21 Supplementary documentation 22 Issue date and topicality of the operating instructions 23 Copyright and trademark rights 23 Explanation of information symbols used 23 List of abbreviations 24 Definition of directions 26 Schematic views 26 Environme...

Page 6: ... risks associated with using the truck and attachments 45 Overview of hazards and countermeasures 48 Danger to employees 50 Safety tests 52 Carrying out regular inspections on the truck 52 Insulation testing 52 Regularly testing the electrical safety 54 Safety regulations for handling consumables 55 Permissible consumables 55 Oils 55 Hydraulic fluid 56 Battery acid 57 Disposal of consumables 58 Em...

Page 7: ...ect function 92 Warming up the hydraulic oil at cold ambient temperatures 94 Checking the steering system for correct function 95 Driver s seat 96 Adjusting the MSG 65 and MSG 75 driver s seat 96 Seat belt 102 Adjusting the armrest 105 Switching on 107 Switching on using the key switch 107 Switching on via push button variant 108 Display operating unit 110 Operating the display operating unit 110 ...

Page 8: ...sprint mode 153 Driving 155 Safety regulations when driving 155 Roadways 157 Selecting drive programmes 1 to 3 161 Selecting drive programme A or B 161 Configuring drive programmes A and B 162 Selecting the drive direction 164 Actuating the drive direction switch with the multiple lever version 165 Actuating the drive direction switch with the mini lever version 165 Actuating the drive direction s...

Page 9: ...ystem using a quadruple mini lever 207 Controlling the lifting system using the Fingertip 207 Controlling the lifting system using the Joystick 4Plus 210 Dynamics of the hydraulic movements 212 Selecting load programs 1 to 3 213 Fork wear protection variant 214 Changing the fork arms 215 Fork extension variant 217 Operation with reversible fork arms variant 219 Malfunctions during lifting mode 220...

Page 10: ...trol 2 variant 273 Load measurement variant 279 Calibrating the load measurement 280 Precision load measurement variant 282 Tare function variant 284 Total load variant 286 Zeroing the assistance systems 289 Zeroing process 289 Depressurising the hydraulic system 292 Need to depressurise the hydraulic system 292 Wizard for depressurising the hydraulic system 293 Depressurising the hydraulic system...

Page 11: ... mini lever 327 Controlling attachments using the triple mini lever and the 5th function 329 Controlling attachments using a quadruple mini lever 331 Controlling attachments using the quadruple mini lever and the 5th function 333 Controlling attachments using the Fingertip 334 Controlling attachments using the Fingertip and the 5th function 336 Controlling attachments using the Joystick 4Plus 338 ...

Page 12: ...ng via the drive direction switch drive direction selection lever 403 Emergency lowering 404 Emergency actuation of the electric parking brake variant 406 Towing 408 Connecting and disconnecting the battery male connector 411 Connecting the battery male connector 411 Disconnect the battery male connector 412 Charging quick access 413 Charging quick access above the battery door variant 413 On boar...

Page 13: ...ing to lithium ion batteries 465 Opening and closing the battery door 466 Special notes for installing the lithium ion battery 469 Replacing the battery using a truck 469 Replacing the battery using a lift truck and a battery change frame 475 Replacing the battery using a hydraulic battery carrier variant 482 Transporting the lead acid battery by crane 488 Transporting the lithium ion battery by c...

Page 14: ...terlock 522 Maintaining the seat belt 523 Checking the driver s seat 524 Servicing the heating system or air conditioning 525 Servicing wheels and tyres 527 Servicing the steering axle 528 Checking the battery 529 Adjusting the warning zone light 529 Replacing the fuses 529 Checking the hydraulic system for leak tightness 530 Check the hydraulic oil level 532 Lubricating the lift mast and roller t...

Page 15: ...atasheet RX20 18 with swing axle 559 RX20 20 swing axle VDI datasheet 563 Eco design requirements for electric motors and variable speed drives 566 Battery specifications for lead acid batteries 568 Battery specifications for X Line lithium ion batteries 570 Battery specifications for C Line lithium ion batteries 572 Information on the auxiliary hydraulics 572 Table of contents XIII 56368011501 EN...

Page 16: ......

Page 17: ...1 Foreword ...

Page 18: ...riving condition information and all messages are issued via a large colour display The display operating unit uses the current battery charge state and the selected drive programme to calculate the remaining available time until the battery has to be recharged and displays this time It also supports all FleetManager 4 x functions Assistance systems The STILL RX20 14 20 can be equipped with assist...

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

Page 20: ... The required setting for the current application can be se lected via the display operating unit Steering The kickback free hydraulic rear wheel steer ing with Curve Speed Control CSC ensures driving stability when cornering allowing the truck to achieve a small turning circle and ne gotiate narrow aisle widths Operating The multi lever the Fingertip mini lever and the Joystick 4Plus are availabl...

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

Page 22: ...an Union EU UKCA in the United Kingdom UK EAC in the Eurasian Economic Union The conformity marking is applied to the nameplate A declaration of conformity is is sued for the EU and UK markets An unauthorised structural change or addition to the industrial truck can compromise safety thus invalidating the declaration of conformity conformity symbols Foreword 1 Your truck 6 56368011501 EN 04 2022 1...

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

Page 24: ...for the cab variant Two keys for the storage box containing the charging cable for the on board charger variant A hexagon socket wrench for emergency lowering in the compartment A battery change frame not for trucks with the hydraulic battery carrier variant Foreword 1 Your truck 8 56368011501 EN 04 2022 13 ...

Page 25: ...Foreword 1 Your truck 9 56368011501 EN 04 2022 13 ...

Page 26: ...Labelling points 6219_003 010_V3 1 2 12 1 13 4 5 3 8 8 9 4 11 10 6 7 2 3 4 5 6 7 8 10 11 12 9 13 Foreword 1 Your truck 10 56368011501 EN 04 2022 13 ...

Page 27: ...f short circuit due to shearing Warning sign Cleaning electrical system parts with water is forbidden 1 2 3 4 Warning sign Danger due to shearing Decal information Parking brake applied Decal information Parking brake released Decal information Tyre filling pressure Decal information Lifting gear fixing point Decal information Washer system filling Warning sign Dangerous electrical voltage Decal i...

Page 28: ...30 geprüft gemäß DIN VDE 0701 0702 VDE Prüfung 0009386994 6219_003 011_V4 Foreword 1 Your truck 12 56368011501 EN 04 2022 13 ...

Page 29: ...information Caution Read the oper ating instructions Decal information Lifting point Warning sign Danger due to shearing on rotary seat variant Warning sign Ventilator Decal information VDE test 23 24 25 26 27 28 29 30 31 Nameplate Variant 1 Industrial trucks built up to 12 2021 1 Model 2 Serial number 3 Year of manufacture 4 Tare weight in kilograms 5 Maximum permitted battery weight in kilograms...

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

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

Page 32: ...Technology 3 Transport information 4 General operating notes 5 CE labelling 6 Data matrix code for the authorised serv ice centre 7 UKCA labelling 8 Safety information 9 Data technical data 10 Address of manufacturer Foreword 1 Your truck 16 56368011501 EN 04 2022 13 ...

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

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

Page 35: ...the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down The electrolyte may freeze and damage the batteries The truck is then not ready for opera tion At ambient temperatures of below 10 C only park the truck for short periods of time The operating company must ensure suitable fire protection for the relevant application in the truck s surrou...

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

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

Page 38: ...l attachment A special towing device Customised attachments When fitted with a CO the industrial truck is provided with additional documentation This may take the form of an insert or separate operating instructions The original operating instructions for this in dustrial truck are valid for the operation of standard equipment and variants without re striction The operational and safety informa ti...

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

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

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

Page 42: ...ints in this documentation the mostly sequential operation of certain func tions or operating procedures is explained Schematic diagrams of a counterbalance truck are used to illustrate these procedures NOTE These schematic views are not representative of the structural state of the documented truck The views are used solely for the purpose of clarifying procedures 6210_001 031 4 2 3 1 Foreword 1 ...

Page 43: ...display of the display and operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values may vary 12 6 h 10 35 6219_003 021_V3 Foreword 1 Information about the documentation 27 56368011501 EN 04 2022 13 ...

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

Page 45: ...2 Safety ...

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

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

Page 48: ...e for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety 2 Definition of responsible persons 32 56368011501 EN 04 2022 13 ...

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

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

Page 51: ...provided by the battery manufacturer regarding the proce dure in the event of a fire Water can be used to cool down an incipient fire Transport In certain circumstances transporting the lith ium ion battery outside the premises may re quire a special transport container Contact the authorised service centre for more information Safety 2 Basic principles for safe operation 35 56368011501 EN 04 2022...

Page 52: ... catches fire The nameplate is used to identify the lithium ion battery that is fitted Observe the instructions for the lithium ion battery used in your truck in the corre sponding operating instructions All lithium ion batteries are essentially associ ated with the risk of a fire starting of the battery exploding and of the battery causing chemical burns If the batteries are used properly no haza...

Page 53: ...at 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 truck may only be converted with written approval from the manufacturer If ne...

Page 54: ...er Operation of the truck without an overhead guard is prohibited at a lift height greater than 1800 mm At lift heights of 1800 mm and above only use the truck in conjunction with an overhead guard The operating company is only permitted to make modifications to the truck independently if the manufacturer goes into liquidation and the company is not taken over by another le gal person The operatin...

Page 55: ... by falling loads or the truck tipping over may result in buckling of the modified overhead guard and no pro tection for the driver Do not perform welding on the overhead guard Do not perform drilling on the overhead guard CAUTION Heavy roof loads damage the overhead guard To ensure the stability of the overhead guard at all times a roof load may only be mounted on the over head guard if the struc...

Page 56: ... can have the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g connecting a radio additional headlights etc is only per mitted with the manufacturer...

Page 57: ...cturer Only use high quality products Wheels and tyres approved by the manufac turer can be found on the spare parts list If other wheels or tyres are to be used au thorisation from the manufacturer must be ob tained beforehand Contact the authorised service centre on this matter When changing wheels or tyres always en sure that this does not cause the truck to tilt to one side e g always replace ...

Page 58: ...rings Gas springs are complex components that are subject to high inter nal pressures up to 300 bar They may under no circumstances be opened unless instructed to do so and may be installed only when not under pres sure If required the authorised service centre will depressurise the gas spring in accordance with the regulations before removal Gas springs must be depressurised before recycling Avoi...

Page 59: ...f gravity may shift as a result of dynamic forces such as braking A load that is otherwise resting safely on the fork arms may move forwards and fall If the fork arms are too long they can catch on loading units behind the load that is to be picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre...

Page 60: ...structed regarding these risks that arise through use of the truck In addition we draw attention to the safety regula tions in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Falling tripping etc whe...

Page 61: ...inst slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as cen trally as possible with the truck and trans port in this position Avoid turning and diagonally driving across slopes or gradients Never have the load facing downhill when travelling on slopes or gradients Pick ...

Page 62: ...use the truck correctly and without the risk of accidents Safety 2 Residual risk 46 56368011501 EN 04 2022 13 ...

Page 63: ...Safety 2 Residual risk 47 56368011501 EN 04 2022 13 ...

Page 64: ...ised persons O Truck not safe for op eration Periodic inspection and rectification of de fects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due to...

Page 65: ... the operating in structions O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Sa...

Page 66: ...e on Industrial Safety and Health BetrSichV No person detection when placing goods in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the German Ordinance on In dustrial Safety and Health BetrSichV and labour protection law ArbSchG the operat ing company must determine and assess haz ards during ...

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

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

Page 69: ...tage Measurements Nominal volt age UBatt Test values Battery 50 VDC Batt Batt Battery tray 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω 100 VDC 80 volts 4000 Ω Test values for the entire truck Nominal volt age Test voltage Test values for new trucks Minimum values over the duration of the service life 24 volts 50 VDC Min 50 kΩ 24 kΩ 48 volts 100 VDC Min 100 kΩ 48 kΩ 80 volts 100 VDC Min 200 kΩ 80 kΩ Sa...

Page 70: ...t in accordance with the national regulations for the country of use e g DIN VDE 0701 0702 in Germany Contact the authorised service centre on this matter Before each use check the charging cable for damage Do not use a damaged charging cable geprüft gemäß DIN VDE 0701 0702 VDE Prüfung 0009386994 6331_003 003 Safety 2 Safety tests 54 56368011501 EN 04 2022 13 ...

Page 71: ...he permissible con sumables can be found in the maintenance data table Oils DANGER Oils are flammable Follow the statutory regulations Do not allow oils to come into contact with hot engine parts No smoking fires or naked flames DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse thoroughly for...

Page 72: ...rding to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of ac cording to the regulations Dispose of old oils according to the regula tions Hydraulic fluid WARNING These fluids are pressurised during op erati...

Page 73: ...ve gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers that comply with regulations Avoid spills Spilt hydraulic fluid should be removed im mediately with oil binding agents and dis posed of according to the regulations Dispose of old hydraulic fluid according to the regulations ...

Page 74: ...f used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair main tenance and cleaning must be collected prop erly and disposed of in accordance with the national regulations for the country in which the truck is being used Work must only be carried out in areas designated for that pur pose Care must be taken to minimi...

Page 75: ...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 noise pollution If necessary these...

Page 76: ...e 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 individual vibration load on the driver over the course of a working day must be deter mined by the operating company in accord ance with Directive 2002 44 EC at the actual place of use in order to consider a...

Page 77: ...rning zone light variant are assigned to risk group 2 medium risk due to their photobiological hazard potential The Laser Smartfork assistance system var iant is assigned to laser class 1M DANGER Risk of injury Looking into the laser beam can damage the eyes laser radiation laser class 1M If there is a possibility that people are at risk switch off the laser immediately Never look directly into th...

Page 78: ...Safety 2 Emissions 62 56368011501 EN 04 2022 13 ...

Page 79: ...3 Overviews ...

Page 80: ...Overview Overviews 3 Overview 64 56368011501 EN 04 2022 13 ...

Page 81: ...nt Drive axle Front lighting Fork arms 1 2 3 4 5 6 7 Fork carriage Lift cylinder Rear lighting Battery door Steering axle Towing device Counterweight 8 9 10 11 12 13 14 NOTE The truck equipment may differ from the equipment shown Overviews 3 Overview 65 56368011501 EN 04 2022 13 ...

Page 82: ...Driver s compartment Overviews 3 Driver s compartment 66 56368011501 EN 04 2022 13 ...

Page 83: ...t caused by blocked pedals Objects may fall into the footwell during travel as a result of steering or braking They can slip between and under the pedals 2 They then block the ped als It may then not be possible to brake the truck when necessary Only store objects that fit on the shelves 1 3 Bottles with a maximum size of 1 5 litres may be stored in the cup holder 3 Make sure that objects cannot f...

Page 84: ...Automatic mast vertical positioning Menu button Scrolling buttons Right turn indicator display Back button Main display button Driving speed or parking brake Left turn indicator display Reverse drive direction indicator Forward drive direction indicator Display for direction of movement of the truck Brightness sensor 9 10 11 12 13 14 15 16 17 18 19 20 21 STILL Easy Control is a third generation di...

Page 85: ...y operating unit is attached to the armrest except in trucks equipped with mul ti lever operation If the truck is equipped with multi lever operation the display operat ing unit is swivel mounted on the right A pillar For information on swivelling the display op erating unit see the section entitled Adjust ing the swivelling display operating unit in the chapter entitled Checks and tasks be fore d...

Page 86: ...e chapter entitled Display ele ments in the STILL Lithium ion batteries operating instructions Emergency off switch The emergency off switch 1 is situated on the right hand side of the steering column It disconnects the drives from the power supply Do not use this switch to park the truck safely 6209_003 002 1 2 3 Service LED red Temperature LED yellow red Charge state LEDs red green 1 2 3 Overvie...

Page 87: ... Operating lever for attachments variant Function key for the 5th or 6th function variants Signal horn button 6 7 8 NOTE In the dual pedal version variant the drive direction switch 1 is used exclusively to acti vate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version Overviews 3 Operating devices and display elements 71 56368011...

Page 88: ...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 72 56368011501 EN 04 2022 13 ...

Page 89: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 5 Overviews 3 Operating devices and display elements 73 56368011501 EN 04 2022 13 ...

Page 90: ...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 74 56368011501 EN 04 2022 13 ...

Page 91: ...ctivate the cruise control function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign different functions to the F1 function key 6 Overviews 3 Operating devices and display elements 75 56368011501 EN 04 2022 13 ...

Page 92: ...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 76 56368011501 EN 04 2022 13 ...

Page 93: ...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 77 56368011501 EN 04 2022 13 ...

Page 94: ...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 95: ... the 4th hydraulic function Vertical rocker button for the drive direction Shift key F Signal horn button 5 6 7 8 9 NOTE In the dual pedal version variant the ver tical drive direction rocker button 7 is used exclusively to activate the cruise con trol function variant The drive direction is selected exclusively via the pedals in the dual pedal version The authorised service centre can assign diff...

Page 96: ...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 97: ...4 Operating ...

Page 98: ...on points of these components If damage or other defects are identified on the truck or the attachment variant during the following inspections the truck must not be used until it has been prop erly repaired Damage or other defects must be reported to the supervisor or the responsi ble fleet manager immediately so that repairs by the authorised service centre can be ar ranged Ensure that the truck...

Page 99: ... tyre wear replace both tyres Observe the safety regulations in the section enti tled Tyres Axle Make sure that no consumables are escaping from the axle Overhead guard guard grille variant Visually inspect for sound condition Check for secure mounting Steps Make sure they are clean free of ice not slippery Panes of glass variant Visually inspect for sound condition Make sure they are clean also f...

Page 100: ...hat the linchpin is present and working cor rectly chain rope split pin Labelling adhesive label Check that labels are present and intact legible Replace damaged or missing adhesive labels in ac cordance with the section entitled Labelling points Driver s seat seat belt Check the integrity and function Display operating unit assistance systems Check the function of the assistance systems lis ted i...

Page 101: ... with oil there is a risk of slipping There is a risk of hitting your head on the overhead guard post or of your clothes becoming stuck when climbing out of the truck Ensure that the footwell cover is not slippery Do not jump into or out of the truck Ensure that you have a secure grip on the truck WARNING Risk of injury when jumping out of the truck If your clothing or jewellery e g watch ring etc...

Page 102: ...g forwards Grip the handle 1 with your left hand and do not let go Place your left foot into the footwell 4 Climb into the truck with your right foot 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 do not let go Stand up from the driver s seat and place your left foot in the footwell 4 Climb out of the truck right foot first Adj...

Page 103: ...ar The display operating unit can be swivelled from the neutral position to 15 to the left right up and down The unit cannot rotate around its own axis To change the resistance for adjusting the dis play operating unit there are two socket head screws 2 on the support for the display op erating unit The hexagon socket wrench for emergency lowering can be used to loosen or tighten the socket head s...

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

Page 105: ... the truck forwards slowly Push the emergency off switch 1 The truck will coast to a stop The message Emergency off ac tive appears on the display operating unit Stop the truck by actuating the brake pedal NOTE In trucks with an electric parking brake the electric parking brake will be applied as soon as the truck comes to a stop Turn the emergency off switch 1 clockwise until it pops out The truc...

Page 106: ...gnal horn is used to warn people against imminent danger or to announce your intention to overtake Press the signal horn button 1 The signal horn sounds 1 1 1 Operating 4 Checks and tasks before daily use 90 56368011501 EN 04 2022 13 ...

Page 107: ...tips over The cab door must be sturdy and be closed in order for the driver s cab to function as a driver restraint system Fabric covered cabs variant with doors made of plastic or canvas do not constitute a driver restraint system and offer no protection from the consequences of the truck tipping over Close the cab door before use If the door is open or has been removed use a comparably secure re...

Page 108: ...e speed Depending on the charge state of the battery re generative braking may be insufficient when driving downhill meaning that the maximum permissible speed of the truck is exceeded Press the brake pedal 1 If the driving speed is restricted or if the op posite drive direction is selected the truck is braked using the electric brake To actuate this release the accelerator pedal 2 The truck must ...

Page 109: ...ite the parking brake being applied stop the truck using the service brake In an emergency secure the truck with wedges on the downhill facing side to pre vent it from rolling away Have the parking brake checked and re paired by the authorised service centre Checking the parking brake on a level surface WARNING Risk of accident from abrupt deceleration The truck will decelerate abruptly if the par...

Page 110: ... brake unlock the emergency off switch If the truck only coasts and does not decel erate or decelerates only slightly stop the truck using the service brake Secure the truck with chocks so that the truck does not roll away Have the parking brake checked and re paired by the authorised service centre Warming up the hydraulic oil at cold ambient temperatures If the truck has been exposed to low ambi...

Page 111: ...until the warm up phase is complete Checking the steering system for correct function DANGER If the hydraulics fail there is a risk of accident as the steering characteristics have changed Do not operate the truck if it has a defective steer ing system Operate the steering wheel 1 The steer ing play while stationary must not be more than two finger widths 6219_003 312 1 Operating 4 Checks and task...

Page 112: ...so that all operating devices can be actuated safely Ensure that the seat and the seat backrest are securely engaged WARNING On some equipment variants the amount of head clearance on the truck may be restricted On these specific equipment variants the distance between the driver s head and the lower edge of the roofing sheet must be at least 40 mm NOTE Observe any separate operating instructions ...

Page 113: ... not apply pressure to the seat backrest when adjusting the seat backrest Raise the lever 2 and hold it in position Push the seat backrest into the required po sition Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structure of the truck 7094_003 006 1 7094_003 008 2 Operating 4 Driver s seat 97 5636801...

Page 114: ...e ini tial central position each time before raising it again a click can be heard when this position is reached Retract the weight adjusting lever once the adjustment is complete NOTE The correct driver s weight has been selected when the arrow 4 is in the centre position in the inspection window Once the minimum or maximum weight setting is reached the seat will not move any further even when yo...

Page 115: ...horizontal sus pension move the locking lever 5 to the right B NOTE If the longitudinal horizontal suspension is blocked the suspension comfort is significant ly lower Impacts are much more noticeable Adjusting the lumbar support variant NOTE The lumbar support can be adjusted to suit the contours of the individual driver s spine Adjusting the lumbar support moves a convex support cushion into the...

Page 116: ...he backrest extension move it past the end stop by firmly pushing it upwards Switching the seat heater variant on and off NOTE The seat heater only works when the driver is sitting on the driver s seat Switch the seat heater 8 on or off using the switch 6321_003 040_V3 7 6321_003 041_V3 8 Operating 4 Driver s seat 100 56368011501 EN 04 2022 13 ...

Page 117: ...iver s seat To swivel the driver s seat pull the lever 9 back and hold it in position Swivel the driver s seat to the right until it reaches the stop Move the lever 9 forwards again Make sure that the driver s seat is securely engaged Swivelling the driver s seat to the right is inten ded only for reverse travel The driver s seat must be swivelled back into place for forward travel To swivel the s...

Page 118: ... the driver s cab variants with closed fixed doors constitute driver restraint systems Plastic doors weather protection do not constitute a restraint system If the doors are open or have been removed you must use an alternative suitable restraint system e g a seat belt Fastening the seat belt DANGER Mortal danger when driving without wearing a seat belt If the seat belt is not fastened and the tru...

Page 119: ... your back is resting on the seat backrest The automat ic blocking mechanism permits sufficient free dom of movement on the seat Click the belt tongue 2 into the buckle 1 Check the tension of the seat belt The belt must fit closely around your body Special feature for trucks with a cab variant If the truck is equipped with a cab variant it will have a cab door sensor If the seat belt is not fasten...

Page 120: ...asing the seat belt Push the red button 4 on the buckle 1 Slowly guide the belt tongue back to the retractor by hand NOTE Slowly allow the seat belt to retract The auto matic blocking mechanism may be triggered if the belt tongue strikes the housing It will then no longer be possible to pull the seat belt out with the usual force Using increased force pull the seat belt around 10 to 15 mm out of t...

Page 121: ...tional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the armrest while driving Adjust the armrest so that all operating devices can be actuated safely Ensure that the armrest is securely tightened Adjusting the length of the armrest Release the star grip handle 1 by turning to the left Shift the armrest 2 into the d...

Page 122: ... Tighten the hand wheel by turning to the right Check that the armrest is firmly attached Operating 4 Driver s seat 106 56368011501 EN 04 2022 13 ...

Page 123: ...code variant the display initially changes to the input menu for access authorisation Once the truck is ready for operation the main screen is shown on the display Main screen 1 Selected drive programme with driving dynamics display 2 Load information variants 3 Status bar battery charge operating hours time 4 Selected load dynamics programme with dynamics bar 5 Right turn indicator display 6 Driv...

Page 124: ...thorisation with PIN code variants In place of the key switch the truck has a push button 1 that is used to switch the truck on and off To switch on the truck press the push but ton 1 or sit on the driver s seat A mes sage on the display operating unit asks the operator to place the FleetManager card in position or to enter the PIN code Authorisation via the FleetManager card or the PIN code must ...

Page 125: ...but ton 1 and hold for 1 second NOTE For the variant with Access authorisation with PIN code see the relevant section FleetManager see the original operating instructions for FleetManager Operating 4 Switching on 109 56368011501 EN 04 2022 13 ...

Page 126: ...using the control and enter keys 5 8 and the soft keys 4 10 The display 2 shows informa tion about the current driving programme load programme and the configuration of the fa vourites bars 1 3 The brightness sensor 9 automatically adjusts the brightness of the dis play based on the truck s surroundings Operating 4 Display operating unit 110 56368011501 EN 04 2022 13 ...

Page 127: ...his button clears input entered in the settings menus This button switches between upper case and lower case for alphanumeric entries Back button 7 When the back button is pressed the display switches to the next menu level up This button cancels input entered in the settings menus Main display button 8 Pressing the main display button at any menu level takes you directly back to the main display ...

Page 128: ... is ready for use If the input was incorrect enter the PIN code again NOTE The authorised service centre can configure access authorisation so that the PIN code has to be re entered each time after someone leaves the truck When the driver s seat is occupied again the message Log in appears The display then changes to the Access authorisation in put menu Changing the PIN codes The fleet manager can...

Page 129: ...t can be con figured by the users themselves Access to these settings is protected by a fleet manager password Three options are available for the Access authorisation for the fleet manager variant 1 No fleet manager password Access to the configuration menus is not enabled If access is required at a later Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Change...

Page 130: ...sword is noted on the order confirmation and on the truck invoice NOTE Access to the settings menu is only availa ble if the truck is at a standstill and the park ing brake is applied If the parking brake is released prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the softkey The first menu level appears Press the Access authorisa tion softkey...

Page 131: ...rect is dis played If this happens enter the password again NOTE While the Access authorisation for the fleet manager is activated Fleet manager is displayed in an orange bar at the bottom of the screen When the users switches to the main display the access authorisation expires again Changing the fleet manager password Activate the Access authorisation for the fleet manager Enter password 6219_00...

Page 132: ...s auth menu appears Press the Change password ac cess auth softkey Follow the instructions on the display Fleet manager Calibration Relieve hydraulics Shock sensor Change password access auth Version list 6219_003 275_en Operating 4 Display operating unit 116 56368011501 EN 04 2022 13 ...

Page 133: ...question stored by default is Truck ready for opera tion If the question is answered with No an entry is made in the history No restrictions in truck function for this scenario are stored by default The authorised service centre can replace this question with a question from the question catalogue In addition the fleet manager has the follow ing options The fleet manager can view the results of al...

Page 134: ...Check is still active and the truck functions are restricted To acknowledge the message press the softkey Switch on and check the function to be tes ted e g lighting Press the back button to go back to the Pre Shift Check Answer the question based on the result of the function check The next question appears NOTE If no questions regarding the Pre Shift Check have been compiled the question Truck r...

Page 135: ...eck during commissioning Are the fork arms damaged e g bent or cracked Are the fork arms securely mounted and the locking devices un damaged Are the roller tracks on the lift mast and lift chassis suffi ciently greased Are the load chains damaged Are the load chains sufficiently tensioned and loaded equally Are all attachments securely mounted and undamaged Are they in working order Are operating ...

Page 136: ...e the lift mast or the fork carriage obviously damaged Do the working hydraulics work properly according to the label ling Are the mirrors dirty or damaged Is the gas tank or its mounting obviously damaged Can unusual noises be heard when the industrial truck is used Is there any other obvious damage to the truck Does the washer system work Is the bonnet undamaged and securely closed If no Pre Shi...

Page 137: ...ll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 121 56368011501 EN 04 2022 13 ...

Page 138: ...tion To access the main display press the main display button Displaying the history The fleet manager can display a Pre Shift Check history Activate the Access authorisation for the fleet manager Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Random sequence Fixed sequence 6219_003 273_en Operating 4 Pre Shift Check 122 56368011501 EN 04 2022 1...

Page 139: ...ll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 123 56368011501 EN 04 2022 13 ...

Page 140: ...ays requested 24 hours after the last check was performed The fleet manager can define up to three shifts and their start times The Pre Shift Check is then always requested at this time Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Pre Shift Check results 27 09 19 15 11 nicht ok Funktioniert die Feststellbremse einwandfrei 27 09 19 15 06 nicht ok Sind die Ga...

Page 141: ...ructions Activate the Access authorisation for the fleet manager Press the Service softkey Press the scroll keys until the Pre Shift Check menu appears Press the Pre Shift Check softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Operating 4 Pre Shift Check 125 56368011501 EN 04 2022 13 ...

Page 142: ...time The orange activation bar indicates which shifts are activated To edit a shift press the corresponding soft key Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operating 4 Pre Shift Check 126 56368011501 EN 04 2022 13 ...

Page 143: ... requested from this shift start time The display reverts to the previous menu To deactivate a certain shift start select the relevant shift Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivate Save Cancel 6219_003 272_en Fleet manager Shift start 2 Shift start 3 Shift start 1 6219_003 271_en Operating 4 Pre Shift Check 127 56368011501 EN 04 2022 13 ...

Page 144: ...in display button Resetting the truck restrictions If truck functions are restricted due to checks with a bad result the fleet manager can reset these restrictions The fleet manager can also do this if a previously detected problem has been rectified Activate the Access authorisation for the fleet manager Press the Service softkey Fleet manager Enter shift start Clear 06 Shift start 1 00 Deactivat...

Page 145: ...ift Check menu appears Press the Reset restriction softkey Fleet manager Maintenance interval Version list Pre Shift Check Calibration Message list 6219_003 268_en Fleet manager Reset restriction Shift start Question sequence History 6219_003 269_en Operating 4 Pre Shift Check 129 56368011501 EN 04 2022 13 ...

Page 146: ...The display reverts to the previous menu To cancel press the softkey The truck functions remain restricted The dis play reverts to the previous menu To access the main display press the main display button 6219_003 274_en Fleet manager Reset the truck restrictions The entry remains in the history Operating 4 Pre Shift Check 130 56368011501 EN 04 2022 13 ...

Page 147: ...profile Selected drive programme 1 to 3 Load dynamics Efficiency and drive modes Blue Q sprint mode If a driver without an existing driver profile logs in using the Access authorisation with PIN code or FleetManager variants a driver profile is generated This driver profile corre sponds to the settings when the truck was delivered If the truck is not equipped with these variants drivers must selec...

Page 148: ... ing brake is applied If the parking brake is released prematurely the settings menu will close Stop the truck Apply the parking brake Press the button Press the softkey Press the Driver profiles soft key Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Operating 4 Driver profiles 132 56368011501 EN 04 2022 13 ...

Page 149: ...les Both the fleet manager and the driver can cre ate up to ten driver profiles NOTE If the truck is equipped with the Access au thorisation with PIN code or FleetManager variants the driver profile is generated auto matically when logging in for the first time Apply the parking brake Press the button Press the softkey Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operatin...

Page 150: ...on NOTE Unoccupied storage locations that do not con tain a driver profile are indicated by Availa ble storage position Configure favourites Truck settings Truck information Driver profiles Display settings 6219_003 293_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operating 4 Driver profiles 134 56368011501 EN 04 2022 13 ...

Page 151: ...will then be available the next time that the driver logs in Renaming driver profiles Driver profiles can be renamed Drivers can only rename their own driver profile The fleet manager has access authorisation to rename all driver profiles Renaming by the driver Apply the parking brake Press the button Press the softkey Press the Truck settings softkey Enter driver name Clear Driver name Horst abc ...

Page 152: ... press the button Renaming by the fleet manager Activate the Access authorisation for the fleet manager Press the Truck settings softkey Rename driver profiles Driving programme 6219_003 298_en Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Operating 4 Driver profiles 136 56368011501 EN 04 2022 13 ...

Page 153: ...s softkey Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Operating 4 Driver profiles 137 56368011501 EN 04 2022 13 ...

Page 154: ...Activate the Access authorisation for the fleet manager Press the Truck settings softkey Press the Manage driver profiles softkey Enter driver name Clear Driver name Horst abc ABC Save Cancel 6219_003 295_en 0 Fleet manager Auxiliary hydraulics Change PIN codes Manage driver profiles On board charger Lift height preselection 6219_003 296_en Operating 4 Driver profiles 138 56368011501 EN 04 2022 13...

Page 155: ...he driver profile to be deleted The driver profile is deleted Fleet manager Delete driver profiles Rename driver profiles 6219_003 297_en Horst Lisa Driver 4 Available storage position 5 Guido 6219_003 294_en Operating 4 Driver profiles 139 56368011501 EN 04 2022 13 ...

Page 156: ...of working spotlights Only the symbols of the lighting devices that are installed in the truck can be selected When one of the lighting devices is switched on the activation bar next to the relevant sym bol lights up orange NOTE If the truck is equipped with the StVZO Ger man Road Traffic Licensing Regulations var iant the hazard warning system works even when the truck is switched off 1 This func...

Page 157: ...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 158: ...tions variant the parking light is also switched on when the working spotlights are switched on The licence plate lamp if present is also switched on when the forward facing working spotlights are switched on Working spotlights on the roof and the side of the lift mast The roof spotlights light up the working area when the fork carriage is raised To switch on the roof spotlights 5 push the associa...

Page 159: ...ss the softkey The activation bar next to the symbol lights up The working spotlight does not yet light up Set the drive direction to Reverse The working spotlight for reverse travel lights up If the drive direction is set to Forward the working spotlight goes out Turn indicators The turn indicators are switched on and off via the travel direction selector and indicator module Operating 4 Lighting...

Page 160: ...is play 2 or 3 on the display operating unit flash To switch off the turn indicators push the lever 1 back to the centre position All turn indicators and the turn indicator dis plays on the display operating unit stop flash ing 6219_003 098 2 71 m 7 1 6 t 2 3 6219_003 301 432 h 08 20 Operating 4 Lighting 144 56368011501 EN 04 2022 13 ...

Page 161: ...or displays on the display operating unit stop flashing Specific features of the StVZO German Road Traffic Licensing Regulations variant For the StVZO German Road Traffic Licens ing Regulations variant the hazard warning system cannot be switched on and off via the display operating unit It is switched on and off using the hazard warning button on the steer ing column The hazard warning system in ...

Page 162: ...his softkey is used to switch off all light ing devices that are not permitted on roads subject to German traffic regulations StVO This relates to the following variants of lighting equipment STILL SafetyLight and STILL Safety Light 4Plus Warning zone light and warning zone light plus Working spotlight Rotating beacon To switch this lighting equipment off press the softkey The orange activation ba...

Page 163: ... The rotating beacon is switched on To switch off the rotating beacon push the Softkey again The rotating beacon goes out STILL SafetyLight and STILL SafetyLight 4Plus var iants WARNING Danger of damage to eyes from look ing into the STILL SafetyLight and STILL SafetyLight 4Plus Do not look into the STILL SafetyLight or STILL SafetyLight 4Plus STILL SafetyLight and STILL SafetyLight 4Plus are visu...

Page 164: ...ant for exam ple it can be used as an additional light for the working spotlight for reverse travel The STILL SafetyLight or the STILL Safety Light 4Plus can also be switched on and off on the display operating unit To do so press the softkey NOTE If the truck is to be operated on public roads the STILL SafetyLight and the STILL Safety Light 4Plus must be switched off Warning zone light and warnin...

Page 165: ...off again together with the truck If the truck has StVZO German Road Traffic Licensing Regulations equipment the warn ing zone light plus can be switched on and off via the display operating unit To do so press the softkey NOTE If the truck is to be operated on public roads the warning zone light must be switched off Before using the truck make sure that the warning zone light is working and has b...

Page 166: ... lower speeds are reached than would be the case if the efficiency mode was not activated As in STILL Classic mode the maximum speed is 20 km h Blue Q has no influence on Maximum speed Climbing capability Pulling force Braking characteristics Effects on additional consumers The following table shows conditions that cause certain additional consumers to shut down when Blue Q is activated The additi...

Page 167: ...at switch Truck is stationary Drive direction Screen heating X No shut off for StVZO German Road Traffic Licensing Regulations equipment variant Operating 4 Efficiency and drive modes 151 56368011501 EN 04 2022 13 ...

Page 168: ...mode is switched on To switch off Blue Q efficiency mode push the associated softkey again The Blue Q symbol disappears and Blue Q ef ficiency mode is switched off NOTE The fleet manager can also use his access authorisation to activate Blue Q efficiency mode permanently See the next section Operating 4 Efficiency and drive modes 152 56368011501 EN 04 2022 13 ...

Page 169: ...ftkey The orange activation bar appears next to the pushed softkey The main display button takes you to the main display STILL Classic and sprint mode The drive modes affect the handling of the truck Two different drive modes are available 1 STILL Classic This mode is active after the truck has been switched on This mode is the default setting and provides a bal ance between hydraulic functions an...

Page 170: ...l the truck will consume more energy As a result the battery is discharged faster and the traction drives and energy supply may become too hot The battery voltage and the temperature of the traction drives and energy supply are moni tored continuously If under voltage does not apply to lithium ion batteries or overheating occurs sprint mode is automatically deactiva ted If the truck is automatical...

Page 171: ... 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 172: ...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 173: ... for areas outside the EU The required aisle widths depend on the di mensions of the load Required aisle widths with pallet Model Type Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX20 14C 6219 3186 3311 RX20 16C 6220 3186 3311 RX20 16 6221 3269 3394 RX20 16L 6222 3377 3502 RX20 18 6223 3269 3394 RX20 18L 6224 3377 3502 RX20 20L 6225 3390 3516 RX20 16P 6226 3362 3...

Page 174: ...han 15 CAUTION Risk of component damage due to reduced ground clearance with the hydraulic battery carrier variant Trucks fitted with a hydraulic battery carrier variant have a reduced ground clearance and the permitted climbing capability is therefore reduced Irregularities in the ground such as railway sleepers must also be driven over with caution Please note the following The ground clearance ...

Page 175: ...ents must not exceed the gradients listed above and must have a rough surface The top and bottom of the gradient must fea ture smooth and gradual transitions to prevent the load from falling to the ground or the truck being damaged Warning in the event that components protrude beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or conta...

Page 176: ...all height of the lift mast and the dimensions of the load see the chapter entitled Technical data Rules for roadways and the working area It is only permitted to drive on routes author ised for traffic by the operating company or its representatives Traffic routes must be free from obstacles The load must only be set down and stored in the designated locations The operating company and its repres...

Page 177: ...he drive programme is selected using the display operating unit under the Drive menu item Press the softkey to select the desired drive programme If the drive programmes are saved as a fa vourite on a softkey press the softkey until the number of the desired drive pro gramme is shown on the display The number of dynamic bar segments indi cates the driving dynamics of the selected drive programme O...

Page 178: ... a favourite on a softkey press the soft key until the letter of the desired drive pro gramme is shown on the display Configuring drive programmes A and B The drive programmes can be configured by the driver NOTE Access to the settings menu is only availa ble if the truck is at a standstill and the park ing brake is applied If the parking brake is released prematurely the settings menu will close ...

Page 179: ...ity and 5 indi cates the greatest agility Braking Determines the electrical brake retardation when the accelerator pedal is released in five stages 1 indicates the lowest delay and 5 indicates the greatest delay To select a higher stage press the soft key To select a lower stage press the soft key To save the setting press the softkey The settings are saved To cancel the setting press the softkey ...

Page 180: ...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 181: ...ion selection lever in the chapter entitled Procedure in emergen cies Actuating the drive direction switch with the mini lever ver sion For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction pull the drive direction switch 1 backwards NOTE If the drive direction switch 1 is defective and the truck stops in a danger area the drive direction sel...

Page 182: ... Procedure in emergen cies Actuating the vertical rocker but ton for the drive direction with the Joystick 4Plus version For the forwards drive direction push the vertical rocker button for the drive direc tion 1 upwards For the backwards drive direction push the vertical rocker button for the drive di rection 1 downwards NOTE If the drive direction switch 1 is defective and the truck stops in a d...

Page 183: ... enti tled Emergency driving via the drive direction switch drive direction selection lever in the chapter entitled Procedure in emergencies Starting drive mode DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations whe...

Page 184: ...travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the accelerator pedal is released NOTE The truck is also held in place on ascending or descending gradients even if the electric parking brake is not engaged DANGER Risk of accident due to brake failure The regenerative brake only functions if the truck is switched on the emerg...

Page 185: ...he truck still cannot be operated park the truck securely and con tact the authorised service centre Starting drive mode dual pedal version variant DANGER Being trapped under a rolling or tipping truck could cause fatal injuries Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter enti tled Safety regulations when driving The...

Page 186: ...ards 1 or reverse 2 lights up on the display operating unit NOTE Depending on the equipment the following variants of warning units for reverse travel may be present An acoustic signal will be heard The STILL SafetyLight lights up The hazard warning system flashes The truck travels in the selected drive direc tion The speed is controlled by the accelera tor pedal position The truck brakes when the...

Page 187: ...raked Once the electrical fault has been corrected it will be possible to drive the truck again by releasing the accelerator pedal and then actuating the accelerator pedal again If the truck still cannot be operated park the truck securely and con tact the authorised service centre Operating the service brake The regenerative brake converts the accelera tion energy of the truck into electrical ene...

Page 188: ...eds that are too high there is a danger that the truck could slip or overturn The braking distance of the truck depends on various factors such as the weather conditions and the level of contamination on the roadway Note that the basic braking distance increases with the square of the speed Adapt your driving and braking style to suit the weather conditions and the level of contamination on the ro...

Page 189: ...arking brake symbol appears on the display in place of the speed information When a drive direction is selected and the ac celerator pedal is actuated the message Re lease parking brake appears Releasing the parking brake Pull the parking brake lever 1 back Push down the knob 2 and hold it down Move the parking brake lever 1 forwards and release both the lever and the knob The parking brake is rel...

Page 190: ...pplying the parking brake The truck starts moving approximately 20 seconds after the parking brake is applied Activation and intervention of the function Cause Effect The driver s seat is vacated and the parking brake has not been applied A warning signal sounds Sitting in the driver s seat silences the warning signal The truck needs to be switched off but the park ing brake has not been applied T...

Page 191: ...cy 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 must not be applied manually when the driver leaves the truck The parking brake is applied automatically Despite these automatic aids the driver is al ways responsible for parking the truck safely The safety information about parking th...

Page 192: ...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 electric parking brake will make a noise when it releases and t...

Page 193: ...teady light until the control units switch off The emergency off switch is actuated The electric parking brake is immediately ap plied with an audible sound The LED 2 lights up with a steady light If the electric parking brake has applied auto matically the symbol appears in the dis play operating unit The LED 2 lights up To release the electric parking brake the driver must sit down on the driver...

Page 194: ...al times The electric parking brake cannot be released by actuating the accelerator pedal WARNING Risk of accident The truck may decelerate abruptly Fasten the seat belt Automatically triggered actuation when the truck is in motion Cause Effect The driver s seat is vacated The truck is braked in accordance with the se lected drive programme Once the truck has come to a standstill the electric park...

Page 195: ...he truck accelerates sharply even though the accelerator pedal has not been actuated The parking brake is immediately applied with an audible sound The LED 2 lights up with a steady light The symbol appears in the display Malfunctions in the electric park ing 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 th...

Page 196: ...rking brake when the truck is stationary There are two ways to apply the parking brake Press and hold the push button 1 for at least five seconds and then release the push button or Press the push button 1 several times in succession so that the push button is actu ated for a total of five seconds The parking brake is applied with an audi ble sound After the push button is released the parking bra...

Page 197: ...d Activation and intervention by the Safe parking function Cause Effect The driver s seat is vacated The electric park ing brake cannot be applied or previously could not be applied The following message appears in the display Parking brake cannot be applied To confirm press the softkey A warning signal sounds when the driver s seat is vacated Sitting in the driver s seat silences the warning sign...

Page 198: ...mergency actuation mechanism se cure the truck with wedges to prevent it from rolling away Have the parking brake repaired by an au thorised service centre Message Parking brake cannot be applied If the truck control unit detects a malfunction in the parking brake the truck cannot be switch ed off The Parking brake cannot be applied message appears on the dis play operating unit The LED 2 on the p...

Page 199: ...g brake cannot be applied auto matically or via the push button apply the parking brake via the emergency actuation process See the section entitled Emergen cy actuation of the parking brake variant in the chapter entitled Behaviour in emer gencies If the parking brake cannot be applied via the emergency actuation process secure the truck with wedges so that the truck can not roll away Have the pa...

Page 200: ... the truck by turning the steering wheel 1 accordingly Turning the steering wheel to the left L steers the truck to the left L Turning the steering wheel to the right R steers the truck to the right R The arrow 2 displays the direction in which the truck is moving For information on the turning radius see the Technical data 1 L L R L R R 6219_003 109 2 Operating 4 Driving 184 56368011501 EN 04 202...

Page 201: ...g Before using this function familiarise yourself with the change to the driving and steering characteris tics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steering Do not turn off the key switch while driving Actua...

Page 202: ...nics of the truck If the cab door is not closed and the seat belt is not fastened the driving speed is limited to 4 km h The message Close cab door or seat belt appears in the display If the cab door is opened while the truck is in motion the truck brakes automatically to a speed of 4 km h The message Close cab door appears in the display If the seat belt is released with the cab door closed no me...

Page 203: ...appears next to the symbol The speed restriction is switched on To switch off the speed restriction press the softkey again Configuring the speed restriction NOTE Access to the settings menu is available on ly if the truck is at a standstill and the park ing brake is applied If the parking brake is released prematurely the settings menu will close Access is only granted when the pass word is enter...

Page 204: ... the maximum speed press the Enter max speed softkey The Speed restriction menu opens Using the softkeys set a maximum speed between 2 km h and 20 km h The maximum speed is dependent on the truck equipment and may be restricted by a factory setting To save press the button The maximum speed is entered To clear press the scroll button The entry is deleted To cancel press the back button The display...

Page 205: ...he hydraulic functions When the cruise control function is activated the driver can save the speed when driving forwards at a speed of at least 6 0 km h by pressing a button and can continue driving without actuating the accelerator pedal The pictogram 3 for operating the cruise control function is located on the operating de vice for the hydraulic functions Putting the cruise control function on ...

Page 206: ... the cruise control function WARNING Risk of accident from failing to adjust speed Driving at excessive speeds can cause accidents e g the truck could tip over when cornering Adjust speed along the entire distance being trav elled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise con trol function and the dangers associa...

Page 207: ...for for wards travel NOTE In the dual pedal version variant the drive direction switch 2 is used exclusively to acti vate and deactivate the cruise control function variant 2 F 2 2 2 3 3 3 3 Operating 4 Driving 191 56368011501 EN 04 2022 13 ...

Page 208: ...tion can be acti vated at any time when the accelerator pedal is depressed by pressing the drive direction switch for forwards travel again When the cruise control function is deactiva ted the symbol 1 is greyed out NOTE The easiest way to deactivate the cruise con trol function is to touch the accelerator pedal The following actions deactivate the cruise control function Actuating the foot brake ...

Page 209: ...ces the truck is initially braked via the drive unit The following message appear on the display Release the accelerator pedal The truck will continue to drive only when the accelerator pedal is released and then actu ated again If these conditions have changed again the speed that was initially saved is set again NOTE If the truck is configured with automatic func tions to reduce the driving spee...

Page 210: ...to life caused by a falling load or if truck components are being lowered Lower the load fully before leaving the truck CAUTION Batteries may freeze If the truck is parked in an ambient temperature of below 10 C for an extended period the batteries will cool down For lead acid batteries the electrolyte can freeze and damage the batteries The truck is then not ready for operation At ambient tempera...

Page 211: ...ps of the fork arms rest on the ground If attachments variant are fitted retract the working cylinders see the chapter entitled General instructions for controlling attach ments Turn the switch key to position 0 and re move the key Operating 4 Parking 195 56368011501 EN 04 2022 13 ...

Page 212: ... used to prevent the truck from rolling away on a slope It is located on the right hand mudguard Pull the latch forward 1 and hold it in place Grip the wheel chock by its handle 3 Remove the wheel chock from the support mounting via the guide 2 Push the wheel chock under a front axle wheel on the side facing the descending gradient After use reinsert the wheel chock in the support mounting Make su...

Page 213: ...s when handing loads Page 223 Lift mast versions DANGER Risk of accident if the lift mast or the load collides with low ceilings or entrances Note that the inner lift mast or load may be higher than the fork carriage Observe the heights of ceilings and entrances One of the following lift masts may be attach ed to the truck Telescopic lift mast When lifting the lift mast rises above the out er lift...

Page 214: ...ximum height 2 NOTE When lifting above the free lift the fork car riage always remains at the upper edge of the extending lift mast Triple 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 maximum height 2 2 3 2 3 Operating 4 Lifting 198 56368011501 EN 04 2022 13 ...

Page 215: ...er has an unobstructed view past the lift mast to the left and right and can also see over the lift mast Data Height lift mast re tracted h1 1650 mm Height lift h3 2137 mm Rated capacity load Q 2000 kg Operating devices for the lifting system The method of operating the lifting system de pends on the operating devices included in the truck s equipment Possible equipment variants include Multi leve...

Page 216: ... delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 1 2 assistance systems Work with particular attention and care NOTE If several hydraulic functions are used at the same time these fun...

Page 217: ...fferent configuration has been con figured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 1 The adhesive label with the corresponding pictogram 4 is located on the operating lever The tilting movement of the lift mast is con tr...

Page 218: ...direction of the arrow C To tilt the lift mast backwards Move the tilting operating lever 2 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 202 56368011501 EN 04 2022 13 ...

Page 219: ...ust make all drivers aware of the fact that a different configuration has been con figured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic func tions 1 or 2 is affixe...

Page 220: ... of the arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 204 56368011501 EN 04 2022 13 ...

Page 221: ... drivers aware of the fact that a different configuration has been con figured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting lowering and tilting movements of the lift mast are controlled using the lift mast 360 lever 3 The adhesive label bearing the pictograms for the hydraulic functions 1 or 2 is affixed at the desi...

Page 222: ...he lift mast 360 lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 206 56368011501 EN 04 2022 13 ...

Page 223: ...e all drivers aware of the fact that a different configuration has been con figured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 3 The adhesive label bearing the corresponding pictograms 1 is affixed at the designated point 6...

Page 224: ...the lift mast operating lever 4 in the direction of the arrow C To tilt the lift mast backwards Move the lift mast operating lever 4 in the direction of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 208 56368011501 EN 04 2022 13 ...

Page 225: ...iguration has been con figured Observe the pictograms on the operating levers Before use check that the hydraulic functions are working correctly The lifting and lowering movements of the lift mast are controlled using the lift lower oper ating lever 4 The adhesive label with the corresponding pictogram 3 is located on the operating lever The tilting movement of the lift mast is con trolled using ...

Page 226: ...ds Operate the lifting system from the driver s seat only WARNING Risk of accident as a result of an operating error These operating instructions describe how to operate the lifting system in the factory configuration If the authorised service centre has configured a dif ferent configuration the newly applied pictograms must be observed to ensure safe operation The operating company must make all ...

Page 227: ... Pull the Joystick 4Plus 1 backwards B To lower the fork carriage Push the Joystick 4Plus 1 forwards A Tilting the lift mast To tilt the lift mast forwards Tilt the horizontal rocker button 3 to the left C To tilt the lift mast backwards Tilt the horizontal rocker button 3 to the right D F 6219_003 167_V3 1 2 A B F 6219_003 165_V3 D C 3 4 Operating 4 Lifting 211 56368011501 EN 04 2022 13 ...

Page 228: ...es not stop immedi ately upon release It only stops after approximately one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 1 2 assistance systems Work with particular attention and care The authorised service centre can reduce the dynamics of the hydraulic movements to adapt the hydraulic movements to the application re quirements The hydrau...

Page 229: ...ement only decelerates slow ly The fork carriage therefore continues to run for some time before the movement comes to a standstill Selecting load programs 1 to 3 The truck has three load programs for the dif ferent lifting behaviours of the fork carriage and the lift mast The higher the number of the load program selected the greater the load dynamics Differences between the load programs Load pr...

Page 230: ... complete Refer to the section entitled Warming up the hydraulic oil at cold ambient tempera tures in the chapter entitled Operation Checks and tasks before daily use Fork wear protection variant The fork wear protection variant ensures that the fork arms do not touch the ground The fork arms are protected against wear and the building floor is protected against damage There are two types of fork ...

Page 231: ...DANGER There is a risk of fatal injury from being run over if the truck rolls away Do not park the truck on a gradient Apply the parking brake Change the fork extension in a cordoned off safe location on a level surface WARNING There is a risk of injury when changing the fork arms the weight of the fork arms could cause them to fall on your legs feet or knees The space to the left and right of the...

Page 232: ...rriage until the lower edges of the fork arms are approx 3 cm higher than the height of the pallet Actuate the parking brake and make sure it is applied securely Turn the switch key to the left and pull it out Undo the locking screw 2 on the right or left Pull the locking lever 1 upwards and push the fork arms outwards onto the pallet Installing Position the fork arms on a pallet to the left or ri...

Page 233: ...ge the fork extension in a cordoned off safe location on a level surface WARNING There is a risk of injury There is a risk of crushing due to the weight of the fork extension There is a risk of cutting on sharp edges or burrs Wear protective gloves and safety shoes WARNING There is a risk of tipping The weight and dimensions of the fork extension af fect the stability of the truck The permissible ...

Page 234: ...th the fork extension Push the fork extension all the way to the back of the fork Make sure that 60 of the length of the fork ex tension is on the fork arm Always secure the fork extension with the secur ing bolt Always secure the securing bolt with the linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork ex tension 1 Push the fork extension onto the for...

Page 235: ... the reversible fork arms if there is no load support A fork extension variant cannot be secured against slipping Do not use a fork extension variant WARNING Risk of accident from the truck tipping over When driving the centre of gravity of the load 2 must not be more than 600 mm above the ground The truck may tip forwards when driving or braking Only drive with a load centre of gravity up to a ma...

Page 236: ... Hi Lo lift masts variant and triplex lift masts variant an incorrect extension sequence may occur i e the inner lift mast may extend before the free lift is complete As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for in stance result from The hydraulic oil temperature being too low Blocking of the fork carria...

Page 237: ...st become blocked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on 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 hyd...

Page 238: ...NOTE Only the emergency steering function remains available Operating 4 Lifting 222 56368011501 EN 04 2022 13 ...

Page 239: ...the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver Use a closed roof covering variant in addition Capacity rating plate The load capacity indicated for the truck on the capacity rating plate must not be excee ded The...

Page 240: ...tation of the capaci ty rating plate Only the capacity rating plates on the truck are valid The figures show examples Only observe the capacity rating plate on the truck DANGER Risk of fatal injury from the truck losing stability If the permissible loading of the attachments variant and the reduced load capacity of the truck and at tachment combination is exceeded there is a risk of loss of stabil...

Page 241: ... the attachment If an attachment is attached a second capacity rating plate is fitted the residual load capacity rating plate This plate shows the load capacity taking the attachment into account In the case of inte grated attachments only a basic capacity rat ing plate is created as the integrated devices cannot be easily removed from the truck The example values used here are marked in black To ...

Page 242: ...ifted higher than 5880 mm The load capacity specified for certain nominal lifts applies up to this nominal lift If the lift value of the first line is exceeded the load capacity from the second line applies up to the lift of the second line Residual load capacity rating plate for built in devices and attachments NOTE The residual load capacity rating plate for at tachments is read according to the...

Page 243: ...city rating plate applies to the maximum possible sideshift The driver is responsible for complying with the load capacity and sideshift information on the residual load capacity rating plate If in doubt use the load capacity for the maximum possi ble sideshift Special capacity rating plate for off cen tre loads If unbalanced loads are regularly transported a special capacity rating plate for off ...

Page 244: ...ariant should also be used Removable roof panels may not be removed Adjusting the fork Lift the locking lever 1 and move the fork arms to the desired position Allow the locking lever to snap back into place The load centre of gravity must be midway between the fork arms Only actuate the fork prong positioner var iant when the fork is not carrying a load Danger area The danger area is the area in w...

Page 245: ... immediately Secure the truck against use by unauthorised par ties DANGER Danger of death from falling loads Never walk or stand underneath sus pended loads Transporting pallets As a rule loads e g pallets must be trans ported individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the technical requirements have been met The driver mu...

Page 246: ...at begin to swing can result in the following risks Follow the Instructions for transporting suspen ded loads Risks due to suspended loads Impaired braking characteristics and steer ing movement Tipping over the front axle Tipping the truck at right angles to the drive direction Risk of crushing of accompanying persons Reduced visibility DANGER Loss of stability Slipping or swinging suspended load...

Page 247: ...Never drive on slopes with a suspended load Transporting containers holding fluids as hanging loads is not permitted Picking up a load DANGER There is a risk to life from a falling load or from truck components being lowered Never walk or stand underneath suspended loads or raised fork arms Never exceed the maximum load values specified on the capacity rating plate Otherwise stability cannot be gu...

Page 248: ...rack Position the forks Set the lift mast to vertical Lift the fork carriage to the stacking height CAUTION Risk of component damage When the fork is inserted into the rack take care not to damage the rack or the load Operating 4 Handling loads 232 56368011501 EN 04 2022 13 ...

Page 249: ...l the load is resting entirely on the fork DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear DANGER Due to the risk of tipping never tilt the lift mast with a raised load Lower the load before tilting the lift mast Reverse carefully and slowly until the load is clear of the rack Brake gently Operating 4 Handling loads 233 56368011501 EN 04 ...

Page 250: ... Lower the load while maintaining ground clearance Tilt the lift mast backwards The load can be transported Operating 4 Handling loads 234 56368011501 EN 04 2022 13 ...

Page 251: ... conditions can be evaluated by de termining the size of the area that is not visi ble A If the area that is not visible exceeds 1085 mm EN16842 2 A3 the visibility conditions are inadequate Procedure Sit down on the driver s seat and adopt the seat position Determine the area that is not visible A using the load height C and the length of the route D 4000 mm This area that is not visible A must n...

Page 252: ...d and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards Drive slowly and carefully around corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating ...

Page 253: ... to perform tasks such as emptying containers of bulk material The shake function moves the fork carriage quickly up and down via the Lifting function This function may only be used for a limited load and must not be used with a full nominal load Maximum permissible load for the shake function Maximum 30 of the nominal load If an attachment is being used its weight must be subtracted from this val...

Page 254: ...orously and frequently the operating device is moved the more in tense the shaking is NOTE Once the function has been activated the driver has two seconds to start the shaking If two seconds elapse without the shake function being used the shake function is deactivated again WARNING The shake function remains active for two seconds following activation If the driver simply wants to lift or lower t...

Page 255: ...t perform the shake function close to the lift height of a lift limit Cancel the lift limit by pressing the F button See the note below NOTE The lift limit can be cancelled by pressing the F button See also the section entitled Inter mediate lift cut out variant For this option contact the authorised service centre The following section shows how the shake function is activated via the standard as...

Page 256: ...ple mini lever Move the 360 lever 3 back and forth between positions A and B four times Then continue to move the component in the same way Quadruple mini lever Move the operating lever 4 back and forth between positions A and B four times Then continue to move the component in the same way Operating 4 Handling loads 240 56368011501 EN 04 2022 13 ...

Page 257: ...may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take partic ular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from falling load If the fork or the load remains suspended during low ering the load may fall When removing from stoc...

Page 258: ...wer the load until it rests securely on the rack DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear Move the truck back until the fork arms can be lowered without touching the stack Lower the fork while maintaining ground clearance Tilt the lift mast backwards and drive away Operating 4 Handling loads 242 56368011501 EN 04 2022 13 ...

Page 259: ... descending gradients at an angle Do not park the truck on ascending or de scending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and sta bility values Before driving on ascen...

Page 260: ...ight Park the truck securely and switch it off Determine the unit weights by reading the truck nameplate and if necessary the nameplate on the attachment variant and or by weighing the load to be lifted Add together the determined individual weights to obtain the total weight of the truck Net weight 1 Max permissible battery weight 2 Ballast weight variant 3 Net weight of attachment variant Weight...

Page 261: ... bridge is properly at tached and secured and has a sufficient load ca pacity e g lorry bridge Ensure that the lorry onto which you will be driving is secured to prevent it from shifting and that it can support the load of the truck Determining the total actual weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the nameplate on the attachment ...

Page 262: ...of the lift mast and a reflector 1 on the fork carriage NOTE The LED sensor unit and reflector are adjus ted at the factory Follow up adjustments are carried out by the authorised service centre The LED lift height sensor constantly emits a light signal that is reflected by the reflector The truck control unit calculates the current lift height based on the travel time of the light signal NOTE Alt...

Page 263: ... display The message Clean lift height sensor appears in the display Clean the sensor glass 2 and the reflec tor 1 using a soft cloth and water Also clean the dust protection cover 3 if necessary A small amount of cleaning agent can be add ed to the water CAUTION Component damage caused by incorrect cleaning The sensor glass and the reflector can be damaged as a result of incorrect cleaning proced...

Page 264: ...in the display operating unit If the malfunction no longer exists or has been rectified the system is automatically available again Truck functions that are dependent on the lift height are restricted in the event of a malfunc tion in the height measurement system Mal functions must therefore be rectified immedi ately Contamination The driver can resolve a temporary interrup tion of the light sign...

Page 265: ...t value The following assistance systems can contin ue to be operated but with the restrictions of emergency operation Intermediate lift cut out Release the lifting operating device so that it can return to the zero position The fork carriage can then continue lifting at a reduced speed Lift mast end stop damping Release the lifting operating device so that it can return to the zero position WARNI...

Page 266: ...tre must adjust this value The system works across the entire lift range from ground level up to the maximum lift height When properly configured the measurement inaccuracy is as follows Repeatability 5 mm Maximum measure ment inaccuracy 45 mm NOTE If the prerequisites on the truck have changed e g the tyres are worn the value displayed for the lift height may differ more from reality In this case...

Page 267: ... in this section NOTE Check the lift heights set here before use via the Intermediate lift cut out menu NOTE The fleet manager can use his access author isation to set the lift heights at which the in termediate lift cut out takes effect If no fleet manager access is enabled the authorised service centre must set the desired lift heights The intermediate lift cut out is always active when the truc...

Page 268: ...ight If the fork carriage is lowered to below the configured lift height for the intermediate lift cut out the intermediate lift cut out function is switched on again WARNING Risk of accident due to unintentional switch off of the intermediate lift cut out If the truck is also equipped with the intermediate lift cut out variant and the shake function is performed close to an intermediate lift cut ...

Page 269: ...riod Continue lifting within one second as other wise the function will intervene again If the function intervenes again the black symbol will reappear Switching off the intermediate lift cut out Press the button The first menu level appears Press the softkey Press the softkey The orange coloured activation bar next to the softkey goes out The symbol disappears from the main dis play The function ...

Page 270: ...ift cut out softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 254 56368011501 EN 04 2022 13 ...

Page 271: ...button The menu closes The storage locations are displayed An orange activation bar indicates that the intermediate lift cut out 1 is activated Fleet manager Intermediate lift cut out 2 Intermediate lift cut out 3 End lift cut out Intermediate lift cut out 1 6219_003 315_en Fleet manager Enter desired height Clear Intermediate lift cut out 1 6 892 Activate Save Cancel 6219_003 316_en m Operating 4...

Page 272: ... telescopic lift masts NiHo lift masts and triple masts This protects the load against jerking movements Lift mast end stop damping var iant This assistance system in conjunction with the optical height measuring system ensures that the fork carriage reaches the lifting stops gently This prevents the lifting movement from stopping abruptly If the truck is equipped with the automatic mast vertical ...

Page 273: ... Switching off the end lift cut out Stop the truck Apply the parking brake Press the button The first menu level appears Press the softkey Press the softkey The symbol goes out The end lift cut out is switched off To switch the end lift cut out on again press the softkey again NOTE The maximum lift height cannot be modified by the driver It can be changed either by the authorised service centre or...

Page 274: ...ift cut out softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 258 56368011501 EN 04 2022 13 ...

Page 275: ...oses An orange activation bar indicates that the End lift cut out is activated Fleet manager Intermediate lift cut out 2 Intermediate lift cut out 3 End lift cut out Intermediate lift cut out 1 6219_003 315_en Fleet manager Enter desired height Clear Intermediate lift cut out 1 6 892 Activate Save Cancel 6219_003 316_en m Operating 4 Lift height dependent assistance systems 259 56368011501 EN 04 2...

Page 276: ... the truck NOTE This lift height can be changed up to 500 mm either by the authorised service centre or with the Access authorisation for the fleet manag er via the display operating unit Configuration by the fleet manager Entering the lift height Activate the Access authorisation for the fleet manager Press the button Press the softkey Fleet manager Enter desired height Clear Intermediate lift cu...

Page 277: ...striction for lift softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 261 56368011501 EN 04 2022 13 ...

Page 278: ... menu closes Entering the speed restriction The maximum speed can be defined just like the lift height Activate the Access authorisation for the fleet manager Press the button Press the softkey Fleet manager Speed restriction Lift height 6219_003 321_en Fleet manager Enter desired height Clear Speed reduction when the fork carriage is raised Lift height Save Cancel 6219_003 322_en_V2 Operating 4 L...

Page 279: ...striction for lift softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Lift height dependent assistance systems 263 56368011501 EN 04 2022 13 ...

Page 280: ...r the speed using softkeys 0 to 9 To save press the button The menu closes Fleet manager Speed restriction Lift height 6219_003 321_en Enter maximum speed 2 20km h km h 10 Speed restriction 6219_003 193_en Operating 4 Lift height dependent assistance systems 264 56368011501 EN 04 2022 13 ...

Page 281: ...tive when the truck is switched on The fork wear protection symbol appears in the display Only the authorised service centre may deactivate the function If the symbol is grey the assistance system is switched on If the symbol is black the assistance system is taking effect The fork carriage does not lower to a level that is higher than the set level Lowering to the ground NOTE The fork wear protec...

Page 282: ... section entitled Zeroing the assis tance systems Configuration by the fleet manager The height of the fork wear protection can be configured for example for retraction into pal lets with a different height or uneven ground Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck settings softkey Operating 4 Lift height dependent assistance systems...

Page 283: ...utton The menu closes Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Fleet manager Enter desired height Clear Fork wear protection 0 120 Save Cancel 6219_003 320_en m Operating 4 Lift height dependent assistance systems 267 56368011501 EN 04 2022 13 ...

Page 284: ...vertical position ing variant CAUTION Risk of damage to property due to the lift mast collid ing with racks or other objects Before using the automatic mast vertical position ing assistance system position the truck at a suf ficient distance from racks and other objects The automatic mast vertical positioning as sistance system can be used to set down the goods so that the goods are exactly ver ti...

Page 285: ...The symbol appears in the display Tilt back the lift mast until it reaches the end stop Tilt the lift mast forwards The lift mast stops in the vertical position NOTE The lift mast also stops in the vertical position if it is tilted forwards by 3 from a backward tilt NOTE The automatic mast vertical positioning must be calibrated in order to ensure accuracy at all times The access authorisation for...

Page 286: ...ift mast must stop in the vertical position The automatic mast vertical positioning can be used If the lift mast does not stop in the vertical position do not use the assistance system In this case contact your authorised service centre Calibrating the automatic mast vertical positioning The automatic mast vertical positioning is cali brated using a wizard on the display operating unit NOTE The wi...

Page 287: ...anding on a HGV ramp for ex ample Lift the fork carriage slightly Apply the parking brake Attach a tilt angle template with a spirit level to the outer lift mast Bring the lift mast to the vertical position according to the spirit level Press the button Press the Softkey Activate the Access authorisation for the fleet manager Press the Service softkey 80 90 80 7 0 6 0 7 0 6 0 Operating 4 Tilt angl...

Page 288: ...en completed successfully the message Calibration successful appears Switch the truck off and on again The calibration is now complete NOTE If the message A6701 Fault Monitor ing of assistance system ap pears during the calibration perform the cali bration again Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Fleet manager ...

Page 289: ...igher than the nominal load The overload detection restricts the hydraulic functions as follows If the rated capacity or the maximum load set by the authorised service centre is ex ceeded the lifting speed is reduced If the rated capacity or the set maximum load are exceeded by more than 10 the Lifting function is disabled NOTE Please note the following special considera tions If the load pressure...

Page 290: ... Press the softkey Press the Truck settings softkey Press the Overload detection soft key Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Load dependant assistance systems 274 56368011501 EN 04 2022 13 ...

Page 291: ...ting movements are configured to use low dynamics the lifting system responds after a delay when the operating device is released even in an emergency The fork carriage does not stop immedi ately instead it takes approx one second This behaviour may also occur when specific settings are configured for the Dynamic Load Control 1 Work with particular attention and care Observe the Dynamics of the hy...

Page 292: ... speed is reduced to 5 km h at a lift height of 2 1 m and higher or in the second lifting stage NOTE When the fork carriage has been lowered be low the lift heights mentioned above the driver can deactivate the speed restriction again Re lease the accelerator pedal for a short period to do this If a sensor belonging to Dynamic Load Con trol 1 fails the level of intervention from the function is in...

Page 293: ...ol 2 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria Lift height Load weight Load centre of gravity Dynamic Load Control 2 intervenes in the fol lowing operating situations With a telescopic lift mast The fork carriage is at least 2 1 m off the ground With a triple lift mast or NiHo lift mast The fork carriage is in the second lifting stage T...

Page 294: ...en segments A Grey area The dynamics of the lifting movements and tilting movements are not noticeably reduced B Yellow area If a load that is close to the nominal load is picked up the display moves into the yellow area The dynamics of the lifting movements and tilting movements are noticeably re duced Handle the load with the appropriate level of care C Red area When the combination of load weig...

Page 295: ...he rated capacity Observe the following safety information DANGER Risk of accident from a falling load The load may fall if the load centre of gravity has not been taken into account or the load has not been picked up securely Pick up the load securely see the chapter entitled Picking up loads WARNING Risk of accident as a result of exceeding the residual load capacity If the weight determined by ...

Page 296: ...ction entitled Zeroing the assis tance systems Calibrating the load measure ment If the truck is equipped with the load meas urement assistance system then this assis tance system must be calibrated The load measurement is calibrated using a wizard on the display operating unit NOTE The calibration procedure requires access au thorisation for the fleet manager Access to the settings menu is only a...

Page 297: ...rvice softkey Press the scroll keys until the Cal ibration menu appears Fleet manager Maintenance interval Calibration Shock sensor Change password access auth Relieve hydraulics 6219_003 277_en Operating 4 Load dependant assistance systems 281 56368011501 EN 04 2022 13 ...

Page 298: ...bration again Precision load measurement variant This assistance system is available only if the truck is equipped with the load measurement variant The Precision load measurement variant al lows the weight of the load being picked up to be measured and displayed on the display op erating unit accurate to within 3 of the rated capacity of the truck NOTE If the load is to be measured exclusive of t...

Page 299: ...he fork carriage increases the measurement accuracy in trucks with mul ti lever operation The value is calculated The Calc ongo ing message appears 0 0 0 70 m 1 5 t t 6219_003 222 1 0 0 0 70 m 1 5 t 6219_003 223_V3_en Lower fork slightly Operating 4 Load dependant assistance systems 283 56368011501 EN 04 2022 13 ...

Page 300: ...ad measurement function should not factor in the weight of a load container the tare function must be run It is then possible to determine the net weight of the raised load NOTE During the following process the fork carriage must be lowered slightly When doing so the fork must not touch the ground as otherwise the result will be inaccurate Set the lift mast to vertical Pick up the empty load conta...

Page 301: ...is played The Precision load measurement can be performed To clear the tare weight press the soft key again WARNING Risk of accident due to incorrect load specification If the requirements for the precision load measure ment function change the tare function must be run again for example if a precision load measurement needs to be performed without a crate Otherwise the new precision load measurem...

Page 302: ... up the load and call up the load menu 2 Measure the load 3 Add subtract the load WARNING Risk to stability If the weight determined by a load measurement ex ceeds the permissible residual load capacity of the truck the truck cannot be operated safely Do not lift the load higher than 800 mm Set down and reduce the load immediately If necessary use another truck with sufficient load bearing capacit...

Page 303: ... is explained here using Press the softkey The menu for storage location appears This menu provides the following functions Tare Precision load measurement Add load Subtract load Delete total load Measure load Press the softkey Measure the load 0 00 0 00 0 00 t 0 00 t Operating 4 Load dependant assistance systems 287 56368011501 EN 04 2022 13 ...

Page 304: ...ract the current load press the softkey The current load is subtracted from the sum The load is saved automatically NOTE If for instance this load was added to the wrong total load it is also possible to perform a subtraction with the previously measured and added load Delete total load To delete the total load press the soft key The Clear total load message is displayed To clear press the softkey...

Page 305: ...lacing a worn pair of tyres if the front and rear tyres are worn to different levels If the front and rear tyres show different levels of wear Electrical fork wear protection When changing fork arms NOTE The zeroing for the load measurement assis tance system is shown here as an example Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck setti...

Page 306: ...ocesses for zeroing the other assis tance systems are almost identical Fleet manager Change PIN codes Manage driver profiles On board charger Zeroing Auxiliary hydraulics 6219_003 323_en Fleet manager Lift height Tilt angle Fork wear protection Load weight 6219_003 324_en Operating 4 Zeroing the assistance systems 290 56368011501 EN 04 2022 13 ...

Page 307: ...ollowed the messages Zeroing successful or Zeroing failed are displayed If zeroing failed try again If zeroing fails repeatedly contact your au thorised service centre Fleet manager Lower forks Load weight 6219_003 325_en Operating 4 Zeroing the assistance systems 291 56368011501 EN 04 2022 13 ...

Page 308: ... persons The specifications provided by the manufacturer and supplier of the attach ments must be observed during installation of the attachments Before changing attachments the hydraulic system must be depressurised This is done using a wizard on the display operating unit If the truck has a 5th hydraulic function or 6th hydraulic function the hydraulic circuits of these functions must also be de...

Page 309: ...quires access authorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied If the parking brake is released prematurely the settings menu will close Set the load down if necessary Apply the parking brake Starting the wizard Press the button Press the softkey Activate the Access authorisation for the fleet manager...

Page 310: ...menu appears Push the Relieve hydraulics soft key The following message appears Caution the lift mast may move To confirm press the softkey Press the softkey to exit the wizard Operating 4 Depressurising the hydraulic system 294 56368011501 EN 04 2022 13 ...

Page 311: ...ssure has built up in the hydraulic system again the function for relieving the hy draulics becomes inactive Depressurising the hydraulic system using multi lever opera tion Start the wizard for depressurising the hy draulic system Depressurising the hydraulic circuits for the basic functions The basic functions include the first four hy draulic functions The basic functions are con trolled via th...

Page 312: ...r 2 can be assigned the sideshift and the fork adjustment functions In this case press the button 1 and hold it down Push the operating lever 2 once in the direction of the arrow until the end position is reached Release the button 1 The hydraulic circuits of the sideshift and fork adjustment are now depressurised The plug connectors on the lift mast are depressurised Completing the depressurisati...

Page 313: ...d hold it down Push the operating lever 4 once in the direction of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Press the button 2 and hold it down Push the operating lever 3 once in the direction of the arrow until the end position is reached The hydraulic circuit of the 6th...

Page 314: ...justment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the cross lever 1 for controlling the additional functions once in the direc tion of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To complet...

Page 315: ...Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the cross lever 1 once in the direc tion of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Complet...

Page 316: ...nt Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To comp...

Page 317: ...ctuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the direction of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Compl...

Page 318: ...t Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisation To compl...

Page 319: ...2 Actuate the function key for the 5th func tion 2 The LED for the 5th function lights up Push the operating lever 1 once in the direction of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func tion 2 The LED for the 5th function goes out Co...

Page 320: ...k adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Actuate the operating levers 1 2 for con trolling the additional functions once in the direction of the arrow until the end positions are reached The hydraulic circuits of the additional func tions are now depressurised Completing the depressurisati...

Page 321: ... relevant pictogram for the 5th function Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Push the operating levers 1 or 4 once in the direction of the arrow until the end position is reached The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Actuate the function key for the 5th func ...

Page 322: ... functions The additional features include features such as the sideshift and fork adjustment Clamping attachments are also connected to these hy draulic circuits These functions are controlled via hydraulic circuits three and four Push the Joystick 4Plus 1 once in the di rection of the arrow until the end position is reached The hydraulic circuits of the additional func tions are now depressurise...

Page 323: ...unction Press and hold shift key F 1 Push the Joystick 4Plus 3 once in the di rection of the arrow until the end position is reached Push the horizontal rocker button 2 once in the direction of the arrow The hydraulic circuit of the 5th hydraulic func tion is depressurised The plug connectors on the lift mast are depressurised Release shift key F 1 Completing the depressurisation To complete the d...

Page 324: ...ed Clamp locking mechanism variant in the chapter entitled Attachments Exiting the wizard After the hydraulics have been depressur ised press the softkey to confirm The wizard for depressurising the hydraulics is switched off The truck is ready for operation Operating 4 Depressurising the hydraulic system 308 56368011501 EN 04 2022 13 ...

Page 325: ...ent person If the visibili ty is deemed insufficient visual aids must be used such as mirrors a camera a monitor system etc Observe the following warning notices DANGER Risk of fatal injury from falling load If attachments that hold the load by clamping it or exerting pressure on it do not have a second method of operating the function lock the load can work loose and fall off Ensure that the seco...

Page 326: ... specific residual load capacity rating plate to be fitted to the truck Arrange for the operating devices to be re label led Arrange for the authorised service centre to adjust the hydraulic system to the requirements of the attachment e g adjust the pump motor speed NOTE If the required labelling is not provided with the attachment contact the authorised service centre promptly Alternating operat...

Page 327: ...urer and supplier or sub supplier of the attachment when doing so NOTE Please observe the definition of the following responsible person competent person Switch off the truck Install the attachment Switch on the truck Check and ensure that all functions of the installed attachment are working properly Load capacity with attachment The permissible load capacity of the attach ment and the permissibl...

Page 328: ...p with a 5th function variant Joystick 4Plus Joystick 4Plus with a 5th function variant To control attachments see the sections re lating to the respective operating devices in this chapter WARNING Use of attachments can give rise to additional haz ards such as a change in the centre of gravity addi tional danger areas etc Attachments must only be deployed for their inten ded use as described in t...

Page 329: ...tion var iant the fleet manager can adjust the speed of the auxiliary hydraulics for attachments See also the section entitled Adjusting the hydraulic speed for attachments in this chapter Attachment example for the connection of the auxiliary hy draulics NOTE The authorised service centre will tell you which attachments can be used with this truck The connection of attachments to the auxiliary hy...

Page 330: ...here NOTE If one switch valve is used the auxiliary hy draulic functions 1 3 and 2 4 that are sup plied by this switch valve cannot be operated simultaneously The switch valve supplies ei ther auxiliary hydraulics 1 3 or 2 4 Adjusting the hydraulic speed for attachments If different attachments are mounted the fleet manager can adjust the hydraulic speed for attachments and thus the flow rate of h...

Page 331: ...or the fleet manager Press the Auxiliary hy draulics softkey This menu lists all the available hydraulic axles for attachments Refer to the operating instructions of the at tachment to determine which hydraulic axle is occupied by the attachment The authorised service centre will help you determine the axles Setting the revolution speed Push the softkey for the hydraulic axle to be configured Flee...

Page 332: ...e revolution speed press the or softkey To save the setting press the softkey The settings are saved To cancel the setting press the softkey The settings return to the most recently set value Locking the flow rate You can also lock the hydraulic oil flow rate in full To do so press the softkey The hydraulic oil flow for this hydraulic axle is locked Setting the return flow rate separately Dependin...

Page 333: ...a falling load If other attachments in addition to the clamp are used on this truck the clamp locking mechanism must be reassigned to the corresponding operating device ev ery time the clamp is reassembled Make sure that the authorised service centre reas signs the function of the clamp locking mechanism to the corresponding operating device Make sure that the additional clamp locking mech anism f...

Page 334: ... See the section concerning the relevant op erating device Operating 4 Attachments 318 56368011501 EN 04 2022 13 ...

Page 335: ...in the upper part of the pic togram Move the operating lever backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Note the following attachment functions and pictograms Picto gram Attachment function Move the side shift frame or fork for wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adju...

Page 336: ...ns is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism NOTE For technical reasons no clamp locking mech anism is available for the multi lever operating device Operating 4 Attachments 320 56368011501 EN 04 2022 13 ...

Page 337: ...pictogram Move the operating lever 3 4 backwards The attachment moves in the direction of movement shown in the lower part of the pic togram Press and hold the switch 1 The additional function of the attachment is activated and can be controlled as the 5th function with the operating lever 4 NOTE The movement action of the 5th function can be found in the operating instructions of the attachment t...

Page 338: ...e to the right Tip shovel over Tip shovel back Swivel the fork to the left Swivel the fork to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary If the attachment is known the re...

Page 339: ...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 340: ...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 341: ...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 342: ...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 343: ...pective functions that are activated by these levers The following applies Move the operating lever 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the operating lever 2 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown in the pictogram Picto gram Attachment funct...

Page 344: ...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 345: ...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 346: ...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 347: ...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 348: ...2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is automat ically reactivated To open the clamp push the operating lev er ...

Page 349: ...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 350: ...ating lever 2 and the adhesive label 4 for the op erating lever 1 are affixed at the designated points If the adhesive labels become illegible or are missing please contact your authorised service centre Observe the pictograms for the attachment functions on the adhesive labels 3 4 The pictograms on the operating levers show the respective functions that are activated by these levers The following...

Page 351: ... au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Clamp locking mechanism To release the clamp locking mechanism push the operating lever 2 forwards The clamp locking mechanism is released The LED for the clamp release 1 lights up and remains lit while the clamp locking mech anism is released NOTE The hydraulic function for...

Page 352: ...ible or are missing please contact your authorised service centre The following applies Actuate the function key for the 5th func tion 2 The LED for the 5th function 3 lights up Move the operating lever 4 or 6 in the direction of the arrow E or F The attachment moves accordingly in the di rections E or F as shown in the pictogram NOTE The place where the adhesive label bearing the pictograms 1 or ...

Page 353: ... to the right NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the au thorised service centre must check that the pictograms bear the correct representation and must change them if necessary Operating 4 Attachments 337 56368011501 EN 04 2022 13 ...

Page 354: ...show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus The following applies Move the Joystick 4Plus 1 in the direction of the arrow A or B The attachment moves accordingly in the di rections A or B as shown in the pictogram Move the slider 4 in the direction of the arrow C or D The attachment moves accordingly in the di rections C or D as shown...

Page 355: ...ush the slider 1 to the left The clamp locking mechanism is released The LED for the clamp release 2 lights up and remains lit while the clamp locking mech anism is released To open the clamp push the slider 1 to the left again NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism is...

Page 356: ... on the adhesive label regard ing operation of the Joystick 4Plus show the respective functions that are activated by the individual operating devices of the Joy stick 4Plus Note the following attachment functions and pictograms Operating device Function of the at tachment 1 Shift key F and Joystick 4Plus Adjust fork arms close open 2 Shift key F and horizontal rocker button Adjust fork back wards...

Page 357: ...hments must only be deployed for their inten ded use as described in the relevant operating in structions Drivers must be taught how to operate the attach ments WARNING Risk of accident Loads may only be picked up and transported with attachments if the loads are securely grasped and attached Where necessary loads must also be se cured against slipping rolling falling over swinging or tipping over...

Page 358: ... g in the event of an accident This data can be electronically read out and evalu ated If you have any questions please contact your authorised service centre Driver restraint systems var iants Different driver restraint systems are available as variants for this truck The description and operation for these systems can be found in the separate Driver restraint systems operat ing instructions Actu...

Page 359: ... off press the softkey repeatedly until the symbol 1 ap pears again on the display The activation bar next to the symbol goes out Rear window wiper and washer To activate the On operating stage press the corresponding softkey 5 The On operating stage is activated The symbol 7 appears To activate the Intermittent mode operat ing stage press the softkey again The symbol 6 is shown with an orange bac...

Page 360: ...as long as the softkey is pressed Once the window is clean release the soft key The previous operating stage is reactivated To switch off the speed limitation press the softkey again Filling the washer system Open the filler cap 1 of the washer sys tem Fill the washer reservoir 2 with washer flu id as described in the Maintenance data table CAUTION Damage due to the effects of frost When water fre...

Page 361: ...n assistance system that automatically re duces the driving speed of the truck within halls However this assistance system does not release the driver from the responsibility of observing the speed limits on company prem ises Depending on the system setting the ceiling sensor can detect overhead structures above the truck at a height of 2 m to 24 m above the sensor If the truck is equipped with a ...

Page 362: ... to the maximum speed permitted for outdoor areas the speed limitation must still be unlocked To do this release the accelerator briefly and then operate the ac celerator again Switching on the truck in a hall If the truck is switched on inside a hall the ceiling sensor system detects the hall ceil ing and reduces the driving speed to the maximum speed that is set for halls Possible limitations fo...

Page 363: ...to loosen it Disconnect the electrical connec tion assembly by pulling out the plug On the underside of the assembly base plate on the overhead guard hold four nuts 3 in place Unscrew four socket head screws 2 The key 5 is secured with a nut under the assembly baseplate Carefully remove the ceiling sensor 1 Deckensensor_Anbau 1 4 2 3 5 Deckensensor_Einstellschlüssel_V2 Operating 4 Auxiliary equipm...

Page 364: ...rewdriver CAUTION The settings for DIP switches 6 to 8 are the factory settings of the manufacturer Do not change the factory settings of the manufac turer Factory settings of the manufacturer DIP switch 6 7 8 1 1 0 The possible settings for DIP switches 1 to 5 are shown in the following tables DIP switch 1 2 3 Range 0 0 0 2 m 0 0 1 3 m 0 1 0 4 m 0 1 1 6 m 1 0 0 8 m 1 0 1 12 m 1 1 0 16 m 1 1 1 24 ...

Page 365: ...nsor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following table Sensitivity Range Beam angle Low 1 2 m 22 5 4 m 22 5 8 m 20 16 m 15 24 m 5 Medium 2 2 m 35 4 m 30 8 m 25 16 m 22 5 24 m 10 2 3 4 1 2 3 4 Operating 4 Auxiliary equipment 349 56368011501 EN 04 2022 13 ...

Page 366: ...quite a long time to start up when the truck is switched on Waiting for the additional device to start up after a short interruption of operation is annoying To avoid this the run on time of the power supply can be adjusted via the display operating unit After the truck has been switched off the additional device continues to be supplied with power during the run on time Activate the Access author...

Page 367: ...Press the Run on time softkey Fleet manager Run on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Lift cut out 6219_003 314_en Operating 4 Auxiliary equipment 351 56368011501 EN 04 2022 13 ...

Page 368: ...itch off completely The power supply for terminals remains active No infor mation appears on the display However the display may glow slightly This is normal Press the scroll button to deactivate the run on time The menu closes Fleet manager Enter run on time Clear Run on time 45 Deactivate Save Cancel 6219_003 326_en Min Operating 4 Auxiliary equipment 352 56368011501 EN 04 2022 13 ...

Page 369: ...d camera Rear camera 1 2 3 Left hand camera Monitor 4 5 The camera system consists of four cameras and a monitor for the camera images It pro vides a 360 circumferential view and supports the driver in handling the truck The camera Operating 4 Optical assistance systems 353 56368011501 EN 04 2022 13 ...

Page 370: ...due to improper use The camera system must only be used for its inten ded purpose as set out and described in these oper ating instructions Any other use is improper use and therefore not permitted CAUTION Possible component damage The camera inputs are live No moisture or conduc tive objects may enter the inputs CAUTION The camera system is an aid to the driver However the driver is always respon...

Page 371: ...NOTE The monitor is fitted with a cover to protect it from operating errors The components of the camera system must not be opened Only the authorised service centre may in stall and maintain the camera system Monitoring area of the camera Front camera Right hand camera Rear camera Left hand camera 1 2 3 4 Monitor Front field of vision Right hand field of vision Left hand field of vision 5 6 7 8 O...

Page 372: ...ith one hand Move the monitor to the desired position and hold it Display of camera images in all driving situa tions The monitor shows the images from all four fields of vision simultaneously in all driving sit uations NOTE If another monitor display is desired contact your authorised service centre For example other possible settings are Increasing the rear field of vision for reverse travel Inc...

Page 373: ...left hand sides In the rear camera image the rear part of the counterweight must be visible Cleaning Clean the camera lenses with compressed air or use a small amount of glass cleaner to moisten the lenses Then carefully wipe away with a lint free cloth Do not use an aggressive cleaning agent or solvents Do not use high pressure cleaning equip ment Carefully wipe the monitor with a lint free cloth...

Page 374: ...the lift mast 3 Monitor 4 Rear view camera on the overhead guard These cameras can only be ordered individu ally or in the following combinations Front view camera in the lift mast rear view camera on the overhead guard Camera on the right hand fork arm rear view camera on the overhead guard Operating 4 Optical assistance systems 358 56368011501 EN 04 2022 13 ...

Page 375: ... due to improper use The camera system must only be used for its inten ded purpose as set out and described in these oper ating instructions Any other use is improper use and therefore not permitted CAUTION Possible component damage The camera inputs are live No moisture or conduc tive objects may enter the inputs CAUTION The camera system is an aid to the driver However the driver is always respo...

Page 376: ...and A pil lar via a double joint To adjust the desired position of the monitor proceed as follows Turn the wing screw 1 anti clockwise to loosen it Hold the monitor with one hand Move the monitor to the desired position and hold it Re tighten the wing screw 1 by turning it clockwise Depending on the cameras installed on the truck different images are transmitted to the monitor Camera Monitor image...

Page 377: ...ion from backwards to for wards To change the default settings of the moni tor images contact the authorised service centre Information about the cameras Rear view camera The camera angle is chosen in such a way that the counterweight is always visible and thus the immediate surroundings of the truck STILL recommends not changing this setting The image is displayed the correct way round just like ...

Page 378: ... daily operation check that the cam era lens is uncovered clean and undam aged CAUTION Possible risk of injury or component damage If one fork arm is damaged or worn always replace both fork arms If there is damage or wear on one fork arm it can be assumed that the counterpart also has or will have corresponding damage or wear CAUTION Risk of damage to components Do not expose the fork arms to lat...

Page 379: ...em is an optical lift height positioning support e g for placing a load on a shelf A laser 1 in the tip of the right hand fork arm projects a horizon tal line onto the shelf directly in front of the fork arm This allows the driver to estimate the height on the racking at which the fork arms are located The system therefore assists driv ers when placing loads into stock and remov ing loads from sto...

Page 380: ...ions Any other use is improper use and therefore not permitted CAUTION Possible risk of injury or component damage If one fork arm is damaged or worn always replace both fork arms If there is damage or wear on one fork arm it can be assumed that the counterpart also has or will have corresponding damage or wear CAUTION Risk of damage to components Do not expose the fork arms to lateral forces Do n...

Page 381: ...correctly before starting work Check that the lens of the laser is uncov ered clean and undamaged If necessary clean the lens see the chapter entitled Cleaning Using Laser Smartfork CAUTION Risk of damage due to miscalculation of the lift height The Laser Smartfork is an assistance system that helps the driver to place loads into stock and remove loads from stock at significant lift heights The dr...

Page 382: ...imes or switch off speed contact the authorised service centre Depending on the variant switch on the laser Manual Press the button on the display operating unit and access the Load sub menu Then press the soft key You can also set this softkey as a fa vourite on the first level of the display oper ating unit See the chapter entitled Config uring favourites in the separate operating instructions f...

Page 383: ... rack Switch on the laser and lift the fork to the height of the reference object The laser line must run exactly parallel to the reference object If the line is not parallel proceed as follows Loosen the four grub screws 1 on the cov er plate 2 and carefully remove the cover plate Loosen the grub screw 3 that prevents the laser from rotating by turning the grub screw anti clockwise Carefully rota...

Page 384: ...fork tip only when the laser is switched off Clean the lens with a lint free cloth or cotton swab If necessary moisten the swab with a commercially available glass cleaner Do not use an aggressive cleaning agent or solvents Do not use high pressure cleaning equip ment Frequency of cleaning The lens must be cleaned when necessary and at least once every three months Operating 4 Optical assistance s...

Page 385: ...and the seat belt is fastened the truck decelerates and is restricted to a driving speed of 4 km h The message Close cab door appears in the display If the seat belt is released with the cab door closed no message appears Opening the cab door from the outside Insert the key in the door lock 5 unlock the door and remove the key Pull the handle 4 Unlock the door lock Open the cab door 3 by pulling i...

Page 386: ...y in the corresponding stop slot Opening the front side window Squeeze the handle 3 Slide the front side window 1 backwards Opening the rear side window The rear side window 2 can be opened in the same way as the front side window Closing the front side window Slide the front side window 1 forwards us ing the handle 3 until it snaps into place Closing the rear side window The rear side window 2 ca...

Page 387: ...ers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the radio WARNING The driver s attention is adversely affected by operat ing the radio or listening to it at excessive volumes while driving or handling loads Risk of accident Do not operate the radio when driving or when handling loads Adjust the radio volume so that ...

Page 388: ... of fire due to overheating The heating system can overheat if the hot air cannot escape from it The heating system may only be switch ed on if the blower is running and the heating system is not covered by objects such as a jacket or cover Always switch the blower on first Do not switch the heating system on until the blower is switched on Move any objects away from the heating system or air dist...

Page 389: ...red position Selecting blower settings To select a lower fan output turn the fan control knob 2 anticlockwise To select a high blower output turn the fan control knob 2 clockwise Setting heating levels To set a lower heater power turn the heat ing level control knob 1 anticlockwise To set a higher heater power turn the heat ing level control knob 1 clockwise Setting the air vent control knob To di...

Page 390: ...lways supplied with air It is not necessary to adjust the heating system using the operating devi ces To open the air distributor push the inden tation 1 on the disc The discs open Grasp the discs to align the air flow The discs can be adjusted to the desired an gle The air distributor can be rotated Press down again to close the discs Changing fuses DANGER Risk of fire as a result of short circui...

Page 391: ... Push the on off switch 5 The LED on the switch lights up red The air conditioning is switched on Press the on off switch 5 again The LED on the switch goes out The air con ditioning is switched off Defrost function The defrost function can be used to de ice and dehumidify the windscreen quickly To do this turn the air vent control knob 3 anti clock wise to the position Open the air distribu tors ...

Page 392: ... Pushed up at the rear Completely pushed up Two handles 2 5 and two locking bolts 3 4 are located on the right hand side for this pur pose To push up and close the roof window stop the truck and apply the parking brake Pushing up and closing the roof window at the front To push up the roof window pull out the locking bolt 4 with your right hand and keep hold of the locking bolt Use your left hand ...

Page 393: ... keep hold of the locking bolt Use your right hand to take hold of the han dle 2 on the roof window 1 and push upwards until the locking bolt 3 engages The roof window 1 is held in the pushed up position To close the roof window pull out the lock ing bolt 3 with your left hand and keep hold of the locking bolt Use your right hand to take hold of the han dle 2 on the roof window 1 and pull down unt...

Page 394: ...front 4 To adjust the sun visor 2 grasp it and move it to the desired position To move the sun blind 4 up and down grasp the tab 3 and move the sun blind If necessary fully unroll the sun blind for the roof 1 and attach the ends 5 in the extended position To roll up slowly roll the blind 1 back up Operating 4 Cab 378 56368011501 EN 04 2022 13 ...

Page 395: ...he truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the towed load present corresponds to the rated capacity of the truck it is not permitted to transport a load on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe t...

Page 396: ...k is to be used for towing on a more regular basis Coupling pin in the counter weight Coupling the trailer DANGER Risk to life if the truck rolls away If you briefly leave the truck to couple it or uncouple it there is a risk of fatal injury caused by the truck rolling away and running you over Apply the parking brake Lower the fork to the ground Switch off the truck Remove the switch key or block...

Page 397: ...nts If the coupling pin or securing bush is lost or dam aged during towing the trailer will become loose and uncontrollable Only use original coupling pins that have been checked Ensure that the coupling pin is correctly inserted and secured Insert the coupling pin into the counter weight press downwards against the spring pressure and turn it by 90 The coupling pin is now locked in this position ...

Page 398: ... Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER Risk of fatal injury from detaching trailers The tow coupling is not designed for support loads and could be deformed or destroyed The supported load or the trailers could come loose The tow coupling should be subjected only to hori zontal loads i e the tiller must be horizontal DAN...

Page 399: ...coupling can damage the racking or the tow coupling itself when manoeuvring If a collision with the tow coupling oc curs the tow coupling must be checked for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufficient room In the case of a collision check the tow coupling for damage Have a damaged tow coupling replaced by the authorised servic...

Page 400: ...for a tow bar eye in accordance with DIN 74054 bore diameter 40 mm or DIN 8454 bore diameter 35 mm Take measures to prevent the trailer from rolling away e g using wedges Adjust the towing eye of the tiller so that it is in the middle of the towing jaws Push the hand lever 2 upwards until it en gages The tow coupling is opened CAUTION When being coupled the tow bar eye must engage in the middle of...

Page 401: ... m and then move it back slightly On the coupling pin check again that the control pin does not protrude out of its guide Remove any items used to prevent the trail er from rolling away Tow the trailer Model RO 244 Closing the coupling DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for exam ple a tow rope is to be secured in the tow coupling only actuat...

Page 402: ...iller so that it is in the middle of the towing jaws Push the hand lever 5 upwards The tow coupling is opened DANGER People can become trapped between the truck and trailer When coupling ensure that there are no persons present between the truck and the trailer Slowly move the truck backwards DANGER Risk of accident due to open coupling pin A protruding safety handle means that the tow bar eye has...

Page 403: ...rances gates etc observe the dimen sions of the trailer and load When towing multiple trailers ensure a suf ficient minimum distance to fixed installa tions when turning and cornering The permissible length of the trailer trains de pends on the roadways to be driven and may need to be determined during the test drive It is the responsibility of the operating compa ny to instruct the drivers regard...

Page 404: ...nguished by two different temperature ranges 1 Constant use in the temperature range down to 5 C short term use at temper atures down to 10 C Operation possible with standard equip ment and standard hydraulic oil 2 Alternating between indoor use down to 32 C and outdoor use up to 25 C briefly up to 40 C Operation possible only with cold store equipment and low temperature hydraulic oil NOTE When c...

Page 405: ...de temperature may result in the formation of condensation water This water may freeze on re en try to the cold store blocking moving parts of the truck It is essential that close attention is paid to the dura tion of deployment in the different temperature rang es for both types of application Before being used in the cold store the truck must be dry and warmed up The truck must not leave the col...

Page 406: ...component damage The lead acid batteries must not be left in the cold store overnight without power uptake or charging Charge the battery outside the cold store and operate the truck using a replacement battery Using batteries in the cold store To compensate for the reduction in capacity at low temperatures it is advisable to use lead acid batteries with the maximum nominal capacity in the respect...

Page 407: ...ot freeze Water top up systems must not be used at temperatures below 0 C as this could cause the systems and the water present in the hose lines to freeze The battery voltage when discharged is thus generally lower at low temperatures The final discharged voltage is reached earlier i e the capacity is lower Operating 4 Cold store application 391 56368011501 EN 04 2022 13 ...

Page 408: ...sage is displayed until either the cause has been corrected or the message has been acknowledged In the case of successive events the respec tive messages are displayed one after another on the display Messages about operation If messages about operation appear on the display operating unit an action must be per formed Code Shown on display Cause action Log in The access authorisation variant is p...

Page 409: ...ated due to the battery temperature be ing too high This message about the on board charger is triggered by different causes The truck was heavily used before charging and the battery has become very hot The ambient temperature is too high and the battery cannot cool down The charging profile is configured incorrectly Allow the battery to cool down Allow the battery temperature symbol on the displ...

Page 410: ...working The charging process is continued without elec trolyte circulation Intermediate charging can cause damage to the battery Cancel the charging process Contact the authorised service centre Development mode ac tive This message is not displayed during normal operation Contact the authorised service centre Drive unit blocked This message follows earlier messages e g overtemperature It is not p...

Page 411: ...m ion battery Switch the truck off and on again If the message continues to appear please contact the authorised service centre Fault Battery The truck control unit detects an error in the lithium ion battery Switch the truck off and on again If the message continues to appear please contact the authorised service centre V7074 V7051 Mains voltage error This message about the on board charger is tr...

Page 412: ...o matically Apply the parking brake by pressing the but ton Release parking brake via button The electric parking brake cannot be released automatically Release the parking brake by pressing the button Parking brake Mainte nance required The truck control unit detects that the electric parking brake needs servicing Secure the truck with wedges so that the truck does not roll away Contact your auth...

Page 413: ...f switch is unlocked Unlock the emergency off switch Emergency operation If the truck experiences a power reduction for example due to a battery charge state that is too low this message appears Observe the previous message Emerg direct via drive direction lever The drive direction switch on the hydraulic oper ating device has failed Emergency driving is possible to do so Move the drive direction ...

Page 414: ...f the hazard warning system variant is switch ed on when the truck is switched off the dis play operating unit remains active Then when a truck function is called up this message ap pears Switch on the truck Shock event detected If the truck control unit detects a very strong acceleration or deceleration e g in the event of an accident this message appears Service required If the maintenance inter...

Page 415: ...rotection variant this mes sage appears if an excessive load is picked up Set down the load Overtemp Drive unit The drive units are protected against overtem perature If the temperature at the drive units is too high this message appears Acceleration and maximum speed are reduced Allow the truck to cool down Overtemperature bat tery If the truck control unit detects an excessive battery temperatur...

Page 416: ...witch does not open Stand up from the driver s seat and sit down again A3035 Fault Brake fluid Brake fluid switch A3143 Check lift height sensor and reflector Lift height sensor measurement error A5934 Re insert charging plug Error on the charging connector detection Disconnect the connection assembly and re connect it A5961 Battery overtempera ture Overtemperature of the lithium battery Switch of...

Page 417: ...ll be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the key switch before disconnecting the battery male connector Do not disconnect the battery male connector while the key switch is switched on except in an emergency In an emergency all functions of the truck can be shut down Press the emergency off switch 1 or dis conne...

Page 418: ...potentially fatal conse quences There is a risk to life Failure to comply with the limits specified in these operating instructions e g driving on unacceptably steep gradients or failing to adjust speed when cor nering can cause the truck to tip over If the truck starts to tip over do not leave the truck under any circumstances This increases the danger of being hit by the truck Do not release you...

Page 419: ...he face when smashing a pane of glass Pull the emergency hammer out of its sup port mounting at the handle Using one of the two metal tips on the head of the emergency hammer hit the pane of glass with force until it breaks Emergency driving via the drive direction switch drive direction selection lever Under certain conditions the emergency driv ing function can be used to remove the truck from a...

Page 420: ...sired drive di rection Press the accelerator pedal Drive the truck to a safe area and park the truck safely If the error occurs frequently contact the authorised service centre Emergency lowering If the hydraulic controller fails whilst a load is raised emergency lowering can be performed An emergency lowering screw designed for this purpose is located on the valve block DANGER There is a risk to ...

Page 421: ...1 5 revolutions to loosen it WARNING The load is lowered Unscrewing the emergency lowering screw regulates the lowering speed Observe the list of points below The following applies Tightening torque Max 2 5 Nm Unscrewing the emergency lowering screw slightly The load is lowered slowly Unscrewing the emergency lowering screw further The load is lowered quickly After lowering 6219_003 260 6219_003 2...

Page 422: ...dges on the downhill facing side to prevent it from rolling away Manually release the parking brake only when the truck is at a standstill with the fork lowered The electric parking brake can be released and applied via an emergency actuation mechanism The electric parking brake must be manually actuated under the following conditions The electric parking brake is not operating properly The truck ...

Page 423: ... the parking brake To apply the parking brake push down the hand wheel 1 and turn it clockwise until the force required to do so increases signifi cantly and the truck is held securely Remove the hand wheel 1 turn it round and then insert it again Fold the cover down again If the condition of the parking brake can not be reliably determined secure the truck with wedges 1 2 6219_003 228 1 6219_003 ...

Page 424: ...rive into the towing vehicle when the towing vehicle brakes For safety reasons only a tested tow bar may be used Use a tested tow bar CAUTION If the truck drive between the drive motor and the drive axle is not interrupted the drive may be dam aged Set the drive direction switch to the neutral posi tion CAUTION Potential for damage to the battery male connector If the battery male connector is dis...

Page 425: ...t all times WARNING Risk of accident if the truck is not steered If the truck is not steered while it is being towed it may veer out in an uncontrolled manner The truck being towed must also be steered by a driver The driver of the truck being towed must sit in the driver s seat and fasten the seat belt before towing Use the available restraint systems Procedure Set down the load and lower the for...

Page 426: ...rolled effectively at all times 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 NOTE Emergency actuation of the electric parking brake variant may be necessary on a faulty truck see the section above entitled Emer gency actuation of the electric parking brake Operating 4 Procedure in emergencies 410 56...

Page 427: ...and the plug connection 3 are dry clean and free of foreign objects Insert the battery male connector 2 fully into the plug connection on the truck The orange latch 1 must engage CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery door Ensure that the battery cable does not come into contact with the battery door NOTE The appe...

Page 428: ... male connector unlocks Pull out the battery male connector 2 from the plug connection 3 on the truck and set it down safely CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery door Ensure that the battery cable does not come into contact with the battery door NOTE The appearance of a lithium ion battery differs from this illu...

Page 429: ...lithi um ion battery chapter Observe and follow the safety information below Safety information DANGER Risk of explosion due to flammable gases During charging the lead acid batteries release a mixture of oxygen and hydro gen oxyhydrogen gas This gas mixture is explosive and must not be ignited There must be no flammable materi als or spark forming operating materials within 2 m of either the truc...

Page 430: ...d as this will result in excessive wear and pose a fire hazard If the mains plug needs be pulled out before the end of the charging process cancel the charging process at the battery charger first DANGER Risk of explosion from connecting and disconnecting connection assemblies Even when the truck and the battery charger are switched off oxyhydrogen gas in the vicinity can explode if connec tion as...

Page 431: ...d off 4 Lithium ion battery with truck switched on Opening the lid Gently press in the lid 1 and release it The lid 1 is partially opened by a spring Then open the lid 1 completely by hand and hold it The lid 1 is secured against unintentional opening by a spring Closing the lid When the charging cable is disconnected from the charging quick access 2 the lid 1 closes automatically by spring pull N...

Page 432: ...ing cable from the charging quick access 2 3 Lithium ion battery with truck switch ed off Connect the charging cable to the charging quick access 2 Battery charging takes place The display operating unit shows the charging state dis play 3 When the charging process is complete disconnect the charging cable from the charging quick access 2 4 Lithium ion battery with truck switch ed off Connect the ...

Page 433: ... error The charging quick ac cess 2 may not recognise the charging ca ble In this case disconnect the charging cable from the charging quick access and re es tablish the connection If the charging process is running the charg ing state display 3 is animated in green If the charging process is not running the charging state display 3 flashes in grey 7 3 kW 10 48 88 6219_003 337 3 Operating 4 Chargi...

Page 434: ...mA Protective conductor NOTE All messages for the on board charger are lis ted in the section entitled Messages about operation in the Display messages chapter Conditions for the operation of the on board charger The on board charger must only be used to charge batteries that are located in the same truck as the charger and are connected to the truck The housing of the on board charger must not be...

Page 435: ...r has not been configured for the battery type used and for example an excessively high battery capacity has been set this may result in excessive heating and significant gas emissions Oxyhydrogen gas and sulphur compounds form as a result Observe the following conditions which may mean that a reconfiguration of the battery charger is required The battery charger must be configured for the battery...

Page 436: ... the battery type used Fleet manager access authorisation variant allows the fleet manag er to do this NOTE The configuration process requires access au thorisation for the fleet manager Access to the settings menu is only available if the truck is at a standstill and the parking brake is ap plied If the parking brake is released prema turely the settings menu will close Apply the parking brake Pr...

Page 437: ...teristic curves are displayed The orange activation bar displays the current selection Push the softkey that corresponds to the selection The display reverts to the On board charger menu Charging start time Press the Charging start time soft key Fleet manager Charging start time Charging current limitation Maintenance charge Charging characteristic curve 6219_003 285_en Fleet manager Standard Fast...

Page 438: ...e charging plug is plugged in outside the specified charging start time a charging state indicator 2 appears in grey Battery charging does not take place The time remaining 1 until the specified charging start time is displayed in the top left The softkey allows you to start charging directly To do so press the 3 softkey Fleet manager Enter time to start charging Clear 00 Charging start time 00 Ac...

Page 439: ...ts Press the Charging current limi tation softkey Charging current limitation menu Enter the charging current as a percent age 1 using softkeys 0 to9 The charging current is displayed under the input window in amperes 2 To save press the button The display reverts to the On board charger menu Maintenance charge If the truck remains stationary over a pro longed period and maintenance charge is 6219...

Page 440: ...ixture is explo sive and must not be ignited There must be no flammable materi als or spark forming operating materials within 2 m of either the truck when it is parked for charging or the battery charg er When working with batteries take the following safety precautions Keep away from open flames and do not smoke Ensure that work areas are adequately ven tilated Disconnect the battery male connec...

Page 441: ...the relevant socket DANGER Risk of fire due to overheated connec tion assembly Do not pull out the mains plug under load as this will result in excessive wear and pose a fire hazard If the mains plug needs be pulled out before the end of the charging process cancel the charging process manually first see the section entitled Stopping the charging process man ually DANGER Risk of explosion due to s...

Page 442: ... and discon necting connection assemblies Even when the truck and the battery charger are switched off oxyhydrogen gas in the vicinity can explode if connec tion assemblies are connected or dis connected Sufficiently ventilate the battery com partment of the truck and the charg ing area CAUTION Possible component damage Make sure that the charging cable does not cross any traffic routes Do not rou...

Page 443: ... a suitable CEE 16 A socket and switch off the truck Take the supplied charging cable out of the storage container Open the cover 1 of the charger socket 3 on the truck DANGER Risk of explosion due to formation of oxyhydrogen gas If the ventilation slots 2 over the cov er of the charger socket are covered or dirty ventilation is not guaranteed The oxyhydrogen gas collects in the battery compartmen...

Page 444: ...it If the charging state display 7 does not ap pear or the LED 6 lights up permanently in red there is a fault It is possible that the charger socket 3 does not recognise the truck plug 4 In this case pull out the truck plug 4 and plug it in again If the charging process is running the charg ing state display 7 is animated in green If the charging process is not running the charging state display ...

Page 445: ... start phase Yellow Recharging phase active lead acid battery Yellow Battery almost fully charged lithium ion battery Residual charge with reduced current Yellow green Battery fully charged Green Trickle charging only for lead acid batteries Green Deep discharge start possible press push button for 2 s Red Malfunction e g mains connection or battery faulty internal error Charging not possible Red ...

Page 446: ...ndividual LEDs in the tail lights begin to flash go out and flash again one after anoth er running from one side to the other side This light signal is displayed over the entire duration of the charging process Up to a charging state of 50 only the LEDs in the left tail light begin to flash The fewer LEDs that flash the lower the charging state As soon as the charging state exceeds 50 the LEDs in ...

Page 447: ...or the truck plug at the same time Pull the truck plug out of the charger socket Pull the charging cable out of the CEE 16 A socket and attach the protective cap Place the charging cable in the storage con tainer on the counterweight Close the cover of the charger socket It is possible to stop the charging process manually at any time See the following sec tion entitled Stopping the charging proce...

Page 448: ...p and con figure this pump in the battery charger Using an electrolyte circulation pump reduces the charging time of a lead acid battery and enables intermediate charging If the truck is equipped with an electrolyte circulation pump a battery designed for elec trolyte circulation must always be used The pump can be damaged without the counter pressure from the battery The charger detects an error ...

Page 449: ... Before the charging process is started manually you must there fore measure all cell voltages in the battery and compare them for any irregularities If one cell voltage is significantly smaller than the others the battery is probably defective The charging process must not be started In addition the filling quantity of the acid in the cells must be checked and if necessary re filled according to ...

Page 450: ...erloading as well as excessive gas emissions and overheating of the battery Only use intact batteries approved by STILL CAUTION Risk of damage to components If batteries other than those listed here are used it is not possible to guarantee that the batteries will not incur damage and will charge correctly Use only the batteries listed here In addition to proprietary STILL lithium ion batteries onl...

Page 451: ...approved by the following battery manufacturers Hoppeke Hawker MIDAC TAB Exide 3 Gel batteries are charged only in accord ance with the standard characteristic curve IUIa If in doubt contact the authorised service centre Performance data Input Mains voltage 400 V AC Network frequency 45 to 65 Hz Maximum power consumption 10 7 kW Maximum current draw 15 5 A Output Maximum output power 10 kW Maximum...

Page 452: ... or battery charg er and for the battery Observe the following safety regulations when maintaining charging and changing the battery Maintenance personnel Batteries must only be charged maintained and replaced by properly trained personnel in accordance with the instructions compiled by the manufacturers of the battery battery charger and industrial truck The handling instructions for the battery ...

Page 453: ...ing and maintaining the battery observe the manufacturer s maintenance in structions for the battery and the battery charger Fire protection measures DANGER Risk of explosion if the battery is not extended If the truck is equipped with an electric battery carrier variant the following applies The battery carrier reduces the space between the battery and the battery hood During charging lead acid b...

Page 454: ...ly disconnect when the industrial truck and battery charger are switched off The battery door must remain open during charging Expose the surfaces of the battery cells Do not place any metal objects on the bat tery Fully open any protective structures e g fabric covered cab Have fire extinguishing equipment ready Battery weight and dimensions DANGER Risk of tipping due to change in battery weight ...

Page 455: ...attery cable does not come into contact with the battery door CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected or con nected while the key switch is switched on or while the battery charger is under load an arc or a tran sition spark will be produced at the battery male connector This can lead to erosion at the contacts and can considerably s...

Page 456: ...ce with the battery manufacturer s operating instructions The operating instructions for the battery charger must also be followed Only the instructions that came with the battery charger are valid If any of these instructions are missing request the relevant instructions from the dealer The battery maintenance information is com posed of the following sections Checking the status acid level and a...

Page 457: ...the au thorised service centre Open filler cap 1 and check the acid level For batteries with caged cell plugs the liquid must reach the bottom of the cage For batteries without caged cell plugs the liquid must reach a height of approx 10 to 15 mm above the lead plates Top up missing fluid with distilled water on ly Clean the battery cell cover and dry if nec essary Remove any oxidation residues on...

Page 458: ...ged state Apply the parking brake Switch on the truck Read the charge status on the display of the display operating unit Charge a discharged or partly discharged battery Meaning of the colours in the display 1 Green The battery is sufficiently charged 2 Yellow Charge the battery soon 3 Red Stop working Charge the battery imme diately The battery is at risk of deep dis charge Calibrating the batte...

Page 459: ...n the display operating unit Activate the Access authorisation for the fleet manager Press the button Press the softkey Press the Truck settings softkey Press the Battery softkey Battery Driving programme 6219_003 327_en Operating 4 Handling the lead acid battery 443 56368011501 EN 04 2022 13 ...

Page 460: ...g fabric covered cabs ensure adequate ven tilation in the cab variant DANGER Risk of explosion due to old batteries Old and inadequately maintained batteries can cause excessive gas emissions and excessive heating dur ing charging The increased production of explosive gas can lead to an explosion If an increased build up of heat or a sulphurous odour is detected stop the charging process im mediat...

Page 461: ...e battery male connector If the battery male connector is disconnected while the truck is switched on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the truck before the battery male con nector is disconnected Do not disconnect the battery male connector while the truck is switched on except in an ...

Page 462: ...tery charger Adjust the settings of the battery charger to the battery capacity of the lead acid battery Start the battery charger NOTE Observe the information in the operating in structions for the battery and the battery charger DANGER Risk of explosion To ensure adequate ventilation the bat tery door must be locked in the charging position using the support bracket during the charging process O...

Page 463: ...e battery charger Swing the support bracket 1 back into po sition and lock it into the support eyelet 2 on the battery door Open the battery door and lock it into the open position Disconnect the battery male connector from the plug for the battery charger Connect the battery male connector to the truck DANGER Risk of explosion Only disconnect the connection assem blies when the truck and battery ...

Page 464: ...y capacity An equalising charge should be carried out in accordance with the battery manufacturer s instructions several times a month after the normal charging process NOTE Depending on the battery charger used the equalising charge may not begin until 24 hours have elapsed A period when no shifts are running such as the weekend is therefore ideal for performing the equalising charge Observe the ...

Page 465: ...perating instructions from the manufacturer of the battery charg er CAUTION Damage to the connection assembly is possible If you disconnect the charging cable while the battery charger is switched on an arc will be produced This can lead to erosion at the contacts which considera bly shortens the service life of the contacts Switch off the battery charger before you discon nect the charging cable ...

Page 466: ...in with soap and water Eye irritation can occur in the event of contact with the eyes Immediately rinse eyes thoroughly with wa ter for 15 minutes then consult a doctor Maintenance personnel The lithium ion battery is virtually mainte nance free and can be charged by the driver If you have any questions please contact your authorised service centre The handling instruction for the battery and the ...

Page 467: ...taining the battery observe the manufacturer s maintenance in structions for the battery and battery charg er Fire protection measures DANGER There is a risk of damage short circuiting and ex plosion Do not place any metal objects or tools on the battery Keep away from naked flames and do not smoke DANGER Increased risk of fire Damaged lithium ion batteries pose an increased fire hazard In the eve...

Page 468: ...afety regulations for lithium ion batteries The following safety regulations generally ap ply to operating lithium ion batteries Comply with the specifications stated in the safety data sheets of the battery manufac turer Protect the battery against mechanical damage to prevent internal short circuits If batteries have even the slightest external damage dispose of them in accordance with national ...

Page 469: ... eyes are straightened they lose their rigidity The lifting eyes are then no longer able to support the weight of the battery The battery may fall Do not straighten bent lifting eyes Have bent lifting eyes replaced by the authorised service centre NOTE When switching to lithium ion batteries have the truck electronics adapted by the author ised service centre Operating 4 Handling the lithium ion b...

Page 470: ... de energised when the battery is au tomatically switched off The truck will then not be decelerated by the regenerative brake To brake actuate the service brake The STILL C Line lithium ion batteries are de signed and built for indoor use The ambient temperature range must be between 5 C 45 C If the temperature is below or above this range the battery may switch off under certain circumstances Th...

Page 471: ...d by the drives while driving Driving downhill over long distances at high driving speeds and with a high battery charge status can cause the battery to overcharge To pro tect the battery from overcharging the battery switches itself off This must be taken into ac count in the hazard assessment performed by the operating company and in any company directive that the operator company compiles Drivi...

Page 472: ... load capacity of the stor age area refer to the manufacturer s speci fications regarding battery weight To protect batteries against moisture do not store them directly on the floor Due to the fire risk store batteries outside buildings Store in a cool dry and well ventilated area Never subject the battery to temperatures below 35 C and above 80 C Long term storage below 10 C or above 50 C has a ...

Page 473: ...n batteries separately from other types of batteries no mixed storage Maintain a safety margin of at least 2 5 m from other goods To avoid a deep discharge observe the specifications of the battery manufacturer regarding the maximum permissible storage period If you have any questions contact your au thorised service centre Operating 4 Handling the lithium ion battery 457 56368011501 EN 04 2022 13...

Page 474: ...harge Reading from the battery indicator The battery indicator is located on the side of the battery tray Like the display operating unit the battery indicator shows the charge state of the lithium ion battery Warnings are issued only on this battery indicator If you have any questions contact your au thorised service centre Charge state LEDs When the battery is connected to the truck and the truc...

Page 475: ...e temperature falls into the normal range Colour of LED Cause Consequence Flashing yellow Slightly increased temperature 60 C Power reduction Solid yellow Increased temperature 65 C Shut off Flashing red Greatly increased temperature 70 C Shut off Solid red Greatly increased temperature 75 C Shut off Procedure if a lithium ion battery has a low charge state WARNING Risk of component damage or dest...

Page 476: ...r may result in damage to components Follow the operating instructions for the charging station or battery charger and for the battery CAUTION Risk of danger to components Using battery male connectors and battery charger plugs from different manufacturers can result in dam age They are not designed to be used together Use battery male connectors and battery charger connectors from the same manufa...

Page 477: ...the battery charger The charging process starts automatically The display signals the charging process by illuminating the LEDS as a chase light The battery charger will indicate when the bat tery is fully charged Only disconnect the bat tery from the charger if no current is flowing The battery has no memory effect Therefore it can be charged in any charge state without the capacity of the batter...

Page 478: ...After charging The battery charger will switch off automatical ly Swing the support bracket 1 back into po sition and lock it into the support eyelet 2 on the battery door Open the battery door and lock it into the open position Disconnect the battery male connector from the plug on the battery charger Fully insert the battery male connector into the plug connection on the truck CAUTION There is a...

Page 479: ...door The truck is equipped with a door contact switch for the battery door If the battery door is not fully closed the message Close battery door appears on the display of the display operating unit The truck will not move 6210_600 001 Operating 4 Handling the lithium ion battery 463 56368011501 EN 04 2022 13 ...

Page 480: ...as a variant The load capacity of the lifting accessory used must at least match the battery weight see the battery nameplate Changing to a different battery type The truck can be converted to a different bat tery type and capacity The new battery capacity and new battery type must be set in the display operating unit If this is not done the actual battery dis charge status cannot be determined Th...

Page 481: ...rm the battery capacity according to the battery nameplate Switch the truck off and on again The changed settings will be active once the truck is switched on Converting to lithium ion batter ies If the truck is fitted with a lead acid battery at the factory the truck can be converted to a lithium ion battery The conversion must be performed by the authorised service centre The authorised service ...

Page 482: ... pulling it forwards The hinge of the battery door holds the battery door in the open position Opening the battery door on trucks with charging quick access variant Grasp the battery door by pushing your thumb into the recess 1 Open the battery door by pulling it forwards The hinge of the battery door holds the battery door in the open position 6219_003 335 Operating 4 Replacing and transporting t...

Page 483: ... the battery door limbs could become trapped There is a risk of crushing When closing the battery door nothing should come between the battery door and the edge of the chassis Carefully close the battery door Only close the battery door if there are no parts of the body in the way WARNING When closing the battery door the bat tery cable could become trapped There is risk of short circuit due to th...

Page 484: ... locked NOTE The apertures in the door are necessary for forced ventilation and must not be blocked If the battery door is fully open grasp the battery door by its handle and open it slight ly further This will release the latch in the hinge Close the battery door by hand until it en gages in the lock The battery door must be locked in place The truck is equipped with a door contact switch for the...

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

Page 486: ...the battery male connector Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connector WARNING Risk of crushing shearing No one must stand directly next to the battery or between the battery and the truck when removing and inserting the battery CAUTION Risk of damage Position the battery cable on the bat tery in such...

Page 487: ...tely Slowly remove the battery from the battery compartment Transporting and setting down the bat tery WARNING Risk of crushing shearing The battery must be transported very carefully i e at a low speed using a slow steering movement and careful braking Do not use the methods described here to trans port the battery over long distances Transport the battery to the intended stor age space CAUTION R...

Page 488: ... a way that it will not become trapped when the battery is inserted The load carrying equipment is at a right angle to the truck The gaps are maintained for the entire time that the battery is being inserted and that the battery is inserted to a sufficient depth the display on the lithium ion battery var iant points towards the battery door DANGER Risk of crushing shearing While inserting the batt...

Page 489: ...ll be produced This jump spark can damage the contacts and considerably shorten the service life of the con tacts Do not connect the battery male connector with the key switch switched on Make sure that the key switch is switched off be fore connecting the battery male connector Close the battery lock 1 NOTE The battery door will close only when the bat tery is locked Operating 4 Replacing and tra...

Page 490: ... Insert the battery male connector fully into the plug connection on the truck Close the battery door Operating 4 Replacing and transporting the battery 474 56368011501 EN 04 2022 13 ...

Page 491: ...ing change frames The battery remains on the change frame for charging and storage Preparation Check the nameplate 3 on the change frame to ensure that the selected change frame has the required load capacity Check the change frame for deformation and breaks or cracks Faulty change frames must not be used They must be replaced by the authorised service centre The distance between the feet 6 can be...

Page 492: ...s with a dis tance of 400 mm between the outer edges of the fork arms the stop 8 must be removed When using pallet trucks with a distance of 525 mm between the outer edges of the fork arms the stop must be installed The stop 8 is connected to the battery change frame via the mounting 7 Types of change frames Observe the nameplate of the change frame The following information is listed on the namep...

Page 493: ...tery 16 3 kWh BG 8 2 511 Lithium ion battery 16 3 kWh BG 9 1 Lithium ion battery 49 0 kWh BG 9 2 Removing the battery Park the truck securely Open the battery door CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the key switch is on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens ...

Page 494: ... damage to the battery ca ble Position the battery cable on the bat tery in such a way that it cannot be crushed either when removing or in serting the battery or when closing the battery door Open the battery lock 1 NOTE If the battery lock cannot be opened by hand the coupling pin 2 from the counterweight can be used as a lever extension Operating 4 Replacing and transporting the battery 478 563...

Page 495: ... tery WARNING Risk of injury when transporting the battery The battery must be transported very carefully i e at a low speed using a slow steering movement and careful braking Do not use the methods described here to trans port the battery over long distances Transport the battery to the intended stor age space CAUTION Potential for damage to the battery The change frame and battery must be stored...

Page 496: ...ot straighten any bent lifting eyes In stead have them replaced by the authorised service centre Carefully insert the battery into the battery compartment Carefully place the battery onto the battery holding fixtures DANGER Risk of crushing shearing When inserting do not allow your hands to come between the battery and the chassis CAUTION Potential for damage to the battery ca ble Position the bat...

Page 497: ... is connected while the key switch is switched on or while the battery charger is under load a transition spark will be produced at the battery male connector This can lead to erosion of the contacts and can considerably shorten the service life of the contacts Switch off the truck and the battery charger before connecting the battery male connector Close the battery door Operating 4 Replacing and...

Page 498: ...ition 2 The following prerequisites must be fulfilled when replacing a battery using a hydraulic battery carrier The extension area 1 must be free of ob stacles The ground must clean even and offer suf ficient load capacity The fork must be safely set down on the ground The parking brake must be applied The emergency off switches on the driver s compartment and on the carriage of the bat tery carr...

Page 499: ...Risk of injury Open the battery door until the door lock engages and the door cannot close by itself CAUTION Risk of danger to components When extending the carriage the battery cable may collide with components and become damaged Ensure that the battery cable does not become stuck or crushed In the event of a malfunction release the exten sion button and correct the malfunction A Remove the lid o...

Page 500: ...ts up green The carrier is ready for use D Remove and pull out the remote control The remote control is attached to an extracta ble cable to prevent loss The operation must be carried out outside the extension area E Push and release the extension button Push the extension button again and hold down the button 6219_003 033 Operating 4 Replacing and transporting the battery 484 56368011501 EN 04 20...

Page 501: ...he battery and remove the obstacle Ensure that the battery cable is not dam aged when the carriage is extended After extending the battery fully Place a rubber mat on any batteries that have exposed terminals or connectors to prevent short circuits Disconnect the battery male connector from the plug connection of the carrier and place the battery male connector safely on the battery Operating 4 Re...

Page 502: ...can damage the contacts and considerably shorten the service life of the con tacts Do not connect the battery male connector with the key switch switched on Make sure that the key switch is switched off be fore connecting the battery male connector J Insert the battery male connector into the plug connection of the battery carrier K Push and release the retraction button Push the retraction button...

Page 503: ...the carrier N Insert the battery male connector into the plug connection of the truck O Refit the lid of the battery male connec tor Close the battery door NOTE If the truck is equipped with the FleetManag er variant and this feature is to be used the driver must authenticate themself Otherwise the truck will switch off after a certain period of time Operating 4 Replacing and transporting the batt...

Page 504: ...with open terminals or connectors with a rubber mat Observe the operating instructions for the lifting gear Attach the battery 1 to suitable lifting gear 2 Lift the battery carefully and ensure that it hangs straight on the lifting gear The lifting gear must be vertical when lifting so that no lateral pressure is applied to the tray Set the battery down carefully Remove the lifting gear after the ...

Page 505: ...y only be transported by crane using a lifting gear and bridge piece 2 that are suitable in terms in size and load capacity Pull out the two lifting eyes 1 on each side and tilt them towards each other The lifting eyes are locked in this position Observe the operating instructions for the lifting gear Attach the lifting gear to the four lifting eyes Lift the battery carefully and ensure that it ha...

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

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

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

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

Page 510: ...to the battery male con nector and plug connection can lead to an electrical short circuit Use compressed air to dry the battery male con nector and the plug connection before connecting them Use compressed air to remove any foreign objects that may be lodged in the battery male connector and the plug connection Carefully dry the truck e g using com pressed air Lubricate the joints and actuators L...

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

Page 512: ... wedge 1 in front of each front wheel and behind each back wheel CAUTION Potential for damage to the battery male connector If the battery male connector is disconnected while the key switch is on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the key switch before disconnecting the battery male co...

Page 513: ...nd the coupling pin as shown and lash the truck at an angle towards the front DANGER The load may slip if the lashing straps tension belts slip The truck must be lashed securely so that it cannot move during transportation Make sure that the lashing straps tension belts are tightened securely and that the pads cannot slip off Crane loading Crane loading is only intended for transport ing the compl...

Page 514: ...with the harnesses expressly provided and ap proved for this purpose Do not load the truck by crane Operating 4 Transporting the truck 498 56368011501 EN 04 2022 13 ...

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

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

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

Page 518: ...Operating 4 Decommissioning 502 56368011501 EN 04 2022 13 ...

Page 519: ...5 Maintenance ...

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

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

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

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

Page 524: ...tors may necessitate shorter maintenance intervals Dirty poor quality roadways Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures and extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components Service menu The date when the truck requires maintenance is stored in the Servic...

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

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

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

Page 528: ... working correctly and check for damage Check the battery lock for damage Grease the battery door hinges Variant Check the oil level of the hydraulic battery carrier and check for leaks Check all moving parts for wear and lubricate them Wheels and tyres Check tyres for wear and check the air pressure if necessary Check the wheels for damage and check the tightening torques Drive axle Check the mou...

Page 529: ...Clean the fans and the air ducts Clean the cooling fins on the converter and the traction motors Battery and accessories Check the lead acid battery for damage and check the acid density observe the manufacturer s maintenance instructions Variant Replace the non return valve on lead acid batteries with electrolyte circula tion Variant Observe the manufacturer s maintenance instructions for lithium...

Page 530: ...un out barrier Check the tilt cylinders and connections for damage and for leaks Check the fork carriage for damage and for wear Check the fork arm interlock for damage and check that it is working correctly Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Special equipment Check the condition of the antistatic belt or antist...

Page 531: ...e spare parts as per the manufactur er s instructions The use of unapproved spare parts can result in an increased risk of acci dents due to insufficient quality or incorrect assignment Anyone using unapproved spare parts shall assume unlimited liability in the event of damage or harm Quality and quantity of the re quired operating materials Only the operating materials specified in the maintenanc...

Page 532: ... filter changes or any work on the hydraulic system carefully clean the area around the part in volved When topping up working materials use only clean containers Maintenance 5 General maintenance information 516 56368011501 EN 04 2022 13 ...

Page 533: ...ing nipple on each of the two lift mast bearings 1The respective lubricant specification can be found in the Maintenance data table section below under this Code This lubrication plan describes the series production truck with standard equipment For mainte nance points on variant trucks see the relevant chapter and or instructions provided by the manufacturer Maintenance 5 General maintenance info...

Page 534: ...in question Controls joints Code Unit Operating materials Specifications Dimension Lubrication High pressure grease ID no 0147873 As required Oil SAE 80 MIL L2105 API GL4 As required Dual pedal opera tion High pressure grease ID no 0147873 As required Hydraulic system Code Unit Operating materials Specifications Dimension System filling Hydraulic oil HVLP 68 DIN 51524 Part 3 23 to 30 l Dependent o...

Page 535: ... formation on truck Min tread depth 1 6 mm Steering axle Code Unit Operating materials Specifications Dimension A Axle stub bearing spherical bearing Multi purpose grease DIN 51825 KPF2 As required Wheel nuts Torque wrench Swing axle For further informa tion refer to the workshop manual for the truck in question Steering axle For further informa tion refer to the workshop manual for the truck in q...

Page 536: ... lift mast bearing Torque wrench For further informa tion refer to the workshop manual for the truck in question Load chains Code Unit Operating materials Specifications Dimension C Lubrication High load chain spray Fully synthetic Temperature range 35 C to 250 C ID no 0156428 As required Washer system Code Unit Operating materials Specifications Dimension System filling Screen wash Winter ID no 1...

Page 537: ...ngs and joints according to the maintenance data table Driver s seat guide Cab door hinges variant Battery door hinges or battery cover hinges Actuating rod 1 for valves with multi lever operation 6210_606 030_V2 1 Maintenance 5 Preserving operational readiness 521 56368011501 EN 04 2022 13 ...

Page 538: ...ove easily Always check the interlock after an accident NOTE The interval for greasing is influenced signifi cantly by the application conditions and the environmental conditions affecting the truck Visual inspections and function checking of the interlock must be carried out as required and after every 1000 hours Grease all moving parts of the interlock as necessary Open the battery door 1 Check ...

Page 539: ...entre Only use genuine spare parts Do not make any changes to the belt NOTE Carry out the following checks on a regular basis monthly In the case of significant strain a daily check is necessary Checking the seat belt Pull out the belt 3 completely and check for wear The belt must not be frayed or cut The stitch ing must not be loose Check whether the belt is dirty Check whether parts are worn or ...

Page 540: ...as necessary but with out using chemical cleaning materials a brush will suffice Replacement after an accident As a rule the seat belt must be changed after an accident Checking the driver s seat WARNING Risk of injury After an accident check the driver s seat with at tached restraining belt and fastening Check the controls for correct operation Check the condition of the seat e g wear on the upho...

Page 541: ...r mat is grey in colour replace it NOTE Change the filter mat at least every two months Cleaning the fresh air inlet The fresh air inlet must be cleaned if the filter mat Is damaged Is incorrectly seated in the filter frame Has not been replaced every two months Remove the filter mat 2 1 1 Maintenance 5 Preserving operational readiness 525 56368011501 EN 04 2022 13 ...

Page 542: ...ws 1 on the filter frame 2 Remove the filter frame 2 Remove any dust and dirt from the fresh air inlet 1 beneath the filter mat carrier 1 2 1 Maintenance 5 Preserving operational readiness 526 56368011501 EN 04 2022 13 ...

Page 543: ... manufacturers must not be mixed If you wish to use a type of tyre or tyre manufac turer that has not been approved by STILL obtain approval from STILL prior to use Do not change rim parts and do not mix rim parts from different manufacturers Checking the condition and wear of the tyres Remove any foreign bodies embedded in the tyres 1 The level of wear exhibited by tyres on the same axle must be ...

Page 544: ...ntry in which the truck is being used The steering arms of the steering axle each have two lubricating nipples per side Lubricate the lubricating nipples with grease in accordance with the maintenance data table If after a few strokes there is no longer any old grease escaping actuate the steering WARNING Risk of crushing Do not actuate the steering during lubrication Switch on the truck Actuate t...

Page 545: ...2 to adjust each head light Adjust the headlight 1 The distance from the light bar to the truck must be between 70 75 cm Re tighten the nuts 2 Replacing the fuses DANGER Danger from electrical current High voltages are present in the fuse box There is a risk of electric shock Do not open the fuse box The fuses must be replaced only by the authorised service centre 6219_003 230 1 2 Maintenance 5 Pr...

Page 546: ...wo years if they are subject to a high level of wear Comply with the specifications of DGUV 113 020 in Germany Outside of Germany observe the national regula tions for the country of use Check pipe and hose connection screw joints for leaks traces of oil Replace hose lines if they display the following abnormalities Outer layer has been damaged or is brittle or cracked Leaking Deformation e g with...

Page 547: ...Maintenance 5 Preserving operational readiness 531 56368011501 EN 04 2022 13 ...

Page 548: ...ile the key switch is on under load an arc will be produced This can lead to erosion at the contacts which considerably shortens the service life of the contacts Switch off the key switch before disconnecting the battery male connector Do not disconnect the battery male connector while the key switch is switched on except in an emergency Disconnect the battery male connector Fold up the floor mat ...

Page 549: ... View Telescopic lift mast NiHo and triple mast 2 0 t 1 6 to 1 8 t 2 0 t 1 6 t 1 8 t 2 0 t 1 2610 3010 2610 2110 2160 1910 23 3 2 3060 3260 2660 3260 2160 2660 2210 2710 1960 2310 25 3 3 2710 2760 2360 29 9 CAUTION Risk of damage If the hydraulic oil level is too low the steering is restricted and the pump may be damaged If the oil level is too low do not use the truck and contact the authorised s...

Page 550: ...ce data table Page 518 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Preserving operational readi ness for cold store application On trucks for cold store application var iant check all rollers and chains in the lift mast for ease of movement once a week 1 6210_800 020 6210_900 002 Maintenance 5 Preserving ope...

Page 551: ...onnections for leaks WARNING Risk of injury Observe safety regulations for working on the lift mast see the Working at the front of the truck chapter Check hydraulic connections and lift cylin ders for leaks visual inspection Have leaking screw joints or leaking hy draulic cylinders repaired by the authorised service centre 7094_810 004 Maintenance 5 1000 hour maintenance annual maintenance 535 56...

Page 552: ...rms in pairs Check that the fork latch 3 is functioning correctly Make sure that the locking screw 2 is present and cannot fall out Checking the reversible fork arms NOTE This check is only required for reversible fork arms variant Check the outside of the fork bend 1 for cracks Contact your service centre 2 1 3 Maintenance 5 1000 hour maintenance annual maintenance 536 56368011501 EN 04 2022 13 ...

Page 553: ...ecurely posi tioned Check that all screws are sealed with lock ing varnish Checking the battery change over frame The screw joints and welded seams of the battery changeover frame must be subjec ted to a visual inspection 6327_003 026 Maintenance 5 1000 hour maintenance annual maintenance 537 56368011501 EN 04 2022 13 ...

Page 554: ...Maintenance 5 1000 hour maintenance annual maintenance 538 56368011501 EN 04 2022 13 ...

Page 555: ...6 Technical data ...

Page 556: ...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 557: ...Dimensions L α C x 2 1 y Q h 2 h 3 h 4 b3 b1 b10 b11 m 2 h 10 h 7 h 1 h 6 m 1 l2 s e β Seat is adjustable 90 mm 1 Fork spacing is adjustable 2 Technical data 6 Dimensions 541 56368011501 EN 04 2022 13 ...

Page 558: ...NOTE Measurements h1 h3 h4 h6 and b1 are cus tomised and can be taken from the order con firmation Technical data 6 Dimensions 542 56368011501 EN 04 2022 13 ...

Page 559: ...y load Q kg 1400 Load centre of gravity distance c mm 500 Load distance x mm 374 Wheelbase y mm 1319 Weights Model RX20 14C Type number 6219 Net weight kg 2926 Front axle load laden kg 3826 Rear axle load laden kg 500 Front axle load unladen kg 1498 Rear axle load unladen kg 1428 Wheels chassis frame Model RX20 14C Type number 6219 Tyres Superelastic Tyre size front 180 70 8 Tyre size rear 125 75 ...

Page 560: ... height h7 mm 965 Coupling height h10 mm 473 Overall length l1 mm 2661 Length including fork back l2 mm 1861 Overall width b1 mm 1099 Fork arm thickness s mm 40 Fork arm width e mm 80 Fork arm length l mm 800 Fork carriage Standard class form DIN 15173 II A Fork carriage width b3 mm 980 Ground clearance with load below lift mast m1 mm 90 Ground clearance at the middle of the wheelbase m2 mm 114 Ai...

Page 561: ... Max climbing capability with load 30 3 Max climbing capability without load 27 9 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 Service brake Electr mech Gradients The values specified in the Performance da ta table as the maximum climbing capability can be used only to compare the performanc...

Page 562: ...nce with EN 16796 kWh h 3 3 Handling performance t h 116 Energy consumption at this han dling performance kWh h 5 1 Other Model RX20 14C Type number 6219 Working pressure for attachments bar 240 Oil volume for attachments l min 26 5 Sound pressure level LpAZ Driver s compartment dB A 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 Tow coupling DIN type model Bolt Technical data 6 V...

Page 563: ...00 500 500 Load distance x mm 374 374 374 Wheelbase y mm 1319 1409 1517 Weights Model RX20 16C RX20 16 RX20 16L Type number 6220 6221 6222 Net weight kg 3125 3057 3127 Front axle load laden kg 4160 4112 4133 Rear axle load laden kg 565 545 594 Front axle load unladen kg 1500 1520 1611 Rear axle load unladen kg 1625 1537 1516 Wheels chassis frame Model RX20 16C RX20 16 RX20 16L Type number 6220 622...

Page 564: ...ht h7 mm 965 965 965 Coupling height h10 mm 473 473 473 Overall length l1 mm 2661 2744 2852 Length including fork back l2 mm 1861 1944 2052 Overall width b1 mm 1099 1099 1099 Fork arm thickness s mm 40 40 40 Fork arm width e mm 80 80 80 Fork arm length l mm 800 800 800 Fork carriage Standard class form DIN 15173 II B DIN 15173 II A B DIN 15173 II A Fork carriage width b3 mm 980 980 980 Ground clea...

Page 565: ...bing capability without load 24 24 24 Max climbing capability with load 27 6 28 27 4 Max climbing capability without load 26 27 4 28 7 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 5 7 5 4 5 1 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Electr mech Gradients The ...

Page 566: ...ce with EN 16796 kWh h 3 8 3 7 3 7 Handling performance t h 135 131 133 Energy consumption at this han dling performance kWh h 5 7 5 5 5 6 Other Model RX20 16C RX20 16 RX20 16L Type number 6220 6221 6222 Working pressure for attachments bar 240 240 240 Oil volume for attachments l min 26 25 26 25 26 25 Sound pressure level LpAZ Driver s compartment dB A 66 66 66 Human vibration acceleration ac cor...

Page 567: ...0 500 500 Load distance x mm 374 374 388 Wheelbase y mm 1409 1517 1517 Weights Model RX20 18 RX20 18L RX20 20L Type number 6223 6224 6225 Net weight kg 3231 3419 3486 Front axle load laden kg 4440 4450 4860 Rear axle load laden kg 590 769 623 Front axle load unladen kg 1524 1612 1689 Rear axle load unladen kg 1707 1806 1794 Wheels chassis frame Model RX20 18 RX20 18L RX20 20L Type number 6223 6224...

Page 568: ...mm 965 965 965 Coupling height h10 mm 473 473 473 Overall length l1 mm 2744 2852 2866 Length including fork back l2 mm 1944 2052 2066 Overall width b1 mm 1149 1149 1149 Fork arm thickness s mm 40 40 40 Fork arm width e mm 80 80 80 Fork arm length l mm 800 800 800 Fork carriage Standard class form DIN 15173 II A B DIN 15173 II A DIN 15173 II A B Fork carriage width b3 mm 980 980 980 Ground clearanc...

Page 569: ...pability without load 24 24 18 1 Max climbing capability with load 25 1 25 3 23 Max climbing capability without load 26 28 3 27 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 2 5 8 5 5 5 2 5 8 5 5 5 3 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Electr mech Gradients The values ...

Page 570: ... with EN 16796 kWh h 4 1 4 3 4 6 Handling performance t h 141 149 155 Energy consumption at this han dling performance kWh h 5 8 6 0 6 2 Other Model RX20 18 RX20 18L RX20 20L Type number 6223 6224 6225 Working pressure for attachments bar 240 240 240 Oil volume for attachments l min 26 5 26 5 26 5 Sound pressure level LpAZ Driver s compartment dB A 66 66 66 Human vibration acceleration ac cording ...

Page 571: ... of gravity distance c mm 500 500 Load distance x mm 374 374 Wheelbase y mm 1429 1537 Weights Model RX20 16P RX20 16PL Type number 6226 6227 Net weight kg 3018 3178 Front axle load laden kg 4098 4121 Rear axle load laden kg 520 657 Front axle load unladen kg 1520 1612 Rear axle load unladen kg 1498 1567 Wheels chassis frame Model RX20 16P RX20 16PL Type number 6226 6227 Tyres Superelastic Superela...

Page 572: ...ding height h7 mm 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2837 2945 Length including fork back l2 mm 2037 2145 Overall width b1 mm 1099 1099 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form DIN 15713 II A DIN 15713 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 90 G...

Page 573: ...lity without load 24 24 Max climbing capability with load 27 8 27 6 Max climbing capability without load 27 8 28 9 Acceleration time with load Blue Q STILL Classic sprint mode s 5 7 5 4 5 1 5 7 5 4 5 1 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as the m...

Page 574: ...cordance with EN 16796 kWh h 3 6 3 8 Handling performance t h 129 135 Energy consumption at this han dling performance kWh h 5 5 5 7 Other Model RX20 16P RX20 16PL Type number 6226 6227 Working pressure for attachments bar 240 240 Oil volume for attachments l min 26 5 26 5 Sound pressure level LpAZ Driver s compartment dB A 66 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 6 Tow...

Page 575: ...of gravity distance c mm 500 500 Load distance x mm 374 374 Wheelbase y mm 1429 1537 Weights Model RX20 18P RX20 18PL Type number 6228 6229 Net weight kg 3254 3178 Front axle load laden kg 4439 4435 Rear axle load laden kg 616 543 Front axle load unladen kg 1538 1612 Rear axle load unladen kg 1717 1567 Wheels chassis frame Model RX20 18P RX20 18PL Type number 6228 6229 Tyres Superelastic Superelas...

Page 576: ...ing height h7 mm 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2837 2945 Length including fork back l2 mm 2037 2145 Overall width b1 mm 1149 1149 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form DIN 15173 II A B DIN 15173 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 90 ...

Page 577: ...ility without load 24 24 Max Climbing capability with load 24 8 25 4 Max climbing capability without load 26 28 6 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 2 5 8 5 5 5 2 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as the ma...

Page 578: ...ccordance with EN 16796 kWh h 4 1 4 0 Handling performance t h 142 139 Energy consumption at this han dling performance kWh h 5 8 5 8 Other Model RX20 18P RX20 18PL Type number 6228 6229 Working pressure for attachments bar 240 240 Oil volume for attachments l min 26 5 26 5 Sound pressure level LpAZ Driver s compartment dB A 66 65 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 7 To...

Page 579: ...of gravity distance c mm 500 500 Load distance x mm 388 388 Wheelbase y mm 1429 1537 Weights Model RX20 20P RX20 20PL Type number 6230 6231 Net weight kg 3474 3449 Front axle load laden kg 4858 4851 Rear axle load laden kg 616 598 Front axle load unladen kg 1616 1696 Rear axle load unladen kg 1858 1754 Wheels chassis frame Model RX20 20P RX20 20PL Type number 6230 6231 Tyres Superelastic Superelas...

Page 580: ...tanding height h7 mm 965 965 Coupling height h10 mm 537 537 Overall length l1 mm 2851 2959 Length including fork back l2 mm 2051 2159 Overall width b1 mm 1149 1149 Fork arm thickness s mm 40 40 Fork arm width e mm 80 80 Fork arm length l mm 800 800 Fork carriage Standard class form DIN 15173 II A DIN 15173 II A Fork carriage width b3 mm 980 980 Ground clearance with load below lift mast m1 mm 90 9...

Page 581: ...ity without load 18 1 18 1 Max climbing capability with load 22 9 23 1 Max climbing capability without load 25 1 27 2 Acceleration time with load Blue Q STILL Classic sprint mode s 5 8 5 5 5 3 5 8 5 5 5 3 Acceleration time without load Blue Q STILL Classic sprint mode s 5 4 5 1 4 8 5 4 5 1 4 8 Service brake Electr mech Electr mech Gradients The values specified in the Performance da ta table as th...

Page 582: ... 240 240 Oil volume for attachments l min 26 5 26 5 Sound pressure level LpAZ Driver s compartment dB A 66 66 Human vibration acceleration ac cording to EN 13059 m s2 0 6 0 6 Tow coupling DIN type model Bolt Bolt Eco design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation EU 2019 1781 because these motors do not meet the desc...

Page 583: ...re exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given in Article 2 Scope Item 1 b Technical data 6 Eco design requirements for electric motors and variable speed drives 567 56368011501 EN 04 2022 13 ...

Page 584: ...OTE Battery specifications according to DIN 43531 cells in accordance with DIN EN 60254 2 48 V circuit A or 48 V circuit B The battery weight can be found on the nameplate of the battery Lead acid batteries Battery designa tion Capacity Ah Circuit Weight ballast weight kg Battery compartment di mensions mm Tray Length Width Height 4PzV 400 400 A 708 155 830 522 627 364 4PzV 440 440 4PzS 460 460 4P...

Page 585: ...y Ah Circuit Weight ballast weight kg Battery compartment di mensions mm Tray Length Width Height 5PzV 550 550 5PzS 575 575 5PzS 625 650 Technical data 6 Battery specifications for lead acid batteries 569 56368011501 EN 04 2022 13 ...

Page 586: ... BG 2 17 2 kWh 28 6 kWh and 51 5 kWh Battery group 2 4 Battery group 2 5 Battery group 2 6 Nominal voltage V 47 71 47 71 47 71 Nominal capacity Ah 360 600 1080 Nominal energy kWh 17 2 28 6 51 5 Length mm 1030 1030 1030 Width mm 529 529 529 Height mm 627 627 627 Weight kg 856 856 856 X Line Li Ion 48 V BG 3 17 2 kWh 28 6 kWh and 51 5 kWh Battery group 3 4 Battery group 3 5 Battery group 3 6 Nominal...

Page 587: ...oup 9 6 Nominal voltage V 47 71 47 71 47 71 Nominal capacity Ah 360 600 1080 Nominal energy kWh 17 2 28 6 51 5 Length mm 830 830 830 Width mm 738 738 738 Height mm 627 627 627 Weight kg 1013 1013 1013 Technical data 6 Battery specifications for X Line lithium ion batteries 571 56368011501 EN 04 2022 13 ...

Page 588: ...ity Ah 402 402 Nominal energy kWh 19 3 19 3 Length mm 1030 830 Width mm 529 630 Height mm 627 627 Weight kg 856 456 Information on the auxiliary hydraulics The information on the auxiliary hydraulics dif fers depending on the truck Take this into consideration when selecting the attachment Maximum system pressure Pmax 280 bar Maximum volume flow rate Qmax 30 l min Trigger of the switch valve 12 V ...

Page 589: ... 5th function 329 Controlling with multi lever operation and the 5th function 321 Controlling with multi lever operation and the 6th function 321 Controlling with the fingertip 334 Controlling with the fingertip and the 5th function 336 General controlling 312 Information on the auxiliary hydraulics 572 Load capacity 311 Mounting 311 Picking up a load 341 Safety information 309 Special risks 45 Au...

Page 590: ...ple mini lever 328 Releasing the mechanism with the fin gertip 335 Releasing the mechanism with the joy stick 4Plus 339 Cleaning 490 Cleaning the electrical system 492 Cleaning the truck 490 Cleaning the windows 494 Clean the truck After cleaning 494 Climbing into the truck 85 Climbing out of the truck 85 Clipboard 376 Cold store application 388 Batteries 390 Operation 388 Types of application 388...

Page 591: ...ty in accordance with the Machinery Directive 7 Efficiency and drive modes 150 Electrical fork wear protection 265 Electric parking brake Emergency actuation 406 Emergencies Emergency actuation of the electric parking brake 406 Truck tipping over 402 Using the emergency hammer 403 Emergency drive direction 403 Emergency driving 403 Emergency hammer 403 Emergency lowering 404 Emergency shutdown 401...

Page 592: ... 21 Information for carrying out maintenance 507 Maintenance timeframe 508 Next maintenance interval 508 Information on the auxiliary hydraulics 572 Information symbols 23 Insulation testing 52 Drive battery test values 53 Test values for the truck 53 Insurance cover on company premises 33 Intended use 17 Interior lighting 371 Issue date of the operating instructions 23 J Jacking up 505 Joystick 4...

Page 593: ...rs 36 Regulations for storing 456 Safety regulations 450 452 Special features 33 Transport outside the premises 35 Lithium ion battery display 70 Load Determining visibility conditions when driving with a load 235 Driving 236 Picking up 231 Setting down 241 Load dependant assistance systems Load measurement 279 Overload detection 273 Precision load measurement 282 Total load 286 Load dependent ass...

Page 594: ...tible batteries 434 Configuring 420 General 418 Maintenance charge 423 Performance data 435 Regularly testing the electrical safety 54 Opening closing the battery door 466 Opening closing the cab door 369 Opening closing the side window 370 Operating Display operating unit 110 Operating company 30 Operating devices and display elements 68 Operating devices for hydraulic and driving functions Doubl...

Page 595: ...truck 475 Using a truck 469 Residual dangers 44 Residual risk 44 Residual risks 44 Retrofitting 37 Retrofitting lighting equipment 140 Reversible fork arms 219 Checking 536 Roadways 157 160 Components protruding beyond the truck contour 159 Descending gradients 158 Gradients 158 Rotating beacon Switching on and off 147 Rules for roadways and the working area 160 Run on time for additional devices ...

Page 596: ...axle Lubricating 528 Servicing 528 Steering system Checking for correct function 95 Storing the truck 499 StVZO Road Traffic Licensing Regula tions information 15 Sun blind 378 Sun visor 378 Switching off the truck 194 Switching on using the key switch 107 via the push button 108 T Tare function 284 Technical data 0 Dimensions 541 Tilt angle dependent assistance systems Automatic mast vertical pos...

Page 597: ...al lift height measuring system 246 Overload detection 273 Pre Shift Check 117 Precision load measurement 282 Push up roof window 376 Radio 371 Reversible fork arms 219 Shake function 237 Shock recognition 342 Speed reduction when the fork carriage is raised 260 Speed restriction 187 STILL SafetyLight and STILL Safety Light 4Plus 147 Sun blind 378 Sun visor 378 Switching on via the push button var...

Page 598: ...s and washers Switching on and off 342 Winter tyres 527 Working at the front of the truck 506 Working on the electrical equipment 504 Working on the hydraulic equipment 504 Working spotlight for reverse travel Switching on and off 143 Working spotlights Switching on and off 142 Y Your truck 2 Z Zeroing the assistance systems 289 Index 582 56368011501 EN 04 2022 13 ...

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Page 600: ...STILL GmbH 56368011501 EN 04 2022 13 ...

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