Still RX60-25 Original Instructions Manual
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Still RX60-25 Original Instructions Manual

Electric forklift truck
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Original instructions
Electric forklift truck
RX60-25
RX60-25/600
RX60-25L
RX60-25L/600
RX60-30
RX60-30L
RX60-30L/600
RX60-35
6345 6346 6347 6348 6353
6354 6355 6356
56338011803 EN - 10/2016

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  • Page 1 Original instructions Electric forklift truck RX60-25 RX60-25/600 RX60-25L RX60-25L/600 RX60-30 RX60-30L RX60-30L/600 RX60-35 6345 6346 6347 6348 6353 6354 6355 6356 56338011803 EN - 10/2016...
  • Page 3 Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de 56338011803 EN - 10/2016...

  • Page 5: Table Of Contents

    Table of contents Foreword Your truck ............2 General .
  • Page 6 Table of contents Changes and retrofitting ..........29 Changes to the overhead guard and roof loads .
  • Page 7 Table of contents Operation Checks and tasks to be carried out prior to commissioning ..... . 68 Visual inspections ........... 68 Filling the washer system .
  • Page 8 Table of contents Reducing speed when turning (Curve Speed Control) ......128 Lifting ............129 Lifting system variants .
  • Page 9 Table of contents Controlling attachments using the three-way mini-lever and the 5th function ..185 Controlling attachments using a quadruple mini-lever ......187 Controlling attachments using the four-way mini-lever and the 5th function .
  • Page 10 Table of contents Resetting the daily kilometres and daily operating hours ..... . . 240 Setting the language ..........241 Soft key button for operating various equipment variants .
  • Page 11 Table of contents Decommissioning ........... 313 Parking the truck securely and switching it off .
  • Page 12 Dimensions ............372 VDI datasheet for RX60-25 and RX60-25/600 ....... 374 VDI datasheet for RX60-25L and RX60-25L/600 .

  • Page 13: Foreword

    Foreword...

  • Page 14: Your Truck

    Foreword Your truck Your truck General The truck described in these operating instruc- tions corresponds to the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used.

  • Page 15: Ec Declaration Of Conformity In Accordance With Machinery Directive

    Foreword Your truck EC declaration of conformity in accordance with Machinery Directive Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the according to these operating instructions Industrial truck according to these operating instructions Model conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 16: Accessories

    Foreword Your truck Accessories • Key for key switch (2 pieces) • Key for cab (variant) • Hexagon socket wrench for emergency lowering • Battery replacement frame 56338011803 EN - 10/2016...

  • Page 17: Information About The Documentation

    Foreword Information about the documentation Information about the documentation Documentation scope • Original operating instructions • Original operating instructions for attach- ments (variant) • Spare parts list • VDMA rules for the proper use of industrial trucks These operating instructions describe all mea- sures necessary for the safe operation and proper maintenance of your truck in all pos- sible variants available at the time of printing.

  • Page 18: Issue Date And Topicality Of The Operating Instructions

    The issue date of these operating instructions can be found on the title page. STILL is constantly engaged in the further development of trucks. These operating instructions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.

  • Page 19: List Of Abbreviations

    Foreword Information about the documentation CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruction. NOTE For technical requirements that require special attention. ENVIRONMENT NOTE To prevent environmental damage. List of abbreviations NOTE This list of abbreviations applies to all types of operating instructions.
  • Page 20 Foreword Information about the documentation Abbrevi- Meaning Explanation ation European standard European Federation of Materials Han- Fédération Européene de la Manutention dling and Storage Equipment Maximum power maximum Force German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless GPRS...

  • Page 21: Definition Of Directions

    Foreword Information about the documentation Abbrevi- Meaning Explanation ation Verein Deutscher Ingenieure German technical/scientific association Verband Deutscher Maschinen- und German Mechanical Engineering Industry VDMA Anlagenbau e.V. Association WLAN Wireless LAN Wireless local area network Definition of directions The directions "forwards" (1), "backwards" (3), "right"...
  • Page 22 Foreword Information about the documentation View of the display operating unit NOTE Views of operating 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.

  • Page 23: Environmental Considerations

    Foreword Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during transport. This packaging must be removed completely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck. Disposal of components and batteries The truck is composed of different materials.
  • Page 24 Foreword Environmental considerations 56338011803 EN - 10/2016...

  • Page 25: Introduction

    Introduction...

  • Page 26: Using The Truck

    Introduction Using the truck Using the truck Proper usage The truck described in these operating in- structions is suitable for lifting, transporting and stacking loads. The truck may only be used for its proper purpose as set out and described in these operating instructions.

  • Page 27: Place Of Use

    Introduction Using the truck DANGER There is a risk of fatal injury from falling off the truck while it is moving! – It is prohibited to carry passengers on the truck. The truck may not be operated in areas where there is a risk of fire, explosion or corrosion, or in areas that are particularly dusty.

  • Page 28: Parking In Temperatures Below -10°C

    Introduction Using the truck CAUTION Batteries can freeze! If the truck is parked in an ambient temperature of below –10 °C for an extended period, the batteries cool down. The electrolyte may freeze and damage the batteries. The truck is then not ready for opera- tion.

  • Page 29: Residual Risk

    Introduction Residual risk Residual risk Residual dangers, residual risks Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the truck cannot be entirely excluded. The truck and all other system components comply with current safety requirements. Nevertheless, even when the truck is used for its proper purpose and all instructions are followed, some residual risk cannot be...

  • Page 30: Special Risks Associated With Using The Truck And Attachments

    Introduction Residual risk The manufacturer is not held responsible for accidents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or carelessly. Stability The stability of the truck has been tested to the latest technological standards and is guaran- teed provided that the truck is used properly and according to its intended purpose.
  • Page 31 Introduction Residual risk 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.

  • Page 32: Overview Of Hazards And Countermeasures

    Introduction Residual risk Overview of hazards and counter- measures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
  • Page 33 Introduction Residual risk Hazard Measure Check note Notes √ Complete - Not applicable Impermissible usage Issuing of operating German Ordinance on (improper usage) instructions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of German Ordinance on instruction to driver Industrial Safety and...
  • Page 34 Introduction Residual risk Hazard Measure Check note Notes √ Complete - Not applicable When charging the Note the German Association for traction battery Ordinance on Electrical, Electronic Industrial Safety and and Information Health (BetrSichV), Technologies (VDE) the operating regulation 0510: In instructions and the particular German Engineering...

  • Page 35: Danger To Employees

    Introduction Residual risk Hazard Measure Check note Notes √ Complete - Not applicable Driveways intersect Announce right-of- German Ordinance on way rule Industrial Safety and Health (BetrSichV) No person detection Employee training German Ordinance on during depositing and Industrial Safety and retrieval Health (BetrSichV) Danger to employees...
  • Page 36 Introduction Residual risk operational hazards are involved, they must also be taken into consideration. The conditions of use for trucks are broadly similar in many plants, so the hazards can be summarised in one overview. Observe the information provided by the relevant employers’...

  • Page 37: Safety

    Safety...

  • Page 38: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal person or group who operates the truck or on whose authority the truck is used. The operating company must ensure that the truck is only used for its proper purpose and in compliance with the safety regulations set out in these operating instructions.

  • Page 39: Drivers

    Safety Definition of responsible persons regarding the industrial truck to be tested and the risk being assessed Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised rep- resentative, and have been specifically in-...
  • Page 40 Safety Definition of responsible persons DANGER The use of drugs, alcohol or medications that affect reactions impair the ability to drive the truck! Individuals under the influence of the aforementio- ned substances are not permitted to perform work of any kind on or with the truck. Prohibition of use by unauthorised persons The driver is responsible for the truck during...

  • Page 41: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises In many cases, company premises are restricted public traffic areas. NOTE The business liability insurance should be reviewed to ensure that, in the event of any damage caused in restricted public traffic areas, there is insurance cover for the truck in respect of third parties.
  • Page 42 Safety Basic principles for safe operation DANGER Risk of injury if truck tips over! Even when using an approved restraint system, there is some residual risk that the driver might be injured if the truck tips over. This risk of injury can be reduced through the combined use of a restraint system and the seat belt.
  • Page 43 Safety Basic principles for safe operation DANGER Risk to life from falling load! If the truck is not equipped with an overhead guard, there is a risk to the driver’s life, as he may be struck by a load falling from a lift height of 1800 mm or greater.

  • Page 44: Changes To The Overhead Guard And Roof Loads

    STILL. CAUTION Installation and/or use of such products may there- fore have a negative impact on the design features of the truck and thus impair active and/or passive driving safety.

  • Page 45: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation Damage, defects and misuse of safety systems Damage or other defects on the truck or attachment must be reported to the supervisor or responsible 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.

  • Page 46: Medical Equipment

    Safety Basic principles for safe operation The following rules must be observed to ensure stability: • Only use tyres with equal and permitted levels of wear on the same axle • Only use wheels and tyres of the same type on the same axle, e.g.

  • Page 47: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation Exercise caution when handling gas springs and accumulators WARNING Gas springs are under high pressure. Improper removal results in an elevated risk of injury. For ease of operation, various functions 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).
  • Page 48 Safety Basic principles for safe operation picked up. These other loading units then fall over when the load is raised. – For help with selecting the correct fork arms, contact the authorised service centre. 56338011803 EN - 10/2016...

  • Page 49: Safety Tests

    Safety Safety tests Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, a complete check of the technical condition of the truck must be performed with regard to accident safety.
  • Page 50 Safety Safety tests – For insulation testing, contact the autho- rised service centre. The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck’s electrical system and drive batte- ries must be checked separately. Test values for the drive battery Recommended Nominal...

  • Page 51: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables DANGER Failure to observe the safety regulations relating to consumables may result in a risk of injury, death or damage to the environment. – Observe the safety regulations when handling such materials.

  • Page 52: Hydraulic Fluid

    Safety Safety regulations for handling consumables WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin! – Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin with soap and water, and then apply a skin care product.

  • Page 53: Battery Acid

    Safety Safety regulations for handling consumables WARNING These fluids are pressurised during operation of the truck and are hazardous to your health. – Do not allow the fluids to come into contact with the skin. – Avoid inhaling spray. – Penetration of pressurised fluids into the skin is particularly dangerous if these fluids escape at high pressure due to leaks in...

  • Page 54: Disposal Of Consumables

    Safety Safety regulations for handling consumables WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, never wear a watch or jewellery. –...

  • Page 55: Emissions

    Safety Emissions Emissions The values specified apply to a standard truck (compare the specifications in the "Technical data" chapter). Different tyres, lift masts, additional units etc. may produce different values. Noise emissions The values were determined based on measuring procedures from the standard EN 12053 "Safety of industrial trucks.
  • Page 56 Safety Emissions Vibrations The vibrations of the machine have been determined on an identical machine in ac- cordance with the standards DIN EN 13059 "Safety of industrial trucks - Test methods for measuring vibration" and DIN EN 12096 "Mechanical vibration - Declaration and verifi- cation of vibration emission values".
  • Page 57 Safety Emissions Battery DANGER Risk of explosion due to flammable gases! During charging, the battery releases a mixture of oxygen and hydrogen (oxyhydrogen gas). This gas mixture is explosive and must not be ignited. – Make sure that there is always sufficient ventilation in working areas that are entirely or partially enclosed.
  • Page 58 Safety Emissions 56338011803 EN - 10/2016...

  • Page 59: Overviews

    Overviews...

  • Page 60: General View

    Overviews General view General view 6321_003-073_V2 Lift mast Battery Overhead guard Drive axle with traction motor Driver’s compartment Fork carriage Traction electronics Fork arms Steering axle 56338011803 EN - 10/2016...
  • Page 61 Overviews General view 56338011803 EN - 10/2016...

  • Page 62: General View Of Driver's Compartment

    Overviews General view of driver’s compartment General view of driver’s compartment 6321_003-132_V3 56338011803 EN - 10/2016...
  • Page 63 Overviews General view of driver’s compartment Parking brake lever Bottle holder for max. 0.5 l bottles Steering wheel Compartment and storage location for Key switch operating instructions Display operating unit Driver’s seat Operating devices for hydraulic and traction Accelerator pedal functions Brake pedal Emergency off switch (only in multiple-lever...

  • Page 64: Operating Devices And Display Elements

    Overviews Operating devices and display elements Operating devices and display elements Display operating unit 6210_003-082_V3 Hazard warning system button Reverse travel display Front windscreen wiper button Power rating display Working spotlight button Time display (digital) Drive programme selector button Not assigned Lighting button Rotating beacon display Lighting symbol...
  • Page 65 Overviews Operating devices and display elements – If you have any questions, please contact your authorised service centre. 56338011803 EN - 10/2016...

  • Page 66: Operating Devices For Hydraulic And Traction Functions

    Overviews Operating devices and display elements Operating devices for hydraulic and traction 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: • Multiple-lever •...

  • Page 67: Multi-Lever

    Overviews Operating devices and display elements Multi-lever 5060_003-107 "Lift/lower" operating lever "Tilt" operating lever Operating lever for attachment (variant) Operating lever for attachments with 5th function (variant) "5th function" function switch (variant) Drive direction switch NOTE In the dual-pedal version (variant), the truck is equipped with a signal horn button instead of the drive direction switch.

  • Page 68: Double Mini-Lever

    Overviews Operating devices and display elements Double mini-lever 7312_003-002 "Lift mast" 360° lever Function key "5th function" Function key F1 "Attachments" cross lever Function key F2 Emergency stop switch "Drive direction / turn indicator" cross lever Signal horn button NOTE Depending on the specification, various electric attachment parts can be controlled via function keys (2) and (3).

  • Page 69: Three-Way Mini-Lever

    Overviews Operating devices and display elements Three-way mini-lever 5060_003-089 "Lift mast" 360° lever "Auxiliary hydraulics 1" operating lever Function key F1 "Auxiliary hydraulics 2" operating lever Function key F2 Emergency stop switch "Drive direction / turn indicator" cross lever Signal horn button Function key "5th function"...

  • Page 70: Four-Way Mini-Lever

    Overviews Operating devices and display elements Four-way mini-lever 5060_003-088 "Lift/lower" operating lever Function key "5th function" "Tilt" operating lever "Auxiliary hydraulics 1" operating lever Function key F1 "Auxiliary hydraulics 2" operating lever Function key F2 Emergency stop switch "Drive direction / turn indicator" cross lever Signal horn button NOTE Depending on the specification, various...

  • Page 71: Joystick 4Plus

    Overviews Operating devices and display elements Joystick 4Plus 6210_003-087 Horizontal rocker button for "3rd hydraulic LED for clamp locking mechanism (variant) function", tilt the lift mast Slider for the "4th hydraulic function", e.g. Pictograms for the basic hydraulic functions reach frame forwards/backwards Pictograms for the 5th hydraulic function and Vertical rocker button for the "drive direction"...

  • Page 72: Fingertip

    Overviews Operating devices and display elements Fingertip 6321_003-004 Function key F1 Emergency stop switch Function key F2 "Attachments" operating lever Left-hand turn indicator button "Attachments" operating lever Signal horn button "Tilt" operating lever Right-hand turn indicator button "Lift/lower" operating lever Button for 5th function Travel direction switch NOTE...

  • Page 73: Mini Console

    Overviews Operating devices and display elements Mini console The mini console is located on the steering column below the steering wheel. 7311_003-056 Travel direction switch Direction indicator switch 56338011803 EN - 10/2016...

  • Page 74: Identification Points

    Identification points Overview DANGER STOP DANGER xx xxxx x xxxxx Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr Rated capacity Unladen mass STILL GmbH Hamburg Capacité nominale Masse à vide Nenn-Tragfähigkeit Leergewicht BATTERIESERVICE Regelmäßige Prüfung Battery voltage Tension batterie (FEM 4.004) Batteriespannung min.*...
  • Page 75 Overviews Identification points Decal information: Fasten the seat belt Decal information: Lifting gear attachment Decal information: Caution / Read the point operating instructions Decal information: Hydraulic oil tank Warning sign: Passengers are not allowed Decal information: FEM audit Warning sign: Danger due to shearing Manufacturer’s name Warning sign: Danger due to high fluid Manufacturer’s name...

  • Page 76: Nameplate

    Overviews Identification points Nameplate The truck can be identified from the informa- tion on the nameplate. Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr Rated capacity Unladen mass Capacité nominale Masse à vide Nenn-Tragfähigkeit Leergewicht Battery voltage Tension batterie min.* Batteriespannung Rated drive power Puissance motr.nom.

  • Page 77: Production Number

    Overviews Identification points Production number xx xxxx x xxxxx NOTE The production number is used to identify the truck. It can be found on the nameplate and must be referred to in all technical questions. The production number contains the following coded information: (1) Production location (2) Model...
  • Page 78 Overviews Identification points 56338011803 EN - 10/2016...

  • Page 79: Operation

    Operation...

  • Page 80: Checks And Tasks To Be Carried Out Prior To Commissioning

    Operation Checks and tasks to be carried out prior to commissioning Checks and tasks to be carried out prior to commissioning Visual inspections WARNING Risk of accident due to damage or other defects on the truck or on the attachment (variant)! Damage to the truck or the attachment (variant) can lead to unpredictable and dangerous situations.
  • Page 81 Operation Checks and tasks to be carried out prior to commissioning • Attachments (variant) must be properly mounted and function according to the operating instructions. • All decal information signs must be in place and legible. Replace damaged or missing adhesive labels in accordance with the overview in the "Identification points"...

  • Page 82: Filling The Washer System

    Operation Checks and tasks to be carried out prior to commissioning WARNING Risk of component damage! A deformed or damaged battery male connector can cause overheating and the related consequen- tial damage. – Check the battery male connector for damage. –...

  • Page 83: Checking The Condition Of The Wheels And Tyres

    Operation Checks and tasks to be carried out prior to commissioning Checking the condition of the wheels and tyres WARNING Risk of accident! Uneven wear reduces the stability of the truck and increases the braking distance. – Renew left and right worn or damaged tyres without delay.

  • Page 84: Adjusting The Msg 65/Msg 75 Driver's Seat

    Operation Checks and tasks to be carried out prior to commissioning Adjusting the MSG 65/MSG 75 driver’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.
  • Page 85 Operation Checks and tasks to be carried out prior to commissioning Moving the driver’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.
  • Page 86 Operation Checks and tasks to be carried out prior to commissioning Adjusting the seat suspension NOTE The driver’s seat can be adjusted to suit the weight of the individual driver. In order to achieve the best seat suspension setting, the driver should perform the adjustment whilst sitting in the seat.
  • Page 87 Operation Checks and tasks to be carried out prior to commissioning Adjusting the lumbar support (variant) NOTE The lumbar support can be adjusted to suit the contours of the individual driver’s spine. Adjusting the lumbar support moves a convex support cushion into the upper or lower part of the backrest.

  • Page 88: Adjusting The Armrest

    Operation Checks and tasks to be carried out prior to commissioning Switching the seat heater (variant) on and off NOTE The seat heater only functions if the seat contact switch is active, i.e. when the driver is sitting on the driver’s seat. –...

  • Page 89: Adjusting The Steering Column

    Operation Checks and tasks to be carried out prior to commissioning – Tighten the hand wheel by turning it clock- wise. – Check that the armrest is firmly attached. Adjusting the steering column – Press down the steering column adjustment lever (2).

  • Page 90: Commissioning

    Operation Commissioning Commissioning Climbing in and out of the truck WARNING Risk of injury when climbing into and out of the truck due to slipping, striking parts of the truck or becoming stuck! If the footwell cover is very dirty or smeared with oil, there is a risk of slipping.
  • Page 91 Operation Commissioning To assist with climbing into and out of the truck, the footwell must be used as a step (4) and the handle (1) must be used for support. The post of the overhead guard (5) can also be used for support.

  • Page 92: Connecting The Battery Male Connector

    Operation Commissioning Connecting the battery male connec- – Open the battery cover. CAUTION Component damage possible! If you connect the battery male connector with the key switch switched on (under load), an arc will be produced. This can cause the contacts to weld, which considerably shortens their service life.

  • Page 93: Unlocking The Emergency Off Switch

    Operation Commissioning Unlocking the emergency off switch – Pull out/turn the emergency off switch (1) until it unlocks. 6321_003-145 Switching on the key switch WARNING Before switching on the key switch, all tests and operations prior to commissioning must be perfor- med without any defects being detected.
  • Page 94 Operation Commissioning line. To do this, rotate the steering wheel by approximately half a turn. – Insert switch key (1) into the key switch and turn to position "I". 5060_003-029_V2 This initiates a self-test. All lamps in the drive direction and turn indicator displays light up briefly.
  • Page 95 Operation Commissioning When the key switch is switched on, the display shows the welcome screen in the set language until the truck controller has fully started up. If the truck is ready for operation, the standard displays are shown. If the truck is equipped with the "access authorisation with PIN code"...

  • Page 96: Access Authorisation With Pin Code (Variant)

    Operation Commissioning Access authorisation with PIN code (variant) Description Trucks 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.
  • Page 97 The driver PINs are stored in the truck control unit. These are still available if the display and operating unit has been changed. The authorised service centre can use a diagnostic device to read out the driver PIN and, if necessary, restore the factory default driver PIN.
  • Page 98 Operation Commissioning If an incorrect driver PIN is entered, the message appears for a short time. INVALID When the message goes out, the driver PIN can be re-entered. BQ_023_en_V2 After three invalid entry attempts, the mes- sage appears. The input is CODE DENIED then locked for five minutes before another attempt can be made.
  • Page 99 Operation Commissioning Defining the driver PIN NOTE The driver PIN can only be defined by persons with the corresponding access authorisation, e.g. fleet managers. In order for the fleet manager to define the driver PIN, the confi- guration menu must be accessed. The confi- guration menu is password-protected.
  • Page 100 Operation Commissioning appears in the display. CONFIGURATION – Use the drive program selection button (1) and the menu change button (3) to select menu. ACCESS CODE – Confirm your selection by pressing the button (2). ENTER BQ_31_en Selecting the driver PIN In the menu, there are fifty ACCESS CODE...
  • Page 101 Operation Commissioning appears in the display. NEW CODE – Enter the desired driver PIN using the buttons (5). The digits entered do not appear in the display. Instead they are represented by circles in the field (6). NEW CODE appears in the display. CONFIRM submenu is used to confirm CONFIRM...
  • Page 102 Operation Commissioning If the driver PIN entered in the sub- CONFIRM menu does not match the driver PIN entered previously in the submenu, the NEW CODE message will appear. INVALID The message will then disappear after a short time. The new driver PIN can be entered in submenu for further confirma- CONFIRM tion.
  • Page 103 Operation Commissioning 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.
  • Page 104 Operation Commissioning appears in the display. CONFIGURATION – Use the drive program selection button (1) and the menu change button (3) to select menu. PASSWORD – Confirm your selection by pressing the button (2). ENTER BQ_032_en appears in PASSWORD/PASSWORD LEVEL the display.
  • Page 105 Operation Commissioning appears in the display. NEW CODE The four-digit password can be entered using the buttons (1). CAUTION Do not enter the password 1777! If this password is entered, the configuration op- tions for the fleet manager are restricted to driver authorisations and cannot be reset independently.

  • Page 106: Operating The Signal Horn

    Operation Commissioning 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 to announce your intention to overtake. 6210_003-095 56338011803 EN - 10/2016...

  • Page 107: Seat Belt

    Operation Commissioning Seat belt DANGER Even when using an approved restraint system, there is some residual risk that the driver might be injured if the truck tips over. This risk of injury can be reduced through the combined use of the restraint system and the seat belt.
  • Page 108 Operation Commissioning – Pull the seat belt (3) out of the belt retractor without jerking and fasten closely around the body over the thighs. NOTE Sit as far back as possible so that your back is leaning against the seat backrest. The automatic blocking mechanism permits sufficient freedom of movement on the seat.
  • Page 109 Operation Commissioning Releasing the seat belt – Push the red button (4) on the buckle (1). – Manually guide the belt tongue slowly back to the retractor. NOTE Do not allow the seat belt to retract too quickly. The automatic blocking mechanism may be triggered if the belt tongue strikes the housing.

  • Page 110: Driver's Cab

    Operation Commissioning Driver’s cab DANGER Risk of fatal injury in the event of falling from the truck if it tips over! In order to prevent the driver from sliding under- neath the truck and being crushed if the truck tips over, a restraint system must be in place and must be used.

  • Page 111: Checking The Steering System For Correct Function

    Operation Commissioning Checking the parking brake DANGER If the truck rolls away, there is a risk of being run over and therefore a danger to life! – The truck must not be parked on a slope. – In emergencies, secure with wedges on the side facing downhill.

  • Page 112: Checking The Emergency Off Function

    Operation Commissioning Checking the emergency off function WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch will disconnect the drives from the power supply. – To brake, actuate the service brake. –...
  • Page 113 Operation Commissioning NOTE Accurate zero adjustment is only possible if the fork is not carrying a load. Do not take up a load yet. NOTE Accurate zero adjustment is only possible within the first lifting stage of the lift mast. When carrying out the zero adjustment, do not raise the fork more than 800 mm above the ground.

  • Page 114: Checking The Vertical Lift Mast Position (Variant) For Correct Function

    Operation Commissioning Checking the vertical lift mast position (variant) for correct function NOTE The function check of the lift mast vertical position (variant) must be carried out every time a truck is commissioned. – Actuate function key (1) to switch on the comfort feature "lift mast vertical position".

  • Page 115: Traction

    Operation Traction Traction Safety regulations when driving Driving conduct The driver must follow the public rules of the road when driving in company traffic. The speed must be appropriate to the local conditions. For example, the driver must drive slowly around corners, in tight passageways, when driving through swing-doors, at blind spots, or on uneven surfaces.
  • Page 116 There is a risk of accident! – Do not use devices during travel or when hand- ling loads. – Set the volume so that warning signals can still be heard. WARNING In areas where use of mobile phones is prohibited, use of a mobile phone or radio telephone is not permitted.

  • Page 117: Roadways

    The required aisle widths depend on the dimensions of the load. For pallets, these are: Aisle width [mm] With pallet With pallet Type Model 800 x 1200 1000 x 1200 lengthwise crosswise RX60-25 6345 3678 3877 RX60-25/600 6346 3683* 3882 RX60-25L 6347 3830 4030...
  • Page 118 The truck may be driven on the following upwards or downwards gradients: Maximum gradient [%] Type Model With battery With load Without load carrier RX60-25 6345 25.5 29.7 RX60-25/600 6346 24.0 28.3 RX60-25L 6347 24.2...
  • Page 119 Operation Traction 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 dimensioned for this purpose. However, movable parts may project beyond the truck contour and be damaged or torn off.

  • Page 120: Setting The Drive Programme

    Operation Traction Hazard areas Hazard areas on roadways must be marked by standard traffic signs or, if necessary, by additional warning signs. Setting the drive programme The driving and braking characteristics of the drive can be set on the display and operating unit.

  • Page 121: Reducing Speed With A Raised Load (Variant)

    Operation Traction Reducing speed with a raised load (variant) This function (variant) reduces the speed of the truck with a raised load. 7321_003-052_en_V2 Selecting the drive direction The desired drive direction of the truck must be selected using the drive direction switch before attempting to drive.

  • Page 122: Actuating The Drive Direction Switch, Multiple-Lever Version

    Operation Traction from suddenly starting if the accelerator pedal is pressed inadvertently. – 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".

  • Page 123: Actuating The Drive Direction Switch, Mini-Lever Version

    Operation Traction Actuating the drive direction switch, mini-lever version – For the "forwards" drive direction, push the cross lever (1) forwards – For the "backwards" drive direction, push the cross lever backwards 5060_003-096 Actuating the vertical rocker switch for the "drive direction", joy- stick 4Plus version –...

  • Page 124: Actuate The Drive Direction Switch, Fingertip Version

    Operation Traction Actuate 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. 5060_003-097 Actuating the drive direction switch, mini-console version –...
  • Page 125 Operation Traction The driver’s seat is equipped with a seat switch. This checks whether the driver’s seat is occupied. If it is not occupied or in the case of malfunction of the seat switch, the truck cannot be moved and all lift functions are locked out.
  • Page 126 Operation Traction – Actuate the accelerator pedal (3). The truck will travel in the selected drive direc- tion. The speed is controlled by the accelera- tor pedal position. When the accelerator pedal is released, the truck decelerates. NOTE The truck can briefly be stopped on upward or downward gradients without actuating the parking brake (electric brake).

  • Page 127: Starting Drive Mode, Dual-Pedal Version (Variant)

    Operation Traction truck still cannot be operated, park it securely and contact your authorised service centre. Starting drive mode, dual-pedal version (variant) DANGER Being trapped under a rolling or tipping truck could cause fatal injuries. – Sit down on the driver’s seat.
  • Page 128 Operation Traction The indicator for the selected drive direction ("forwards" (3) or "backwards" (4)) lights up on the display and operating unit. NOTE 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.

  • Page 129: Operating The Service Brake

    Operation Traction released and then actuated again, provided that the electrical fault has been corrected. If the truck still cannot be operated, park it securely and contact your authorised service centre. Operating the service brake The electric brake converts the acceleration energy of the truck into electrical energy.

  • Page 130: Parking Brake

    Operation Traction – Brake the truck by releasing the accelerator pedal (1). – If the braking effect is inadequate, use the brake pedal (2) as well to apply the mechanical brake. Parking brake Operation of the parking brake depends on which parking brake the truck is fitted with.
  • Page 131 Operation Traction Apply the parking brake – Pull the parking brake lever (1) down fully and release. The parking brake lever swivels back half the distance into the middle position automati- cally. The parking brake is engaged and the wheels are blocked.

  • Page 132: Actuate The Electric Parking Brake

    Operation Traction Actuate the electric parking brake The electric parking brake is intended for working cycles that require the driver to leave the truck frequently. The driver does not need to manually apply or release the parking brake. Despite these automatic aids, the driver is always responsible for parking the truck safely.
  • Page 133 Operation Traction Cause Effect You will hear the parking brake engage imme- When the key switch is turned off: diately and the LED (2) illuminates briefly with a steady light until the control units switch off. If the emergency off switch is actuated, follow- The parking brake is applied.
  • Page 134 Operation Traction If the parking brake was not applied by the ac- celerator pedal being released or the driver’s seat being vacated, then drive operation is not possible until the parking brake has been re- leased by pressing the button. The message appears in the RELEASE PARKING BRAKE display.
  • Page 135 Operation Traction Actuating the parking brake when the truck is stationary Applying the parking brake manually – Press push button (1). The parking brake will make a noise when it is applied and the LED (2) lights up continuously. The parking brake is applied automatically 6210_003-050_V4 If the electric parking brake is applied, the message...
  • Page 136 Operation Traction Releasing the parking brake manually NOTE When the truck is ready for operation, the electric parking brake can be released at any time by pressing the button. – Sit down on the driver’s seat. – Press push button (1). You will hear the parking brake being released and the LED (2) goes out.
  • Page 137 Operation Traction Cause Effect The truck will roll to a stop. If the truck is at If the emergency off switch is actuated, follow- a standstill, you will hear the parking brake ing the emergency off function: engage and the LED (2) illuminates briefly with a steady light.
  • Page 138 Operation Traction DANGER Risk of fatal injury from being run over if the truck rolls away! If the parking brake is faulty, the truck must be parked safely and secured so that it cannot roll away. To do this, strictly adhere to the following instructions: –...

  • Page 139: Steering

    Operation Traction Steering DANGER If the hydraulics fail, there is a risk of accident as the steering characteristics have changed. – Do not operate the truck if it has a defective steering system. – Steer the truck by turning the steering wheel (1) accordingly.

  • Page 140: Reducing Speed When Turning (Curve Speed Control)

    DANGER The Curve Speed Control function cannot override the physical limits of stability. Despite this function, 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.

  • Page 141: Lifting

    Operation Lifting Lifting Lifting system variants The movement of the fork carriage and the lift mast heavily depends on the following equipment: • The lift mast with which the truck is equipped, see ⇒ Chapter "Types of lift mast", P. 5-134 •...

  • Page 142: Lift Mast Vertical Position (Variant)

    Operation Lifting Overriding and reactivating the auto- matic lift cut out If a load needs to be lifted to the truck’s maximum lift height and the automatic lift cut out function is not required, it is possible to override the lift cut out. It is automatically reactivated when the truck is switched off and back on again.
  • Page 143 Operation Lifting CAUTION Risk of damage to property due to the lift mast colliding with racks or other objects! – Before using the "lift mast vertical position" comfort feature, position the truck at a sufficient distance from racks and other objects. The "lift mast vertical position"...
  • Page 144 Operation Lifting 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 position". The arrow above the bar marks the vertical position of the lift mast.
  • Page 145 Operation Lifting Tilting the lift mast forwards with the "lift mast vertical position" – Actuate the button (1) to switch on the "lift mast vertical position" comfort feature; the function display (2) in the display shows the activated status. – Tilt the lift mast forwards. NOTE The way in which the lifting system is operated depends on the operating devices included in...

  • Page 146: Types Of Lift Mast

    Operation Lifting Possible restrictions on the "lift mast vertical position" In some circumstances, the lift mast cannot move exactly into the preset vertical position. Possible causes include: • Uneven ground • Bent fork • Bent attachment • Worn tyres • Severely deformed lift mast The vertical position can be corrected by tilting the lift mast using the relevant operating device.
  • Page 147 Operation Lifting 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.

  • Page 148: Malfunctions During Lifting Mode

    Operation Lifting Triplex lift mast (variant) During lifting, the inner lift cylinder moves up to free lift (3), and then the outer lift cylinders raise the inner lift mast up to the max. height (2). DANGER Risk of accident due to collision of the lift mast or load with low ceilings or entrances.

  • Page 149: Lifting System Operating Devices

    Operation Lifting Load chains not under tension DANGER Danger caused by a falling load! – Make sure that the chain(s) does (do) not become slack when lowering the load. Slack chains can, for instance, result from: • Resting the fork carriage or the load on the racking.

  • Page 150: Hydraulic Blocking Function

    Operation Lifting DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. – Observe the safety regulations for handling loads.

  • Page 151: Multi-Lever Lifting System

    Operation Lifting Multi-lever lifting system DANGER Reaching or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. – Always observe the safety regulations for hand- ling loads;...

  • Page 152: Controlling The Lifting System Using A Double Mini-Lever

    Operation Lifting Controlling the lifting system using a double mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. –...

  • Page 153: Controlling The Lifting System Using A Triple Mini-Lever

    Operation Lifting Controlling the lifting system using a triple mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. –...

  • Page 154: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operation Lifting Controlling the lifting system using a quadruple mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. –...

  • Page 155: Controlling The Lifting System Using The Joystick 4Plus

    Operation Lifting Controlling the lifting system using the joystick 4Plus DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. –...
  • Page 156 Operation Lifting 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...

  • Page 157: Controlling The Lifting System With The Fingertip Console

    Operation Lifting Controlling the lifting system with the fingertip console DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equipment, load carrying devices etc.) can lead to serious injury or death and is therefore prohibited. –...

  • Page 158: Changing The Fork Arms

    Operation Lifting Changing the fork arms DANGER There is a risk of being run over if the truck rolls away, and therefore a danger to life. – Do not park the truck on a gradient. – Apply the parking brake. –...
  • Page 159 Operation Lifting Removal – Select a pallet corresponding to the fork arm size. – Position the pallet to the left or right of the fork carriage. – Raise the fork carriage until the lower edges of the fork arms are approx.3 cm higher than the height of the pallet.

  • Page 160: Fork Extension (Variant)

    Operation Lifting Fork extension (variant) DANGER There is a risk of being run over if the truck rolls away and therefore a danger to life. – Do not park the truck on a slope. – Apply the parking brake. – Change the fork extension in a separate, safe location on a level surface.
  • Page 161 Operation Lifting Attachment DANGER Risk to life from falling load! At least 60% of the length of the fork extension must lie on the fork arm. A maximum 40% overhang over the fork arm end is permissible. The fork extension must also be secured against slipping from the fork arm.

  • Page 162: Operation With Reversible Fork Arms (Variant)

    Operation Lifting Operation with reversible fork arms (variant) DANGER Risk to life from falling load! Standard fork arms are not structurally designed for reverse operation. If this instruction is not observed, it can lead to material failure and the load falling. –...
  • Page 163 Operation Lifting Reversible fork arms (1) can be used to reach an additional lift height. The reversible fork arms are installed on the fork carriage in the same manner as standard fork arms. Loads may be lifted on and beneath the reversible fork arms.

  • Page 164: Handling Loads

    Operation Handling loads Handling loads Safety regulations when handing loads The safety regulations for handling loads are shown in the following sections. DANGER There is a risk to life caused by falling loads or if parts of the truck are being lowered. –...

  • Page 165: Before Taking Up Load

    Operation Handling loads Before taking up load Load capacity The load capacity indicated for the truck on the capacity rating plate may not be exceeded. The load capacity is influenced by the load centre of gravity and the lift height as well as by the tyres, if applicable.

  • Page 166: Load Measurement (Variant)

    Operation Handling loads Example Weight of load to be lifted: 880 kg (3) Load distance from fork back: 500 mm (1) Permitted lift height: 5230 mm (2) WARNING Risk of accident from the truck losing stability! The permissible load of the attachments (variant) and the reduced lifting capacity of the combination 5230 of truck and attachment must not be exceeded.
  • Page 167 Operation Handling loads The load measurement has an accuracy of +/-3% of the rated capacity of the truck. NOTE In order to ensure accuracy at all times, a zero adjustment of the load measurement must be carried out. Zero adjustment is required. as part of daily commissioning •...
  • Page 168 Operation Handling loads NOTE The method of operating the lifting system depends on the operating devices included in the truck’s equipment. – Ensure that the truck has been in operation for a period of time before carrying out the load measurement. –...

  • Page 169: Picking Up Loads

    Operation Handling loads If load measurement has been carried out correctly, the determined load weight (3) is shown on the display of the display-operating unit. NOTE If the load measurement is invalid, the value "-9999 kg" is displayed in the operating unit. 6210_003-073_en Picking up loads To make sure that the load is securely sup-...

  • Page 170: Danger Area

    Operation Handling loads Adjusting the fork – Lift the locking lever (1) and move the fork arms to the desired position. – Allow the locking lever to snap back into place. The load centre of gravity must be midway between the fork arms. –...

  • Page 171: Transporting Pallets

    Operation Handling loads DANGER Danger of death from falling loads! – Never walk or stand underneath suspended loads. Transporting pallets As a rule, loads (e.g. pallets) must be transpor- ted individually. Transporting multiple loads at the same time is only permitted: •...

  • Page 172: Load Pick Up

    Operation Handling loads DANGER Loss of stability. Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. – When transporting suspended loads, observe the following instructions Instructions for transporting suspended loads: •...
  • Page 173 Operation Handling loads – Only store pallets which do not exceed the specified maximum size. Damaged loading equipment and incorrectly formed loads must not be stored. – Attach or secure the load to the load- carrying equipment so that the load cannot move or fall.
  • Page 174 Operation Handling loads – Insert the fork as far under the load as possible. Stop the truck as soon as the fork back is resting on the load. The centre of gravity of the load must be positioned between the fork arms in the middle. 6210_800-007 –...
  • Page 175 Operation Handling loads – Lower the load while maintaining ground clearance. 5060_003-102 – Tilt the lift mast backwards. The load can be transported. 5060_003-101 56338011803 EN - 10/2016...

  • Page 176: Transporting Loads

    Operation Handling loads Transporting loads NOTE Observe the information in the chapter entitled "Safety regulations when driving". DANGER The higher a load is lifted, the less stable it beco- mes. The truck can tip over or the load can fall, increasing the risk of accident! Driving with a raised load and the lift mast tilted forward is not permitted.

  • Page 177: Setting Down Loads

    Operation Handling loads – Never drive with a load protruding to the side (e.g. with the sideshift)! 6210_800-014 Setting down loads DANGER Risk of accident due to changed moment of tilt! Please note that the lift mast can be tilted far enough forward with a raised load to cause the truck to tip over.
  • Page 178 Operation Handling loads load capacity diagram must be created as the stability will be affected. Contact the authorised service centre on • this matter. – Drive up to the stack with the load lowered in accordance with regulations. – Set lift mast to vertical. –...

  • Page 179: Driving On Ascending And Descending Slopes

    Operation Handling loads Driving on ascending and descend- ing slopes DANGER Danger to life! On ascending and descending slopes the load must be carried facing uphill. It is only permitted to drive on ascending and descending slopes if they are marked as traffic routes and can be used safely.
  • Page 180 Operation Handling loads Determining the actual total weight – Park the truck securely, see ⇒ Chap- ter "Parking the truck securely and switch- ing it off", P. 5-313. – Determine the unit weights by reading the Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr truck nameplate and, if necessary, the Rated capacity Unladen mass...

  • Page 181: Driving On Loading Bridges

    Operation Handling loads Driving on loading bridges DANGER Risk of accident from the truck crashing! Steering movements can cause the tail end to veer off the loading bridge towards the edge. This may cause the truck to crash The lorry driver and the truck driver must agree on the lorry’s departure time.

  • Page 182: Working With Attachments

    Fitting attachments If the truck is equipped with an integrated attachment (variant) at the factory, the specifi- cations in the STILL operating instructions for integrated attachments must be observed. If attachments are fitted at the place of use, the specifications in the operating instructions of the attachment manufacturer must be observed.
  • Page 183 Operation Working with attachments DANGER There is risk to life caused by a falling load! Attachments that hold the load by exerting pressure on it (e.g. clamps) must be controlled additionally by a second operating function (lock) that is actuated to prevent an unintentional release of the load.

  • Page 184: Releasing The Pressure From The Hydraulic System

    Operation Working with attachments Load capacity with attachment The permissible load capacity of the attach- ment and the allowable load (load capacity and load moment) of the truck must not be ex- ceeded by the combination of attachment and payload. The specifications of the manufac- turer and supplier of the attachment must be complied with.
  • Page 185 Operation Working with attachments Releasing pressure, joystick 4Plus, mini-lever and fingertip switch NOTE In trucks with the "FleetManager" or "access authorisation with PIN code" equipment va- riants, access authorisation must be enabled. – Switch on the key switch. – Lower the fork carriage. –...

  • Page 186: General Instructions For Controlling Attachments

    Operation Working with attachments General instructions for controlling attachments The way in which attachments (variant) are controlled depends on the operating devices included in the truck’s equipment. Essentially, a distinction is drawn between: • Multiple-lever • Multiple-lever with a 5th function (variant) •...
  • Page 187 Operation Working with attachments directions of movement can be seen on the pictograms on the operating devices. NOTE All 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.

  • Page 188: Controlling Attachments Using Multi-Lever Operation

    Operation Working with attachments Controlling attachments using multi-lever operation In this equipment, the attachments (variant) are controlled via the operating lever (1). The pictograms on the operating lever show the functions that are activated by this lever. The meanings are as follows: –...

  • Page 189: Controlling Attachments Using Multi-Lever Operation And The 5Th Function

    Operation Working with attachments Controlling attachments using multi-lever operation and the 5th function The attachments (variant) are controlled in this version using operating levers (1) and (2). On the operating lever (1) you can, with the aid of switch (3), initiate a function changeover so that this operating lever then controls the "5th function".
  • Page 190 Operation Working with attachments – Note the following attachment functions and pictograms. Move side shift frame or fork for- wards/backwards Move sideshift to the left/right Adjust fork arms: open/close Release/clamp load retainer Push off/pull in load Turn to the left/right Tip shovel over/tip shovel back Swivel lift mast or fork to the left/right Open/close clamps...

  • Page 191: Controlling Attachments Using A Double Mini-Lever

    Operation Working with attachments Controlling attachments using a double mini-lever The attachments (variants) are controlled in this version using the "attachments" cross lever (1). The pictograms on the "attachments" cross lever show the respective functions that are activated by this lever. This essentially involves the following: –...
  • Page 192 Operation Working with attachments – Note the following attachment functions and pictograms. Move sideshift frame or fork forwards Move sideshift frame or fork back- wards Move sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Swivel lift mast or fork to the left Swivel lift mast or fork to the right Release load retainer...

  • Page 193: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operation Working with attachments Controlling attachments using the double mini-lever and the 5th function NOTE The "lift mast" 360° lever and the "attach- ments" cross lever control four hydraulic func- tions. The "5th function" designation refers to the fact that switching functions using the "5th function"...
  • Page 194 Operation Working with attachments – Note the following attachment functions and pictograms. Move sideshift frame or fork forwards Move sideshift frame or fork back- wards Move sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Swivel lift mast or fork to the left Swivel lift mast or fork to the right Release load retainer...

  • Page 195: Controlling Attachments Using A Triple Mini-Lever

    Operation Working with attachments Controlling attachments using a triple mini-lever The attachments (variant) are controlled in this version using operating levers (1) and (2). The pictograms on the operating levers show the respective functions that are activated by these levers. This essentially involves the following: –...
  • Page 196 Operation Working with attachments – Note the following attachment functions and pictograms. Move sideshift frame or fork forwards Move sideshift frame or fork back- wards Move sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Swivel lift mast or fork to the left Swivel lift mast or fork to the right Release load retainer...

  • Page 197: Controlling Attachments Using The Three-Way Mini-Lever And The 5Th Function

    Operation Working with attachments Controlling attachments using the three-way mini-lever and the 5th function NOTE Four hydraulic functions are controlled using the "lift mast" 360° lever and operating levers (1) and (2). The designation "5th function" refers to the fact that the function change-over uses the function key (3) , which then allows the 5th hydraulic function to be controlled with the operating lever (1).
  • Page 198 Operation Working with attachments – Note the following attachment functions and pictograms. Adjust fork arms: open Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory. If an attachment with other functions is fitted, the pictograms must be checked for the correct representation and changed if necessary.

  • Page 199: Controlling Attachments Using A Quadruple Mini-Lever

    Operation Working with attachments Controlling attachments using a quadruple mini-lever The attachments (variant) are controlled in this version using operating levers (1) and (2). The pictograms on the operating levers show the respective function that is activated by these levers. This essentially involves the following: –...
  • Page 200 Operation Working with attachments – Note the following attachment functions and pictograms. Move sideshift frame or fork forwards Move sideshift frame or fork back- wards Move sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Swivel lift mast or fork to the left Swivel lift mast or fork to the right Release load retainer...

  • Page 201: Controlling Attachments Using The Four-Way Mini-Lever And The 5Th Function

    Operation Working with attachments Controlling attachments using the four-way mini-lever and the 5th function NOTE Operating levers (1) to (4) are used to control 4 hydraulic functions. The designation "5th function" refers to the fact that the function change-over uses the "5th function" function key (5), which then allows the 5th hydraulic function to be controlled using the operating lever (3).
  • Page 202 Operation Working with attachments – Note the following attachment functions and pictograms. Adjust fork arms: open Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms shown correspond to the attachments fitted to this truck at the factory. If an attachment with other functions is fitted, the pictograms must be checked for the correct representation and changed if necessary.

  • Page 203: Controlling Attachments Via The Joystick 4Plus

    Operation Working with attachments Controlling attachments via the joystick 4Plus In this equipment, the attachments (variant) are controlled via the joystick 4Plus (1). The pictograms on the decal information about operation of the joystick 4Plus show the respective functions that are activated by the individual operating devices of the joystick 4Plus.

  • Page 204: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operation Working with attachments Controlling attachments using the joystick 4Plus and the 5th function – Note the following attachment functions and pictograms. Operating Function of the device attachment Horizontal Release/open clamp rocker button + shift button "F" NOTE 6210_003-096 The 5th hydraulic function can be used to control an attachment.

  • Page 205: Controlling The Attachments With Fingertip

    Operation Working with attachments Controlling the attachments with fingertip The attachments (variant) are controlled in this version using the operating levers (1). The pictograms on the operating levers always show the functions that are activated by that lever. – Move operating lever (1) forwards. The attachment moves in the direction of movement shown in the upper part of the pictogram.

  • Page 206: Controlling Attachments With Fingertip And The 5Th Function

    Operation Working with attachments Controlling attachments with finger- tip and the 5th function NOTE The designation "5th function" refers to the fact that the four operating levers control four functions, while the "5th function" can be controlled by switching functions. The attachments (variant) are controlled using the operating levers (1).
  • Page 207 Operation Working with attachments – Press the function key (4). NOTE The arrow (5) under the function key indicates which operating lever is equipped with the "5th function". The "5th function" is switched to the 3rd operating lever; see adhesive label (6). 6210_003-033 –...

  • Page 208: Clamp Locking Mechanism (Variant)

    Operation Working with attachments – Note the following attachment functions and pictograms. Move side shift frame or fork for- wards/backwards Move sideshift to the left/right Adjust fork arms: open/close Swivel lift mast or fork to the left/right Release/clamp load retainer Push off/pull in load Open/close clamps Turn to the left/right...
  • Page 209 Operation Working with attachments Multi-lever – Press and hold the (2) button to release the clamp locking mechanism. NOTE The hydraulic function for opening the clamp is only available if the button is pressed. After releasing the button, the clamp locking mechanism is automatically reactivated.
  • Page 210 Operation Working with attachments Triple mini-lever – To release the clamp locking mechanism, push the operating lever (1) forwards. The LED for button F2 (2) lights up as long as the clamp locking mechanism is released. NOTE The hydraulic function for opening the clamp is available for one second after the clamp locking mechanism is released.

  • Page 211: Taking Up A Load Using Attachments

    Operation Working with attachments – To operate clamping attachments, see the section entitled "Controlling attachments using the quadruple mini-lever and the 5th function". 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.

  • Page 212: Operating Auxiliary Equipment

    Operation Operating auxiliary equipment Operating auxiliary equipment Switching the lighting on and off Driving lights – To switch on the parking light, 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.

  • Page 213: Switching The Rotating Beacon On And Off

    Operation Operating auxiliary equipment Switching the rotating beacon on and – Push the button (1) for switching on the rotating beacon. The rotating beacon symbol (2) appears on the display. The rotating beacon is switched NOTE Pushing the button again switches the rotating beacon off again.

  • Page 214: Switching Direction Indicators On And Off

    Operation Operating auxiliary equipment Switching direction indicators on and Mini-lever version – Switch on the direction indicators by moving the corresponding drive direction/turn indicator cross lever (1) to the left or right. 5060_003-096 The direction indicators and the correspon- ding direction indicator lights (2) or (3) flash. –...
  • Page 215 Operation Operating auxiliary equipment Fingertip version – Switch on the direction indicators by moving the corresponding turn indicator button (1) to the left or to the right. – Turn off the direction indicators by pushing the other turn indicator button. 5060_003-100 Mini-console version –...

  • Page 216: Switching The Double Working Spotlights On And Off

    Operation Operating auxiliary equipment The direction indicators and the correspon- ding turn indicator displays (2) or (3) flash. – Switch off the direction indicators by moving the turn indicator switch to the centre position. 5060_003-012_V2 Switching the double working spotlights on and off. The double working spotlights are fitted up on the front right and left on the overhead guard.
  • Page 217 Operation Operating auxiliary equipment – Turn the key switch to position "I". – Press button (1). NOTE Pressing the button again switches the work- ing spotlights off again. Switching the upper working spotlights on/off automatically – Turn the key switch to position "I". –...

  • Page 218: Operating The Windscreen Wiper/Washer

    Operation Operating auxiliary equipment The lower working spotlights light up. The upper working spotlights are switched on by the proximity switch when the fork carriage reaches or exceeds the preset lift height. The upper working spotlights are switched off by the proximity switch when the fork carriage falls below the preset lift height again.

  • Page 219: Accident Recorder (Variant)

    This data can be electronically read out and evaluated. For further informa- tion, contact your STILL service centre. Driver restraint systems (variants) Different driver restraint systems are available as variants for this truck. The description and operation for these systems can be found in the separate "Driver restraint systems"...

  • Page 220: Cab Operation

    Operation Cab operation Cab operation Opening the cab door DANGER There is a risk of damage through collision if the cab door opens while driving. – The cab door must be latched securely in the engaged position. Opening the cab door from the outside: –...

  • Page 221: Closing The Cab Door

    Operation Cab operation Closing the cab door DANGER There is a risk of damage caused by collision if the cab door opens while driving. – The cab door must be latched securely in the engaged position. Opening the side windows WARNING There is a risk of crushing between the window frame and side window from the side windows...

  • Page 222: Operating The Interior Lighting

    Operation Cab operation Operating the interior lighting 7312_003-013 – Switch the interior lighting (7) on or off using the switch (8) or button (1). The "interior lighting" symbol (2) appears in the display. 6311_003-013_V2 56338011803 EN - 10/2016...

  • Page 223: Operating The Rear Window Heating

    There is a risk of accident! – Do not use the radio when driving or when handling loads. 6321_003-015 – Set the radio volume so that you can still hear warning signals. 56338011803 EN - 10/2016...

  • Page 224: Heating System (Variant)

    Operation Cab operation Heating system (variant) Switching on the blower and heating system DANGER By taking in heavily polluted surroun- ding air into the closed cab there is a danger of poisoning! The heater must not be operated in the vicinity of storage areas or the like in which fuel vapours or fine dust (e.g.
  • Page 225 Operation Cab operation DANGER The heating system housing can become very hot when the heating system is operating. There is a risk of burns if it is touched! – Do not touch the heating system housing during operation. – Only touch the switches provided. –...
  • Page 226 Operation Cab operation Turn off the heating system and blower DANGER The heating system overheats if the hot air cannot escape from it. There is a risk of fire! The blower may only be turned off if the heating system is turned off. –...

  • Page 227: Push-Up Roof Window (Variant)

    Operation Cab operation Push-up roof window (variant) WARNING Risk of crushing! – When closing the roof window, do not reach between the roof window and the overhead guard. – Do not reach in to touch components as they are being closed. The push-up roof window (1) is an equipment variant.

  • Page 228: Trailer Operation

    Operation Trailer operation Trailer operation Towed load DANGER There is an increased risk of accident when using a trailer. Using a trailer changes the truck handling charac- teristics. When towing, operate the truck such that the trailer train can be safely driven and braked at all times.

  • Page 229: Coupling Pin In The Counterweight

    Operation Trailer operation CAUTION Risk 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.
  • Page 230 Operation Trailer operation – Push the coupling pin (2) down, turn 90° and pull out. – Adjust tiller height. DANGER People can become trapped between the truck and trailer. When hooking up, ensure that no one is between the truck and trailer. –...

  • Page 231: Automatic Tow Coupling

    Operation Trailer operation – Push the coupling pin (2) down, turn 90° and pull out. – Slowly move the truck forwards and guide the tow-bar eye completely out of the counterweight. – Insert the coupling pin into the counter- weight, press downwards against the spring pressure and turn 90°...
  • Page 232 Operation Trailer operation DANGER If you briefly leave the truck to couple or uncouple the trailer, there is a risk to life caused by the truck rolling away and running you over. – Apply the parking brake. – Lower the forks to the ground. –...
  • Page 233 Operation Trailer operation WARNING Risk of component damage if the tiller in the tow coupling is tilted! The tiller should be kept as horizontal as possible when towing. This ensures that the rotation range is sufficient at the top and bottom. The authorised service centre can adjust the assembly height for the tow coupling to the tiller height if necessary.
  • Page 234 Operation Trailer operation 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 towed in this condition.
  • Page 235 Operation Trailer operation Coupling model RO*244 A NOTE Trailer coupling RO 244 is intended for a tow bar eye in accordance with DIN 74054 (bore diameter 40 mm) or DIN 8454 (bore diameter 35 mm). – Take measures to prevent the trailer from rolling away, e.g.
  • Page 236 Operation Trailer operation 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. –...
  • Page 237 Operation Trailer operation NOTE To protect the lower coupling pin bush against contamination, always keep the tow coupling closed. Coupling model RO*245 NOTE Trailer coupling RO 245 is intended for a tow-bar eye in accordance with DIN 74054 (bore diameter 40 mm) or DIN 8454 (bore diameter 35 mm).
  • Page 238 Operation Trailer operation Uncoupling model RO*245 – Take measures to prevent the trailer from rolling away, e.g. use wheel chocks. – Push the hand lever (5) upwards. – Slowly drive the truck forwards until the tow- bar eye and towing jaws are disconnected. –...

  • Page 239: Towing Trailers

    Operation Trailer operation 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 towed in this condition.
  • Page 240 Operation Trailer operation NOTE Please observe the definition of the following responsible persons: "operating company" and "driver". 56338011803 EN - 10/2016...

  • Page 241: Use In Cold Stores

    Operation Use in cold stores Use in cold stores The truck features cold store equipment (variant), making it suitable for use in cold stores. It is equipped for two different types of applica- tion and marked with the cold store symbol. Cold store-compatible oils (for hydraulics and the gearbox) and greases (for moving parts, gearing and chains) are used with...
  • Page 242 Operation Use in cold stores Operation CAUTION Changing from a cold inside temperature to a warm outside temperature may result in the formation of water condensation. This water may freeze on re-entering the cold store, blocking moving parts of the truck. It is essential that close attention is paid to the duration of deployment in the different temperature ranges for both types of application.
  • Page 243 Operation Use in cold stores batteries with the maximum nominal capacity in the respective battery dimensions for the range. Electric forklift trucks must not be parked for any longer than necessary in a cold area. This also applies to unused batteries. The charging station and the parking area for trucks and batteries must be at normal room temperature (not below 10 °C).

  • Page 244: Operating The Display And Operating Unit

    Operation Operating the display and operating unit Operating the display and operating unit Indicators Standard displays In the factory setting, the following indicators can be seen in the display and operating unit: Battery charge Displays the available battery capacity as a segmented bar graph in 10% increments.
  • Page 245 Operation Operating the display and operating unit CAUTION Deep discharges shorten the service life of the battery. If no bar is shown (0% of the available battery capacity, i.e. around 20% of the nominal capacity), deep discharge begins. – Deep discharge (no bar on the display) must be avoided.
  • Page 246 Operation Operating the display and operating unit Additional indicators Menu change button When the menu change button is pressed, the following additional indi- cators appear: "Service in" display Displays the remaining time in operating hours until the next maintenance opera- tion is due according to the maintenance schedule in the maintenance instruc- tions.

  • Page 247: Adjusting The Displays

    Operation Operating the display and operating unit Adjusting the displays NOTE The parking brake must always be engaged when you adjust the displays. The displays cannot be adjusted if the parking brake is not engaged. NOTE When adjusting the displays, do not actuate the hydraulic system operating devices.
  • Page 248 Operation Operating the display and operating unit Symbols for operating messages Description Symbol Empty field No display Please wait Service required Lift limitation Reference cycle Battery charging Drive program Hour meter Odometer Daily hour meter Daily odometer Speed Steering angle Load Time Hydraulic system...
  • Page 249 Operation Operating the display and operating unit Description Symbol Are you sure? Oil pressure Symbols for error messages Description Symbol Brake system malfunction Overheating of the engine Overheating Malfunction in the electrical system General malfunction Symbols for auxiliary equipment soft key functions For the auxiliary equipment, the following symbols for the soft key functions are used on...
  • Page 250 Operation Operating the display and operating unit Description Symbol Heater blower OFF Heater blower ON Rotating beacon OFF Rotating beacon ON Seat heater OFF Seat heater ON Signal horn OFF Signal horn ON Symbols for the soft key functions for menu navigation and for acknowledging messages For menu navigation and to acknowledge...
  • Page 251 Operation Operating the display and operating unit Description Function off LED OFF Function on LED ON Symbols for numeric keypad The available inputs and the positions of the keys are shown for inputting digits, ENTER Keys for the digits 1 to 7 and the keys for inputting the fleet manager ENTER password...

  • Page 252: Setting The Date Or Time

    Operation Operating the display and operating unit Setting the date or time – Switch to the "CONFIGURATION" menu; see ⇒ Chapter "Adjusting the dis- plays", P. 5-235. – Press the drive program key (1) or menu selection key (2) until the option TIME appears.Confirm your selection by pressing the Return key (4).

  • Page 253: Setting The Language

    Operation Operating the display and operating unit NOTE The daily operating hours are reset in the same manner. Setting the language 1 2 3 4 The displays can be shown in additional languages: – Switch to the "CONFIGURATION" menu; see ⇒ Chapter "Adjusting the dis- plays", P.
  • Page 254 Operation Operating the display and operating unit A grey bar (3) highlights the active soft key column, i.e. the soft keys in this column can be operated. To change the soft key column: – Briefly press the "Menu change button"(1). The grey bar jumps to the other soft key column.

  • Page 255: Blue-Q Efficiency Mode

    Operation Blue-Q efficiency mode Blue-Q efficiency mode Functional description The Blue-Q efficiency mode affects both the drive unit and the activation of the additional consumers, and reduces the truck’s energy consumption. If the efficiency mode has been activated, the acceleration behaviour of the truck changes to make acceleration more moderate.

  • Page 256: Switching Efficiency Mode Blue-Q On And Off

    Operation Blue-Q efficiency mode Truck stopped Shut-off Seat switch Drive direction Front working Backwards > 3 km/h spotlight* Rear working Forwards spotlight* Top double working > 3 km/h spotlight* Headlight* Side light Front wiper Backwards > 3 km/h Rear wiper Forwards Seat heater Cab heating...

  • Page 257: Configuring Blue-Q Efficiency Mode

    Operation Blue-Q efficiency mode – Press the Blue-Q button (1). The Blue-Q symbol (2) appears next to the drive programme symbol in the display and operating unit, which means that the Blue-Q efficiency mode is activated. Pressing the Blue-Q button once again turns the Blue-Q efficiency mode off again.
  • Page 258 Operation Blue-Q efficiency mode – Switch to the menu; CONFIGURATION see ⇒ Chapter "Adjusting the dis- 1 2 3 4 plays", P. 5-235 – Keep pressing the drive programme button (1) or the menu change button (2) until op- tion appears.

  • Page 259: Display Messages

    Operation Display messages Display messages Display content On the display of the display-operating unit, event-related messages may appear due to certain truck conditions. The following types of message may appear individually or in combination: • A graphic symbol (2) • The message (3) •...
  • Page 260 Seat switch has not been actuated for approx. 8 hours. SEAT SWITCH A302 Truck may still drive at a reduced speed and with reduced lifting capacity. Stand up briefly and then sit down again. If this does not resolve the problem, contact your authorised service centre.
  • Page 261 Operation Display messages Message text (English) / Comment Error code Sensor fault; no or limited hydraulic drive function. TILTING A3107 Notify your authorised service centre. A3108 No hydraulic function. MAST VERTICAL A3130 Turn off "lift mast vertical position". A3131 Notify your authorised service centre. A3132 No hydraulic function.

  • Page 262: General Messages

    Operation Display messages Message text (English) / Comment Error code No or limited function of drive unit and hydraulic drive. SURVEILLANCE A2295 Notify your authorised service centre. Temperature sensor fault DRIVE A5031 Notify your authorised service centre. A5041 A5046 A5301 A5331 A5361 The support roller for the hydraulic battery carrier is not fully...
  • Page 263 However, the truck can still roll until the drive wheel units are blocked. For this reason, the parking brake must always be applied before you leave the...
  • Page 264 Operation Display messages BRAKE SENSOR message If the message appears in BRAKE SENSOR 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 DENIED message If the message appears on CODE DENIED...
  • Page 265 Operation Display messages – Release the parking brake by pressing the button. PARKING BRAKE: APPLY HAND- BRAKE! message If the message PARKING BRAKE: APPLY appears on the display, the HANDBRAKE! electric parking brake is faulty. – Release the parking brake by pressing the button.
  • Page 266 Operation Display messages 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 is equipped with an emergency off switch.
  • Page 267 Operation Display messages – To drive again, lower the fork to a maximum of 300 mm above the ground. The truck can now be driven again with no speed limitation. SAFETY BELT message DANGER Risk of fatal injury in the event of falling from the truck if it tips over! If the truck tips over, the driver is at risk of injury even if a restraint system...
  • Page 268 Operation Display messages If the seat belt is released while driving, the truck will be limited to low driving speeds or will be braked to a halt. DANGER Risk of accident! – The speed must be adjusted to suit the driving situation! The increased safety provided by this function must not be misused in order to take safety risks.
  • Page 269 Operation Display messages The seat switch is not actuated while the ac- celerator pedal or steering wheel is actuated The accelerator pedal or the steering wheel is actuated, even though no one is sitting in the driver’s seat. The message SEAT SWITCH appears on the display.
  • Page 270 Operation Display messages The shift time has been exceeded NOTE The shift time is adjustable. If the key switch is switched on and the driver does not leave the seat before the set shift time is exceeded, appears SEAT SWITCH on the display.

  • Page 271: Drive-Specific Messages

    Operation Display messages SURVEILLANCE message If the message appears SURVEILLANCE in the display, there is a fault in the process monitoring. This shuts off the drive unit. – Switch the key switch to the "0" position and then back to the "I" position. –...
  • Page 272 Operation Display messages – Interrupt work and allow the truck to cool down. Do not switch off the key switch. NOTE If the operational capacity is impaired, notify your authorised service centre. OVERHEATING message If the message appears OVERHEATING in the display, the traction motors have overheated.
  • Page 273 Operation Display messages If the fork is raised above a certain height, the following happens: Lifting the load at a standstill The key switch is switched on. The driver sits on the seat with the belt fastened. The load is lifted.

  • Page 274: Operating In Special Operating Situations

    Operation Operating in special operating situations Operating in special operating situations Transport CAUTION Danger of material damage from overloading! If the truck is driven onto a means of transport, the load capacity of the means of transport, the ramps and loading bridges must be greater than the actual total weight of the truck.
  • Page 275 Operation Operating in special operating situations DANGER Risk of accident from the truck crashing! Steering movements can cause the tail end to veer off the loading bridge towards the edge. This may cause the truck to crash. – Before driving over a loading bridge, ensure that it is installed and secured properly.
  • Page 276 Operation Operating in special operating situations Lashing CAUTION Abrasive lashing straps can rub against the surface of the truck and cause damage. – Position slip-resistant pads beneath the lifting points (e.g. rubber mats or foam). – Attach lashing straps (1) to both sides of the truck and lash the truck to the rear.

  • Page 277: Towing

    Operation Operating in special operating situations Towing DANGER The brake system on the towing vehicle may fail. There is a risk of accident! If the brake system of the towing vehicle is not adequately sized, the vehicle may not brake safely or the brakes may fail.
  • Page 278 Operation Operating in special operating situations DANGER People can be crushed between the truck and towing vehicle during manoeuvring. There is danger of death! The towing vehicle may only be manoeuvred and the tow bar may only be attached using a second person as a guide.

  • Page 279: Crane Loading

    Operation Operating in special operating situations – Where possible, activate the restraint systems provided. – Release the parking brake. – Select a towing speed that allows the truck and towing vehicle to be effectively braked and controlled at all times. –...
  • Page 280 Operation Operating in special operating situations Hooking on the lifting straps CAUTION Harnesses may damage the truck’s paintwork! Harnesses may damage paintwork by chafing and pressing on the surface of the truck. Particularly hard or sharp-edged harnesses, such as wires or chains, can quickly damage the surface.
  • Page 281 Operation Operating in special operating situations – Loop the lifting straps around the counter- weight (5) as shown. – Determine the truck’s centre of gravity, see "Dimensions" chapter. 6321_003-070 – Adjust the length of the harnesses so that the lifting eye (6) is vertically above the truck’s centre of gravity.

  • Page 282: Procedure In Emergencies

    Operation Procedure in emergencies 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 suspended loads. – Do not allow the truck to bump into anything whilst it is being lifted, or allow it to move in an uncontrolled way.
  • Page 283 Operation Procedure in emergencies while the key switch is switched on, except in an emergency. In an emergency, all functions of the truck can be shut down: – Press the emergency off switch (1) or disconnect the battery male connector (2). In drive mode, this has the following effect: •...

  • Page 284: Procedure If Truck Tips Over

    Operation Procedure in emergencies Procedure if truck tips over DANGER If the truck tips over, the driver could fall out and slide under the truck with potentially fatal conse- quences. There is a risk to life. Failure to comply with the limits specified in these operating instructions, e.g.

  • Page 285: Emergency Hammer

    Operation Procedure in emergencies Emergency hammer The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazardous situation, for example if the truck has toppled over and the cab door cannot be opened. Single-pane safety glass can be struck rela- tively safely using the emergency hammer in order for the driver to escape or be rescued...
  • Page 286 Operation Procedure in emergencies – Remove the hexagon socket wrench (1) from the compartment on the right next to the driver’s seat. NOTE In this procedure, a distinction is made be- tween the types of operating devices. 6210_003-108_V2 For the Joystick 4Plus version and the mini- 6210_003-100_V2 lever version (A): –...

  • Page 287: Emergency Operation Of The Electric Parking Brake

    Operation Procedure in emergencies – Return the hexagon socket wrench to the support mounting in the compartment. – Install the valve cover. DANGER If the truck is operated with the hydraulic controller blocked, there is an increased risk of accidents! –...
  • Page 288 Operation Procedure in emergencies – Place the hand wheel with the tappet lugs (5) on the tappet (6) and press down against the spring force. NOTE Do not rotate the hand wheel to the stop, because this will trigger the relubrication device.

  • Page 289: Handling The Battery

    Operation Handling the battery Handling the battery Safety regulations when handling the battery – National statutory provisions for the country of use must be followed when setting up and operating battery charging stations. CAUTION Risk of component damage! Incorrect connection or operation of the charging station or battery charger may result in damage to components.
  • Page 290 Operation Handling the battery The battery must only be replaced in accor- dance with the directions in these operating instructions. – When charging and maintaining the battery, observe the manufacturer’s maintenance instructions for the battery and battery charger. Fire protection measures DANGER Risk of explosion due to flammable gases!
  • Page 291 Operation Handling the battery Battery weight and dimensions DANGER Risk of tipping due to change in battery weight! The battery weight and dimensions affect the sta- bility of the truck. When replacing the battery, the weight ratios must not be changed. The battery weight must remain within the weight range speci- fied on the nameplate.

  • Page 292: Opening/Closing The Battery Cover

    Operation Handling the battery CAUTION Potential for damage to the male battery connector! If the battery male connector is disconnected or connected while the key switch is switched on or the battery charger is under load, an arc will be produced at the battery male connector. This can lead to erosion at the contacts, and can considerably shorten the service life of the contacts.
  • Page 293 Operation Handling the battery – Pull on the interlock (2) of the battery cover and lift battery cover at (A) grip position. The cover catch snaps into place. Closing the battery cover WARNING When closing the battery cover, limbs could be- come trapped —...
  • Page 294 Operation Handling the battery – Before closing the battery cover, close the battery safety catches (5) until they lock into place. DANGER If the battery is not locked correctly, the battery can slide out of the truck, with potentially fatal consequences! –...

  • Page 295: Disconnecting The Battery Male Connector

    Operation Handling the battery NOTE The apertures in the flap (arrowed) are ne- cessary for forced ventilation and must not be blocked. 6210_600-002 Disconnecting the battery male connector CAUTION Risk of component damage! If you remove the battery male connector when the key switch is switched on (under load), an arc will be produced.

  • Page 296: Maintaining The Battery

    Operation Handling the battery – Disconnect the battery male connector (1) by pulling in the direction of the arrow at the plug connection. – Place the battery male connector on the battery. CAUTION There is a risk of short circuit if the cables are damaged.
  • Page 297 Operation Handling the battery dition, acid level and acid density", "Checking the battery charge status", "Charging the bat- tery" and "Equalising charge to prevent a deep discharge of the battery" together. 56338011803 EN - 10/2016...

  • Page 298: Checking The Battery Condition, Acid Level And Acid Density

    Operation Handling the battery Checking the battery condition, acid level and acid density WARNING The electrolyte (dilute sulphuric acid) is poisonous and caustic! – Observe safety regulations for handling battery acid; see chapter "Battery acid". – Wear personal protective equip- ment (rubber gloves, apron and protection goggles).

  • Page 299: Checking The Battery Charge Status

    Operation Handling the battery For a discharged battery, the acid density must be no lower than 1.14 kg/l. Checking the battery charge status CAUTION Deep discharges shorten the service life of the battery. If no bar is shown in the battery charge display (1) (0% of the available battery capacity, i.e.
  • Page 300 Operation Handling the battery WARNING Battery acid is toxic and corrosive! – Observe the safety regulations in the chapter entitled "Battery acid". CAUTION Risk of component damage! Incorrect connection or operation of the charging station or battery charger may result in damage to components! –...
  • Page 301 Operation Handling the battery by the authorised service centre if neces- sary. – Disconnect the battery male connector (2) by pulling the handle. DANGER Explosive gases are generated during charging! – Ensure that work areas are adequately ventilated. – For trucks with a cab (including fabric-covered cabs), ensure adequate ventilation in the cab (variant).

  • Page 302: Equalising Charge To Prevent A Deep Discharge Of The Battery

    Operation Handling the battery – Insert the battery male connector (1) fully into the plug connection on the truck. CAUTION There is a risk of short circuit if the cables are damaged. Do not crush the battery cable when closing the battery cover. –...
  • Page 303 Operation Handling the battery no shifts are running, such as the weekend, is ideal for performing the equalising charge. – Observe the information in the operating instructions of the charger regarding how to perform an equalising charge. Starting the equalising charge –...

  • Page 304: Changing To A Different Battery Type

    Operation Handling the battery Changing to a different battery type It is generally possible for a truck to be con- verted to a different battery type and a different capacity by the authorised service centre. Note the following points: • The display-operating unit must be adjusted to the new battery capacity.

  • Page 305: Replacing The Battery Using Forklift Truck Or Pallet Truck

    Operation Handling the battery Replacing the battery using forklift truck or pallet truck CAUTION Risk of damage! The battery should only be removed on a level, smooth floor in accordance with the operating instructions of the truck or pallet truck used. Preparation –...
  • Page 306 Operation Handling the battery WARNING Risk of accident! The load capacity of the truck in use must at least match the battery weight (see battery identification plate). – Before picking up the battery, the fork arms must be adjusted to match the opening in the chassis (A).
  • Page 307 Operation Handling the battery – Put the battery down on a stable base so that it is secure. Position the battery against the stops on the base. – Pick up the new battery and transport it to the forklift truck. –...

  • Page 308: Battery Transport With Crane

    Operation Handling the battery Battery transport with crane DANGER If the load is dropped, the conse- quences could potentially be fatal! – Never walk or stand underneath suspended loads. – Ensure there is sufficient distance between the truck and any obstacles so that the truck is not damaged when the crane is used.
  • Page 309 Operation Handling the battery fits between the battery holding fixtures in the battery compartment of the truck. Once the battery has been set down onto its holding fixtures, the change frame is moved back out of the truck. Preparation – Park the truck securely. –...
  • Page 310 Operation Handling the battery WARNING Risk of accident! The load capacity of the truck/lift truck in use must at least match the battery weight (see battery identification plate). – Ensure that the maximum load capacity of the change frame is not exceeded. The maximum load capacity of the change frame is specified on the identification plate.
  • Page 311 Operation Handling the battery – Fold the battery safety catches (2) to the side. – Carefully move the change frame under the battery. – Carefully lift the battery up and out of the truck. Pay attention to the distance to the chassis.
  • Page 312 Operation Handling the battery – If a substructure (3) is used to set down the battery (1), ensure that the change frame (2) does not protrude beyond the battery. – Set the battery down on a stable base so that it is secure. Position the battery against the stops on the base.

  • Page 313: Replacing The Battery With The Hydraulic Battery Carrier

    Operation Handling the battery Replacing the battery with the hydraulic battery carrier Preconditions The following preconditions apply when changing a battery using the hydraulic battery carrier: • The extension area must be free of obsta- cles • The ground must be stable, clean and even NOTE When the battery is fully discharged, it is not possible to use the battery carrier.
  • Page 314 Operation Handling the battery Extending the battery hydraulically – Apply the parking brake. 6321_003-074 – Make sure that there is no load on the driver’s seat. – Open the battery cover fully. 6321_003-075 56338011803 EN - 10/2016...
  • Page 315 Operation Handling the battery – Open the battery safety catches. WARNING Risk of crushing/shearing! When extending the battery carrier, there must be no personnel in the extension area. There is a risk of crushing and shearing when the battery carrier extends.
  • Page 316 Operation Handling the battery – Ensure that the battery cable is not dam- aged when the carriage is extended. DANGER DANGER NOTE If the movement of the carriage is restricted by obstacles, release the push button. The carriage can only be retracted. If the push button is actuated continuously, the drive switches off after 50 seconds.
  • Page 317 Operation Handling the battery – Lift the battery sideways out of the truck. Ensure that there is sufficient distance from the battery cover. CAUTION Component damage possible! – Do not allow slack lifting gear to fall onto the battery cells. DANGER Risk of death from suspended loads! –...
  • Page 318 Operation Handling the battery WARNING Risk of injury! – Personnel must stand beside the counterweight outside the retraction area. CAUTION Component damage possible! When retracting the carriage, the battery cable may collide with components and become damaged. – Make sure that the battery cable does not become stuck or crushed.
  • Page 319 Operation Handling the battery – Press the retract push button until the carriage has reached its end position. – Release the push button. NOTE If the movement of the carriage is restricted by obstacles, release the push button. WARNING Risk of crushing! Never reach under the battery to remove obstacles.

  • Page 320: Charging The Battery With The Battery Charging Flap

    Operation Handling the battery Messages and errors during use of the hydraulic battery carrier Remedy Error code Cause Allow the truck to cool down for 5920 The unit is overheated. one hour. 5910 Notify authorised service 5930 centre 5931 Message Remedy Cause Press the "Retract battery"...
  • Page 321 Operation Handling the battery Battery charging flap (variant) – Park the truck securely. – Press the release buttons (1). The release buttons pop out. – Turn the release buttons (1). The release buttons unlock the battery charg- ing flap (2). –...
  • Page 322 Operation Handling the battery WARNING The electrolyte (dilute sulphuric acid) is poisonous and caustic! – Observe safety regulations for handling battery acid; see chapter "Battery acid". – Rinse away spilt battery acid immediately with plenty of water! – Before charging, check the battery cable and the charging cable for damage, and have the cables replaced by the authorised service centre if necessary.
  • Page 323 Operation Handling the battery CAUTION Risk of component damage! If you disconnect the charging cable while the bat- tery charger is switched on, an arc will be produced. This can lead to erosion at the contacts, which con- siderably shortens their service life. –...
  • Page 324 Operation Handling the battery – Close the battery cover completely. When doing so, ensure that no cable is crushed between the chassis and the cover. 6210_600-001 56338011803 EN - 10/2016...

  • Page 325: Decommissioning

    Operation Decommissioning Decommissioning Parking the truck securely and switching it off DANGER There is a risk of fatal injury from being run over if the truck rolls away. – The truck must not be parked on a slope. – In emergencies, secure with wed- ges on the side facing downhill.
  • Page 326 Operation Decommissioning – 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".

  • Page 327: Wheel Chock (Variant)

    Operation Decommissioning Wheel chock (variant) The wheel chock (variant) is used to prevent the truck from rolling away on a slope. – Lift handle (2) on the support mounting. – Remove wheel chock (1) from the support mounting. – Push the wheel chock under a front axle wheel on the side facing the downhill slope.
  • Page 328 Operation Decommissioning – Apply oil or grease thinly to all untreated moving parts. – Grease the forklift truck. – Lubricate the joints and controls. – Lubricate the slide elements and guides of the hydraulic battery carrier (variant); see chapter "Lubricating the slide elements". –...

  • Page 329: Recommissioning After Storage

    Operation Decommissioning CAUTION Risk of damage from corrosion due to condensation 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.
  • Page 330 Operation Decommissioning During commissioning, the following must be checked in particular: • Drive, control, steering • Brakes (service brake, parking brake) • Lifting system (lifting accessories, load chains, mounting) NOTE For further information, see the truck work- shop manual or contact the authorised service centre.

  • Page 331: Cleaning

    Operation Cleaning Cleaning Cleaning the truck – Park the truck securely. CAUTION Risk of component damage! If you remove the battery male connector with the key switch switched on (under load), an arc will be produced. This can lead to corrosion at the contacts, which considerably shortens their service life.
  • Page 332 Operation Cleaning CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. – Adhere strictly to the following steps. – Only use high-pressure cleaners with a maximum output power of 50 bar and at a maximum temperature of 85°C.

  • Page 333: Cleaning The Electrical System

    Operation Cleaning – Only clean plastic parts with plastic cleaning materials. – Note the manufacturer’s guidelines for working with cleaning materials. Washing the truck exterior – Clean the truck exterior with water-soluble cleaning materials and water (water jet, sponge, cloth). –...

  • Page 334: Cleaning Load Chains

    Operation Cleaning Cleaning load chains WARNING Risk of accident! Load chains are safety elements. The use of cold cleaning solvents, chemical clea- ners or fluids that are corrosive or contain acid or chlorine can damage the chains; use of these items is forbidden! –...

  • Page 335: Cleaning The Windows

    Operation Cleaning Cleaning the windows Any panes of glass, e.g. cab windows (vari- ant), must always be kept clean and free of ice. This is the only means of guaranteeing good visibility. CAUTION Do not damage the rear window heater (inside). –...
  • Page 336 Operation Cleaning 56338011803 EN - 10/2016...

  • Page 337: Maintenance

    Maintenance...

  • Page 338: General Maintenance Information

    Maintenance General maintenance information General maintenance information Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. The annual testing must be carried out by a qualified person. The examination and assessment of the qualified person must be unaffected by operational and economic conditions and must be conducted solely from a safety perspective.
  • Page 339 Maintenance General maintenance information timal performance and service life. It is also a precondition for any warranty claims. Maintenance timeframe – Carry out maintenance work on the truck in accordance with the "Service in" display (1). – The maintenance check lists indicate the maintenance work that is due.
  • Page 340 Maintenance General maintenance information 56338011803 EN - 10/2016...

  • Page 341: Maintenance - 1000 Hours/Annually

    Maintenance General maintenance information Maintenance — 1000 hours/annually At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Chassis, bodywork and fittings Check chassis for cracks Check overhead guard/cab and panes of glass for damage Check controls, switches and joints for damage, and apply grease and oil Check driver’s seat for correct function and for damage Check driver restraint system for correct function and for damage, and clean.
  • Page 342 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check lighting and indicator lights Battery and accessories Check the lead-acid battery for damage and check the acid density; observe the manufacturer’s maintenance instructions Lead-acid battery with electrolyte circulation: replace the non-return valve Lithium-ion battery: observe the manufacturer’s maintenance instructions...
  • Page 343 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check attachments for wear and damage; observe manufacturer’s maintenance instructions Check trailer coupling for wear and damage; observe manufacturer’s maintenance instructions General Read out error numbers and delete list...
  • Page 344 Maintenance General maintenance information 56338011803 EN - 10/2016...

  • Page 345: Maintenance - 3000 Hours/Every Two Years

    Maintenance General maintenance information Maintenance - 3000 hours/every two years Carried At operating hours 3000 6000 9000 12000 15000   Note Perform all 1000-hour maintenance work Power unit Check the gearbox and multi-disc brake and change the gearbox oil Brake Electric parking brake variant: Replace actuation push button Hydraulics...

  • Page 346: Lubrication Plan

    Maintenance General maintenance information 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.
  • Page 347 Maintenance General maintenance information Lubrication point Code Four lubricating nipples on each side of the steering axle for the axle stub bearing and track rod arm Sliding surfaces on the lift mast Load chains One lubricating nipple on each of the two lift mast bearings See the following chapter, "Maintenance data table", under this Code.

  • Page 348: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table General lubrication points Operating materials Specifications Code Unit Amount Lubrication High-pressure ID no. 0147873 As required grease Battery Operating materials Specifications Code Unit Amount System filling Distilled water As required Insulation DIN 43539 For further resistance VDE 0510...
  • Page 349 Maintenance General maintenance information Hydraulic system Operating materials Specifications Code Unit Amount Hydraulic oil HVLP 68 System filling DIN 51524 Part 3 Hydraulic oil for USDA H1 the food industry DIN 51524 (variant) Hydraulic oil, HFC/HFDU Max. 32.5 l fire-retardant Hydraulic oil, HEES biological...
  • Page 350 Maintenance General maintenance information Drive axle Operating materials Specifications Code Unit Amount Wheel nuts/screws Torque wrench 640 Nm Wheel gear Gearbox oil Fuchs TITAN Gear Hyp LD SAE 80W-90 API-GL5 Lift mast Operating materials Specifications Code Unit Amount Lubrication High-pressure ID no.

  • Page 351: Safety Regulations For Maintenance

    Maintenance Safety regulations for maintenance Safety regulations for maintenance General information To prevent accidents during maintenance and repair work, all necessary safety measures must be taken, e.g.: – Apply the parking brake. – Turn off the key switch and remove the key. –...

  • Page 352: Safety Devices

    Maintenance Safety regulations for maintenance To prevent damage to electronic systems with electronic components, such as an electronic driving regulator or lift control, these components must be removed from the truck prior to the start of electric welding. Work on the electrical system (e.g. connecting a radio, additional headlights etc.) is only permitted with approval from the authorised service centre.

  • Page 353: Working At The Front Of The Truck

    Maintenance Safety regulations for maintenance Working at the front of the truck DANGER Risk of accident! If the lift mast or fork carriage is raised, no work may be performed on the lift mast or at the front of the truck unless the following safety measures are observed.
  • Page 354 Maintenance Safety regulations for maintenance – 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. –...

  • Page 355: Providing Access To Maintenance Points

    Maintenance Providing access to maintenance points Providing access to maintenance points Removing/installing the valve cover Removing the valve cover – For trucks with a heating system (variant), unscrew the five screws (2) and remove the heating system panelling (3). 6210_762-002 –...

  • Page 356: Servicing

    If the battery falls out there is a danger of being crushed. – If the interlock is deformed, damaged or difficult to move, inform STILL Service immediately. Do not operate the truck. – Check that the interlocks function correctly.
  • Page 357 Maintenance Servicing – Check that the battery lock (1) moves easily and that it is not deformed or damaged. 6321_003-137 – Check that the battery cover lock (3) moves easily and that it is not deformed or dam- aged. – Check that the rest plate (2) of the battery cover lock is seated correctly, and that it is not deformed or damaged.

  • Page 358: Maintaining The Seat Belt

    Maintenance Servicing Maintaining the seat belt DANGER There is a risk to life if the seat belt fails during an accident! If the seat belt is faulty, it may tear or open during an accident and no longer keep the driver in the driver’s seat.

  • Page 359: Checking The Driver's Seat

    Maintenance Servicing – The belt tongue (2) must release when the red button (4) is pressed. – The automatic blocking mechanism must be tested at least once a year: – Park the forklift truck on level ground. – Pull out the belt with a jerk. The automatic blocking mechanism must block extension of the belt.

  • Page 360: Maintaining Wheels And Tyres

    Maintenance Servicing Maintaining wheels and tyres WARNING Risk of accident! Uneven wear reduces the stability of the truck and increases the braking distance. – Change worn or damaged tyres without delay. WARNING Risk of tipping! Tyre quality affects the stability of the truck. If you wish to use a different type of tyre on the truck from the tyres approved by the truck manufacturer, or tyres from a different manufacturer, you must first...
  • Page 361 Maintenance Servicing – If necessary, remove any foreign bodies imbedded in the tyre profile (1). NOTE The wear of the tyres on an axle must be approximately the same. Super elastic tyres and solid rubber tyres • can be worn down to the wear mark (2) 6311_003-005 Checking wheel fastenings –...

  • Page 362: Servicing The Steering Axle

    Maintenance Servicing Servicing the steering axle – Park the truck securely. Checking the steering axle – Check the condition and wear of the rubber parts of the axle swivel bearings. – Check the stub axle bearing (1) and tie rod joint (2) for play and wear.
  • Page 363 Maintenance Servicing – At the lubricating nipples (4), lubricate the axle stub bearing and the steering lever bearings with grease in accordance with the "maintenance data table". If, after a few strokes, there is no longer any old grease escaping, actuate the steering. WARNING Risk of crushing! Do not actuate the steering during lubrication.

  • Page 364: Checking The Battery

    Maintenance Servicing – Check the tightening torque of the axle stub nut (5) in accordance with the "maintenance data table" and tighten the axle stub nut as necessary. Checking the battery – For information on checking the battery, see the chapter entitled "Checking the battery condition, acid level and acid density".
  • Page 365 Maintenance Servicing CAUTION Risk of component damage! If you remove the battery male connector when the key switch is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens their service life. –...

  • Page 366: Replacing Fuses

    Maintenance Servicing – Check the condition of the main fuse (2) (no 3 4 5 damage to the porcelain body) and check that it is securely positioned; tighten the clamping screws if necessary. – Check the condition of fuses (3) to (3), check that the cable connections are secure and check for oxidation residues.
  • Page 367 Maintenance Servicing CAUTION Risk of component damage! If you remove the battery male connector when the key switch is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens their service life. –...

  • Page 368: Checking The Hydraulic Oil Level

    Maintenance Servicing Checking the hydraulic oil level – Park the truck securely. CAUTION Risk of component damage! If you remove the battery male connector when the key switch is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens their service life.

  • Page 369: Checking The Hydraulic System For Leaks

    Maintenance Servicing – Connect the battery male connector. Checking the hydraulic system for leaks WARNING Hydraulic oil under pressure can escape from leaking lines and cause injuries to the skin. Wear suitable protective gloves, industrial goggles etc. WARNING Hydraulic hoses become brittle! Hydraulic hoses should not be used longer than 6 years.

  • Page 370: Lubricating The Lift Mast And Roller Track

    Maintenance Servicing Lubricating the lift mast and roller track – Remove dirt and lubricant residue from the roller track. – Lubricate the roller tracks (1) of the outside, middle, and inside mast with a super- pressure adhesion lubricant to reduce wear.
  • Page 371 Maintenance Servicing Model RO*243 – Pull out the safety handle (3). – Push the hand lever (2) upwards. – Grease using the lubricating nipple(1) in accordance with the maintenance data table; see ⇒ Chapter "Maintenance data table", P. 6-336. – Close the coupling by raising the coupling pin with a suitable tool.
  • Page 372 Maintenance Servicing Model RO*245 – Lubricate via the points provided for this purpose (lubricating nipple, opened cou- pling) in accordance with the maintenance data table; see ⇒ Chapter "Maintenance data table", P. 6-336. – Grease the supporting surface for the tow-bar eye.

  • Page 373: Maintenance For Trucks Used In Cold Stores

    Maintenance Servicing Maintenance for trucks used in cold stores – On trucks used in cold stores (variant), check all rollers and chains in the lift mast for ease of movement once a week. 6210_900-002 Maintaining the heater – Loosen the fixing screw (1) and remove the cover (2).
  • Page 374 Maintenance Servicing – Check the filter mat (3) for soiling. If the filter mat is grey in colour, replace it. NOTE Change the filter mat at least every 2 months. 6321_003-092 – Clean the fresh-air inlet (4) of dust and dirt. 6321_003-093 56338011803 EN - 10/2016...

  • Page 375: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other tasks – Perform all maintenance work; see the "Maintenance" chapter. Checking the cable connections – Check that the pump motor feed cable (1) and traction motor feed cable (2) are securely attached, in good condition and insulated.

  • Page 376: Checking The Hydraulic Oil Level Of The Hydraulic Battery Carrier

    Maintenance 1000-hour maintenance/annual maintenance When the battery cover sensor (1) is func- tioning correctly, the message CLOSE THE will appear in the display. DOOR – If the message appears CLOSE THE DOOR in the display, close the battery cover. The message disappears.
  • Page 377 Maintenance 1000-hour maintenance/annual maintenance WARNING If the battery carrier is not at a sufficient safety distance from mechanical components when it is actuated hands or feet can be crushed. There is risk of injury! – Actuating beyond the carrier is prohibited. –...

  • Page 378: Lubricating The Slide Elements

    Maintenance 1000-hour maintenance/annual maintenance Lubricating the slide elements Lubricating the slide elements – Extend the battery with the hydraulic battery carrier and remove the battery, see ⇒ Chapter "Replacing the battery with the hydraulic battery carrier", P. 5-301. – Remove dirt and contaminated lubricant residues.
  • Page 379 Maintenance 1000-hour maintenance/annual maintenance WARNING Risk of injury! If the battery carrier is actuated while maintenance work is being carried out, hands or feet may be crushed. – De-energise the truck before performing mai- ntenance work. WARNING Risk of crushing! If the support rollers swing away when the battery is inserted, the battery carrier with the battery can land on feet.

  • Page 380: Checking The Lift Cylinders And Connections For Leaks

    Maintenance 1000-hour maintenance/annual maintenance – Lubricate the catch rails with oil according to the maintenance data table - do not use grease! – Connect the battery male connector. – Pull the emergency off switch. – Switch on the key switch. –...

  • Page 381: Checking Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking fork arms – Inspect the fork arms (1) for any visible deformation. The wear must not amount to more than 10 % of the original thickness. CAUTION Worn fork arms should always be replaced in pairs. –...

  • Page 382: Checking The Double Pedal

    Maintenance 1000-hour maintenance/annual maintenance Checking the double pedal – Remove the floorplate. – Check that the support and springs of the double pedal mechanism are securely positioned. – Check that all screws are sealed with locking varnish. 6327_003-026 Checking the battery changeover frame –...

  • Page 383: Technical Data

    Technical data...

  • Page 384: Dimensions

    Technical data Dimensions Dimensions Seat is adjustable ±90 mm Fork spacing is adjustable 56338011803 EN - 10/2016...
  • Page 385 Technical data Dimensions NOTE Measurements h and b customised and can be taken from the order confirmation. Centre of gravity "S" (distance measured from the front axle) (6345) RX60-25 774 mm (6346) RX60-25/600 774 mm (6347) RX60-25L 842 mm (6348) RX60-25L/600...

  • Page 386: Vdi Datasheet For Rx60-25 And Rx60-25/600

    Technical data VDI datasheet for RX60-25 and RX60-25/600 VDI datasheet for RX60-25 and RX60-25/600 NOTE This VDI datasheet specifies only the techni- cal values of the truck version with standard equipment. Different tyres, lift masts, additio- nal units etc. may produce different values.
  • Page 387 Technical data VDI datasheet for RX60-25 and RX60-25/600 Model RX60-25 RX60-25/600 Type number 6345 6346 180/70-8 180/70-8 Rear tyre size (18x7-8) (18x7-8) Number of front wheels (x = driven) Number of rear wheels (x = driven) b10 (mm) Front track width...
  • Page 388 Technical data VDI datasheet for RX60-25 and RX60-25/600 Model RX60-25 RX60-25/600 Type number 6345 6346 Ground clearance at centre of wheelbase m2 (mm) Aisle width for pallet 1000x1200 cross- Ast (mm) 3678 3683 wise Aisle width for pallet 800x1200 length-...
  • Page 389 Technical data VDI datasheet for RX60-25 and RX60-25/600 Electric motor Model RX60-25 RX60-25/600 Type number 6345 6346 Traction motor, power rating S3 60 min Lift motor, power rating at 15% ED 16.3 16.3 Battery in accordance with DIN DIN 43536 A...

  • Page 390: Vdi Datasheet For Rx60-25L And Rx60-25L/600

    Different tyres, lift masts, additio- nal units etc. may produce different values. Key data Model RX60-25L RX60-25L/600 Type number 6347 6348 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seated Seated Rated capacity/load Q (kg) 2500...
  • Page 391 Technical data VDI datasheet for RX60-25L and RX60-25L/600 Model RX60-25L RX60-25L/600 Type number 6347 6348 180/70-8 180/70-8 Rear tyre size (18x7-8) (18x7-8) Number of front wheels (x = driven) Number of rear wheels (x = driven) b10 (mm) Front track width b11 (mm) Rear track width Basic dimensions...
  • Page 392 Technical data VDI datasheet for RX60-25L and RX60-25L/600 Model RX60-25L RX60-25L/600 Type number 6347 6348 m2 (mm) Ground clearance at centre of wheelbase Aisle width for pallet 1000x1200 cross- Ast (mm) 3830 3835 wise Aisle width for pallet 800x1200 length- Ast (mm) 4030 4035...
  • Page 393 Technical data VDI datasheet for RX60-25L and RX60-25L/600 Electric motor Model RX60-25L RX60-25L/600 Type number 6347 6348 Traction motor, power rating S3 60 min Lift motor, power rating at 15% ED 16.3 16.3 Battery in accordance with DIN DIN 43536 A DIN 43536 A 43531/35/36 A, B, C, no Battery voltage...

  • Page 394: Vdi Datasheet For Rx60-30 And Rx60-35

    Different tyres, lift masts, additio- nal units etc. may produce different values. Characteristics Model RX60-30 RX60-35 Type number 6353 6356 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seated Seated Rated capacity/load Q (kg) 3000...
  • Page 395 Technical data VDI datasheet for RX60-30 and RX60-35 Model RX60-30 RX60-35 Type number 6353 6356 180/70-8 180/70-8 Rear tyre size (18x7-8) (18x7-8) Number of front wheels (x = driven) Number of rear wheels (x = driven) b10 (mm) Front track width 1002 b11 (mm) Rear track width...
  • Page 396 Technical data VDI datasheet for RX60-30 and RX60-35 Model RX60-30 RX60-35 Type number 6353 6356 Ground clearance at centre of wheelbase m2 (mm) Aisle width for pallet 1000x1200 cross- Ast (mm) 3760 3879 wise Aisle width for pallet 800x1200 length- Ast (mm) 3960 4079...
  • Page 397 Technical data VDI datasheet for RX60-30 and RX60-35 Electric motor Model RX60-30 RX60-35 Type number 6353 6356 Traction motor, power rating S3 60 min Lift motor, power rating at 15% ED 16.3 16.3 Battery in accordance with DIN DIN 43536 A DIN 43536 A 43531/35/36 A, B, C, no Battery voltage...

  • Page 398: Vdi Datasheet For Rx60-30L And Rx60-30L/600

    Different tyres, lift masts, additio- nal units etc. may produce different values. Characteristics Model RX60-30L RX60-30L/600 Type number 6354 6355 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seated Seated Rated capacity/load Q (kg) 3000...
  • Page 399 Technical data VDI datasheet for RX60-30L and RX60-30L/600 Model RX60-30L RX60-30L/600 Type number 6354 6355 180/70-8 180/70-8 Rear tyre size (18x7-8) (18x7-8) Number of front wheels (x = driven) Number of rear wheels (x = driven) b10 (mm) Front track width 1002 b11 (mm) Rear track width...
  • Page 400 Technical data VDI datasheet for RX60-30L and RX60-30L/600 Model RX60-30L RX60-30L/600 Type number 6354 6355 Ground clearance at centre of wheelbase m2 (mm) Aisle width for pallet 1000x1200 cross- Ast (mm) 3850 3850 wise Aisle width for pallet 800x1200 length- Ast (mm) 4050 4050...
  • Page 401 Technical data VDI datasheet for RX60-30L and RX60-30L/600 Electric motor Model RX60-30L RX60-30L/600 Type number 6354 6355 Traction motor, power rating S3 60 min Lift motor, power rating at 15% ED 16.3 16.3 Battery in accordance with DIN DIN 43536 A DIN 43536 A 43531/35/36 A, B, C, no Battery voltage...

  • Page 402: Ergonomic Dimensions

    Technical data Ergonomic dimensions Ergonomic dimensions 40 mm WARNING Danger of impact injuries to the head! If the head of the operator is located too close to the underside of the roof, the suspension of the driver’s seat or an accident may cause the head to strike the overhead guard.

  • Page 403: Battery Specifications

    Battery specifications according to DIN 43536; cells in accordance with DIN EN 60254-2, 80 V circuit B. – The battery weight can be found on the nameplate of the battery. RX60-25 (6345), RX60-25/600 (6346), RX60-30 (6353) Battery Capacity Battery compartment dimensions [mm] Tray...
  • Page 404 Technical data Battery specifications RX60-25L (6347), RX60-25L/600 (6348), RX60-30L (6354), RX60-30L/600 (6355), RX60-35 (6356) Battery Battery compartment dimensions [mm] Tray Capacity designation [Ah] Depth Height Width 4 PzV 480 4 PzW 560 ® HAWKER wf 200plus 1028 4 PzS 560 4 PzS 620 4 CSM 640 5 PzV 600...

  • Page 405: Fuse Assignment

    Technical data Fuse assignment Fuse assignment Fuse assignment standard equip- 3 4 5 6 7 ment 6210_604-002 400 A Main fuse Heating system 50 A Voltage converter 20 A 10 A CPP rear 10 A Option board, solenoid valve on the attachment 25 A CPP/RPP roof 25 A...

  • Page 406: Fuse Assignment Equipment Variants

    Technical data Fuse assignment Fuse assignment equipment vari- ants 7312_003-042 5th hydraulic function 24/48 V 10 A Variant (e.g. MMS) 10 A Variant (e.g. light) 10 A 56338011803 EN - 10/2016...
  • Page 407 Index Attachments Assembly ....170 Access authorisation Controlling using a double Changing the password ... 91 mini-lever .
  • Page 408 Index Checking the charge status ..287 Checking the double pedal ..370 Battery Checking the driver’s seat ..347 Changing the battery type .
  • Page 409 Index Declaration of conformity ... . . 3 Double mini-lever ....56 Defects ......33 Lifting/lowering the fork carriage .
  • Page 410 Index Fingertip ......60 Information for carrying out mainte- nance ....326 Lifting/lowering the fork carriage .
  • Page 411 Index Lifting system Maintenance for trucks used in cold stores ....361 Controlling using a double mini-lever ....140 Maintenance personnel for batteries .
  • Page 412 Index MSG 65/MSG 75 driver’s seat Parking brake ....118 Adjusting ..... 72 Electric parking brake .
  • Page 413 Index Rules for roadways and the working Setting the drive programme ..108 area ..... . 107 Setting the language .
  • Page 414 Safety principles ....33 RX60-25 ..... 374 RX60-25/600 .
  • Page 416 STILL GmbH 56338011803 EN – 10/2016...

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