Still RX60 25-35 Original Instructions Manual
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Still RX60 25-35 Original Instructions Manual

Electric truck
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Table of Contents

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Original instructions
Electric truck
RX60 25-35 Cat. 3GD
For use in potentially explosive areas
6301 6302 6304 6305 6307 6308
6309
56378011526 EN - 03/2021 - 01

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  • Page 1 Original instructions Electric truck RX60 25-35 Cat. 3GD For use in potentially explosive areas 6301 6302 6304 6305 6307 6308 6309 56378011526 EN - 03/2021 - 01...
  • Page 3 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. 56378011526 EN - 03/2021 - 01...
  • Page 4  You can request to download the spare parts list by copying and pasting the address https:// sparepartlist.still.eu into a web browser or by scanning the QR code shown to the side. On the web page, enter the following pass-...

  • Page 5: Table Of Contents

    Table of contents Foreword Your truck ............Description of the truck .
  • Page 6 Table of contents Safety Definition of responsible persons......... Operating company .
  • Page 7 Operating devices and display elements ........Display-operating unit "STILL Easy Control" ........
  • Page 8 STILL Classic and sprint mode ........
  • Page 9 Table of contents Actuating the drive direction switch with the multiple-lever version....Actuating the drive direction switch with the mini-lever version....Actuating the drive direction switch with the Fingertip version .
  • Page 10 Table of contents Picking up loads ............Danger area.
  • Page 11 Table of contents Depressurising the hydraulic system using the Joystick 4Plus ....Depressurising the hydraulic system using the Joystick 4Plus and the 5th function..Special feature for clamping attachments .
  • Page 12 Table of contents Trailer operation............Safety information for trailer operation .
  • Page 13 Table of contents Cleaning the truck ........... . Note on flame proof enclosures.
  • Page 14 Table of contents Preserving operational readiness ........Changing the light bulb .

  • Page 15: Foreword

    Foreword...

  • Page 16: Your Truck

    Your truck Description of the truck General The STILL RX60 25-35 is an electrically driven counterbalanced truck with a rear swing axle and has a load capacity of up to 3.5 tonnes. Alternatively, a load capacity of up to 3.0 tonnes with a load centre of gravity of 600 mm is available.
  • Page 17 Drive Both front wheels of the STILL RX60 25-35 are driven by maintenance-free three-phase drives in the front axle with 80-volt technology. Power is supplied by a lead-acid battery that can be replaced from the side.
  • Page 18 Acceleration and braking be- haviour can be individually selected from three different drive programmes. The "STILL Easy Control" display-operating unit simplifies daily use of the truck by provid- ing personally configurable favourites. The display-operating unit also monitors the truck functions.

  • Page 19: General

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

  • Page 20: Explosion Protection Notice

    Foreword Your truck Explosion protection notice  The explosion protection notice indicates that the manufacturer complies with the explosion protection licensing regulations. 6036_001-001 56378011526 EN - 03/2021 - 01...

  • Page 21: 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 Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 22: Accessories

    Foreword Your truck Accessories Two keys for the key switch (not for trucks ● with the "Switch on via push button" variant) Two keys for the cab (variant) ● A hexagon socket wrench for emergency ● lowering (in the compartment) A battery change frame ●...
  • Page 23 Foreword Your truck 56378011526 EN - 03/2021 - 01...

  • Page 24: Labelling Points

    Foreword Your truck Labelling points CAT. 2G 6301_901-001 56378011526 EN - 03/2021 - 01...
  • Page 25 Foreword Your truck Decal information: Caution / Read the oper- Warning sign: Dangerous electrical voltage ating instructions / Fasten seat belt / Apply Decal information: Load measurement parking brake when leaving the truck / Pas- Warning sign: Cable cross-section sengers are not allowed / Do not jump off if Decal information: Explosion protection the truck is tipping over / Lean in the oppo- mark and equipment category...
  • Page 26 Foreword Your truck 0044 S.r.l. 20812 LIMBIATE (MB) ‒ Via Marconi, CBH ‒ 5 II 573714 3 Year 20 Ex d IIC T II 2 (1) GD Ex tb IIIC T °C Db IP66 ATEX 043X T.amb. = ‒20°C to + 60°C CABLE ENTRIES : SEE INSTRUCTIONS T cable °C...

  • Page 27: Nameplate

    Foreword Your truck Decal information: Hydraulic oil tank Decal information: StVZO (German Road Warning sign: Do not stand underneath the Traffic Licensing Regulations) information fork/Do not stand on the fork Nameplate with CE labelling Warning sign: Danger due to shearing / Decal information: Battery service Danger due to high fluid pressure Decal information: Regular testing...

  • Page 28: Nameplate Of The Pressure-Tight Housing

    Foreword Your truck Nameplate of the pressure-tight  housing The flame proof enclosures are marked with a nameplate. The data on the plate corresponds to the approved area of application for the flame proof enclosure. The plate must be posi- 0044 S.r.l.

  • Page 29: Stvzo (Road Traffic Licensing Regulations) Information

    Foreword Your truck StVZO (Road Traffic Licensing Reg-  ulations) information This label includes information on the weight and load distribution of the truck in kg. Tare weight Total permissible weight Permitted front axle load Permitted rear axle load Payload 56378011526 EN - 03/2021 - 01...

  • Page 30: Nameplate Of The Battery

    Foreword Your truck Nameplate of the battery The nameplate of the battery is mounted on the battery tray. The information on this name- plate describes the permitted area of use of the battery. Only use explosion-protected batteries – that are approved for the area in which the truck is to be used.
  • Page 31 Foreword Your truck NOTE In this example, the company HAWKER ® quoted as the battery supplier. If the truck is equipped with an explosion-protected battery from another manufacturer, the authorised service centre will provide assistance in de- coding the nameplate of the battery. 56378011526 EN - 03/2021 - 01...

  • Page 32: Diagnostic Interface

    Foreword Your truck Diagnostic interface  The truck is equipped with a diagnostic inter- face for monitoring and reading out the truck control unit. Only the authorised service centre may operate the diagnostic interface. The di- agnostic interface is identified by the decal in- formation (see illustration).

  • Page 33: Using The Truck

    Foreword Using the truck Using the truck Basic information on explosion protection DANGER Risk of explosion! The truck may only be operated in the potentially explosive areas for which it is approved! – Check the area of application by com- paring it with the nameplate informa- tion.
  • Page 34 Foreword Using the truck temperature. This enables ignition caused by overheated equipment surfaces to be preven- ted. Potentially explosive areas for flammable gases, vapours and fumes are divided into zones 0, 1 and 2. Division of potentially explosive areas for gases, vapours and fumes Zone Description Permanent, long-term or frequent dangerous explosive atmosphere...

  • Page 35: Commissioning

    Foreword Using the truck Equipment in group II (gas) is divided in ac- cordance with the characteristics of the explo- sive atmosphere for which it is intended. Equipment in group II (gas) Group Description Propane Ethylene Hydrogen Equipment in group III (dust) is divided in ac- cordance with the characteristics of the explo- sive atmosphere for which it is intended.

  • Page 36: Proper Use

    Foreword Using the truck work and adjustment work that cannot be per- formed by the operating company. See also the chapter entitled "Definition of responsible persons". – To commission the truck, contact the au- thorised service centre. Proper use The truck described in these operating instruc- tions is suitable for lifting, transporting and stacking loads.

  • Page 37: Proper Use During Towing

    Foreword Using the truck Proper use during towing DANGER Risk of explosion! Trailers and tow couplings that do not fulfil explosion-protection regulations can lead to explosions in the surrounding at- mosphere within potentially explosive areas! Do not use the truck for towing. Improper use The operating company or driver, and not the manufacturer, is liable for any hazards caused...
  • Page 38 Foreword Using the truck DANGER Risk of explosion! The truck must not be operated in fire hazard areas or potentially explosive areas that do not conform to the truck's classification. The truck must not be operated in areas where there is a risk of corrosion or in areas with high levels of dust that do not conform to the truck's classification.

  • Page 39: Place Of Use

    Foreword Using the truck Place of use  DANGER There is a risk of explosion during use in potentially explosive areas. The truck may only be operated in the potentially explosive areas for which it is approved! – Check the area of application by com- paring it with the nameplate informa- tion.
  • Page 40 Foreword Using the truck arise during normal operation due to gases, vapours or mists. Zone 21 – category 2D ● Use is permitted in areas where hazardous, potentially explosive atmospheres may arise during normal operation due to dusts. Zone 1 and zone 21 – category 2GD ●...

  • Page 41: Parking In Temperatures Below -10 °C

    Foreword Using the truck Driving on upward and downward gradients is permitted, provided the stipulated data and specifications are observed. The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: −10°C to +40°C).
  • Page 42 Foreword Using the truck DANGER Risk of explosion! Working with working platforms that do not meet explosion-protection regula- tions can lead to explosions in the sur- rounding atmosphere within potentially explosive areas! – Only use working platforms that com- ply with the explosion-protection regu- lations.

  • Page 43: Information About The Documentation

    Foreword Information about the documentation Information about the documentation Scope of the documentation Original operating instructions of the truck ● Original operating instructions of the dis- ● play-operating unit Operating instructions of the installed var- ● iants that are not mentioned in the afore- mentioned original operating instructions "UPA"...

  • Page 44: Supplementary Documentation

    Foreword Information about the documentation Store all documentation safely. Hand over the documentation to the next operating company if the truck is transferred or sold. NOTE Please note the definition of the following re- sponsible persons: "operating company" and "driver". Thank you for reading and complying with these operating instructions.

  • Page 45: Issue Date And Topicality Of The Operating Instructions

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

  • Page 46: List Of Abbreviations

    Foreword Information about the documentation CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc- tion. NOTE For technical requirements that require special attention. ENVIRONMENT NOTE To prevent environmental damage -protection information For components, points and procedures rele- vant to explosion protection List of abbreviations This list of abbreviations applies to all types of...
  • Page 47 Foreword Information about the documentation Abbrevi- Meaning Explanation ation European standard European Federation of Materials Han- Fédération Européene de la Manutention dling and Storage Equipment maximum Force Maximum power German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless net- GPRS...

  • Page 48: Definition Of Directions

    Foreword Information about the documentation Abbrevi- Meaning Explanation ation Verband Deutscher Maschinen- und Anla- German Mechanical Engineering Industry VDMA genbau e. V. Association WLAN Wireless LAN Wireless local area network Definition of directions  The directions "forwards" (1), "backwards" (3), "right"...
  • Page 49 Foreword Information about the documentation View of the display-operating unit  NOTE 12,6 10:35 Views of operating statuses and values in the display of the display and operating unit are examples and partly dependent on the truck equipment. As a result, the displays shown of the actual operating statuses and values may vary.

  • Page 50: Environmental Considerations

    Foreword Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.

  • Page 51: Safety

    Safety...

  • Page 52: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal person 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 53: Competent Person For Explosion Protection Checks

    Safety Definition of responsible persons Competent person for explosion protection checks Competent persons for explosion protection checks (hereinafter referred to as "competent person") are service technicians or persons who fulfil the following requirements: A completed vocational qualification that ● demonstrably proves their professional ex- pertise This proof must consist of a vocational qual- ification or a similar document.

  • Page 54: Drivers

    Safety Definition of responsible persons The competent person is permitted to work on industrial trucks manufactured by STILL that have been converted by Miretti. Drivers This truck must only be driven by persons who fulfil the following points: The driver must: Be physically and mentally able to drive the ●...
  • Page 55 Safety Definition of responsible persons The driver must: Have read and understood the operating in- ● structions; Have familiarised themselves with safe op- ● eration of the truck Adhere to the rules of behaviour in areas at ● risk of explosions Clothing The driver must wear protective equipment (protection suit, safety shoes, safety helmet,...

  • Page 56: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company prem- ises In many cases, company premises are restric- ted public traffic areas. NOTE The business liability insurance should be re- viewed 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 57 Safety Basic principles for safe operation We warn against installing and using restraint systems that have not been approved by the manufacturer. DANGER Risk of explosion from additional bores in the battery hood! Explosive gases can escape and can lead to potentially fatal injuries if they ex- plode.

  • Page 58: Changes To The Overhead Guard And Roof Loads

    Original parts, attachments and accessories are specially designed for this truck. We spe- cifically draw your attention to the fact that parts, attachments and accessories supplied by other companies have not been tested and approved by STILL. 56378011526 EN - 03/2021 - 01...

  • Page 59: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation 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 driv- ing safety. We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts.

  • Page 60: Tyres

    Safety Basic principles for safe operation Tyres  DANGER Risk of explosion! In potentially explosive areas, wheels and tyres that do not meet explosion- protection regulations may lead to explo- sions in the surrounding atmosphere. – Only use approved, electrically con- ductive tyre types.

  • Page 61: Medical Equipment

    Safety Basic principles for safe operation Changing rim wheel parts ● Combining rim wheel parts from different ● manufacturers Therefore, the above-mentioned factors are prohibited. The following rules must be observed to en- sure stability: – Only use tyres with equal and permitted lev- els of wear on the same axle.

  • Page 62: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation Medical equipment, such as pacemakers or hearing aids, may not work properly when the truck is in operation. – Ask your doctor or the manufacturer of the medical equipment to confirm that the medi- cal equipment is sufficiently protected against electromagnetic interference.
  • Page 63 Safety Basic principles for safe operation addition, be aware that the load centre of gravity may shift as a result of dynamic forces, such as braking. A load that is otherwise rest- ing safely on the fork arms may move for- wards and fall.

  • Page 64: Residual Risk

    Safety Residual risk Residual risk Residual dangers, residual risks DANGER Risk of explosion in the event of fire or smouldering! In the worst case scenario, polluted, damaged or defective components can result in fire or smouldering. If you smell fire: –...
  • Page 65 Safety Residual risk Risks can include: Escape of consumables due to leakages, ● rupture of lines and containers etc. Risk of accident when driving over difficult ● ground such as gradients, very smooth or uneven surfaces, or with poor visibility etc. Falling, tripping etc.

  • Page 66: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risk – Drive with the load lowered. – Even with sideshifts, align the load as cen- trally as possible with the truck and trans- port in this position. – Avoid turning and driving diagonally across slopes or gradients. –...
  • Page 67 Safety Residual risk 56378011526 EN - 03/2021 - 01...

  • Page 68: Overview Of Hazards And Countermeasures

    Safety Residual risk Overview of hazards and countermeasures 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 69 Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and la- bour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver...

  • Page 70: Danger To Employees

    Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal- German Ordinance on correct/slipped Industrial Safety and...
  • Page 71 Safety Residual risk included in the hazard assessment. Attach- ments possess their own CE labelling and likewise are not included for that reason. The operating company must, however, select the type and equipment of the trucks so as to comply with the local provisions for deploy- ment.

  • Page 72: Safety Tests

    Safety Safety tests Safety tests Carrying out regular inspections on  the truck 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, the technical condi- tion of the truck must be completely tested with regard to accident safety.

  • Page 73: Explosion-Protection Checks

    Safety and Health once every three years by a competent person; see also "Definition of re- sponsible persons - Competent person". How- ever, as a manufacturer, STILL recommends Nächste Prüfung that this test is carried out annually. If the truck is subject to harsh application conditions, the interval between tests must be shortened.

  • Page 74: Testing The Electrical System

    Safety Safety tests Testing the electrical system DANGER Risk of explosion! Trucks to be used in potentially explo- sive areas are designed for certain ex- plosion groups, categories and tempera- ture ranges. In potentially explosive areas, trucks that do not meet explosion- protection regulations may lead to explo- sions in the surrounding atmosphere.
  • Page 75 Safety Safety tests NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values test voltage age U Batt 50 VDC 24 volts > 1200 Ω Batt+ Battery 100 VDC...

  • Page 76: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Consumables can be dangerous! – Observe general information and safety informa- tion regarding the use of consumables. – Refer to the chapter entitled "Safety regula- tions for handling consumables". –...

  • Page 77: 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 78: Battery Acid

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

  • Page 79: Disposal Of Consumables

    Safety Safety regulations for handling consumables WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, nev- er wear a watch or jewellery. –...

  • Page 80: Emissions

    Safety Emissions Emissions The values specified apply to a standard truck (compare the specifications in the "Technical data" chapter). Different tyres, lift masts, addi- tional units etc. may produce different values. Noise emissions The values were determined based on meas- uring procedures from the standard EN 12053 "Safety of industrial trucks - Test methods for measuring noise emissions", based on...
  • Page 81 Safety Emissions Vibrations The vibrations of the machine have been de- termined on an identical machine in accord- ance with the standards DIN EN 13059 "Safe- ty of industrial trucks - Test methods for meas- uring vibration" and DIN EN 12096 "Mechani- cal vibration - Declaration and verification of vibration emission values".
  • Page 82 Radiation In accordance with the guidelines DIN EN 62471:2009-03 (VDE 0837-471:2009-03), the STILL Safety- Light and the warning zone light (variant) are assigned to risk group 2 (medium risk) due to their photobiological hazard potential. 56378011526 EN - 03/2021 - 01...

  • Page 83: Overviews

    Overviews...

  • Page 84: Overview

    Overviews Overview Overview 6301_003-020 56378011526 EN - 03/2021 - 01...
  • Page 85 Overviews Overview Lift mast Fork carriage Overhead guard Lift cylinder Driver's compartment Rear lighting Battery (in the battery compartment) Battery door Drive axle with traction motors Steering axle Front lighting Towing device Fork arms Counterweight NOTE The truck equipment may differ from the equipment shown.

  • Page 86: Driver's Compartment

    Overviews Driver's compartment Driver's compartment 6301_901-003 56378011526 EN - 03/2021 - 01...
  • Page 87 Emergency off switch Brake pedal Key switch or pushbutton Bottom plate Compartment Pneumatic signal horn Display-operating unit "STILL Easy Control" Steering column adjustment lever Operating devices for hydraulics and driving Reset button functions Explosion-protection warning lights Compartment for storing the operating in-...

  • Page 88: Shelves

    Overviews Shelves Shelves 6219_901-015_V3 56378011526 EN - 03/2021 - 01...
  • Page 89 Overviews Shelves WARNING Risk of accident caused by blocked pedals! Objects may fall into the footwell during travel as a result of steering or braking. They can slip between and under the pedals (3, 4). They then block the ped- als.

  • Page 90: Operating Devices And Display Elements

    Display for direction of movement of the Selected load programme with load dynam- truck ics display Brightness sensor Right-hand favourites bar "STILL Easy Control" is a third-generation dis- play-operating unit for industrial trucks. 56378011526 EN - 03/2021 - 01...
  • Page 91 – For information about the other display op- tions, see the original operating instructions entitled "STILL Easy Control display-operat- ing unit". The display-operating unit is attached to the armrest, except in trucks equipped with multi- lever operation.

  • Page 92: Explosion-Protection Warning Lights

    Overviews Operating devices and display elements Explosion-protection warning lights  DANGER Risk of explosion! During operation, the surface tempera- tures and insulation values of various components are monitored by sensors. – Do not operate the truck when a warning light is illuminated. The explosion-protection warning lights are lo- cated on the left-hand post, in the driver's field of view.
  • Page 93 Overviews Operating devices and display elements Push-and-turn version  6219_901-018 Turn version  NOTE This battery isolating switch can be secured in the "OFF" position by using a lead seal or a padlock to prevent the switch from being actu- ated without authorisation.

  • Page 94: Emergency Off Switch

    Overviews Operating devices and display elements Emergency off switch  The emergency off switch (1) is situated on the right-hand side of the steering column. It disconnects the drives from the power supply. Do not use this switch to park the truck safely. Reset button ...

  • Page 95: Multi-Lever Operation

    Overviews Operating devices and display elements Multi-lever operation 6219_003-004_V3 Drive direction switch Operating lever for attachments (variant) "Lift/lower" operating lever Function key for the "5th or 6th function" "Tilt" operating lever (variants) Operating lever for attachments (variant) Signal horn button Function key for the "5th function"...

  • Page 96: Double Mini-Lever

    Overviews Operating devices and display elements Double mini-lever Drive direction switch "F1" function key Cross lever "Attachments" "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions Signal horn button 56378011526 EN - 03/2021 - 01...
  • Page 97 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 98: Triple Mini-Lever

    Overviews Operating devices and display elements Triple mini-lever Drive direction switch Signal horn button "Auxiliary hydraulics 1" operating lever "F1" function key "Auxiliary hydraulics 2" operating lever "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions 56378011526 EN - 03/2021 - 01...
  • Page 99 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 100: Quadruple Mini-Lever

    Overviews Operating devices and display elements Quadruple mini-lever Drive direction switch Signal horn button "Tilt" operating lever "F1" function key "Auxiliary hydraulics 1" operating lever "Lift/lower" operating lever "Auxiliary hydraulics 2" operating lever Display field for the hydraulic functions Function key for the "5th function" 56378011526 EN - 03/2021 - 01...
  • Page 101 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 102: Fingertip

    Overviews Operating devices and display elements Fingertip Signal horn button Drive direction switch LED for the "5th function" "Lift/lower" operating lever Function key for the "5th function" "Tilt" operating lever LED for the "Clamp release" "F1" function key Operating lever for "Auxiliary hydraulics 1" LED for "F1"...

  • Page 103: Joystick 4Plus

    Overviews Operating devices and display elements Joystick 4Plus 6219_003-210_V2 Horizontal rocker button for the "3rd and LED for the "clamp release" (variant) 4th hydraulic function": tilting the lift mast Slider for the "4th hydraulic function" Pictograms for the hydraulic functions: lift- Vertical rocker button for the "drive direction"...

  • Page 104: Travel Direction Selector And Indicator Module (Variant)

    Overviews Operating devices and display elements Travel direction selector and indica-  tor module (variant) The travel direction selector and indicator module is located on the steering column be- low the steering wheel. NOTE If the drive direction switch on the operating device is defective and the truck stops in a danger area, the drive direction selection lever on the travel direction selector and indicator...

  • Page 105: Operating

    Operating...

  • Page 106: Checks And Tasks Before Daily Use

    Operating Checks and tasks before daily use Checks and tasks before daily use Visual inspections and function checking WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and fall- ing.
  • Page 107 Operating Checks and tasks before daily use Component Course of action Perform a visual inspection to ensure that the Load chains chains are intact and have adequate and even ten- sion. Ensure that the attachments are mounted correctly in accordance with the operating instructions from the manufacturer.
  • Page 108 Check the setting of the warning zone light. Perform a visual inspection for integrity. Ensure cleanliness. Make sure that the antistatic belt(3) is still long Antistatic belt (3), corona electrode (4) enough to touch the ground in all situations. (See the following illustration.) The discharge wires of the corona electrode (4) must not touch the ground.

  • Page 109: Climbing Into And Out Of The Truck

    Operating Checks and tasks before daily use Depending on the tyres used, the truck is  fitted with one or more antistatic belts (3) and/or with a corona electrode (4). These components ensure that the truck cannot charge statically. – Do not use the truck if there is any damage or defects.
  • Page 110 Operating Checks and tasks before daily use WARNING Risk of injury when jumping out of the truck! If your clothing or jewellery (e.g. watch, ring etc.) be- comes stuck on a component while you are jumping into or out of the truck, this can lead to serious inju- ries (from falling, loss of fingers etc.).

  • Page 111: Safety Information Regarding Electrostatic Charge

    Operating Checks and tasks before daily use Safety information regarding elec- trostatic charge DANGER Risk of explosion due to static charge! – Always wear an antistatic protection suit when working in a potentially ex- plosive area. This seat is covered in electrically con- ductive material.

  • Page 112: Switching On The Battery Isolating Switch

    Operating Checks and tasks before daily use Switching on the battery isolating switch Push-and-turn version  – Turn the battery isolating switch (1) clock- wise until it unlocks. 6219_901-018 Turn version  – Turn the battery isolating switch (1) in a clockwise direction to the "ON"...
  • Page 113 Operating Checks and tasks before daily use To change the resistance for adjusting the dis-  play-operating unit, there are two socket head screws (2) on the support for the display-oper- ating unit. The hexagon socket wrench for emergency lowering can be used to loosen or tighten the socket head screws (2).

  • Page 114: Unlock The Emergency Off Switch

    Operating Checks and tasks before daily use Unlock the emergency off switch  – Turn the emergency off switch (1) clockwise until it pops out. Checking the emergency off func-  tion WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch disconnects the drives from the power supply.

  • Page 115: Operating The Signal Horn

    Operating Checks and tasks before daily use Operating the signal horn  The signal horn is used to warn people against imminent danger or to announce your intention to overtake. – Press the signal horn button (1). The signal horn sounds. 56378011526 EN - 03/2021 - 01...

  • Page 116: Using The Driver's Cab

    Operating Checks and tasks before daily use Operating the pneumatic signal  horn The signal horn is used to warn people against imminent danger or to announce your intention to overtake. Depending on the application and configura- tion, the truck is equipped with a pneumatic signal horn.

  • Page 117: Checking The Brake Oil Level

    Operating Checks and tasks before daily use 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 underneath the truck and being crushed if the truck tips over, a restraint system must be in place and must be used.
  • Page 118 Operating Checks and tasks before daily use – Lift the cover (1) and fold it up.  The brake oil level must be within the area (2) of the taper up to the neck. Do not top up the brake oil. –...
  • Page 119 Operating Checks and tasks before daily use 56378011526 EN - 03/2021 - 01...

  • Page 120: Checking The Brake System For Correct Function

    Operating Checks and tasks before daily use Checking the brake system for cor- rect function DANGER Risk of accident in the event of failure of the brake system! If the brake system fails, the truck will be insufficient- ly braked. –...
  • Page 121 Operating Checks and tasks before daily use – Accelerate the unladen truck in a clear area. – Press the brake pedal (1) firmly. The truck must decelerate noticeably. Checking the parking brake on a gradi- ent or a HGV ramp DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the...

  • Page 122: Warming Up The Hydraulic Oil At Cold Ambient Temperatures

    Operating Checks and tasks before daily use NOTE When the emergency off switch is actuated, note the following: The electric brake is disabled. The truck no ● longer responds to the command issued by the accelerator pedal. The power steering is no longer available. ●...

  • Page 123: Checking The Steering System For Correct Function

    Operating Checks and tasks before daily use – Actuate all hydraulic lifting functions several times. Limiting the load dynamics to load program 1  during the warm-up phase NOTE During the warm-up phase, the load dynamics are limited to load program 1. The adjacent symbol appears on the display until the warm- up phase is complete.

  • Page 124: Driver's Seat

    Operating Driver's seat Driver's seat Adjusting the driver's seat WARNING Risk of accident from sudden adjustment of the seat or of the seat backrest! The inadvertent adjustment of the seat or of the seat backrest can lead to uncontrolled movements by the driver.
  • Page 125 Operating Driver's seat Moving the driver's seat  – Raise the lever (1) and hold it in position. – Push the driver's seat into the required po- sition. – Release the lever. – Ensure that the driver's seat is securely en- gaged.
  • Page 126 Operating Driver's seat Adjusting the MSG 65/MSG 75 seat  suspension NOTE The MSG 65/MSG 75 driver's seat is designed for people weighing between 45 kg and 170 kg. The driver's seat can be adjusted to suit the weight of the individual driver. To ob- tain optimal settings for the seat suspension, the driver must perform the adjustment whilst sitting on the seat.
  • Page 127 Operating Driver's seat Adjusting the lumbar support (variant)  NOTE The lumbar support can be adjusted to suit the contours of the individual driver's spine. Ad- justing the lumbar support moves a convex support cushion into the upper or lower part of the backrest.

  • Page 128: Seat Belt

    DANGER Risk of injury if the 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. This risk of injury can be reduced through the combined use of the re- straint system and the seat belt.
  • Page 129 Operating Driver's seat Fastening the seat belt  DANGER Mortal danger when driving without wearing a seat belt! If the seat belt is not fastened and the truck tips over or crashes into an obstacle, the driver can be thrown out of the truck.
  • Page 130 Operating Driver's seat Special feature for trucks with a cab (variant) If the truck is equipped with a cab (variant), it will have a cab door sensor. If the seat belt is not fastened and the cab door is not closed, the driving speed is limited to 4 km/h.
  • Page 131 Operating Driver's seat Releasing the seat belt – Push the red button (4) on the buckle (1).  – Slowly guide the belt tongue back to the re- tractor by hand. NOTE Slowly allow the seat belt to retract. The auto- matic blocking mechanism may be triggered if the belt tongue strikes the housing.

  • Page 132: Adjusting The Armrest

    Operating Driver's seat Adjusting the armrest DANGER There is a risk of accident if the armrest lowers suddenly, causing the driver to move in an uncon- trolled manner. This may result in unintentional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion.

  • Page 133: Switching On

    Operating Switching on Switching on Switching on using the key switch WARNING All checks and tasks required before daily use must have been performed without any defects being iden- tified before switching on the truck. – Perform the "visual inspections and functional checks".

  • Page 134: Switching On Via Push Button (Variant)

    Operating Switching on – Refer to the chapter entitled "Display mes- sages". NOTE After connecting the battery, the correct charge state may not be displayed until the battery is placed under load by driving or lifting operations. Switching on via push button (var- iant) WARNING All checks and tasks required before daily use must...
  • Page 135 Operating Switching on – To switch off the truck, press the push but- ton (1) and hold for 1 second. NOTE For the variant with "Access authorisation with PIN code", see ● the relevant section. "FleetManager", see the "original operating ●...

  • Page 136: Display-Operating Unit

    Operating Display-operating unit Display-operating unit Operating the display-operating unit 08:20 7° 2,71 km/h 6219_003-310 The display-operating unit is operated using the control and enter keys (5...8) and the soft- keys (4, 10). The display (2) shows informa- tion about the current driving programme, load programme and the configuration of the fa- vourites bars (1, 3).

  • Page 137: Access Authorisation With Pin Code (Variant)

    Operating Display-operating unit Functions of the control and enter keys Designation Position Functions The softkeys correspond to the adjacent functions or input options. If functions have been stored in the favourites bars (1, 3), these functions can be switched on and off by pressing the Softkeys 4, 10 adjacent softkey.
  • Page 138 Operating Display-operating unit When the key switch is switched on, the  input menu ap- cess authorisation pears. All hydraulic functions and drive functions of the truck are blocked. In the StVZO (German Road Traffic Licensing Regulations) variant, the function of the hazard warning system (variant) is guaranteed.

  • Page 139: Access Authorisation For The Fleet Manager (Variant)

    Operating Display-operating unit – Press the softkey.  Service – Press the scroll keys until the  menu appears. Change PIN codes – Press the softkey. Change PIN codes Calibration – Follow the instructions on the display. Relieve hydraulics Shock sensor Change password (access auth.) Change PIN codes Fleet manager...
  • Page 140 Operating Display-operating unit date, the authorised service centre must set up a fleet manager password. Standard fleet manager password The standard fleet manager password is "1111". For safety reasons, this standard fleet manager password must be changed af- ter the first use. See also the section enti- tled "Changing the fleet manager pass- word".
  • Page 141 Operating Display-operating unit The display changes to the  Access au- menu. thorisation – Enter the fleet manager password using the softkeys. – To confirm, press the button. Enter password 6219_003-208_V3_en The message  Fleet manager access appears. authorisation granted –...
  • Page 142 Operating Display-operating unit – Press the softkey.  Service – Press the scroll buttons until the  Change password (access menu appears. auth.) – Press the Version list Change password (ac- softkey. cess auth.) – Follow the instructions on the display. Calibration Relieve hydraulics Shock sensor...

  • Page 143: Pre-Shift Check

    Operating Pre-Shift Check Pre-Shift Check Description of the Pre-Shift Check (variant) The Pre-Shift Check is a guided dialogue in the display-operating unit. It also helps the driver conduct the necessary "visual inspec- tions and function checking" before everyday use. After the truck has been switched on, the driver must answer questions about the condi- tion of the forklift truck with "...

  • Page 144: Process

    The main display contains the message complete Pre-Shift Check, press This means that the Pre-Shift Check is still ac- tive and the truck functions are restricted. – To acknowledge the message, press the 6219_003-265_en softkey.

  • Page 145: All Questions

    Operating Pre-Shift Check – Switch on and check the function to be tes- ted, e.g. lighting. – Press the back button to go back to the  Pre-Shift Check. – Answer the question based on the result of Pre-S the function check. The next question appears.
  • Page 146 Operating Pre-Shift Check Is the tyre pressure correct? Is the overhead guard visibly damaged? Is the entry area or footwell dirty or slippery? Are the windows clean and undamaged? Are the maintenance lids securely closed? Is the battery door/hood undamaged and securely closed? Is the battery lock present, undamaged and closed? Is the battery connection assembly dirty or damaged (e.g.

  • Page 147: Defining The Question Sequence

    Operating Pre-Shift Check Defining the question sequence The questions for the Pre-Shift Check can be defined in a random sequence or in a fixed se- quence. The random sequence is advisable, because the questions are then read more consciously by the driver. This means that there is no rou- tine aspect.

  • Page 148: Displaying The History

    Operating Pre-Shift Check The Pre-Shift Check menu appears.  – Press the "Question sequence" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en Pressing the softkey allows fixed or random  question sequences to be selected. The orange activation bar displays the current selection.
  • Page 149 Operating Pre-Shift Check – Press the softkey.  Service – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en 56378011526 EN - 03/2021 - 01...

  • Page 150: Defining The Shift Start

    Operating Pre-Shift Check The Pre-Shift Check menu appears.  – Press the "History" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en The Pre-Shift Check results display opens.  This display shows all checks and questions that have been answered with the date and Pre-Shift Check results time.
  • Page 151 Operating Pre-Shift Check – Activate the "Access authorisation for the fleet manager". – Press the softkey.  Service – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration...
  • Page 152 Operating Pre-Shift Check The Pre-Shift Check menu appears.  – Press the "Shift start" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en In this menu, you can call up the shift to be  defined and its start time. The orange activation bar indicates which shifts are activated.
  • Page 153 Operating Pre-Shift Check In this menu you can define the shift start.  – Enter the time using softkeys "0 to 9". – To , press the button. save Shift start 1 The shift start is now defined. The Pre-Shift Check is always requested from this shift start time.

  • Page 154: Resetting The Truck Restrictions

    Operating Pre-Shift Check – Press the scroll button to deactivate the  shift. – To confirm, press the button. Shift start 1 The time is shown in grey. The shift is deactivated. The display returns to the previous menu. There is no activation bar next to this shift.
  • Page 155 Operating Pre-Shift Check – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en The Pre-Shift Check menu appears.  –...
  • Page 156 Operating Pre-Shift Check A question pops up asking if you want to reset  the truck restrictions. – To confirm, press the softkey. The full scope of the truck functions is now available. The display returns to the previous Reset the truck restrictions? The entry remains in the history menu.

  • Page 157: Driver Profiles

    Operating Driver profiles Driver profiles Driver profiles (variant)  This variant allows up to ten individual driver profiles to be created. The driver is greeted with the selected name after logging in. Once the softkey is pressed, the main display is shown.
  • Page 158 Operating Driver profiles equipped with these variants, drivers must se- lect their profiles manually. NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is re- leased prematurely, the settings menu will close.

  • Page 159: Creating Driver Profiles

    Operating Driver profiles The orange activation bar displays the current  selection. – Press the softkey for the required driver profile. Guido The driver profile is active. The driver is gree- ted with the selected name the next time that Horst the truck is switched on.
  • Page 160 Operating Driver profiles – Press the soft-  Driver profiles Driver profiles Truck information Display settings Configure favourites Truck settings 6219_003-293_en This menu provides storage space for saving  ten driver profiles. – Press the softkey for the required storage location.

  • Page 161: Renaming Driver Profiles

    Operating Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name The driver profile is active. The driver is gree- ted with the selected name after the next log- Any changes that drivers make to the settings Enter driver name while they are logged in are saved.
  • Page 162 Operating Driver profiles – Press the  Rename driver profiles softkey. Driving programme Rename driver profiles 6219_003-298_en menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Renaming by the fleet manager –...
  • Page 163 Operating Driver profiles – Press the  Manage driver profiles softkey. Lift height preselection Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Fleet manager 6219_003-296_en – Press the  Rename driver profiles softkey. Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en 56378011526 EN - 03/2021 - 01...

  • Page 164: Deleting Driver Profiles

    Operating Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Enter driver name Horst = Clear = abc -> ABC = Save = Cancel 6219_003-295_en Deleting driver profiles The fleet manager has access authorisation to...
  • Page 165 Operating Driver profiles – Press the  Delete driver profiles softkey. Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en – Press the softkey for the driver profile to be  deleted. The driver profile is deleted. Guido Horst Lisa Driver 4 Available storage position 5 6219_003-294_en...

  • Page 166: Lighting

    – To access this sub-menu, push the but- Symbols for the lighting and their meanings Parking light Headlights Hazard warning system Rotating beacon STILL SafetyLight Warning zone light Front working spotlights Rear working spotlights Roof working spotlights Only the symbols of the lighting devices that are installed in the truck can be selected.

  • Page 167: Driving Lights

    Operating Lighting Driving lights  – To switch on the parking light (1), push the associated Softkey on the display-operating unit. The front side lights and the tail lights light up. – To switch on the driving light (2), press the associated Softkey on the display-operating unit.

  • Page 168: Working Spotlights

    Operating Lighting Working spotlights Front and rear working spotlights  – To switch on the front working spot- lights (3), push the associated Softkey on the display-operating unit. The front working spotlights light up. – To switch off the front working spot- lights (3), push the Softkey again.

  • Page 169: Working Spotlight For Reverse Travel (Variant)

    Operating Lighting Working spotlight for reverse travel (variant) In this equipment variant, a working spotlight for reverse travel is fitted on the rear of the overhead guard and provides optimum illumi- nation of the roadway during reverse travel. – Press the softkey.
  • Page 170 Operating Lighting – To switch on the left or right turn indicator,  move the lever (1) to the desired direction. 6219_003-098 The turn indicators and the turn indicator dis-  play (2) or (3) on the display-operating unit flash. 08:20 –...

  • Page 171: Hazard Warning System

    Operating Lighting Hazard warning system  Switching the hazard warning system on and off is different for trucks with and without the StVZO (German Road Traffic Licensing Regu- lations) variant. – To switch on the hazard warning system, push the associated Softkey on the display- operating unit.

  • Page 172: Rotating Beacon

    Operating Lighting The turn indicators and the turn indicator dis-  plays (2, 3) on the display-operating unit flash. 08:20 – To switch off the hazard warning system, push the hazard warning button (1) again. All direction indicators and the turn indicator 7°...

  • Page 173: 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 junc- tions.

  • Page 174: Warning Zone Light (Variant)

    Operating Lighting Warning zone light (variant)  WARNING Danger of damage to eyes from looking into the warning zone light. Do not look into the warning zone light. Adjust the warning zone light so as not to dazzle bystanders or the driver when climbing in and out of the truck.

  • Page 175: Efficiency And Drive Modes

    Therefore, on distances of up to ap- prox. 40 m, lower speeds are reached than would be the case if the efficiency mode was not activated. As in "STILL Classic" mode, the maximum speed is 20 km/h. has no influence on: Maximum speed ●...
  • Page 176 Operating Efficiency and drive modes Shut-off Seat switch Truck is stationary Drive direction Screen heating *No shut-off for StVZO (German Road Traffic Licensing Regulations) equipment (variant) 56378011526 EN - 03/2021 - 01...

  • Page 177: Switching Blue-Q On And Off

    Operating Efficiency and drive modes Switching Blue-Q on and off – To switch on Blue-Q efficiency mode, push the softkey The Blue-Q symbol appears on the dis- play/operating unit and Blue-Q efficiency mode is switched on. – To switch off Blue-Q efficiency mode, push the associated softkey again.

  • Page 178: Configuring Blue-Q

    The orange activation bar appears next to the pushed softkey. The main display button takes you to the main display. STILL Classic and sprint mode  The drive modes affect the handling of the truck. Two different drive modes are available:...
  • Page 179 The symbol disappears and the mode is switched off. The truck is then back in STILL Classic mode. Automatic switch off for sprint mode If the truck is operated in sprint mode at the maximum performance level, the truck will consume more energy.

  • Page 180: Driving

    Operating Driving Driving 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 181 There is a risk of acci- dent! – Do not use devices during travel or when handling 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 per- mitted.

  • Page 182: Roadways

    Operating Driving Roadways Dimensions of roadways and aisle widths The following dimensions and aisle width re- quirements apply under the specified condi- tions to ensure safe manoeuvring. In each case, it must be checked whether a larger aisle width is necessary, e.g. in the case of dif- ferent load dimensions.
  • Page 183 Operating Driving Driving on ascending and descending gradients WARNING Risk of accident due to the drive unit switching off! Driving up and down longer gradients can cause the drive unit to overheat and switch off. The truck will then no longer decelerate when the accelerator ped- al is released and will coast.
  • Page 184 Operating Driving Warning in the event that components protrude beyond the truck contour Trucks are often required to drive through very narrow or very low spaces such as aisles or containers. The dimensions of the trucks are designed for this purpose. However, movable components may protrude beyond the truck contour and be damaged or torn off.

  • Page 185: Selecting Drive Programmes 1 To 3

    Operating Driving Hazardous areas Hazardous areas on roadways must be indica- ted by standard traffic signs or, if necessary, by additional warning signs. Selecting drive programmes 1 to 3  The truck has three drive programmes with different preset driving and braking character- istics.

  • Page 186: Configuring Drive Programmes A And B

    Operating Driving Selecting drive programme A or B  The truck has two driving programmes for per- sonalised handling and braking characteris- tics. Unlike the fixed drive programmes "1 to 3", the programs "A" and "B" can be configured. The procedure for this is described in the following section.
  • Page 187 Operating Driving – Press the associated softkey for drive programme A drive programme Configuring the drive programs using the "drive programme A" is explained here. The menu  Set drive programme A appears. The following parameters can be set: ● max.

  • Page 188: Selecting The Drive Direction

    Operating Driving Selecting the drive direction  The drive direction of the truck must be selec- ted using the drive direction switch/drive direc- tion selection lever before attempting to drive. The method of actuating the drive direction switch/drive direction selection lever depends on the operating devices that are fitted in the truck.

  • Page 189: Actuating The Drive Direction Switch With The Multiple-Lever Version

    Operating Driving Actuating the drive direction switch  with the multiple-lever version – For the "forwards" drive direction, push the drive direction switch (1) downwards. – For the "backwards" drive direction, push the drive direction switch (1) upwards. NOTE If the drive direction switch (1) is defective and the truck stops in a danger area, the drive di- rection selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 190: Actuating The Vertical Rocker Button For The "Drive Direction", Joystick 4Plus Version

    Operating Driving Actuating the drive direction switch  with the Fingertip version – For the "forwards" drive direction, push the drive direction switch (1) forwards. – For the "backwards" drive direction, pull the drive direction switch (1) backwards. NOTE If the drive direction switch (1) is defective and the truck stops in a danger area, the drive di- rection selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 191: Indicator Module Version

    Operating Driving Actuating the drive direction selec-  tion lever with the travel direction selector and indicator module ver- sion – For the "forwards" drive direction, push the drive direction selection lever (1) forwards. – For the "backwards" drive direction, push the drive direction selection lever (1) back- wards.
  • Page 192 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● – Press the accelerator pedal (3).

  • Page 193: Starting Drive Mode, Dual Pedal Version (Variant)

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.
  • Page 194 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● The truck travels in the selected drive direc- tion.

  • Page 195: Operating The Service Brake

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.

  • Page 196: Actuating The Electric Parking Brake

    Operating Driving DANGER There is a risk of accident if the service brake fails! If the regenerative braking effect noticeably deterio- rates, a component failure may have occurred. It will no longer be possible to sufficiently brake the truck. – When braking with the service brake, it may be necessary to use the parking brake to assist the braking process.
  • Page 197 Operating Driving Despite these automatic aids, the driver is al- ways responsible for parking the truck safely. The safety information about parking the truck safely applies. NOTE The electric parking brake can be actuated or released only if the battery male connector has been connected and the truck is switched If the parking brake is applied, this is indicated by a symbol in the display-operating unit in-...
  • Page 198 Operating Driving The driving speed display is replaced by the symbol Automatic actuation of the electric park- ing brake when the truck is stationary The electric parking brake is applied automati- cally when the truck is stationary in the follow- ing situations: Automatically triggered actuation when the truck is stationary Cause...
  • Page 199 Operating Driving Actuation of the electric parking brake  when the truck is in motion Manual actuation when the truck is in motion – Press the push button (1). The truck is braked with the drive unit in ac- cordance with the selected drive programme. Once the truck has come to a standstill, the electric parking brake is applied with an audi- ble sound.

  • Page 200: Malfunctions In The Electric Parking Brake

    Operating Driving Cause Effect The truck will coast to a stop. Once the truck has come to a standstill, the electric parking brake is applied with an audible The emergency off switch is actuated. sound. The LED (2) lights up with a steady light. The symbol appears in the display.
  • Page 201 A possible cause of the malfunction is that the parking brake cannot determine whether the 6219_003-006_V2 truck is stationary or still in motion. The follow- ing section describes how to actuate the park- ing brake when it is faulty: Actuating a faulty parking brake when the...
  • Page 202 Operating Driving The parking brake is applied. NOTE The truck brakes more strongly if the push button (1) is pressed and held down for longer or pressed several times. "Safe parking" function This function monitors the braking effect after the truck is parked. If a sensor is fitted on the lift mast (variant), it also checks whether the fork carriage is lowered.
  • Page 203 Operating Driving DANGER Risk of fatal injury from being run over if the truck rolls away! Park the truck securely if the parking brake is faulty. Secure the industrial truck to prevent it from rolling away. – To do this, strictly adhere to the following instruc- tions: –...
  • Page 204 Operating Driving NOTE If the parking brake is released via the emer- gency actuation mechanism, it is possible to drive the truck at a low speed. The truck can be moved out of the hazard- ● ous situation or to the repair location. Driving with a faulty parking brake requires ●...

  • Page 205: Steering

    Operating Driving Steering  DANGER Risk of accident! If the hydraulics fail, there is a risk of accident as the steering characteristics will have changed. – Do not operate the truck if it has a defective steer- ing system. – Steer the truck by turning the steering wheel (1) accordingly.

  • Page 206: 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 characteris- tics of the truck.

  • Page 207: Speed Reduction When The Fork Carriage Is Raised (Variant)

    Operating Driving Speed reduction when the fork car- riage is raised (variant) If the truck is equipped with this variant, the driving speed is automatically reduced to 5 km/h (forwards and backwards) from a lift height of more than 500 mm. If the fork carriage is lowered below this lift height again, the driving speed limitation is de- activated.

  • Page 208: Speed Limitation (Variant)

    Operating Driving NOTE There is a variant that prevents the truck from being driven when the cab door is open. The message Close cab door appears in the display. Speed limitation (variant)  The speed limitation (variant) is a function that can be configured by the fleet manager.
  • Page 209 Operating Driving – Activate the "Access authorisation for the fleet manager". The "Settings menu" opens on the display. – Press the softkey Truck settings – Press the softkey. Speed limitation The menu that opens offers the following func- tions: ● Permanent Enabling this function limits the speed until the fleet manager disables this function.

  • Page 210: Cruise Control (Variant)

    Operating Driving Cruise control (variant)  The "cruise control" assistance function allows the driver to maintain a constant truck speed over a reasonable distance. In addition, the cruise control function can be used to comply with any speed restriction that is in force on the company's premises.
  • Page 211 Operating Driving – Press the "cruise control" softkey.  The orange-coloured activation bar next to the 08:20 "cruise control" softkey lights up. The cruise control function is ready. The greyed-out "cruise control" symbol (1) appears on the display. Taking the cruise control function off standby Pressing the "cruise control "...
  • Page 212 Operating Driving – Actuate the drive direction switch (2) for for-  wards travel. NOTE In the dual-pedal version (variant), the drive direction switch (2) is used exclusively to acti- vate and deactivate the cruise control function (variant). 56378011526 EN - 03/2021 - 01...
  • Page 213 Operating Driving The cruise control function is active. The cur-  rent speed is saved. 08:20 Two beeps signal that the cruise control func- tion is active. The symbol (4) appears in black in the display. – Take your foot off the accelerator pedal. The truck continues to drive at the selected speed until the cruise control function is deac- tivated.
  • Page 214 Operating Driving Other conditions that will cause the truck con- trol unit to deactivate the cruise control func- tion are: Vacating the driver's seat ● Truck speed less than 2.5 km/h. ● Speed limit set to less than 4.5 km/h. ●...

  • Page 215: Parking

    Operating Parking Parking Parking the truck securely and switching it off DANGER There is a risk of fatal injury from being run over if the truck rolls away. – Do not park the truck on a gradient. – In emergencies, secure the truck us- ing wedges on the side facing down- hill.
  • Page 216 Operating Parking – Lower the fork carriage to the ground.  – Tilt the lift mast forwards until the tips of the fork arms rest on the ground. – If attachments (variant) are fitted, retract the working cylinders; see the chapter entitled "General instructions for controlling attach- ments".
  • Page 217 Operating Parking – In the "push button ignition" variant, press  the button. (1) Depending on the truck version: – Push the battery isolating switch (1).  6219_901-018 56378011526 EN - 03/2021 - 01...

  • Page 218: Wheel Chock (Variant)

    Operating Parking – Turn the battery isolation switch (1) anti-  clockwise up to the stop and into the "OFF" position. NOTE Switch keys, FleetManager cards (variant), FleetManager transponder chips (variant) and the PIN code for access authorisation (variant) must not be handed over to other persons un- less explicit instructions to this effect have been given by the responsible fleet manager.

  • Page 219: Lifting

    Operating Lifting Lifting Lifting system variants The movement of the fork carriage and the lift mast heavily depends on the following equip- ment: The lift mast with which the truck is equip- ● ped, see C hapter "Lift mast versions", ⇒ ...

  • Page 220: Operating Devices For The Lifting System

    Operating Lifting NiHo 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 maximum height (2). NOTE When lifting above the free lift, the fork car- riage always remains at the upper edge of the extending lift mast.
  • Page 221 Operating Lifting Fingertip ● Joystick 4Plus ● For clarity, the movements of the lifting system  are referred to by the letters (A, B, C, D) in this subchapter. Lower the fork carriage Lift the fork carriage Tilting the lift mast forwards Tilting the lift mast backwards –...

  • Page 222: Controlling The Lifting System Using Multi-Lever Operation

    Operating Lifting Controlling the lifting system using  multi-lever operation DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 223 Operating Lifting Tilting the lift mast To tilt the lift mast forwards: – Move the "tilting" operating lever (2) in the direction of the arrow (C). To tilt the lift mast backwards: – Move the "tilting" operating lever (2) in the direction of the arrow (D).

  • Page 224: Controlling The Lifting System Using A Double Mini-Lever

    Operating 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 equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 225 Operating Lifting – Move the "lift mast" 360° lever (3) in the di- rection of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the di- rection of the arrow (C). To tilt the lift mast backwards: –...

  • Page 226: Controlling The Lifting System Using A Triple Mini-Lever

    Operating 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 equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 227 Operating Lifting – Move the "lift mast" 360° lever (3) in the di- rection of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the di- rection of the arrow (C). To tilt the lift mast backwards: –...

  • Page 228: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operating 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 equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 229 Operating Lifting – Move the "lifting/lowering" operating lev- er (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" operating lever (4) in the direction of the arrow (C). To tilt the lift mast backwards: –...
  • Page 230 Operating Lifting Controlling the lifting system using  the Fingertip DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...

  • Page 231: Controlling The Lifting System Using The Joystick 4Plus

    Operating Lifting Tilting the lift mast To tilt the lift mast forwards: – Move the "tilting" operating lever (1) in the direction of the arrow (C). To tilt the lift mast backwards: – Move the "tilting" operating lever (1) in the direction of the arrow (D).
  • Page 232 Operating Lifting the pictograms for the hydraulic functions are located in positions (2) and (4). The pictograms are arranged according to the directions of movement of the Joy- stick 4Plus (1) and the horizontal rocker but- ton (3). Lifting/lowering the fork carriage ...

  • Page 233: Dynamics Of The Hydraulic Movements

    Operating Lifting Fork carriage sideshift  To move the fork carriage to the left: – Push the Joystick 4Plus (1) to the left (E). To move the fork carriage to the right: – Push the Joystick 4Plus (1) to the right (F). Movements of the lifting system and meanings of the pictograms Lowering...

  • Page 234: Selecting Load Programs 1 To 3

    When the operating device is released, the ● hydraulic movement decelerates very quick- The fork carriage quickly comes to a stand- still. Minimum dynamics The hydraulic movement accelerates very ● slowly when actuating the operating device.

  • Page 235: Fork Wear Protection (Variant)

    Operating Lifting – If the load programs are saved as a favour-  ite on a softkey, press the softkey until the number of the desired load program is shown on the display. The number of dynamic bar segments shows the load dynamics of the selected load pro- gram.

  • Page 236: Changing The Fork Arms

    Operating Lifting protection must be continually adjusted as the wear on the front tyres increases. – Contact the authorised service centre on this matter. Changing the fork arms DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere.
  • Page 237 Operating Lifting WARNING If the fork arms fall on your legs, feet or knees during replacement, there is a risk of injury due to their weight. The space to the left and right of the fork is a danger area. –...
  • Page 238 Operating Lifting Removing  – Select the pallet according to the size of the fork arms. – Position the pallet to the left or right of the fork carriage. – Raise the fork carriage until the lower edges of the fork arms are approx. 3 cm higher than the height of the pallet.

  • Page 239: Fork Extension (Variant)

    Operating Lifting Fork extension (variant) DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! – Do not perform any work on trucks in potentially explosive areas.
  • Page 240 Operating Lifting WARNING There is a risk of tipping! The weight and dimensions of the fork extension af- fect the stability of the truck. The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance. If the truck is equipped with a fork extension ex works, then the capacity rating plate will already have been adjusted accordingly.

  • Page 241: Operation With Reversible Fork Arms (Variant)

    Operating Lifting – Insert the securing bolt located behind the fork back fully into the fork extension. – Insert the linch pin into the securing bolt and secure. Detaching – Remove the linch pin (3) from the securing bolt (2). –...
  • Page 242 Operating Lifting DANGER Risk of explosion! Only reversible fork arms that comply with explosion-protection regulations may be used in potentially explosive areas. These fork arms are specially coated to prevent sparks forming when coming in- to contact with the load or floor. –...

  • Page 243: Malfunctions During Lifting Mode

    Operating Lifting Reversible fork arms (1) can be used to reach  an additional lift height. The reversible fork arms are attached to the fork carriage in the same manner as standard fork arms. Loads may be lifted on and beneath the reversible fork arms.

  • Page 244: Hydraulic Blocking Function

    Operating Lifting – Notify your service centre 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 ●...
  • Page 245 Operating Lifting NOTE Only the emergency steering function remains available. 56378011526 EN - 03/2021 - 01...

  • Page 246: Handling Loads

    Operating 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 247: Before Picking Up A Load

    Operating Handling loads Before picking up a load Load capacity  The load capacity indicated for the truck on the capacity rating plate must not be excee- ded. The load capacity is influenced by the load centre of gravity and the lift height as well as by the tyres, if applicable.

  • Page 248: Picking Up Loads

    Operating 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) 5230 mm WARNING Risk of accident from the truck losing stability! The permissible loading of the attachments (variant) and the reduced load capacity of the combination of truck and attachment must not be exceeded.

  • Page 249: Danger Area

    Operating Handling loads DANGER Risk of accident from a falling load! When transporting small items, attach a load safety guard (variant) to prevent the load from falling on the driver. A closed roof covering (variant) should also be used. Removable roof panels may not be removed. Adjusting the fork ...

  • Page 250: Transporting Pallets

    Operating Handling loads DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position. If persons fail to leave the danger area despite warnings: –...

  • Page 251: Transporting Suspended Loads

    Operating Handling loads Transporting suspended loads  Before transporting suspended loads, consult the national regulatory authorities (in Germa- ny, the employer's liability insurance associa- tions). National regulations may place restrictions on these operations. Contact the relevant authori- ties. DANGER Suspended loads that begin to swing can result in the following risks: Impaired braking characteristics and steer- ●...

  • Page 252: Transporting Swinging Loads

    Operating Handling loads DANGER Risk of accident! When transporting suspended loads, never perform or end driving and load movements abruptly. Never drive on slopes with a suspended load. Transporting containers holding fluids as hanging loads is not permitted. Transporting swinging loads DANGER Risk of explosion from spark discharge! Suspended loads can swing uncontrolla-...
  • Page 253 Operating Handling loads – Approach the rack carefully, brake gently  and stop just in front of the rack. – Position the forks.  – Set the lift mast to vertical. – Lift the fork carriage to the stacking height. CAUTION Risk of component damage! When the fork is inserted into the rack, take care not...
  • Page 254 Operating Handling loads – Insert the fork as far under the load as pos-  sible. Stop the truck as soon as the fork back is resting on the load. The load centre of gravity must be midway between the fork arms.
  • Page 255 Operating Handling loads – Lower the load while maintaining ground  clearance. – Tilt the lift mast backwards.  The load can be transported. 56378011526 EN - 03/2021 - 01...

  • Page 256: Transporting Loads

    Operating 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 be- comes. The truck can tip over. The load can fall. There is an increased risk of accidents.

  • Page 257: Shake Function (Variant)

    Operating Handling loads – Never drive with a load protruding to the  side (e.g. with the sideshift)! Shake function (variant) NOTE The shake function is intended only for short- term use, as it reduces the service life of the load chains due to the increased loading on them.
  • Page 258 Operating Handling loads Operation To activate the shake function: – Move the corresponding operating device for the "Lifting" function over the zero posi- tion four times in quick succession. The fork carriage moves as normal. The shake function is active after the fourth time the operating device is moved.
  • Page 259 Operating Handling loads Joystick 4Plus:  – Move the Joystick 4Plus (1) back and forth between positions (A) and (B) four times. Then continue to move the component in the same way. 6210_003-089 Double mini-lever:  – Move the 360° lever (2) back and forth be- tween positions (A) and (B) four times.
  • Page 260 Operating Handling loads Triple mini-lever:  – Move the 360° lever (3) back and forth be- tween positions (A) and (B) four times. Then continue to move the component in the same way. Quadruple mini-lever:  – Move the operating lever (4) back and forth between positions (A) and (B) four times.

  • Page 261: Setting Down A Load

    Operating Handling loads Setting down a load 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. The truck may tip forwards.

  • Page 262: Driving On Ascending And Descending Gradients

    Operating Handling loads – Lower the load until it rests securely on the  rack. DANGER Risk of accident! – Beware of any people in the danger area. – Ensure that the roadway behind you is clear. – Move the truck back until the fork arms can be lowered without touching the stack.

  • Page 263: Driving On Lifts

    Operating Handling loads – Reduce the driving speed on descending gradients. It is not permitted to drive on long ascending and descending gradients greater than 15% due to the specified minimum braking and sta- bility values. – Before driving on ascending and descend- ing gradients greater than 15%, consult the authorised service centre.
  • Page 264 Operating Handling loads Determining the total actual weight  – Park the truck safely and switch it off. – Determine the unit weights by reading the truck nameplate and, if necessary, the at- tachment (variant) nameplate and/or by weighing the load to be lifted. –...

  • Page 265: Driving On Loading Bridges

    Operating Handling loads Driving on loading bridges  DANGER Risk of accident from the truck falling! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge. This may cause the truck to crash. The lorry driver and the forklift truck driver must agree on the departure time of the lorry.

  • Page 266: Tilt Angle-Dependent Assistance Systems

    Operating Tilt angle-dependent assistance systems Tilt angle-dependent assistance systems Mast tilt angle display  Knowing the actual tilt angle of the lift mast makes it easier to place loads into stock and remove loads from stock. If the truck is equip- ped with the "mast tilt angle display"...
  • Page 267 Operating Tilt angle-dependent assistance systems increasing work safety. Automatic mast verti- cal positioning reduces wear on various com- ponents, thereby reducing repair costs. The "automatic mast vertical positioning" as- sistance system consists of the following indi- vidual functions: Display of the "Automatic mast vertical posi- ●...

  • Page 268: Function Checking Of The Automatic Mast Vertical Positioning Function (Variant)

    Operating Tilt angle-dependent assistance systems – See the section entitled "Calibrating the au- tomatic mast vertical positioning". Function checking of the automatic mast vertical positioning function (variant) CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! –...
  • Page 269 Operating Tilt angle-dependent assistance systems NOTE The wizard requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is released prematurely, the settings menu will close.
  • Page 270 Operating Tilt angle-dependent assistance systems – Press the softkey.  Service – Press the scroll keys until the  Cal- menu appears. ibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en 56378011526 EN - 03/2021 - 01...
  • Page 271 Operating Tilt angle-dependent assistance systems – Press the softkey.  Lift mast tilting The wizard for calibrating the load measure- ment is started. Lift mast tilting – Follow the instructions on the display. – If the message Calibration Load measurement appears, press the softkey.

  • Page 272: Load-Dependant Assistance Systems

    Operating Load-dependant assistance systems Load-dependant assistance systems Overload detection (variant) WARNING Risk of accident as a result of exceeding the permis- sible load capacity! This assistance system does not replace the driver's duty to observe the load capacity specified on the nameplate.

  • Page 273: Dynamic Load Control 1

    Operating Load-dependant assistance systems Dynamic Load Control 1 WARNING Risk of accident as a result of overloading! Dynamic Load Control 1 is not a safety function and does not release the driver from the duty to observe the information specified in the load capacity dia- gram! WARNING Risk of accident due to the slow response of the lift-...

  • Page 274: Dynamic Load Control 2

    Operating Load-dependant assistance systems NOTE When the fork carriage has been lowered be- low the lift heights mentioned above, the driver can deactivate the speed limitation again. Re- lease the accelerator pedal for a short period to do this. If a sensor belonging to Dynamic Load Con- trol 1 fails, the level of intervention from the function is increased to a maximum.
  • Page 275 Operating Load-dependant assistance systems The fork carriage is at least 2.1 m off the ground. With a triple lift mast or NiHo lift mast: ● The fork carriage is in the second lifting stage The truck centre of gravity has shifted to an ●...

  • Page 276: Load Measurement (Variant)

    Operating Load-dependant assistance systems When the combination of load weight and load centre of gravity exceeds the speci- fied value, the display moves into the red area. The dynamics of the lifting movements and tilting movements are significantly re- duced. –...

  • Page 277: Calibrating The Load Measurement

    Operating Load-dependant assistance systems WARNING Risk of accident as a result of exceeding the residual load capacity. If the weight determined by a load measurement ex- ceeds the permissible residual load capacity of the truck, the truck cannot be operated safely. –...
  • Page 278 Operating Load-dependant assistance systems – Apply the parking brake. – Press the button. – Press the "Settings" Softkey – Activate the "Access authorisation for the fleet manager". – Press the softkey.  Service – Press the scroll keys until the ...

  • Page 279: Precision Load Measurement (Variant)

    Operating Load-dependant assistance systems – Press the softkey.  Load measurement The wizard for calibrating the load measure- ment is started. Lift mast tilting – Follow the instructions on the display. – If the message Calibration Load measurement appears, press the softkey.
  • Page 280 Operating Load-dependant assistance systems – Press the "Precision load measure-  ment" (1) softkey. 0,70 --,-- 0,0° 6219_003-222 prompt is  Lower fork slightly displayed. – Lower the fork carriage. NOTE 0,70 Lower Slowly lowering the fork carriage increases the 0,0°...

  • Page 281: Tare Function

    Operating Load-dependant assistance systems If the calculation was successful, the meas-  ured weight of the load (1) is displayed. NOTE If the tare function was not active, the full 0,70 weight of the load being picked up is dis- 1,32 played.
  • Page 282 Operating Load-dependant assistance systems – Press the "Tare" softkey (1).  The activation bar next to the "Tare" sym- lights up. 0,70 --,-- 0,0° 6219_003-225 prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The message Zero- is displayed.

  • Page 283: Total Load (Variant)

    Operating Load-dependant assistance systems Total load (variant)  Use the "total load" variant to calculate the to- tal weight of multiple loads. The "total load" is an additional function of the "load measure- ment". It records the individual loads and stores up to three total loads.
  • Page 284 Operating Load-dependant assistance systems The first menu level appears. – Press the "Load" softkey – Press the "Total load" softkey The "Total load" menu appears. A total of  three load totals can be saved. The total load is explained here using 0,00 –...
  • Page 285 Operating Load-dependant assistance systems prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The Calc. ongo- message appears. 0,70 Lower If the calculation was successful, the load is 0,0° fork slightly displayed. Adding a load –...

  • Page 286: Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Depressurising the hydraulic system Need to depressurise the hydraulic system To enable additional hydraulic functions other  than the basic functions to be used, the truck has plug connectors (1) on the lift mast. Clamping and non-clamping attachments can be connected to these plug connectors.

  • Page 287: Wizard For Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Wizard for depressurising the hy- draulic system The hydraulics are depressurised using a wiz- ard on the display-operating unit. If this function is required for daily operation, contact your authorised service centre. The authorised service centre can enable the func- tion for the driver.
  • Page 288 Operating Depressurising the hydraulic system – Press the scroll keys until the  menu appears. lieve hydraulics – Push the soft- Relieve hydraulics key. The following message appears:  Caution, the lift mast may move! – To confirm, push the softkey.

  • Page 289: Depressurising The Hydraulic System Using Multi-Lever Operation

    Operating Depressurising the hydraulic system The following message appears:  Disengage all hydraulic axles, then switch off the truck – Depressurise the hydraulics; see the corre- sponding section. WARNING The movements of the load lift system present a risk of crushing. During the depressurisation process, the fork car- riage or the lift mast can move slightly.

  • Page 290: 6Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 291: Depressurising The Hydraulic System Using A Double Mini-Lever

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th and 6th hydraulic function" If the truck has a "5th and 6th hydraulic func- tion", their hydraulic circuits must also be dep- ressurised. The procedure is similar to the de- pressurisation of the hydraulic circuits for the basic functions and the additional functions.

  • Page 292: Depressurising The Hydraulic System Using The Double Mini-Lever And The 5Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 293: Depressurising The Hydraulic System Using A Triple Mini-Lever

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 294: Depressurising The Hydraulic System Using The Triple Mini-Lever And The 5Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 295: Depressurising The Hydraulic System Using A Quadruple Mini-Lever

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 296: 5Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 297: Depressurising The Hydraulic System Using The Fingertip

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 298: Depressurising The Hydraulic System Using The Fingertip And The 5Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 299: Depressurising The Hydraulic System Using The Joystick 4Plus

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  1 2 3 the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 300: Depressurising The Hydraulic System Using The Joystick 4Plus And The 5Th Function

    Operating Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 301: Special Feature For Clamping Attachments

    Operating Depressurising the hydraulic system – Start the "wizard for depressurising the hy- draulic system". Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised.

  • Page 302: Exiting The Wizard

    Operating Depressurising the hydraulic system Push the operating device once in the ● "Open" direction. Push the operating device once in the ● "Close" direction. – Observe the section entitled "Clamp locking mechanism (variant)" in the chapter entitled "Attachments". Exiting the wizard –...

  • Page 303: Attachments

    If the truck is equipped with an integrated at- tachment (variant) at the factory, the specifica- tions in the STILL operating instructions for in- tegrated attachments must be observed. If attachments are fitted at the place of use,...
  • Page 304 Operating Attachments used, such as mirrors, a camera, a monitor system etc. – Observe the following warning notices. DANGER Risk of fatal injury from falling load! If attachments that hold the load by clamping it or ex- erting pressure on it do not have a second method of operating the function (lock), the load can work loose and fall off.
  • Page 305 Operating Attachments Alternating operation using an electrical switch valve If non-integrated attachments for alternating operation are used in conjunction with an elec- trical switch valve for the 5th and 6th hydraulic function, the electrical switch valve must oper- ate at 12 V. –...
  • Page 306 Operating Attachments specifications of the manufacturer and suppli- er of the attachment. – Observe the residual load capacity rating plate; see the chapter entitled "Picking up a load using attachments". 56378011526 EN - 03/2021 - 01...

  • Page 307: General Instructions For Controlling Attachments

    Operating Attachments General instructions for controlling attachments Attachments can be controlled via the first four hydraulic functions but also as a variant via the 5th or 6th function. The 5th or 6th function is activated via a button on the operating de- vice and by moving the operating device or additional push buttons.

  • Page 308: Attachment Example For The Connection Of The Auxiliary Hydraulics

    Operating Attachments WARNING Use of attachments can give rise to additional haz- ards such as a change in the centre of gravity, addi- tional danger areas etc. Attachments must only be deployed for their inten- ded use as described in the relevant operating in- structions.
  • Page 309 Operating Attachments In the menu for the available hydraulic axles for attachments, the designation Hydraulic specifies the connection of the corre- axle sponding auxiliary hydraulics. See also the section entitled "Adjusting the hydraulic speed for attachments" in this chapter. Attachment example for an attachment for ad- ...
  • Page 310 Operating Attachments NOTE The adjustment procedure requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is ap- plied. If the parking brake is released prema- turely, the settings menu will close.
  • Page 311 Operating Attachments This menu indicates the supply flow.  The return flow is shown in a lighter colour. The currently set speed of the hydraulic ● Auxiliary hydraulics 2 pump is given in The currently set supply flow rate is given in ●...

  • Page 312: Clamp Locking Mechanism (Variant)

    Operating Attachments The return flow is displayed in addition to the  supply flow at full brightness. To adjust the speed, push the "Plus" "Minus" softkey. Auxiliary hydraulics 2 – To save the setting, press the "Confirm" softkey. Forwards 3 900 1/min The settings are saved.
  • Page 313 Operating Attachments – See the section concerning the relevant op- erating device. 56378011526 EN - 03/2021 - 01...

  • Page 314: Controlling Attachments Using Multi-Lever Operation

    Operating Attachments Controlling attachments using multi-  lever operation In this version, the attachments (variant) are controlled using the operating levers (1, 3). The pictograms for the hydraulic func- tions (2, 4) are affixed to the operating levers. – Observe the pictograms (2) or (4). The pictograms are arranged according to the directions of movement of the operating lev- er (1) or (3).
  • Page 315 Operating Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism NOTE For technical reasons, no clamp locking mech-...

  • Page 316: Controlling Attachments Using Multi-Lever Operation And The 5Th And 6Th Function

    Operating Attachments Controlling attachments using multi-  lever operation and the 5th and 6th function The function keys for the "5th and 6th func- tion" (1, 2) and the operating levers (3, 4) are used to control the "5th function" or the "6th function".
  • Page 317 Operating Attachments – Note the following attachment functions and pictograms. Picto- Attachment function gram Move the side shift frame or fork for- wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Push off the load...

  • Page 318: Controlling Attachments Using A Double Mini-Lever

    Operating Attachments Controlling attachments using a  double mini-lever In this version, the attachments (variant) are controlled using the "attachments" cross lev- er (1). The adhesive label bearing the picto- grams for the hydraulic functions (2) is affixed at the designated point. –...
  • Page 319 Operating Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism ...

  • Page 320: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operating Attachments Controlling attachments using the  double mini-lever and the 5th func- tion NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (3) and the cross lever (1) are used to control the "5th function".
  • Page 321 Operating Attachments Example using the pictograms for configura-  tion (1): If the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork is exten- ded. If the function key for the "5th function" (3) is actuated and the "attachments"...

  • Page 322: Controlling Attachments Using A Triple Mini-Lever

    Operating Attachments Controlling attachments using a tri-  ple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 323 Operating Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 324: Controlling Attachments Using The Triple Mini-Lever And The 5Th Function

    Operating 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". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".
  • Page 325 Operating Attachments Example using the pictograms for configura-  tion (1): If the operating lever (1) is moved in the direc- tion of the arrow (E), the sideshift moves to the left. If the function key for the "5th function" (2) is actuated and the operating lever (1) is moved in the direction of the arrow (E), the fork arms open.

  • Page 326: Controlling Attachments Using A Quadruple Mini-Lever

    Operating Attachments Controlling attachments using a  quadruple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 327 Operating Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 328: Controlling Attachments Using The Quadruple Mini-Lever And The 5Th Function

    Operating 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". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".

  • Page 329: Controlling Attachments Using The Fingertip

    Operating Attachments Picto- Attachment function gram Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.
  • Page 330 Operating Attachments Picto- Attachment function gram Move the side shift frame or fork for- wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Release load retainer Clamp load retainer Open clamps...

  • Page 331: Controlling Attachments Using The Fingertip And The 5Th Function

    Operating Attachments It is not necessary to release the clamp lock- ing mechanism in order to close the clamp. – To close the clamp, pull the operating lev- er (2) backwards. Controlling attachments using the  1 2 3 Fingertip and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function.
  • Page 332 Operating Attachments Picto- Attachment function gram Adjust fork arms: open Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 333: Controlling Attachments Using The Joystick 4Plus

    Operating Attachments Controlling attachments using the  Joystick 4Plus In this version, the attachments (variant) are controlled via the Joystick 4Plus (1) and the slider (4). The adhesive label bearing the pic- tograms for the hydraulic functions (2) for the Joystick 4Plus (1) and the adhesive label (3) for the slider (4) are affixed at the designated points.
  • Page 334 Operating Attachments Picto- Attachment function gram Rotate to the left Rotate to the right Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 335: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operating Attachments Controlling attachments using the  Joystick 4Plus and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. Use shift key "F" (4) and the Joystick 4Plus (2) and the horizontal rocker button (1) to control the "5th function".

  • Page 336: Picking Up A Load Using Attachments

    Operating Attachments The attachment moves accordingly in the di- rections (E) or (F) as shown in the pictogram. – Push the horizontal rocker button (1) in the direction (G) or (H). The attachment moves accordingly in the di- rections (G) or (H) as shown in the pictogram. –...

  • Page 337: Auxiliary Equipment

    Operating Auxiliary equipment Auxiliary equipment General note Depending on which zone the truck has been modified for, the number of pieces and the ap- pearance of auxiliary equipment will vary. FleetManager (variant) FleetManager is an equipment variant and can be fitted to the truck in different versions. The description and operation information can be found in the separate operating instructions for the corresponding FleetManager versions.
  • Page 338 Operating Auxiliary equipment Press softkey Operating stage 3rd time Hold (possible in all Washer operating stages) Front windscreen wiper and washer  – To activate the "On" operating stage, press the softkey (1). The "On" operating stage is activated. The symbol (3) appears –...
  • Page 339 Operating Auxiliary equipment Rear window wiper and washer  – To activate the "On" operating stage, press the corresponding softkey (5). The "On" operating stage is activated. The symbol (7) appears – To activate the "Intermittent mode" operat- ing stage, press the softkey again. The symbol (6) is shown with an orange back- ground.

  • Page 340: Filling The Washer System

    Operating Auxiliary equipment Filling the washer system  – Open the filler cap (1) of the washer sys- tem. – Fill the washer reservoir (2) with washer flu- id as described in the "Maintenance data ta- ble". CAUTION Damage due to the effects of frost! When water freezes, it expands.

  • Page 341: Ceiling Sensor (Variant)

    Operating Auxiliary equipment – To switch on the rear window heating, push  the associated softkey on the display-oper- ating unit. The rear window heating is switched on. – To switch off the rear window heating, push the softkey again. The rear window heating is switched off.
  • Page 342 Before the truck is able to acceler- ate to the maximum speed permitted for outdoor areas, the speed limitation must still be unlocked. To do this, release the accel- erator briefly and then operate the accelera- tor again.
  • Page 343 Operating Auxiliary equipment Changing the sensor settings NOTE The ceiling sensor system is supplied by STILL with the following factory settings: Sensitivity: High ● Ceiling height: 24 m ● – Park the truck securely and switch it off. – Turn the union nut (4) anti-clockwise to ...
  • Page 344 Operating Auxiliary equipment The sensor is adjusted using DIP switches (6).  – To access the DIP switches, open the cover on the underside of the sensor housing with the key (5). During this process, the two tabs of the key (5) fit into the recesses of the cover.
  • Page 345 Operating 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". The sensor has different beam angles de- 2 3 4 pending on the combination of range and sen- sitivity that has been set.
  • Page 346 Operating Auxiliary equipment Sensitivity Range Beam angle 42° 33° High (3) 22.5° 16 m 20° 24 m 15° 45° 43° Very high (4) 30° 16 m 22.5° 24 m 18° – After the adjustment, refit the cover. – Refit the ceiling sensor and connect it. –...

  • Page 347: Cab

    Operating Opening and closing the cab door  DANGER Risk of explosion due to static charge! The plastic parts on category 2 trucks are coated with a special antistatic paint. This paint prevents the build-up of an electrostatic charge in plastic compo- nents.

  • Page 348: Opening And Closing The Side Window

    Operating – Pull the handle (4). Unlock the door lock. – Open the cab door (3) by pulling it out- wards. Opening the cab door from the inside: – Take hold of the handle (2) and the latch (1). – Push in the latch. Push the cab door out- wards.

  • Page 349: Turning The Interior Lighting On Or Off (Variant)

    Risk of accident! – Do not operate the radio when driving or when handling loads. – Adjust the radio volume so that you can still hear warning signals. 56378011526 EN - 03/2021 - 01...

  • Page 350: Heating System (Variant)

    Operating Heating system (variant) DANGER There is a risk of poisoning if heavily polluted surrounding air is aspirated in- to the closed cab! – Do not operate the heating system in the vicinity of storage areas or similar areas in which fuel vapours or fine dust (e.g.
  • Page 351 Operating Operating devices of the heating sys-  The operating devices of the heating system include: Heating level control knob Fan control knob Air vent control knob Switching on the blower and heating system – Turn the fan control knob (2) to the desired blower position.
  • Page 352 Operating Switching off the heating system and blower – Turn the heating level control knob (1) in an anticlockwise direction until it reaches the stop. The heating system is shut off. – Turn the fan control knob (2) in an anti- clockwise direction until it reaches the stop.

  • Page 353: Clipboard (Variant)

    Operating Clipboard (variant)  The removable clipboard (1) is an equipment variant. Push-up roof window (variant)  WARNING Risk of crushing! – When closing the roof window, do not reach be- tween the roof window and the overhead guard. – Do not reach in to touch the components as they are being closed.
  • Page 354 Operating – Use your left hand to take hold of the han- dle (5) on the roof window (1) and push upwards until the locking bolt (4) engages. The roof window (1) is held in the pushed-up position – To close the roof window, pull out the lock- ing bolt (4) with your right hand and keep hold of the locking bolt.

  • Page 355: Sun Visor And Sun Blind

    Operating Sun visor and sun blind  The truck can be equipped with a sun vi- sor (2), a sun blind for the roof (1) and a sun blind for the driver's view to the front (4). – To adjust the sun visor (2), grasp it and move it to the desired position.

  • Page 356: Trailer Operation

    Operating Trailer operation Trailer operation Safety information for trailer opera- tion DANGER Risk of explosion! Trailers, tow couplings and coupling pins that do not meet explosion-protection regulations can cause explosions in the surrounding atmosphere within potential- ly explosive areas! – Only use trailers, tow couplings and coupling pins that meet explosion- protection regulations.

  • Page 357: Towed Load

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

  • Page 358: Coupling Pin In The Counterweight

    Operating Trailer operation This truck is suitable for the occasional towing of trailers. If the truck is equipped with a tow- ing device, this occasional towing must not ex- ceed 2% of the daily operating time. The man- ufacturer must be consulted if the truck is to be used for towing on a more regular basis.
  • Page 359 Operating Trailer operation – Push the coupling pin (1) downwards, turn  the pin by 90° and pull the pin out. – Adjust the tiller height. DANGER People can become trapped between the truck and trailer. When coupling, ensure that there are no persons present between the truck and the trailer.

  • Page 360: Tow Coupling Ro*244

    Operating Trailer operation – Push the coupling pin (2) downwards, turn  the pin by 90° and pull the pin out. – Slowly move the truck forwards and guide the tow-bar eye completely out of the re- cess (2) in the counterweight. –...
  • Page 361 Operating Trailer operation DANGER If you briefly leave the truck to couple or uncouple the trailer, there is a risk to life caused by the truck rolling away and running you over. – Apply the parking brake. – Lower the forks to the ground. –...
  • Page 362 Operating Trailer operation WARNING Risk of component damage if the tiller in the tow cou- pling is tilted! The tiller should be kept as horizontal as possible when towing. This ensures that the rotation range is sufficient at the top and bottom. The authorised serv- ice centre can adjust the assembly height for the tow coupling to the tiller height if necessary.
  • Page 363 Operating Trailer operation NOTE The coupling pin is correctly engaged if the control pin (3) does not protrude out of its guide. DANGER If the coupling pin drops out during towing, the trail- er will work loose and can no longer be controlled. Risk of accident! The control pin (3) must not protrude out of its guide.

  • Page 364: Towing Trailers

    Operating Trailer operation – Close the tow coupling by actuating the closing lever (1). NOTE To protect the lower coupling pin bush against contamination, always keep the tow coupling closed. Towing trailers  7090_900-011 – Drivers who are towing a trailer for the first time must practise driving with a trailer in a suitable area.

  • Page 365: Cold Store Application

    Operating Cold store application Cold store application  The truck is suitable for use in cold stores. Cold store equipment with low-temperature hydraulic oil may be required. The truck is equipped for two different types of application. The cold store symbol indicates the variant with cold store equipment that uses low-tem- perature hydraulic oil.
  • Page 366 Operating Cold store application WARNING Risk of accident due to restricted operational readi- ness! At very low temperatures, the display-operating unit requires a longer period of time to reach operational readiness. The truck is not ready for operation during this time. This status is shown in the display as follows: –...
  • Page 367 Operating Cold store application Limiting the load dynamics to load program 1  during the warm-up phase NOTE During the warm-up phase, the load dynamics are limited to load program 1. The adjacent symbol appears on the display until the warm- up phase is complete.
  • Page 368 Operating Cold store application 10°C, the battery cannot be fully charged with the usual charging parameters. – Charge the battery fully before each shift. – During the gassing phase, always top up with distilled water. The distilled water will mix with the battery acid so that it does not freeze.
  • Page 369 Operating Cold store application 56378011526 EN - 03/2021 - 01...

  • Page 370: Display Messages

    Operating Display messages Display messages Behaviour when the explosion-pro-  tection warning lights are illumina- DANGER Risk of explosion! During operation, the temperatures and insulation values of various components are monitored by sensors. The explo- sion-protection warning lights indicate when limit values have been reached. If dangerous limit values are detected, the truck control unit automatically shuts down the drive unit.
  • Page 371 Operating Display messages NOTE Observe the "Actuating the reset button after automatic emergency shutdown" section in the chapter entitled "Procedure in emergen- cies". Traction motor and pump motor monitoring Surface temperature of the right- hand traction motor The maximum surface temperature of the right-hand traction motor has been reached.

  • Page 372: Messages

    Operating Display messages – Tow the truck out of the potentially explo- sive area. – See the section entitled "Towing" in the chapter entitled "Operating in special oper- ating situations". Actuating the reset button is prohibited in the event of an insulation fault. –...
  • Page 373 Operating Display messages Code Shown on display Cause/action The access authorisation (variant) is preventing the use of the truck. Log in - Enable the access authorisation. The battery charge state is too low for truck use. Battery empty - Charge the battery. V6905 V6985 The battery charge state is low.
  • Page 374 Operating Display messages Code Shown on display Cause/action The battery door is open. The truck will not move. Close the battery door - Close the battery door. The lithium-ion battery is too cold. Battery too cold - Move the truck to a warmer environment. The desired action is only possible after releas- ing the brake pedal.
  • Page 375 Operating Display messages Code Shown on display Cause/action If the truck is switched off without having first applied the parking brake, this message ap- Switch off truck? pears. - Apply the parking brake. If the truck is to be switched off although the parking brake is not applied, this message ap- Switch off truck any- pears.
  • Page 376 Operating Display messages Code Shown on display Cause/action The parking brake cannot be applied due to a technical fault. - Apply the parking brake according to the sec- Parking brake cannot be tion entitled "Malfunctions in the electric parking applied brake".
  • Page 377 Operating Display messages Code Shown on display Cause/action If the truck is equipped with an integrated charg- er (variant) and charging is complete, this mes- sage appears. Remove charging cable - Disconnect the charger plug from the plug connection on the truck. The charging button on the truck plug of the charging cable has been held down too long.
  • Page 378 Operating Display messages Code Shown on display Cause/action This message is not displayed during normal operation. Parameter calibration - Contact the authorised service centre. If the configured sequence for applying the re- straint systems is not observed, this message Seatbelt sequence appears.

  • Page 379: Messages About The Truck

    Operating Display messages Code Shown on display Cause/action If the battery experiences under-voltage or too high a temperature, this message appears. Sprint mode blocked — Sprint mode is no longer available. battery - Observe the previous message. If the temperature at the drive units is too high, this message appears.
  • Page 380 – Switch the truck off and on again. – If the message still appears, please contact the authorised service centre. The messages are sorted in ascending order according to their code:...

  • Page 381: Procedure In Emergencies

    Operating Procedure in emergencies Procedure in emergencies Emergency shutdown  WARNING No electric braking assistance is available if the emergency off switch or the battery isolating switch has been actuated. Actuating the emergency off switch (1) disconnects the drives from the power supply. Actuating the bat- tery isolating switch(2) disconnects the entire truck from the power supply.

  • Page 382: Actuating The Reset Button After Automatic Emergency Shutdown

    Operating Procedure in emergencies No power steering effect; the steering ● forces are increased by the remaining emergency steering function The "Curve Speed Control" system (auto- ● matic reduction in truck speed when corner- ing) does not function. Brake the truck using the service brake.
  • Page 383 Operating Procedure in emergencies WARNING Risk of injury from automatic emergency shutdown! If the truck controller automatically shuts down the drive units, no drive functions are available. – Stop the truck with the service brake. NOTE It is essential that the safety officer gives ap- proval to the following operation! In an emergency (e.g.

  • Page 384: Procedure If Truck Tips Over

    Operating 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 385: Emergency Driving Via The Drive Direction Switch/Drive Direction Selection Lever

    Operating Procedure in emergencies WARNING When glass is smashed there is a risk of injury caused by glass splinters! When the cab glass is smashed, splinters of glass can shoot into the face and cause damage to skin and eyes through cuts. When a pane of glass is smashed, the face should be turned away and cov- ered with the crook of the free arm.

  • Page 386: Emergency Lowering

    Operating Procedure in emergencies – Fasten the seat belt. – Release the parking brake. – Push the drive direction switch/drive direc- tion selection lever in the desired drive di- rection. – Press the accelerator pedal. – Drive the truck to a safe area and park the truck safely.
  • Page 387 Operating Procedure in emergencies – Remove the hexagon socket wrench (2)  from the compartment on the right next to the driver's seat. 6219_003-260 – Using the hexagon socket wrench, turn the  emergency lowering screw (3) a maximum of 1.5 revolutions to loosen it. WARNING The load is lowered! Unscrewing the emergency lowering screw regulates...

  • Page 388: Emergency Actuation Of The Electric Parking Brake

    Operating Procedure in emergencies Emergency actuation of the electric parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away. The truck can roll away when the park- ing brake is released. –...
  • Page 389 Operating Procedure in emergencies – Lift the cover (1) and fold it up.  Release parking brake CAUTION Risk of damage to components. If the emergency actuation mechanism (2) will not move, the brake pedal has not been depressed far enough.

  • Page 390: Towing

    Operating Procedure in emergencies Towing  Safety information DANGER Risk of explosion through spark forma- tion! If the truck has to be towed out of a po- tentially explosive area, the towing vehi- cle and tow bar used must comply with explosion-protection regulations.
  • Page 391 Operating Procedure in emergencies DANGER There is a risk of fatal injury during manoeuvring! People can be crushed between the truck and towing vehicle during manoeuvring. The towing vehicle may only be manoeuvred and the tow bar may only be attached using a second person as a guide.
  • Page 392 Operating Procedure in emergencies CAUTION Possibility of damaging the battery male connectors! If the battery male connectors are disconnected while the key switch is switched on (under load), an arc will be produced. This can cause the contacts to erode, which considerably shortens the service life of the contacts.
  • Page 393 Operating Procedure in emergencies NOTE If the service brake is actuated very strongly, the parking brake may apply. In this case, manually release the parking brake. – Once the towing procedure is complete, al- low the parking brake to apply by actuating the brake pedal.

  • Page 394: Connecting And Disconnecting The Battery Male Connector

    Operating Connecting and disconnecting the battery male connector Connecting and disconnecting the battery male connector Connecting the battery male con- nector DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. Do not perform any work on the truck in potentially explosive areas! CAUTION...
  • Page 395 Operating Connecting and disconnecting the battery male connector – Use a stainless steel, flat-blade screwdriver  to turn the fuse (2) to the "open" position – Connect the battery male connectors (1) by screwing them into the truck connec- tions (3). –...

  • Page 396: Disconnect The Battery Male Connector

    Operating Connecting and disconnecting the battery male connector Disconnect the battery male con- nector DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! CAUTION Risk of damage to the battery male connectors!
  • Page 397 Operating Connecting and disconnecting the battery male connector – Use a stainless steel, flat-blade screwdriver  to turn the fuse (2) to the "open" posi- tion – Disconnect the battery male connectors (1) by pulling them backwards and unscrewing them from the truck connections (3). –...

  • Page 398: Handling The Lead-Acid Battery

    Operating Handling the lead-acid battery Handling the lead-acid battery Safety regulations for handling the battery DANGER There is a risk of explosion if non-ex- plosion-protected batteries are used! Batteries intended for use in potentially explosive areas are designed for certain explosion groups, categories and tem- perature ranges.
  • Page 399 Operating Handling the lead-acid battery CAUTION Potential for damage to the battery charger! Incorrect connection or incorrect opera- tion of the charging station or the battery charger may result in damage to compo- nents. – Follow the operating instructions for the charging station or battery charg- er and for the battery.
  • Page 400 Operating Handling the lead-acid battery WARNING Risk of crushing and shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. There is a risk of injury if any parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed.
  • Page 401 Operating Handling the lead-acid battery – Keep the battery door open during charg- ing. – Do not place any metal objects on the bat- tery. – Fully open any protective structures (e.g. fabric-covered cab). – Have fire extinguishing equipment ready. Lifting accessories DANGER Risk of accident!
  • Page 402 Operating Handling the lead-acid battery – For information on handling battery acid, see the "Battery acid" section in the chapter entitled "Safety regulations for handling consumables". Damage to cables and battery male  connectors CAUTION There is a risk of short circuit if the ca- bles are damaged.

  • Page 403: Maintaining The Battery

    Operating Handling the lead-acid battery Maintaining the battery DANGER Danger to life and limb! – Observe the instructions in the chapter entitled "Safety regulations when handling the battery". WARNING Battery acid is toxic and corrosive! – Observe the safety regulations in the chapter enti- tled "Battery acid".

  • Page 404: Checking The Battery Condition, Acid Level And Acid Density

    Operating Handling the lead-acid battery Checking the battery condition, acid level and acid density WARNING The electrolyte (diluted sulphuric acid) is poisonous and corrosive! – Observe the safety regulations for handling battery acid; see the chapter entitled "Battery acid". – Wear personal protective equipment (rubber gloves, apron and protection goggles).
  • Page 405 Operating Handling the lead-acid battery – A defective battery must only be repaired by the authorised service centre. – Open the 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.

  • Page 406: Checking The Battery Charge Status

    Operating Handling the lead-acid battery Checking the battery charge status  CAUTION Deep discharges shorten the service life of the bat- tery. Deep discharge begins when the battery charge dis- play is red (3) (0% of the available battery capacity, i.e.
  • Page 407 Operating Handling the lead-acid battery DANGER Risk of explosion if the battery is not extended! If the truck is equipped with an electric battery carrier (variant), the following applies: The battery carrier reduces the space between the battery and the battery hood. During charging, lead- acid batteries generate explosive oxyhydrogen gas.
  • Page 408 Operating Handling the lead-acid battery CAUTION Risk of damage to the battery charger! Incorrect connection or incorrect opera- tion of the charging station or the battery charger may result in damage to compo- nents. – Follow the operating instructions for the charging station or battery charg- er and for the battery.
  • Page 409 Operating Handling the lead-acid battery – Connect the battery male connector to the plug on the battery charger. – Adjust the settings of the battery charger to the battery capacity of the lead-acid battery. – Start the battery charger. NOTE Observe the information in the operating in- structions for the battery and the battery charger.
  • Page 410 Operating Handling the lead-acid battery The battery door can be locked in the open  position using a support bracket. – Pull the support bracket (1) upwards. Re- move the support bracket from its support mounting (2) on the battery door. –...

  • Page 411: Equalising Charging To Preserve The Battery Capacity

    Operating Handling the lead-acid battery – Close the battery door. When doing so, en-  sure that no cables are crushed between the chassis and the battery door. The battery door must be locked in place. The truck is equipped with a door contact switch for the battery door.
  • Page 412 Operating Handling the lead-acid battery The battery charger remains switched on. De- pending on the type of battery charger, the equalising charge begins between 6 and 24 hours after the end of the actual charging process. The equalising charge takes up to 2 hours.

  • Page 413: Replacing And Transporting The Battery

    Operating Replacing and transporting the battery Replacing and transporting the battery General information on replacing the battery DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...

  • Page 414: Changing To A Different Battery Type

    Operating Replacing and transporting the battery Changing to a different battery type The truck can be converted to a different bat- tery type and capacity. The new battery capacity and new battery type must be set in the display-operating unit. If this is not done, the actual battery dis- ●...

  • Page 415: Wire Cross-Section Of The Battery Cable On The "High Performance" Variant

    Operating Replacing and transporting the battery – Press the Back button – Press the softkey. Capacity – Press the corresponding softkey for the bat- tery capacity according to the nameplate of the battery. The activation bar next to the selection lights The main display button takes you to the main display.

  • Page 416: Closing The Battery Door

    Operating Replacing and transporting the battery Closing the battery door  Opening the battery door – Grasp the door handle (1) on the battery door. Open the battery door by pulling it backwards. The hinge of the battery door holds the battery door in the open position.
  • Page 417 Operating Replacing and transporting the battery Locking the battery door in a slightly  open position The battery door can be locked in the open position using a support bracket. – Pull the support bracket (1) upwards. Re- move the support bracket from its support mounting (2) on the battery door.
  • Page 418 Operating Replacing and transporting the battery WARNING Risk of accident due to the battery door opening! An unlocked battery door may open if the truck de- celerates sharply. If the battery door opens while driving, there is risk of damage from a collision. –...

  • Page 419: Replacing The Battery Using A Truck

    Operating Replacing and transporting the battery Replacing the battery using a truck  Preparation WARNING Risk of accident! The load capacity of the truck in use must at least match the battery weight (see the battery name- plate). – Observe the nameplates of the battery and of the change frame.
  • Page 420 Operating Replacing and transporting the battery – Disconnect the battery male connector.  WARNING Risk of crushing/shearing! Nobody may stand directly next to the battery or between the battery and the truck when removing and inserting the battery. CAUTION Risk of damage! –...
  • Page 421 Operating Replacing and transporting the battery Transporting and setting down the bat- tery WARNING Risk of crushing or shearing! Carefully transport the battery: low speed, slow steering movement and careful braking. – Do not use the methods described here to trans- port the battery over long distances.
  • Page 422 Operating Replacing and transporting the battery CAUTION Risk of damage! – Position the battery cables on the bat- tery in such a way that the cables cannot be crushed either when re- moving or inserting the battery or when closing the battery door. Once the battery is correctly positioned in the battery compartment: –...

  • Page 423: Replacing The Battery Using A Change Frame (Variant)

    Operating Replacing and transporting the battery – Connect the battery male connectors.  – Close the battery door. 6301_901-006 Replacing the battery using a change frame (variant) WARNING Risk of accident! The load capacity of the truck or lift truck in use must at least match the weight of the battery and the weight of the change frame.
  • Page 424 Operating Replacing and transporting the battery Removing the battery – Park the truck securely and switch it off. – Open the battery door. CAUTION Possibility of damaging the battery male connectors! If the battery male connectors are disconnected while the key switch is switched on (under load), an arc will be produced.
  • Page 425 Operating Replacing and transporting the battery – Open the battery locks (1).  NOTE If the battery locks cannot be opened by hand, the coupling pin (2) from the counterweight can be used as a lever extension. – Ensure that the maximum load capacity of the change frame is not exceeded.
  • Page 426 Operating Replacing and transporting the battery Transporting and setting down the bat- tery WARNING Risk of crushing or shearing! Carefully transport the battery: low speed, slow steering movement and careful braking. – Do not use the methods described here to trans- port the battery over long distances.
  • Page 427 Operating Replacing and transporting the battery – Carefully place the battery onto the battery holding fixtures. – Carefully remove the change frame from under the battery. – Close the battery locks.  NOTE The battery door will close only when the bat- tery is locked.

  • Page 428: Transporting The Lead-Acid Battery By Crane

    Operating Replacing and transporting the battery Transporting the lead-acid battery  by crane DANGER There is risk of fatal injury from being struck by falling loads! – Never walk or stand underneath sus- pended loads. The tray for the lead-acid battery (1) is equip- ped with four lifting eyes.

  • Page 429: Cleaning The Truck

    Operating Cleaning the truck Cleaning the truck Note on flame proof enclosures Depending on the category of the truck, it can be equipped with one or more flame proof en- closures. These flame proof enclosures con- tain components of the truck control unit and other electrical and electronic components.
  • Page 430 Operating Cleaning the truck DANGER Risk of fire due to flammable cleaning materials! Flammable cleaning materials can be ig- nited by hot components. – Do not use any flammable cleaning materials. DANGER Risk of fire due to flammable materials! Deposits and solids can be ignited by hot components, e.g.
  • Page 431 Operating Cleaning the truck CAUTION Abrasive cleaning materials can damage the surfa- ces of components! Using abrasive cleaning materials that are unsuitable for plastics can cause plastic parts to dissolve or be- come brittle. The screen on the display-operating unit could become cloudy.

  • Page 432: Cleaning The Electrical System

    Operating Cleaning the truck Cleaning the electrical system WARNING Danger of electric shocks due to residual capacity! – Never reach into the electrical system with your bare hands. CAUTION Cleaning electrical system parts with wa- ter can damage the electrical system. Cleaning electrical system parts with wa- ter is forbidden! –...

  • Page 433: Cleaning The Windows

    Operating Cleaning the truck – 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 environ- mentally friendly manner.

  • Page 434: After Cleaning

    Operating Cleaning the truck After cleaning  CAUTION Risk of short circuit! Ingress of moisture or dirt into the battery male con- nector and plug connection can lead to an electrical short circuit. – Use compressed air to dry the battery male con- nector and the plug connection before connecting them.

  • Page 435: Transporting The Truck

    Operating Transporting the truck Transporting the truck Transport DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...
  • Page 436 Operating Transporting the truck DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck 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 437 Operating Transporting the truck Lashing down DANGER The load may slip if the harnesses slip! The truck must be lashed securely so that it cannot move during transportation. – Use only harnesses that are adequately sized in relation to the weight of the truck. –...

  • Page 438: Crane Loading

    Operating Transporting the truck Lashing at the rear  – Position the harness for the coupling pin around the coupling pin as shown. – Lash the truck at an angle towards the front. Crane loading Crane loading is only intended for transporting the complete truck, including the lift mast, for its initial commissioning.

  • Page 439: Decommissioning

    Operating Decommissioning Decommissioning Safety information for shutting down and restarting DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work may be performed on the truck in potentially explosive areas. –...
  • Page 440 Operating Decommissioning Measures to be implemented before de- commissioning – Clean the truck thoroughly; see the chapter entitled "Cleaning the truck". – Lift the fork carriage to the stop several times. – Tilt the lift mast forwards and backwards several times and, if fitted, move the attach- ment repeatedly.

  • Page 441: Use After Storage Or Decommissioning

    Operating Decommissioning CAUTION Tyre deformation as a result of continuous loading on one side! Have the truck raised and jacked up by the author- ised service centre so that all wheels are off the ground. This prevents permanent deformation of the tyres.
  • Page 442 Operating Decommissioning that were carried out before initial commis- sioning. – The explosion protection inspection must be performed by the authorised service centre. – Perform the "visual inspections and func- tional checks". The following points in particular must be checked: Drive ●...

  • Page 443: Maintenance

    Maintenance...

  • Page 444: Safety Regulations For Maintenance

    Maintenance Safety regulations for maintenance Safety regulations for maintenance General information DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...

  • Page 445: Working On The Hydraulic Equipment

    Maintenance Safety regulations for maintenance – Avoid collisions with the ceiling of the hall and the resultant damage. Working on the hydraulic equipment The hydraulic system must be depressurised prior to all work on the system. Working on the electrical equipment DANGER Risk of explosion! Work on the electrical equipment must...

  • Page 446: Lifting And Jacking Up

    Maintenance Safety regulations for maintenance Lifting and jacking up DANGER There is a risk to life if the truck tips over! If not raised and jacked up properly, the truck may tip over and fall off. Only the hoists specified in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity.
  • Page 447 Maintenance Safety regulations for maintenance Removing the lift mast DANGER Risk of accident! This work must only be performed by an authorised service technician. – Commission the authorised service centre to re- move the lift mast. Securing the lift mast against falling off DANGER Risk of accident! This work must only be performed by an authorised...

  • Page 448: General Maintenance Information

    Maintenance General maintenance information General maintenance infor- mation Personnel qualifications DANGER Risk of explosion! The operating company is responsible for its work equipment in accordance with the German Ordinance on Industrial Safety and Health (BetrSichV). It is the operating company's responsibility to en- sure that testing and repairs are carried out properly.

  • Page 449: Maintenance Of The Explosion Protection Components

    Maintenance General maintenance information Maintenance personnel for batteries Batteries must only be charged, serviced, and replaced by personnel who have received ap- propriate training in accordance with the in- structions from the manufacturers of the bat- tery, battery charger and truck. –...

  • Page 450: Information For Carrying Out Maintenance

    Maintenance General maintenance information According to the standard "DIN EN 1755:2015-02" they include: checking the flame proof enclosure of the ● truck control unit and the restricted breath- ing housing for damage and integrity compliance with the minimum intervals for ●...
  • Page 451 Maintenance General maintenance information Maintenance timeframe If maintenance is needed, the message appears on the Service required display. – Arrange for the authorised service centre to perform the maintenance work on the truck. – The maintenance check lists indicate the maintenance work that is due.

  • Page 452: Monthly

    Maintenance General maintenance information The "Settings menu" opens on the display. – Press the softkey. Service The "Service menu" opens on the display. – Press the Maintenance interval softkey. This menu shows the operating hours remain- ing until the next scheduled maintenance in- terval or the latest date of the next scheduled maintenance interval.

  • Page 453: Maintenance By The Authorised Service Centre: Explosion-Protection Components - 1000 Hours/Yearly

    Maintenance General maintenance information At operating hours 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000 3150 3300 3450 3600 3750 3900 4050 4200 4350 4500 4650 4800 4950 5100 5250 5400 5550 5700 5850 6000 6150 6300...

  • Page 454: Maintenance - 1000 Hours/Annually

    Maintenance General maintenance information Maintenance - 1000 hours/annually At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Chassis, bodywork and fittings Check the chassis for cracks. Check the overhead guard, plus the cab and glass panes where relevant, for dam- age.
  • Page 455 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the mounting of the steering axle and check the steering axle for leak tight- ness. Grease all lubricating nipples on the steering axle Check the steering stop.
  • Page 456 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the oil level. Lift mast RX60-25-35: Check the lift mast bearings for damage and check the tightening tor- que. RX60-40-50: Check the lift mast bearings for damage, lubricate the lift mast bear- ings and check the tightening torque.
  • Page 457 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Reset the maintenance interval. Check that the labelling is complete. Perform a test drive. 56378011526 EN - 03/2021 - 01...

  • Page 458: Maintenance - 3000 Hours/Every Two Years

    Maintenance General maintenance information Maintenance - 3000 hours/every two years Carried At operating hours 3000 6000 9000 12000 15000   Note Perform all 1000-hour maintenance work. Power unit Change the gearbox oil in the drive wheel units. Brake Change the actuation oil for the foot brake. Hydraulics Change the hydraulic oil.

  • Page 459: Quality And Quantity Of The Required Operating Materials

    Maintenance General maintenance information – The Miretti job number can be found on the nameplate of the truck. Quality and quantity of the required operating materials Only the operating materials specified in the maintenance data table may be used. – The required consumables and lubricants can be found in the maintenance data table.

  • Page 460: Lubrication Plan

    Maintenance General maintenance information Lubrication plan 6301_003-034 Code Lubrication point Swing axle: four lubricating nipples on each side of the steering axle on the steering arm Sliding surfaces on the lift mast Load chains One lubricating nipple on each of the two lift mast bearings The respective lubricant specification can be found in the "Maintenance data table"...

  • Page 461: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table DANGER Risk of explosion due to static charge! If bio-hydraulic oils are used, hydraulic systems become prone to the build-up of static charges. This can lead to static discharge; in potentially explosive areas, this can subsequently lead to explosions in the surrounding atmosphere.
  • Page 462 Maintenance General maintenance information NOTE When changing to a different type of hydraulic oil, the authorised service centre must adjust the parameters of the truck control unit. Hydraulic system Code Unit Operating materials Specifications Dimension System filling Hydraulic oil HVLP 68 38.5 l to 50.0 l DIN 51524, Part 3 Dependent on the lift...
  • Page 463 Maintenance General maintenance information Code Unit Operating materials Specifications Dimension Lift mast bearing Grease Aralub 4320 Fill with grease until DIN 51825-KPF2N20 a small amount of ID no. 0148659 fresh grease escapes Screws for the lift Torque wrench For further informa- mast bearing tion, refer to the workshop manual for...

  • Page 464: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Changing the light bulb DANGER Risk of explosion if incorrect light bulbs are used! The lighting of the truck is designed to enable it to enter approved zones. Other light bulbs increase sur- face temperatures.

  • Page 465: Lubricating The Joints And Controls

    Maintenance Preserving operational readiness Lubricating the joints and controls  – Oil or grease bearings and joints according to the "maintenance data table". Driver's seat guide ● Cab door hinges (variant) ● Battery-door hinges or battery-cover hinges ● Actuating rod (1) for valves (with multi-lever ●...

  • Page 466: Maintaining The Seat Belt

    Maintenance Preserving operational readiness – Check that the door lock (2) and the battery lock (4) move easily and that they are not deformed or damaged. – Check that the indexing bolt (3) on the door lock is seated correctly and that it is not de- formed or damaged.
  • Page 467 Maintenance Preserving operational readiness Checking the seat belt – Pull out the belt (3) completely and check  for wear. The belt must not be frayed or cut. The stitch- ing must not be loose. – Check whether the belt is dirty. –...

  • Page 468: Checking The Driver's Seat

    6327_342-010 – After an accident, check the driver's seat and its attached restraining belt and check that the seat is still securely fastened. – Have the seat repaired by the authorised service centre if you identify any damage during the checks.

  • Page 469: Checking The Antistatic Paint Layer

    Maintenance Preserving operational readiness Maximum permissi- Category of the truck ble damaged area IIB + H IIB + C 20 cm IIB + H – Please contact your authorised service cen- tre for replacement or advice if you have any questions. Checking the antistatic paint layer DANGER Risk of explosion due to static charge!

  • Page 470: Servicing The Heating System Or Air Conditioning

    Maintenance Preserving operational readiness Refer to the table below! For repairs, it is absolutely essential to use ● antistatic paint made by the same manufac- turer and with the same specifications. Maximum permissible damage to the surfa- Maximum permissi- Category of the truck ble damaged area 100 cm IIB + H...
  • Page 471 Maintenance Preserving operational readiness – Check the filter mat (1) for contamination.  – If the filter mat is grey in colour, replace it. NOTE Change the filter mat at least every two months. Cleaning the fresh-air inlet The fresh-air inlet must be cleaned if the filter mat: Is damaged, ●...
  • Page 472 Maintenance Preserving operational readiness – Remove any dust and dirt from the fresh-air  inlet (1) beneath the filter mat carrier. 56378011526 EN - 03/2021 - 01...

  • Page 473: Servicing Wheels And Tyres

    – If you wish to use a type of tyre or tyre manufac- turer that has not been approved by STILL, obtain approval from STILL prior to use. – Do not change rim parts and do not mix rim parts from different manufacturers.

  • Page 474: Servicing The Steering Axle

    Maintenance Preserving operational readiness Checking the condition and wear of the  tyres – Remove any foreign bodies embedded in the tyres (1). The level of wear exhibited by tyres on the same axle must be approximately the same. Superelastic tyres and solid rubber tyres can be worn down to the "60J wear limit"...

  • Page 475: Checking The Battery

    Maintenance Preserving operational readiness "maintenance data table" until old grease begins to escape. WARNING Risk of crushing! Do not actuate the steering during lubrication. NOTE If, after a few strokes, there is no old grease escaping, the steering must be actuated. This makes it easier for grease to escape from the joints.

  • Page 476: Adjusting The Warning Zone Light

    Maintenance Preserving operational readiness Adjusting the warning zone light  – Switch on the truck. – Make sure that the parking brake is applied. – Loosen the nuts (2) to adjust each head- light. – Adjust the headlight (1). The distance from the light bar to the truck must be between 70...75 cm.
  • Page 477 Maintenance Preserving operational readiness CAUTION Hydraulic hoses become brittle! – Do not store hydraulic hoses for more than two years. – Do not use hydraulic hoses for more than six years if they are subject to normal wear. – Do not use hydraulic hoses for more than two years if they are subject to a high level of wear.

  • Page 478: Check The Hydraulic Oil Level

    Maintenance Preserving operational readiness Check the hydraulic oil level  6219_901-016_V2 90° WARNING Hydraulic oils are hazardous to your health. – Observe the safety regulations set out in the sec- tion entitled "Hydraulic fluid". 90° NOTE When changing to a different type of hydraulic oil, the authorised service centre must adjust the parameters of the truck control unit.
  • Page 479 Maintenance Preserving operational readiness – Keep the breather filter and dipstick in a horizontal position. – Check the oil level on the dipstick. ENVIRONMENT NOTE Carefully collect any spilt hydraulic oil. Dis- pose of this hydraulic oil in accordance with environmental regulations.

  • Page 480: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness Lubricating the lift mast and roller  track – Remove dirt and lubricant residue from the roller track. – Lubricate the roller tracks (1) of the outside, middle, and inside mast with a super-pres- sure adhesion lubricant to reduce wear. C hapter "Maintenance data table", ⇒ ...

  • Page 481: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other work that must be carried out – Perform all tasks required to maintain full operability; see the chapter entitled "Re- maining ready for operation". Checking the lift cylinders and con-  nections for leaks WARNING Risk of injury Observe safety regulations for working on the lift...
  • Page 482 Maintenance 1000-hour maintenance/annual maintenance holes allow the remaining cladding thickness to be determined. The surface of the back of the fork (4) is also clad with the same material. There must be no cracks or deformations visi- ble on the fork arms in the area around the fork bend (3).

  • Page 483: Checking The Reversible Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking the condition and correct op-  eration of the latch – Check the fork arms (1) for any visible de- formation. Wear must not amount to more than 10% of the original thickness. CAUTION Risk of component damage! Always replace worn fork arms in pairs.

  • Page 484: Checking The Double Pedal

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

  • Page 485: Technical Data

    Technical data...

  • Page 486: 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 487: Dimensions

    Technical data Dimensions Dimensions β α 6301_003-039 Seat is adjustable ± 90 mm Fork spacing is adjustable 56378011526 EN - 03/2021 - 01...
  • Page 488 Technical data Dimensions NOTE Measurements h and b are cus- tomised and can be taken from the order con- firmation. 56378011526 EN - 03/2021 - 01...

  • Page 489: Vdi Datasheet Rx60-25, Rx60-25/600 And Rx60-25L/600

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-25/60 Model RX60-25 RX60-25L/600 Type number 6301 6302 6304 Manufacturer STILL GmbH STILL GmbH STILL GmbH Drive Electric Electric Electric Operation Seat Seat Seat Load capacity/load Q (kg)
  • Page 490 Technical data VDI datasheet RX60-25, RX60-25/600 and RX60-25L/600 Model RX60-25 RX60-25/600 RX60-25L/600 Type number 6301 6302 6304 Number of front wheels (x = driven) Number of rear wheels (x = driven) Track width, front b10 (mm) Track width, rear b11 (mm) Basic dimensions Model RX60-25...
  • Page 491 Technical data VDI datasheet RX60-25, RX60-25/600 and RX60-25L/600 Model RX60-25 RX60-25/600 RX60-25L/600 Type number 6301 6302 6304 Aisle width for pallet 1000 x 1200 Ast (mm) 3700 3705 3905 crosswise Aisle width for pallet 800 x 1200 Ast (mm) 3890 3895 4116 lengthwise...
  • Page 492 Technical data VDI datasheet RX60-25, RX60-25/600 and RX60-25L/600 Model RX60-25 RX60-25/600 RX60-25L/600 Type number 6301 6302 6304 Climbing capability (Plus perform- ance /Standard performance) 29.5/26.6 27.4/27.4 28.0/24.2 without load Max. climbing capability (Plus per- formance /Standard performance) 31.9/25.5 30.8/24.7 30/24 with load Max.
  • Page 493 Technical data VDI datasheet RX60-25, RX60-25/600 and RX60-25L/600 Electric motor RX60-25/60 Model RX60-25 RX60-25L/600 Type number 6301 6302 6304 Traction motor, power at S2 60 min (Plus performance /Standard per- 2x10.5/2x8.5 2x10.5/2x8.5 2x10.5/2x8.5 formance) Lift motor, power at S3 15% (Plus performance /Standard perform- 25/20...

  • Page 494: Vdi Datasheet Rx60-30, Rx60-30/600 And Rx60-30L/600

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-30L/60 Model RX60-30 RX60-30/600 Type number 6305 6307 6308 Manufacturer STILL GmbH STILL GmbH STILL GmbH Drive Electric Electric Electric Operation Seat Seat Seat Load capacity/load Q (kg)
  • Page 495 Technical data VDI datasheet RX60-30, RX60-30/600 and RX60-30L/600 RX60-30L/60 Model RX60-30 RX60-35 Type number 6305 6307 6308 180/70-8 180/70-8 180/70-8 Tyre size, rear (18x7-8) (18x7-8) (18x7-8) Number of front wheels (x = driven) Number of rear wheels (x = driven) Track width, front b10 (mm) 1002...
  • Page 496 Technical data VDI datasheet RX60-30, RX60-30/600 and RX60-30L/600 RX60-30L/60 Model RX60-30 RX60-35 Type number 6305 6307 6308 Ground clearance with load below m1 (mm) lift mast Ground clearance at the middle of m2 (mm) the wheelbase Aisle width for pallet 1000 x 1200 Ast (mm) 3742 3913...
  • Page 497 Technical data VDI datasheet RX60-30, RX60-30/600 and RX60-30L/600 RX60-30L/60 Model RX60-30 RX60-35 Type number 6305 6307 6308 Max. pulling force (Plus perform- ance /Standard performance) 18360/17140 20250/17156 20160/17117 without load Climbing capability (Plus perform- ance /Standard performance) 20.1/14.6 20.1/14.6 19.4/14.1 with load Climbing capability (Plus perform- ance...
  • Page 498 Technical data VDI datasheet RX60-30, RX60-30/600 and RX60-30L/600 Electric motor Model RX60-30 RX60-35 RX60-30L/600 Type number 6305 6307 6308 Traction motor, power at S2 60 min (Plus performance /Stand- 2x10.5/2x8.5 2x10.5/2x8.5 2x10.5/2x8.5 ard performance) Lift motor, power at S3 15% (Plus performance /Standard perform- 25/20...

  • Page 499: Vdi Datasheet Rx60-35L

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX60-35L Type number 6309 Manufacturer STILL GmbH Drive Electric Operation Seat Load capacity/load Q (kg) 3500 Load centre of gravity...
  • Page 500 Technical data VDI datasheet RX60-35L Model RX60-35L Type number 6309 Track width, front b10 (mm) 1002 Track width, rear b11 (mm) Basic dimensions Model RX60-35L Type number 6309 Forwards tilt of lift mast/fork carriage Degrees Backwards tilt of lift mast/fork carriage Degrees Height with lift mast retracted h1 (mm)
  • Page 501 Technical data VDI datasheet RX60-35L Performance data Model RX60-35L Type number 6309 Driving speed (Blue-Q/Standard/Sprint) with load km/h 18/18/20 Driving speed (Blue-Q/Standard/Sprint) without load km/h 18/18/21 Lifting speed (Plus performance /Standard perform- 0.53/0.44 ance) with load Lifting speed (Plus performance /Standard perform- 0.57/0.51 ance) without load...
  • Page 502 Technical data VDI datasheet RX60-35L WARNING To use the truck safely – with or without a load – the maximum ascending or descending gradient permit- ted for travel is 15%. – If you have any questions, contact your authorised service centre. Electric motor Model RX60-35L...

  • Page 503: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Technical data Eco-design requirements for electric motors and variable speed drives Eco-design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation (EU) 2019/1781 because these motors do not meet the description giv- en in Article 2 "Scope", Item (1) (a) and be- cause of the provisions in Article 2 (2) (h) "Mo- tors in cordless or battery-operated equip-...

  • Page 504: Battery Specifications

    Technical data Battery specifications Battery specifications DANGER There is a risk of explosion from using a battery with the incorrect specifica- tion! Using batteries that do not correspond to explosion-protection regulations may lead to explosions in the surrounding at- mosphere in potentially explosive areas! –...
  • Page 505 Technical data Battery specifications Battery specifications according to DIN 43536; cells in accordance with DIN EN 60254-2, 80-V circuit A Battery designa- Capacity Tray Weight/ Battery compartment di- Circuit tion [Ah] ballast mensions [mm] weight [kg] Length Width Height 4PzV 400 4PzV 460 4PzS 500 1026...

  • Page 506: Information On The Auxiliary Hydraulics

    Technical data Information on the auxiliary hydraulics – Use only a battery tray that is approved for the potentially explosive area. – If you have any questions, contact your au- thorised service centre. Information on the auxiliary hydraulics DANGER Risk of explosion! Only use attachments that comply with the required explosion-protection regula- tions.
  • Page 507 Index Mounting..... . . 291 Picking up a load....Access authorisation for the fleet manag- Safety information.
  • Page 508 Index Condition of the roadways... . 170 Consumables..... . . 62 Cab.
  • Page 509 Actuating the reset button..368 STILL Classic....164 Emergency actuation of the parking brake.
  • Page 510 Index Information about the documentation..Information for carrying out maintenance. General......435, Maintenance timeframe.
  • Page 511 Meaning of the symbols... Malfunctions during lifting mode..STILL SafetyLight....159 Malfunctions in the parking brake..
  • Page 512 Index Operational readiness Trucks for cold store application..466 Quadruple mini-lever Overhead guard Lifting/lowering the fork carriage..214 Drilling......44 Tilting the lift mast.
  • Page 513 Index Parking the truck securely..Speed limitation Performing battery maintenance..Configuring..... 194 Safety regulations for maintenance Switching on and off.
  • Page 514 Index Towing Interior lighting....Procedure..... . 378 Lifting systems.
  • Page 515 Index Wedging the wheels....Working at the front of the truck..432 Wheel chock..... . Working on the electrical equipment.
  • Page 518 STILL GmbH 56378011526 EN - 03/2021 - 01...

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