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Still RX70-40, Original Instructions Manual

The Still RX70-40 is a top-quality material handling machine equipped with advanced features for efficient performance. To ensure optimal use, it is important to refer to the Original Instructions Manual. Visit our website to freely download the comprehensive manual and unlock the full potential of your Still RX70-40.

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Table of contents

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Ceiling sensor (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Air conditioning (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Changing the LPG cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Changing the LPG cylinder in a double-cylinder holder . . . . . . . . . . . . . . . . . . . . . . . . 280
Filling the LPG tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Disconnecting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

VIII

57348011850 EN - 02/2019 - 11

Summary of Contents for RX70-40

Page 1: ...Original instructions LPG trucks RX70 40 RX70 45 RX70 50 7335 7336 7337 7338 57348011850 EN 02 2019 11 ...

Page 2: ......

Page 3: ...es of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for the safe operation of industrial trucks Information on the use of industrial trucks Information on transport initial commis sioning and storage of industrial trucks Internet address an...

Page 4: ......

Page 5: ...ocumentation 13 Documentation scope 13 Supplementary documentation 14 Issue date and topicality of the operating instructions 15 Copyright and trademark rights 15 Explanation of information symbols used 15 List of abbreviations 16 Definition of directions 18 Schematic views 18 Environmental considerations 20 Packaging 20 Disposal of components and batteries 20 2 Safety Definition of terms used for r...

Page 6: ...ruck 40 Carrying out regular safety inspections on the LPG system 40 Regularly checking the level of harmful substances in the exhaust gas 41 Insulation testing 42 Safety regulations for handling consumables 43 Permissible consumables 43 Oils 44 Hydraulic fluid 45 Battery acid 46 LPG 47 Coolant and cooling fluid 50 Disposal of consumables 50 Emissions 52 3 Overviews Truck overview 56 Overview of dri...

Page 7: ... shut off valve 101 Starting the engine 103 Checking the brake system for correct function 104 Checking the steering system for correct function 105 Checking the emergency off function 105 Zero adjustment of the load measurement variant 106 Checking the vertical lift mast position variant for correct function 107 Filling the washer system 108 Cleaning the dust valve 109 Operating the display opera...

Page 8: ...ients 142 Reducing speed with a raised load variant 143 Automatic shut off of the internal combustion engine variant 143 Parking 144 Parking the truck securely and switching it off 144 Wheel chock variant 146 Lifting 147 Lifting system variants 147 Automatic lift cut out variant 147 Lift mast vertical position variant 148 Types of lift mast 152 Malfunctions during lifting mode 153 Hydraulic blocki...

Page 9: ...ling attachments using the quadruple mini lever and the 5th function 206 Controlling attachments via the joystick 4Plus 208 Controlling attachments using the joystick 4Plus and the 5th function 209 Controlling the attachments with the fingertip 210 Controlling attachments with the fingertip and 5th function 211 Clamp locking mechanism variant 213 Taking up a load using attachments 216 Auxiliary equi...

Page 10: ...c tow coupling 247 Towing trailers 255 Display messages 257 Display content 257 Error code table 257 General messages 260 Drive specific messages 269 Refuelling 277 Changing the LPG cylinder 277 Changing the LPG cylinder in a double cylinder holder 280 Filling the LPG tank 282 Procedure in emergencies 285 Emergency shutdown 285 Procedure if truck tips over 286 Emergency hammer 287 Emergency lowerin...

Page 11: ...tenance 314 Maintenance 1000 hours annually 317 Maintenance 3000 hours every two years 321 Maintenance instructions 323 Ordering spare parts and wearing parts 323 Quality and quantity of the required operating materials 323 Lubrication plan 324 Maintenance data table 325 Providing access to maintenance points 328 Opening the side service flap 328 Closing the side service flap 329 Opening the bonnet ...

Page 12: ... 351 Other tasks 353 1000 hour maintenance yearly maintenance 354 Cleaning the radiator checking for leaks 354 Checking the reversible fork arms 354 Checking the fork arms 355 Checking the hydraulic oil level 355 Checking the lift cylinders and connections for leaks 357 Checking the hydraulic system for leak tightness 357 6 Technical data Dimensions 360 VDI datasheet 362 Wheels and tyres 365 Fuse ...

Page 13: ...1 Foreword ...

Page 14: ...nossenschaftliche Vorschrift German accident prevention regulations CE Communauté Européenne Confirms conformity with product specific European directives CE mark CEE Commission on the Rules for the Approval of the Electrical Equipment International commission on the rules for the approval of electrical equipment DC Direct Current Direct current DFÜ Datenfernübertragung Remote data transmission DIN ...

Page 15: ...umber 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 VDE Verband de...

Page 16: ...and help to avoid accidents and to keep the truck ready for operation beyond the warranty period Therefore Before commissioning the truck read the operating instructions and follow the instructions Always follow all of the safety information contained in the operating instructions and on the truck CE Symbol CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with t...

Page 17: ...13 Hamburg Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH 57348011850 EN 02 2019 11 5 ...

Page 18: ...1 Foreword Your truck Accessories overview Key for key switch 2 pieces Key for cab variant Hexagon socket wrench for emergency lowering 6 57348011850 EN 02 2019 11 ...

Page 19: ...nt on both sides of the truck 10 Decal information Armrest adjustment 11 Decal information Lifting gear attachment points 12 Decal information Caution Read the operating instructions Fasten seat belt Apply parking brake when leaving the truck Passengers are not allowed Do not jump off if the truck is tipping over Lean in the opposite direction to which the truck is tipping 13 Decal information Cap...

Page 20: ...weight in kg 7 Ballast weight in kg 8 Address of manufacturer 9 Refer to the technical data listed in these operating instructions for more detailed information 10 CE labelling 11 Nominal drive power in kW 12 Battery voltage in V 13 Rated capacity in kg Nameplate The truck can be identified from the informa tion on the nameplate The information for the battery weights 5 6 and the ballast weight 7 o...

Page 21: ...ructions is suitable for lifting transporting and stacking loads The truck may only be used for its proper purpose as set out and described in these operating 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 a...

Page 22: ...TE Please observe the definition of the following responsible persons operating company and driver Use for purposes other than those described in these operating instructions is prohibited DANGER There is a risk of fatal injury from falling off the truck while it is moving It is prohibited to carry passengers on the truck The truck may not be operated in areas where there is a risk of fire explosion...

Page 23: ...rom the Tropics to Nordic regions temperature range 12 C to 40 C This truck is not designed to be operated in cold stores The operating company must ensure that suitable fire protection is available for the rel evant 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 ob...

Page 24: ...ing platforms is regulated by na tional 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 national regulatory authorities 12 57348011850 EN 02 2019 11 ...

Page 25: ...r requirements UPA are documented in separate operating instructions If you have any questions please contact your authorised service centre Enter the production number and year of manufacture from the nameplate in the space provided Production number Year of manufacture Please quote the production number in all technical enquiries Each truck comes with a set of operating instructions These instru...

Page 26: ...ase contact the authorised service centre Supplementary documentation This industrial truck can be fitted with un planned equipment UPA that deviates from the standard equipment and or the variants The UPA may be for example Special sensors Special attachments Towing devices Customised attachments In this case the industrial truck has additional documentation This may be in the form of an insert or...

Page 27: ...cannot be asserted Please contact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts except with the express written approval of the manufacturer Explanation of information symbols used DANGER Indicates procedures that must be stric...

Page 28: ...G Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations CE Communauté Européenne Confirms conformity with product specific European directives CE mark CEE Com...

Page 29: ... backs MAK Maximum workplace concentration Maximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without lo...

Page 30: ...the front Schematic views 6210_003 062 View of functions and operations This documentation explains the usually sequential chain of certain functions or oper ations Schematic diagrams of a counterbal ance truck are used to illustrate these proce dures NOTE These schematic diagrams are not represen tative of the structural state of the documented truck The diagrams are used solely for the purpose o...

Page 31: ...ting statuses and values in the display of the display operating unit are examples and partly dependent on the truck equipment As a result the displays shown of the actual operating statuses and values can vary Information that is not relevant for descriptions is not shown 57348011850 EN 02 2019 11 19 ...

Page 32: ...operly after delivery of the truck Disposal of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispo sing of batteries ENVIRONMENT NOTE...

Page 33: ...2 Safety ...

Page 34: ...service engineer or a person who fulfils the following requirements A completed vocational qualification that demonstrably proves their professional expertise This proof should consist of a vocational qualification or a similar document Professional experience indicating that the qualified person has gained practical experience of industrial trucks over a proven period during their career During this ...

Page 35: ... been trained in accordance with BGG General Employers Liability Insurance Association Act 925 Observe the national regulations for your country Driver rights duties and rules of be haviour The driver must be trained in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety helmet industrial goggles and ...

Page 36: ... of the aforementio ned substances are not permitted to perform work of any kind on or with the truck Prohibition of use by unauthorised persons The driver is responsible for the truck during working hours He must not allow unautho rised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key 24 57348011850 EN 02 2019 11 ...

Page 37: ...ndling 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 modified with prior written approval from the manufacturer Brakes Steering Operating devices Safety systems Equipment variants Attachments The...

Page 38: ...er than 1800 mm At lift heights of 1800 mm and above only use the truck in conjunction with an overhead guard The operating company is only permitted to make modifications to the truck independently if the manufacturer goes into liquidation and the company is not taken over by another legal person The operating company must also fulfil the following prerequisites Design documents test documents and ...

Page 39: ...falling loads or the truck tipping over may result in buckling of the modified overhead guard and no protection for the driver Do not perform welding on the overhead guard Do not perform drilling on the overhead guard CAUTION Heavy roof loads damage the overhead guard To ensure the stability of the overhead guard at all times a roof load may only be mounted on the overhead guard if the structural d...

Page 40: ...e the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g connecting a radio additional headlights etc is only permitted with the manufacturer s written...

Page 41: ...tors can lead to a loss of stability and are therefore prohibited Different tyres on the same axle e g pneumatic tyres and superelastic tyres Tyres not approved 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 ensure stability Only use tyres with equal and permit...

Page 42: ...superelastic tyres to pneu matic tyres the load diagram must be changed accordingly Contact the authorised service centre on this matter Medical equipment WARNING Electromagnetic interference may 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 ...

Page 43: ...tempe ratures over 80 C and heavy contamination Damaged or defective gas springs must be changed immediately Contact the authorised service centre WARNING Accumulators are under high pressure Improper installation 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 DAN...

Page 44: ...principles for safe operation picked up These other loading units then fall over when the load is raised For help with selecting the correct fork arms contact the authorised service centre 32 57348011850 EN 02 2019 11 ...

Page 45: ...dent or breakdown etc WARNING All persons that are in the vicinity of the truck must be instructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regulati ons in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gra...

Page 46: ...t operation and losing stability can never be excluded The loss of stability can be avoided or min imised by the following actions Always secure the load against slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as centrally as possible with the truck and transport in thi...

Page 47: ... time the truck is used in a manner that falls outside the scope of normal use and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci dents 57348011850 EN 02 2019 11 35 ...

Page 48: ...ly for authorised persons O Truck not in a safe condition Recurrent testing and rectification of defects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when using working platforms Compliance with national regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability insurance associations Impaired visibility ...

Page 49: ...labour protection law ArbSchG Impermissible usage improper usage Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O When fuelling a Diesel Note the German Ordinance on Industrial Safety and Health BetrSichV the operating instructions and the German Engineering Federation VDMA rules O b LPG Note German So...

Page 50: ...dustrial Safety and Health BetrSichV employers liability insurance association regulation 104 and the operating instructions O German Ordinance on Industrial Safety and Health BetrSichV and employers liability insurance association regulation 104 With driverless transport systems Roadway quality inadequate Clean clear driveways O German Ordinance on Industrial Safety and Health BetrSichV Load carr...

Page 51: ...hazard assessment At tachments possess their own CE labelling and likewise are not included for that reason The operating company must however select the type and equipment of the trucks so as to com ply with the local provisions for deployment The result must be documented 6 Arb SchG In the case of truck applications involv ing similar hazard situations the results may be summarised This overview...

Page 52: ... The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe guidelines for checks carried out on the truck in accordance with FEM 4 004 The operator is responsible for ensuring any defects are remedied without delay Contact your service centre NOTE Observe the national regulations for your country C...

Page 53: ...be retained until the next inspection The inspec tion documents must be available for viewing by the authorities at any time The type and scope of tests may differ accord ing to the country Any differing legal provi sions in the respective country of operation must be observed when using trucks with an LPG system The operating company is responsible for ensuring any defects are remedied without de...

Page 54: ... lation resistance For this reason insulation testing in accordance with DIN EN 1175 and DIN 43539 VDE 0117 and VDE 0510 must be conducted at least once every year NOTE Contact your service centre to arrange for an insulation test Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage test voltage 500 V Ensure that all voltage sources have been disconnected from ...

Page 55: ...opane concentration of max 95 LPG with a butane concentration of max 80 and a propane concentration of at least 20 NOTE The authorised service centre will need to adjust the engine control unit for a butane concentration of 70 or more The LPG quality must comply with the re quirements of DIN 51622 as a minimum The quality is optimum when the LPG complies with the requirements of EN 589 automotive ...

Page 56: ...r and then consult an eye specialist If swallowed do not induce vomiting Seek immediate medical attention WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There i...

Page 57: ...t spill the fluids Follow the statutory regulations Do not allow the fluids to come into contact with hot engine parts WARNING These fluids are pressurised during operation of the truck and are hazar dous to your health Do not allow the fluids to come into contact with the skin Avoid inhaling spray Penetration of pressurised fluids into the skin is particularly danger ous if these fluids escape at high ...

Page 58: ...battery acid at all costs In case of injury seek medical advice immediately WARNING Battery acid contains dissolved sulphuric acid This is corrosive When working with battery acid use appropriate PSA rubber gloves apron protection goggles When working with battery acid never wear a watch or jewellery Do not allow any acid to get onto clothing or skin or into the eyes If this does happen rinse imme...

Page 59: ...the outside temperature and can reach up to 25 bar or more NOTE In these operating instructions liquid gases are called LPG DANGER Risk of explosion LPG immediately becomes gaseous when it escapes meaning that a hazardous explosive atmosphere is created immediately Use only anti static treated tools that do not produce sparks Anti static clothing and footwear are recommended DANGER Risk of fire No ...

Page 60: ... cavities drains without liquid seals ventilation shafts and light wells or combustible material 7311_003 038 1 Safe use of LPG trucks The LPG system must be checked for dam age and leaks at least once a year by a person qualified in LPG systems see Chapter Car rying out regular safety inspections on the LPG system P 2 40 The LPG system is subject to prescribed maintenance intervals that must be ob...

Page 61: ...s or in their immediate vicinity not on steps of outdoor installations not in specially marked escape routes not in garages not in work rooms NOTE Please observe the section entitled General requirements for pressurised gas containers Operating pressurised gas containers in the technical regulations for pressurised gas containers TRG 380 and 404 in addition to your relevant national guidelines Ele...

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

Page 63: ...Safety 2 Safety regulations for handling consumables Neutralise any spilt battery acid immedi ately Always observe national regulations con cerning the disposal of used oil 57348011850 EN 02 2019 11 51 ...

Page 64: ... emission values Weighted effective value of acceleration to which the body feet or seat surface is subjected 0 6 m s2 Uncertainty K 0 18 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or on the controls in the truck is less than 2 5 m s 2 There are therefore no measurement guidelines for these measurements The personal vibration load on the drive...

Page 65: ...r components that carry exhaust gases e g exhaust pipes can become so hot that direct body contact can cause burns to the skin and materials that are too close can be burned or singed Do not grasp or touch hot exhaust pipes Keep combustible materials away from the exhaust pipe In the event of burns seek first aid immediately If materials start to burn take fire protection measures immediately 573480...

Page 66: ...2 Safety Emissions 54 57348011850 EN 02 2019 11 ...

Page 67: ...3 Overviews ...

Page 68: ...ew Truck overview 7335_003 001 1 2 7 4 5 6 8 9 10 3 1 Lift mast 2 Overhead guard 3 Driver s compartment 4 LPG tank 5 Towing device 6 Steering axle 7 Bonnet 8 Drive axle 9 Fork arms 10 Fork carriage 56 57348011850 EN 02 2019 11 ...

Page 69: ...for the operating instructions 6 Operating devices for hydraulic and drive functions 7 Compartment 8 Bottle holder for max 1 5 l bottles 9 Driver s seat 10 Compartment 11 Filler cap for windscreen washer reservoir 12 Accelerator pedal 13 Brake pedal 14 Steering column adjustment lever NOTE The truck equipment may differ from the equipment shown 57348011850 EN 02 2019 11 57 ...

Page 70: ...y 19 Interior lighting display 20 Rear window heating display 21 Interior light rotating beacon button 22 Rear window heating particle filter regener ation button 23 Menu change button 24 Lighting button 25 Blue Q button 26 Rear window wiper button NOTE Buttons 5 21 22 and the accompanying display elements 6 17 18 19 20 are assigned according to the installed equipment variant The assignment shown ...

Page 71: ... devices and display elements The truck can be equipped with the following operating devices Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip switch Mini console 57348011850 EN 02 2019 11 59 ...

Page 72: ... Function key F2 4 Drive direction turn indicator cross lever 5 Function key 5th function 6 Attachments cross lever 7 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 2 and 3 For alterations contact the authorised service centre 60 57348011850 EN 02 2019 11 ...

Page 73: ...ve direction turn indicator cross lever 5 Function key 5th function 6 Auxiliary hydraulics 1 operating lever 7 Auxiliary hydraulics 2 operating lever 8 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 2 and 3 For alterations contact the authorised service centre 57348011850 EN 02 2019 11 61 ...

Page 74: ...on key F2 5 Drive direction turn indicator cross lever 6 Function key 5th function 7 Auxiliary hydraulics 1 operating lever 8 Auxiliary hydraulics 2 operating lever 9 Signal horn button NOTE Depending on the specification various electric attachment parts can be controlled via function keys 3 and 4 For alterations contact the authorised service centre 62 57348011850 EN 02 2019 11 ...

Page 75: ...e basic hydraulic functions 3 Pictograms for the 5th hydraulic function and the clamp locking mechanism variant 4 Pictograms for the 3rd 4th hydraulic functions 5 LED for clamp locking mechanism variant 6 Slider for the 4th hydraulic function e g reach frame forwards backwards 7 Vertical rocker button for the drive direction 8 Shift key F 9 Signal horn button 57348011850 EN 02 2019 11 63 ...

Page 76: ...on 5 Right turn indicator button 6 Function key 5th function 7 Attachments operating lever 8 Attachments operating lever 9 Tilt operating lever 10 Lift lower operating lever 11 Drive direction switch NOTE Depending on the specification various electric attachment parts can be controlled via function keys 1 and 2 For alterations contact the authorised service centre 64 57348011850 EN 02 2019 11 ...

Page 77: ...ng devices and display elements 7311_003 056 1 2 1 Travel direction switch 2 Direction indicator switch Mini console The mini console is located on the steering column below the steering wheel 57348011850 EN 02 2019 11 65 ...

Page 78: ...3 Overviews Operating devices and display elements 66 57348011850 EN 02 2019 11 ...

Page 79: ...4 Operation ...

Page 80: ... 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 accessories Perform a visual inspection to check for deformation and wear e g to check if th...

Page 81: ...is working correctly Check the close function and close the cover Coupling pin tow coupling variant Perform a visual inspection for deformation and wear for example bent torn broken Check the securing bush in the counterweight for integrity and that it is working correctly Check that the linchpin is present and working correctly chain rope split pin Labelling adhesive label Check for presence inte...

Page 82: ...serve the safety regulations in the section entitled Tyres Axle Make sure that no consumables are escaping from the axle Engine Check the engine oil level Top up if necessary Check the cooling fluid level Top up if necessary Do not use the truck if there is any damage or defects Contact your authorised service centre Checking the side cover is locked Check whether the side cover is locked see Chapt...

Page 83: ...ruck WARNING Risk of injury when jumping out of the truck If your clothing or jewellery e g watch ring etc becomes stuck on a component while you are jumping out of the truck this can lead to serious injuries e g from falling loss of fingers etc It is forbidden to jump out of the truck Do not jump out of the truck Do not wear jewellery at work Do not wear loose fitting workwear CAUTION Components ma...

Page 84: ...he handle 1 with your left hand and hold on Stand up from the driver s seat and place your left foot on the step 4 Climb out of the truck right foot first Climbing into and out of a truck with a raised driver s cab WARNING Risk of injury when climbing into and out of the truck due to slipping striking parts of the truck or becoming stuck If the footwell cover is very dirty or smeared with oil there...

Page 85: ...f the truck and may be damaged due to misuse Only use the fittings specifically designed for the purpose of climbing into and out of the truck If the truck is equipped with a raised driver s cab the driver s compartment is significantly higher than that of a standard truck For this reason particular care must be taken when climbing into and out of the truck The following section describes the best pr...

Page 86: ...r right foot on the bottom step 5 Place your left foot on the ground and climb down from the truck 7331_344 001 1 2 3 1 Shelves and cup holders WARNING Objects may fall into the footwell and obstruct the pedals which poses a risk of accident Objects to be stored must be of the correct size so that they do not fall from the shelves 1 or out of the cup holder 2 Objects that fall into the footwell du...

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

Page 88: ...eat is securely engaged 7094_003 008 2 Adjusting the seat backrest Do not put pressure on the seat backrest while engaging it Lift and hold the lever 2 Push the seat backrest into the desired position Release the lever Ensure that the seat backrest is securely engaged NOTE The backwards tilt angle of the seat backrest can be restricted by the structural condition of the truck 76 57348011850 EN 02 ...

Page 89: ...th electric air suspension that is activated using an electric switch instead of the lever 3 Fully extend the weight adjusting lever 3 Pump it up or down to set the driver s weight Return the weight adjusting lever to the central initial position before each new lift audible click Fully fold in the weight adjusting lever once adjustment is complete NOTE The driver s weight has been selected cor re...

Page 90: ...t moves a convex support cushion into the upper or lower part of the backrest Turn the turning knob 5 up or down until the lumbar support is in the desired position 6321_003 040 6 Adjusting the backrest extension variant Adjust the backrest extension 6 by pulling it out or pushing it into the desired position To remove the backrest extension move it past the end stop by jolting it upwards 78 57348...

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

Page 92: ...eel by turning it clock wise Check that the armrest is firmly attached 6210_424 001 1 2 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 steering column adjustme...

Page 93: ...1 Pull out the emergency off switch 1 until it unlatches Switching on the key switch WARNING Before switching on the key switch all tests prior to commissioning must be performed without any defects being detected Perform tests prior to commissioning Do not operate the truck if defects have been detected Notify the authorised service centre 57348011850 EN 02 2019 11 81 ...

Page 94: ...ily use 7090_001 002 0 I 1 Insert the switch key 1 into the key switch and turn to position I 7312_003 085 This initiates a self test All lamps in the drive direction and turn indicator displays light up briefly 82 57348011850 EN 02 2019 11 ...

Page 95: ...y field The EMPTY message will only appear flashing in the display field shortly before the gas runs out 2 Drive programme The current drive programme 1 5 appears in the display field 3 Operating hours The operating hours appear in the display field 4 Time The current time appears in the display field NOTE Have all repair and maintenance work perfor med by an authorised service centre This is the only w...

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

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

Page 98: ...ered the message INVALID appears for a short time When the message goes out the driver PIN can be re entered 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three invalid entry attempts the mes sage CODE DENIED appears The input is then locked for five minutes before another attempt can be made 86 57348011850 EN 02 2019 11 ...

Page 99: ...enu 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 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the four digit password factory ...

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

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

Page 102: ...ODE submenu the message INVALID will appear The message will then disappear after a short time The new driver PIN can be entered in the CONFIRM submenu for further confirma tion 8 9 6 7 4 2 0 1 3 5 BQ_024_en_V2 After three incorrect entries the CODE DE NIED message appears The display switches back to the ACCESS CODE menu The desired driver PIN must be re defined 90 57348011850 EN 02 2019 11 ...

Page 103: ...TE The password can only be changed when the parking brake is applied Push the drive program selection button 1 and the menu change button 2 at the same time 8 9 6 7 4 2 0 1 3 5 1 2 BQ_030_en_V2 1 2 6 7 3 4 5 ESC PASSWORD appears in the display Enter the current password using the buttons 1 Confirm the input using Softkey 2 57348011850 EN 02 2019 11 91 ...

Page 104: ... 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 3 4 BQ_033_en 2 1 PASSWORD PASSWORD LEVEL appears in the display Use the drive program selection button 1 and the menu change button 4 to select the desired PASSWORD LEVEL 2 Confirm your selection using Soft key 3 92 57348011850 EN 02 2019 11 ...

Page 105: ...pendently The authorisations can only be reset by the autho rised service centre Enter the new desired password using the buttons 1 The digits entered are shown in plain text in the NEW CODE field 4 Confirm your selection 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 switches back to PASS WORD PASSWORD LEVEL ...

Page 106: ...on to overtake Seat belt DANGER Even when using an approved restraint system there is some residual risk that the driver might be injured if the truck tips over This risk of injury can be reduced through the combined use of the restraint system and the seat belt In addition the seat belt protects against the consequences of rear end collisions and falling off a ramp We therefore recommend that you...

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

Page 108: ...t tongue slowly back to the retractor NOTE Do not allow the seat belt to retract too quickly The automatic blocking mechanism may be triggered if the belt tongue strikes the housing It will then no longer be possible to pull the seat belt out with the usual force Using increased force pull the seat belt around 10 15 mm out of the retractor to disengage the blocking mechanism Slowly allow the seat ...

Page 109: ...int system only if the cab door is sturdy and closed Fabric covered cabs variant with doors made of plastic or canvas do not consti tute a driver restraint system and offer no protection from the consequences 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 system We recommend that you always use the seat belt O...

Page 110: ...TION Opening the cylinder valve too quickly can lead to the system icing over Open the cylinder valve slowly 7311_136 003 2 1 Open the cylinder valve 1 by slowly turning the star grip handle anti clockwise Check whether the smell of gas is evident Check whether the hose 2 is securely connected to the gas cylinder Check to see whether the hose and connec tion screw joints have iced over 98 57348011...

Page 111: ... Do not start the engine Close the cylinder valve Notify your authorised service centre LPG cylinders should be opened in well ventilated spaces away from openings in the ground DANGER Risk of explosion from spark dis charge Do not use a striking tool when opening and closing WARNING LPG can cause frostbite on the skin Wear protective gloves CAUTION Opening the cylinder valve too quickly can lead ...

Page 112: ...rning it clockwise 1 2 3 4 To open the lower gas cylinder 1 push the lever 2 up Open the cylinder valve 3 of the lower gas cylinder by slowly turning the star grip handle anti clockwise Check the cylinder valve 4 of the upper gas cylinder The valve must be closed If necessary close the valve of the upper gas cylinder by turning it clockwise Check whether the smell of gas is evident Check whether t...

Page 113: ...Chap ter LPG P 2 47 Check whether the smell of gas is evident DANGER Risk of explosion due to escaping LPG Do not start the engine if a leak or smell of gas or other such indications are evident Do not start the engine Contact your STILL service centre Check if the hose 1 is securely connected to the LPG tank DANGER Risk of explosion from spark dis charge Striking tools must not be used for openin...

Page 114: ...tion screw joints have iced over If a leak is detected Do not start the engine Close the shut off valve 2 Contact your supervisor and or STILL service centre 7314_003 011 75 h 2 234 7 12 15 3 The fuel level display 3 variant displays how much LPG is available 102 57348011850 EN 02 2019 11 ...

Page 115: ...n I If the START display lights up turn the switch key to position II and hold in this position until the engine starts Release the switch key as soon as the engine has started If the engine does not start after 20 seconds stop the starting procedure and repeat after one minute CAUTION Risk of engine damage If the OIL PRESSURE message appears on the display after starting the engine there may be i...

Page 116: ...elerate the unladen truck in a clear area Press the brake pedal firmly The truck must decelerate noticeably 6210_342 005 Checking the parking brake DANGER If the truck rolls away there is a risk of being run over and therefore a danger to life The truck must not be parked on a slope In emergencies secure with wedges on the side facing downhill Only leave the truck when the parking brake is applied ...

Page 117: ...tion is removed as soon as the steering wheel is moved out of a cornering position into the straight ahead position This requires a change in steering angle of about half a revolution 6321_003 142 1 Checking the emergency off function WARNING No electric braking assistance is available when the emergency off switch is actuated Actuating the emergency off switch will de energise the entire electric...

Page 118: ... times Zero adjustment is required Before daily use after changing the fork arms after fitting or changing attachments 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 abo...

Page 119: ...lightly 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 symbol 2 is displayed 6210_003 067_V2 2 1 Checking the vertical lift mast position variant for correct function NOTE The function check of the lift mast vertical position variant must be carried out ever...

Page 120: ...aged due to the build up of ice in freezing conditions Always use washer fluid containing anti freeze The windscreen washer reservoir is under the compartment behind the driver s seat The sight glass 1 displays the fill level 7331_341 001 2 1 Open filler cap 2 for the windscreen washer reservoir Fill the windscreen washer reservoir with washer fluid and anti freeze in accor dance with the maintenance ...

Page 121: ...de under the driver s cab see Chap ter Opening the side service flap P 5 328 Press the dust valve 1 on the air filter housing between your fingers until no more dust is emitted Close the service flap on the right hand side under the driver s cab again see Chap ter Closing the side service flap P 5 329 57348011850 EN 02 2019 11 109 ...

Page 122: ...as the engine is started 4 Time Displays the current time digitally in hours and minutes The time can be adjusted see the chapter entitled Setting the time 990h 0 0km 0 0km T 1 2h T 6 7 5 8 9 Additional indicators 5 Menu change button When the menu change button is pressed the following additional indi cators appear 6 Service in indicator Displays the remaining time in hours until the next service...

Page 123: ...ke 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 are adjusted in the CONFIGU RATION menu Turn the key switch to position I Blue Q_029_V2 1 2 Press the drive program button 1 and the menu change button 2 at the same time 57348011850 EN 02 2019 11 111 ...

Page 124: ...e centre 7312_003 056_en_V3 ESC 1 2 3 Press the Softkey 3 The display changes to the CONFIGURA TION menu The following settings are possible and can be found in the corresponding chapter Setting the date and time Resetting the daily kilometres and daily operating hours Setting the language Configure Blue Q Symbols in the display Messages To show operating messages warning messages or error messages...

Page 125: ...r Daily hour meter Daily odometer Speed Steering angle Load Time Hydraulic system Exh gas purifier Coolant temperature Fuel level Blue Q Power rating average Power rating trend Symbols for warning messages Description Symbol Parking brake Actuate seat switch Safety belt Battery acid level Neutral warning message Are you sure Oil pressure 57348011850 EN 02 2019 11 113 ...

Page 126: ...on the left of the display for auxiliary equipment Description Symbol Empty field No display General function OFF General function ON Rear working spotlight OFF Rear working spotlight ON Front working spotlight OFF Front working spotlight ON Windscreen heating OFF Windscreen heating ON Rear window heating OFF Rear window heating ON Interior lighting OFF Interior lighting ON Roof wiper washer OFF Ro...

Page 127: ...ement zero adjustment ON Load measurement OFF Load measurement ON Symbols for softkey functions for menu navigation and for acknowledging messages The following symbols for the softkey functions are used on the left of the display for menu navigation and to acknowledge messages Description Symbol Empty field No display Cancel input Confirm input Confirm information Reset Back by one menu level Back t...

Page 128: ...s 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 BQ_037 1 2 6 7 3 4 5 ESC Screen for entering the fleet manager pass word 116 57348011850 EN 02 2019 11 ...

Page 129: ... the Menu change button 2 repeatedly until the TIME option appears Confirm your selection using the Soft key 4 The TIME 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 t...

Page 130: ...layed mileage using Soft key 4 Use the Softkey 3 to exit the menu and return to the next level up NOTE The daily operating hours are reset in the same manner 8 9 0 6 7 4 3 5 7312_003 058_en_V4 1 2 3 4 Setting the language The displays can be shown in additional languages Switch to the CONFIGURATION menu see the chapter entitled Adjusting the displays Press the drive programme button 1 or the menu ...

Page 131: ...ht hand column is only populated with additional functions if the truck has more than three equipment variants that can be switched on and off using Softkeys In this case proceed as follows to switch between the two columns Briefly press the Menu change button 1 The grey bar jumps to the left hand col umn These additional functions can now be switched on and off via the corresponding Softkeys 2 NOT...

Page 132: ...u 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 appears Press drive program button 1 or menu change button 2 until the desired effi ciency mode appears in the display Confirm the set efficiency mode using Softkey 4 Use t...

Page 133: ...unit If you have any questions please contact your authorised service centre Additional settings By entering a password it is possible to set or find other values The values must only be changed by your service centre 57348011850 EN 02 2019 11 121 ...

Page 134: ...ciency mode For moderate speeds of at least approx 7 km h acceleration is gentler Therefore on distances of up to approx 40 m lower speeds are reached than would be the case if the efficiency mode was not activated Blue Q has no influence on Maximum speed Climbing capability Traction Braking characteristics NOTE The Blue Q efficiency mode can be swit ched on and off in the STANDARD and FI XED FLEX op...

Page 135: ...rking spotlights 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 efficiency mode does not switch off the lighting devices headlights and working spotlights side lights rear lights and license plate lamps...

Page 136: ... tion 2 2 1 3 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 mode is switched off 124 57348011850 EN 02 2019 11 ...

Page 137: ...ing suddenly turning quickly and overtaking at dangerous or blind spots must be avoided Initial driving practice must be carried out in an empty space or on a clear roadway The following are forbidden during driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Adjusting the steering column R...

Page 138: ...re that the driving lane is clear When transporting goods that impair visibility the driver must drive the truck in reverse If this is not possible a second person acting as a guide must walk in front of the truck In this case the driver must only move at walking pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be us...

Page 139: ... 1000 x 1200 crosswise with pallet 800 x 1200 lengthwise RX70 40 3912 4112 RX70 45 3942 4142 RX70 50 4037 4237 The truck may only be used on roadways that do not have excessively sharp bends excessively steep gradients or excessively narrow or low entrances Driving on gradients WARNING Driving up and down longer gradients may cause the drive unit to overheat and switch off Driving up and down long...

Page 140: ... project beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers The dimensions of the trucks are designed for this purpose However movable parts may project beyond the truck contour and be damaged or torn off Examples of these components are A folding roof panel in the driver s cab Cab doors Folding LPG cylinders Condition of...

Page 141: ... the designated locations The operating com pany and its representatives must ensure that unauthorised third parties keep away from the working area Hazard areas Hazardous areas on the roadways must be marked by standard traffic signs or if necessary by additional warning signs 7312_003 167_V3 1 1 2 Setting the drive programmes The driving and braking characteristics of the drive can be set on the ...

Page 142: ...A B Actuating the vertical rocker switch for the drive direction joy stick 4Plus version For the forwards drive direction push the vertical rocker button for the drive direction 1 upwards A For the reverse drive direction push the vertical rocker button for the drive direction 1 downwards B 5060_003 096 F1 F2 1 Actuating the drive direction switch mini lever version Push the cross lever 1 forwards...

Page 143: ... drive direction push the drive direction switch backwards 1 6210_003 101 A B Actuating the vertical rocker switch for the drive direction joy stick 4Plus version For the forwards drive direction push the vertical rocker button for the drive direction 1 upwards A For the reverse drive direction push the vertical rocker button for the drive direction 1 downwards B 57348011850 EN 02 2019 11 131 ...

Page 144: ...r 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 malfunctions All lifting functions are disabled The SEAT SWI...

Page 145: ... leased the truck brakes automatically via the regenerative brake NOTE The regenerative brake holds the truck briefly even on ascending or descending gradients without the parking brake being actuated The truck will then begin to creep downhill slowly DANGER Risk of accident due to brake failure The electric brake only functions while the key switch is switched on the emergency off switch variant h...

Page 146: ... still cannot be operated park the truck securely and contact your authorised service centre Starting drive mode dual pedal version variant 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 chapter entitled Safety regulations when driving The driver s seat has a seat switch ...

Page 147: ...E Depending on the equipment an acoustic signal variant may sound a warning during reverse travel the warning light variant may light up or the hazard warning system variant may flash The truck will travel in the selected drive direc tion The accelerator pedal position controls the speed When the accelerator pedal is re leased the truck brakes automatically via the regenerative brake NOTE The regen...

Page 148: ...r foot from the accelerator pedal Actuate the accelerator pedal for the other direction The truck will travel in the selected drive direction NOTE If an electrical fault occurs in the accelerator the drive unit switches off The truck is braked by the regenerative brake Once the electrical fault has been corrected it will be possible to drive the truck again by releasing the accelerator pedal and t...

Page 149: ... the truck to a standstill by applying the parking brake Do not operate the truck again until the service brake has been repaired DANGER Risk of tipping and risk of slipping The braking distance of the truck depends on the weather conditions and the level of contamination on the roadway The braking distance increases with the square of the speed There is a danger that the truck could slip or overt...

Page 150: ... brake via the brake pedal Actuating the mechanical parking brake DANGER There is a risk of being run over if the truck rolls away and therefore a danger to life The truck must not be parked on a slope In emergencies secure with wedges on the side facing downhill Only leave the truck when the parking brake is applied NOTE Once the parking brake is released the previously selected drive direction i...

Page 151: ... possible The drive direction indicator 2 on the display and operating unit goes out 6210_494 002 Releasing the parking brake Pull the parking brake lever 1 down fully out of the middle position In the lower lever position pull out the lever knob and then guide the parking brake lever up fully NOTE The parking brake lever swivels to the upper position automatically by means of spring force and sho...

Page 152: ...uck if it has a defective steering system Steer the truck by turning the steering wheel 1 accordingly Turning the steering wheel in the direction of arrow A steers the truck in drive direction A Turning the steering wheel in the direction of arrow B steers the truck in drive direction B For turning radius information see Chap ter Technical data P 359 140 57348011850 EN 02 2019 11 ...

Page 153: ... onto or along ascending and descending gradients at an angle Do not park the truck on ascending or descending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and stability value...

Page 154: ... onto or along ascending and descending gradients at an angle Do not park the truck on ascending or descending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and stability value...

Page 155: ...UTOUT MODE appears in the display Conditions that apply simultaneously The truck is stationary The parking brake is applied The driver s seat is not occupied Particle filter regeneration is not in progress There are no consumers switched on that require a significant amount of energy such as the air conditioning The waiting time only starts when all condi tions apply simultaneously If one of the con...

Page 156: ...risk of explosion LPG is heavier than air It collects at the floor where it may form hazardous explosive mixtures of gas and air Do not park the truck near pits cel lars staircases heating systems or other heat sources Do not park the truck below ground level Protect gas cylinders against heat Observe the safety regulations for working with LPG Apply the parking brake Lower the fork to the ground T...

Page 157: ...an still be operated but your authorised service centre must be notified of the error immediately The error message is shown on the display and operating unit until the error has been rectified by the authorised service centre NOTE The switch key FleetManager transponder chip variant or FleetManager PIN code variant may not be passed to others unless explicit instructions to this effect have been gi...

Page 158: ...ant 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 support mounting and press the handle 2 down again 146 57348011850 EN 02 2019 11 ...

Page 159: ...ns that the load cannot be lifted above a preset height This function uses a sensor that is welded on at the factory at the required lift mast limit height Once attached the height cannot be easily changed Application If the ceiling of the building is lower than the maximum lift height of the truck this variant can prevent the lift mast from accidentally hitting the ceiling which can result in dam...

Page 160: ...he automatic lift cut out back on Press Softkey 1 Automatic lift cut out is switched on The symbol is displayed Loads can be lifted only to the set lift height for the truck Lift mast vertical position variant Description If the truck is equipped with the automatic mast vertical positioning comfort feature variant the driver can lower goods such as paper rolls vertically with precision and therefo...

Page 161: ...e consists of the following individual functions Display of the lift mast vertical position Automatic movement into the automatic mast vertical position End stops are approached gently F1 F1 F2 F2 F1 F2 7314_003 059 2 1 4 5 3 The lift mast vertical position comfort feature is only available as a variant if the truck is equipped with one of the following operating devices Double mini lever 1 Triple...

Page 162: ... is displayed Tilt the lift mast forwards The lift mast stops automatically as soon as the preselected setting for automatic mast vertical positioning is reached If the comfort feature is switched off the lift mast tilts forwards past the automatic mast vertical positioning without stopping If the lift mast is tilted backwards it moves past the lift mast vertical position without stopping regardle...

Page 163: ... arrow above the bar shown on the screen of the display and operating unit represents the lift mast vertical position Tilting the lift mast forwards beyond the vertical position Release the operating device to tilt and actuate again The lift mast is tilted beyond the vertical position up to the end stop The current mast tilt is shown in the display and operating unit To switch off the automatic ma...

Page 164: ... frequently the lift mast vertical position should be calibrated 6210_003 070_en_V2 1 2 3 Calibrating the lift mast vertical position Set the lift mast to the required position Press and hold down Softkey 1 for at least five seconds The message VERTICAL POSITION appears on the display Storing the mast position Press the Drive programme selection button 3 to confirm The current mast position is store...

Page 165: ... Triplex lift mast variant During lifting the inner lift cylinder moves up to free lift 3 and then the outer lift cylinders raise the inner lift mast up to the max height 2 DANGER Risk of accident due to collision of the lift mast or load with low ceilings or entrances Note that the inner lift mast or load may be higher than the fork carriage Note the heights of ceilings and entrances Malfunctions...

Page 166: ...hains not under tension DANGER Danger caused by a falling load Make sure that the chain s does do not become slack when lowering the load Slack chains can for instance result from Resting the fork carriage or the load on the racking Fork carriage rollers becoming blocked in the lift mast due to contamination If the fork carriage or the load comes to an unexpected stop lift the fork carriage until ...

Page 167: ...the load after the hydraulics blocking function has been triggered If the truck s hydraulics are disabled by the exhaust valve of the hydraulic blocking func tion either permanently or due to a technical fault it is possible to lower a raised load with emergency lowering at the valve block see Chapter Emergency lowering P 4 288 Lifting system operating devices The method of operating the lifting s...

Page 168: ... the truck e g lift mast sideshifts working equipment load carrying devices etc can lead to serious injury or death and is therefore prohibited Observe the safety regulations for handling loads Only operate the lifting system from the driver s seat 156 57348011850 EN 02 2019 11 ...

Page 169: ...ting system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower the fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the l...

Page 170: ...g system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Move the lift mast 360 lever 1 in the direction of arrow B To lower the fork carriage Move the lift mast 360 lever 1 in the direction of arrow A Tilting the lift mast To tilt the lift mast forwards Move the lift mast 360 lever 1 in the direction of arrow C To tilt the lift mast backwards Move the lift...

Page 171: ...he driver s seat only Tilting the lift mast To tilt the lift mast forwards Move the lift mast operating lever 1 in the direction of arrow A To tilt the lift mast backwards Move the lift mast operating lever 1 in the direction of arrow B Lifting lowering the fork carriage To lift the fork carriage Move the lift lower operating lever 2 in the direction of arrow D To lower the fork carriage Move the ...

Page 172: ...ying devices etc can lead to serious injury or death and is therefore prohibited Observe the safety regulations for handling loads Only operate the lifting system from the driver s seat 6210_003 089 1 A B Lifting lowering the fork carriage To lift the fork carriage Pull the joystick 4Plus 1 backwards B To lower the fork carriage Push the joystick 4Plus 1 forwards A 160 57348011850 EN 02 2019 11 ...

Page 173: ...ds Tilt the horizontal rocker button 2 to the right D 1 6210_003 091 E F Fork carriage sideshift To move the fork carriage to the left Push the joystick 4Plus 1 to the left E To move the fork carriage to the right Push the joystick 4Plus 1 to the right F NOTE The symbols on the joystick 4Plus indicate the direction of movement of the lift mast or the fork carriage 57348011850 EN 02 2019 11 161 ...

Page 174: ...loads Operate the lifting system from the driver s seat only Lifting lowering the fork carriage To lift the fork carriage Pull the lift lower operating lever 1 backwards To lower the fork carriage Push the lift lower operating lever 1 forwards Tilting the lift mast To tilt the lift mast forwards Push the tilt operating lever 2 forwards To tilt the lift mast backwards Pull the tilt operating lever ...

Page 175: ...ve gloves and safety footwear when changing the fork arms Ensure that no one stands in the danger area Do not pull on the fork arms The fork arms must always be carried by two people if necessary use a hoist NOTE For installation and removal a transport pallet is recommended for supporting the fork arms The pallet size depends on the fork arm size used and should be dimensioned such that the fork ...

Page 176: ...ce the fork arms on a pallet next to the fork carriage on the side chosen for installation Pull up the locking lever 1 and push the fork arms onto the fork carriage one after the other Place the fork arms in the required position and push down the locking lever Ensure that the locking lever snaps into place Screw in and tighten the locking screw 2 DANGER There is a risk of fatal injury from a fall...

Page 177: ... footwear WARNING There is a risk of tipping The weight and dimensions of the fork extension affect the stability of the truck The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance The truck is equipped with a fork extension ex works the capacity rating plate is already adjusted accordingly Observe load capacity see the Before picking...

Page 178: ...n is on the fork arm Always secure the fork extension with a securing bolt Always secure the securing bolt with a linch pin Remove the linch pin 3 from the securing bolt 2 Remove the securing bolt from the fork extension 1 Push the fork extension onto the fork arms until it is flush with the fork back Insert the securing bolts located behind the fork back fully into the fork extension Insert the li...

Page 179: ...extension variant cannot be secured against slipping Do not use a fork extension variant WARNING Risk of accident from the truck tipping over When driving the centre of gravity of the load 2 must not be higher than 600 mm above the ground The truck may tip forwards when driving or braking Only drive with a load centre of gravity up to a max of 600 mm above the ground NOTE If the truck is equipped ...

Page 180: ...rsible fork arms The mast is lifted and tilted in the same manner Only work in reverse operation using reversible fork arms Do not use a fork extension variant If the load measurement comfort feature is available perform a zero adjustment of the load measurement To drive raise the load centre of gravity 2 to a max of 600 mm above the ground Observe the information in the section entitled Transport...

Page 181: ...loads or raised fork arms Never exceed the maximum load indicated on the capacity rating plate Otherwise stability cannot be guaranteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safety guard variant to prevent ...

Page 182: ...icable The position of the capacity rating plate can be found in the chapter entitled Identification points WARNING The figures show examples Only the capacity rating plates on the truck are valid The attachment of additional weights to increase load capacity is prohibited DANGER Risk to life from the truck losing stability Never exceed the maximum loads shown These values apply to compact and homog...

Page 183: ...Observe the special capacity rating plate infor mation shown on the truck and the attachment Load measurement variant Description Knowing the weight of the load to be trans ported gives the driver greater security If the truck is equipped with the load measure ment variant comfort feature the weight of the lifted load can be measured and shown in the display and operating unit Load measurement is ...

Page 184: ...s CAUTION If the weight determined by a load measurement exceeds the permissible residual load capacity of the truck the truck cannot be operated safely Set down and reduce load immediately If necessary use another truck with sufficient load bearing capacity NOTE Accurate load measurement is only possible under the following conditions The hydraulic oil is at normal operating temperature The load i...

Page 185: ...E If the truck is equipped with mini levers or fingertip operation the F1 button can also be pressed as an alternative NOTE During the following process the fork carriage must be lowered slightly and then stopped abruptly While doing so the fork must not touch the ground otherwise the load measurement will not be accurate To stop the lowering procedure quickly release the operating device for lower...

Page 186: ...d are positioned as far as possible under the load If possible the load should rest on the back of the fork The load must not protrude too far over the fork tips nor should the fork tips protrude too far out from the load Loads are to be picked up and transported as close to the middle as possible DANGER Risk of accident from a falling load When transporting small items attach a load safety guard ...

Page 187: ... working equipment its load carrying equipment e g attachments or the load Also included are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all per...

Page 188: ... carefully positioned loads may be transported 6210_001 007 Transporting suspended loads Before transporting suspended loads con sult the national regulatory authorities in Germany the employer s liability insurance associations National regulations may place restrictions on these operations Contact the relevant authorities DANGER Suspended loads that begin to swing can result in the following ris...

Page 189: ...uspended loads and prevent the loads from swinging Take particular care to ensure that there is no one in the drive direction in the driving lane If despite this the load begins to swing ensure that no person is placed at risk DANGER Risk of accidents When transporting hanging loads never perform or end driving and load movements abruptly Never drive on slopes with a suspended load Transporting co...

Page 190: ...specified aisle width is not reduced by protruding parts 6210_800 005 Approach the racking carefully brake gently and stop just in front of the racking 6210_800 006 Position the forks Set lift mast to vertical Lift the fork carriage to the stacking height CAUTION Component damage possible When inserting the fork into the racking ensure that the racking and load are not damaged 178 57348011850 EN 02...

Page 191: ...iddle 6210_800 008 Lift the fork carriage until the load is resting entirely on the forks DANGER Risk of accidents Beware of any people in the danger area Ensure that the roadway 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 Brak...

Page 192: ...4 Operation Handling loads 5060_003 102 Lower the load while maintaining ground clearance 5060_003 101 Tilt the lift mast backwards The load can be transported 180 57348011850 EN 02 2019 11 ...

Page 193: ... Driving with a raised load and the lift mast tilted forward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards 6210_800 013 Drive slowly and carefully round corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the informati...

Page 194: ...The truck may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forwards take parti cular care to ensure that the truck does not tip forwards and that the load does not slip WARNING Risk of accident from a falling load If the fork or the load remains suspended during lowering the load may fall When removin...

Page 195: ...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 Shake function variant Description The shake function of the hydraulics is de signed to make it easier for the driver to per form tasks such as emptying containers ...

Page 196: ...ng device is moved the more intense the shaking is NOTE After the function has been activated the driver has four seconds to start the shaking If the four seconds elapse without the shake function being used the shake function is deactivated again WARNING The shake function remains active for four seconds following activation If the driver simply wants to raise or lower the load during this time i...

Page 197: ...89 1 A B Joystick 4Plus Move the joystick 4Plus 1 back and forth four times between positions A and B Then continue to move the component in the same way Double mini lever Move the 360 lever 2 back and forth four times between positions A and B Then continue to move the component in the same way 57348011850 EN 02 2019 11 185 ...

Page 198: ...forth four times between positions A and B Then continue to move the component in the same way Quadruple mini lever Move the operating lever 4 back and forth four times between positions A and B Then continue to move the component in the same way 186 57348011850 EN 02 2019 11 ...

Page 199: ...ifts with a sufficient rated capacity and for which the operating company has been granted authorisation DANGER There is a risk to life if you are crushed or run over by the truck There must be no personnel already in the lift when the truck is driven into the lift Personnel are only permitted to enter the lift once the truck is secure and must exit the lift before the truck is driven out 573480118...

Page 200: ...ht variant 2 Attachment net weight variant Weight of the load to be lifted 100 kg allowance for 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 lift to prevent uncontrolled movements of the load or the truck 6210_001 010 Driving on loading bridges DANGER Risk of accident if the truck crashes Steering m...

Page 201: ... Betriebsanleitung kg kg kg kg kg kW V D 22113 Hamburg Berzeliusstr 10 2 1 Determining the actual total weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the attachment variant nameplate and if necessary by weighing the load to be lifted Add the determined unit weights to obtain the actual total weight of the truck Tare weight 1 Ballast weigh...

Page 202: ...ment and the visibility from the driver s position with and without a load must be checked by a competent person If the visibility is deemed insufficient visual aids such as mirrors a camera monitor system etc must be used In addition it is essential that the warnings below are observed CAUTION Attachments must be CE certified If the truck is not fitted with an attachment specific residual load capaci...

Page 203: ...llation Never grab or climb on moving parts of the truck 7090_900 001 Hydraulic connection Before installing the attachment release the pressure from the hydraulic system CAUTION Risk of damage to components Open connections of plug connectors can become dirty The plug connectors can become stiff and dirt can enter the hydraulic system Once the attachment has been disassembled attach the protectiv...

Page 204: ...horised personnel in accordance with the information provided by the manufacturer and supplier of the attachments After each instal lation the attachment must be checked for correct function prior to initial commissioning NOTE The pressure release procedure is dependent on the operating devices for controlling the hydraulic functions see the section entitled Lifting system operating devices NOTE B...

Page 205: ...184 Actuate the operating lever 1 for control ling the hydraulic functions repeatedly in the direction of the arrow as far as the end position The valves open and the hydraulic system is depressurised Switch off the key switch 57348011850 EN 02 2019 11 193 ...

Page 206: ...of attachments can give rise to additional hazards such as a change in the centre of gravity additional danger areas etc Attachments must only be used for their intended purpose as described in the relevant operating instructions Drivers must be taught how to operate the attachments Loads may only be picked up and transported with attachments if the loads are securely grasped and attached Where ne...

Page 207: ...the attachments described fall into the category of equipment variants Please see the respective operating instructions for an exact description of the respective movements actions of the attachment fitted 57348011850 EN 02 2019 11 195 ...

Page 208: ...e the attachments 1 cross lever in the direction of the arrow A The attachment moves in accordance with the pictogram in position A Move the attachments 1 cross lever in the direction of the arrow B The attachment moves in accordance with the pictogram in position B Move the attachments 1 cross lever in the direction of the arrow C The attachment moves in accordance with the pictogram in position ...

Page 209: ...o the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pic...

Page 210: ...ver 2 show the respective functions that are activated by this lever This essentially involves the following Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 1 and move the attachments cross lever 2 in the direction of arrow F The attac...

Page 211: ... wards 5 Move sideshift to the left 6 Move sideshift to the right 7 Adjust fork arms open 8 Adjust fork arms close 9 Swivel lift mast or fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Rotate to the left 16 Rotate to the right 17 Tip shovel over 18 Tip shovel back 57348011850 EN 02 2019 11 199 ...

Page 212: ...the pictogram in position A Move the operating lever 1 towards B The attachment moves in accordance with the pictogram in position B Move the operating lever 2 towards C The attachment moves in accordance with the pictogram in position C Move the operating lever 2 towards D The attachment moves in accordance with the pictogram in position D NOTE The pictograms are attached depending on the pre ass...

Page 213: ... 5 Move sideshift to the left 6 Move sideshift to the right 7 Adjust fork arms open 8 Adjust fork arms close 9 Swivel lift mast or fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back 57348011...

Page 214: ...n the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 4 and move operating lever 1 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 4 and move operating lever 1 towards F The attachment moves in accordance with the pictog...

Page 215: ...4 Attachments 5060_003 122 3 4 1 2 Note the following attachment functions and pictograms 1 Adjust fork arms open 2 Adjust fork arms close 3 Rotate to the left 4 Rotate to the right 57348011850 EN 02 2019 11 203 ...

Page 216: ...in the direction shown in pictogram A Move the operating lever 1 towards B The attachment moves in the direction shown in pictogram B Move the operating lever 2 towards C The attachment moves in the direction shown in pictogram C Move the operating lever 2 towards D The attachment moves in the direction shown in pictogram D NOTE The pictograms are attached depending on the pre assembled attachment...

Page 217: ... 5 Move sideshift to the left 6 Move sideshift to the right 7 Adjust fork arms open 8 Adjust fork arms close 9 Swivel lift mast or fork to the left 10 Swivel lift mast or fork to the right 11 Release load retainer 12 Clamp load retainer 13 Push off the load 14 Pull in the load 15 Open clamps 16 Close clamps 17 Rotate to the left 18 Rotate to the right 19 Tip shovel over 20 Tip shovel back 57348011...

Page 218: ...rams on the operating levers show the respective functions that are activated by these levers This essentially involves the following Actuate the 5th function function key 5 and move operating lever 3 towards E The attachment moves in accordance with the pictogram in position E Actuate the 5th function function key 5 and move operating lever 3 towards F The attachment moves in accordance with the ...

Page 219: ...4 Attachments 5060_003 122 3 4 1 2 Note the following attachment functions and pictograms 1 Adjust fork arms open 2 Adjust fork arms close 3 Rotate to the left 4 Rotate to the right 57348011850 EN 02 2019 11 207 ...

Page 220: ...ating device Function of the attachment 1 Joystick 4Plus Move sideshift to the left right 2 Joystick 4Plus or slider Adjust fork arms open close 3 Slider Move reach frame or fork carriage forwards backwards 4 Joystick 4Plus or slider Rotate attachment left right 5 Slider Tip shovel over tip shovel back NOTE The pictograms on the joystick 4Plus are attached according to the attachments fitted to thi...

Page 221: ...tachments that are controlled using the 5th hydraulic function the procedures for operation are as follows Press and hold shift key F 1 on the joystick 4Plus Simultaneously actuate the horizontal rocker button 2 in the direction shown in the pictogram The attachment moves in the selected direc tion NOTE The pictograms are attached depending on the pre assembled attachment If an attachment with oth...

Page 222: ... lower part of the pictogram NOTE The pictograms are attached depending on the pre assembled attachment If an attachment with other functions is fitted the pictograms must be checked for the correct representation and changed if necessary Contact the authorised service centre if required 6210_003 031 2 3 6 4 7 9 10 5 8 Note the following attachment functions and pictograms 2 Move side shift frame o...

Page 223: ...functions in which case the corresponding operating lever controls the 5th function The upper and lower parts of the pictogram 3 behind the operating lever show the function that is activated with this lever This essentially involves the following Move the operating lever forwards The attachment moves in the direction of movement shown in the upper part of the pictogram Move the operating lever ba...

Page 224: ...key indicates which operating lever is equipped with the 5th function The 5th function is switched to the 4th operating lever see sticker 9 NOTE The movement action of this 5th function can be found in the operating instructions of the fitted attachment NOTE The pictograms are attached depending on the pre assembled attachment If an attachment with other functions is fitted the pictograms must be ch...

Page 225: ... fitted with a clamp locking mechanism as a variant This prevents the clamp from opening unintentionally if the operating function is inadvertently triggered DANGER There is a risk of fatal injury from falling loads if the correct function of the clamp locking mechanism is not guaranteed If other attachments are used on this truck in addi tion to the clamp make sure that the clamp locking mechanism...

Page 226: ...hout releasing the clamp locking mechanism To close the clamp pull the cross lever 1 backwards 7325_003 048 1 2 Triple mini lever To release the clamp locking mechanism push the operating lever 1 forwards The LED for button F2 2 lights up as long as the clamp locking mechanism is released NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanis...

Page 227: ...6210_003 097 Joystick 4Plus To release the clamp locking mechanism press and hold shift key F 3 and move the horizontal rocker button 1 to the right Keep shift key F 3 pressed and move the horizontal rocker button 1 back to the neutral position The LED 2 lights up as long as the clamp locking mechanism is released To open the clamp press and hold shift key F 3 and move the horizontal rocker button...

Page 228: ...he operating lever 1 backwards 1 2 3 7090_860 002 Taking up a load using attachments WARNING Risk of accidents Attachments may only be used for their intended purpose as described in the relevant operating instructions Drivers must be instructed in the handling of the attachments WARNING Risk of accidents Loads may only be picked up and transported with attachments if they are securely attached Wh...

Page 229: ...press the button 1 The front sidelights and the rear lights light up On the variant with StVZO German Road Traffic Licensing Regulations equipment the licence plate lamp also lights up To switch on the headlights press the button 1 again The headlights light up in addition to the parking light To switch off the driving lights press the button 1 again The driving lights go out 57348011850 EN 02 2019...

Page 230: ...d when the working spotlights are switched on Rear lights Licence plate lamp Sidelights Switching the working spotlight for reverse travel on and off The working spotlight for reverse travel is attached to the overhead guard at the rear It provides optimal illumination of the roadway if the truck is travelling in reverse 2 1 Press the softkey 1 The symbol 2 is displayed The rear working spotlight ...

Page 231: ...eacon goes out The symbol 2 is displayed 5060_003 011_V2 1 2 Switching the hazard warning system on and off To switch on the hazard warning system press the button 1 All turn indicators and indicator lights 2 flash To switch off the hazard warning system press the button 1 again The hazard warning system goes out NOTE To switch on the hazard warning system without the key switch being switched on p...

Page 232: ... the turn indicators by moving the cross lever of the drive direction turn indicator 1 to the left or to the right 2 3 5060_003 012_V2 The turn indicators and the corresponding turn indicator displays 2 or 3 flash Switch off the turn indicators by moving the cross lever to the centre position 220 57348011850 EN 02 2019 11 ...

Page 233: ...n indicators by actuation the corresponding left hand or right hand turn indicator button 1 2 3 5060_003 012_V2 The turn indicators and the corresponding turn indicator displays 2 or 3 flash Switch off the turn indicators by actuating the other turn indicator button 57348011850 EN 02 2019 11 221 ...

Page 234: ...icators by moving the turn indicator switch 1 to the left or to the right 2 3 5060_003 012_V2 The turn indicators and the corresponding turn indicator displays 2 or 3 flash Switch off the turn indicators by moving the turn indicator switch to the centre position 222 57348011850 EN 02 2019 11 ...

Page 235: ...ight illuminates the working area directly in front of the truck Depending on the equipment the upper working spotlights can be switched on off automatically or manually Switching the upper working spotlights on off manually NOTE The upper working spotlights can be switched on off independently of the lower working spotlights For information about switching on the lower working spotlights see the ...

Page 236: ...matically when 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 precise adjustment is made If more lifts are carried out during this time the upper working spotlights will remain switched off NOTE The upper working spotlights are switched off automaticall...

Page 237: ...o the STILL 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 junctions 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...

Page 238: ...etween the operating stages in the sequence shown 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 effects 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 conditio...

Page 239: ...arate operating instructions for the corresponding FleetManager versions Shock recognition variant The shock recognition is an equipment variant of the FleetManager variant in which an acceleration sensor is installed in the truck The acceleration sensor records data arising from rapid accelerations or decelerations of the truck e g in the event of an accident This data can be electronically read ...

Page 240: ...hen travelling at speeds below 6 0 km h Depending on the truck equipment the cruise control can be switched on and off via the drive direction switch or the display and operating unit 7325_003 057 F1 F1 F2 F2 F1 F2 1 1 1 Switching on and off via the drive direction switch 1 228 57348011850 EN 02 2019 11 ...

Page 241: ...ed along the entire distance being travelled Pay particular attention to cornering speed Observe safety regulations when driving Observe the special behaviour of the cruise control function and the dangers associated with it Start drive mode Accelerate the truck to the required speed at least 6 0 km h 7325_003 057 F1 F1 F2 F2 F1 F2 1 1 1 Press the drive direction switch 1 for forward travel again ...

Page 242: ...ng brake Actuate the accelerator pedal Move the drive direction switch 1 into the neutral position or reverse Actuate the corresponding Softkey see arrows previous picture on the display operating unit NOTE If the seat switch is not actuated the truck s cruise control function and drive function are switched off The accelerator pedal can be used to switch off the cruise control function depending ...

Page 243: ...r these systems can be found in the separate Driver restraint systems operating instructions Ceiling sensor variant Description 1 The ceiling sensor 1 on the overhead guard is an assistance system that automatically reduces the driving speed of the truck within halls However this assistance system does not release the driver from the responsibility of observing the speed limits on company premises...

Page 244: ...etres away from the hall exit Before the truck is able to accelerate to the maximum speed permitted for outdoor areas the speed limitation must still be unlocked To do this release the accelerator briefly and then operate the accelerator again Switching on the truck in a hall If the truck is switched on inside a hall the ceiling detector system detects the hall ceiling and reduces the driving speed...

Page 245: ...iling sensor system is supplied by STILL with the following factory settings Sensitivity High Ceiling height 24 m Pull out the connecting cable from the sensor 1 On the underside of the assembly baseplate on the overhead guard loosen the four nuts 1 on the sensor Carefully remove the sensor 2 Using the supplied key 2 open the sensor housing to gain access to the DIP switches 57348011850 EN 02 2019...

Page 246: ...he manufacturer They must not be changed Factory settings of the manufacturer do not change 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 The sensor has different beam angles de p...

Page 247: ...able Sensitivity Range Beam angle 2 m 22 5 4 m 22 5 8 m 20 16 m 15 Low 1 24 m 5 2 m 35 4 m 30 8 m 25 16 m 22 5 Medium 2 24 m 10 Sensitivity Range Beam angle 2 m 42 4 m 33 8 m 22 5 16 m 20 High 3 24 m 15 2 m 45 4 m 43 8 m 30 16 m 22 5 Very high 4 24 m 18 57348011850 EN 02 2019 11 235 ...

Page 248: ...2 3 4 1 2 3 4 Representation of the beam angle depending on the sensitivity of the sensor that has been set from 1 low to 4 very high Additional labelling Adhesive label next to the display operating unit 236 57348011850 EN 02 2019 11 ...

Page 249: ...e Take hold of the handlebar 4 and latch 5 Press the latch in and push the cab door outwards 7331_341 007 4 2 1 3 Opening the side windows WARNING There is a risk of crushing between the window frame and side window from the side windows slipping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the rear side window Press the handle 2 tog...

Page 250: ... engages Make sure that the cab door is fully closed 7314_003 040 4 5 2 1 3 Opening the side windows WARNING There is risk of crushing between the window frame and side window caused by the side windows slipping inadvertently during travel Make sure that the handle engages securely in the corresponding stop slot Opening the rear side window Press the handle 2 together and slide the rear side windo...

Page 251: ...ly during travel Make sure that the handle engages securely in the corresponding stop slot Closing the rear side window Press the handle 2 together and pull the rear side window 1 to the rear Make 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 57348011850 EN 02 2019 11 239 ...

Page 252: ...2_003 013 7 8 Operating the interior lighting 6311_003 013_V2 2 1 Switch the interior lighting 7 on or off using the switch 8 or button 1 The interior lighting symbol 2 appears in the display 240 57348011850 EN 02 2019 11 ...

Page 253: ... 015 1 2 Radio variant The radio 1 and the loudspeakers 2 are an equipment variant If the truck is equipped with a radio and loudspeakers they are integrated into the roof lining The description and operation can be found in the separate operating instructions for the radio WARNING The driver s attention is adversely affected by operating the radio or listening to excessive volume while driving or...

Page 254: ...To switch on the blower turn on the blower switch 1 The blower runs at the speed level set at the switch Switching on the heating system DANGER Risk of fire Do not cover the heater DANGER Risk of burns Do not touch housing during opera tion NOTE Only switch on the heating system when the blower is running To switch on the heating system turn on the heating switch 2 The heating system is in operatio...

Page 255: ...tioning variant Switching on the air conditioning 1 2 7331_346 001 3 Switch the blower switch 1 on Set the cryostat 2 to the desired level Switch on the air conditioning by pressing the switch 3 Switching off the air conditioning Switch off the air conditioning by pressing the switch 3 Switch off the blower switch 1 57348011850 EN 02 2019 11 243 ...

Page 256: ...erloading can lead to component damage on the truck The sum of the actual towed load and the actual load on the fork must not exceed the rated capacity If the existing towed load corresponds to the rated capacity of the truck no load may be transported on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust it to correspond t...

Page 257: ...operating time If the truck is to be used for towing on a more regular basis the manufacturer should be consulted Coupling pin in the counterweight Coupling the trailer DANGER If you briefly leave the truck to couple or uncouple there is a risk to life caused by the truck rolling away and running you over Apply the parking brake Lower the fork to the ground Turn off the key switch and remove the ke...

Page 258: ...coupling pin or the securing bush during towing the trailer works loose and becomes uncontrollable meaning there is a risk of accident Use only original coupling pins that have been checked for good condition Ensure that the coupling pin is correctly inserted and secured Insert the coupling pin into the counter weight press downwards against the spring pressure and turn 90 the coupling pin is lock...

Page 259: ...ween the truck and trailer DANGER Never jack up the truck on the tow coupling or use it for crane lifting The tow coupling is not designed for this and could be deformed or damaged This could cause the truck to fall 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: ...e to its overhang The tow coupling can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow coupling test 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 test the tow coupling for damage Replace tow coupling if damaged if necessary co...

Page 261: ...a tow bar eye in accordance with DIN 74054 bore diameter 40 mm Take measures to prevent the trailer from rolling away e g use wheel chocks 1 Adjust the tow bar eye of the tiller so that it is at the centre of the towing jaws 3 7321_003 064 2 Pull out the safety handle 3 Push the hand lever 2 upwards DANGER Persons may become trapped between the truck and trailer When hooking up ensure that no one ...

Page 262: ...243 by hand DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for example a tow rope is to be secured in the tow coupling use only a suitable device to close the tow coupling e g assembly lever Use a suitable device e g assembly lever to push the coupling pin up The coupling pin is released from the latch and the tow coupling then closes automatically 3 73...

Page 263: ...eople can become trapped between the truck and trailer When hooking up ensure that no one is between the truck and trailer CAUTION When being coupled the tow bar eye must engage in the middle of the coupling jaw Failure to follow these instructions could result in damage to the coupling jaw or to the tow bar eye Ensure that the tow bar eye enters the coupling jaw centrally Move the truck back slow...

Page 264: ...ove any items used to prevent the trailer from rolling away Tow the trailer Closing model RO 244 A by hand DANGER Risk of injury from hand becoming trapped Do not reach into the coupling pin area If for example a tow rope is to be secured in the tow coupling only actuate the tow coupling via the closing lever 1 Press the closing lever 1 downwards as far as it will go The tow coupling is closed Unc...

Page 265: ...ever 5 upwards The tow coupling is opened DANGER People can become trapped between the truck and trailer When hooking up ensure that no one is between the truck and trailer Slowly move the truck back DANGER If the coupling pin drops out during towing the trailer 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...

Page 266: ...41 is intended for a tow bar eye in accordance with DIN 74054 bore diameter 40 mm Take measures to prevent the trailer from rolling away e g use wheel chocks Push the hand lever 7 upwards until it snaps into place DANGER People may be trapped between truck and trailer When hooking up ensure that no one is between the truck and trailer CAUTION When being coupled the tow bar eye must engage in the m...

Page 267: ...drive the truck forwards until the tow bar eye and towing jaws are disconnected Close the tow coupling 7090_900 011 Towing trailers Drivers who are towing a trailer for the first time must practise driving with a trailer in a suitable area When passing through narrow road areas entrances gates etc observe the dimen sions of the trailer and load When towing multiple trailers ensure a sufficient minim...

Page 268: ...4 Operation Trailer operation NOTE Please observe the definition of the following responsible persons operating company and driver 256 57348011850 EN 02 2019 11 ...

Page 269: ...according to the event In the case of successive events the respec tive messages are displayed one after another on the display After a few seconds the display will alternate between the last shown operating display and the message The frequency of alternation depends on the type of event If a message appears follow these operat ing instructions Once the event is remedied the message will disappea...

Page 270: ...A3020 Switch error no or limited drive unit function Notify your authorised service centre VERTICAL MAST ERROR A3135 No hydraulic function Turn off vertical lift mast position Notify your authorised service centre LIFTING A3102 A3103 Sensor fault no or limited hydraulic drive function Notify your authorised service centre CONFIGURATION A2111 Parametrisation error or defective printed circuit board...

Page 271: ...o oil pressure or sensor faulty Engine is switched off for protection Notify your authorised service centre SEAT SWITCH A302 Seat switch has not been operated for approx 8 hours Truck can possibly still be driven at a reduced speed and with reduced lifting capacity Stand up briefly and then sit down again If this does not resolve the problem contact your authorised service centre CONTROL UNIT A3305...

Page 272: ...circuit Truck cannot be driven Notify your authorised service centre EXT1 A3112 A3113 Sensor fault no or limited hydraulic drive function Notify your authorised service centre EXT2 A3117 A3118 Sensor fault no or limited hydraulic drive function Notify your authorised service centre General messages NOTE Some of the following messages are equip ment specific and may not appear on the display and ope...

Page 273: ...til 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 parking brake and then vacate the driver s seat the APPLY HANDBRAKE message will appear in the display variant An optional signal tone sounds Apply the parking brake The APPLY HANDBRAKE message disap pears If the truck moves even thoug...

Page 274: ...ing off of the truck is verified Press the corresponding softkey on the display and operating unit to switch off the truck or cancel the operation PARKING BRAKE ACTIVE message If the electric parking brake is applied the PARKING BRAKE ACTIVE message ap pears on the display for 5 seconds Release the parking brake to enable driving mode RELEASE PARKING BRAKE message If the message RELEASE PARKING BRA...

Page 275: ...pears in the display variant An optional signal tone sounds Lower the fork to the ground The message LOWER FORKS disappears STEERING message If the STEERING message appears in the display the truck will only move at emergency mode speed The steering angle sensor must be checked Notify the authorised service centre TILTING SPEED message If the message TILTING SPEED appears on the display after the ...

Page 276: ...CLE message If the fork was lowered after the truck was switched off the control electronics do not know the position of the fork when the truck is restarted The truck will only travel at a reduced driving speed Depending on the position of the fork the message REFERENCE CYCLE variant may appear in the display To align the position with the control electronics the fork must be raised Switch on the...

Page 277: ...ill not drive at all Depending on the configuration selected the working hydraulics functions lifting tilting are either available as normal slowed down or not available at all The SAFETY BELT message with the restric ted driving and lifting functions is triggered by the following circumstances Seat belt not worn and driver s seat occu pied The seat belt is constantly fastened but the driver s seat...

Page 278: ...ssage The truck is equipped with a seat switch If the SEAT SWITCH message appears the driving functions and the working hydraulics are blocked The SEAT SWITCH message is triggered by the following situations The seat switch is not actuated while the accelerator pedal or steering wheel is actuated The seat switch is not actuated while the operating device for the working hydraulics is actuated The ...

Page 279: ...seat and fasten the seat belt The truck can be driven again without restric tions 7325_003 054_en_V2 F1 F2 The seat switch is not actuated while the operating device for the working hydraulics is actuated An operating device for the working hydraulics is actuated even though no one is sitting in the driver s seat The message SEAT SWITCH appears on the display The working hydraulics functions canno...

Page 280: ...OTE The operating time is adjustable If the key switch is switched on the parking brake is released and the driver does not leave the seat before the set operating time is exceeded and if neither the operating devices for the working hydraulics nor the accelerator pedal are actuated during this time SEAT SWITCHappears on the display The truck will not move Depending on the configuration the working...

Page 281: ...aired notify your authorised service centre NOT VALID message If the message NOT VALID appears on the display an incorrect driver PIN has been entered when entering the access code Once the message goes out enter the driver PIN again Drive specific messages NOTE Some of the following messages are equip ment specific and may not appear on the display and operating unit of every truck The following me...

Page 282: ...cle filter system must be repaired by the authorised service centre To avoid damage take the truck out of operation until it is repaired Notify the authorised service centre CUTOUT MODE message When automatic shut off is activated the message CUTOUT MODE appears on the display see the section entitled Automatic shut off of the internal combustion engine variant Sit on the driver s seat The message ...

Page 283: ...dBlue ADBLUE QUALITY message This truck is equipped with a sensor that measures the quality of the exhaust gas cleaned using AdBlue If the quality of the exhaust gas deteriorates the ADBLUE QUALITY message appears on the display and operating unit If the exhaust gas quality deteriorates further the driving speed is limited to 5 km h Maintain the quality of the AdBlue see the section entitled Maint...

Page 284: ...essage HYBRID SYSTEM is shown on the display the energy storage system has been deactivated because of an error The truck remains operational However the fuel consumption increases marginally Contact the authorised service centre in order to rectify the error HYDRAULIC PUMP message If the HYDRAULIC PUMP message appears on the display there was an error in the hydraulic pump volume control The engi...

Page 285: ...age If the cooling fluid level is low this indicates a leak in the cooling system Check the cooling system for leaks see the chapter entitled Cleaning the radiator checking for leaks EMPTY message If the message EMPTY flashes on the display the gas supply is almost exhausted Change the LPG cylinder or fill the LPG tank ALTERNATOR message If the ALTERNATOR message appears in the display this means tha...

Page 286: ...sed service centre AIR FILTER message If the AIR FILTER message appears on the display the filter insert or the filter cartridge must be replaced Replace the filter insert or the filter cartridge OIL PRESSURE message CAUTION Risk of engine damage If the OIL PRESSURE message appears in the display the engine s oil pressure is too low Stop the engine immediately The message can have different causes The...

Page 287: ...rked regeneration of the particle filter is required urgently Perform parked regeneration Until parked regeneration has been carried out the maximum speed of the truck is re duced to 2 km h The lifting speed is restricted PARK REG ERROR message If the message PARK REG ERROR appears on the display parked regeneration was interrupted by applying the parking brake or by a malfunction in the internal c...

Page 288: ... messages Perform parked regeneration START IC ENGINE message If the message START IC ENGINE appears on the display the internal combustion engine of the truck can be started Start the engine 276 57348011850 EN 02 2019 11 ...

Page 289: ...o not smoke and do not use an open flame or fire Check that the LPG cylinders are approved Only change LPG cylinders in well ventilated spaces away from openings in the ground Observe the safety regulations for working with LPG DANGER Risk of explosion from spark dis charge Striking tools must not be used to aid opening and closing DANGER Open flames red hot objects etc may cause explosions Frozen sy...

Page 290: ...n After removal the cylinder cap must imme diately be screwed onto the cylinders fitted with a lock nut The valves must be opened slowly Leaking gas cylinders must not be reused Taking all precautions into account leaking gas cylinders must immediately be emptied outside by blowing and marked as leaking If damaged gas cylinders are supplied the provider or a representative service station attendant...

Page 291: ...pwards and remove the hook 6 from the support mounting Remove the upper part of the cylinder holder 5 Exchange the empty gas cylinder for a full one When installing the gas cylinder make sure that the connection screw joint of the cylinder shut off valve points vertically downwards Secure the gas cylinder properly in the cylinder holder Open the cylinder valve 1 by slowly turning the star grip han...

Page 292: ...ith an expired inspection date Observe the inspection intervals stipulated in the Pressure Equip ment Directive The most recent inspection date marked on the LPG cylinder is the date that applies Observe the national regulations in the relevant country Switch off the engine Do not smoke or use a naked flame lighter Ensure that permissible LPG cylinders are used Only change LPG cylinders in well ven...

Page 293: ...pper part of the cylinder holder 6 Remove the empty gas cylinder and screw on the cylinder cap 7 Install the full gas cylinder When installing the gas cylinder make sure that the connection screw joint of the cylinder shut off valve points vertically downwards Insert the upper part of the cylinder holder Fit the hook to the holder and swivel the handle of the tensioning device downwards Securely g...

Page 294: ...iking tool DANGER Risk of explosion during thawing of gas system Gas can ignite and explode when exposed to excessive heat naked flames glowing objects and objects that produce sparks Frozen system components may only be thawed using warm air warm water warm sand bags or similar The temperature of the applied heat must not exceed 50 C Warm air must not be applied directly using a heating appliance ...

Page 295: ... piping and related accessories for gas in the liquid phase and LPG containers must not be exposed to an impermissible level of heat Explosions involving gas cylinders or LPG systems must be reported immediately to the employers liability insurance association and the responsible industrial inspectorate even if no accident occurs applicable for Germany Store damaged parts until the investigation h...

Page 296: ...se the main LPG filling station shut off valve CAUTION It is possible to underfill or overfill the LPG tank Fill the LPG tank until the tank valve switches itself off Do not fill according to the content level indicator 4 Carefully unscrew the pistol type nozzle from the filling valve Screw the locking cap 5 back onto the filling valve DANGER Risk of explosion in the event of irregularities If any irreg...

Page 297: ...eering function Use the emergency off switch only in an emer gency or to carry out a functional test Steer with a higher level of force NOTE Only LPG trucks with a joystick 4Plus variant have an emergency off switch Actuating the emergency off switch in drive mode switches off the regenerative brake the hydraulic system and the drive unit This has the following effect No reduction in truck speed w...

Page 298: ... to adjust speed when cornering 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 wheel with your hands Br...

Page 299: ... area Using the emergency hammer WARNING When glass is smashed there is a risk of injury caused by glass splinters When the cab glass is smashed splinters of glass can shoot into the face and cause damage to skin and eyes through cuts When a pane of glass is smashed the face should be turned away and covered with the crook of the free arm Protect the face when smashing a pane of glass Pull the eme...

Page 300: ... a risk of fatal injury from falling loads or parts of the truck being lowered Do not walk beneath the raised load Adhere to the steps detailed below WARNING The load is lowered The lowering speed is regulated by unscrewing the emergency lowering screw Note the list of points below Remember the following Tightening torque Max 2 5 Nm When unscrewed a little The load lowers slowly When unscrewed a l...

Page 301: ...rench 2 is attached near to the engine control unit Both of these components can be reached by opening the bonnet The hexagon socket wrench must remain in the truck at all times Open the bonnet see Opening the bon net Take the hexagon socket wrench 2 out of the support mounting 57348011850 EN 02 2019 11 289 ...

Page 302: ...nscrewed a little load is lowered slowly Unscrewed a lot load is lowered quickly Screw the emergency lowering screw 3 back in after the load is lowered Tightening torque max 2 5 Nm Return the Allen key to the support mount ing provided Close the bonnet see Closing the bonnet DANGER If the truck is operated with the hydraulic controller blocked there is an increased risk of accidents After the emer...

Page 303: ...ing towing the truck may drive into the towing vehicle when the towing vehicle brakes Use a tested tow bar for safety reasons Use a tested tow bar CAUTION If the truck drive between the drive motor and the drive axle is not interrupted the drive may be damaged Place the drive direction switch in the neutral position DANGER While manoeuvring there is a risk of fatal injury in the area between the t...

Page 304: ...rection switch to the neutral position Apply the parking brake Switch off the key switch Check the pulling and braking forces of the towing vehicle With a second person as a guide manoeu vre the towing vehicle to the truck Secure the tow bar to the tow coupling on the towing vehicle and on the truck Sit in the driver s seat of the truck being towed and fasten the seat belt Where possible activate ...

Page 305: ...r disconnected in the incorrect order If the batteries negative terminals are connected to the negative cable both bodies are also conducti vely connected to one another If the positive cable touches one of the two bodies as further cables are connected a short circuit can occur Ensure that the correct order is followed when connecting and disconnecting the jump leads Open side cover see Chapter O...

Page 306: ...l on the current giving battery Disconnect the positive cable 2 from the positive terminal on the discharged battery Disconnect the positive cable from the positive terminal on the current giving battery NOTE Leave the engine to run because the battery is not yet sufficiently charged Close side cover see Chapter Closing the side service flap P 5 329 Disconnecting the battery In the event of a danger...

Page 307: ...ocedure in emergencies 7331_690 001 Release battery terminal clip from the negative terminal Lift the battery terminal clip off of the battery negative terminal and place it to the side 57348011850 EN 02 2019 11 295 ...

Page 308: ...Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V D 22113 Hamburg Berzeliusstr 10 2 1 Determining the total actual weight Park the tru...

Page 309: ... secured against moving Maintain a safety distance from the edges loading bridges ramps working platforms etc Drive slowly and carefully onto the transport vehicle 7331_003 002 Inserting wedges Use two wedges to secure each of the front and rear wheels against rolling away Lashing down CAUTION Abrasive lashing straps can rub against the surface of the truck and cause damage Position slip resistant...

Page 310: ...that the lashing straps are tightened securely and that the pads cannot slip off Crane loading Crane loading is only intended for transporting the complete truck including the lift mast for its initial commissioning For application conditions that require frequent loading or that are not dealt with here please contact the manufacturer with regard to special equipment variants Trucks may only be la...

Page 311: ...ight 1 Ballast weight variant 2 Attachment net weight variant Loading weight Hooking on the lifting straps CAUTION Harnesses may damage the truck s paintwork Harnesses may damage paintwork by rubbing and pressing on the surface of the truck Particularly hard or sharp edged harnesses such as wires or chains can quickly damage the surface Use textile harnesses e g lifting straps with edge protectors...

Page 312: ...main traverse 3 on the outer mast of the lift mast Hook crane hooks onto the lifting points 4 intended for the truck rear weight The lifting points are marked with the crane hook symbol Secure the tow bolt Locate the truck s centre of gravity 300 57348011850 EN 02 2019 11 ...

Page 313: ...ed or destroyed LPG may leak out if LPG systems are damaged Secure harnesses in such a way that they do not touch any attachment parts If applicable the LPG cylinder or LPG tank should be disassembled by trained personnel 7335_136 001 Check that harnesses cannot collide with attachment parts Loading the truck DANGER If the raised truck swings in an uncontrolled fashion it may crush people There is...

Page 314: ...n be ignited by hot components Do not use any flammable cleaning materials CAUTION Risk of fire due to flammable materi als Deposits and solids can be ignited by hot components e g drive units Remove deposits and solids CAUTION If water penetrates the electrical system there is a risk of short circuit The engine must be switched off during washing Do not use water to clean the area around the central...

Page 315: ...f at least 20 cm between the nozzle and the object being cleaned Do not aim the cleaning jet directly at adhesive labels or decal information Remove all deposits and accumulations of foreign materials in the vicinity of hot components Use only non flammable fluids for cleaning Observe the manufacturer s guidelines for working with cleaning materials Clean plastics only with cleaning materials intend...

Page 316: ...ements 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 cleaning materials Place a collection vessel under the lift mast Clean with paraffin derivatives such as benzine When using a steam jet do not use addi tional cleaning agents Remove any water in the chain links...

Page 317: ...ow 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 7311_003 058 After washing Carefully dry the truck e g with com pressed air Sit on the driver s seat and start up the truck in accordance with regulations CAUTION Risk of short circuit If any moisture has penetrated into the engin...

Page 318: ... batteries Spray all exposed electrical contacts with a suitable contact spray Preserve the engine as specified by the manufacturer CAUTION Danger of tyre deformation by continuously loading on one side Jack up the truck so that all the wheels are clear of the ground This prevents permanent deformation of the tyres Raise and jack up the truck CAUTION Danger of damage from corrosion due to conden sa...

Page 319: ...LPG cylinder P 4 277 Check the LPG system for leaks with leak spray Check the screw joints of the LPG system for tightness Change the brake fluid DANGER Risk of explosion If the truck has been at a standstill for a long period of time in an enclosed room ventilate the room thoroughly before switching on the electrical system Put the truck into operation During start up check in particular LPG syste...

Page 320: ...4 Operation Decommissioning 308 57348011850 EN 02 2019 11 ...

Page 321: ...5 Maintenance ...

Page 322: ...y or start up inadvertently If required have the truck jacked up by the authorised service centre Have the raised fork carriage or the ex tended lift mast secured against accidental lowering by the authorised service centre Insert an appropriately sized wooden beam as an abutment between the lift mast and the cab and secure the lift mast to prevent it tilting backwards unintentionally Observe the ...

Page 323: ...is only permitted with approval from the authorised service centre Working on the ignition system To prevent personal injury and or destruction of the ignition system please observe the following Only connect and disconnect ignition system lines including high voltage lines and measuring device lines with the ignition switched off If the engine is to be operated at starting speed but not actually ...

Page 324: ...d for the necessary safety and load capacity Only have the truck raised and jacked up by the authorised service centre Only jack the truck up at the points specified in the workshop manual The truck must be raised and jacked up for various types of maintenance work The authorised service centre must be informed that this is to take place Safe handling of the truck and the corresponding hoists is de...

Page 325: ... length matching the total width b1 of the truck is recommended Obtain the dimensions b1 and b3 from the corresponding VDI datasheet 1 2 3 6210_001 030_V3 Clamp the hardwood beam 1 between the driver protection structure 2 and the lift mast 3 Removing the lift mast DANGER Risk of accident This work must only be performed by an authorised service technician Arrange for an authorised service technic...

Page 326: ...principles for testing trucks Maintenance work without special qualifications Simple maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel A qualification such as those held by a competent person is not required to carry out this work The required tasks are described in the chapter entitled Remaining ready for operation Information for carrying out maint...

Page 327: ...he following factors may necessitate shorter maintenance intervals Contaminated poor quality roads Dusty or salty air High levels of air humidity Extremely high or low ambient tempera tures or extreme changes in temperature Multi shift operation with a high duty cycle Specific national regulations for the truck or individual components CAUTION Risk of component damage Any deviating technical inform...

Page 328: ...5 Maintenance General maintenance information 316 57348011850 EN 02 2019 11 ...

Page 329: ...ary Check wheels for damage and check the tightening torques Power unit Check the screw joints and for leaks on the drive axle and clean the cooling fins Check the oil level in the drive wheel unit and multi disc brake Internal combustion engine Check the condition of the internal combustion engine visual inspection Change the engine oil and replace the oil filter Check the toothed belt spur gears a...

Page 330: ... Check that the duration of engine run on before the engine stops is acceptable Steering Check the steering system for correct function and leaks Check that the steering wheel is firmly seated and check the turning handle for da mage Steering axle Check that it is firmly attached check for leaks and apply grease Check the steering stop Brake Check all mechanical brake parts for condition and correct...

Page 331: ...nnections for damage and leaks Check the fork carriage for damage and wear Check the fork arm interlock for damage and correct function Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Special equipment variant Check the fresh air filter in the heating system and beat out the filter if necessary Heating system Check for damage ...

Page 332: ...5 Maintenance General maintenance information 320 57348011850 EN 02 2019 11 ...

Page 333: ...safety cartridge in the air filter Replace the coolant DEUTZ every 6000 hours or 4 years VW every 9000 hours or every 5 years DEUTZ Replace the filter element in the diesel particle filter every 6000 hours LPG system Change all the hoses on the LPG system Hydraulics Change the hydraulic oil Replace the return line filter and the breather filter Replace the high pressure filter For RX70 50 600 7334 7338 ...

Page 334: ...5 Maintenance General maintenance information 322 57348011850 EN 02 2019 11 ...

Page 335: ... For maintenance tasks only use original spare parts and only use consumables that have been prescribed in the overview of consumables Ordering spare parts and wearing parts Spare parts are provided by our spare parts service department The information required for ordering parts can be found in the spare parts list Only use spare parts as per the manufac turer s instructions The use of unapproved...

Page 336: ... only clean containers Lubrication plan Code1 Lubrication point A Four lubricating nipples on each side of the steering axle for the axle stub bearing and track rod arm B Sliding surfaces on the lift mast C Load chains D One lubricating nipple each on both lift mast bearings 1 See the following chapter Maintenance data table under this Code for the respective lubricant specificationThis lubrication...

Page 337: ...1000 Ω V against earth Controls joints Code Unit Operating materials Specifications Dimension High pressure grease ID no 0147873 As required Lubrication Oil SAE 80 MIL L2105 API GL 4 As required Electrical system Code Unit Operating materials Specifications Dimension Insulation resistance DIN EN 1175 VDE 0117 Min 1000 Ω V against earth Hydraulic system Code Unit Operating materials Specifications Dim...

Page 338: ... Unit Operating materials Specifications Dimension Wheel nuts on drive axle Torque wrench 640 Nm Wheel gear Mineral oil FUCHS TITAN GEAR HYP LD SAE 80W 90 Right hand side 1 52 l Left hand side 0 57 l Lift mast Code Unit Operating materials Specifications Dimension B Lubrication High pressure grease ID no 0147873 As required Stop Play Min 2 mm D Lift mast bearing Grease Aralub 4320 DIN 51825 KPF2N20 ...

Page 339: ...sion Standard cab 1400 g System filling Refrigerant ID no 7449600005 Beverage cab 1485 g Fuel tank Code Unit Operating materials Specifications Dimension LPG cylinder LPG tank LPG DIN 51622 EN 589 Approx 11 kg Engine Code Unit Operating materials Specifications Dimension System filling Engine oil SAE 5W 30 in accordance with VW 50700 With filter change 6 9 litres Air filter Filter cartridge and safety c...

Page 340: ...01 1 3 2 Opening the side service flap Turn the left hand quick release clamp 1 clockwise Turn the right hand quick release clamp 2 anticlockwise NOTE The side service flap 3 is secured to the chassis by a lock washer 4 7331_314 002 4 Carefully fold down the side service flap 328 57348011850 EN 02 2019 11 ...

Page 341: ...sis Turn the left hand quick release clamp 2 anticlockwise Turn the right hand quick release clamp 3 clockwise Ensure that the side cover is within the truck contour and is securely locked Opening the bonnet WARNING Risk of injury Switch off the engine before opening the bonnet CAUTION When opening the bonnet the driver s seat may be damaged if it is not positioned all the way forward Slide the dr...

Page 342: ...11_120 001 1 2 Move the steering column 1 as far for wards as possible and secure see section entitled Adjusting the steering column Slide the driver s seat 2 all the way for ward see section entitled Adjusting the MSG 65 MSG 75 driver s seat On trucks equipped with a rear window variant push the seat backrest for wards see section entitled Adjusting the MSG 65 MSG 75 driver s seat 7300_003 007_V2...

Page 343: ...on lock variant make sure that the latch is engaged To replace the gas spring contact the authorised service centre 7300_003 008 2 1 Closing the bonnet WARNING When closing the bonnet there is a risk of crushing When closing the bonnet nothing must come between the bonnet and the edge of the chassis Do not grasp any edges Always close the bonnet by placing both hands on the handles CAUTION Risk of...

Page 344: ...ibly engages 7311_120 001 1 2 Adjust the seat 2 see the section on Adjusting the MSG 65 MSG 75 driver s seat Adjust the steering column 1 see the section on Adjusting the steering column Installing and removing the bottom plate Removing the bottom plate CAUTION Risk of short circuit if cables are damaged Check the connection cables for damage When removing and reinstalling the bottom plate make su...

Page 345: ...E The accelerator pedal is attached to the bottom plate and is removed with the bottom plate The connecting plug for the accelerator is located underneath the bottom plate Open the bonnet Remove the rubber mat Grasp the recess in the bottom plate 1 Raise the bottom plate slightly 7311_003 013 1 Pull out the bottom plate under the brake pedal and set it down upright 57348011850 EN 02 2019 11 333 ...

Page 346: ... limbs or objects are between the bottom plate and frame edge when the bottom plate is closed they can be crushed Make sure that when you close the bottom plate there is nothing between the bottom plate and the frame edge Set down the bottom plate upright in the footwell Connect the connection assembly to the accelerator pedal Position the bottom plate at the front Carefully guide the bottom plate...

Page 347: ...s closed The gas flow to the evaporator is blocked Try to start the engine again If the engine starts leave it running until it stalls again due to the lack of gas This will discharge any gas still in the evaporator CAUTION Risk of damage to components If the engine is prematurely turned off via the key switch residue gas may remain in the evaporator Undercooled gas left in the evaporator expands u...

Page 348: ...ating coil in devices of this kind Applying warm air with a warm air hose is permitted De ice frozen system parts with a temperature 50 C Heating appliances must be set up at a sufficiently safe distance from the truck De ice the evaporator Connect the connection assembly 1 The gas shut off valve is opened The gas flow to the evaporator is available again Switch on the key switch Start engine If the...

Page 349: ... Closing the bonnet Topping up the coolant and checking the coolant concentration CAUTION Risk of engine damage If the cooling fluid level is low this indicates a leak in the cooling system Check the cooling system for leaks see Chapter Cleaning the radiator checking for leaks P 5 354 WARNING Coolant and coolant additives are hazardous to your health Observe the safety regulations for handling cool...

Page 350: ...ter Screw the coolant reservoir filler cap 1 back on tightly Concentration of the coolant additive CAUTION Risk of corrosion The percentage of coolant additive must always be at least 40 even if frost protection is not needed in warmer climates If an increased level of frost protection is required for climatic reasons the percentage of coolant can be increased to up to 60 The percentage of coolant ...

Page 351: ...cording to the manu facturer s guidelines 8 9 0 6 7 4 3 5 7312_003 070_en_V2 Replacing the air filter cartridges NOTE The filter cartridge must be replaced when the AIR FILTER message appears on the display and operating unit or every two years Open the side service flap see the chapter entitled Opening the side service flap 7321_003 075 1 1 1 2 Release the three clamps 1 on the air filter and remove t...

Page 352: ...in the air filter housing until all residual dirt has been removed from the housing so that no dirt enters the intake system Wipe out the air filter housing using a damp cloth 4 7321_003 077 Remove the safety cartridge 4 check for contamination and change it if necessary Refit the safety cartridge Insert a new main cartridge 3 340 57348011850 EN 02 2019 11 ...

Page 353: ... joints according to the maintenance data table see Chapter Maintenance data table P 5 325 Driver s seat guide Lubricate bonnet hinges at the lubricating nipple Control linkage for valves In the cab lubricate door hinges at the lubricating nipple variant Lubricate shafts and joints in dual pedal operation variant Checking the door latch Inspect the condition of the catch bolt and check for wear Ch...

Page 354: ...ave a defective belt replaced by your service centre Only use genuine spare parts Do not make any changes to the belt NOTE Carry out the following checks on a regular basis monthly In the case of significant strain a daily check is necessary Checking the seat belt 6327_342 009 1 2 3 Pull out the belt 3 completely and check for wear The belt must not be frayed or cut The stitching must not be loose ...

Page 355: ...extension of the belt Cleaning the seat belt Clean the seat belt as necessary but without using chemical cleaning materials a brush will suffice Replacement after an accident As a rule the seat belt must be changed after an accident 6327_342 010 Checking the driver s seat WARNING Risk of injury After an accident check the driver s seat with attached restraining belt and fastening Check the controls...

Page 356: ...1_003 091 2 1 Model RO 243 Pull out the safety handle 3 Push the hand lever 2 upwards Grease using the lubricating nipple 1 in accordance with the maintenance data table see Chapter Maintenance data table P 5 325 Close the coupling by raising the coupling pin with a suitable tool For journeys with a rigid drawbar trailer lubricate the underside of the tow bar eye and the supporting surface on the ...

Page 357: ...Maintenance data table P 5 325 Grease coupling pin tow bar eye and its supporting surface 7321_003 094 Model RO 245 Lubricate via the points provided for this purpose lubricating nipple opened cou pling in accordance with the maintenance data table see Chapter Maintenance data table P 5 325 Grease the supporting surface for the tow bar eye 57348011850 EN 02 2019 11 345 ...

Page 358: ...ly the same Worn or damaged tyres left or right must be replaced immediately When changing wheels or tyres ensure that this does not cause the truck to tilt to one side e g always replace right hand and left hand wheels at the same time Changes must only be made following consulta tion with the manufacturer WARNING Risk to stability Tyre quality affects the stability of the truck There is a risk o...

Page 359: ...iant can be worn down to the 60 J wear mark Remove any foreign bodies embedded in the tyre Pneumatic tyres variant Check the tread depth on all four tyres The tread depth for pneumatic tyres variant must be at least 1 6 mm at every point on the tread If the tread is worn down to the wear mark 2 at any point on the tyre replace the tyres on one axle Remove any foreign bodies embedded in the tyre 57...

Page 360: ...pressure of all four tyres and compare with the air pressure values stated on the adhesive labels Add or release air as required if the air pressure deviates from the values stated 4 7321_003 112 Checking wheel fastenings Check that all wheel fastenings 4 are se curely fastened and retighten as necessary Observe the relevant torques see section entitled Maintenance data table Servicing the battery...

Page 361: ...ica tor changes back to green Transparent light coloured The charge status is no longer adequate for the truck to start reliably The battery must be replaced Charging the battery For batteries that are not maintenance free check the level of the battery acid WARNING The electrolyte dilute sulphuric acid is poisonous and caustic Observe the safety regulations for handling battery acid Chap ter Batt...

Page 362: ...s must be clear to ensure sufficient ventilation The charging area must be properly ventilated Keep the bonnet open during char ging avoid spark formation near the battery Charge discharged batteries immediately until they are fully charged again The charging current must not exceed 1 10 of the capacity The battery cell covers must be kept dry and clean Any spilled battery acid must be neutralised ...

Page 363: ... Close the cover to secure the fuse box Install the back covers Perform a function check If the error persists or if the fuse is still defective notify your authorised service centre 1 6210_800 020 Lubricating the lift mast and roller track Remove dirt and lubricant residue from the roller track Lubricate the roller tracks 1 of the outside middle and inside mast with a super pressure adhesion lubr...

Page 364: ...5 Maintenance Preserving operational readiness 352 57348011850 EN 02 2019 11 ...

Page 365: ...Maintenance 5 Preserving operational readiness Other tasks Perform all tasks required to maintain full operability see the chapter entitled Remaining ready for operation 57348011850 EN 02 2019 11 353 ...

Page 366: ...bar Check the radiator and coolant hoses for leaks and tighten the clips if necessary CAUTION Risk of engine damage If the cooling fluid level is low this indicates a leak in the cooling system Check whether the leakage has been eliminated If not notify the authorised service centre Close the bonnet Checking the reversible fork arms NOTE This check is only required for reversible fork arms variant ...

Page 367: ...correct operation of the fork latch Move the locking lever 3 into a vertical position It must be possible to move the fork arm Move the locking lever into a horizontal position The latch must engage in a recess on the fork carriage It must not be possible to move the fork arm Replace faulty fork latches Checking the hydraulic oil level CAUTION Hydraulic oils are hazardous to your health and are un...

Page 368: ...level pour hydraulic oil of the corresponding specification see Chapter Maintenance data table P 5 325 into the filler neck until it reaches the upper mark as a maximum NOTE Use a funnel Insert the breather filter with oil dipstick back into the filler neck and screw it in tightly Close the side cover again see chapter entitled Closing the side cover ENVIRONMENT NOTE Carefully collect any spilled oil ...

Page 369: ...G Hydraulic oil is hazardous to health Hydraulic oil under pressure can escape from leaking pipes and lines and cause injuries Wear suitable protective gloves protection 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 for more than...

Page 370: ...abnormalities Outer layer has been damaged or is brittle or cracked Leaking Deformation e g with blisters or kinks A fitting has come loose A fitting is badly damaged or corroded Replace pipes if they display the following abnormalities Abrasion Deformation and bending Leaking 358 57348011850 EN 02 2019 11 ...

Page 371: ...6 Technical data ...

Page 372: ... is adjustable 80 mm Seat is adjustable 90 mm Fork spacing is adjustable NOTE Measurements h1 h3 h4 h6 and b1 are customised and can be taken from the order confirmation Centre of gravity S distance measured from the front axle 360 57348011850 EN 02 2019 11 ...

Page 373: ... e g the type of lift mast any attachments or the driver protection structure This can vary from one truck to another If necessary the centre of gravity S must be determined individually for each truck Please contact the qualified service centre in relation to this matter 57348011850 EN 02 2019 11 361 ...

Page 374: ...tre of gravity c mm 500 500 500 600 Load distance x mm 540 540 540 550 Wheelbase y mm 2005 2005 2070 2125 Weight RX70 40 RX70 45 RX70 50 RX70 50 600 Net weight kg 6075 6279 6590 7174 Axle weight with front load kg 8896 9632 10468 11014 Axle load without front rear load kg 2821 3255 2798 3480 2956 3635 3308 3866 Wheels chassis frame RX70 40 RX70 45 RX70 50 RX70 50 600 Tyres superelastic SE solid ru...

Page 375: ...2300 2300 2300 2300 Seat height h7 mm 1298 1298 1298 1298 Coupling height h10 mm 496 496 496 496 Total length l1 mm 4027 4071 4198 4368 Length from Fork back l2 mm 3027 3071 3098 3168 Total width b1 1380 1506 1506 1506 Fork arm dimensions s e l mm 50 120 1000 50 120 1000 50 120 1000 50 210 1200 Fork carriage according to ISO 2328 Class Form A B Category III Form A Category III Form A Category III ...

Page 376: ... with without load 30 30 30 30 Acceleration time with with out load s Service brake Mechanical Mechanical Mechanical Mechanical Engine RX70 40 RX70 45 RX70 50 RX70 50 600 Engine manufacturer type VW CKPA VW CKPA VW CKPA VW CKPA Engine power rating as per ISO 1585 kW 55 55 55 55 Nominal speed rpm 1200 1200 1200 1200 Maximum torque Nm 255 255 255 255 Number of cylinders cc cm3 6 3600 6 3600 6 3600 6...

Page 377: ... from the tyres approved by the truck manufacturer or tyres from a different manufacturer you must first obtain approval from the truck manufacturer WARNING Risk to stability When using pneumatic tyres or solid rubber tyres rim parts must never be changed and rim parts from different manufacturers must not be mixed Consultation with the authorised service centre is recommended before changing over ...

Page 378: ... 00 15 5 5 250 15 1364 1120 Up to 3250 Up to 3200 Pneumatic tyres Pneumatic 1136 250 15 18PR 250 15 1136 1120 Up to 3250 Up to 3200 Pneumatic 153 A5 XZM TL 250 70R15 250 15 1136 1120 Up to 3250 Up to 3200 Pneumatic 1364 twin tyres 7 00 15 250 15 1364 1120 Up to 3250 Up to 3200 RX70 45 tyres Type of tyre Tyre size Track width mm Lift mast Overall height in mm Front Rear Front Rear Telescopic Triple...

Page 379: ... 50 15 250 15 1210 1120 Up to 3250 Up to 3200 SIT 355 50 15 250 15 1210 1120 Up to 3250 Up to 3000 SIT 355 50 15 250 15 1210 1120 Up to 3250 Up to 3200 SITn 355 50 15 250 15 1210 1120 Up to 3250 Up to 3200 SITa 28x12 5 15 250 15 1210 1120 Up to 3250 Up to 3000 SITa 7 00 15 5 5 250 15 1364 1120 Up to 3250 Up to 3200 Pneumatic tyres Pneumatic 1364 twin tyres 7 00 15 250 15 1364 1120 Up to 3250 Up to...

Page 380: ...5 250 15 1364 1120 Up to 3250 Up to 3200 Pneumatic tyres Pneumatic 1364 twin tyres 7 00 15 250 15 1364 1120 Up to 3250 Up to 3200 Fuse assignment Fuse Connection Comment 1F08 10 A 12 volt battery constant positive terminal Reserve 1F09 10 A Switch lock terminal 30 1F10 10 A Coolant pump RX70 40 50 LPG 1F11 10 A Converter 1F12 15 A Reserve 1F15 10 A 12 volts for TCU display and operating unit 1F16 ...

Page 381: ... A Exhaust gas controller butterfly valve RX70 40 50 DOC 15 A Spark ignition control unit RX70 60 80 1F22 15 A Pulse valve ignition module 4 6 RX70 40 50 LPG 4F01 10 A Signal horn 5F11 30 A CPP1 roof 5F12 20 A CPP2b lighting 5F13 30 A CPP3 seat 5F14 20 A 12 volts for ECU Deutz ECU 9F03 10 A 12 volts for Option Board 20 A Starter terminal 50 RX70 40 50 LPG 9F04 30 A Fuel pump RX70 40 50 DOC DPF NOTE...

Page 382: ...6 Technical data Fuse assignment 370 57348011850 EN 02 2019 11 ...

Page 383: ...lus and the 5th function 209 Controlling using the quadruple mini lever and the 5th function 206 Controlling using the triple mini lever and the 5th function 202 Controlling via the joystick 4Plus 208 Controlling with a quadruple mini lever 204 Controlling with a triple mini lever 200 Controlling with the fingertip 210 Controlling with the fingertip and 5th function 211 General controlling 194 Mount...

Page 384: ...t valve 109 Cleaning the electrical system 304 Cleaning the truck 302 Cleaning the windows 305 Climbing into the truck 71 Climbing out of the truck 71 Closing the bonnet 331 Closing the cab door 238 Closing the side windows 239 Consumables 43 Coolant and cooling fluid safety information 50 Disposal 50 Safety information for handling battery acid 46 Safety information for handling oils 44 Safety inf...

Page 385: ... lights Switching on and off 217 Driving on gradients 127 Driving on lifts 187 Driving on loading bridges 188 E EC declaration of conformity in accordance with Machinery Directive 5 Emergencies Disconnecting the battery 294 Truck tipping over 286 Using the emergency hammer 287 Emergency hammer 287 Emergency lowering 288 Emergency shutdown 285 Emissions 52 Exhaust gases 52 Heat 53 Noise emissions 5...

Page 386: ...the roller track 351 Removing 313 Securing against falling off 313 Securing against tilting backwards 313 Lift mast versions Triplex lift mast 153 Lift mast vertical position 148 Automatic approach 150 Calibrating 152 Description 148 Display 150 Possible restrictions 152 Run in to end stops 150 Tilting the lift mast backwards 151 Tilting the lift mast forwards 151 Lifting 312 Lifting system Contro...

Page 387: ...Y HANDBRAKE 261 ARE YOU SURE 266 ASH LOAD 272 BRAKE SENSOR 261 CODE DENIED 262 COOLANT LEVEL 273 CUTOUT MODE 270 EMERGENCY SWITCH 263 EMPTY 273 EXH GAS PURIFIER 269 EXH GAS PURIFIER PLEASE WAIT 270 EXH GAS PURIFIER SERVICE 270 FUEL FILTER 273 GLOW 272 HYBRID SYSTEM 272 HYDRAULIC PUMP 272 LOWER FORKS 263 LPG AUTO VALVE 274 NOT VALID 269 OIL PRESSURE 274 OVERHEATING 268 PARK REG ERROR 275 PARK REG U...

Page 388: ... compartment 57 Truck 56 P Packaging 20 Parking brake Mechanical parking brake 138 Parking the truck securely 144 Personnel qualifications 314 Picking up loads 174 Place of use 10 Procedure if truck tips over 286 Production number 8 Prohibition of use by unauthorised persons 24 Proper usage 9 Q Quadruple mini lever Lifting lowering the fork carriage 159 Tilting the lift mast 159 R Radiator Checking...

Page 389: ...function 183 Double mini lever 185 Fingertip switch 187 Joystick 4Plus 185 Quadruple mini lever 186 Triple mini lever 186 Shock recognition 120 227 Shutdown 306 Shutting down the truck 306 Side service flap Closing 329 Opening 328 Special risks 34 Stability 34 Starting drive mode Dual pedal version 134 Starting the engine 103 Starting to drive 132 Status LEDs 116 Steering 140 Steering system Checki...

Page 390: ...hock 146 Windscreen wiper washer 226 Zero braking 138 Vertical lift mast position Checking for correct function 107 View of functions and operations 18 View of operating procedures 18 Views of the display operating unit 19 Visual inspections 68 W Warning regarding non original parts 27 Wheel chock 146 Wheels and tyres Checking condition and wear of the tyres 347 Checking the air pressure 348 Check...

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Page 392: ...STILL GmbH 57348011850 EN 02 2019 11 ...

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