Still RX60-60 Original Instructions Manual
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Still RX60-60 Original Instructions Manual

Electric forklift truck
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Table of Contents

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Original instructions
Electric forklift truck
RX60-60
RX60-70
RX60-80
RX60-80/900
6341 6342 6343 6344
56358042501 EN - 10/2018

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Summary of Contents for Still RX60-60

  • Page 1 Original instructions Electric forklift truck RX60-60 RX60-70 RX60-80 RX60-80/900 6341 6342 6343 6344 56358042501 EN - 10/2018...
  • Page 3 • Information on transport, initial commis- sioning and storage of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 56358042501 EN - 10/2018...

  • Page 5: Table Of Contents

    Table of contents Foreword Your truck ............2 Description of the truck .
  • Page 6 Table of contents Changes and retrofitting ..........31 Changes to the overhead guard and roof loads .
  • Page 7 Table of contents Operation Checks and tasks before daily use ........70 Visual inspections .
  • Page 8 Table of contents Actuate the drive direction switch, fingertip version ......130 Actuating the drive direction switch, mini-console version ..... . 131 Starting drive mode .
  • Page 9 STILL SafetyLight (variant) ........
  • Page 10 Table of contents Push-up roof window (variant) ......... . 234 Clipboard (variant) .
  • Page 11 Table of contents Releasing the spring-operated brake ........296 Towing .
  • Page 12 Table of contents Checking the driver's seat ..........342 Checking the door latch .

  • Page 13: Foreword

    Foreword...

  • Page 14: Your Truck

    Foreword Your truck Your truck Description of the truck General The electrically driven counterbalanced trucks from series RX60–60/70/80 have a load capacity of up to eight tonnes with a load centre of gravity of 900 mm. This means that the truck can reach a top speed of 17 km/h, which can be increased to 20 km/h thanks to sprint mode and PowerPlusLife battery.
  • Page 15 Foreword Your truck is released. Completely removing your foot from the accelerator pedal causes the truck to brake until it comes to a standstill. A parking brake ensures that the truck remains securely in place when parked. Steering The truck is equipped with a swing axle and has kickback-free, hydraulic rear-wheel steer- ing.

  • Page 16: General

    Foreword Your truck Operating devices The truck is characterised by an accessible operating concept. When purchasing the truck, a variety of operating devices and equipment variants are available: • Double mini-lever • Triple mini-lever • Quadruple mini-lever • Joystick 4Plus •...

  • Page 17: Ce Labelling

    Foreword Your truck The driving permit must be obtained from the appropriate office. The truck has been fitted with state-of-the- art technology. Following these operating instructions will allow the truck to be handled safely. By complying with the specifications in these operating instructions, the functionality and the approved features of the truck will be retained.

  • Page 18: 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 19: Accessories

    Foreword Your truck Accessories • Key for key switch (two pieces) • Key for cab (variant) • Hexagon socket wrench for emergency lowering 56358042501 EN - 10/2018...

  • Page 20: Overview

    1430 1500 1500 3430 3430 1210 1210 1330 1330 1470 1470 1500 1500 800 700 DANGER DANGER STILL GmbH Hamburg Regelmäßige Prüfung (FEM 4.004) BATTERIESERVICE nach nationalen Vorschriften DANGER basierend auf den EG-Richtlinien: Nächste Prüfung 2009/104/EG, 99/92/EG Nächste Prüfung DANGER Ihr STILL Service Die Prüfplakette ersetzt nicht das Prüfprotokoll...
  • Page 21 Foreword Your truck Decal information: Caution/Read the op- Decal information: StVZO (German Road erating instructions/Fasten seat belt/Apply Traffic Licensing Regulations) information parking brake when leaving the truck/Pas- (variant) sengers are not allowed/Do not jump off if Decal information: Nameplate the truck is tipping over/Lean in the opposite Decal information: Inspection sticker direction to which the truck is tipping Decal information: FEM test...
  • Page 22 Foreword Your truck Labelling points, right DANGER DANGER 10 bar DANGER 56358042501 EN - 10/2018...

  • Page 23: Nameplate

    Foreword Your truck Decal information: Parking brake released Decal information: 12-V socket Decal information: Parking brake applied Warning sign: Risk of short circuit due to Decal information: Lifting gear attachment shearing point Warning sign: Danger due to shearing Manufacturer's label text Decal information: Tyre filling pressure Decal information: Caution/read the operat- Decal information: To unlock, turn 90°...

  • Page 24: Production Number

    Foreword Using the truck 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 25: Proper Usage

    Foreword Using the truck The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company. See also the chapter entitled "Definition of responsible persons".

  • Page 26: Impermissible Use

    Foreword Using the truck Impermissible use The operating company or driver, and not the manufacturer, is liable for any hazards caused by improper use. NOTE Please observe the definition of the following responsible persons: "operating company" and "driver". Use for purposes other than those described in these operating instructions is prohibited.

  • Page 27: Parking In Temperatures Below -10°C

    Foreword Using the truck The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: -20 °C to +40 °C). This truck is not designed to be operated in cold stores. CAUTION Batteries may freeze! If the truck is parked in an ambient temperature of...

  • Page 28: Using Working Platforms

    Foreword Using the truck Using working platforms WARNING The use of working platforms is regulated by na- tional law. The use of working platforms is only permitted by virtue of the jurisdiction in the country of use. – Observe national legislation. –...

  • Page 29: 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 • Depending on the truck equipment, "UPA" operating instructions may also be provided NOTE Refer to the additional information in the section entitled "Rules for the operating...

  • Page 30: Supplementary Documentation

    Foreword Information about the documentation The personnel responsible for operating and maintaining the equipment must be familiar with these operating instructions. The operating company must ensure that all users have received, read and understood these operating instructions. Safely store the complete documentation and pass on to the subsequent operating company when transferring or selling the truck.

  • Page 31: 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 32: List Of Abbreviations

    Foreword Information about the documentation 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. Not all of the abbre- viations that are listed here will necessarily appear in these operating instructions.
  • Page 33 Foreword Information about the documentation Abbrevi- Meaning Explanation ation German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless GPRS General Packet Radio Service networks ID no. ID number International Organization for Standard- International standardisation organisation ization...

  • Page 34: Units

    Foreword Information about the documentation Units Unit symbol Explanation Unit name Degree Celsius Unit of temperature °C Degree Fahrenheit Unit of temperature °F Ampere Unit of electrical current Unit of electrical charge storage capacity (nominal Ampere hour capacity) Unit of sound intensity Decibel Unit of length (1 cm = 10 mm) Centimetre...

  • Page 35: Definition Of Directions

    Foreword Information about the documentation Unit symbol Explanation Unit name Unit of mass (1 t = 1000 kg) Tonne Unit of electrical voltage Volt Unit of electrical power Watt W/kg Watt/kilogram Performance by mass (power density) Unit of electrical work (nominal energy) Watt-hours Wh/kg Watt-hours/kilogram...
  • Page 36 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 37: 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 38 Foreword Environmental considerations 56358042501 EN - 10/2018...

  • Page 39: Safety

    Safety...

  • Page 40: 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 41: 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 42 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 43: 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 44 DANGER Risk of injury if truck tips over! Even if an approved restraint system is in use, there is still a residual risk that the driver could be injured if the truck tips over. The risk of injury can be reduced by using the restraint system in conjunction with the seat belt.

  • Page 45: Changes To The Overhead Guard And Roof Loads

    Safety Basic principles for safe operation if the manufacturer goes into liquidation and the company is not taken over by another legal person. The operating company must also fulfil the following prerequisites: • Design documents, test documents and assembly instructions associated with the modification must be permanently archived and remain accessible at all times.

  • Page 46: Warning Regarding Non-Original Parts

    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 47: Tyres

    Safety Basic principles for safe operation permitted with the manufacturer's written approval. All electrical system interventions must be documented. Even if they are removable, roof panels may not be removed, as they are designed to protect against small falling objects. Tyres DANGER Risk to stability!

  • Page 48: Medical Equipment

    Safety Basic principles for safe operation tilt to one side (e.g. always replace right- hand and left-hand wheels at the same time). Changes must only be made following consultation with the manufacturer. If the type of tyre used on an axle is changed, for example from superelastic tyres to pneu- matic tyres, the load diagram must be changed accordingly.

  • Page 49: 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 50 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. 56358042501 EN - 10/2018...

  • Page 51: Residual Risk

    Safety 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 52: Special Risks Associated With Using The Truck And Attachments

    Safety 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 53 Safety 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 54: Overview Of Hazards And Countermeasures

    Safety 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 55 Safety 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 56 Safety 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 57: Danger To Employees

    Safety Residual risk Danger to employees According to the German Ordinance on Indus- trial Safety and Health (BetrSichV) and labour protection law (ArbSchG), the operating com- pany must determine and assess hazards during operation, and establish the labour protection measures required for employ- ees (BetrSichVO).

  • Page 58: 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 59 Safety Safety tests 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 voltage Component Measurements Test values...

  • Page 60: 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 61: 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 62: Battery Acid

    Safety Safety regulations for handling consumables WARNING These fluids are pressurised during operation of the truck and are hazar- dous to your health. – Do not allow the fluids to come into contact with the skin. – Avoid inhaling spray. –...

  • Page 63: Coolant And Cooling Fluid

    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 64: Disposal Of Consumables

    Safety Safety regulations for handling consumables – Soak up any spilt coolant or cooling fluid immediately using an oil binding agent and dispose of it in accordance with the national regulations for the country of use. – Dispose of old coolant or cooling fluid in accordance with the national regulations for the country of use.

  • Page 65: 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 66 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 67 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 68 Safety Emissions 56358042501 EN - 10/2018...

  • Page 69: Overviews

    Overviews...

  • Page 70: Overview

    Overviews Overview Overview Left-hand side (when viewed in the drive direction) 6341_003-019_V2 Lift mast Drive axle Driver's compartment Tilt cylinder Overhead guard Fork arms Left side cover Fork carriage Steering axle Lift cylinder 56358042501 EN - 10/2018...
  • Page 71 Overviews Overview Right-hand side (when viewed in the drive direction) Fresh air filter for heating system Cover, front right Battery cover Coupling pin Rear cover 56358042501 EN - 10/2018...

  • Page 72: Driver's Compartment

    Overviews Driver's compartment Driver's compartment Parking brake lever Bottle holder for bottles of max. 0.5 l Steering wheel Driver's seat Key switch Storage compartment / storage compart- Display and operating unit ment with cover (variant) Document holder / storage compartment for Compartment operating instructions Filler cap for windscreen washer reservoir...

  • Page 73: Operating And Display Elements

    Overviews Operating and display elements Operating and display elements Display operating unit 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 Softkey for lighting Rotating beacon display Lighting symbol Interior light display...

  • Page 74: Operating Devices For Hydraulic And Driving Functions

    Overviews Operating and display elements Operating devices for hydraulic and driving functions Different versions of the operating devices are available for operating the truck's hydraulic and traction functions. The truck can be equipped with the following operating devices: • Double mini-lever •...

  • Page 75: Double Mini-Lever

    Overviews Operating 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 76: Three-Way Mini-Lever

    Overviews Operating 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 77: Four-Way Mini-Lever

    Overviews Operating 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 78: Joystick 4Plus

    Overviews Operating 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 79: Fingertip

    Overviews Operating 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 Depending on the specification, various...

  • Page 80: Mini Console

    Overviews Operating 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 56358042501 EN - 10/2018...

  • Page 81: Operation

    Operation...

  • Page 82: Checks And Tasks Before Daily Use

    Operation Checks and tasks before daily use Checks and tasks before daily use Visual inspections WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling. Use suitable equipment to reach higher points on the truck.
  • Page 83 Operation Checks and tasks before daily use Component Course of action Ensure the attachments are mounted correctly in accordance with the operating instructions of the manufacturer. Perform a visual inspection to ensure the attach- Attachments (variant) ments are intact and not leaking. Perform checks to ensure the attachments are working correctly.
  • Page 84 Operation Checks and tasks before daily use Component Course of action Perform a visual inspection for deformation and wear (for example, bent, torn, broken). Check the securing bush in the counterweight for Coupling pin, tow coupling (variant) integrity and to ensure that it is working correctly. Check that the linchpin is present and working correctly (chain, rope, split pin).

  • Page 85: Climbing Into And Out Of The Truck

    Operation Checks and tasks before daily use Climbing into 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 86 Operation Checks and tasks before daily use Climbing in and out of trucks featuring a single wheel and two steps When climbing into and out of the truck, use the handles (2) and (4) for support. The overhead guard post (1) can also be used for support.
  • Page 87 Operation Checks and tasks before daily use Climbing in and out of trucks featuring two wheels and three steps When climbing into and out of the truck, use the handles (2) and (4) for support. The overhead guard post (1) can also be used for support.

  • Page 88: Shelves And Cup Holders

    Operation Checks and tasks before daily use Shelves and cup holders WARNING Risk of accident! Objects that fall into the footwell during travel as a result of steering or braking may slip between the pedals (3) and prevent them from working correctly. It may then be impossible to brake the truck.
  • Page 89 Operation Checks and tasks before daily use WARNING To obtain optimum seat cushioning, you must ad- just the seat suspension to your own body weight. This is better for your back and protects your health. – To prevent injury, make sure that there are no objects within the swivel area of the seat Moving the driver's seat –...
  • Page 90 Operation Checks and tasks before daily use 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 91 Operation Checks and tasks before daily use 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 92: Adjusting The Armrest

    Operation Checks and tasks before daily use 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. – Switch the seat heater (7) on or off using the switch.

  • Page 93: Adjusting The Steering Column

    Operation Checks and tasks before daily use Adjusting the length of the armrest – Release the star-grip handle (1) by turning it anti-clockwise. – Shift the armrest (2) into the desired posi- tion. – Tighten the star-grip handle by turning it clockwise.

  • Page 94: Unlocking The Emergency Off Switch

    Operation Checks and tasks before daily use Unlocking the emergency off switch – Pull the emergency off switch (1) until it is unlocked. 7312_003-183 Operating the signal horn NOTE The signal horn is used to warn people against imminent danger or to announce your intention to overtake.

  • Page 95: Seat Belt

    Operation Checks and tasks before daily use 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 96 Operation Checks and tasks before daily use – 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.
  • Page 97 Operation Checks and tasks before daily use 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 98: Using The Driver's Cab

    Operation Checks and tasks before daily use Using the 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 99 Operation Checks and tasks before daily use Checking the service brake – Release the parking brake. – Depress the brake pedal (1). There must be a slight pedal clearance and then a noticeable pressure point at the brake. – Accelerate the unladen truck in a clear area. –...
  • Page 100 Operation Checks and tasks before daily use WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch will de-energise the entire electrical system. The regenerative brake will not be available. CAUTION No power steering is available when the emergency off switch is actuated! The truck is equipped with a hydraulic power stee-...

  • Page 101: Checking The Steering System For Correct Function

    Operation Checks and tasks before daily use Checking the regenerative brake DANGER Risk of accident due to reduced braking power! The regenerative brake may not be sufficient for emergency braking. – Always actuate the brake pedal (1) for emer- gency braking. If the driving speed is restricted or if the opposite drive direction is selected, the truck brakes electrically.

  • Page 102: Checking The Emergency Off Function

    Operation Checks and tasks before daily use Checking the emergency off function WARNING There is no electric braking assistance when the emergency off switch is actuated! Actuating the emergency off switch will de-energise the entire electrical system. The truck will not be held on a slope by the electric brake.

  • Page 103: Checking The Vertical Lift Mast Position (Variant) For Correct Function

    Operation Checks and tasks before daily use 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. – Press the Softkey (1).
  • Page 104 Operation Checks and tasks before daily use 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 105: Switching On

    Operation Switching on Switching on 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. – Carry out checks and operations before commis- sioning.
  • Page 106 Operation Switching on This initiates a self-test. All lamps in the drive direction and turn indicator displays light up briefly. 7312_003-085 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.

  • Page 107: Access Authorisation With Pin Code (Variant)

    Operation Switching on Standard display elements Battery charge The available battery capacity is shown in the display field. Drive program The current traction program (1–5) appears on the display. Power rating The average power consumption and consumption trends are shown in the display field.
  • Page 108 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 109 Operation Switching on ACCESS CODE input menu The driver enters the five-digit driver PIN (00000 to 99999) in this input menu. The driver PIN is entered using the buttons or Softkeys (1). The digits entered for the driver PIN (2) are not visible but are represented by circles instead.
  • Page 110 Operation Switching on 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. BQ_024_en_V2 Defining the driver PIN NOTE The driver PINs can be defined only by per- sons with the appropriate access authorisa- tion, e.g.
  • Page 111 Operation Switching on appears in the display. PASSWORD – Enter the four-digit password (factory default: 2777) using the buttons (1). – Confirm the input using Softkey (2). BQ_030_en_V2 appears in the display. CONFIGURATION – Use the drive program selection button (1) and the menu change button (3) to select menu.
  • Page 112 Operation Switching on Selecting the driver PIN In the menu, there are fifty ACCESS CODE possible driver PINs to choose from. The digit sequences can be set or changed in submenu. NEW CODE Once the menu has been ac- ACCESS CODE cessed, the selection field (2) contains CODE...
  • Page 113 Operation Switching on appears in the display. CONFIRM submenu is used to confirm CONFIRM the new driver PIN. – Enter the new driver PIN for a second time in the field (8) using the buttons CONFIRM or Softkeys (7). If the entry matches the new driver PIN previously entered, the system will accept the new driver PIN once the last digit has been entered.
  • Page 114 Operation Switching on After three incorrect entries, the CODE DE- message appears. NIED The display switches back to the ACCESS menu. The desired driver PIN must be CODE re-defined. BQ_024_en_V2 Changing the password It is recommended that you change the factory default password.
  • Page 115 Operation Switching on appears in the display. PASSWORD – Enter the current password using the buttons (1). – Confirm the input using Softkey (2). BQ_030_en_V2 appears in the display. CONFIGURATION – Use the drive program selection button (1) and the menu change button (3) to select menu.
  • Page 116 Operation Switching on appears in PASSWORD/PASSWORD LEVEL the display. – Use the drive program selection button (1) and the menu change button (4) to select the desired (2). PASSWORD LEVEL – Confirm your selection using Soft- (3). BQ_033_en appears in the display. NEW CODE The four-digit password can be entered using the buttons (1).

  • Page 117: 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 118 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 119: Adjusting The Displays

    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 120 Operation Operating the display and operating unit NOTE When adjusting the displays, do not actuate the hydraulic system operating devices. If you do, entry is interrupted and the display returns to the operating display. The displays are adjusted in the CONFIGU- menu.

  • Page 121: Symbols In The Display

    Operation Operating the display and operating unit – Press the Softkey (3). The display changes to the CONFIGURA- menu. TION The following settings are possible and can be found in the corresponding chapter: • Setting the date and time • Resetting the daily kilometres and daily operating hours •...
  • Page 122 Operation Operating the display and operating unit Description Symbol Load Time Hydraulic system Exh.gas purifier Coolant temperature Fuel level Blue-Q Power rating (average) Power rating (trend) Symbols for warning messages Description Symbol Parking brake Actuate seat switch Safety belt Battery acid level Neutral warning message Are you sure? Oil pressure...
  • Page 123 Operation Operating the display and operating unit Symbols for softkey functions of auxiliary equipment The following symbols for softkey functions are used on the left of the display for auxiliary equipment: Description Symbol Empty field No display General function OFF General function ON Rear working spotlight OFF Rear working spotlight ON...
  • Page 124 Operation Operating the display and operating unit Description Symbol Load measurement zero adjustment OFF Load measurement zero adjustment ON Load measurement OFF Load measurement ON Symbols for softkey functions for menu navigation and for acknowledging messages The following symbols for the softkey functions are used on the left of the display for menu navigation and to acknowledge messages: Symbol...
  • Page 125 Operation Operating the display and operating unit Symbols for numeric keypad The buttons and Softkeys that can be used to enter numbers and to cancel or confirm input values are shown in the display. Screen for entering the fleet manager pass- word: BQ_037 Screen for entering the driver PIN (access...

  • Page 126: Setting The Date Or Time

    Operation Operating the display and operating unit Setting the date or time – Switch to the menu; CONFIGURATION see the chapter entitled "Adjusting the displays". – Press the Drive programme button (1) or the Menu change button (2) repeatedly until option appears.

  • Page 127: 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 menu; CONFIGURATION see the chapter entitled "Adjusting the displays".

  • Page 128: Configuring Blue-Q Efficiency Mode

    Operation Operating the display and operating unit Changing the Softkey functions: A grey bar (3) highlights the Softkey column. This is the right-hand column in the example shown here. These additional functions can now be switched on and off via the corresponding Softkeys (2).
  • Page 129 Operation Operating the display and operating unit FIXED-FLEX • Blue-Q is turned on whenever the truck is commissioned. The driver can use the Blue-Q button to switch efficiency mode on and off at any time while the truck is being operated –...

  • Page 130: 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 131: Switching Off Additional Consumers

    Operation Blue-Q efficiency mode Switching off additional consumers If the Blue-Q efficiency mode is activated, the controller switches off various additional consumers after a few seconds in certain con- ditions. The additional consumers available depend on the truck equipment. The following table shows the conditions that cause addi- tional consumers to be switched off.
  • Page 132 Operation Blue-Q efficiency mode configuring the Blue-Q operating modes, see the "Configuring Blue-Q efficiency mode" sec- tion. – Press the Blue-Q button (2) to switch on Blue-Q. The Blue-Q symbol (1) is displayed. The LED (3) illuminates in blue. Blue-Q efficiency mode is switched on.

  • Page 133: 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 134 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 135: 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 RX60-60 6341 RX60-70 6342 4907 5107 RX60-80 6343 RX60–80 6344 4999 5199...
  • Page 136 Operation Traction Maximum gradient [%] Type Model With load Without load RX60-60 6341 16.3 25.0 (LSP 600) RX60-70 6342 15.5 25.3 (LSP 600) RX60-80 6343 14.0 23.4 (LSP 600) RX60–80 6344 12.0 18.3 (LSP 900) LSP = load centre of gravity The stated values are used only to compare performance of trucks in the same category.

  • Page 137: Setting The Drive Programme

    Operation Traction Condition of roadways Roadways must be sufficiently firm, level and free from dirt and fallen objects. Drainage channels, level crossings and similar obstacles must be evened out, and if necessary, ramps must be provided so that trucks can drive over these obstacles with as few bumps as possible.
  • Page 138 Operation Traction – Push the drive programme button (1) repeatedly until the number of the desired drive programme appears on the display (2). Drive programs 1–5 are available. Essentially, the higher the drive program number is, the greater the driving dynamics. 6311_003-028_V2 The following drive programmes are available: Drive values...

  • Page 139: Sprint Mode (Variant)

    Operation Traction Battery designation Maximum speed (km/h) 8 PzS 1240 ® TENSOR TCSM 2545 Sprint mode (variant) NOTE Sprint mode is only possible in combination with the PowerPlusLife battery. Switching on sprint mode The performance of the electric drive can be increased by switching on sprint mode.

  • Page 140: Selecting The Drive Direction

    Operation Traction Switching off sprint mode – Push button (1). Sprint mode is switched off, the symbol has a light background. 6311_003-026_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 141: Actuating The Drive Direction Switch, Mini-Lever Version

    Operation Traction from suddenly starting if the accelerator pedal is inadvertently pressed. – Briefly select the drive direction switch for the direction opposite to the current direction. The drive direction indicator on the display and operating unit goes out. NOTE When the seat is vacated, the drive direction switch is set to "Neutral".

  • Page 142: Actuating The Vertical Rocker Switch For The "Drive Direction", Joystick 4Plus Version

    Operation Traction Actuating the vertical rocker switch for the "drive direction", joy- stick 4Plus version – For the "forwards" drive direction, push the vertical rocker button for the "drive direction"(1) upwards (A). – For the "reverse" drive direction, push the vertical rocker button for the "drive direction"(1) downwards (B).

  • Page 143: Actuating The Drive Direction Switch, Mini-Console Version

    Operation Traction Actuating the drive direction switch, mini-console version – For the "forwards" drive direction, push the drive direction switch (1) forwards. – For the "backwards" drive direction, push the drive direction switch to the rear. NOTE Alternatively, the drive direction can also be selected using the drive direction switches on the operating devices.
  • Page 144 Operation Traction The indicator for the selected drive direction ("forwards" (1) or "reverse" (2)) lights up on the display-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 145 If the truck still cannot be operated, park the truck securely and contact the authorised service centre.

  • Page 146: Starting Drive Mode, Dual Pedal Version (Variant)

    Operation Traction Starting drive mode, dual pedal version (variant) DANGER Risk to life if the truck rolls away or tips over! – Sit on the driver's seat. – Fasten the seat belt. – Activate the available restraint systems. Observe the information in the chapter entitled "Safety regulations when driving".
  • Page 147 Operation Traction The indicator for the selected drive direction ("forwards" (3) or "reverse" (4)) lights up on the display-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 148 If the truck still cannot be operated, park the truck securely and contact the authorised service centre.

  • Page 149: Operating The Service Brake

    Operation Traction Operating the service brake The electric brake converts the acceleration energy of the truck into electrical energy. This causes the truck to decelerate. Electrical braking recovers energy for the battery. This results in a longer operating time between charging operations and less wear to the brakes.

  • Page 150: Actuating The Mechanical Parking Brake

    Operation Traction Actuating the mechanical parking brake DANGER There is a risk of being run over if the truck rolls away, and therefore a danger to life. – The truck must not be parked on a slope. – In emergencies, secure with wedges on the side facing downhill.
  • Page 151 Operation Traction Releasing the parking brake – Pull the parking brake lever (1) down fully out of the middle position. – In the lower lever position, pull out the lever knob and then guide the parking brake lever up fully. NOTE The parking brake lever swivels to the upper position automatically by means of spring...

  • Page 152: 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 153: 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 154: Driving On Ascending And Descending Gradients

    Operation Traction Driving on ascending and descend- ing gradients DANGER Danger to life! Driving on ascending and descending gradients carries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 155: 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 56358042501 EN - 10/2018...

  • Page 156: Parking

    Operation Parking Parking Parking the truck securely and switching it off DANGER 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 wedges on the side facing downhill.

  • Page 157: Wheel Chock (Variant)

    Operation Parking unless explicit instructions to this effect have been given. 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.

  • Page 158: 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. 4-151 •...

  • Page 159: 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 160 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 161 Operation Lifting Automatic approach towards the "lift mast vertical position" – Switch on the "lift mast vertical position" comfort feature via the button (1) on the display and operating unit. – Tilt the lift mast forwards using the corre- sponding operating device. The lift mast stops automatically as soon as the prese- lected setting is reached for the "lift mast vertical position".
  • Page 162 Operation Lifting The lift mast is tilted forwards and stops as soon as the vertical position is reached. The arrow above the bar shown on the screen of the display and operating unit represents the "lift mast vertical position". Tilt the lift mast forwards beyond the vertical position: –...

  • Page 163: Types Of Lift Mast

    Operation Lifting Calibrating the "lift mast vertical position" – Set the lift mast to the required position. – Press and hold the button (1) for the "lift mast vertical position" for at least five seconds. The message " " ? VERTICAL POSITION will appear on the display.

  • Page 164: 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 165: Hydraulic Blocking Function

    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 166: Lifting System Operating Devices

    Operation Lifting – Sit down on the driver's seat. All the relevant functions of the working hydraulics will be available again. NOTE If it is not possible to release the block on the hydraulics when the load is raised because of a technical fault, the load must be lowered using the "emergency lowering"...

  • Page 167: 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 168: 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 169: 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 170: 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 171 Operation Lifting Tilting the lift mast To tilt the lift mast forwards: – Tilt the horizontal rocker button (2) to the left (C). To tilt the lift mast backwards: – Tilt the horizontal rocker button (2) to the right (D). 6210_003-090 7312_003-022_V2 Fork-carriage sideshift...

  • Page 172: 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 173: Changing The Fork Arms

    Operation Lifting Changing the fork arms DANGER Risk of fatal injury from being run over if the truck rolls away! – Do not park the truck on a gradient. – Apply the parking brake. – Change the fork arms in a separate, safe location on a level surface.
  • Page 174 Operation Lifting Removal – Select a pallet corresponding to the fork arm size. – Set down the pallet next to the fork carriage on the side chosen for removal. – Lift the fork carriage until the fork arms are approx. 3 cm above the pallet. –...

  • Page 175: Fork Extension (Variant)

    Operation Lifting ged. Otherwise, correct load measurement cannot be guaranteed. 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. –...
  • Page 176 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 177: 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 178 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 179: 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 180: 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 181: 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 182 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 183 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 184: Picking Up Loads

    Operation Handling loads When load measurement has been performed correctly, the determined load weight (3) is shown on the display. 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- ported, it must be ensured that the fork arms are sufficiently far apart and are positioned as...

  • Page 185: 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 186: 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 187: 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 188 Operation Handling loads 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. – Store the load so that the specified aisle width is not reduced by protruding parts.
  • Page 189 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 190 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 56358042501 EN - 10/2018...

  • Page 191: 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 192: 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! The load centre of gravity and the moment of tilt move due to tilting the lift mast forwards with a raised load or due to the load slipping.
  • Page 193 Operation Handling loads – Drive up to the stack with the load lowered in accordance with regulations. – Set lift mast to vertical. – Lift the load to the stacking height. – Drive the truck towards the rack carefully. 6210_800-015 –...

  • Page 194: Driving On Lifts

    Operation Handling loads Driving on lifts The driver is only allowed to use this truck on lifts with a sufficient load capacity and for which the operating company (see ⇒ Chap- ter "Definition of responsible persons", P. 28) has been granted authorisation. DANGER There is a risk to life from being crushed or run over by the truck.

  • Page 195: 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 196: 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 197 Operation 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 additionally controlled by a second operating function (lock) that is actuated to prevent an unintentional release of the load. If such an attachment is retrofitted, a second opera- ting function for actuation must also be retrofitted.

  • Page 198: Releasing The Pressure From The Hydraulic System

    Operation 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 199 Operation Attachments Releasing the pressure 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. – Switch on the hazard warning system (variant).

  • Page 200: General Instructions For Controlling Attachments

    Operation 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: • Double mini-lever • Double mini-lever with a 5th function (variant) •...
  • Page 201 Operation Attachments 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. 56358042501 EN - 10/2018...

  • Page 202: Controlling Attachments Using A Double Mini-Lever

    Operation 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 203 Operation 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 204: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the double mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. NOTE The "lift mast" 360° lever (3) and the "attach- ments" cross lever (2) control four hydraulic functions.
  • Page 205 Operation 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 206: Controlling Attachments Using A Triple Mini-Lever

    Operation 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 207 Operation 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 208: Controlling Attachments Using The Triple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the triple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. NOTE The "lift mast" 360° lever and operating levers (1) and (2) control four hydraulic functions. The designation "5th function"...
  • Page 209 Operation 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 210: Controlling Attachments Using A Quadruple Mini-Lever

    Operation 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 211 Operation 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 212: Controlling Attachments Using The Quadruple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the quadruple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. NOTE Operating levers (1) to (4) are used to control four hydraulic functions. The designation "5th function"...
  • Page 213 Operation 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 214: Controlling Attachments Via The Joystick 4Plus

    Operation 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 215: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operation Attachments Controlling attachments using the joystick 4Plus and the 5th function NOTE For technical reasons, clamping attachments cannot be controlled via the 5th function. NOTE The 5th hydraulic function can be used to control an attachment. The pictograms on the joystick 4Plus show which attachment functions can be controlled using the 5th function.

  • Page 216: Controlling The Attachments With Fingertip

    Operation 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 217: Controlling Attachments With Fingertip And The 5Th Function

    Operation Attachments Controlling attachments with finger- tip and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. NOTE The designation "5th function" refers to the fact that the four operating levers control four functions, while the "5th function"...
  • Page 218 Operation 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 219: Clamp Locking Mechanism (Variant)

    Operation 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 Turn to the left/right Tip shovel over/tip shovel back 6210_003-035...
  • Page 220 Operation Attachments Double mini-lever – To release the clamp locking mechanism, push the cross lever (1) forwards. The LED for button (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 221 Operation Attachments Quadruple mini-lever – To release the clamp locking mechanism, push the operating lever (1) forwards. The LED for button (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 222: Taking Up A Load Using Attachments

    Operation Attachments Fingertip – To release the clamp locking mechanism, push the operating lever (1) forwards. The LED for button (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 223: Auxiliary Equipment

    Operation Auxiliary equipment • Load capacity Q (kg) (1) • Lift height h (mm) (2) • Load distance C (mm) (3) Auxiliary equipment Switching the lighting on and off Driving lights – To switch on the parking light, press the button (1).

  • Page 224: Switching The Working Spotlight For Reverse Travel On And Off

    Operation Auxiliary equipment Working spotlights – To switch on the working spotlights (front and rear), press the button (1). The working spotlights light up. – To switch off the working spotlights, press the button (1) again. The working spotlights go out. NOTE In trucks with StVZO (German Road Traffic Licensing Regulations) equipment (variant),...

  • Page 225: Switching The Rotating Beacon On And Off

    Operation Auxiliary equipment Switching the rotating beacon on and – Press the Softkey (1) to switch on the rotating beacon. The rotating beacon is switched on. The symbol is displayed. – To switch off the rotating beacon, press the Softkey The rotating beacon goes out.

  • Page 226: Switching The Turn Indicators On And Off

    Operation Auxiliary equipment Switching the turn indicators on and Mini-lever version – Switch on the turn indicators by moving the cross lever of the drive direction/turn indicator (1) to the left or to the right. 5060_003-096 The turn indicators and the corresponding turn indicator displays (2) or (3) flash.
  • Page 227 Operation Auxiliary equipment Mini-console version – Switch on the turn indicators by moving the turn indicator switch (1) to the left or to the right. 5060_003-046 The turn indicators and the corresponding turn indicator displays (2) or (3) flash. – Switch off the turn indicators by moving the turn indicator switch to the centre position.

  • Page 228: Switching The Double Working Spotlights On And Off

    Operation Auxiliary equipment 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. Each double working spotlight consists of an upper working spotlight (2) and a lower working spotlight (3).
  • Page 229 Operation Auxiliary equipment – Press Softkey (1) to switch on the working spotlights. The working spotlights are switched on. The symbol is displayed. – Press Softkey to switch off the working spotlights. The working spotlights are switched off. The symbol is displayed. Switching the upper working spotlights on/off automatically –...

  • Page 230: Still Safetylight (Variant)

    Danger of damage to eyes from looking into the STILL SafetyLight. Do not look into the STILL SafetyLight. The STILL SafetyLight is a visual warning unit designed to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junctions.

  • Page 231: Operating The Windscreen Wiper/Washer

    Operation Auxiliary equipment NOTE If the truck is to be operated on public roads, the STILL SafetyLight must be switched off. Operating the windscreen wiper/washer – Press the button (1) to activate the front wiper/washer (variant) and the roof panel wiper (variant).

  • Page 232: Fleetmanager (Variant)

    Operation Auxiliary equipment – Open filler cap (2) for the windscreen washer reservoir. – Fill the windscreen washer reservoir with washer fluid and anti-freeze in accor- dance with the maintenance data table; see ⇒ Chapter "Maintenance data ta- ble", P. 5-325. –...

  • Page 233: 12-V Socket

    Operation Auxiliary equipment 12-V socket To the right of the driver's seat, there is a 12-V socket (1) for connecting an external electrical consumer. CAUTION Risk of short circuit! The nominal current of the connected consumer must not exceed 10 A. –...

  • Page 234: Ceiling Sensor (Variant)

    Before the truck is able to accelerate to the maximum speed permitted for outdoor areas, the speed limitation must still be unlocked. To do this, release the 56358042501 EN - 10/2018...
  • Page 235 For more information, refer to the next chapter. Changing the sensor settings The ceiling sensor system is supplied by STILL with the following factory settings: Sensitivity: High Ceiling height: 24 m – Pull out the connecting cable from the sensor.
  • Page 236 Operation Auxiliary equipment – On the underside of the assembly baseplate on the overhead guard, loosen the four nuts (1) on the sensor. – Carefully remove the sensor. – Using the supplied key (2), open the sensor housing to gain access to the DIP switches. 56358042501 EN - 10/2018...
  • Page 237 Operation Auxiliary equipment – Using the DIP switches "1" to "5" (3), adjust the range and the sensitivity of the sensor. The DIP switches can be adjusted using a small screwdriver. CAUTION The settings for DIP switches "6" to "8" are the factory settings of the manufacturer.
  • Page 238 Operation Auxiliary equipment sensitivity that has been set. See the following table: Sensitivity Range Beam angle 22.5° 22.5° Low (1) 20° 16 m 15° 24 m 5° 35° 30° Medium (2) 25° 16 m 22.5° 24 m 10° Sensitivity Range Beam angle 42°...
  • Page 239 Operation Auxiliary equipment Representation of the beam angle depending on the sensitivity of the sensor that has been set, from (1)"low" to (4)"very high". 2 3 4 Additional labelling Adhesive label next to the display-operating unit 56358042501 EN - 10/2018...

  • Page 240: Cab

    Operation Opening 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 cab door from the outside: –...

  • Page 241: Closing The Cab Door

    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 slipping inadvertently during travel.

  • Page 242: Operating The Interior Lighting

    Operation Closing the front side window: The front side window (4) can be closed in the same way as the rear side window. 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"...

  • Page 243: 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. 56358042501 EN - 10/2018...

  • Page 244: Heating System (Variant)

    Operation Heating system (variant) DANGER Risk of explosion! There is a risk of explosion if the heater is operated in the vicinity of storage areas or similar areas where fuel vapours or coal dust, wood dust and crop dust can accumulate. –...
  • Page 245 Operation Switching on the blower – To switch on the blower, turn on the blower switch (1). The blower runs at the speed level set at the switch. Switching on the heating system NOTE The heating system only heats up when the blower is switched on.

  • Page 246: Push-Up Roof Window (Variant)

    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 247: 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 248: Coupling Pin In The Counterweight

    Operation Trailer operation CAUTION Damage to the tow coupling due to overloading! Tow couplings RO*243 and RO*244 must be individually checked to ensure that they are suitable for the planned towing operation. The permissible rigidity value of the tow coupling must always be taken into account.
  • Page 249 Operation Trailer operation – Take measures to prevent the trailer from rolling away, e.g. use wheel chocks (1). 7090_900-008 – Push the coupling pin (2) down, turn 90° and pull out. – Adjust the tiller height. DANGER People can become trapped between the truck and trailer.

  • Page 250: Automatic Tow Coupling

    Operation Trailer operation Uncoupling the trailer – Take measures to prevent the trailer from rolling away, e.g. use wheel chocks. – 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.
  • Page 251 Operation Trailer operation DANGER If you briefly leave the truck to couple or uncouple, there is a risk to life caused by the truck rolling away and running you over. – Apply the parking brake. – Lower the fork to the ground. –...
  • Page 252 Operation Trailer operation CAUTION Risk of component damage if the tiller in the tow coupling is tilted! The tiller should if possible be kept horizontal when towing. This ensures a sufficient rotation range 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 253 Operation Trailer operation – Pull out the safety handle (3). – Push the hand lever (2) upwards. DANGER Persons may become trapped between the truck and trailer. When hooking up, ensure that no one is between the truck and trailer. CAUTION When being coupled, the tow-bar eye must engage in the middle of the coupling jaw.
  • Page 254 Operation Trailer operation Uncoupling model RO*243 – Take measures to prevent the trailer from rolling away, e.g. use wheel chocks. – Pull out the safety handle (3). – Push the hand lever (2) upwards. – Slowly drive the truck forwards until the tow- bar eye and towing jaws are disconnected.
  • Page 255 Operation Trailer operation DANGER Persons may become trapped between the truck and trailer! When hooking up, ensure that no one is between the truck and trailer. CAUTION When being coupled, the tow-bar eye must engage in the middle of the coupling jaw. Failure to follow these instructions could result in damage to the coupling jaw or to the tow-bar eye! –...
  • Page 256 Operation Trailer operation Closing model RO*244 A by hand DANGER Risk of injury from hand becoming trapped! Do not reach into the coupling pin area with your hand. If, for example, a tow rope is to be secured in the tow coupling, only actuate the tow coupling via the closing lever (1).
  • Page 257 Operation Trailer operation Coupling model RO*245 NOTE Tow 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). – Take measures to prevent the trailer from rolling away, e.g.

  • Page 258: Towing Trailers

    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 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 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 the display, the driver PIN has been entered incorrectly three times. The input is then locked for five minutes before another attempt can be made.
  • Page 265 Operation Display messages 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. LOWER FORKS message DANGER There is a risk of fatal injury from a falling load or parts of the truck being lowered! Parking the truck with the load lifted is dangerous and is not permitted under any circumstances! The...
  • 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 is...
  • Page 268 Operation Display messages 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. ARE YOU SURE ? message If the message appears on ARE YOU SURE ?
  • 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: Connecting And Disconnecting The Battery Male Connector

    Operation Connecting and disconnecting the battery male connector Connecting and disconnecting the battery male connector Connecting the battery male connec- CAUTION Risk of damage to the battery male connector when connecting! If the battery male connector is connected while the key switch is switched on under load, a jump spark will be produced.

  • Page 275: Disconnecting The Battery Male Connector

    Operation Connecting and disconnecting the battery male connector Disconnecting the battery male connector CAUTION Risk of damage to the battery male connector when disconnecting! If the battery male connector is disconnected while the key switch is switched on under load, an arc will be produced.
  • Page 276 Operation Connecting and disconnecting the battery male connector – Hang the battery male connector (3) on the front of the battery tray (1). CAUTION When closing the battery cover, there is a risk of damage to the battery male connector! When you close the battery cover, the battery cover may collide with the battery male connector that you have hung on the battery tray.

  • Page 277: Handling The Battery

    Operation Handling the battery Handling the battery Safety regulations when handling the battery Maintenance personnel WARNING Risk of crushing/shearing! The battery is very heavy. There is a risk of serious injury if limbs are trapped underneath the battery or between the battery cover and the edge of the chassis.
  • Page 278 Operation Handling the battery – Disconnect the battery male connector when the key switch is switched off or the battery charger is switched off. – Keep the battery cover open during charg- ing. – Expose the surfaces of the battery cells. –...
  • Page 279 Operation Handling the battery Damage to cables and battery male connectors CAUTION There is a risk of short circuit if the cables are damaged. – Do not crush the battery cable when closing the battery cover. – Check the battery cable for da- mage.

  • Page 280: Checking The Battery Charge Status

    Operation Handling the battery Checking the battery charge status CAUTION Deep discharges shorten the service life of the battery. If there are no bars on the battery charge display (1) (0% of the available battery capacity, i.e. around 20% of the nominal capacity), it indicates the start of deep discharge.
  • Page 281 Operation Handling the battery CAUTION Risk of component damage! Incorrect connection or operation of the charging station or battery charger may result in damage to components! – Follow the operating instructions for the charging station or battery charger and for the battery. CAUTION Possible damage to the male battery connector! –...
  • Page 282 Operation Handling the battery – Open the fastener (4) for the battery male connector (3) by pulling the fastener to the left. – Disconnect the battery male connector (3) from the plug connection by pulling the handle (2) in the direction of the arrow. –...

  • Page 283: Equalising Charging To Preserve The Battery Capacity

    Operation Handling the battery – Open the fastener (6) for the battery charger plug (5) by pulling the fastener to the left. – Disconnect the battery male connector (3) from the battery charger plug by pulling the handle (2) in the direction of the arrow. –...
  • Page 284 Operation Handling the battery NOTE Depending on the battery charger used, the equalising charge may not begin until 24 hours have elapsed. A period when no shifts are running, such as the weekend, is therefore ideal for performing the equalising charge. –...

  • Page 285: Replacing And Transporting The Battery

    Operation Replacing and transporting the battery – Insert the battery male connector fully into the plug connection on the truck. Replacing and transporting the battery General information on replacing the battery CAUTION Risk of components being damaged by the lifting accessory and battery rolling away! The lifting accessory and battery may roll away in an uncontrolled manner if the battery is not replaced...

  • Page 286: Opening And Closing The Battery Cover

    Operation Replacing and transporting the battery NOTE ® When converting to PowerPlusLife batteries, the maximum speed of the truck can be increased to 20 km/h. Contact your authorised service centre. • NOTE ® When converting from PowerPlusLife batte- ries to other batteries, the maximum speed of the truck must be limited to 17 km/h for techni- cal reasons.
  • Page 287 Operation Replacing and transporting the battery – Unlock the quick release clamp (1) with a 1/4 turn in a clockwise direction. – Open the battery cover lock (3) using the key. – To release the battery cover, pull the handle (4) and at the same time use the other handle (2) to swivel the battery cover upwards.

  • Page 288: Replacing The Battery

    Operation Replacing and transporting the battery – To close the battery cover, take hold of the handles (2) and (4) at the same time and pull down firmly. – Make sure that the battery cover lock engages when you close it. –...
  • Page 289 Operation Replacing and transporting the battery – Open the battery cover. CAUTION Do not disconnect the battery male connector while the key switch is switched on! – Ensure that the key switch is switched off. – Open the fastener (4) for the battery male connector (3) by pulling the fastener to the left.
  • Page 290 Operation Replacing and transporting the battery – Adjust the distance (A) between the fork arms of the lifting accessory to match the distance (A) between the forked fittings in the battery base frame. – Swivel the battery lock (1) upwards. The battery lock is held in the raised position by means of the tension spring.
  • Page 291 Operation Replacing and transporting the battery – Set the battery and battery base frame down carefully. The battery always remains on the battery base frame. Installing the battery CAUTION Damage to the battery possible! If the battery is not used in the truck in conjunction with the battery base frame, the battery cannot be securely positioned in the battery compartment.
  • Page 292 Operation Replacing and transporting the battery The slide rail (1) serves as an installation aid and guides the battery base frame at a right angle into the battery compartment. The impact protection (2) protects the flap support from damage during insertion of the battery.
  • Page 293 Operation Replacing and transporting the battery Once the battery is positioned correctly in the battery compartment: – Carefully lower the battery. – Check that the detent cams (2) are fully engaged in the bores (1) and that the battery is level. –...

  • Page 294: Powerpluslife Battery

    ® The PowerPlusLife battery is a protected in-house development by STILL GmbH. ® Advantages of the PowerPlusLife battery: • Higher driving speeds and greater handling performance •...
  • Page 295 Operation PowerPlusLife battery NOTE ® When converting to PowerPlusLife batteries, the maximum speed of the truck can be increased to 20 km/h. Contact your authorised service centre. • Cooling air flow CAUTION If the cooling air flow is low, the cooling of the battery malfunctions.

  • Page 296: Powerpluslife ® Temperature Monitoring

    Operation PowerPlusLife battery ® PowerPlusLife temperature monitoring The control unit detects the core temperature of the battery and adjusts the fan control for cooling. The LEDs continuously indicate the cooling state of the battery. If the red LED (1) is illuminated, the battery temperature is high and cooling is active.
  • Page 297 Operation PowerPlusLife battery Internal error If an LED flashes at frequent intervals, it indicates the presence of an internal fault. The error can be read using the diagnostics function. The diagnostic connector (1) is located on the battery management device, on the right alongside the LEDs.

  • Page 298: Cleaning

    Operation Cleaning Cleaning Cleaning the truck WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling. Use suitable equipment to reach higher points on the truck. –...
  • Page 299 Operation Cleaning CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. – Adhere strictly to the following steps. CAUTION Abrasive cleaning materials can damage the surfa- ces of components! Using abrasive cleaning materials that are unsuita- ble for plastics can cause plastic parts to dissolve or become brittle.

  • Page 300: Cleaning The Electrical System

    Operation Cleaning – Before lubrication, clean the oil filling openings and the area around the oil filling openings, as well as the lubricating nipples. Cleaning the electrical system WARNING Danger of electric shocks due to residual capacity! – Never reach into the electrical system with your bare hands.

  • Page 301: Cleaning The Windows

    Operation Cleaning Move the chain several times during this procedure. – Immediately after drying the chain, spray it with chain spray. Move the chain several times during this procedure. For chain spray specifications, see the "Main- tenance data table" chapter. ENVIRONMENT NOTE Dispose of any fluid that has been spilled or collected in the collection vessel in an...
  • Page 302 Operation Cleaning – Grease the truck. – Lubricate the joints and controls. – Lubricate the battery cover interlock. – Check that the battery male connector is dry before you connect the battery male connector. NOTE The more often the truck is cleaned, the more frequently the truck must be lubricated.

  • Page 303: Procedure In Emergencies

    Operation Procedure in emergencies Procedure in emergencies Emergency shutdown WARNING Electrical and hydraulic functions will no longer be available following an emergency shutdown! The emergency shutdown procedure disables the hydraulic functions. The entire electrical system is de-energised. – Only use this safety system in the event of an emergency.
  • Page 304 Operation Procedure in emergencies Emergency shutdown via the emergency off switch – Push the emergency off switch (1). – Steer the truck to a safe place by applying greater steering power. – Decelerate the truck with the service brake by depressing the brake pedal. –...

  • Page 305: 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 306: 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 307 Operation Procedure in emergencies socket wrench must remain in the truck at all times. – Remove the bottom plate. – Take the hexagon socket wrench (1) out of the support mounting. – Open the front right cover. 7341_003-014 – Loosen the emergency lowering screw (3) on the control block (2) by a maximum of 1.5 revolutions using the hexagon socket wrench.

  • Page 308: Releasing The Spring-Operated Brake

    However, the truck can still be moved until the drive wheel units are blocked. In order to tow the truck, the spring-operated brake must be released by actuating the brake valve.
  • Page 309 Operation Procedure in emergencies Period after releasing the Hydraulic oil spring-operated brake until temperature it is blocked once again °C Minutes Seconds Actuate the brake valve by means of a cou- pling pin: – Take the coupling pin out of the counter- weight.
  • Page 310 If the bottom plate is not inserted, there is a danger of footwear getting stuck, causing you to fall. Even when the bottom plate is installed, there is still a danger of slipping and injury if the rubber mat is not used.

  • Page 311: Towing

    Operation Procedure in emergencies Towing DANGER Risk of accident due to failure of the brake system of the towing vehicle! If the brake system of the towing vehicle is not adequately sized, the vehicle may not brake safely or the brakes may fail. The towing vehicle must be designed such that it is able to absorb the tractive and braking forces from the unbraked towed load (the actual total weight of the truck).
  • Page 312 Operation Procedure in emergencies DANGER While manoeuvring, there is a risk of fatal injury in the area between the truck and the towing vehicle! Inform the driver of the towing vehicle and the mechanic attaching the tow bar about the risks. When you fit the tow bar, always use a second person to guide the towing vehicle manoeuvres.
  • Page 313 Operation Procedure in emergencies – Apply the parking brake. – Switch off the key switch. – Disconnect the battery male connector. – Check the tractive and braking forces of the towing vehicle. – With the help of a guide, manoeuvre the towing vehicle to the truck.

  • Page 314: Transporting The Truck

    Operation Transporting the truck Transporting the truck Transportation CAUTION Risk 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 the loading bridges must be greater than the actual total weight of the truck.
  • Page 315 Operation Transporting the truck 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 across a loading bridge, ensure that the loading bridge is properly attached and secured.

  • Page 316: Crane Loading

    Operation Transporting the truck – Attach a harness (1) to each side of the truck. Lash the truck towards the rear. – Attach a harness (1) to the coupling pin (2) or loop the harness around the coupling pin. – Lash the truck to the side. DANGER The truck may slip if the harnesses slip! The truck must be lashed securely to ensure that it...
  • Page 317 Operation Transporting the truck Determining the loading weight – Park the truck securely; see the chapter entitled "Parking the truck securely". – Determine the unit weights by reading them off the truck nameplate and, if necessary, Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr the attachment (variant) nameplate.
  • Page 318 Operation Transporting the truck NOTE The lifting points are indicated by a hook symbol. – Loop the lifting straps around the main traverse (3) on the outer mast of the lift mast as shown. – Loop the lifting straps around the counter- weight (4) as shown.
  • Page 319 Operation Transporting the truck – Adjust the length of the harnesses so that the lifting eye (6) is vertically above the truck's centre of gravity. This ensures that the truck hangs level when lifted. – Attach the lifting straps to the lifting eye and insert the safety device (5).

  • Page 320: Shutdown

    Operation Shutdown Shutdown Shutting down and storing the truck CAUTION Component damage due to incorrect storage! Storing the truck improperly or decommissioning the truck for more than two months will result in corrosion on the truck. If the truck is parked in an area with an ambient temperature of below -10°C for an extended period, the batteries will cool down.
  • Page 321 Operation Shutdown Measures to be implemented before shutdown – Store the truck in a dry, clean, frost-free and well-ventilated environment. – Clean the truck thoroughly; see the chapter entitled "Cleaning". – Lift the fork carriage to the stop several times. –...

  • Page 322: Re-Commissioning After Shutdown

    Operation Shutdown Re-commissioning after shutdown If the truck has been decommissioned for longer than six months, the truck must be carefully checked before being recommis- sioned. As with the yearly safety inspection, this check must also include all safety-related aspects of the truck. –...

  • Page 323: Maintenance

    Maintenance...

  • Page 324: 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 325: 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 326: 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 327 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 328: General Maintenance Information

    Maintenance General maintenance information General maintenance information Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Reg- ular safety checks and checks after unusual incidents must be performed by a competent person. The competent person must conduct their evaluation and assessment from a safety standpoint, unaffected by operational and economic conditions.
  • Page 329 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 330 Maintenance General maintenance information 56358042501 EN - 10/2018...

  • Page 331: Maintenance - 1000 Hours/Annually

    Maintenance General maintenance information Maintenance - 1000 hours/annually At operating hours 1000 2000 4000 5000 7000 Carried out 8000 10000 11000 13000 14000   Chassis, bodywork and fittings Check the chassis for cracks Check the overhead guard/cab and panes of glass for damage Check the controls, switches and joints for damage, and apply grease and oil Check the driver's seat for correct function and for damage Check the driver restraint system for correct function and for damage, and clean...
  • Page 332 Maintenance General maintenance information At operating hours 1000 2000 4000 5000 7000 Carried out 8000 10000 11000 13000 14000   Electrical system Check all power cable connections Check the contacts of the main contactors. Check the switches, transmitters and sensors for correct function Check the lighting and indicator lights Cooling system (power electronics and hydraulics) Check the coolant level and quality...
  • Page 333 Maintenance General maintenance information At operating hours 1000 2000 4000 5000 7000 Carried out 8000 10000 11000 13000 14000   Check the fork carriage for damage and wear Check the fork arm interlock for damage and correct function Check the fork arms for wear and deformation Check that there is a safety screw on the fork carriage or on the attachment Check the auxiliary hydraulics hoses for damage Special equipment...

  • Page 334: Maintenance - 3000 Hours/Every Two Years

    Maintenance General maintenance information Maintenance - 3000 hours/every two years At operating hours Carried out 3000 6000 9000 12000 15000   Note Perform all 1000-hour maintenance work. Power unit Change the gearbox oil Replace the bleeder screws on the drive wheel units Cooling system (power electronics and hydraulics) Replace the coolant (every 2 years) Hydraulics...
  • Page 335 Maintenance General maintenance information Oil and grease types of a different quality must not be mixed. This negatively affects the lubricity. If a change between different manufacturers cannot be avoided, drain the old oil thoroughly. Before carrying out lubricating work, filter changes or any work on the hydraulic system, carefully clean the area around the part involved.

  • Page 336: Lubrication Plan

    Maintenance General maintenance information Lubrication plan 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 337: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table General lubrication points Operating material Specifications Code Unit Measurement Lubrication High-pressure ID no. 0147873 As required grease Battery Operating material Specifications Code Unit Measurement System contents Distilled water As required Insulation resistance DIN 43539 For further VDE 0510 information, refer...
  • Page 338 Maintenance General maintenance information Tyres Operating material Specifications Code Unit Measurement Minimum tread depth Min. 1.6 mm Superelastic tyres Wear limit To wear mark AL80-01 steering axle Operating material Specifications Code Unit Measurement Wheel nuts/screws Torque wrench DIN 74361-A 20-10 640 Nm Axle stub bearing, Grease...
  • Page 339 Maintenance General maintenance information Load chains Operating material Specifications Code Unit Measurement (C) Lubrication High-load chain Fully synthetic As required spray Temperature range: -35°C to +250°C ID no. 0156428 Cooling system (power electronics/hydraulic oil) Operating material Specifications Code Unit Measurement System contents Corrosion inhibitor 40% coolant/60%...

  • Page 340: Providing Access To Maintenance Points

    Maintenance Providing access to maintenance points Providing access to maintenance points Removing and attaching the left side cover Removing the cover – Release the quick release clamps (1) with a 1/4 revolution. – Remove the cover (2) and put carefully aside.
  • Page 341 Maintenance Providing access to maintenance points NOTE The accelerator pedal is attached to the bottom plate and is removed with this also. The connecting plug for the accelerator is located underneath the bottom plate. – Open the bonnet. – Remove the rubber mat. –...

  • Page 342: Opening/Closing The Front Right Cover

    Maintenance Providing access to maintenance points – Set down the bottom plate upright in the footwell. – Connect the connection assembly to the accelerator pedal. – Position the bottom plate at the front. – Carefully guide the bottom plate down and close.

  • Page 343: Removing And Attaching The Rear Cover

    Maintenance Providing access to maintenance points – Swivel the cover (2) downwards. – Lock the quick release clamp (3) with a 1/4 revolution. 7341_003-007 Removing and attaching the rear cover CAUTION Risk of component damage! If a load is placed on the exhaust air grille (2), this can lead to deformation or cause the exhaust air grille to come away.

  • Page 344: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Checking the coolant level WARNING Risk of scalding due to hot coolant! The cooling system is pressurised! Opening the cooling fluid tank may result in hot cooling fluid leaking out. Only open the cooling fluid tank when the cooling system is cool.

  • Page 345: Topping Up Cooling Fluid And Checking Coolant Content

    Maintenance Preserving operational readiness The cooling fluid level must be between the upper marking (4) and the lower marking (5). – If the cooling fluid level is below the lower marking, top up the cooling fluid to no higher than the upper marking. –...
  • Page 346 Maintenance Preserving operational readiness – Pull up the locking pin (1) on the cooling fluid tank (2). – Pull out the cooling fluid tank from under the rear cover. – Slowly open the tank cap (3) and release the over pressure. –...
  • Page 347 Maintenance Preserving operational readiness The cooling fluid level must be between the upper marking (4) and the lower marking (5). – Check the cooling fluid level. – If the cooling fluid level is below the lower marking, top up the cooling fluid to no higher than the upper marking –...

  • Page 348: Cleaning The Radiator And Checking The Radiator For Leak Tightness

    Maintenance Preserving operational readiness Cleaning the radiator and checking the radiator for leak tightness WARNING Risk of burns due to hot components! Cooling system components can be so hot that direct contact may burn the skin. – Ensure that the cooling system has cooled down. –...
  • Page 349 Maintenance Preserving operational readiness NOTE Make sure that the radiator grille is screwed tightly into place. – Fit the rear cover. – Fit the cover on the left-hand side. 56358042501 EN - 10/2018...

  • Page 350: Checking The Battery Condition, Acid Level And Acid Density

    Maintenance Preserving operational readiness Checking the battery condition, acid level and acid density – Remove the battery from the truck. DANGER Risk to life! – Observe the chapter entitled "Safety regulations when handling the battery". WARNING The electrolyte (diluted sulphuric acid) is poisonous and corrosive! –...

  • Page 351: Changing The Heating System Fresh Air Filter

    Maintenance Preserving operational readiness – Open filler cap (1) and check the acid level. For batteries with "caged cell plugs", the liquid must reach the bottom of the cage. For batteries without "caged cell plugs", the liquid must reach a height of approx. 10 to 15 mm above the lead plates.

  • Page 352: Lubricating The Joints And Controls

    Maintenance Preserving operational readiness – Loosen the quick-release clamp (1) by turning it and remove the cover (2). 7341_003-047 – Grasp the filter insert (3) at the finger opening (4) and remove it completely from the filter housing. – Check the filter insert for contamination and beat out.

  • Page 353: Maintaining The Seat Belt

    Maintenance Preserving operational readiness 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 354: Checking The Driver's Seat

    Maintenance Preserving operational readiness – 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 355: Checking The Door Latch

    Maintenance Preserving operational readiness Checking the door latch – Inspect the condition of the catch bolt and check for wear. – Check the lock mechanism for easy opera- tion. Replacing the recirculated air filter for the heating system The recirculated air filter for the heating system is located on the right-hand side of the cab, underneath the heating system panelling (1).

  • Page 356: Servicing Wheels And Tyres

    Maintenance Preserving operational readiness Servicing wheels and tyres WARNING Risk of accident! Uneven wear reduces the stability of the truck and increases the braking distance. The level of wear exhibited by tyres on the same axle must be approximately the same. –...
  • Page 357 Maintenance Preserving operational readiness Pneumatic tyres (variant) – Check the tread depth on all four tyres. The tread depth for pneumatic tyres (variant) must be at least 1.6 mm at every point on the tread. If the tread is worn down to the wear mark (2) at any point on the tyre, replace the tyres on one axle.

  • Page 358: Replacing The Fuses

    Maintenance Preserving operational readiness Checking wheel fastenings – Check that all wheel fastenings (4) are se- curely fastened and retighten as necessary. – Observe the relevant torques; see section entitled "Maintenance data table". 7321_003-112 Replacing the fuses DANGER Risk of fire and risk of injury! The truck must be de-energised before any work is carried out on the electrical system.
  • Page 359 – Close the cover to secure the fuse box. – Close the front right cover. – Perform a function check. If the error persists or if the fuse is still defective, notify your authorised service centre. 7311_003-021 56358042501 EN - 10/2018...

  • Page 360: Checking The Hydraulic Oil Level

    – Close the cover to secure the fuse box. – Attach the left side cover. – Perform a function check. If the error persists or if the fuse is still defective, notify your authorised service centre. 7311_003-021 Checking the hydraulic oil level...
  • Page 361 Maintenance Preserving operational readiness – Unscrew breather filter (1). 7341_003-051_V2 The lower mark, (1) or (2), indicates the minimum filling level. The top mark, (max), indicates the maximum filling quantity. The lower mark that is applicable for the specific truck depends on the lift mast, the relevant lift height (see table below) and the resulting filling quantities.

  • Page 362: Checking The Hydraulic System For Leak Tightness

    Maintenance Preserving operational readiness – Add hydraulic oil with the correct specifi- cation according to the maintenance data table. – Top up the hydraulic oil only as far as the top (max) mark. ENVIRONMENT NOTE Carefully collect any spilled oil and dispose of it in an environmentally friendly manner.

  • Page 363: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness – Check pipe and hose connection screw joints for leaks (traces of oil). Replace hose lines if they display the following abnormalities: • Outer layer has been damaged, or is brittle or cracked • Leaking • Deformation (e.g. with blisters or kinks) •...
  • Page 364 Maintenance Preserving operational readiness NOTE Close the coupling before cleaning with a high-pressure cleaner. After cleaning, lubricate the coupling pin, tow bar eye and its supporting surface again. Model RO*243 – Pull out the safety handle (3). – Push the hand lever (2) upwards. –...
  • Page 365 Maintenance Preserving operational readiness – Grease using the lubricating nipple(1) in accordance with the maintenance data table; see ⇒ Chapter "Maintenance data table", P. 5-325. – Grease coupling pin, tow bar eye and its supporting surface. Wartung_Rockinger 244 A Model RO*245 –...
  • Page 366 Maintenance Preserving operational readiness Model RO*841 – Lubricate via the points provided for this purpose (lubricating nipple, opened cou- pling) in accordance with the maintenance data table; see ⇒ Chapter "Maintenance data table", P. 5-325. – Grease the supporting surface for the tow-bar eye.

  • Page 367: 1000-Hour Maintenance/Annual Maintenance

    1000-hour maintenance/annual mainte- nance...

  • Page 368: Other Tasks

    1000-hour maintenance/annual maintenance Other tasks Other tasks – Perform all tasks required to maintain full operability; see the chapter entitled "Remaining ready for operation". Checking the lift cylinders and the hydraulic connections for leak tightness WARNING Risk of injury! Observe safety regulations for working on the lift mast, see the "Working at the front of the truck"...

  • Page 369: Checking The Reversible Fork Arms

    1000-hour maintenance/annual maintenance Checking the reversible fork arms It must be possible to move the fork arm. – Move the locking lever into a horizontal position. The latch must engage in a recess on the fork carriage. It must not be possible to move the fork arm.
  • Page 370 1000-hour maintenance/annual maintenance Checking the reversible fork arms 56358042501 EN - 10/2018...

  • Page 371: Technical Data

    Technical data...

  • Page 372: Dimensions

    Technical data Dimensions Dimensions Fork spacing is adjustable NOTE Measurements h and b customised and can be taken from the order confirmation. 56358042501 EN - 10/2018...
  • Page 373 Technical data Dimensions Centre of gravity "S" (distance measured from the front axle) RX60-60 1006 mm RX60-70 1006 mm RX60-80 1006 mm RX60-80 (LSP 900) 1006 mm NOTE The specified centre of gravity "S" relates to trucks with standard equipment. If, for...

  • Page 374: Vdi Datasheet

    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. Characteristics RX60-80 Model RX60-60 RX60-70 RX60-80 LSP 900 Type carrier 6341 6342...
  • Page 375 Technical data VDI datasheet Wheels, chassis frame RX60-80 Model RX60-60 RX60-70 RX60-80 LSP 900 Tyres: superelastic (SE), solid rubber (V), pneu- matic (L) Front wheel size 355/50-20 8.25-15 315/70-15 315/70-15 Rear wheel size 250-15 250-15 250-15 28x12.5–15 Number of front wheels...
  • Page 376 Technical data VDI datasheet RX60-80 Model RX60-60 RX60-70 RX60-80 LSP 900 s (mm) Fork arm thickness e (mm) Fork arm width Fork arm length l (mm) 1200 1200 1200 1200 Fork carriage, class/form A, B ISO IV A ISO IV A...
  • Page 377 To use the truck safely—with or without a load—the maximum ascending or descending gradient per- mitted for travel is 15%. – If you have any questions, please contact the authorised service centre. Electric motor RX60-80 Model RX60-60 RX60-70 RX60-80 LSP 900 Traction motor, power rating 2x10.5 2x10.5 2x10.5 2x10.5...

  • Page 378: 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 379: Battery Specifications

    Technical data Battery specifications Battery specifications CAUTION The battery weight and dimensions affect the stability of the truck. When replacing the battery, the weight ratios must not be changed. The battery weight must remain within the weight range specified on the nameplate.
  • Page 380 Technical data Battery specifications adapted by the authorised service centre. If the maximum speed is not adapted, it can lead to technical faults in drive mode. Contact your authorised service centre. • 56358042501 EN - 10/2018...

  • Page 381: Fuse Assignment

    Technical data Fuse assignment Fuse assignment NOTE The electrical fuses for the truck are located in two separate fuse boxes. Depending on the specification, not all fuses will be present in the truck. Fuse assignment - Front fuse box Power Distribution Unit and 80-V technology SU control unit/MCU control unit (10 A) Not assigned Not assigned...
  • Page 382 Technical data Fuse assignment Fuse assignment - rear fuse box 12-V technology 1F16 Proportional technology (10 A) 5F11 Roof CPP - control unit (30 A) 9F03 Option board (10 A) 5F13 Seat CPP - control unit (30 A) 5F12 Front CPP - control unit (20 A) 1F10 Cooling pump (10 A) 9F32...
  • Page 383 Index NUMBERS AND SYMBOLS Attachments Controlling using a double 12-V socket ..... 221 mini-lever ....190 Controlling using the double mini-lever and the 5th function .
  • Page 384 Index Changing the heating system fresh air filter ..... . 339 Battery Changing the password ... . 102 Changing the battery type .
  • Page 385 Index Double mini-lever ....63 Lifting/lowering the fork carriage . . . 155 Damage ......34 Tilting the lift mast .
  • Page 386 Index FleetManager ....220 Shock recognition ....220 Identification points Fork arms Overview .
  • Page 387 Load chains ....327 STILL SafetyLight ....218 Steering axle ....326 Switching on and off .
  • Page 388 Index Message ! PARKING BRAKE OIL PRES- Nameplate ..... . . 11 SURE ....259 Neutral position .
  • Page 389 Index Production number ....12 Rules for roadways and the working area ..... . 125 Prohibition of use by unauthorised persons .
  • Page 390 Index Setting the language ....115 Turn indicators ....214 Setting the time .
  • Page 391 Index Visual inspections ....70 Working on the electrical equipment . . . 312 Working on the hydraulic equipment . . . 312 Working spotlight for reverse travel Warning regarding non-original parts .
  • Page 394 STILL GmbH 56358042501 EN – 10/2018...

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