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Still RX70 Series, Original Instructions Manual

The Still RX70 Series boasts exceptional reliability and performance. Enhance your user experience with our user-friendly Quick Reference Manual, available for free download on our website. Maximize productivity and efficiency with this comprehensive manual, ensuring seamless operation of your RX70 Series.

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Table of contents

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Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Recommissioning after decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

5 Maintenance

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Maintenance - 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Maintenance - 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 324
Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Opening the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Closing the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Removing and attachingthe left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Installing and removing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Opening and closing the right-hand service flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Remaining ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Cleaning the dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Checking the pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Checking the oil tank on the oil bath air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Checking the cooling fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

57348011800 EN - 11/2018

IX

Summary of Contents for RX70 Series

Page 1: ...Original instructions Diesel trucks With SCR Selective Catalytic Reduction RX70 60 RX70 70 RX70 80 RX70 80 900 7341 7342 7343 7344 57348011800 EN 11 2018 ...

Page 2: ......

Page 3: ...ies 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 a...

Page 4: ......

Page 5: ...ssible use 15 Place of use 16 Using working platforms 17 Information about the documentation 18 Documentation scope 18 Supplementary documentation 19 Issue date and topicality of the operating instructions 20 Copyright and trademark rights 20 Explanation of information symbols used 20 List of abbreviations 21 Definition of directions 23 Schematic views 23 Environmental considerations 25 Packaging 2...

Page 6: ...45 Safety tests 46 Regular safety inspection of the truck 46 Checking the diesel engine emissions 46 Particle filter 47 Insulation testing 48 Safety regulations for handling consumables 49 Permissible consumables 49 Oils 49 Hydraulic fluid 50 Battery acid 51 Diesel fuel 52 Coolant and cooling fluid 54 Disposal of consumables 54 Emissions 56 3 Overviews Overview 60 Driver s compartment 62 Operating de...

Page 7: ...g 94 Switching on the key switch 94 Access authorisation with PIN code variant 97 Starting the engine 107 Operating the display and operating unit 109 Displays 109 Adjusting the displays 110 Symbols in the display 111 Setting the date or time 116 Resetting the daily kilometres and daily operating hours 117 Setting the language 117 Softkeys for operating various equipment variants 118 Configuring Bl...

Page 8: ...lift cut out variant 145 Lift mast vertical position variant 146 Types of lift mast 150 Malfunctions during lifting mode 151 Hydraulic blocking function 152 Lifting system operating devices 153 Controlling the lifting system using a double mini lever 154 Controlling the lifting system using a triple mini lever 155 Controlling the lifting system using a quadruple mini lever 156 Controlling the lift...

Page 9: ...n 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 equipment 217 Switching the lighting on and off 217 Switching the worki...

Page 10: ...essages 257 Display content 257 Error code table 258 General messages 261 Drive specific messages 270 Refuelling 277 Diesel fuel Specifications 277 Filling up with diesel fuel 280 Using the fuel hand pump 281 Topping up AdBlue 283 Cleaning 284 Cleaning the truck 284 Cleaning the electrical system 286 Cleaning load chains 286 Cleaning the windows 287 After washing 287 Procedure in emergencies 288 Eme...

Page 11: ...ance 314 Maintenance 500 hours 317 Maintenance 1000 hours annually 319 Maintenance 3000 hours every two years 323 Ordering spare parts and wearing parts 323 Quality and quantity of the required operating materials 324 Lubrication plan 325 Maintenance data table 326 Providing access to maintenance points 329 Opening the bonnet 329 Closing the bonnet 331 Removing and attachingthe left side cover 333...

Page 12: ... latch 356 Replacing the recirculated air filter for the heating system 356 Servicing wheels and tyres 357 Replacing the fuses 359 Checking the hydraulic oil level 360 Checking the hydraulic system for leak tightness 362 Lubricating the lift mast and roller track 363 Greasing the automatic tow coupling 363 6 1000 hour maintenance annual maintenance Other tasks 368 Checking the exhaust gas system 36...

Page 13: ...1 Foreword ...

Page 14: ...d an SCR system This means that it is suitable for indoor and outdoor use and complies with the currently applicable emission directives The series is suitable for multi shift operation and supports all FleetManager 4 x functions Brake system The brake system of the truck is comprised of three different brakes Service brake Regenerative brake Parking brake The service brake is based on a wear free...

Page 15: ...ic circuits can be used to activate attachments variant Depending on the equipment a hydraulic accumulator is also available in the lifting circuit for the purpose of dampening pressure peaks in the hydraulic system Drive concept The truck is equipped with an internal combus tion engine with an engine power rating of 80 kW This uses an AC motor to generate current for an electrical traction motor ...

Page 16: ...operational movements to allow efficient working The forces that need to be applied for this purpose are reduced to a minimum thanks to the compact steering wheel Operational information such as the fuel level or an indication that the Blue Q energy saving mode is enabled is shown in the display operating unit For drive mode the truck features either single pedal or dual pedal operation The acceler...

Page 17: ... technology understand it and use it safely these operating instructions provide the necessary information 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 ...

Page 18: ...e truck can be operated without restrictions CE Symbol CE labelling The manufacturer uses CE labelling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is confirmed by the issued EC declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addition to the truck can compromise safety thus inv...

Page 19: ...113 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 57348011800 EN 11 2018 7 ...

Page 20: ...1 Foreword Your truck Accessories Key for key switch two pieces Key for cab variant Hexagon socket wrench for emergency lowering 8 57348011800 EN 11 2018 ...

Page 21: ...Foreword 1 Your truck 57348011800 EN 11 2018 9 ...

Page 22: ...üfung FEM 4 004 nach nationalen Vorschriften basierend auf den EG Richtlinien 2009 104 EG 99 92 EG Die Prüfplakette ersetzt nicht das Prüfprotokoll Nächste Prüfung 56344391019 Mitglied der Fédération Européene de la Manutention STILL GmbH Hamburg 20xx 4 6 10 16 17 12 10 bar 9 8 DANGER 7 13 14 11 15 9 4 2 3 5 18 8 9 14 13 10 11 1 12 7 6 15 17 16 10 57348011800 EN 11 2018 ...

Page 23: ...bonnet 7 Decal information Hydraulic oil tank 8 Decal information Tyre filling pressure variant 9 Warning sign Do not stand underneath the fork Do not stand on the fork 10 Decal information StVZO German Road Traffic Licensing Regulations information variant 11 Decal information Nameplate 12 Warning sign Actuate accumulator brake pedal 30x read operating instructions 13 Warning sign Danger due to she...

Page 24: ...1 Foreword Your truck Overview of the rear of the truck and the right hand side of the truck 4 6 5 7 1 2 11 DANGER DANGER 9 6 8 5 7 10 bar 1 2 3 10 3 3 8 9 10 11 12 57348011800 EN 11 2018 ...

Page 25: ... 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 1 2 3 4 4 5 6 7 9 10 11 12 13 6210_921 003_V3 8 1 Type 2 Production number 3 Year of manufacture 4 Tare weight in kg 5 Max permissible battery weight...

Page 26: ... 2 Model 3 Year of manufacture 4 Sequential number 7094_003 098 1 2 3 4 5 1 Tare weight in kg 2 Permitted total weight in kg 3 Permitted front axle weight in kg 4 Permitted rear axle weight in kg 5 Payload in kg StVZO Road Traffic Licensing Regulations information This label includes information on the weight and load distribution of the truck Using the truck Proper usage The truck described in the...

Page 27: ...ing of trailers and is equipped with a towing device for this purpose This occasional towing may not exceed 2 of the daily operating time If the truck is to be used for towing on a more regular basis the manufacturer should be consulted The regulations regarding trailer operation must be observed see chapter Trailer operation Impermissible use The operating company or driver and not the manufactur...

Page 28: ...the country in which it is being used The ground must have an adequate load capacity concrete asphalt and a rough surface Routes work areas and aisle widths must conform to the specifications in these operating instructions see the Routes chapter Driving on upward and downward gradients is permitted provided the specified data and specifications are observed see the Routes chapter The truck is suitab...

Page 29: ...nt systems e g catalytic converters particle filters or comparable systems can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure sufficient ventilation Using working platforms WARNING The ...

Page 30: ...er 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 instr...

Page 31: ...lease 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 ...

Page 32: ... 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 stri...

Page 33: ...BGG 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 C...

Page 34: ...rk 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 ...

Page 35: ... 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 ...

Page 36: ...rating 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 24 57348011800 EN 11 2018 ...

Page 37: ...properly 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 NO...

Page 38: ...1 Foreword Environmental considerations 26 57348011800 EN 11 2018 ...

Page 39: ...2 Safety ...

Page 40: ...eer 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 time this per...

Page 41: ...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 gloves...

Page 42: ...e 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 30 57348011800 EN 11 2018 ...

Page 43: ...handling 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 T...

Page 44: ...ter 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 45: ... 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 ...

Page 46: ...esponsible fleet manager immediately so that they can have the defect rectified Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired Do not remove or deactivate safety systems and switches Fixed set values may only be changed with the approval of the manufacturer Work on the electrical system e g connecting a radio additional headligh...

Page 47: ...ly use wheels and tyres approved by the manufacturer Only use high quality products Wheels and tyres approved by the manu facturer can be found on the spare parts list If other wheels or tyres are to be used au thorisation from the manufacturer must be obtained beforehand Contact the authorised service centre on this matter When changing wheels or tyres always ensure that this does not cause the t...

Page 48: ...ctions on the truck can be supported by gas springs Gas springs are complex components that are subject to high internal pressures up to 300 bar They may under no circumstances be opened unless instructed to do so and may be installed only when not under pressure If required the authorised service centre will depressurise the gas spring in accordance with the regulations before removal Gas springs...

Page 49: ...up In addition be aware that the load centre of gravity may shift as a result of dynamic forces such as braking A load that is otherwise resting safely on the fork arms may move forwards and fall If the fork arms are too long they can catch on loading units behind the load that is to be picked up These other loading units then fall over when the load is raised For help with selecting the correct f...

Page 50: ...cident 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 g...

Page 51: ...ect 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 t...

Page 52: ...sk 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 40 57348011800 EN 11 2018 ...

Page 53: ...Safety 2 Residual risk 57348011800 EN 11 2018 41 ...

Page 54: ...only 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 visibilit...

Page 55: ...d 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 ...

Page 56: ...ndustrial 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 car...

Page 57: ...e 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 overvi...

Page 58: ...om the inspection must be retained until a further two inspections have been carried out The inspection date is indicated by an adhe sive label on the truck Arrange for the service centre to perform periodic safety inspections on the truck Observe 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 de...

Page 59: ...stems e g catalytic converters particle filters or comparable systems can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure that there is sufficient ventilation available NOTE Observe the ...

Page 60: ...ufficient insu lation resistance For this reason insulation testing in accordance with DIN EN 1175 and DIN 43539 VDE 0117 and VDE 0510 must be conducted at least once every year NOTE Contact your service centre to arrange for an insulation test Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage test voltage 500 V Ensure that all voltage sources have been disco...

Page 61: ...e substances that are necessary for operation see Chapter Maintenance data table P 5 326 Oils DANGER Oils are flammable Follow the statutory regulations Do not allow oils to come into contact with hot engine parts No smoking fires or naked flames DANGER Oils are toxic Avoid contact and consumption If vapour or fumes are inhaled move to fresh air immediately In the event of contact with the eyes rinse...

Page 62: ... immediately with oil binding agents and disposed of according to the regulations ENVIRONMENT NOTE Oil is a water polluting substance Always store oil in containers that comply with the applicable regulations Avoid spilling oils Spilt oil should be removed immediately with oil binding agents and disposed of according to the regulations Dispose of old oils according to the regula tions Hydraulic flu...

Page 63: ...e appropriate personal protective equipment e g protective gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers that comply with regulations Avoid spills Spilt hydraulic fluid should be removed immediately with oil binding agents and disposed of according to the regulations Dispose o...

Page 64: ...ately rinse away spilt battery acid with plenty of water Follow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Diesel fuel WARNING Diesel fuel is combustible Observe statutory regulations Do not allow diesel fuel to come into contact with hot engine components Do not smoke WARNING Diesel fuel is toxic Avoid contact and swallowing If ...

Page 65: ...ely change soaked clothing and shoes WARNING Risk of slipping due to spilled diesel fuel particularly in combination with water Immediately collect spilled diesel fuel using an oil binding agent and dispose of it in accordance with regulations ENVIRONMENT NOTE Diesel fuel is a water polluting substance Always store in regulation containers Avoid spilling diesel fuel Immediately collect spilled die...

Page 66: ...Observe 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 67: ...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 57348011800 EN 11 2018 55 ...

Page 68: ...t LpAZ Measurement uncertainty KpA 75 0 dB A 4 dB A The values were determined in the test cycle on an identical machine from the weighted values for operating statuses and idling Time proportions Lifting 18 Idling 58 Driving 24 However the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC ...

Page 69: ...nty 0 31 m s2 0 093 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than 2 5 m s2 There are therefore no measure ment guidelines for these measurements The personal vibration load on the driver over a working day must be determined by the operating company at the actual place of use in accordance with Dire...

Page 70: ...d risk of poisoning when operating the truck Always observe the national laws and regulati ons of the country of use when using trucks with an internal combustion engine in entirely or par tially enclosed working areas Always ensure sufficient ventilation Heat DANGER Risk of burns due to hot exhaust gases Exhaust gases or components that carry exhaust gases e g exhaust pipes can become so hot that ...

Page 71: ...3 Overviews ...

Page 72: ...he drive direction 1 2 3 4 5 6 7 8 9 10 11 7341_003 002_V3 1 Lift mast 2 Driver s compartment 3 Overhead guard 4 Bonnet 5 Battery maintenance lid 6 Steering axle 7 Drive axle 8 Tilt cylinder 9 Fork arms 10 Fork carriage 11 Lift cylinder 60 57348011800 EN 11 2018 ...

Page 73: ...ew Right hand side when viewed in the drive direction 3 2 1 5 4 6 1 Fresh air filter for heating system 2 AdBlue filler neck 3 Tank filler neck 4 Right hand service flap 5 Coupling pin 6 Pre cleaner 57348011800 EN 11 2018 61 ...

Page 74: ...or operating instructions 6 Operating devices for hydraulic and traction functions 7 12 V socket 8 Compartment 9 Bottle holder for bottles of max 0 5 l 10 Driver s seat 11 Storage compartment storage compart ment with cover variant 12 Compartment 13 Filler cap for windscreen washer reservoir variant 14 Accelerator pedal 15 Brake pedal 16 Steering column adjustment lever NOTE The truck equipment ma...

Page 75: ...tor 15 Operating hours display 16 Time display digital 17 Particle filter display 18 Rotating beacon display 19 Interior lighting display 20 Rear window heating display 21 Softkey Interior light rotating beacon 22 Softkey Rear window heating particle filter regeneration 23 Menu change button 24 Lighting button 25 Blue Q button 26 Rear window wiper button NOTE The Softkeys 5 21 22 and the accompa nyi...

Page 76: ...for hydraulic and driving functions Different versions of the operating devices are available for operating the truck s hydraulic and traction functions 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 64 57348011800 EN 11 2018 ...

Page 77: ...3 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 57348011800 EN 11 2018 65 ...

Page 78: ...ive 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 66 57348011800 EN 11 2018 ...

Page 79: ...tion 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 57348011800 EN 11 2018 67 ...

Page 80: ...the 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 68 57348011800 EN 11 2018 ...

Page 81: ...ton 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 57348011800 EN 11 2018 69 ...

Page 82: ...ing 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 70 57348011800 EN 11 2018 ...

Page 83: ...4 Operation ...

Page 84: ...rom top to bottom before daily use of the truck If damage or other defects are identified on the truck or the attachment variant the truck must not be used until it has been properly repaired Ensure that the truck is safe for operation each day before it is used Component Course of action Fork arms general lifting accessories Perform a visual inspection to check for deformation and wear e g to chec...

Page 85: ...and 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 ...

Page 86: ...r are fitted In the event of uneven tyre wear replace both tyres Observe 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 74 57348011800 E...

Page 87: ...re 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 may become damaged through incorrect use Truck components such as the driver s seat steering wheel parking brake lever etc are not designed to be use...

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

Page 89: ...ld on Place your left foot on the bottom step 5 Place your right foot on the middle step 6 Place your left foot on the top step 7 Place your right foot into the footwell 8 Enter the truck and sit down on the driver s seat 3 Always climb out of the truck backwards Grip handle 2 with your left hand and hold on Stand up from the driver s seat and place your left foot on the top step 7 Grip the handle...

Page 90: ...er s seat DANGER There is a risk of accident if the seat or seat backrest shifts suddenly which could cause the driver to move in an uncontrolled manner This may result in unintentional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion Do not adjust the seat or seat backrest while driving Adjust the seat and the seat backrest so that...

Page 91: ... s seat Lift and hold the lever 1 Push the driver s seat into the desired position Release the lever Ensure that the driver s seat 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...

Page 92: ...ed with 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 c...

Page 93: ...upport 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 573...

Page 94: ...the 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...

Page 95: ...nd wheel 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 adj...

Page 96: ...lus variant have an emergency off switch Pull out the emergency off switch 1 until it unlatches F1 F1 F2 F2 7341_003 060 1 1 1 Operating the signal horn Push the signal horn button 1 The signal horn sounds NOTE The signal horn is used to warn people against imminent danger or toannounce yourintention to overtake 84 57348011800 EN 11 2018 ...

Page 97: ...you need to open or remove the doors you must use an alternative suitable restraint system e g a seat belt 7311_003 048 1 2 3 Fastening the seat belt DANGER Risk to life when driving without a seat belt If the truck tips over or crashes into an obstacle and the driver is not wearing the seat belt the driver may be thrown from the truck The driver could slide under the truck or collide with an obst...

Page 98: ...ing mechanism permits sufficient freedom of movement on the seat Click the belt tongue 2 into buckle 1 Check tension of the seat belt It should be close to the body 6210_342 005 Fastening on a steep slope The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient It is not possible to pull the seat belt any further out of the belt retractor Move...

Page 99: ...ll 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 belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold If the buckle or belt retractor is frozen thaw them out and dry them thoroughly to prevent recurrence CAUTION The sea...

Page 100: ...y 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 Checking the br...

Page 101: ...rolls away The truck could run people over if the parking brake is not applied Do not exit the truck during the following check Stop the truck on a steep gradient e g a ramp and actuate the parking brake The parking brake must hold the truck on the incline If the truck rolls back despite the parking brake being applied Secure the truck using the service brake Secure the truck with wedges so that t...

Page 102: ...ll be obstructed Accelerate the truck to walking speed Use the key switch to switch off the engine Apply the parking brake The truck must decelerate and remain station ary If the truck only coasts and does not deceler ate or decelerates only slightly Secure the truck using the service brake Secure the truck with wedges so that the truck does not roll away Contact your authorised service centre 1 2...

Page 103: ...peed limitation 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 Checking the emergency off function NOTE Only trucks with a joystick 4Plus variant have an emergency off switch WARNING No electric braking assistance is available when the emergency off switch is actuated...

Page 104: ...k forwards 6321_003 142 1 Press the emergency off switch 1 The truck will coast Brake the truck to a standstill by actuating the brake pedal Pull out the emergency off switch 1 The knob is unlocked and pops out The truck performs an internal self test and is then ready for operation again Zero adjustment of the load mea surement variant NOTE A zero adjustment must be carried out in order to guaran...

Page 105: ... The zero adjustment of the load measurement is switched on The symbol is displayed The message LOWER FORKS appears on the display 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 zero adjustment will not be accurate To stop the lowering procedure quickly release the operating devi...

Page 106: ...op in the vertical position Release the operating device to tilt and actuate again The lift mast must tilt forwards fully and move gently as far as the end stop Switching on and starting 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 Carry out the checks and tasks that are to be performed ...

Page 107: ... steering wheel by approximately half a turn I 1 0 5060_003 029_V2 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 57348011800 EN 11 2018 95 ...

Page 108: ... elements In the factory setting the following indicators can be seen in the display and operating unit 1 Fuel level Shows the fuel level in the fuel tank as a percentage 2 Drive programme Displays the current drive programme numerically 1 5 The drive programme can be changed see the chapter entitled Setting the drive programme 3 Operating hours Displays the total operating hours completed by the ...

Page 109: ...cks equipped with the Access authori sation with PIN code variant are protected against unauthorised use by a five digit driver PIN Up to fifty different driver PINs can be defined so that the same truck can be used by different drivers each with their own driver PIN NOTE The driver PINs are defined in a truck control unit menu that can only be accessed by persons with the corresponding access authori...

Page 110: ...on as the highest valid driver PIN is 99999 Persons with the appropriate access authorisation e g fleet managers can change the driver PINs in the corresponding menu NOTE When first commissioning the truck we re commend you change the access authorisa tion set at the factory This is the only way to guarantee that the driver PIN is only known to persons with corresponding access authori sation The dr...

Page 111: ...tered for the driver PIN 2 are not visible but are represented by circles instead If the driver PIN entered is correct the familiar screen appears with the standard display and all truck functions are available 8 9 6 7 4 2 0 1 3 5 BQ_023_en_V2 If an incorrect driver PIN is entered the message INVALID appears for a short time When the message goes out the driver PIN can be re entered 57348011800 EN...

Page 112: ... be defined only by per sons with the appropriate access authorisa tion e g fleet managers To set the driver PIN the fleet manager must access the con figuration menu The configuration menu is password protected After entering the pass word the fleet manager can configure general settings for the truck To change the pass word see the chapter entitled Changing the password Push the drive program selection...

Page 113: ...e four digit password factory default 2777 using the buttons 1 Confirm the input using Softkey 2 8 9 6 7 4 2 0 1 3 5 BQ_31_en 1 3 2 CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the ACCESS CODE menu Confirm your selection using Soft key 2 57348011800 EN 11 2018 101 ...

Page 114: ...essed 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 desired driver PIN 1 to 50 Confirm your selection using Soft key 3 NEW CODE appears in the display Enter the desired driver PIN using the buttons or Softkeys 5 The digits entered do not appear in the display Inst...

Page 115: ...sly entered the system will accept the new driver PIN once the last digit has been entered The display switches back to the ACCESS CODE menu Another driver PIN can be defined here 8 9 6 7 4 2 0 1 3 5 BQ_023_en_V2 If the driver PIN entered in the CONFIRM sub menu does not match the driver PIN entered previously in the NEW CODE submenu the message INVALID will appear The message will then disappear a...

Page 116: ...ack to the ACCESS CODE menu The desired driver PIN must be re defined Blue Q_029_V2 1 2 Changing the password It is recommended that you change the factory default password NOTE The password can only be changed when the parking brake is applied Push the drive program selection button 1 and the menu change button 2 at the same time 104 57348011800 EN 11 2018 ...

Page 117: ...play Enter the current password using the buttons 1 Confirm the input using Softkey 2 8 9 6 7 4 2 0 1 3 5 1 2 3 BQ_032_en CONFIGURATION appears in the display Use the drive program selection button 1 and the menu change button 3 to select the PASSWORD menu Confirm your selection using Soft key 2 57348011800 EN 11 2018 105 ...

Page 118: ...red the configuration op tions for the fleet manager are restricted to driver authorisations and cannot be reset independently 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 pass...

Page 119: ...rely or partially enclosed working areas Always ensure sufficient ventilation Apply the parking brake 7071_003 101 0 I 1 II Insert the switch key 1 into the key switch and turn to position I The standard displays are shown on the display Turn the switch key to position II and hold there until the engine starts Release the switch key as soon as the engine has started If the engine does not start aft...

Page 120: ...jump started NOTE If the truck is left turned off for a lengthy period in ambient temperatures below 5 C the truck will need to pre heat at the next start up The message GLOW flashes on the display Preheating can take up to 22 seconds If the message START is displayed start the engine 108 57348011800 EN 11 2018 ...

Page 121: ...soon 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 se...

Page 122: ... brake is not engaged NOTE When adjusting the displays do not actuate the hydraulic system operating devices If you do entry is interrupted and the display returns to the operating display The displays 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 110 57348011800 EN 11 2018 ...

Page 123: ...rvice 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 mess...

Page 124: ...eter 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 112 57348011800 EN 11 2018 ...

Page 125: ...sed 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 OF...

Page 126: ...surement 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 Bac...

Page 127: ...LEDs next to the relevant function key for the additional electrical installation Description LED Function off LED OFF Function on LED ON Symbols for numeric keypad The buttons and Softkeys that can be used to enter numbers and to cancel or confirm input values are shown in the display BQ_037 1 2 6 7 3 4 5 ESC Screen for entering the fleet manager pass word 57348011800 EN 11 2018 115 ...

Page 128: ...1 or 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 ex...

Page 129: ...displayed 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 m...

Page 130: ...right 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 ...

Page 131: ... use the Blue Q button to switch efficiency mode on and off at any time while the truck is being operated 8 9 0 6 7 4 3 5 7312_003 179_en 1 2 3 4 Switch to the CONFIGURATION menu see the chapter entitled Adjusting the displays Keep pressing the drive programme button 1 or the menu change button 2 until op tion BLUE Q CONFIGURATION appears Confirm your selection with Softkey 4 The BLUE Q CONFIGURATIO...

Page 132: ...ficiency 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 o...

Page 133: ...working 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 lam...

Page 134: ...c 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 122 57348011800 EN 11 2018 ...

Page 135: ...pping 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...

Page 136: ...sure 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 ...

Page 137: ...odel Type with pallet 1000 x 1200 crosswise with pallet 800 x 1200 lengthwise RX70 60 7341 4907 5107 RX70 70 7342 4987 5187 RX70 80 7343 5056 5256 RX70 80 LSP 900 7344 5185 5385 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...

Page 138: ... must not exceed the gradients listed above and must have a rough surface Smooth and gradual transitions at the top and bottom of the gradient should prevent the load from falling to the ground or the truck being damaged Warning in case components project beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers The trucks are d...

Page 139: ...or roadways and the working area It is only permitted to drive on routes autho rised for traffic by the operating company or its representatives Traffic routes must be free of obstacles The load may only be set down and stored in the designated locations The operating company and its representatives must ensure that unauthorised third parties do not enter the working area NOTE Please note the definit...

Page 140: ...rds 50 100 120 140 160 Reversing forwards backwards 50 100 120 140 160 Brake retardation electric brake booster 80 90 100 100 100 5060_003 082 1 2 Selecting the drive direction The desired drive direction of the truck must be selected using the drive direction switch before attempting to drive The method of actuating the drive direction switch depends on the operating devices included in the truck...

Page 141: ... the accelerator pedal is inadvertently pressed Briefly select the drive direction switch for the direction opposite to the current direction The drive direction indicator on the display and operating unit goes out NOTE When the seat is vacated the drive direction switch is set to Neutral To drive the drive direction switch must be actuated again 5060_003 096 F1 F2 1 Actuating the drive direction s...

Page 142: ... the drive direction 1 upwards A For the reverse drive direction push the vertical rocker button for the drive direction 1 downwards B F1 F1 F2 F2 7325_003 031 1 Actuating the drive direction switch fingertip version For the forwards drive direction push the drive direction switch 1 forwards For the backwards drive direction push the drive direction switch backwards 130 57348011800 EN 11 2018 ...

Page 143: ...ver 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 S...

Page 144: ...re 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...

Page 145: ...k 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 146: ...OTE 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 reg...

Page 147: ...ur 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 ...

Page 148: ...ng 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 ove...

Page 149: ...ng brake The truck is equipped with a mechanical parking brake 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 p...

Page 150: ...r 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 sh...

Page 151: ...ruck 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 371 57348011800 EN 11 2018 139 ...

Page 152: ...tion there still is a risk of tipping Before using this function familiarise yourself with the change to the driving and steering characteristics of the truck DANGER Increased risk of tipping if the Curve Speed Control function is disabled If the controller fails while the truck is in motion or if the controller is disabled the truck will no longer automatically brake when steering Do not turn off...

Page 153: ...ve 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 val...

Page 154: ...CUTOUT 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 co...

Page 155: ...ly the parking brake Lower the fork carriage to the ground Tilt the lift mast forwards until the tips of the fork arms rest on the ground If attachments variant are fitted retract the working cylinders see the chapter entitled General instructions for controlling attachments Take your foot off the accelerator pedal and allow the engine to continue idling for a short while Turn the switch key to the...

Page 156: ...om 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 144 57348011800 EN 11 2018 ...

Page 157: ...eans 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 d...

Page 158: ...switch the 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 lift mast vertical position comfort feature variant the driver can put goods such as paper rolls down vertically with precision and thus...

Page 159: ... of the following individual functions Display of the lift mast vertical position Automatic approach towards the lift mast vertical position Gentle running in to the end stops 6210_003 069_en_V2 1 Display of the lift mast vertical position The driver can see the mast tilt on the display and operating unit screen The bar in the display shows the current mast tilt relative to the lift mast vertical ...

Page 160: ...vertical position without stopping regardless of whether the comfort feature is switched on or not Gentle running in to the end stops The lift mast is braked gently at the end of the tilt range This prevents the lift mast from stopping harshly in the end position and reduces severe oscillating motions of the truck Tilting the lift mast forwards with the lift mast vertical position 6210_003 067_V2 ...

Page 161: ...the lift mast vertical position actuate the button 1 again Tilting the lift mast backwards with the lift mast vertical position Tilt the lift mast backwards The lift mast is tilted backwards without stopping in the vertical position Possible restrictions on the lift mast vertical position In some circumstances the lift mast cannot move exactly into the preset vertical position Possible causes incl...

Page 162: ...alibration is cancelled Types of lift mast One of the following lift masts may be installed in the truck 6210_810 001 1 Telescopic mast During lifting the lift mast rises over the outer lift cylinders bringing the fork carriage with it via the chains fork carriage rises twice as fast as the inner lift mast The top edge 1 of the inner lift mast can therefore be higher than the fork carriage DANGER ...

Page 163: ...r lift mast may extend before the free lift has finished As a result the overall height is exceeded and damage may occur in passageways or from low ceilings An incorrect extension sequence may for instance result from The hydraulic oil temperature being too low The fork carriage becoming blocked in the inner lift mast Blocking of the free lift cylinder The chain roller becoming blocked at the free ...

Page 164: ...e blocked due to contamination lift the fork carriage until the chains are under tension again Remove the contamination before resuming work WARNING Risk of injury Observe the safety regulations for working on lift masts see Chapter Working at the front of the truck P 5 312 Hydraulic blocking function The hydraulic blocking function ensures that all the functions of the working hydraulics are disa...

Page 165: ...erating devices The method of operating the lifting system depends on the operating devices included in the truck s equipment Possible equipment variants include Double mini lever Triple mini lever Quadruple mini lever Joystick 4Plus Fingertip switch The following information must be observed regardless of the equipment variant DANGER Reaching into or climbing between moving parts of the truck e g...

Page 166: ...fting 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 ...

Page 167: ...ng 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 lif...

Page 168: ... the 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 th...

Page 169: ...rying 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 57348011800 EN 11 2018 157 ...

Page 170: ...ards 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 158 57348011800 EN 11 2018 ...

Page 171: ...g 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 leve...

Page 172: ...tive 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 for...

Page 173: ...lace 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 fa...

Page 174: ...ty 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 picki...

Page 175: ...ion 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 ...

Page 176: ...k 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 equippe...

Page 177: ...ersible 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 Transpor...

Page 178: ... 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 179: ...licable 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 homo...

Page 180: ...d 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 i...

Page 181: ...ads 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...

Page 182: ...TE 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 lowe...

Page 183: ...and 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 guar...

Page 184: ...s 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 pe...

Page 185: ...d 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 ri...

Page 186: ...suspended loads and prevent the loads from swinging Take particular care to ensure that there is no one in the drive direction in the driving lane If despite this the load begins to 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 c...

Page 187: ... 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 57348011800 EN 11 20...

Page 188: ...middle 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 Bra...

Page 189: ...Operation 4 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 57348011800 EN 11 2018 177 ...

Page 190: ...t 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 informat...

Page 191: ... 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 removi...

Page 192: ...ards the rack carefully 6210_800 016 Lower the load until it rests securely on the rack DANGER Risk of accident Beware of any people in the danger area Ensure that the roadway behind you is clear Move the truck back until the fork arms can be lowered without touching the stack Lower the fork while maintaining ground clearance Tilt the lift mast backwards and drive away 180 57348011800 EN 11 2018 ...

Page 193: ...ower 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 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 ...

Page 194: ...yp Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V D 22113 Hamburg Berzeliusstr 10 2 1 Determining the ...

Page 195: ...as Always ensure that there is sufficient ventilation available This truck is equipped with a closed particle filter system that filters carcinogenic soot particles out of the exhaust gas and collects them in the particle filter The use of a particle filter is recommended for applications in closed halls with a low degree of ventilation Operating principle during normal operation The soot particles tha...

Page 196: ...these messages are provided in the chapter entitled Messages regarding parked regeneration on the display and operating unit Interrupting parked regeneration Releasing the parking brake during parked re generation interrupts the parked regeneration process In the display and operating unit the following message appears PARK REG ERROR NOTE If regeneration is interrupted too frequently additional en...

Page 197: ...ted with an exhaust gas extraction unit parked regeneration is not permitted The operating company must determine whether parked regeneration is permitted where the truck is being used or whether the truck must be moved to a separate area for this purpose The parked regeneration must be carried out while the internal combustion engine is running During the regeneration process the truck automatica...

Page 198: ...ot engaged APPLY HANDBRAKE appears on the display As soon as the message EXH GAS PURI FIER appears in the display and operating unit parked regeneration can be performed To do this proceed as follows Park the truck in a place that is suitable for parked regeneration 7071_003 101 0 I 1 II Switch the key switch 1 to position 0 and wait until the display has turned off Turn the key switch back to the...

Page 199: ...e parked regeneration process press the OK button 1 The message START IC ENGINE appears on the display To interrupt the parked regeneration process press the ESC button 2 7071_003 101 0 I 1 II Start the engine To do this turn the switch key 1 to position II and hold it there until the engine has started Then release the switch key 57348011800 EN 11 2018 187 ...

Page 200: ...GE NERATION COMPLETED appears on the display The truck is ready for operation again NOTE The system requests parked regeneration every 500 operating hours at the latest if it has not already been performed due to soot accumulation in the particle filter The message EXH GAS PURIFIER appears on the display and parked regeneration must be performed Particle filter Displays NOTE To guarantee economic us...

Page 201: ...ruck is reduced to 2 km h The lifting speed is restricted PARK REG ERROR Regeneration was interrupted due to an error The parking brake was released during parked regeneration Apply the parking brake and restart regeneration If the message appears more than twice in succession without the parking brake being released during parked regeneration there may be a malfunction in the internal combustion ...

Page 202: ...chment 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 capa...

Page 203: ...tallation Never grab or climb on moving parts of the truck 7341_003 019 Hydraulic connection Before fitting 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 attachments have been disassembled attach the protectiv...

Page 204: ...talled by au thorised 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 chapter entitled Lifting system operating ...

Page 205: ...3 184 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 57348011800 EN 11 2018 193 ...

Page 206: ...e 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 ...

Page 207: ...l 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 57348011800 EN 11 2018 195 ...

Page 208: ...ove 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 positio...

Page 209: ...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 NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory If an attachment with other functions is fitted the pi...

Page 210: ...lever 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 att...

Page 211: ...ck 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 57348011800 EN 11 2018 199 ...

Page 212: ...h 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 a...

Page 213: ...ds 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 573480...

Page 214: ... 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 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 pict...

Page 215: ...n 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 57348011800 EN 11 2018 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 attachmen...

Page 217: ...ds 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 573480...

Page 218: ...grams 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: ...n 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 57348011800 EN 11 2018 207 ...

Page 220: ...erating 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 t...

Page 221: ...ttachments 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 ot...

Page 222: ...e 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 ...

Page 223: ...h 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 ...

Page 224: ...n 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 ...

Page 225: ...e 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 mechanis...

Page 226: ...ithout 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 mechan...

Page 227: ...2 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 butt...

Page 228: ... the 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 ...

Page 229: ...t 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 57348011800 EN 11 20...

Page 230: ...ed 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: ... beacon 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...

Page 232: ...on 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 57348011800 EN 11 2018 ...

Page 233: ...ndicators 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 57348011800 EN 11 2018 221 ...

Page 234: ...light 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 235: ...omatically 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 automatical...

Page 236: ...nto 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 spo...

Page 237: ... between 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 condit...

Page 238: ...parate 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 239: ... when 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 57348011800 EN 11 2018 227 ...

Page 240: ...peed 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 agai...

Page 241: ...king 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 dependin...

Page 242: ...sumer CAUTION Risk of short circuit The nominal current of the connected consumer must not exceed 10 A Before connecting check the nominal current of the device in question Open the dust guard cover 2 Insert the plug of the device to be connected into the socket 1 Place the dust guard cover on the plug Perform a functional check of the electrical connection on the connected device CAUTION Malfunct...

Page 243: ...e sensor Operating the ceiling sensor system The drivers are to be instructed on the use of the ceiling sensor system by the operating company When the driver enters a hall for the first time after starting work he must be certain that the ceiling sensor system is functioning correctly Despite the ceiling sensor system being installed the driver must also check the speed indicator on the display op...

Page 244: ...ures outdoors e g a pedestrian bridge the ceiling sensor system may interpret this overhead structure to be a hall ceiling and reduce the maximum speed In rare cases it may occur that the ceiling sensor system does not recognize a ceiling and does not then reduce the speed This can happen if the signals from the ceiling sensor are insufficiently reflected due to the ceiling geometry for example if t...

Page 245: ...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 57348011800 EN 11 2018 233 ...

Page 246: ...the 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 ...

Page 247: ...table 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 57348011800 EN 11 2018 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 57348011800 EN 11 2018 ...

Page 249: ...ched securely in the engaged position Opening the cab door from the outside Insert the key in the door lock 1 unlock and remove the key Pull the door handle 2 and release the door lock Open the cab door 3 by pulling outwards Opening the cab door from the inside Take hold of the handlebar 4 and latch 5 Press the latch in and push the cab door outwards 57348011800 EN 11 2018 237 ...

Page 250: ...dow Press the handle 2 together and slide the rear side window 1 forwards Make sure that the handle engages in the stop slot 3 Opening the front side window The front side window 4 can be opened in the same way as the rear side window 7331_341 007 4 2 1 3 Closing the side windows WARNING There is a risk of crushing between the window frame and side window from the side windows slipping inadvertent...

Page 251: ...been switched off on the display and operating unit The interior lighting cannot be switched on at the display and operating unit if the switch in the roof lining is in position 0 Switching on the interior lighting Check whether the switch in the roof lining is in position I if not move the switch to position I 6311_003 013_V2 2 1 To turn on the interior lighting press the Softkey 1 The interior l...

Page 252: ...h the switch in the roof lining and the Softkey on the display operating unit must always be actuated to switch on the light Operating the rear window heating 6311_003 014_V2 2 1 Press Softkey 1 to switch on the rear window heating Rear window heating is switched on The symbol is displayed Press Softkey 1 to switch off the rear window heating Rear window heating is switched off The 2 symbol is dis...

Page 253: ...so that you can still hear warning signals Heating system variant DANGER Risk of explosion There is a risk of explosion if the heater is operated in the vicinity of storage areas or similar areas where fuel vapours or coal dust wood dust and crop dust can accumulate Do not expose spray cans or gas cartridges to the flow of hot air Do not operate the heater in hazardous areas DANGER Risk of fire as a...

Page 254: ...ut a fresh air filter and recirculated air filter fitted Switching on the blower 2 6341_003 021 1 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 NOTE The heating system only heats up when the blower is switched on If the blower switch is switched off the heating system will not function regardless of the positio...

Page 255: ...conditioning 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 57348011800 EN 11 2018 243 ...

Page 256: ... an equipment variant To unlock and open the roof window rotate the handle 2 in an anti clockwise direction and use it to push the roof window upwards The roof window is held in the open position by means of gas springs 3 To close and lock the roof window pull the roof window downwards using the handle and rotate the handle in a clockwise direction 6210_003 107 2 1 Clipboard variant The clipboard ...

Page 257: ...rloading 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 towed load present corresponds to the rated capacity of the truck it is not permitted to transport a load on the fork at the same time The load can be distributed between the fork and the trailer Check the load distribution and adjust to corr...

Page 258: ...isk of damage to components A support load is not permitted Do not use trailers with tillers supported by the tow coupling This truck is suitable for the occasional towing of trailers If the truck is equipped with a towing device this occasional towing must not exceed 2 of the daily operating time The manufacturer must be consulted if the truck is to be used for towing on a more regular basis Coup...

Page 259: ...the tiller into the gap 3 of the counterweight DANGER In the event of loss or destruction of the 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 th...

Page 260: ...en the truck and trailer When hooking up ensure that no one is between the truck and trailer DANGER Never jack up or crane load the truck on the tow coupling The tow coupling is not designed for this and could be deformed or destroyed The truck could fall off with potentially fatal consequences Use the tow coupling only for towing For jacking up and crane loading use only the designated lifting po...

Page 261: ...s overhang The tow coupling can damage the racking or the tow coupling itself when manoeuvring If there is a collision with the tow coupling check the tow coupling for damage such as cracks A damaged tow coupling must not be used again Always manoeuvre carefully and with sufficient room In the case of a collision check the tow coupling for damage Replace tow coupling if damaged if necessary contact...

Page 262: ...e to overloading Tow couplings RO 243 and RO 244 must be individually checked to ensure that they are suitable for the planned towing operation The permissible rigidity value of the tow coupling must always be taken into account The authorised service centre can check and or confirm the maximum towed load for the planned towing operation Observe the operating instructions for the tow coupling Infor...

Page 263: ...trolled There is a risk of accident A protruding safety handle means that the tow bar eye has not been coupled correctly The trailer must not be towed in this condition Ensure that the safety handle is flush with the securing bush If the safety handle protrudes repeat the coup ling process Remove any items used to prevent the trailer from rolling away Tow the trailer Closing model RO 243 by hand DA...

Page 264: ... towing operation The permissible rigidity value of the tow coupling must always be taken into account The authorised service centre can check and or confirm the maximum towed load for the planned towing operation Observe the operating instructions for the tow coupling Inform the authorised service centre NOTE Tow coupling RO 244 A is intended for a tow bar eye in accordance with DIN 74054 bore dia...

Page 265: ...ling pin engages NOTE The coupling pin is correctly engaged if the control pin 3 doesnot protrude out of its guide DANGER If the coupling pin drops out during towing the trailer will work loose and can no longer be controlled There is a risk of accident The control pin 3 must not protrude out of its guide Ensure that the coupling pin is engaged cor rectly If the coupling pin is not correctly engag...

Page 266: ...wnwards as far as it will go The tow coupling is closed Uncoupling model RO 244 A Take measures to prevent the trailer from rolling away e g use wheel chocks Push the hand lever 2 upwards until it snaps into place The tow coupling is opened Slowly drive the truck forwards until the tow bar eye and towing jaws are disconnected Close the tow coupling by actuating the closing lever 1 NOTE To protect ...

Page 267: ...sons may 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 been coupled correctly The trailer must not be tow...

Page 268: ...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 minimum distance to fixed installations when turning and cornering The permissible length of the trailer trains depends on the roadways to be driven and may need to be determined during the test drive It is the responsibility of ...

Page 269: ...also lights up Messages are always shown repeatedly and for a certain period of time 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 foll...

Page 270: ...phase limitation of phase current in converter emer gency driving function is retained The error automatically disappears as soon as the tempera ture is below the limit If the error occurs frequently notify your authorised service centre ACCEL SENSOR A3002 A3003 A3004 A3005 A3006 A3007 A3505 Sensor fault truck cannot be driven Contact your service centre ACCEL SENSOR A3008 Accelerator voltages for...

Page 271: ...ault truck moves at emergency mode speed Notify your authorised service centre DIRECTION SWITCH A3020 Switch error no or limited drive unit function Notify your authorised service centre LIFTING A3102 A3103 Sensor fault no or limited hydraulic drive function Notify your authorised service centre TILTING A3107 A3108 Sensor fault no or limited hydraulic drive function Notify your authorised service ...

Page 272: ...orised service centre OIL PRESSURE A5631 Engine faulty no oil pressure or sensor faulty Engine is switched off for protection Notify your authorised service centre COOLANT LEVEL A5611 Fan is not running Cooling fluid level too low check the cooling fluid level and top up the cooling fluid if necessary If this does not resolve the problem contact your authorised service centre AIR FILTER A5651 Replace...

Page 273: ...isplay and operating unit of every truck The following messages are therefore intended only as a reference SERVICE BRAKE message If the message SERVICE BRAKE appears on the display notify the authorised service centre Park the truck securely for checking by the authorised service centre If multi disc brakes in the drive wheel units are blocked tow the truck APPLY HANDBRAKE message DANGER Risk of f...

Page 274: ...ars If the truck moves even though the parking brake is applied Drive the truck onto level ground and park it safely Secure it with wedges if necessary Notify the authorised service centre BRAKE SENSOR message If the BRAKE SENSOR message appears in the display the maximum driving speed will be reduced The brake sensor in the brake pedal must be checked Notify the authorised service centre CODE DEN...

Page 275: ...KING BRAKE appears on the display driving mode cannot be enabled until the parking brake has been released by pressing the button Release the parking brake by pressing the button PARKING BRAKE APPLY HAND BRAKE message If the message PARKING BRAKE APPLY HANDBRAKE appears on the display the electric parking brake is faulty Release the parking brake by pressing the button LOWER FORKS message DANGER T...

Page 276: ... on the display after the welcome screen the tilting speed of the lift mast on this truck is significantly higher than on previous trucks in this family EMERGENCY SWITCH message WARNING No electric braking assistance is available when the emergency off switch is actuated Actuating the emergency off switch will disconnect the drives from the power supply To brake actuate the service brake The truck ...

Page 277: ...l 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 key switch The truck will only travel at a reduced driving speed The message REFERENCE CYCLE may appear in the display Raise the fork The message REFERENCE CYCLE goes out...

Page 278: ...will 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 sea...

Page 279: ...message 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 Th...

Page 280: ...s 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 can...

Page 281: ...NOTE 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 workin...

Page 282: ...mpaired 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 ...

Page 283: ...icle 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 284: ...AdBlue 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 Main...

Page 285: ...message 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 eng...

Page 286: ...mage 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 th...

Page 287: ...rised 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 T...

Page 288: ...parked 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...

Page 289: ...nd US EPA interim Tier 4 standards and also with an exhaust gas follow up treatment concept in the form of a particle filter DPF The truck may be operated only with sulphur free diesel fuels as defined by the following standards EN 590 ASTM D 975 Grade 2 D S15 ASTM D 975 Grade 1 D S15 or non road fuels light fuel oils in line with the EN 590 standard If these fuel types are not used compliance with ...

Page 290: ...nter the use of diesel fuels with a higher cetane number is recom mended Sulphur content in the diesel fuel CAUTION Insufficient lubrication can lead to engine damage Use only sulphur free diesel fuels in accordance with manufacturer specifications Insufficient lubrication capacity in diesel fuels with a sulphur content 500 mg kg can lead to serious problems through wear above all in common rail inje...

Page 291: ...dditives to improve the fluidity Adding petrol can lead to the formation of vapour pockets cavitation in the fuel system This disrupts the function of the fuel injection system and if done over a long period can lead to component damage Non road fuels NOTE In some European countries non road fuels are defined with the same characteristics as light fuel oil The permissibility as a fuel is handled dif...

Page 292: ...the fuel level indicator 1 flashing on the display screen of the display and operating unit DANGER There is a risk of fire when filling up with diesel fuel Turn off the engine before filling up When refuelling smoking or the use of an open flame is strictly forbidden Comply with the legal provisions for handling diesel fuel Observe the safety regulations when handling diesel CAUTION Use of non permissi...

Page 293: ...el tank has been run empty the fuel injection system can draw in air bubbles This can lead to malfunctions in the fuel injection system Never run the fuel tank empty Refuel truck and pre pump diesel fuel 2 1 The fuel hand pump 2 is located on the fuel filter 1 beneath the right service flap If the fuel tank was complete empty it is possible that the fuel cannot be supplied by the fuel pump alone aft...

Page 294: ...1 Open the service flap 1 on the right 1 To pump pull the fuel hand pump 1 out and push it in again ten times NOTE A light hissing sound you may hear indicates that the fuel is flowing and is not a fault on the truck 282 57348011800 EN 11 2018 ...

Page 295: ...ommended that the AdBlue tank be refilled with AdBlue every time the diesel fuel is topped up Turn the locking cap 2 of the AdBlue filler neck to the left and remove Add AdBlue The AdBlue tank holds a maximum of 10 l Place the locking cap onto the AdBlue filler neck and turn completely to the right 57348011800 EN 11 2018 283 ...

Page 296: ...an 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 centra...

Page 297: ...of 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 inten...

Page 298: ...lements 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 link...

Page 299: ...ndow 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 eng...

Page 300: ... down Steering forces are increased by the remai ning emergency steering function Use the emergency off switch only if there is a risk of fire or to carry out a functional test Steer with a higher level of force 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 when t...

Page 301: ... fatal conse quences There is a risk to life Failure to comply with the limits specified in these operating instructions e g driving on unacceptably steep gradients or failing to adjust speed when 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 N...

Page 302: ...ers 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 emergency hammer out of its support mounting at the handle Using one of the two metal tips on the head of the emergency hammer hit the pane of glass with ...

Page 303: ...ax 2 5 Nm When unscrewed a little The load lowers slowly When unscrewed a lot The load lowers quickly NOTE A hexagon socket wrench is located beneath the bottom plate on the brake valve for carrying out the steps detailed below This hexagon socket wrench must remain in the truck at all times Remove the bottom plate 1 7341_003 014 Take the Allen key 1 out of the support mounting 57348011800 EN 11 2...

Page 304: ... block 1 by a maximum of 1 5 revolutions Tighten the emergency lowering screw again after the load has been lowered B Return the Allen key to the support mount ing provided Insert the valve chamber cover and tighten it Attach the rubber edging strip Install the bottom plate DANGER If the truck is operated with the hydraulic controller blocked there is an increased risk of accidents After the emerg...

Page 305: ...ruck is towed with the wheels blocked NOTE The brake valve is installed in front of the driver s seat beneath the bottom plate The coupling pin from the counterweight can be used as an aid to actuate the brake valve If there is no removable coupling pin available on the truck for example if the truck is equipped with automatic tow coupling variant the bottom plate must be raised completely in orde...

Page 306: ...e plate beneath Repeatedly press the coupling pin down vertically The spring operated brake is released NOTE To fully release the spring operated brake press down on the brake valve plate at least 30 times The pressure that builds up in the brake hydraulics as a result releases the spring operated brake Once the spring operated brake is re leased fold the rubber tab in the rubber mat back down Ins...

Page 307: ...ate is not inserted there is a danger of shoes getting stuck causing you to fall Even when the bottom plate is installed there is still a danger of slipping and injury if the rubber mat is not used Install the bottom plate and rubber mat 1 2 3 Disconnecting and connecting the battery Disconnecting the battery Remove the left side cover Loosen the screw joint 2 of the battery terminal clip 1 on the...

Page 308: ...tion entitled Attaching and removing the left side cover Leave the engine of the current giving truck to run Connecting the jump leads Connect the positive cable 2 to the positive terminal on the discharged battery Connect the positive cable to the positive terminal on the current giving battery Connect the negative cable 1 to the negative terminal on the current giving battery Connect the negativ...

Page 309: ... may not brake safely or the brakes may fail The towing vehicle must be designed such that it is able to absorb the pulling and braking forces from the unbraked towed load the actual total weight of the truck Check the pulling and braking forces of the towing vehicle DANGER If the towing vehicle brakes there is a risk that the truck will drive into the towing vehicle If a rigid connection has not ...

Page 310: ... sit in the driver s seat and fasten the seat belt before towing Where possible activate the restraint systems provided CAUTION Component damage as a result of blocked brakes The truck is equipped with a negative spring operated brake As a result when you switch the engine off the multi disc brakes in the drive wheel units block For towing the brake must be released at the brake valve Otherwise th...

Page 311: ...ated brake Sit in the driver s seat of the truck being towed and fasten the seat belt Where possible activate the restraint systems provided Release the parking brake Select a slow towing speed Tow the truck Observe the towing time refer to the table in the section entitled Releasing the spring operated brake and release the spring operated brake again as necessary After towing secure the truck so...

Page 312: ...dèle Typ Serial no No de série Serien Nr year année Baujahr Rated capacity Capacité nominale Nenn Tragfähigkeit Battery voltage Tension batterie Batteriespannung Rated drive power Puissance motr nom Nenn Antriebsleist Unladen mass Masse à vide Leergewicht max min see Operating instructions voir Mode d emploi siehe Betriebsanleitung kg kg kg kg kg kW V D 22113 Hamburg Berzeliusstr 10 2 1 Determinin...

Page 313: ...ort vehicle onto which the truck is to be driven has been sufficiently secured against moving Maintain a safety distance from edges loading bridges ramps working platforms etc Drive slowly and carefully onto the transport vehicle 7331_003 002 Inserting wedges Use two wedges to secure each of the front and rear wheels against rolling away Lashing down CAUTION Harnesses can rub against the seating an...

Page 314: ... not move during transportation Ensure that the harnesses are tightened secu rely 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 equip...

Page 315: ...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 316: ... the lifting straps around the main traverse 3 on the outer mast of the lift mast as shown 4 Loop the lifting straps around the counter weight 4 as shown Determine the truck s centre of gravity see Dimensions chapter 304 57348011800 EN 11 2018 ...

Page 317: ...t parts are in the way e g lighting rear window trademark emblem etc these must be removed before loading Secure harnesses in such a way that they do not touch any attachment parts 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 a risk to life Never walk or stand underneath suspend...

Page 318: ... sed service centre so that all the wheels are clear of the ground This prevents permanent deformation of the tyres CAUTION Danger of damage from corrosion due to conden sation on the truck Many plastic films and synthetic materials are watertight Condensation water on the truck cannot escape through these covers Do not use plastic film as this encourages the formation of condensation water NOTE Sto...

Page 319: ...e as specified by the manufacturer Cover the truck with vapour permeable materials such as cotton in order to protect against dust If the truck is to be shut down for even longer periods contact your authorised service centre to find out about additional measures Recommissioning after decommis sioning If the truck has been decommissioned for longer than six months the truck must be carefully checked...

Page 320: ...ice centre that were carried out before initial commissioning Carry out the checks and tasks that are to be performed before daily use Recommission the truck During recommissioning the following points in particular must be checked Drive control steering Brake system service brake parking brake regenerative brake Lifting system load carrying equipment load chains mounting NOTE For further informat...

Page 321: ...5 Maintenance ...

Page 322: ...ly 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: ...c 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 actuall...

Page 324: ...ed 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 d...

Page 325: ...um 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 techn...

Page 326: ...e 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 mai...

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

Page 328: ...5 Maintenance General maintenance information 316 57348011800 EN 11 2018 ...

Page 329: ...Maintenance 500 hours At operating hours Carried out 500 1000 1500 2000 2500 Note 500 hour maintenance is performed by the operating company itself Exhaust system Deutz TCD 4 1 final Change the main filter of the feed pump 57348011800 EN 11 2018 317 ...

Page 330: ...5 Maintenance General maintenance information 318 57348011800 EN 11 2018 ...

Page 331: ...e if necessary Check wheels for damage and check the tightening torques Power unit Check the mounting of the drive axle and check the drive axle for leaks Check cooling system for leaks and check water pumps for correct function Check gearbox oil level Replace the gearbox oil once after 1000 hours Internal combustion engine Check condition of the internal combustion engine visual inspection Check ...

Page 332: ... all power cable connections Check switches transmitters and sensors for correct function Check lighting and indicator lights Starter battery Measure the cold start current recharge or replace the battery if necessary Hydraulics Check hydraulic system for condition correct function and leaks Check the hydraulics blocking function ISO valve Check the oil level Lift mast Check mast bearings for dama...

Page 333: ...y hydraulics hoses for damage Special equipment Check the fresh air filter in the heating system and beat out the filter if necessary Heating system Check for damage observe manufacturer s maintenance instructi ons Check the fresh air filter and recirculated air filter in the air conditioning and beat out the filters if necessary Air conditioning function check Check attachments for wear and damage obs...

Page 334: ...5 Maintenance General maintenance information 322 57348011800 EN 11 2018 ...

Page 335: ...nal combustion engine general overhaul every 12 000 hours Hydraulics Replace the hydraulic oil Replace the return line filter and the breather filter Replace the high pressure filter Special equipment Replace the fresh air filter and the recirculated air filter in the air conditioning system Replace the accumulator dryer in the air conditioning system and refill with new refrigerant Ordering spare parts...

Page 336: ...mables and lubricants can be found in the maintenance data table Oil and grease types of a different quality must not be mixed This negatively affects the lubricity If a change between different manufacturers cannot be avoided drain the old oil thoroughly Before carrying out lubricating work filter changes or any work on the hydraulic system carefully clean the area around the part involved When to...

Page 337: ...ift mast C Load chains D One lubricating nipple on each of the two lift mast bearings 1 The respective lubricant specification can be found in the Maintenance data table section below under this Code This lubrication plan describes the series production truck with standard equipment For main tenance points on variant trucks see the relevant chapter and or instructions provided by the manufacturer 5...

Page 338: ...73 As required Battery Code Unit Operating material Specifications Dimensions System contents Distilled water As required Insulation resistance For further information refer to the work shop manual for the truck in question Electrical system Code Unit Operating material Specifications Dimensions Insulation resistance For further information refer to the work shop manual for the truck in question Hyd...

Page 339: ...th grease until a small amount of fresh grease escapes Wheel bearing wheel bearing rotary shaft seal Grease DIN 51825 KP2 K 30 lithium saponified ID no 0163488 Fill with grease Drive axle Code Unit Operating material Specifications Dimensions Wheel nuts screws Torque wrench DIN 74361 A 20 10 A2C For further information refer to the workshop manual for the truck in question SAE 80W 90 API GL4 Filling...

Page 340: ... C ID no 0156428 As required Cooling system Code Unit Operating material Specifications Dimensions System contents Corrosion inhibitor and cooling system protecting agent water 40 coolant 60 water for frost protection down to 25 C VW G12 plus violet TL VW 774 F Approx 42 l Air conditioning Code Unit Operating material Specifications Dimensions System contents Refrigerant ID no 7449600005 1350 g Fuel...

Page 341: ... 5 urea solution in accordance with DIN 70070 ISO 22241 Approx 10 l Providing access to maintenance points 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 driver s seat all the way forwards CAUTION If the right hand window of the cab varia...

Page 342: ... 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 4 Firmly insert a narrow screwdriver into the slot 4 of the bonnet release until the interlock opens Use the handle to open the bonnet fully 330 5734801180...

Page 343: ...tion 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 ...

Page 344: ...and lower the bonnet slightly Release the latch Closing the bonnet Holding it by the handle pull down the bonnet until the lock audibly 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 332 57348011800 EN 11 2018 ...

Page 345: ...ION Risk of short circuit if cables are damaged Check the connecting cables for damage When removing and reinstalling the bottom plate make sure that the connecting cables are not damaged CAUTION Placing the bottom plate on top of the rubber edging strip can cause damage to the rubber edging strip Do not place the bottom plate on top of the rubber edging strip NOTE The bottom plate has a recess th...

Page 346: ... safe location Installing the bottom plate WARNING Risk of crushing between bottom plate and frame edge If limbs or objects are between the bottom plate and frame edge when the bottom plate is closed they can be crushed When closing the bottom plate ensure that there is nothing between the bottom plate and the edge of the chassis CAUTION Placing the bottom plate on top of the rubber edging strip c...

Page 347: ...s springs and cause the flap to lower If the gas springs no longer hold the service flap 1 independently notify the authorised service centre 6341_003 033 1 2 3 4 Unlock the quick release clamp 1 with a 1 4 turn in a clockwise direction Open the service flap lock 3 with the key To unlock pull the handle 4 and at the same time use the other handle 2 to swivel the service flap upwards NOTE Beneath the s...

Page 348: ...ap if there are no parts of the body in the way 6341_003 033 1 2 3 4 To close the service flap take hold of the handles 2 and 4 at the same time and pull down firmly Make sure that the service flap lock en gages when you close it Lock 3 the service flap using the key Lock the quick release clamp 1 with a 1 4 turn in an anti clockwise direction NOTE The service flap is only correctly locked if the top s...

Page 349: ...for operation 7341_003 065 Stand on the bottom plate of the driver s cab and turn your body slightly to the left as shown 7341_003 066 Using both hands pull out the oil dipstick 1 and wipe it using a cloth 57348011800 EN 11 2018 337 ...

Page 350: ...sufficient oil level or the use of engine oil with different specifications can lead to the failure of engine lubrication Only use engine oil in line with the maintenance data table 1 If the oil level is at or below the lower mark top up the engine oil via the oil filling opening 1 Insert the oil dipstick to the stop Close the bonnet ENVIRONMENT NOTE Carefully collect any spilled oil and dispose of i...

Page 351: ...damaged 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 maintenan...

Page 352: ...oil bath air filter The oil bath air filter is a further variant of the heavy dust guard equipment variant and is mounted on the rear right of the truck The oil bath air filter filters finer dust and dirt particles that have passed through the pre cleaner out of the intake air WARNING There is a risk of slipping on spilled oil particularly when combined with water The oil tank 4 is filled with oil to th...

Page 353: ... pressurised Coolant may escape if the coolant tank 2 is opened while the engine is hot Switch off the engine and allow it to cool down before opening the filler cap 1 WARNING Coolant and cooling fluid can pose a hazard to health and the environment Observe the safety regulations set out in the section entitled Coolant and cooling fluid CAUTION Risk of engine damage If the coolant level is low this i...

Page 354: ... the filler cap 3 Check the level of the coolant The cam 3 in the coolant tank must be flushed Top up the cooling fluid if necessary refer to the section entitled Topping up the cooling fluid and checking the coolant concentration Check the cooling system for leaks see the section entitled Cleaning the radiator checking for leaks Close the bonnet 342 57348011800 EN 11 2018 ...

Page 355: ...d while the engine is hot Switch off the engine and allow it to cool down before opening the filler cap 1 WARNING Coolant and cooling fluid can pose a hazard to health and the environment Observe the safety regulations set out in the section entitled Coolant and cooling fluid CAUTION Risk of engine damage If the cooling fluid level is low this indicates a leak in the cooling system Switch off engine a...

Page 356: ...corrosion The percentage of coolant must always be at least 40 even if frost protection is not needed in warmer climates If greater frost protection is required for climatic rea sons the percentage of coolant can be increased to up to 60 The percentage of coolant must not exceed 60 otherwise the frost protection is reduced In addi tion the cooling effect is also reduced Only use clean softened wat...

Page 357: ... cam 3 in the coolant tank must be flushed Top up the coolant if necessary 7341_003 050 1 2 Screw the filler cap 1 back on tightly Check the cooling system for leaks refer to the section entitled Cleaning the radiator and checking for leaks Close the bonnet 57348011800 EN 11 2018 345 ...

Page 358: ...ediately Park the truck securely Open the bonnet 7341_003 052 1 Clean the radiator fins 1 on the radiator with a suitable brush and blow them out using compressed air max 2 bar Check the radiator and coolant hoses for leaks and tighten the clips if necessary CAUTION In the event of a leak there is a risk of engine damage due to overheating A loss of cooling fluid from leaking coolant hoses or from t...

Page 359: ... the radiator grille and screw tight NOTE Make sure that the radiator grille is tightly screwed on Draining water from the fuel filter WARNING Diesel fuel is flammable toxic and damages the environment Contact with diesel fuel can cause skin irritation and spilled diesel fuel can cause slipping Observe safety regulations regar ding handling diesel fuel see the Safety regulations for handling consuma...

Page 360: ...the outlet pipe 3 CAUTION Component damage possible The fuel filter is equipped with a level indicator that reports water aggregation in the fuel filter on the display and operating unit The sensor cable 4 is embedded with the screw plug 2 Do not loosen the screw plug more than one revolution otherwise the sensor cable may be damaged Carefully undo the screw plug Undo the screw plug 2 on the fuel fil...

Page 361: ...ed with water The oil tank 4 is filled with oil Carefully remove the oil tank Collect spilt oil immediately using an oil binding agent and dispose of in an environmentally friendly way Observe the safety information for handling oils see the Oils chapter Release the four clamps 2 on the oil tank and carefully remove the oil tank 1 Empty the oil tank and clean using degreas ing cleaning material ENV...

Page 362: ...e air filter cartridges NOTE The air filter cartridges must be changed if the AIR FILTER message appears on the display and operating unit or at least every 3000 hours or every two years Open the bonnet see the chapter entitled Opening the bonnet 7321_003 075 1 1 1 2 Release the three clamps 1 on the air filter and remove the air filter cover 2 350 57348011800 EN 11 2018 ...

Page 363: ...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 filter cartridge 3 57348011800 EN 11 2018 351 ...

Page 364: ...facing upwards Engage the clamps 7 on the air filter Close the bonnet Changing the heating system fresh air filter The fresh air filter for the heating system is on the right on the exterior of the cab 7341_003 047 1 2 Loosen the quick release clamp 1 by turning it and remove the cover 2 352 57348011800 EN 11 2018 ...

Page 365: ...sing and fresh air inlet Insert the filter insert back into the filter housing Ensure that the filter insert sits correctly and precisely in the filter housing Attach the cover and lock the quick release clamp Lubricating the joints and controls Oil or grease other bearings and joints according to the maintenance data table Pivots for right service flap Driver s seat guide Bonnet hinges In the cab lubr...

Page 366: ...a truck with a defective seat belt Have any defective seat belts replaced by your authorised service centre Only use genuine spare parts Do not make any changes to the seat belt NOTE The checks below must be carried out on a regular basis monthly In the case of significant strain a daily check is necessary Checking the seat belt 6327_342 009 1 2 3 Pull out the seat belt 3 completely and check for f...

Page 367: ...round Pull out the seat belt using a jerking move ment The automatic blocking mechanism must block extension of the belt Tilt the seat at least 30 to do this tilt the bonnet Slowly pull out the seat belt The automatic blocking mechanism must block extension of the belt Cleaning the seat belt Clean the seat belt if it is dirty but without using chemical cleaning materials a brush will suffice Replac...

Page 368: ...the condition of the catch bolt and check for wear Check the lock mechanism for easy opera tion 6341_003 037 2 1 2 3 Replacing the recirculated air filter for the heating system The recirculated air filter for the heating system is located on the right hand side of the cab underneath the heating system panelling 1 Unscrew the screws 2 and remove the heating system panelling Completely remove the filt...

Page 369: ...maged 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 of tipping When using p...

Page 370: ...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 35...

Page 371: ...nd 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 Replacing the fuses Open the bonnet DANGER Risk o...

Page 372: ...defective fuse Close the bonnet Checking the hydraulic oil level CAUTION Hydraulic oils are hazardous to health and are pressurised during operation Note the safety regulations in the Hydraulic fluid chapter Park the truck securely Remove the left side cover 7341_003 051_V2 1 Unscrew breather filter 1 360 57348011800 EN 11 2018 ...

Page 373: ...0 5820 9270 6450 8850 5705 9755 Determine which lift mast is fitted to the truck Use the table to determine which lower mark 1 or 2 is applicable Check the oil level on the oil dipstick The oil level must be between the lower mark 1 or 2 and the top mark max If the oil level is too low Insert a funnel into the filler neck Add hydraulic oil with the correct specifi cation according to the maintenance ...

Page 374: ... 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 two years if they are subject to a high level of wear Comply with the specifications of DGUV 113 020 in Germany Outside of Germany observe the national regulations for the count...

Page 375: ...ubricant to reduce wear See Chapter Maintenance data table P 5 326 NOTE Spray the roller track evenly from a distance of approx 15 20 cm Wait approx 15 minutes until the equipment is ready to use again Greasing the automatic tow coupling NOTE Wear to moving parts can be significantly reduced by appropriate servicing and regular lubrication of the coupling Avoid over greasing NOTE Close the coupling...

Page 376: ...able tool For journeys with a rigid drawbar trailer lubricate the underside of the tow bar eye and the supporting surface on the coupling 7321_003 092 Determine the wear on the coupling pin The diameter of the spherical part must not be less than 36 5 mm Model RO 244 A Open coupling Wartung_Rockinger 244 A 1 Grease using the lubricating nipple 1 in accordance with the maintenance data table see Ch...

Page 377: ...nance data table see Chapter Maintenance data table P 5 326 Grease the supporting surface for the tow bar eye 7321_003 095 Model RO 841 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 5 326 Grease the supporting surface for the tow bar eye 57348011800 EN 11 2018 365 ...

Page 378: ...5 Maintenance Remaining ready for operation 366 57348011800 EN 11 2018 ...

Page 379: ...6 1000 hour maintenance annual mainte nance ...

Page 380: ...ge secure fit and leaks 7341_003 053 Checking the lift cylinders and the hydraulic connections for leak tightness WARNING Risk of injury Observe safety regulations for working on the lift mast see the Working at the front of the truck chapter Check the lift cylinders and the hydraulic connections for leak tightness visual inspection Have any leaking lift cylinders and hydraulic connections repaired...

Page 381: ...ng screws 2 are present and securely attached Replace any worn or deformed fork arms Check the condition and correct operation of the fork latch Move the locking lever 3 into a vertical 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...

Page 382: ...6 1000 hour maintenance annual maintenance Checking the reversible fork arms 370 57348011800 EN 11 2018 ...

Page 383: ...7 Technical data ...

Page 384: ...7 Technical data Dimensions Dimensions 1 Seat is adjustable 90 mm 2 Fork spacing is adjustable 372 57348011800 EN 11 2018 ...

Page 385: ...0 1036 mm RX70 70 1036 mm RX70 80 1036 mm RX70 80 LSP 900 1036 mm NOTE The specified centre of gravity S relates to trucks with standard equipment If for example the truck is equipped with a different lift mast attachment or driver protection structure this value is only a guide value If necessary the centre of gravity S must be determined individually for each truck 57348011800 EN 11 2018 373 ...

Page 386: ...ad Q kg 6000 7000 8000 8000 Load centre of gravity distance c mm 600 600 600 900 Load distance x mm 710 720 720 750 Wheelbase y mm 2285 2285 2405 2480 Weights RX70 60 RX70 70 RX70 80 RX70 80 LSP 900 Net weight kg 10477 11370 12274 14690 Axle load with front load kg 14854 16599 18396 20535 Axle load with rear load kg 1623 1771 1878 2155 Axle load without front load kg 5415 5555 6006 7213 Axle load ...

Page 387: ...h4 mm 4440 4240 4240 4140 Height above overhead guard h6 mm 2697 2697 2697 2697 Seat height in relation to SIP standing height h7 mm 1719 1719 1719 1719 Coupling height h10 mm 510 660 510 660 510 660 510 660 Overall length l1 mm 4640 4732 4800 5520 Length including fork back l2 mm 3440 3532 3600 3720 Overall width b1 1597 1998 1998 2140 Fork arm thickness s mm 70 70 70 70 Fork arm width e mm 150 1...

Page 388: ...ring speed with load m s 0 56 0 50 0 50 0 50 Lowering speed without load m s 0 52 0 42 0 42 0 42 Pulling force with load N 51090 46370 46300 43400 Pulling force without load N 31680 32540 35460 36750 Climbing capability2 with load 33 27 24 21 Climbing capability without load 32 30 30 29 Acceleration time with load s 5 4 5 5 5 6 5 7 Acceleration time without load s 4 9 5 0 5 1 5 1 Service brake Mec...

Page 389: ...oard power supply V 12 12 12 12 Other RX70 60 RX70 70 RX70 80 RX70 80 LSP 900 Working pressure for attachments bar 260 260 260 260 Oil flow for attachments l min 60 60 60 60 Capacity of fuel tank l 110 110 110 110 AdBlue tank capacity l 10 10 10 10 Sound pressure level LpAZ driver s compartment 4 dB A 75 75 75 75 Sound power level LwAZ dB A 97 97 97 97 Human vibration accelera tion5 according to EN...

Page 390: ...t and the seat suspen sion must be set to this driver s requirements Due to the individual nature of height and body weight as well as the wide variety of types of driver s seat and overhead guard the minimum head clearance must be ensured in every truck The driver s compartment has been designed taking ergonomics in the workplace into account and in accordance with EN ISO 3411 In general from the...

Page 391: ...Technical data 7 Ergonomic dimensions 57348011800 EN 11 2018 379 ...

Page 392: ...ervo hydraulics 10 A 1F17 Time delay relay terminal 15 10 A 1F18 Coolant pump for converter traction motor 15 A 1F19 12 V for engine control unit ECU 10 A 1F21 Exhaust gas recirculation 10 A 1F22 NOx sensors 15 A 4F01 Signal horn 10 A 5F11 CAN Power Port 1 CPP 1 roof 30 A 5F12 CAN Power Port 2B CPP 2B lighting 20 A 5F13 CAN Power Port 3 CPP 3 seat 30 A 5F14 12 V for engine control unit ECU 20 A 9F...

Page 393: ... Air conditioning variant compressor condenser 20 A 9F11 Air conditioning variant evaporator 20 A Additional fuses Depending on the truck equipment additional fuses are located on a fuse holder to the right of the fuse box 57348011800 EN 11 2018 381 ...

Page 394: ...7 Technical data Fuse assignment 382 57348011800 EN 11 2018 ...

Page 395: ...n 198 Controlling using the joystick 4Plus 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 fun...

Page 396: ... the radiator 346 Cleaning the truck 284 Cleaning the windows 287 Climbing into the truck 75 Climbing out of the truck 75 Clipboard 244 Closing the bonnet 331 Closing the cab door 238 Closing the side windows 238 Condition of the roadways 126 Consumables 49 Coolant and cooling fluid safety information 54 Disposal 54 Safety information for diesel fuel 52 Safety information for handling battery acid ...

Page 397: ...r 65 Lifting lowering the fork carriage 154 Tilting the lift mast 154 Driver rights duties and rules of behaviour 29 Driver s cab Use 88 Drivers 29 Driving Ascending gradients 141 Descending gradients 141 Driving lights Switching on and off 217 Driving on gradients 125 Driving on lifts 181 Driving on loading bridges 182 E EC declaration of conformity in accordance with Machinery Directive 7 Emerge...

Page 398: ...e 315 Information symbols 20 Inserting wedges 301 Insulation testing 48 Insurance cover on company premises 31 Interior lighting 239 Issue date of the operating instructions 20 J Jacking up 312 Joystick 4Plus 68 Fork carriage sideshift 158 Lifting lowering the fork carriage 157 Tilting the lift mast 158 Jump starting 296 L Labelling points 10 Lashing down 301 Left side cover 333 Attaching 333 Remo...

Page 399: ...r filter system 329 Battery 326 Controls joints 326 Cooling system 328 Drive axle 327 Electrical system 326 Engine 328 Exhaust gas treatment SCR 329 Fuel tank 328 General lubrication points 326 Hydraulic system 326 Lift mast 327 Load chains 328 Steering axle 327 Tyres 327 Washer system 329 Maintenance work without special qualifications 314 Malfunctions during lifting mode 151 Measuring the insulati...

Page 400: ...l 261 Mini console 70 Misuse of safety systems 34 MSG 65 MSG 75 driver s seat Adjusting 78 Adjusting the backrest extension 81 Adjusting the lumbar support 81 Adjusting the seat backrest 79 Adjusting the seat suspension 80 Moving 79 Switching the seat heater on and off 82 N Nameplate 13 Neutral position 129 Note regarding exhaust gas treatment 5 O Oil bath air filter Cleaning the oil tank 349 Visua...

Page 401: ...the recirculated air filter for the heating system 356 Resetting the daily kilometres 117 Resetting the daily operating hours 117 Residual dangers 38 Residual risks 38 Retrofitting 31 Reversible fork arm Checking 369 Reversible fork arms 164 Right hand service flap Closing 336 Opening 335 Roadways 125 127 Rotating beacon 219 Rules for roadways and the working area 127 S Safety devices 312 Safety insp...

Page 402: ...nformation 14 Switching off the air conditioning 243 Switching off the truck 143 Switching on the air conditioning 243 Switching on the key switch 94 T Technical data Dimensions 372 VDI datasheet 374 Three way mini lever 66 Topicality of the operating instructions 20 Towed load 245 Towing 297 Proper use 15 Trailers Towing 256 Transport 300 Transporting pallets 173 Transporting suspended loads 173 ...

Page 403: ...ction 94 View of functions and operations 23 View of operating procedures 23 Views of the display operating unit 24 Visual inspection Oil bath air filter 340 Pre cleaner 340 Visual inspections 72 W Warning regarding non original parts 33 Wheel chock 144 Wheels and tyres Checking condition and wear of the tyres 358 Checking the air pressure 359 Checking wheel fastenings 359 Servicing 357 Windscreen ...

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