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Still RX60-60, Original Instructions Manual

The Still RX60-60 is a robust and powerful forklift that guarantees efficient material handling. To ensure safe and optimal usage, it comes with an Original Instructions Manual. This comprehensive manual can be downloaded for free from 88.208.23.73:8080, providing users with detailed guidance and helpful insights.

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Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   241
Push-up roof window (variant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   243
Clipboard (variant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   243
Trailer operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   244
Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   244
Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   245
Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   247
Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   255
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   256
Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   256
Error code table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   256
General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   260
Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   270
Connecting and disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . .   273
Connecting the battery male connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   273
Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   274
Handling the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   276
Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   276
Checking the battery charge status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   279
Charging the lead-acid battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   279
Equalising charging to preserve the battery capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .   283
Replacing and transporting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   285
General information on replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   285
Changing to a different battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   285
Opening and closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   286
Replacing the battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   288
PowerPlusLife battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   295
PowerPlusLife

®

 battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   295

PowerPlusLife

®

 temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   296

PowerPlusLife

®

 error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   297

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   298
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   298
Cleaning the electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   300
Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   300
Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   301
After cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   301
Procedure in emergencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   303
Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   303
Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   305

Table of contents

 

 VIII

56358042501 EN -  -  11

Summary of Contents for RX60-60

Page 1: ...Electric truck RX60 60 RX60 70 RX60 80 RX60 80 900 Original instructions 6341 6342 6343 6344 56358042501 EN 11 ...

Page 2: ......

Page 3: ...industrial 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 Q...

Page 4: ...repartlist 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 56358042501 EN 11 ...

Page 5: ...lace of use 17 Parking in temperatures below 10 C 18 Using working platforms 19 Information about the documentation 20 Documentation scope 20 Supplementary documentation 21 Issue date and topicality of the operating instructions 22 Copyright and trademark rights 22 Explanation of information symbols used 22 List of abbreviations 23 Units 25 Definition of directions 26 Schematic views 27 Environmen...

Page 6: ...ttachments 42 Overview of hazards and countermeasures 44 Danger to employees 46 Safety tests 48 Regular safety inspection of the truck 48 Insulation testing 48 Safety regulations for handling consumables 50 Permissible consumables 50 Oils 50 Hydraulic fluid 51 Battery acid 52 Coolant and cooling fluid 53 Disposal of consumables 54 Emissions 55 3 Overviews Overview 60 Driver s compartment 62 Operat...

Page 7: ...nt 95 Switching on 97 Switching on the key switch 97 Access authorisation with PIN code variant 99 Operating the display operating unit 110 Indicators 110 Adjusting the displays 112 Symbols in the display 114 Setting the date or time 118 Resetting the daily kilometres and daily operating hours 119 Setting the language 119 Softkeys for operating various equipment variants 120 Configuring Blue Q eff...

Page 8: ... mast vertical position variant 150 Types of lift mast 154 Malfunctions during lifting mode 155 Hydraulic blocking function 156 Lifting system operating devices 157 Controlling the lifting system using a double mini lever 158 Controlling the lifting system using a triple mini lever 160 Controlling the lifting system using a quadruple mini lever 161 Controlling the lifting system using the Joystick...

Page 9: ...ertip 212 Controlling attachments with fingertip and the 5th function 213 Clamp locking mechanism variant 215 Taking up a load using attachments 218 Auxiliary equipment 220 Switching the lighting on and off 220 Switching the working spotlight for reverse travel on and off 221 Switching the rotating beacon on and off 221 Switching the hazard warning system on and off 222 Switching the turn indicato...

Page 10: ...ery 276 Checking the battery charge status 279 Charging the lead acid battery 279 Equalising charging to preserve the battery capacity 283 Replacing and transporting the battery 285 General information on replacing the battery 285 Changing to a different battery type 285 Opening and closing the battery cover 286 Replacing the battery 288 PowerPlusLife battery 295 PowerPlusLife battery 295 PowerPlu...

Page 11: ...ntenance 330 Maintenance 1000 hours annually 333 Maintenance 3000 hours every two years 336 Ordering spare parts and wearing parts 336 Quality and quantity of the required operating materials 336 Lubrication plan 338 Maintenance data table 339 Providing access to maintenance points 342 Removing and attachingthe left side cover 342 Installing and removing the bottom plate 342 Opening closing the fr...

Page 12: ...icating the lift mast and roller track 365 Greasing the automatic tow coupling 365 6 1000 hour maintenance annual maintenance Other work that must be carried out 370 Checking the lift cylinders and the hydraulic connections for leak tightness 370 Checking the fork arms 370 Checking the reversible fork arms 371 7 Technical data Dimensions 374 VDI datasheet 376 Eco design requirements for electric m...

Page 13: ...1 Foreword ...

Page 14: ... stability which is guaranteed if the truck is used according to its intended use The truck is equipped with a particularly long life air cooled battery Thanks to the high bat tery capacity of 1240 Ah and battery replace ment from the side the truck is suitable for multi shift use In addition the series supports all the functions of FleetManager4 x Brake system The brake system of the truck compri...

Page 15: ...y sensitive movements and safe handling of the load The hydraulic functions can be parame terised individually by the authorised service centre Up to three hydraulic circuits can be used to activate attachments variant Depending on the equipment a hydraulic accumulator is also available in the lifting circuit for the purpose of dampening pressure peaks in the hydraulic system Drive concept The RX6...

Page 16: ...ruck features either sin gle pedal or dual pedal operation The accel erator pedal is used to accelerate and brake regenerative brake the truck In emergency situations or when carrying heavy loads the driver can also brake the truck using the serv ice brake by pressing the brake pedal In dual pedal operation the truck has one pedal for the Forwards drive direction and one pedal for the Reverse driv...

Page 17: ... the operating instructions and follow the instruc tions Always follow all of the safety information contained in the operating instructions and on the truck Conformity marking The manufacturer uses the conformity mark ing to document the conformity of the industri al truck with the relevant directives at the time of placing on the market CE in the European Union EU UKCA in the United Kingdom UK E...

Page 18: ...GmbH 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...

Page 19: ...Accessories Key for key switch two pieces Key for cab variant Hexagon socket wrench for emergency low ering Foreword 1 Your truck 7 56358042501 EN 11 ...

Page 20: ...Overview Foreword 1 Your truck 8 56358042501 EN 11 ...

Page 21: ...16 8 11 12 1 14 5430 5430 1010 1010 1080 1080 1080 1080 1080 1080 1050 1050 1150 1150 1310 1310 4430 4430 1110 1110 1230 1230 1250 1250 1500 1500 4030 4030 1150 1150 1260 1260 1200 1200 1500 1500 3730 3730 1180 1180 1290 1290 1430 1430 1500 1500 3430 3430 1210 1210 1330 1330 1470 1470 1500 1500 800 800 700 700 500 500 600 5030 1270 2 1 3 9 10 STILL Hamburg Berzeliusstr 10 22113 Hamburg Tel 01804 7...

Page 22: ...e filling pressure Warning sign Do not stand underneath the fork Do not stand on the fork 1 2 3 4 5 6 7 8 Decal information StVZO German Road Traffic Licensing Regulations information variant Decal information Nameplate Decal information Inspection sticker Decal information FEM test Warning sign Danger due to shearing Danger due to high fluid pressure Warning sign Do not stand underneath the fork ...

Page 23: ...Labelling points right 4 6 5 7 1 2 5 8 9 DANGER DANGER 10 6 5 7 10 bar 1 2 3 11 3 3 10 11 DANGER 8 9 12 12 Foreword 1 Your truck 11 56358042501 EN 11 ...

Page 24: ... 90 to the right to lock turn 90 to the left Decal information Ceiling sensor 7 8 9 10 11 12 Nameplate Variant 1 Industrial trucks built up to 12 2021 1 Model 2 Production number 3 Year of manufacture 4 Tare weight in kilograms 5 Maximum permitted battery weight in kilograms only for electric trucks 6 Minimum permitted battery weight in kilo grams only for electric trucks 7 Ballast weight in kilog...

Page 25: ...e 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 Production number NOTE The production number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The producti...

Page 26: ...94_003 098 1 2 3 4 5 Tare weight in kg Permitted total weight in kg Permitted front axle weight in kg Permitted rear axle weight in kg Payload in kg 1 2 3 4 5 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 Ge...

Page 27: ...r 2 Technology 3 Transportation notes 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 15 56358042501 EN 11 ...

Page 28: ... and described in these operat 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 to prevent haz ards The maximum load to be lifted is specified on the capacity rating plate load diagram and must not be exceeded see also ...

Page 29: ...areas where there 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 outdoors 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 ...

Page 30: ... is below 10 C only park the truck for short periods of time The operating company must ensure suitable fire protection for the relevant application in the truck s surroundings Depending on the application additional fire protection must be provided on the truck If in doubt contact the relevant authorities NOTE Please note the definition of operating com pany in the sense of responsible persons Pa...

Page 31: ...ted by national law The use of working platforms is only permitted by virtue of the jurisdiction in the country of use Observe national legislation Before using working platforms consult the na tional regulatory authorities Foreword 1 Using the truck 19 56358042501 EN 11 ...

Page 32: ...ntact your authorised service centre Enter the production number and year of man ufacture from the nameplate in the space pro vided Production number Year of manufacture Please quote the production number in all technical 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 time...

Page 33: ... the variants This CO may consist of Special sensors A special 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 op erating instructions The original operating instructions for this in dustrial truck are valid for the operation of standard equipment and varia...

Page 34: ...ark rights These instructions must not be reproduced translated or made accessible to third parties including as excerpts except with the ex press written approval of the manufacturer Explanation of information 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 ...

Page 35: ...GUV 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 dat...

Page 36: ...ation 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 U...

Page 37: ...ratio of the mass of a body to its vol ume km h Kilometres per hour Unit of speed kN Kilonewton Unit of force 1 kN 1000 N kW Kilowatt Unit of electrical power kWh h Kilowatt hour hour Energy consumption l Litre Unit of volume l h Litres per hour Unit of consumption l min Litres per minute Unit of consumption m Metre Unit of length 1 m 100 cm m s2 Metres per second squared Unit of acceleration min ...

Page 38: ...rs Unit of electrical work nominal energy Wh kg Watt hours kilogram Stored energy per kilogram of mass energy density Definition of directions The directions forwards 1 backwards 3 right 2 and left 4 refer to the installation position of the parts as seen from the driver s compartment the load is to the front 6210_001 031 4 2 3 1 Foreword 1 Information about the documentation 26 56358042501 EN 11 ...

Page 39: ...te of the documented truck The diagrams are used solely for the purpose of clarifying procedures View of the display operating unit NOTE Views of operating statuses and values in the display of the display operating unit are exam ples and partly dependent on the truck equip ment As a result the displays shown of the actual operating statuses and values can vary Information that is not relevant for...

Page 40: ...Disposal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste ...

Page 41: ...2 Safety ...

Page 42: ...alification that demonstrably proves their professional ex pertise This proof should consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven pe riod during their career During this time this person has become familiar with a wide range of symptoms that require check...

Page 43: ...must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety 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 instruc...

Page 44: ...sible 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 56358042501 EN 11 ...

Page 45: ...ing and stability of the truck and can result in accidents Any modifications that adversely affect the stability the load capacity or the circumferen tial view of the truck require written approval from the manufacturer The following components may only be modi fied with prior written approval from the manu facturer Brakes Steering Operating devices Safety systems Equipment variants Attachments Th...

Page 46: ... the battery hood which could cause the driver to perform uncontrolled steering and driving manoeuvres Do not drill any holes in the battery hood DANGER Risk of fatal injury from falling load There is a risk to the driver s life if the truck is not equipped with an overhead guard as the driver may be struck by a load falling from a lift height of 1800 mm or greater Operation of the truck without a...

Page 47: ...on with the following data must be permanently affixed to the truck so that it is clearly visible Type of modification Date of modification Name and address of the company that car ried out the modification Changes to the overhead guard and roof loads DANGER In the event of the overhead guard failing due to a falling load or the truck tipping over there are po tentially fatal consequences for the ...

Page 48: ... the design features of the truck and thus impair active and or passive driv ing safety We recommend that you obtain approval from the manufacturer and if necessary from the relevant regulatory authorities before installing such parts The manufacturer accepts no liability for any damage caused by the use of non original parts and accesso ries without approval Damage defects and misuse of safety sy...

Page 49: ...proved by the manufacturer Excessive tyre wear Tyres of inferior quality Changing rim wheel parts Combining rim wheel parts from different manufacturers The following rules must be observed to en sure stability Only use tyres with equal and permitted lev els of wear on the same axle Only use wheels and tyres of the same type on the same axle e g only superelastic tyres Only use wheels and tyres ap...

Page 50: ... centre on this matter Medical equipment WARNING Electromagnetic interference may occur on medical devices Only use equipment that is sufficiently protected against electromagnetic interference Medical equipment such as pacemakers or hearing aids may not work properly when the truck is in operation Ask your doctor or the manufacturer of the medical equipment to confirm that the medi cal equipment ...

Page 51: ...mination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper in stallation of an accumulator results in an elevated risk of injury Before starting work on the accumulator it must be depressurised Contact the authorised service centre Length of the fork arms DANGER Risk of accident due to the incorr...

Page 52: ...hese other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre Safety 2 Basic principles for safe operation 40 56358042501 EN 11 ...

Page 53: ...be instructed 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 et...

Page 54: ...ainst 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 55: ...the truck correctly and without the risk of acci dents Safety 2 Residual risk 43 56358042501 EN 11 ...

Page 56: ...driver s li cence Usage by unauthorised persons Access with key only for authorised 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 BetrSi...

Page 57: ...hG German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O When fuelling a Diesel German Ordinance on Industrial Safety and Health BetrSichV ob serve 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...

Page 58: ...s blocked Mark routes Keep roadways clear O German Ordinance on Industrial Safety and Health BetrSichV Routes intersect Announce right of way rule O German Ordinance 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...

Page 59: ...sions for deployment The result of the hazard assessment must be documented 6 ArbSchG In the case of truck applications involving similar hazard sit uations the results may be summarised Re fer 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 th...

Page 60: ...tained until a further two in spections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service ce...

Page 61: ... checked separately Test values for the drive battery Component Recommended test voltage 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 Mi...

Page 62: ...ck The 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...

Page 63: ...according to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of ac cording to the regulations Dispose of old oils according to the regula tions Hydraulic fluid WARNING These fluids are pressurised during op e...

Page 64: ...ective 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 regulati...

Page 65: ...h the applicable regulations Coolant and cooling fluid WARNING Coolant and cooling fluid can be hazard ous to your health and the environment Coolants are chemical corrosion inhibi tors and cooling system protecting agents such as Glysantin The cooling fluid is an appropriate mixture of water and coolant Coolant in both concentra ted and dilute form can be hazardous to your health if swallowed or ...

Page 66: ...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 minimise any en vironmental pollution Soak up any spilt fluids such as hydraulic oil or gearbox oil immediately using an oil binding agent Neutralise any spilt ...

Page 67: ...dB A The values were determined in the test cycle on an identical machine from the weighted val ues for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal noise pollution Observe the app...

Page 68: ...at the amplitude of the hand and arm vibrations on the steering wheel or on the operating devices in the truck is less than 2 5 m s2 There are therefore no meas urement guidelines for these measurements The personal vibration load on the driver over a working day must be determined by the op erating company at the actual place of use in accordance with Directive 2002 44 EC in or der to consider al...

Page 69: ...fi cient ventilation in working areas that are entirely or partially enclosed Keep away from open flames and fly ing sparks Do not smoke Observe the safety regulations for handling the battery Radiation In accordance with the guidelines DIN EN 62471 2009 03 VDE 0837 471 2009 03 the STILL Safety Light variant is assigned to risk group 2 me dium risk due to its photobiological hazard potential Safet...

Page 70: ...Safety 2 Emissions 58 56358042501 EN 11 ...

Page 71: ...3 Overviews ...

Page 72: ... direction 1 2 3 4 5 6 7 8 9 10 6341_003 019_V2 Lift mast Driver s compartment Overhead guard Left side cover Steering axle 1 2 3 4 5 Drive axle Tilt cylinder Fork arms Fork carriage Lift cylinder 6 7 8 9 10 Overviews 3 Overview 60 56358042501 EN 11 ...

Page 73: ...ight hand side when viewed in the drive direction 1 2 4 3 5 Fresh air filter for heating system Cover front right Battery cover 1 2 3 Coupling pin Rear cover 4 5 Overviews 3 Overview 61 56358042501 EN 11 ...

Page 74: ...raulic and traction functions Emergency off switch 12 V socket Compartment 1 2 3 4 5 6 7 8 9 Bottle holder for bottles of max 0 5 l Driver s seat Storage compartment storage compart ment with cover variant Compartment Filler cap for windscreen washer reservoir variant Accelerator pedal Brake pedal Steering column adjustment lever 10 11 12 13 14 15 16 17 NOTE The truck equipment may differ from the...

Page 75: ...igned Rotating beacon display Interior light display Rear window heating display Softkey for interior light rotating beacon Softkey for rear window heating Menu change button Lighting button Blue Q button Rear window wiper button 14 15 16 17 18 19 20 21 22 23 24 25 26 NOTE The Softkeys 5 21 22 and the correspond ing indicators 6 7 18 19 20 are assigned according to the auxiliary equipment installe...

Page 76: ...rsions of the operating devices are available for operating the truck s hydraulic functions and drive functions The truck can be equipped with the following operating devices Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip Mini console Overviews 3 Operating devices and display elements 64 56358042501 EN 11 ...

Page 77: ... 2 3 4 Function key 5th function Attachments cross lever Emergency stop switch Signal horn button 5 6 7 8 NOTE Depending on the specification various elec tric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre Overviews 3 Operating devices and display elements 65 56358042501 EN 11 ...

Page 78: ...3 4 5 Auxiliary hydraulics 1 operating lever Auxiliary hydraulics 2 operating lever Emergency stop switch Signal horn button 6 7 8 9 NOTE Depending on the specification various elec tric attachment parts can be controlled via function keys 2 and 3 Changes must only be made by the authorised service centre Overviews 3 Operating devices and display elements 66 56358042501 EN 11 ...

Page 79: ...on key 5th function Auxiliary hydraulics 1 operating lever Auxiliary hydraulics 2 operating lever Emergency stop switch Signal horn button 6 7 8 9 10 NOTE Depending on the specification various elec tric attachment parts can be controlled via function keys 3 and 4 Changes must only be made by the authorised service centre Overviews 3 Operating devices and display elements 67 56358042501 EN 11 ...

Page 80: ...aulic function and for the clamp locking mechanism variant Pictograms for the 3rd 4th hydraulic func tion 1 2 3 4 LED for the clamp locking mechanism var iant Slider for the 4th hydraulic function e g side shift frame forwards backwards Vertical rocker button for the drive direction Shift key F Signal horn button 5 6 7 8 9 Overviews 3 Operating devices and display elements 68 56358042501 EN 11 ...

Page 81: ... 6 Emergency stop switch Attachments operating lever Attachments operating lever Tilt operating lever Lift lower operating lever Travel direction switch 7 8 9 10 11 12 NOTE Depending on the specification various elec tric attachment parts can be controlled via function keys 1 and 2 Changes must only be made by the authorised service centre Overviews 3 Operating devices and display elements 69 5635...

Page 82: ...e mini console is located on the steering column below the steering wheel 7311_003 056 1 2 Travel direction switch Direction indicator switch 1 2 Overviews 3 Operating devices and display elements 70 56358042501 EN 11 ...

Page 83: ...4 Operating ...

Page 84: ...rtant to run through all the checks and tasks listed in the fol lowing table from top to bottom before daily use of the truck If damage or other defects are identified on the truck or the attachment variant the truck must not be used until it has been properly repaired Ensure that the truck is safe for operation each day before it is used Component Course of action Fork arms general lifting access...

Page 85: ... securely and correctly seated on the battery base frame The battery must be level Battery connection assembly Check the battery male connector the plug connec tion and the contacts for integrity and deformation Have any damaged or deformed components re placed by the authorised service centre Inspect the battery male connector and the plug connection for moisture or for any foreign objects that m...

Page 86: ...lt must be long enough to touch the ground adequately Lift and tilt cylinders tank valve block ho ses pipes connections Perform a visual inspection for damage and leak ages Check the area under the truck for leaking consum ables Have damaged components replaced only by the authorised service centre Wheels tyres Perform a visual inspection for wear and damage Make sure that only rims of the same ty...

Page 87: ...ous injuries e g from falling loss of fingers etc It is forbidden to jump out of the truck Do not jump out of the truck Do not wear jewellery at work Do not wear loose fitting workwear CAUTION Components may become damaged through incor rect use Truck components such as the driver s seat steer ing wheel parking brake lever etc are not designed to be used for climbing in and out of the truck and ma...

Page 88: ...he bottom step 5 Place your left foot on the top step 6 Place your right foot into the footwell 7 Enter the truck and sit down on the driver s seat 3 Always climb out of the truck backwards Grip handle 2 with your left hand and hold on Stand up from the driver s seat and place your left foot on the top step 6 Grip the handle 4 with your right hand and hold on Place your right foot on the bottom st...

Page 89: ...e middle step 6 Place your left foot on the top step 7 Place your right foot into the footwell 8 Enter the truck and sit down on the driver s seat 3 Always climb out of the truck backwards Grip handle 2 with your left hand and hold on Stand up from the driver s seat and place your left foot on the top step 7 Grip the handle 4 with your right hand and hold on Place your right foot on the middle ste...

Page 90: ...which could cause the driver to move in an uncontrolled manner This may result in unintentional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the seat or seat backrest while driv ing Adjust the seat and the seat backrest so that all operating devices can be actuated safely Ensure that the seat and seat backrest are ...

Page 91: ... into the desired posi tion Release the lever Ensure that the driver s seat is securely en gaged Adjusting the seat backrest Do not put pressure on the seat backrest while disengaging it Raise the lever 2 and hold it in position Push the seat backrest into the desired po sition Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest ca...

Page 92: ...tead of the lever 3 Fully fold out the weight adjusting lever 3 Pump the lever up or down to set the driv er s weight Return the weight adjusting lever to the ini tial central position before each new lift a click can be heard Fully fold in the weight adjusting lever once adjustment is complete NOTE The driver s weight has been selected correct ly when the arrow 4 is in the centre position of the ...

Page 93: ... of the backrest Turn the turning knob 5 up or down until the lumbar support is in the desired posi tion Adjusting the backrest extension var iant Adjust the backrest extension 6 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by firmly pushing it upwards 6321_003 039 5 6321_003 040 6 Operating 4 Checks and tasks before daily use...

Page 94: ...r 1 on the front right hand side of the driver s seat as viewed in the drive direction can be used to adjust the longitudinal position of the driver s seat Pull the lever 1 upwards and hold it there to unlock the driver s seat Push the driver s seat into the required po sition Release the lever 1 again to lock the driv er s seat If necessary gently slide the seat back and forth to allow the interl...

Page 95: ...sion comfort is significantly low er Impacts are much more noticeable Adjusting the armrest DANGER There is a risk of accident if the armrest lowers suddenly causing the driver to move in an uncon trolled manner This can result in unintentional ac tuation of the steering or the operating devices and thus cause uncontrolled movements of the truck or load Do not adjust the armrest while driving Adju...

Page 96: ...attached Adjusting the steering column DANGER Risk of accidents Adjusting the steering column during travel may cause the truck to career out of control Adjust the steering column only when the truck is at a standstill Ensure that the steering column is engaged Press down and hold the lever 2 for steer ing column adjustment Position the steering column 1 and re lease the lever When the steering co...

Page 97: ...al horn NOTE The signal horn is used to warn people against imminent danger or to announce your intention to overtake Push the signal horn button 1 The signal horn sounds 7312_003 183 F1 F1 F2 F2 1 1 1 F1 F1 F2 F2 6341_003 007_V3 1 F1 F2 1 1 Operating 4 Checks and tasks before daily use 85 56358042501 EN 11 ...

Page 98: ... doors constitute a driver restraint system Plastic doors weather protection do not constitute a restraint system If the doors are open or have been removed you must use an alternative suitable restraint system e g a seat belt Fastening the seat belt DANGER Risk to life when driving without a seat belt If the truck tips over or crashes into an obstacle and the driver is not wearing the seat belt t...

Page 99: ...nst the seat backrest The auto matic blocking mechanism permits sufficient freedom of movement on the seat Click the belt tongue 2 into the buckle 1 Check the tension of the seat belt The belt should fit closely around your body Fastening on a steep slope The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient It is no longer possible to pul...

Page 100: ...eat belt around 10 15 mm out of the retractor to dis engage the blocking mechanism Slowly allow the seat belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold weather condi tions If the buckle or belt retractor is frozen thaw them out and dry them thoroughly to pre vent recurrence CAUTION The seat belt may be damaged by heat Do not subject the buc...

Page 101: ...ips over The driver s cab constitutes a driv er restraint system only if the cab door is sturdy and closed Fabric covered cabs variant with doors made of plastic or canvas do not constitute a driver restraint system and offer no protection from the con sequences of the truck tipping over Close the cab door before operation If the door is open or has been removed use a comparably secure restraint s...

Page 102: ...ssive speed Depending on the charge state of the battery regen erative 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 oppo site drive direction is selected the truck is braked using the electric brake To actuate this release the accelerator pedal 2 The truck m...

Page 103: ...despite the parking brake being applied stop the truck using the service brake In an emergency secure the truck with wedges on the downhill facing side to 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...

Page 104: ...ith a low level of deceleration To increase the level of deceleration either press and hold the actuating button for lon ger or press it several times The truck must decelerate and remain station ary NOTE To release the parking 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...

Page 105: ...gle of about half a revolution Checking the emergency off function WARNING There is no electric braking assistance when the emergency off switch is actuated Actuating the emergency off switch will de energise the entire electrical system The truck will not be held on a slope by the electric brake Brake the truck by depressing the brake pedal CAUTION There is no power steering when the emergency of...

Page 106: ...OTE The function check of the lift mast vertical po sition variant must be carried out every time a truck is commissioned Press the Softkey 1 The comfort feature lift mast vertical position is switched on The symbol 2 is dis played Tilt the lift mast backwards The lift mast must tilt back fully and move gen tly as far as the end stop Tilt the lift mast forward The lift mast must tilt forwards and ...

Page 107: ...ments NOTE Accurate zero adjustment is only possible if the fork is not carrying a load Do not take up a load yet NOTE Accurate zero adjustment is only possible within the first lifting stage of the lift mast When carrying out the zero adjustment do not raise the fork more than 800 mm above the ground NOTE The way in which the lifting system is operated depends on the operating devices included in...

Page 108: ... otherwise the zero adjust ment will not be accurate To stop the lowering procedure quickly release the operating de vice for lowering so that it jumps into the zero position Lower the fork carriage slightly and release the operating device When the zero adjustment has been carried out correctly the value 0 kg appears on the display The zero adjustment of the load measure ment is completed The sym...

Page 109: ...uck if defects have been de tected contact the authorised service centre NOTE When the truck is switched on the maximum driving speed is restricted The driving speed limitation is disabled as soon as the truck is steered out of cornering to drive in a straight line To do this rotate the steering wheel by approximately half a turn Insert switch key 1 into the key switch and turn to position I I 1 0...

Page 110: ... welcome screen in the set lan guage until the truck controller has fully star ted up If the truck is ready for operation the standard displays are shown If the truck is equipped with the access au thorisation with PIN code variant the display initially changes to the input menu for access authorisation 7312_003 085 Operating 4 Switching on 98 56358042501 EN 11 ...

Page 111: ... play If malfunctions occur refer to the informa tion in the chapter entitled Display messag es Access authorisation with PIN code variant Description Trucks equipped with the Access authorisa tion with PIN code variant are protected against unauthorised use by a five digit driver PIN Up to fifty different driver PINs can be de fined so that the same truck can be used by different drivers each wit...

Page 112: ...authorised service centre on this matter The first driver PIN is preset to 11111 at the factory All others are preset to 0xFFF but have no function as the highest valid driver PIN is 99999 Persons with the appropriate access authorisation e g fleet managers can change the driver PINs in the corresponding menu NOTE When first commissioning the truck we rec ommend you change the access authorisation...

Page 113: ... not visible but are represented by circles instead If the driver PIN entered is cor rect the familiar screen appears with the standard display and all truck functions are available If an incorrect driver PIN is entered the mes sage INVALID appears for a short time When the message goes out the driver PIN can be re entered 8 9 6 7 4 2 0 1 3 5 BQ_023_en_V2 Operating 4 Switching on 101 56358042501 E...

Page 114: ...managers To set the driver PIN the fleet manager must access the con figuration menu The configuration menu is password protected After entering the pass word the fleet manager can configure general settings for the truck To change the pass word see the chapter entitled Changing the password Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5...

Page 115: ...ng Softkey 2 CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the ACCESS CODE menu Confirm your selection using Soft key 2 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC 8 9 6 7 4 2 0 1 3 5 BQ_31_en 1 3 2 Operating 4 Switching on 103 56358042501 EN 11 ...

Page 116: ...ifty driver PINs can now be defined Use the drive program selection button 1 and the menu change button 4 to select the desired driver PIN 1 to 50 Confirm your selection using Soft key 3 NEW CODE appears in the display Enter the desired driver PIN using the but tons or Softkeys 5 The digits entered do not appear in the dis play Instead they are represented by circles in the NEW CODE field 6 8 9 6 ...

Page 117: ...n tered The display switches back to the AC CESS CODE menu Another driver PIN can be defined here If the driver PIN entered in the CONFIRM sub menu does not match the driver PIN entered previously in the NEW CODE submenu the message INVALID will appear The message will then disappear after a short time The new driver PIN can be entered in the CONFIRM submenu for further confirma tion 8 9 6 7 4 2 0...

Page 118: ...efined Changing the password It is recommended that you change the factory default password NOTE The password can only be changed when the parking brake is applied Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 Blue Q_029_V2 1 2 Operating 4 Switching on 106 56358042501 EN 11 ...

Page 119: ...2 CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the PASSWORD menu Confirm your selection using Soft key 2 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC 8 9 6 7 4 2 0 1 3 5 1 2 3 BQ_032_en Operating 4 Switching on 107 56358042501 EN 11 ...

Page 120: ...sations and cannot be reset independently The authorisations can only be reset by the author ised service centre Enter the new desired password using the buttons 1 The digits entered are shown in plain text in the NEW CODE field 4 Confirm your selection using Soft key 3 In the NEW CODE field appears briefly The new password is confirmed Press Softkey 2 to correct the new password The display switc...

Page 121: ... To exit the configuration menu press Soft key 2 repeatedly until the standard display appears Operating 4 Switching on 109 56358042501 EN 11 ...

Page 122: ...tes is maintained 2 Drive program Displays the number of the selected drive program To change the drive program refer to the section entitled Setting the drive program The Blue Q icon appears when the Blue Q function is switched on refer to the section entitled Blue Q efficiency mode 3 Power rating The power rating indicator shows the average energy consumption over the last 30 minutes in kilowatt...

Page 123: ...50 Slight increase up to 30 No change Slight decrease up to 30 Decrease up to 50 Significant decrease 50 Additional indicators Menu change button When the menu change button is pressed the following additional indicators appear Service in display Displays the remaining time in operating hours until the next maintenance operation is due according to the maintenance sched ule in the maintenance inst...

Page 124: ...rvice centre when the maintenance interval is reached Adjusting the displays NOTE The parking brake must always be engaged when you adjust the displays The displays cannot be adjusted if the parking brake is not engaged NOTE When adjusting the displays do not actuate the hydraulic system operating devices If you do entry is interrupted and the display returns to the operating display The displays ...

Page 125: ...o enter a password in or der to configure the displays This depends on the configuration of the display operating unit For configuration of the display operating unit contact the authorised service centre Blue Q_029_V2 1 2 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC Operating 4 Operating the display operating unit 113 56358042501 EN 11 ...

Page 126: ...n the display Messages To show operating messages warning mes sages or error messages in the display text messages and symbols are used Symbols for operating messages Description Symbol Empty field No display Please wait Service required Lift limitation Reference cycle Battery charging Drive program Hour meter Odometer Daily hour meter Daily odometer Speed Steering angle Load Time 7312_003 056_en_...

Page 127: ...ols for error messages Description Symbol Brake system malfunction Overheating of the engine Overheating Malfunction in the electrical system General malfunction Symbols for softkey functions of auxili ary equipment The following symbols for softkey functions are used on the left of the display for auxiliary equipment Description Symbol Empty field No display General function OFF General function ...

Page 128: ...Signal horn ON Cruise control OFF Cruise control ON Automatic mast vertical positioning OFF Automatic mast vertical positioning ON Load measurement zero adjustment OFF Load measurement zero adjustment ON Load measurement OFF Load measurement ON Symbols for softkey functions for menu navigation and for acknowledging mes sages The following symbols for the softkey func tions are used on the left of ...

Page 129: ...on is indica ted with LEDs next to the relevant function key for the additional electrical installation Description LED Function off LED OFF Function on LED ON Symbols for numeric keypad The buttons and Softkeys that can be used to enter numbers and to cancel or confirm input values are shown in the display Screen for entering the fleet manager pass word BQ_037 1 2 6 7 3 4 5 ESC Operating 4 Operat...

Page 130: ...IME menu appears Press and hold down the Drive programme button 1 or Menu change button 2 until the desired time appears on the display As the buttons are held down for longer the scrolling speed increases in three levels Confirm the set time using Softkey 4 Use the Softkey 3 to exit the menu and return to the next level up NOTE The date is set in a similar manner 1 2 6 7 3 4 5 8 9 0 BQ_038 8 9 0 ...

Page 131: ... hours are reset in the same manner Setting the language The displays can be shown in additional lan guages Switch to the CONFIGURATION menu see the chapter entitled Adjusting the displays Press the drive programme button 1 or the menu change button 2 repeatedly until the LANGUAGE option appears Confirm your selection using the Soft key 4 The LANGUAGE menu appears Press drive program button 1 or m...

Page 132: ...ts that can be switched on and off using Softkeys In this case proceed as follows to switch be tween the two columns Briefly press the Menu change button 1 The grey bar jumps to the left hand column These additional functions can now be switch ed on and off via the corresponding Soft keys 2 NOTE Press the Menu change button 1 for approx 1 second to switch between the individual me nus on the displ...

Page 133: ... and off at any time while the truck is being oper ated Switch to the CONFIGURATION menu see the chapter entitled Adjusting the displays Keep pressing the drive programme button 1 or the menu change button 2 until op tion BLUE Q CONFIGURATION appears Confirm your selection with Softkey 4 The BLUE Q CONFIGURATION menu ap pears Press drive program button 1 or menu change button 2 until the desired e...

Page 134: ...of at least approx 7 km h acceleration is gentler Therefore on distan ces of up to approx 40 m lower speeds are reached than would be the case if the efficien cy mode was not activated Blue Q has no influence on Maximum speed Climbing capability Traction Braking characteristics NOTE The Blue Q efficiency mode can be switched on and off in the STANDARD and FIXED FLEX operating modes If the FIXED op...

Page 135: ... consumers Condition Seat switch not actu ated Truck stopped Truck is in motion Front working spot lights X X Backwards 3 km h Rear working spot lights X X Forwards Top double working spotlight X X 3 km h Headlights X X Front wiper X X Backwards 3 km h Rear wiper X X Forwards Seat heater X Cab heating X NOTE On the version with StVZO German Road Traffic Licensing Regulations equipment the Blue Q e...

Page 136: ...ode is switched on perma nently For information on configuring the Blue Q operating modes see the Configuring Blue Q efficiency mode section Press the Blue Q button 2 to switch on Blue Q The Blue Q symbol 1 is displayed The LED 3 illuminates in blue Blue Q efficiency mode is switched on To switch it off press the Blue Q button 2 again The Blue Q symbol 1 and the LEDs 3 go out Blue Q efficiency mod...

Page 137: ...ning 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 sea...

Page 138: ...g lane is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at 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...

Page 139: ... mensions of the load For pallets these are Model Type Aisle width mm With pallet 1000x1200 crosswise With pallet 800x1200 lengthwise RX60 60 6341 4907 5107 RX60 70 6342 RX60 80 6343 RX60 80 LSP 900 6344 4999 5199 The truck must be used only on roadways that do not have excessively sharp curves exces sively steep gradients or excessively narrow or low entrances Driving on gradients WARNING Driving...

Page 140: ...ent for travel is 15 If you have any questions contact your authorised service centre The ascending and descending slopes must not exceed the above gradient A rough road surface is non slip and increases tyre grip Even transitions of the road surface to the gra dient prevent impact with the ground This helps to avoid damage to the load the truck and the road surface Warning about components that p...

Page 141: ...ensions of the load see the chapter entitled Technical data Rules for roadways and the working area Only routes approved by the operating compa ny or its representative may be driven on The roadways must be free of obstacles The load must only be set down and stored in the des ignated locations The operating company and its representative must ensure that unauthor ised persons do not enter the wor...

Page 142: ...kwards 80 90 100 110 120 Brake retardation electric brake booster 60 70 80 90 100 NOTE The maximum speed pre set in the drive pro gramme is technically dependent on the bat tery used Depending on the battery type used the preset maximum speed must be adapted by the authorised service centre If the maximum speed is not adapted it can lead to technical faults in drive mode Contact your authorised se...

Page 143: ...e quickly NOTE With sprint mode switched on the truck s en ergy consumption is higher The battery is therefore discharged more quickly Push button 1 Sprint mode is switched on the symbol has a dark background NOTE Sprint mode remains on until the seat is vaca ted or button 1 is pushed again Switching off sprint mode Push button 1 Sprint mode is switched off the symbol has a light background 6311_0...

Page 144: ...erated 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 the truck is stopped for an extended period select the neutral position to prevent the truck from suddenly starting if the accelerator pedal is inadvertently pressed Briefly select the drive direction switch for the d...

Page 145: ...g the vertical rocker but ton for the drive direction Joy stick 4Plus version For the forward drive direction push the vertical rocker button for the drive direc tion 1 upwards A For the backward drive direction push the vertical rocker button for the drive direc tion 1 downwards B 5060_003 096 F1 F2 1 1 6210_003 101 A B Operating 4 Driving 133 56358042501 EN 11 ...

Page 146: ...orwards For the backwards drive direction push the drive direction switch to the rear NOTE Alternatively the drive direction can also be selected using the drive direction switches on the operating devices Starting drive mode DANGER Risk to life if the truck rolls away or tips over Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the...

Page 147: ...ghts up on the display operating unit NOTE Depending on the equipment an acoustic sig nal variant may sound a warning during re verse travel the warning light variant may light up or the hazard warning system variant may flash Press the accelerator pedal 3 The truck will travel in the selected drive direc tion The accelerator pedal position controls the speed When the accelerator pedal is re lease...

Page 148: ...n the emergency off switch has not been actuated and the parking brake is released Use the brake pedal if the electric brake malfunc tions Only leave the truck when the parking brake is ap plied Changing the drive direction Remove your foot from the accelerator ped al Select the desired drive direction Actuate the accelerator pedal The truck will travel in the selected drive direc tion NOTE The dr...

Page 149: ...k to life if the truck rolls away or tips over Sit on the driver s seat Fasten the seat belt Activate the available restraint systems Observe the information in the chapter entitled Safety regulations when driving The driver s seat has a seat switch that checks whether the driver s seat is occupied The truck cannot be moved if the driver s seat is not occupied or if the seat switch malfunc tions A...

Page 150: ...nt may sound a warning during re verse travel the warning light variant may light up or the hazard warning system variant may flash The truck will travel in the selected drive direc tion The accelerator pedal position controls the speed When the accelerator pedal is re leased the truck brakes automatically via the regenerative brake NOTE The regenerative brake holds the truck briefly even on ascen...

Page 151: ...ke pedal if the electric brake malfunc tions Only leave the truck when the parking brake is ap plied Changing the drive direction Remove foot from actuated accelerator pedal Actuate the accelerator pedal for the oppo site direction The truck will travel in the selected drive direc tion NOTE If an electrical fault occurs in the accelerator the drive unit switches off The truck is braked by the rege...

Page 152: ...tices that the electrical braking effect has reduced by 50 and that the drive torque has decreased to 50 of the normal level a component failure may have occurred Bring the truck to a standstill using the brakes Use the parking brake if necessary to assist in this process Notify the authorised service centre Do not operate the truck again until the service brake has been repaired DANGER At speeds ...

Page 153: ...e direction indicator NOTE If you operate the accelerator pedal while the parking brake is applied and a drive direction is selected the message PARKING BRAKE appears in the display Apply the parking brake Pull the parking brake lever 1 down fully and release The parking brake lever swivels back half the distance into the middle position automatically The parking brake is engaged and the wheels ar...

Page 154: ...ll out the lever knob and then guide the parking brake lever up fully NOTE The parking brake lever swivels to the upper position automatically by means of spring force and should be guided only lightly by hand If the adjustment is stiff notify the au thorised service centre 6210_494 002 Operating 4 Driving 142 56358042501 EN 11 ...

Page 155: ...eer the truck by turning the steering wheel 1 accordingly Turning the steering wheel in the direction of arrow A steers the truck in drive direction A Turning the steering wheel in the direction of arrow B steers the truck in drive direction B For turning radius information see Chapter Technical data Page 373 A A B A B B 5060_003 007 1 Operating 4 Driving 143 56358042501 EN 11 ...

Page 156: ...ping 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 steer ing Do not turn off the key switch while driving A...

Page 157: ...escending 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 ascendi...

Page 158: ...Reducing speed with a raised load variant This function variant reduces the speed of the truck with a raised load 7321_003 052_en_V2 Operating 4 Driving 146 56358042501 EN 11 ...

Page 159: ...ruck 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 will then not be ready for op eration At ambient temperatures of below 10 C only park the truck for short periods of time Apply the parking brake Lower the fork carriage to the ground Tilt the lift mast forwards until the tips of t...

Page 160: ...en Wheel chock variant The wheel chock variant is used to prevent the truck from rolling away on a slope Lift handle 2 on the support mounting Remove wheel chock 1 from the support mounting Push the wheel chock under a front axle wheel on the side facing the downhill slope NOTE After use return the wheel chock to the sup port mounting and press the handle 2 down again 7321_003 039_V2 2 1 1 Operati...

Page 161: ...d cannot be lifted above a preset height This function uses a sensor that is wel ded on at the factory at the required lift mast limit height Once attached the height cannot be easily changed Application If the ceiling of the building is lower than the maximum lift height of the truck this variant can prevent the lift mast from accidentally hitting the ceiling which can result in dam age If the tr...

Page 162: ...on Press Softkey 1 Automatic lift cut out is switched on The symbol is displayed Loads can be lif ted only to the set lift height for the truck Lift mast vertical position var iant Description If the truck is equipped with the lift mast verti cal position comfort feature variant the driv er can put goods such as paper rolls down vertically with precision and thus avoid dam age when unloading The t...

Page 163: ...g individual functions Display of the lift mast vertical position Automatic approach towards the lift mast vertical position Gentle running in to the end stops Display of the lift mast vertical position The driver can see the mast tilt on the display and operating unit screen The bar in the dis play shows the current mast tilt relative to the lift mast vertical position The arrow above the bar mar...

Page 164: ...gardless of whether the comfort feature is switched on or not Gentle running in to the end stops The lift mast is braked gently at the end of the tilt range This prevents the lift mast from stop ping harshly in the end position and reduces severe oscillating motions of the truck Tilting the lift mast forwards with the lift mast vertical position Actuate the button 1 to switch on the lift mast vert...

Page 165: ... the button 1 again Tilting the lift mast backwards with the lift mast vertical position Tilt the lift mast backwards The lift mast is tilted backwards without stop ping in the vertical position Possible restrictions on the lift mast vertical position In some circumstances the lift mast cannot move exactly into the preset vertical position Possible causes include Uneven ground Bent fork Bent attac...

Page 166: ...t One of the following lift masts may be installed in the truck Telescopic mast During lifting the lift mast rises over the outer lift cylinders bringing the fork carriage with it via the chains fork carriage rises twice as fast as the inner lift mast The top edge 1 of the inner lift mast can therefore be higher than the fork carriage DANGER Risk of accident due to collision of the lift mast or lo...

Page 167: ...ree lift has finished As a result the over all 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 The fork carriage becoming blocked in the inner lift mast Blocking of the free lift cylinder The chain roller becoming blocked at the free lift cylinder If the hydraulic o...

Page 168: ...ontamination lift the fork carriage until the chains are under ten sion again Remove the contamination be fore resuming work WARNING Risk of injury Observe the safety regulations for working on lift masts see Chapter Working at the front of the truck Page 328 Hydraulic blocking function The hydraulic blocking function ensures that all the functions of the working hydraulics are disabled whenever t...

Page 169: ...riants include Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck e g lift mast sideshifts working equip ment load carrying devices etc can lead to seri ous injury or death and is therefore prohibited Observe the safety reg...

Page 170: ...ny must make all drivers aware of the fact that a different configuration has been config ured 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 bear ing the pictograms for the hydraulic func tions 1 or 2 is a...

Page 171: ...tion of the arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 4 in the di rection of the arrow C To tilt the lift mast backwards Move the lift mast 360 lever 4 in the di rection of the arrow D Movements of the lifting system and meanings of the pictograms A Lowering B Lifting C Tilting forwards D Tilting backwards Operating 4 Lifting 159 56358042501 EN 11 ...

Page 172: ...o lift fork carriage Move the lift mast 360 lever 1 in the di rection of arrow B To lower fork carriage Move the lift mast 360 lever 1 in the di rection of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the di rection of arrow C To tilt the lift mast backwards Move the lift mast 360 lever 1 in the di rection of arrow D NOTE The symbols on the 360 lev...

Page 173: ...ove the lift mast operating lever 1 in the direction of the arrow A To tilt the lift mast backwards Move the lift mast operating lever 1 in the direction of the arrow B Lifting lowering the fork carriage To lift fork carriage Move the lift lower operating lever 2 in the direction of arrow D To lower fork carriage Move the lift lower operating lever 2 in the direction of arrow C NOTE The symbols on...

Page 174: ... can lead to seri ous injury or death and is therefore prohibited Observe the safety regulations for handling loads Only operate the lifting system from the driver s seat Lifting lowering the fork carriage To lift the fork carriage Pull the Joystick 4Plus 1 backwards B To lower the fork carriage Push the Joystick 4Plus 1 forwards A 6210_003 089 1 A B Operating 4 Lifting 162 56358042501 EN 11 ...

Page 175: ...lift mast forwards Tilt the horizontal rocker button 2 to the left C To tilt the lift mast backwards Tilt the horizontal rocker button 2 to the right D 6210_003 090 D C 2 7312_003 022_V2 D C B A Operating 4 Lifting 163 56358042501 EN 11 ...

Page 176: ...stick 4Plus 1 to the left E To move the fork carriage to the right Push the Joystick 4Plus 1 to the right F NOTE The symbols on the Joystick 4Plus indicate the direction of movement of the lift mast or fork carriage 1 6210_003 091 E F Operating 4 Lifting 164 56358042501 EN 11 ...

Page 177: ...ing the fork carriage To lift fork carriage Pull the lift lower operating lever 1 back wards To lower fork carriage Push the lift lower operating lever 1 for wards Tilting the lift mast To tilt the lift mast forwards Push the tilt operating lever 2 forwards To tilt the lift mast backwards Pull the tilt operating lever 2 backwards NOTE The symbols on the operating levers show the direction of movem...

Page 178: ...ty foot wear when changing the fork arms Ensure that no one stands in the danger area Do not pull on the fork arms The fork arms must always be carried by two peo ple if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used and should be dimen sioned such that the fork arms do not pro...

Page 179: ...w is un screwed on the side chosen for installation Place the fork arms on a pallet next to the fork carriage on the side chosen for installa tion Pull up the locking lever 1 and push the fork arms onto the fork carriage one after the other Place the fork arms in the required position and push down the locking lever Ensure that the locking lever snaps into place Screw in and tighten the locking sc...

Page 180: ...r cuts on sharp edges or burrs Always wear protective gloves and safety foot wear WARNING There is a risk of tipping The weight and dimensions of the fork extension af fect the stability of the truck The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance The truck is equipped with a fork extension ex works the capacity rating plate is ...

Page 181: ...fork extension with a securing bolt Always secure the securing bolt with a linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork ex tension 1 Push the fork extension onto the fork arms until it is flush with the fork back Insert the securing bolts located behind the fork back fully into the fork extension Insert the linch pin into the securing bolt and se...

Page 182: ...t cannot be secured against slipping Do not use a fork extension variant WARNING Risk of accident from the truck tipping over When driving the centre of gravity of the load 2 must not be higher than 600 mm above the ground The truck may tip forwards when driving or braking Only drive with a load centre of gravity up to a max of 600 mm above the ground NOTE If the truck is equipped with the load me...

Page 183: ...ifted and tilted in the same manner Only work in reverse operation using rever sible fork arms Do not use a fork extension variant If the load measurement comfort feature is available perform a zero adjustment of the load measurement To drive raise the load centre of gravity 2 to a max of 600 mm above the ground Observe the information in the section enti tled Transporting suspended loads 6341_862...

Page 184: ...d the maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver ...

Page 185: ...he attachment of additional weights to in crease load capacity is prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These val ues apply to compact and homogenous loads Other wise the stability as well as the rigidity of the fork arms and lift mast cannot be guaranteed Improper or incorrect operation or the placement of persons to increase load capa...

Page 186: ...n on the truck and the attachment Load measurement variant Description Knowing the weight of the load to be transpor ted gives the driver greater security If the truck is equipped with the load measurement variant comfort feature the weight of the lif ted load can be measured and shown in the display and operating unit Load measurement is possible only when the truck is at a standstill Before perf...

Page 187: ...determined by a load measurement ex ceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce load immediately If necessary use another truck with sufficient load bearing capacity NOTE Accurate load measurement is only possible under the following conditions The hydraulic oil is at normal operating tem perature The load is at rest at the begi...

Page 188: ...r fin gertip operation the F1 button can also be pressed as an alternative NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the load meas urement will not be accurate To stop the low ering procedure quickly release the operating device for lowering so that it jumps into the zero positi...

Page 189: ...r the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the load Loads are to be picked up and transported as close to the middle as possible DANGER Risk of accident from a falling load When transporting small items attach a load safety guard variant to prevent the load from falling...

Page 190: ...uip ment e g attachments or the load Also in cluded are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all personnel except the driver in his norma...

Page 191: ...spended loads Before transporting suspended loads consult the national regulatory authorities in Germa ny the employer s liability insurance associa tions National regulations may place restrictions on these operations e g in Italy Contact the rel evant authorities If there are no country specific regulations for suspended loads in the country of use the fol lowing instructions for safe handling m...

Page 192: ...t the harness cannot shift or release unintentionally and cannot be damaged When transporting suspended loads suita ble aids e g guy wires or supporting poles must be available so that accompanying persons can guide suspended loads and prevent the loads from swinging Take particular care to ensure that there is no one in the drive direction in the driving lane If despite this the load begins to sw...

Page 193: ...not be guaranteed Only store pallets which do not exceed the specified maximum size Damaged loading equipment and incorrectly formed loads must not be stored Attach or secure the load to the load carry ing equipment so that the load cannot move or fall Store the load so that the specified aisle width is not reduced by protruding parts Approach the racking carefully brake gently and stop just in fr...

Page 194: ...ork into the racking ensure that the racking and load are not damaged Insert the fork as far under the load as pos sible Stop the truck as soon as the fork back is resting on the load The centre of gravity of the load must be positioned be tween the fork arms in the middle 6210_800 006 6210_800 007 Operating 4 Handling loads 182 56358042501 EN 11 ...

Page 195: ...way behind you is clear DANGER Never tilt the lift mast with a raised load due to the risk of tipping Lower the load before tilting the lift mast Move backwards carefully and slowly until the load is clear of the racking Brake gen tly Lower the load while maintaining ground clearance 6210_800 008 5060_003 102 Operating 4 Handling loads 183 56358042501 EN 11 ...

Page 196: ...he less stable it be comes The truck can tip over or the load can fall increasing the risk of accident Driving with a raised load and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards 5060_003 101 6210_800 011 Operating 4 Handling loads 184 56358042501 EN 11...

Page 197: ...pter entitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating the service brake Never drive with a load protruding to the side e g with the sideshift 6210_800 013 6210_800 014 Operating 4 Handling loads 185 56358042501 EN 11 ...

Page 198: ... guaranteed Visibility conditions can be evaluated by deter mining the size of the area that is not visible A Procedure The driver moves into position in his seat The area that is not visible A is deter mined based on the load Y and the length of the route D If the area that is not visible exceeds 1085 mm EN16842 2 A3 the visibility conditions are inadequate In the case of inadequate visibility co...

Page 199: ...avity and the moment of tilt move due to tilting the lift mast forwards with a raised load or due to the load slipping The truck may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take particu lar care to ensure that the truck does not tip for wards and that the load does not slip WARNING Risk ...

Page 200: ...d 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 6210_800 015 6210_800 016 Operating 4 Handling loads 188 56358042501 EN 11 ...

Page 201: ... be lifted Add the determined unit weights to obtain the actual total weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Net weight of attachment variant Weight of the load to be lifted 100 kg allowance for the driver Actual total weight Drive the truck with the forks forwards into the lift without touching the shaft walls Park the truck securely in the lif...

Page 202: ...e unit weights by reading the truck nameplate and if necessary the at tachment variant nameplate and if neces sary by weighing the load to be lifted Add the determined unit weights to obtain the total actual weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Attachment net weight variant Weight of the load to be lifted 100 kg allowance for driver Total actu...

Page 203: ...mpetent 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 ex erting 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...

Page 204: ...ment 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 at tachment 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 o...

Page 205: ...ufacturer 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 permi...

Page 206: ...ormation provided by the manufacturer and supplier of the attachments After each as sembly the attachment must be checked for proper functioning prior to being put into oper ation for the first time NOTE The pressure release procedure is dependent on the operating devices for controlling the hy draulic functions see the chapter entitled Lift ing system operating devices 7341_003 019 Operating 4 At...

Page 207: ... if the truck is not equip ped with a hazard warning system Switching on the hazard warning system prevents the electrical system from being switched off even if the key switch is subsequently switch ed off Switch off the key switch Actuate the operating lever 1 for control ling the hydraulic functions repeatedly in the direction of the arrow as far as the end po sition The valves open and the hyd...

Page 208: ...devices see the relevant sections 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 the relevant operating in structions Drivers must be taught how to operate the attachments Loads may only be picked up and transported with a...

Page 209: ... The directions of movement can be seen in the pictograms on the operating devices NOTE All the attachments described fall into the cat egory of equipment variants Please see the respective operating instructions for an exact description of the respective movements actions of the attachment fitted With fleet manager access authorisation var iant the fleet manager can adjust the speed of the auxili...

Page 210: ...e attachment moves in accordance with the pictogram in position A Move the attachments 1 cross lever in the direction of the arrow B The attachment moves in accordance with the pictogram in position B Move the attachments 1 cross lever in the direction of the arrow C The attachment moves in accordance with the pictogram in position C Move the attachments 1 cross lever in the direction of the arrow...

Page 211: ...amp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the at tachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary...

Page 212: ...d by this lever This essentially involves the following Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow F The attachment moves in accordance with the pictogram in posit...

Page 213: ...right 7 Adjust fork arms open 8 Adjust fork arms close 9 Swivel lift mast or fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Rotate to the left 16 Rotate to the right 17 Tip shovel over 18 Tip shovel back 3 5 11 7 4 6 13 15 17 9 12 14 10 16 18 8 Operating 4 Attachments 201 56358042501 EN 11 ...

Page 214: ...ng lever 1 towards A The attachment moves in accordance with the pictogram in position A Move the operating lever 1 towards B The attachment moves in accordance with the pictogram in position B Move the operating lever 2 towards C The attachment moves in accordance with the pictogram in position C Move the operating lever 2 towards D The attachment moves in accordance with the pictogram in positio...

Page 215: ...amp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the at tachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary...

Page 216: ...er 1 by switching the functions using the function key 3 The pictograms on the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 3 and move operating lever 1 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 3 and move opera...

Page 217: ...t NOTE The pictograms shown correspond to the at tachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if re quired 5060_003 122 3 4 1 2 Operating 4 Attachments 205 56358042501 EN 11 ...

Page 218: ...g Move the operating lever 1 towards A The attachment moves in the direction shown in pictogram A Move the operating lever 1 towards B The attachment moves in the direction shown in pictogram B Move the operating lever 2 towards C The attachment moves in the direction shown in pictogram C Move the operating lever 2 towards D The attachment moves in the direction shown in pictogram D 5060_003 110 1...

Page 219: ...amp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the at tachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary...

Page 220: ...g the functions using the 5th function function key 5 The pictograms on the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 5 and move operating lever 3 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 5 and move operatin...

Page 221: ...t NOTE The pictograms shown correspond to the at tachments fitted to this truck at the factory If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if re quired 5060_003 122 3 4 1 2 Operating 4 Attachments 209 56358042501 EN 11 ...

Page 222: ...hment 1 Joystick 4Plus Move sideshift to the left right 2 Joystick 4Plus or slider Adjust fork arms open close 3 Slider Move side shift frame or fork carriage for wards backwards 4 Joystick 4Plus or slider Rotate attachment left right 5 Slider Tip shovel over tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions...

Page 223: ...th hydraulic function the procedures for op eration are as follows Press and hold shift key F 1 on the Joy stick 4Plus Simultaneously actuate the horizontal rock er button 2 in the direction shown in the pictogram The attachment moves in the selected direc tion NOTE The pictograms are affixed according to the attachment fitted at the factory If an attach ment with different functions is fitted the...

Page 224: ...and pictograms 2 Move side shift frame or forks for wards backwards 3 Move sideshift to the left to the right 4 Adjust fork arms open close 5 Swivel lift mast or forks to the left to the right 6 Release clamp load retainer 7 Push off pull in load 8 Open close clamps 9 Turn to the left to the right 10 Tip shovel over tip shovel back NOTE The pictograms shown correspond to the at tachments fitted to...

Page 225: ...ing operat ing lever controls the 5th function The pictogram 3 behind the operating lever shows in the upper and lower parts the func tion that is activated with this lever The meanings are as follows Move operating lever forwards The attachment moves in the direction of movement shown in the upper part of the pic togram Move operating lever back The attachment moves in the direction of movement s...

Page 226: ...unction is switched to the 4th oper ating lever see adhesive label 9 NOTE The movement action of this 5th function can be found in the operating instructions of the fit ted attachment NOTE The pictograms are applied depending on the pre assembled attachment If an attachment with other functions is fitted the pictograms must be checked for the correct representa tion and changed if necessary Contac...

Page 227: ...revents the clamp from opening unintentionally if the oper ating function is inadvertently triggered DANGER There is a risk of fatal injury from falling loads if the correct function of the clamp locking mechanism is not guaranteed If other attachments are used on this truck in addition to the clamp make sure that the clamp locking mechanism function is reassigned to the correspond ing operating d...

Page 228: ...lamp To close the clamp pull the cross lever 1 back Triple mini lever To release the clamp locking mechanism push the operating lever 1 forwards The LED for button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released After one sec ond the clamp locking mechanism ...

Page 229: ...chanism press and hold shift key F 3 and move the horizontal rocker button 1 to the right Keep shift key F 3 pressed and move the horizontal rocker button 1 back to the neu tral position The LED 2 lights up as long as the clamp locking mechanism is released To open the clamp press and hold shift key F 3 and move the horizontal rocker but ton 1 to the right NOTE The hydraulic function for opening t...

Page 230: ... using attach ments WARNING Risk of accidents Attachments may only be used for their intended pur pose as described in the relevant operating instruc tions Drivers must be instructed in the handling of the at tachments WARNING Risk of accidents Loads may only be picked up and transported with attachments if they are securely attached Where necessary loads should also be secured against slipping ro...

Page 231: ... Load capacity Q kg 1 Lift height h mm 2 Load distance C mm 3 Operating 4 Attachments 219 56358042501 EN 11 ...

Page 232: ... off the driving lights press the button 1 again The driving lights go out Working spotlights To switch on the working spotlights front and rear press the button 1 The working spotlights light up To switch off the working spotlights press the button 1 again The working spotlights go out NOTE In trucks with StVZO German Road Traffic Li censing Regulations equipment variant the following lighting el...

Page 233: ... not yet illuminate Set the drive direction to Reverse The rear working spotlight illuminates NOTE If the drive direction is set to Forwards the rear working spotlight goes out Switching the rotating beacon on and off Press the Softkey 1 to switch on the rotating beacon The rotating beacon is switched on The sym bol is displayed To switch off the rotating beacon press the Softkey The rotating beac...

Page 234: ...arning system goes out NOTE To switch on the hazard warning system with out the key switch being switched on press and hold the button for three seconds Switching the turn indicators on and off Mini lever version Switch on the turn indicators by moving the cross lever of the drive direction turn indica tor 1 to the left or to the right 5060_003 011_V2 1 2 5060_003 096 F1 F2 1 Operating 4 Auxiliary...

Page 235: ...itch off the turn indicators by moving the cross lever to the centre position Mini console version Switch on the turn indicators by moving the turn indicator switch 1 to the left or to the right 2 3 5060_003 012_V2 5060_003 046 1 Operating 4 Auxiliary equipment 223 56358042501 EN 11 ...

Page 236: ... at great lift heights the lower working spotlight illuminates the working area directly in front of the truck Depending on the equipment the upper work ing spotlights can be switched on off automati cally or manually Switching the upper working spotlights on off manually NOTE The upper working spotlights can be switched on off independently of the lower working spotlights For information about sw...

Page 237: ... the lift mast is lifted for a period of at least two seconds NOTE During these two seconds a maximum of two lifts can be executed to prevent the working spotlights from switching on each time a pre cise adjustment is made If more lifts are car ried out during this time the upper working spotlights will remain switched off NOTE The upper working spotlights are switched off automatically when the t...

Page 238: ...SafetyLight The STILL SafetyLight is a visual warning unit designed to enable early detection of trucks in driving areas with low visibility such as drive lanes high racks as well as at blind junc tions The STILL SafetyLight is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations The STILL SafetyLight projects one or more light blue light spots in front o...

Page 239: ...below Button actuation Operating stage Off 1st time On 2nd time Interval 3rd time hold Washer 4th time Off Filling the washer system CAUTION Components may become damaged due to the ef fects of frost Water expands when it freezes If there is no anti freeze in the washer system the system may be damaged due to the build up of ice in freezing condi tions Always use washer fluid containing anti freez...

Page 240: ...escription and operation information can be found in the separate operating instructions for the corresponding FleetManager versions Shock recognition variant The shock recognition is an equipment variant of the FleetManager variant in which an ac celeration sensor is installed in the truck The acceleration sensor records data arising from rapid accelerations or decelerations of the truck e g in t...

Page 241: ...ctional check of the electrical connection on the connected device CAUTION Malfunctions possible The exposed socket may become dirty and dusty if no plug is inserted or the dust guard cover is not closed Over time this can lead to problems with the electrical connection Push the dust guard cover all the way down after using the socket Driver restraint systems var iants Different driver restraint s...

Page 242: ...ng work they must be certain that the ceiling sensor system is working correctly Despite the ceiling sensor system being instal led the driver must also check the speed indi cator on the display operating unit on a regu lar basis to ensure that they do not exceed the maximum speed permitted for the environ ment Entering a hall The ceiling sensor system automatically de tects when the truck enters ...

Page 243: ...hall ceil ing and reduce the maximum speed In rare cases it may occur that the ceiling sensor system does not recognize a ceiling and does not then reduce the speed This can happen if the signals from the ceiling sensor are insufficiently reflected due to the ceiling geometry for example if there are large window areas at a 45 angle In these cases the sensitivity and the range of the ceiling senso...

Page 244: ... ceiling sensor 1 The sensor is adjusted using DIP switches 6 To access the DIP switches open the cover on the underside of the sensor housing with the key 5 During this process the two tabs of the key 5 fit into the recesses of the cover Using the DIP switches 1 to 5 6 adjust the range and the sensitivity of the sensor The DIP switches can be adjusted using a small screwdriver Deckensensor_Anbau ...

Page 245: ...ry 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 m 4 5 Sensitivity 0 0 Very high 0 1 High 1 0 Medium 1 1 Low Operating 4 Auxiliary equipment 233 56358042501 EN 11 ...

Page 246: ...e sensor has different beam angles de pending on the combination of range and sen sitivity that has been set See the following ta ble Sensitivity Range Beam angle Low 1 2 m 22 5 4 m 22 5 8 m 20 16 m 15 24 m 5 Medium 2 2 m 35 4 m 30 8 m 25 16 m 22 5 24 m 10 2 3 4 1 2 3 4 Operating 4 Auxiliary equipment 234 56358042501 EN 11 ...

Page 247: ...m 33 8 m 22 5 16 m 20 24 m 15 Very high 4 2 m 45 4 m 43 8 m 30 16 m 22 5 24 m 18 After the adjustment refit the cover Refit the ceiling sensor and connect it Check that it is working correctly Operating 4 Auxiliary equipment 235 56358042501 EN 11 ...

Page 248: ...n Opening the cab door from the outside Insert the key in the door lock 1 unlock and remove the key Pull the door handle 2 and release the door lock Open the cab door 3 by pulling outwards Opening the cab door from the inside Take hold of the handlebar 4 and latch 5 Press the latch in and push the cab door outwards 7331_341 003 4 5 2 1 3 Operating 4 Cab 236 56358042501 EN 11 ...

Page 249: ...side window from the side windows slip ping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the rear side window Press the handle 2 together and slide the rear side window 1 forwards Make sure that the handle engages in the stop slot 3 Opening the front side window The front side window 4 can be opened in the same way as the rear side w...

Page 250: ...the handle engages securely in the corresponding stop slot Closing the rear side window Press the handle 2 together and pull the rear side window 1 to the rear Make sure that the handle engages in the stop slot 3 Closing the front side window The front side window 4 can be closed in the same way as the rear side window 7331_341 007 4 2 1 3 Operating 4 Cab 238 56358042501 EN 11 ...

Page 251: ...nterior lighting Switch the interior lighting 7 on or off using the switch 8 or button 1 The interior lighting symbol 2 appears in the display 7312_003 013 7 8 6311_003 013_V2 2 1 Operating 4 Cab 239 56358042501 EN 11 ...

Page 252: ...akers 2 are an equipment variant If the truck is equipped with a radio and loudspeakers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the ra dio WARNING The driver s attention is adversely affected by operat ing the radio or listening to excessive volume while driving or handling loads There is a risk of accident Do n...

Page 253: ...ating element may overheat or short circuit Do not cover the air intake opening Do not operate the heating system without a fresh air filter and recircula ted air filter fitted DANGER Risk of burns When the heating system is operated the heating system housing becomes hot and can burn the skin if it is touched Do not touch the heating system housing during operation CAUTION Risk of blower malfunct...

Page 254: ...heating system will not func tion regardless of the position of the heater switch To switch the heating system on first switch on the blower switch 1 and then the heat ing switch 2 The heating system is in operation The air is heated up to the heat output level set at the heating switch 2 Adjusting the air flow Adjust the air flow at the front outlet vents 3 and at the outlet vent in the footwell ...

Page 255: ...pen the roof window rotate the handle 2 in an anti clockwise direction and use it to push the roof window upwards The roof window is held in the open position by means of gas springs 3 To close and lock the roof window pull the roof window downwards using the handle and rotate the handle in a clockwise direc tion Clipboard variant The clipboard 1 with reading lamp 2 is an equipment variant 6210_00...

Page 256: ...the 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 distrib uted between the fork and the trailer Check the load distribution and adjust to corre spond to the rated capacity Observe th...

Page 257: ...ort load is not permitted Do not use trailers with tillers supported by the tow coupling This truck is suitable for the occasional towing of trailers If the truck is equipped with a tow ing device this occasional towing must not ex ceed 2 of the daily operating time The man ufacturer must be consulted if the truck is to be used for towing on a more regular basis Coupling pin in the counter weight ...

Page 258: ...3 in the counterweight DANGER If the coupling pin or securing bush are lost or de stroyed during towing the trailer will work loose and become uncontrollable This poses a risk of ac cident Only use genuine coupling bolts 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 a...

Page 259: ...re that no one is between the truck and trailer DANGER Never jack up or crane load the truck on the tow coupling The tow coupling is not designed for this and could be deformed or destroyed The truck could fall off with potentially fatal consequences Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting points DANGER The tow coupling is not designed ...

Page 260: ...can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow cou pling check the tow coupling for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufficient room In the case of a collision check the tow coupling for damage Replace tow coupling if damaged if necessary contact the authorised service ce...

Page 261: ...RO 244 must be individ ually checked to ensure that they are suitable for the planned towing operation The permissible rigidity value of the tow coupling must always be taken into account The authorised service centre can check and or confirm the maximum towed load for the plan ned towing operation Observe the operating instructions for the tow coupling Inform the authorised service centre NOTE To...

Page 262: ...ntrolled There is a risk of accident A protruding safety handle means that the tow bar eye has not been coupled correctly The trailer must not be towed in this condition Ensure that the safety handle is flush with the se curing bush If the safety handle protrudes repeat the coupling process Remove any items used to prevent the trail er from rolling away Tow the trailer Closing model RO 243 by hand...

Page 263: ...ure that they are suitable for the planned towing operation The permissible rigidity value of the tow coupling must always be taken into account The authorised service centre can check and or confirm the maximum towed load for the plan ned towing operation Observe the operating instructions for the tow coupling Inform the authorised service centre NOTE Tow coupling RO 244 A is intended for a tow b...

Page 264: ...g and the coupling pin engages NOTE The coupling pin is correctly engaged if the control pin 3 doesnot protrude out of its guide DANGER If the coupling pin drops out during towing the trail er will work loose and can no longer be controlled There is a risk of accident The control pin 3 must not protrude out of its guide Ensure that the coupling pin is engaged correctly If the coupling pin is not c...

Page 265: ... The tow coupling is closed Uncoupling model RO 244 A Take measures to prevent the trailer from rolling away e g use wheel chocks Push the hand lever 2 upwards until it snaps into place The tow coupling is opened Slowly drive the truck forwards until the tow bar eye and towing jaws are disconnected Close the tow coupling by actuating the closing lever 1 NOTE To protect the lower coupling pin bush ...

Page 266: ...ler When hooking up ensure that no one is between the truck and trailer Slowly move the truck back DANGER If the coupling pin drops out during towing the trail er will work loose and can no longer be controlled There is a risk of accident A protruding safety handle means that the tow bar eye has not been coupled correctly The trailer must not be towed in this condition Make sure that the control p...

Page 267: ...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 regarding the...

Page 268: ... tive messages are displayed one after another on the display After a few seconds the display will alternate between the last shown operating display and the message The frequency of alternation depends on the type of event If a message appears follow these operat ing instructions Once the event is remedied the message will disappear If a malfunction continues to occur the mes sage will continue t...

Page 269: ...RATOR A3811 Accelerator configuration is invalid The truck cannot be driv en Notify the authorised service centre BRAKE SENSOR A3016 A3017 Sensor fault truck can only be driven at emergency mode speed Notify the authorised service centre CONFIGURATION A2111 A3801 A3812 Parameterisation error drive unit and hydraulic drive not functioning Notify the authorised service centre SEAT SWITCH A302 Seat s...

Page 270: ...the authorised service centre POWER SUPPLY A2242 Transmitter power supply short circuit The truck cannot be driven Notify the authorised service centre SURVEILLANCE A2801 A2802 A2808 A2809 A2810 A2815 Drive unit not functioning Release accelerator pedal If this error occurs sporadically it can be tolerated If the op erational capacity is impaired notify your authorised service centre SURVEILLANCE ...

Page 271: ...ery carrier is overheat ing Allow the truck to cool down for one hour BATTERY CARRIER A5930 Button error Notify the authorised service centre BATTERY CARRIER A5931 Potentiometer plausibility error for hydraulic battery carrier Notify the authorised service centre CONTROL UNIT A3305 CIO not functioning Notify the authorised service centre PARKING BRAKE OIL PRES SURE A3043 The oil pressure in the pa...

Page 272: ...relevant hydraulic function is switched off The message disappears and the hydraulic function is avail able again as soon as the operating device is released If required the authorised service centre can disable moni toring of the hydraulic functions AUXILIARY2 LEVER A4604 The auxiliary hydraulics 2 hydraulic operating device has been moved and held in place for too long The relevant hydraulic fun...

Page 273: ...NOTE The truck is equipped with a negative spring operated brake Switching off the truck will block the multi disc brakes in the drive wheel units after a few minutes However the truck can still roll until the drive wheel units are blocked For this reason the parking brake must always be applied before you leave the truck If you park the truck without applying the park ing brake and then vacate th...

Page 274: ...ain stationary The accelerator must be checked Notify the authorised service centre SWITCH OFF TRUCK message If the SWITCH OFF THE TRUCK mes sage appears on the display the truck switch off is verified Press the corresponding softkey on the dis play and operating unit to switch off the truck or cancel the operation PARKING BRAKE ACTIVE message If the electric parking brake is applied the PARKING B...

Page 275: ... fork is above the height sensor the key switch is turned off and the seat vacated the LOWER FORKS message appears in the dis play variant An optional signal tone sounds Lower the fork to the ground The message LOWER FORKS disappears TILT LEVER LOWER LEVER AUXILI ARY1 LEVER AUXILIARY2 LEVER messages If an operating device is operated continuously for a long period the TILT LEVER LOWER LEVER AUXILI...

Page 276: ...king assistance is available when the emergency off switch is actuated Actuating the emergency off switch will disconnect the drives from the power supply To brake actuate the service brake The truck is equipped with an emergency off switch When this switch is actuated the driv ing functions and the functions of the working hydraulics are blocked The EMERGENCY SWITCH message ap pears periodically ...

Page 277: ...round The truck can now be driven again with no speed limitation SAFETY BELT message DANGER Risk of fatal injury in the event of falling from the truck if it tips over If the truck tips over the driver is at risk of injury even if a restraint system is used The risk of injury can be reduced by using a combination of a restraint system and a seat belt In addition the seat belt protects against the ...

Page 278: ...ll be limited to low driving speeds or will be braked to a halt DANGER Risk of accident The speed must be adjusted to suit the driving sit uation The increased safety provided by this function must not be misused in order to take safety risks SECURE TRUCK AGAINST ROLLING AWAY message This message appears if the truck control unit detects a movement of the truck without the accelerator pedal being ...

Page 279: ...ng time has been exceeded NOTE The operating devices shown in the following illustrations are only examples and may differ from the equipment in your truck The seat switch is not actuated while the ac celerator pedal or steering wheel is actuated The accelerator pedal or the steering wheel is actuated even though no one is sitting in the driver s seat The message SEAT SWITCH appears on the display...

Page 280: ...d NOTE The shift time is adjustable If the key switch is switched on and the driver does not leave the seat before the set shift time is exceeded SEAT SWITCH appears on the display This is also the case if an operat ing device for the working hydraulics or the ac celerator pedal is actuated Depending on the configuration the working hydraulic functions can be executed normally only slowly or not a...

Page 281: ...rom the seat sit back down again and fasten the seat belt The truck can again be operated without re strictions OVERHEATING message If the message OVERHEATING appears in the display the traction motors have overhea ted The acceleration and the speed of the truck are reduced Allow the truck to cool down If the error persists contact your authorised service centre SURVEILLANCE message If the SURVEIL...

Page 282: ... the service brake of the truck is not yet ready for use The driving speed is limited to 5 km h When the service brake is ready for operation the message disappears The speed limitation is cancelled MOT GEN TEMP message If the MOT GEN TEMP message appears the traction motor or the generator is overhea ted or a cable is broken Interrupt work and allow the truck to cool down Do not switch off the ke...

Page 283: ...again Release the operating device LIFT HEIGHT message Speed limitation with a raised load variant This function makes sure that the truck can only move slowly when a load is lifted DANGER Risk of accident Before using this function familiarise yourself with the altered driving characteristics of the truck Optionally the truck can have altered acceleration behaviour and or braking characteristics ...

Page 284: ...ruck can now be driven again with no speed limitation Lifting the load while driving If you are travelling with the load during a stacking unstacking operation and lift the load while travelling the flashing message LIFT HEIGHT appears briefly in the display The truck will travel slowly or will be braked Lower the fork load to just above the ground The truck can now be driven again with no speed l...

Page 285: ...a bles are damaged Do not crush the battery cable when closing the battery cover Switch off the key switch Open the battery cover Ensure that the battery male connector and the plug connection are dry clean and free of foreign objects Hold the battery male connector 2 by the handle 1 and insert the battery male con nector into the plug connection on the truck Push the fastener 3 completely to the ...

Page 286: ...witch is switched off Do not disconnect the battery male connector while under load except in an emergency CAUTION There is a risk of short circuit if the ca bles are damaged Do not crush the battery cable when closing the battery cover Switch off the key switch Open the battery cover Pull the fastener 4 to the left and open the fastener Disconnect the battery male connector 3 from the plug connec...

Page 287: ...tery male connector When you close the battery cover the battery cover may collide with the battery male connector that you have hung on the battery tray As a result the battery male connector may become damaged Leave the battery cover open 6341_003 039 3 1 Operating 4 Connecting and disconnecting the battery male connector 275 56358042501 EN 11 ...

Page 288: ...se oper ating instructions When charging 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 due to flammable gases During charging the battery releases a mixture of oxygen and hydrogen oxyhy drogen gas This gas mixture is explo sive and must not be ignited There must be no flamma...

Page 289: ...and onto persons The battery must be removed only when the truck is on level even ground with sufficient load capacity The load capacity of the lifting accessory in use must at least match the battery weight Ensure the load capacity of the lifting accessory Compare the information on the battery identifica tion plate with the operating instructions or the nameplate Remove the battery on suitable g...

Page 290: ...itch off the key switch or the battery charger Only connect the battery male connector while the key switch is switched off 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 or the battery charger is under load an arc will be produced The arc can damage the contacts and considerably shorten the ...

Page 291: ...arged or partly discharged state Apply the parking brake Switch on the key switch Read the battery charge 1 on the display Charge a discharged or partly discharged battery NOTE The battery charge displays shows the availa ble battery capacity as a segmented bar graph in 10 increments Approx every 10 seconds the display switches between the battery charge and the remaining operating time Charging t...

Page 292: ...tery acid CAUTION Possible damage to components Incorrect connection or incorrect opera tion of the charging station or the battery charger may result in damage to compo nents Follow the operating instructions for the charging station or battery charg er and for the battery CAUTION Potential for damage to the battery male connector Switch off the key switch on the truck Switch off the battery char...

Page 293: ...and do not smoke Inspect the battery cables and charging ca bles for damage replace if necessary Use the handle 4 to hang the battery charger plug 5 on the front edge of the battery tray 1 Hold the battery male connector 3 by the handle 2 and insert the battery male con nector into the battery charger plug 5 Push the fastener 6 for the battery charger plug to the right up to the stop to retract th...

Page 294: ...f the battery charger to the battery capacity of the lead acid battery Start the battery charger Once the charging process is complete Switch off the battery charger Open the fastener 6 for the battery charg er plug 5 by pulling the fastener to the left Disconnect the battery male connector 3 from the battery charger plug by pulling the handle 2 in the direction of the arrow Pick up the battery ch...

Page 295: ...ery cells are evenly charged again This preserves the service life of the battery and the battery capacity An equalising charge should be carried out in accordance with the battery manufacturer s in structions several times a month after the nor mal 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 ar...

Page 296: ...utton on the battery charger Please refer to the operating 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 ...

Page 297: ...essory used must at least match the battery weight see battery identification plate Changing to a different battery type It is generally possible for a truck to be con verted to a different battery type and a differ ent capacity by the authorised service centre Note the following points The display operating unit must be adjusted to the new battery capacity If this is not done the actual battery d...

Page 298: ... that hold it in the opened position When additional load is present for example through heavy objects strong wind or other persons the battery cover can lower suddenly Cold weather and ageing can also reduce the performance of the gas springs and cause the cover to lower Make sure that the battery cover is not being pushed down by strong winds or other persons If the gas springs no longer hold th...

Page 299: ... that the safety hook 1 engages in the gap on the bracket 2 Closing the battery cover CAUTION When closing the battery cover limbs could become trapped risk of crushing When closing the battery cover nothing should come between the battery cover and the edge of the chas sis Do not grasp any edges Always close the battery cover by grasping one of the handles in each hand Close the battery cover car...

Page 300: ...Safety regulations for handling the battery without fail NOTE The battery can be replaced using the follow ing lifting accessories Observe the relevant operating instructions Truck ECU 30 special pallet truck Preparation The load capacity of the lifting accessory in use must at least match the battery weight see battery identification plate The procedure for replacing a battery does not differ dep...

Page 301: ...left Disconnect the battery male connector 3 from the plug connection by pulling the han dle 2 in the direction of the arrow Check the battery cable for damage Hang the battery male connector 3 on the front edge of the battery tray 1 When removing the battery cable make sure that it does not come into contact with any components 6341_003 013_V2 2 4 3 6341_003 039 3 1 Operating 4 Replacing and tran...

Page 302: ... when removing and inserting the battery with the truck Determine the length of the battery base frame and starting from the fork tip mark one of the fork arms dimension B Move the fork arms carefully up to the mark in the forked fittings in the battery base frame Carefully lift the battery and battery base frame up and out of the truck When doing so pay attention to the distance to the chassis Ca...

Page 303: ...compartment This may cause damage to the battery and the truck com ponents Always use the battery in conjunction with the bat tery base frame Pick up the new battery along with the bat tery base frame and carefully transport it to the truck Make sure to hang the battery male con nector 3 on the front edge of the battery tray 1 and ensure that the battery cable does not become trapped during instal...

Page 304: ...are engaged the bat tery is prevented from slipping sideways out of the battery compartment Carefully insert the battery into the battery compartment When doing so take note of the adjustment and entry aids 3 on the left of the battery compartment NOTE The battery must be guided in flush against the adjustment and entry aids 3 This will help the driver to insert the battery without it getting stuc...

Page 305: ...re fully en gaged in the bores 1 and that the battery is level If the battery is not positioned correctly re peat this process Carefully move the fork arms out from the battery base frame Swivel the battery lock 1 downwards 6341_003 035 1 2 6341_003 038 1 Operating 4 Replacing and transporting the battery 293 56358042501 EN 11 ...

Page 306: ...ner 3 completely to the right to retract the battery male connector into the plug connection and to secure the bat tery male connector in position Ensure that the battery cable cannot come into contact with the battery cover Close the battery cover 6341_003 005_V2 1 3 2 Operating 4 Replacing and transporting the battery 294 56358042501 EN 11 ...

Page 307: ...iving speeds and greater handling performance Longer battery life even under severe con ditions Continuous temperature controlled self cooling even when removed from the truck and not connected to a battery charger Ready for use again more quickly after charging Less heat radiated into the driver s compart ment NOTE When converting to PowerPlusLife batteries the maximum speed of the truck can be i...

Page 308: ...ing The LEDs continuously indicate the cooling state of the battery If the red LED 1 is illuminated the battery temperature is high and cooling is active If the yellow LED 2 is illuminated battery cooling is active If the green LED 3 is illuminated the battery is ready for use Especially when PowerPlusLife batteries are used for mixed applications the temperature monitoring function makes it clear...

Page 309: ...D Fluid level The fluid level in the PowerPlusLife battery is checked by a sensor If an LED slowly flashes alternately it indi cates that the fluid level is too low Top up the fluid see the chapter entitled Servicing the battery Internal error If an LED flashes at frequent intervals it indi cates the presence of an internal fault The error can be read using the diagnostics function The diagnostic ...

Page 310: ...ng 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 short...

Page 311: ...covers directly with water Use only high pressure cleaners with a maximum output power of up to 50 bar and 85 C If a high pressure cleaner is used maintain a distance of at least 20 cm between the nozzle and the object being cleaned Do not aim the cleaning jet directly at adhe sive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot com pon...

Page 312: ... s specifications Clean the electrical system parts with a metal free brush and blow the dust off with low pressure compressed air Cleaning load chains WARNING Risk of accident Load chains are safety elements The use of cold chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden Observe the manufacturer s guidelines for working with cleani...

Page 313: ...he only means of guaranteeing good visibility CAUTION Do not damage the rear window heater inside Take great care when cleaning the rear window and do not use any objects with sharp edges Clean the windows using a commercially available glass cleaner After cleaning CAUTION Danger of short circuits Ingress of moisture into the battery male connector can lead to an electrical short circuit Use compr...

Page 314: ...icate the battery cover interlock Check that the battery male connector is dry before you connect the battery male connector NOTE The more often the truck is cleaned the more frequently the truck must be lubricated Operating 4 Cleaning 302 56358042501 EN 11 ...

Page 315: ...n ascending or descending gradi ents Actuate the service brake otherwise the truck will roll down gradients No speed reduction when you release the accelerator pedal The truck will coast Power steering is not available Steering forces are increased by the remaining emergency steering function The Curve Speed Control system auto matic reduction of speed when cornering is not available Hydraulic fun...

Page 316: ...tor 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 the service life of the contacts Do not disconnect the battery male connector while under load except in an emergency Pull the fastener 4 to the left and open the fastener Disconnect the battery male con...

Page 317: ...ep 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 your seat belt Never jump off the truck You must adhere to the rules of behaviour if the truck tips over Rules of behaviour if truck tips over Hold onto the steering ...

Page 318: ...h cuts When a pane of glass is smashed the face should be turned away and cov ered with the crook of the free arm Protect the 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 lowering If the hydraulic controller fails ...

Page 319: ...ol block 2 by a maximum of 1 5 revolutions using the hexagon socket wrench Screw the emergency lowering screw back in after the load is lowered Return the hexagon socket wrench to the support mounting provided Install the bottom plate Close the front right cover WARNING The load is lowered The lowering speed is regulated by unscrewing the emergency lowering screw Note the following list Remember t...

Page 320: ...e multi disc brakes in the drive wheel units after a few minutes However the truck can still be moved until the drive wheel units are blocked In order to tow the truck the spring operated brake must be released by actuating the brake valve Otherwise the truck is towed with the wheels blocked NOTE The brake valve is installed in front of the driv er s seat beneath the bottom plate The coupling pin ...

Page 321: ...fter releasing the spring operated brake until it is blocked once again C Minutes Seconds 20 190 0 20 7 40 50 2 50 95 1 50 Actuate the brake valve by means of a cou pling pin Take the coupling pin out of the counter weight Grip the rubber tab in the rubber mat using the finger opening and pull up the tab 6341_003 034 Operating 4 Procedure in emergencies 309 56358042501 EN 11 ...

Page 322: ...ased fold the rubber tab in the rubber mat back down Insert the coupling pin in the counterweight Actuate the brake valve without a coupling pin Remove the rubber mat Remove the bottom plate Press the brake valve plate 3 down re peatedly The spring operated brake is released NOTE To fully release the spring operated brake press down on the brake valve plate at least 30 times The pressure that buil...

Page 323: ...s able to absorb the tractive and braking forces from the unbraked towed load the ac tual total weight of the truck Check the tractive and braking forces of the tow ing vehicle DANGER If the towing vehicle brakes there is a risk that the truck will drive into the towing vehicle If a rigid connection has not been used for power transmission in two directions during towing the truck may drive into t...

Page 324: ...aching the tow bar about the risks When you fit the tow bar always use a second person to guide the towing vehicle manoeuvres Manoeuvre with a second person as a guide CAUTION Steering is stiff There is no power steering if the hy draulics fail Select a slow towing speed to ensure that the truck and the towing vehicle can be braked and controlled effectively at all times CAUTION If the truck is no...

Page 325: ...ake again as necessary Set down the load and lower the fork arms close to the ground Place the drive direction switch in the neu tral position Apply the parking brake Switch off the key switch Disconnect the battery male connector Check the tractive and braking forces of the towing vehicle With the help of a guide manoeuvre the towing vehicle to the truck Secure the tow bar to the tow coupling on ...

Page 326: ... After towing secure the truck so that it can not roll away e g by applying the parking brake or by using wheel chocks Remove the tow bar Operating 4 Procedure in emergencies 314 56358042501 EN 11 ...

Page 327: ...urely Determine the unit weights by reading the truck nameplate and if necessary the at tachment nameplate variant Add the determined unit weights to obtain the total actual weight of the truck Tare weight 1 Max permissible battery weight 2 Ballast weight variant 3 Attachment net weight variant 100 kg allowance for driver Total actual weight Type Modèle Typ Serial no No de série Serien Nr year ann...

Page 328: ...heel chock 1 in front of each front wheel and behind each back wheel Park the truck securely 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 the service life of the contacts Switch off the key switch On...

Page 329: ... the harnesses are tightened securely and that the pads cannot slip off Crane loading Crane loading is only intended for transporting the complete truck including the lift mast for its initial commissioning For application condi tions that require frequent loading or that are not dealt with here please contact the manu facturer with regard to special equipment var iants Trucks may only be laden by...

Page 330: ...dge protectors or similar protective devices where nec essary DANGER There is a risk of fatal injury if the hoists and harnesses fail and cause the truck to fall Only use hoists and harnesses with sufficient load capacity for the deter mined loading weight Only use the truck s designated lifting points Make sure that harness parts such as hooks shackles belts and similar items are only used in the...

Page 331: ... straps around the main tra verse 3 on the outer mast of the lift mast as shown Loop the lifting straps around the counter weight 4 as shown Determine the truck s centre of gravity see chapter entitled Dimensions 3 4 Operating 4 Transporting the truck 319 56358042501 EN 11 ...

Page 332: ...lem etc these must be removed be fore loading Secure harnesses in such a way that they do not touch any attachment parts Check that harnesses cannot come into contact with attachment parts Loading the truck DANGER If the raised truck swings in an uncon trolled manner it may crush people There is a risk of fatal injury Never walk or stand underneath sus pended loads Do not allow the truck to bump i...

Page 333: ...an arc will be produced The arc can damage the contacts and considerably shorten the service life of the contacts Switch off the key switch Only disconnect the battery male connector while the key switch is switched off CAUTION Tyre deformation as a result of continuous loading on one side Keeping all wheels clear of the ground prevents per manent deformation of the tyres Have the truck raised and...

Page 334: ...f oil or grease to all un coated moving parts Lubricate the truck Oil joints and controls Lubricate the battery cover interlock Ensure that the key switch is switched off Then disconnect the battery male connec tor Check the battery condition acid level and acid density Service the battery Spray all exposed electrical contacts with a suitable contact spray Only have the truck raised and jacked up ...

Page 335: ...aulic oil for condensation water and replace if necessary Have the same checks and tasks carried out by the authorised service centre that were carried out before initial commission ing Carry out the checks and tasks that are to be performed before daily use Recommission the truck During recommissioning the following points in particular must be checked Drive controller steering Brake system servi...

Page 336: ...Operating 4 Decommissioning 324 56358042501 EN 11 ...

Page 337: ...5 Maintenance ...

Page 338: ...re the lift mast to prevent it tilting backwards unintentionally Observe the maximum lift height of the lift mast and compare the dimensions from the technical data with the dimensions of the hall into which the truck is to be driven These steps are taken to prevent a collision with the ceiling of the hall and to avoid any damage caused as a result Working on the hydraulic equip ment The hydraulic...

Page 339: ...and when chang ing 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 tr...

Page 340: ...mm is required The length of the hard wood beam must approximately correspond to the width of the fork carriage b3 To avoid impact injuries the hardwood beam must not protrude beyond the outer contour of the truck A maximum length matching the total width b1 of the truck is recommended Obtain the dimensions b1 and b3 from the corresponding VDI datasheet Clamp the hardwood beam 1 between the driver...

Page 341: ...g off DANGER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technician to secure the lift mast Maintenance 5 Safety regulations for maintenance 329 56358042501 EN 11 ...

Page 342: ...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 personn...

Page 343: ...standard use Shorter maintenance intervals can be defined in consultation with the operating company depending on the application conditions of the truck The following factors may necessitate shorter maintenance intervals Contaminated poor quality roads Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Multi shift operation...

Page 344: ...Maintenance 5 General maintenance information 332 56358042501 EN 11 ...

Page 345: ...and wheels Check the tyres for wear and check the air pressure if necessary Check the wheels for damage and check the tightening torques Power unit Drive axle Check mounting check for leaks clean cooling fins Check the oil level in the drive wheel unit Change gearbox oil once after 1000 hours Steering Check the steering system for correct function and for leaks Check that the steering wheel is sec...

Page 346: ...eck the battery male connector and battery harness for damage Hydraulics Check the condition of the hydraulic system and check for correct function and leaks Check the hydraulics blocking function ISO valve Check the oil level Lift mast Check the mast bearings for damage lubricate them and check the tightening tor que Check the mast profiles for damage and wear Lubricate the mast profiles Check th...

Page 347: ...ystem Replace the fresh air filter Heating system Replace the recirculated air filter Check the heating system for damage observe the manufacturer s maintenance in structions Check the attachments for wear and damage observe the manufacturer s mainte nance instructions Check the trailer coupling for wear and damage observe the manufacturer s mainte nance instructions General Read out the error num...

Page 348: ...s are provided by our spare parts service department The information required for ordering parts can be found in the spare parts list Only use spare parts as per the manufactur er s instructions The use of unapproved spare parts can result in an increased risk of acci dents due to insufficient quality or incorrect as signment Anyone using unapproved spare parts shall assume unlimited liability in ...

Page 349: ...t manufac turers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part in volved When topping up working materials use only clean containers Maintenance 5 General maintenance information 337 56358042501 EN 11 ...

Page 350: ...pple on each of the two lift mast bearings 1See the following chapter Maintenance data table under this Code for the respective lubricant specificationThis lubrication plan describes the series production truck with standard equipment For maintenance points on variant trucks see the relevant chap ter and or instructions provided by the manufacturer Maintenance 5 General maintenance information 338...

Page 351: ...s Dimension Insulation resistance DIN EN 1175 VDE 0117 For further informa tion refer to the workshop manual for the truck 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 Uni...

Page 352: ... wheel bearing Multi purpose grease DIN 51825 KPF2 K 30 lithium saponi fied ID no 0163488 Fill with grease AE80 02 drive axle Code Unit Operating materials Specifications Dimension System contents incl service brake Gearbox oil SAE 80W 90 API GL4 For further informa tion refer to the workshop manual for the truck in question ARAL EP Plus 80W 90 BP Energear HT 80W 90 Castrol Syntrax Uni versal 80W ...

Page 353: ...fications Dimension C Lubrication High load chain spray Fully synthetic Temperature range 35 C to 250 C ID no 0156428 As required Cooling system power electronics hydraulic oil Code Unit Operating materials Specifications Dimension System filling Corrosion inhibitor and cooling system protecting agent water 40 coolant 60 water for frost pro tection down to 25 C VW G12 plus violet TL VW 774 F Appro...

Page 354: ...k of short circuit if cables are damaged Check the connecting cables for damage When removing and reinstalling the bottom plate make sure that the connecting cables are not damaged CAUTION Placing the bottom plate on top of the rubber edging strip can cause damage to the rubber edging strip Do not place the bottom plate on top of the rubber edging strip NOTE The bottom plate has a recess that the ...

Page 355: ...nd place in a safe loca tion Installing the bottom plate WARNING Risk of crushing between bottom plate and frame edge If limbs or objects are between the bottom plate and frame edge when the bottom plate is closed they can be crushed When closing the bottom plate ensure that there is nothing between the bottom plate and the edge of the chassis CAUTION Placing the bottom plate on top of the rubber ...

Page 356: ...avy objects strong winds or other persons There must be no objects on the cover when you open it Make sure that the cover is not being pushed down by strong winds or other persons Release the quick release clamp 3 with a 1 4 revolution Swivel the cover 2 upwards The cover is held in the opened position by the gas spring Closing the cover WARNING Risk of crushing between cover and frame edge If lim...

Page 357: ... not lean or step on the exhaust air grille Do not place any objects on the exhaust air grille Removing the rear cover Unscrew five screws 3 from the rear cover 1 Remove the rear cover 1 Attaching the rear cover Make sure that the top rubber seal of the exhaust air funnel is properly secured Attach the rear cover 1 Screw the rear cover into place with five screws 3 2 3 7341_003 007 1 2 3 3 6341_00...

Page 358: ...rheating A cooling system protects the power electronics and the hydraulic oil against overheating Loss of coolant from leaking coolant hoses or from the radiator re duces the cooling capacity and can cause compo nents to overheat If the cooling fluid level is low this indicates leakages in the cooling system Check the cooling system for leak tightness Remove the cover on the left hand side Pull t...

Page 359: ...sk of scalding due to hot cooling fluid The cooling system is pressurised Opening the cool ing fluid tank may result in hot cooling fluid leaking out Only open the cooling fluid tank when the cool ing system is cool Switch off the truck and leave it to cool down Do not open the cooling fluid tank until the truck has cooled down WARNING Coolant and cooling fluid can pose a hazard to health and the ...

Page 360: ...age can be in creased to 60 The coolant percentage must not exceed 60 If the coolant percentage is above 60 the frost protec tion is reduced and the cooling effect is diminished Only use clean softened water for the water per centage CAUTION Coolant with a different specification must not be mixed in Only use coolant as set out in the maintenance data table to top up the tank Frost protection up t...

Page 361: ...el is below the lower marking top up the cooling fluid to no high er than the upper marking Screw the tank cap 3 back on tightly Slide the coolant tank 2 back into position until the locking pin 1 engages Fit the cover on the left hand side min max 6341_003 024 3 4 5 2 1 Maintenance 5 Preserving operational readiness 349 56358042501 EN 11 ...

Page 362: ...n the cooling system Check the cooling system for leak tightness Park the truck securely Remove the cover on the left hand side Check the cooling fluid level Remove the rear cover and clean the ex haust air grille Clean the radiator grille 1 the exhaust air funnel 2 and the water drain 3 using a suitable brush or blow them out using com pressed air max 2 bar To clean the radiator behind 4 unscrew ...

Page 363: ...NOTE Make sure that the radiator grille is screwed tightly into place Fit the rear cover Fit the cover on the left hand side Maintenance 5 Preserving operational readiness 351 56358042501 EN 11 ...

Page 364: ...nse away spilt battery acid immedi ately using plenty of water CAUTION Damage to the battery possible Follow the information in the operating instructions for the battery The battery must be removed for servicing if necessary change the truck battery Keep away from open flames and do not smoke Always ensure adequate ventilation in the vicinity Expose the surfaces of the battery cells Do not place ...

Page 365: ...l clips 2 to a torque of 22 25 Nm depending on the size of the terminal screws used Check the acid density using an acid si phon After charging this value must lie between 1 28 1 30 kg l For a discharged battery the acid density must not be less than 1 14 kg l Close the filler cap 1 again When using PowerPlusLife batteries Make sure that when cleaning or when fill ing up with liquid none of the li...

Page 366: ...t in the filter hous ing and fresh air inlet Insert the filter insert back into the filter housing Ensure that the filter insert sits correctly and precisely in the filter housing Attach the cover and lock the quick release clamp Lubricating the joints and con trols Oil or grease other bearings and joints ac cording to the maintenance data table Driver s seat guide In the cab lubricate door hinges...

Page 367: ...lt Only have a defective belt replaced by your serv ice centre Only use genuine spare parts Do not make any changes to the belt NOTE Carry out the following checks on a regular basis monthly In the case of significant strain a daily check is necessary Checking the seat belt 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 w...

Page 368: ...elt 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 ...

Page 369: ...ling Completely remove the filter mat 3 from the filter housing Check the filter mat for contamination and beat out NOTE Replace the filter mat when it is clearly grey but at least every two months Remove any dirt that has collected in the fil ter housing and recirculated air inlet Re insert the filter mat into the filter hous ing Make sure that the filter mat sits correctly and accurately in the ...

Page 370: ...cturer WARNING Risk to stability Tyre quality affects the stability of the truck There is a risk of tipping When using pneumatic tyres or solid rubber tyres rim wheel parts must never be changed and rim wheel parts from different manufacturers must not be mixed Obtain approval from the truck manufacturer be fore using a different type of tyre or a different tyre manufacturer Checking condition and...

Page 371: ...pressure NOTE The correct air pressure for pneumatic tyres variant is determined by the type of tyre used The air pressure measured must corre spond to the manufacturer s information Observe the air pressure value indicated on the adhesive label 1 on the truck Check the air pressure of all four tyres and compare with the air pressure values stated on the adhesive labels Add or release air as requi...

Page 372: ...injuries and cause fires in the electrical system There is also a risk of fire if fuses are bridg ed or repaired Fuses with the wrong nominal current can cause short circuits Park the truck securely and de energise Do not bridge or repair fuses Use only fuses with the prescribed nominal cur rent see the chapter entitled Fuse assignment See the chapter entitled Working on the electrical equipment N...

Page 373: ...ce centre as necessary Open the front right cover Open the cover fastenings 1 and remove the cover Replace the defective fuse with nominal current according to Fuse assignment front fuse box Close the cover to secure the fuse box Close the front right cover Perform a function check If the error per sists or if the fuse is still defective notify your authorised service centre 6341_003 030 1 1 1 1 1...

Page 374: ...nt according to Fuse assignment rear fuse box Close the cover to secure the fuse box Attach the left side cover Perform a function check If the error per sists or if the fuse is still defective notify your authorised service centre Checking the hydraulic oil level CAUTION Hydraulic oils are hazardous to health and are pres surised during operation Note the safety regulations in the Hydraulic fluid...

Page 375: ...1 3550 6849 3550 5249 4205 4654 6850 8449 4770 5819 5250 6449 4655 5704 2 8450 8850 5820 9270 6450 8850 5705 9755 Determine which lift mast is fitted to the truck Use the table to determine which lower mark 1 or 2 is applicable Check the oil level on the oil dipstick The oil level must be between the lower mark 1 or 2 and the top mark max If the oil level is too low Insert a funnel into the filler...

Page 376: ...tness WARNING Hydraulic oil is hazardous to health Hydraulic oil under pressure can escape from leaking pipes and lines and cause injuries Wear suitable protective gloves pro tection goggles etc CAUTION Hydraulic hoses become brittle Do not store hydraulic hoses for more than two years Do not use hydraulic hoses for more than six years if they are subject to normal wear Do not use hydraulic hoses ...

Page 377: ...t residue from the roller track Lubricate the roller tracks 1 of the outside middle and inside mast with a super pres sure adhesion lubricant to reduce wear See Chapter Maintenance data table Page 339 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Greasing the automatic tow cou pling NOTE Wear to moving parts c...

Page 378: ...intenance data table see Chapter Maintenance data table Page 339 Close the coupling by raising the coupling pin with a suitable tool For journeys with a rigid drawbar trailer lu bricate the underside of the tow bar eye and the supporting surface on the coupling Determine the wear on the coupling pin The diameter of the spherical part must not be less than 36 5 mm Model RO 244 A Open coupling 3 732...

Page 379: ...s supporting surface Model RO 245 Lubricate via the points provided for this purpose lubricating nipple opened cou pling in accordance with the maintenance data table see Chapter Maintenance da ta table Page 339 Grease the supporting surface for the tow bar eye Wartung_Rockinger 244 A 1 7321_003 094 Maintenance 5 Preserving operational readiness 367 56358042501 EN 11 ...

Page 380: ...ose lubricating nipple opened cou pling in accordance with the maintenance data table see Chapter Maintenance da ta table Page 339 Grease the supporting surface for the tow bar eye 7321_003 095 Maintenance 5 Preserving operational readiness 368 56358042501 EN 11 ...

Page 381: ...6 1000 hour maintenance annual mainte nance ...

Page 382: ...ers and hydraulic connections repaired by the authorised service centre Checking the fork arms CAUTION Fork arms must not be uneven Always replace both fork arms Check the fork arms 1 for visible deforma tion and excessive wear No cracks or deformations must be visible on the fork arms in the area around the fork bend Wear must not amount to more than 10 of the original thickness Check that the lo...

Page 383: ...ecess on the fork carriage It must not be possible to move the fork arm Replace faulty fork latches 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 1000 hour maintenance annual maintenance 6 Checking the reversible fork arms 371 56358042501 EN 11 ...

Page 384: ...1000 hour maintenance annual maintenance 6 Checking the reversible fork arms 372 56358042501 EN 11 ...

Page 385: ...7 Technical data ...

Page 386: ...Dimensions Fork spacing is adjustable 1 NOTE Measurements h1 h3 h4 h6 and b1 are cus tomised and can be taken from the order con firmation Technical data 7 Dimensions 374 56358042501 EN 11 ...

Page 387: ... centre of gravity S relates to trucks with standard equipment If for exam ple the truck is equipped with a different lift mast attachment or driver protection struc ture this value is only a guide value If neces sary the centre of gravity S must be deter mined on an individual basis for each truck Technical data 7 Dimensions 375 56358042501 EN 11 ...

Page 388: ...ctric Electric Operation Seated Seated Seated Seated Rated capacity load Q kg 6000 7000 8000 8000 Load centre of gravity dis tance c mm 600 600 600 900 Load distance x mm 710 720 720 750 Wheelbase y mm 2285 2285 2285 2285 Weights Model RX60 60 RX60 70 RX60 80 RX60 80 LSP 900 Net weight kg 11 996 12 512 13 369 15 915 Axle load with front load kg 15 842 17 751 19 355 21 549 Axle load with rear load ...

Page 389: ... tilt for wards Degree 5 5 5 5 Lift mast fork carriage tilt backwards Degree 8 8 8 8 Height with lift mast retracted h1 mm 2710 2710 2710 2710 Free lift h2 mm 150 150 150 150 Lift height1 h3 mm 3550 3150 3150 2750 Height with lift mast extended h4 mm 4440 4240 4140 4140 Height above overhead guard h6 mm 2697 2697 2697 2697 Seat height in relation to SIP standing height h7 mm 1719 1719 1719 1719 Co...

Page 390: ...60 80 LSP 900 Driving speed with load km h 14 14 14 14 Driving speed without load km h 17 17 17 17 Lifting speed with load m s 0 36 0 30 0 28 0 28 Lifting speed without load m s 0 48 0 37 0 37 0 37 Lowering speed with load m s 0 56 0 53 0 53 0 53 Lowering speed without load m s 0 52 0 42 0 42 0 42 Tractive force with load N 28788 28674 28468 27997 Tractive force without load N 29023 28936 28767 28...

Page 391: ...y voltage U V 80 80 80 80 Battery capacity K5 Ah 1240 1240 1240 1240 Battery weight kg 2824 2824 2824 2824 Energy consumption1 45 VDI working cycles hour kWh h 12 6 14 5 16 0 17 7 Handling performance t h 348 4 376 1 411 4 420 0 Energy consumption versus handling performance kWh h 15 4 17 5 19 2 19 8 Other Model RX60 60 RX60 70 RX60 80 RX60 80 LSP 900 Working pressure for attach ments bar 250 250 ...

Page 392: ...ription giv en in Article 2 Scope Item 1 a and be cause of the provisions in Article 2 2 h Mo tors in cordless or battery operated equip ment and Article 2 2 o Motors designed specifically for the traction of electric vehicles All variable speed drives in this industrial truck are exempt from Regulation EU 2019 1781 because these variable speed drives do not meet the description given in Article 2...

Page 393: ...quirements 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 reac...

Page 394: ... the information on the nameplate Only use a battery tray that is closed at the bot tom Lead acid batteries NOTE Battery specifications to DIN 43536 cells to DIN EN 60254 2 80 V circuit A The battery weight can be found on the nameplate of the battery Battery designation Capacity Ah Battery compartment dimensions mm Tray Depth Width Height 7 PzS 1085 PowerPlusLife 1085 1037 1287 784 238 8 PzS 1120...

Page 395: ... used Depending on the battery type used the preset maximum speed must be adapted by the authorised service centre If the maximum speed is not adapted it can lead to technical faults in drive mode Contact your authorised service centre Technical data 7 Battery specifications 383 56358042501 EN 11 ...

Page 396: ...ruck Fuse assignment Front fuse box Power Distribution Unit and 80 V technology SU control unit MCU control unit 10 A Not assigned Heating system 30 A Reserve 20 A F11 9F5 9F16 F10 Not assigned Voltage transformer U1 10 A Voltage transformers U2 and U3 15 A Voltage transformers U4 and U5 15 A F14 F15 9F17 9F18 Technical data 7 Fuse assignment 384 56358042501 EN 11 ...

Page 397: ...ion board 10 A Front CPP control unit 20 A Not assigned Not assigned 1F16 9F03 5F12 9F32 9F33 Roof CPP control unit 30 A Seat CPP control unit 30 A Cooling pump 10 A Signal horn 10 A Cooling fan 20 A 5F11 5F13 1F10 4F01 9F34 Technical data 7 Fuse assignment 385 56358042501 EN 11 ...

Page 398: ...Technical data 7 Fuse assignment 386 56358042501 EN 11 ...

Page 399: ... 202 Controlling with fingertip 212 Controlling with fingertip and 5th func tion 213 Controlling with Joystick 4Plus and the 5th function 211 General controlling 196 Load capacity 193 Mounting 193 Releasing the pressure from the con nections 194 Safety information 191 Special risks 42 Taking up a load 218 Automatic lift cut out 149 Automatic tow coupling 247 Coupling RO 243 249 Coupling RO 244 A 2...

Page 400: ...id 51 Contact details I Coolant Checking the level 346 Coolant and cooling fluid 53 Cooling fluid 347 Topping up 347 Copyright and trademark rights 22 Coupling pin in the counterweight 245 Crane loading 317 Determining the loading weight 318 Hooking on the lifting straps 318 Curve Speed Control 144 D Damage 36 Danger area 178 Danger to employees 46 Declaration of conformity 6 Defects 36 Defining t...

Page 401: ...4 F Filling the washer system 227 Fingertip 69 Lifting lowering the fork carriage 165 Tilting the lift mast 165 Fitting attachments 191 FleetManager 228 Shock recognition 228 Foreword 0 Fork arms Length 39 Fork extension 168 Four way mini lever 67 Lifting lowering the fork carriage 161 Front right cover Closing 344 Opening 344 Fuse assignment 384 12 V technology 385 80 V technology 384 Front fuse ...

Page 402: ...curing against falling off 329 Securing against tilting backwards 328 Lift mast versions Triplex lift mast 155 Lift mast vertical position 150 Automatic approach 152 Calibrating 154 Description 150 Display 151 Possible restrictions 153 Run in to end stops 152 Tilting the lift mast backwards 153 Tilting the lift mast forwards 152 Lighting STILL SafetyLight 226 Switching on and off 220 List of abbre...

Page 403: ...Misuse of safety systems 36 MSG 65 MSG 75 driver s seat Adjusting 78 Adjusting the backrest extension 81 Adjusting the lumbar support 81 Adjusting the seat backrest 79 Adjusting the seat suspension 80 Moving 79 Switching the seat heater on and off 82 N Nameplate 12 Nameplate of a lithium ion battery 14 Neutral position 132 O Oils 50 Opening the cab door 236 Opening the side windows 237 Operating 0...

Page 404: ...risk 41 Residual risks 41 Retrofitting 33 Reversible fork arm Checking 371 Reversible fork arms 170 Roadways 127 129 Dimensions of aisle widths 127 Rotating beacon 221 Rules for roadways and the working area 129 S Safety 0 Safety devices 327 Safety inspection 48 Safety regulations Consumables 50 Safety regulations for maintenance General information 326 Safety devices 327 Set values 327 Working on...

Page 405: ...allets 179 Transporting suspended loads 179 Triple mini lever Tilting the lift mast 160 Turn indicators 222 Mini console version 223 Mini lever version 222 Types of lift mast 154 Telescopic mast 154 Tyres Safety principles 37 U Units 25 Unlocking the emergency off switch 85 Using the truck 16 Using working platforms 19 V Variant Ceiling sensor 230 Variants Access authorisation with PIN code 99 Aut...

Page 406: ...of the truck 328 Working on the electrical equipment 326 Working on the hydraulic equipment 326 Working spotlight for reverse travel Switching on and off 221 Working spotlights Automatically switching on off 225 Lift height controlled switching on off 225 Manually switching on off 224 Switching on and off 220 224 Y Your truck 2 Z Zero adjustment of the load measurement 95 Index 394 56358042501 EN ...

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Page 408: ...STILL GmbH 56358042501 EN 11 ...

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