Still RX60 35-50 Original Instructions Manual
  1. Manuals
  2. Brands
  3. Still Manuals
  4. Trucks
  5. RX60 35-50
  6. Original instructions manual

Still RX60 35-50 Original Instructions Manual

Electric truck
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
Table of Contents

Advertisement

Quick Links

Download this manual
Original instructions
Electric truck
RX60 35-50
RX60 35-50/Li-Ion
6331 6332 6333 6334 6335 6336
6337
56388011501 EN - 05/2022  -  08

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RX60 35-50 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Still RX60 35-50

Summary of Contents for Still RX60 35-50

  • Page 1 Original instructions Electric truck RX60 35-50 RX60 35-50/Li-Ion 6331 6332 6333 6334 6335 6336 6337 56388011501 EN - 05/2022  -  08...
  • Page 3 ● ing and storage of industrial trucks Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 56388011501 EN - 05/2022  -  08  I...
  • 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 ............ 2 Description of the truck .
  • Page 6 Operating devices and display elements ........ 66 Display-operating unit "STILL Easy Control" ........ 66 Lithium-ion battery display.
  • Page 7 Table of contents   Fingertip............. .  76 Joystick 4Plus .
  • Page 8 STILL Classic and sprint mode ........
  • Page 9 Table of contents   Actuating the electric parking brake ........ 181 Malfunctions in the electric parking brake .
  • Page 10 Table of contents   Driving onto lifts ............ 248 Driving on loading bridges .
  • Page 11 Table of contents   Depressurising the hydraulic system using the Fingertip ...... 307 Depressurising the hydraulic system using the Fingertip and the 5th function .. 308 Depressurising the hydraulic system using the Joystick 4Plus .
  • Page 12 Table of contents   Turning the interior lighting on or off (variant) ....... . .  375 Radio (variant) .
  • Page 13 Table of contents   Checking the battery charge status and calibrating the battery charge indicator .. 445 Charging the lead-acid battery .......... 447 Equalising charging to preserve the battery capacity .
  • Page 14 Table of contents   Set values ............ 505 Lifting and jacking up.
  • Page 15 Table of contents   VDI data sheet RX60-40 (Plus)/Li-Ion and RX60-40 (Plus)/600 Li-Ion ... .  550 VDI data sheet RX60-45 (Plus) Li-Ion and RX60-45 (Plus)/600 Li-Ion ... .  555 VDI data sheet RX60-50 (Plus) Li-Ion and RX60-50 (Plus)/600 Li-Ion .

  • Page 17: Foreword

    Foreword...

  • Page 18: Your Truck

    Your truck Description of the truck General The STILL RX60 35-50 is an electrically driven counterbalanced truck with a rear swing axle. The truck has a load capacity of up to 5.0 tons and can also have a load centre of gravity of 600 mm.
  • Page 19 Foreword Your truck Load-dependent assistance systems Overload detection ● Dynamic Load Control 1 or Dynamic Load ● Control 2 Lift mast tilt angle display ● Automatic mast vertical positioning ● Fork wear protection ● Load measurement, precise load measure- ● ment, total load and tare function Brake system The brake system of the truck is comprised of three different brakes:...
  • Page 20 Your truck of damping pressure peaks in the hydraulic system. Drive Both front wheels of the STILL RX60 35-50 are driven by maintenance-free three-phase drives in the front axle with 80-volt technology. Lead-acid batteries and X-Line lithium-ion bat- teries that can be replaced from the side can be selected as energy supplies.

  • Page 21: General

    "backward" drive direction. 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 pro- viding personally configurable favourites. The display-operating unit also monitors the truck functions, including each individual cell in the lithium-ion battery.

  • Page 22: Conformity Marking

    Foreword Your truck Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...

  • Page 23: Declaration That Reflects The Content Of The Declaration Of Conformity

    Your truck Declaration that reflects the content of the declaration of conformity         Declaration     STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany             We declare that the specified machine conforms to the most recent valid version of the directives specified below:  ...

  • Page 24: 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) ● Two keys for the storage box containing ● the charging cable for the on-board charger (variant) A hexagon socket wrench for emergency ●...
  • Page 25 Foreword Your truck 56388011501 EN - 05/2022  -  08  9...

  • Page 26: Labelling Points

    Foreword Your truck Labelling points 6301_003-018_V3  10 56388011501 EN - 05/2022  -  08...
  • Page 27 Foreword Your truck Decal information: Caution / Read the oper- Warning sign: Cleaning electrical system ating instructions / Fasten seat belt / Apply parts with water is forbidden parking brake when leaving the truck / Pas- Warning sign: Danger due to shearing sengers are not allowed / Do not jump off if Decal information: Lifting gear fixing point the truck is tipping over / Lean in the oppo-...
  • Page 28 Foreword Your truck   VDE-Prüfung geprüft gemäß DIN VDE 0701-0702  12 56388011501 EN - 05/2022  -  08...

  • Page 29: Nameplate

    Foreword Your truck Decal information: Hydraulic oil tank Decal information: Tyre filling pressure Warning sign: Do not stand underneath the Decal information: Load capacity: Attach- fork/Do not stand on the fork ment Warning sign: Danger due to shearing / Decal information: Load capacity: Basic ta- Danger due to high fluid pressure Decal information: Lifting gear fixing point Nameplate without CE labelling...

  • Page 30: Serial Number

    Foreword Your truck Variant 2: Industrial trucks built after  12/2021 Nameplate Manufacturer Model / serial number / year of manufac- ture Industrial truck / Chariot de manutation / Flurförderzeug Tare weight Max. battery weight/min. battery weight (only for electric trucks) Ballast weight (only for electric trucks) Placeholder for "data matrix code"...

  • Page 31: Stvzo (Road Traffic Licensing Regulations) Information

    Capacity equivalent: Weight: CE labelling P/N: B-P/N: Safety information Custumer order no.: Still order no.: Data/technical data Date: Made in Germany Address of manufacturer Safety Advices for Lithium-Ion Batteries Do not crush. Do not heat or incinerate. Do not short-circuit. Do not dismantle.
  • Page 32 Foreword Your truck Variant 1: Industrial trucks built after  12/2021 Manufacturer Technology Transportation notes General operating notes CE labelling Data matrix code for the authorised serv- ice centre UKCA labelling Safety information Data/technical data Address of manufacturer  16 56388011501 EN - 05/2022  -  08...

  • Page 33: Using The Truck

    Foreword Using the truck Using the truck Commissioning Commissioning is the initial intended use of the truck. The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company.

  • Page 34: Improper Use

    Foreword Using the truck The regulations regarding trailer operation must be observed; see chapter "Trailer opera- tion". Improper use The operating company or driver, and not the manufacturer, is liable for any hazards caused by improper use. NOTE Please note the definition of the following re- sponsible persons: "operating company"...
  • Page 35 Foreword Using the truck Driving on upward and downward gradients is permitted provided the specified data and specifications are observed, see the "Routes "chapter. The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: -20°C to +40°C).

  • Page 36: Parking In Temperatures Below -10 °C

    Foreword Using the truck Parking in temperatures below -10 °C  CAUTION Batteries may freeze or switch off! If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down. For lead-acid batteries, the electrolyte can freeze and damage the batteries.

  • Page 37: 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 Original operating instructions of the lithium- ● ion battery (variant) Operating instructions of other variants that ●...

  • Page 38: Supplementary Documentation

    Foreword Information about the documentation Safely store the complete documentation and pass on to the subsequent operating company when transferring or selling the truck. 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 39: Issue Date And Topicality Of The Operating Instructions

    The issue date and the version of these op- erating 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 40: List Of Abbreviations

    Foreword Information about the documentation ENVIRONMENT NOTE To prevent environmental damage. List of abbreviations This list of abbreviations applies to all types of operating instructions. Not all of the abbre- viations that are listed here will necessarily appear in these operating instructions. Abbrevi- Meaning Explanation...
  • Page 41 Foreword Information about the documentation Abbrevi- Meaning Explanation ation International Organization for Standardi- International standardisation organisation zation Uncertainty of measurement of sound   pressure levels Local Area Network Local area network Light Emitting Diode Light emitting diode Sound pressure level at the workplace  ...

  • Page 42: Definition Of Directions

    Foreword Information about the documentation Definition of directions  The directions "forwards" (1), "backwards" (3), "right" (2) and "left" (4) refer to the installation position of the parts as seen from the driver's compartment; the load is to the front. 6210_001-031 Schematic views View of functions and operating proce-...
  • Page 43 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 44: 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 45: Safety

    Safety...

  • Page 46: Definition Of Responsible Persons

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

  • Page 47: Drivers

    Safety Definition of responsible persons Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised represen- tative, and have been specifically instructed to drive the truck.
  • Page 48 Safety Definition of responsible persons Prohibition of use by unauthorised per- sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use, e.g.

  • Page 49: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises In many cases, company premises are 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 50 Safety Basic principles for safe operation Permissible lithium-ion batteries – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Declaring the use of lithium-ion batter- We recommend that the operating company informs the local fire brigade of the planned use of trucks fitted with lithium-ion batteries.
  • Page 51 Safety Basic principles for safe operation – Ventilate the location of the fire well, as the resulting combustion gases are corrosive if inhaled. – Inform the fire brigade that lithium-ion bat- teries are affected by the fire. – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire.

  • Page 52: Product-Specific Dangers Posed By The Lithium-Ion Battery

    Safety Basic principles for safe operation Product-specific dangers posed by the lithium-ion battery Example image Safety valve Hot area around the brake resistor  WARNING Risk of burns due to hot surfaces! The battery has an integrated brake re- sistor that can heat up to over 100°C during operation.

  • Page 53: Modifications And Retrofitting

    Safety Basic principles for safe operation NOTE The brake resistor (1) is installed differently depending on the battery group. The build-up of heat in the area around the brake resistor is harmless. The safety valve (2) opens when the battery is subjected to over pressure or catches fire.
  • Page 54 Safety Basic principles for safe operation Any modifications that adversely affect the stability, the load capacity or the circumferen- tial view of the truck require written approval from the manufacturer. The following components may only be modi- fied with prior written approval from the manu- facturer: Brakes ●...
  • Page 55 Safety Basic principles for safe operation  DANGER Risk of fatal injury from falling load! There is a risk to the driver's life if the truck is not equipped with an overhead guard, as the driver may be struck by a load falling from a lift height of 1800 mm or greater.

  • Page 56: Changes To The Overhead Guard And Roof Loads

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

  • Page 57: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation Damage, defects and misuse of safety systems Damage or other defects on the truck or at- tachment must be reported to the supervisor or responsible fleet manager immediately so that they can have the defect rectified. Trucks and attachments that are not functional or safe to drive may not be used until they have been properly repaired.

  • Page 58: Medical Equipment

    Safety Basic principles for safe operation 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 Only use wheels and tyres of the same type ●...

  • Page 59: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation Exercise caution when handling gas springs and accumulators  WARNING Gas springs are under high pressure. Improper re- moval results in an elevated risk of injury. For ease of operation, various functions on the truck can be supported by gas springs.
  • Page 60 Safety Basic principles for safe operation – For help with selecting the correct fork arms, contact the authorised service centre.  44 56388011501 EN - 05/2022  -  08...

  • Page 61: Residual Risk

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

  • Page 62: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risk with these regulations either intentionally or carelessly. Stability The stability of the truck has been tested to the latest technological standards and is guar- anteed provided that the truck is used properly and according to its intended purpose. These standards only take into account the dynamic and static tipping forces that can arise during specified use in accordance with the operat-...
  • Page 63 Safety Residual risk use the truck correctly and without the risk of accidents. 56388011501 EN - 05/2022  -  08  47...

  • Page 64: 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 65 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 labour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and...

  • Page 66: Danger To Employees

    Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable DGUV rule 113-001 and observe the oper- ating instructions 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-...
  • Page 67 Safety Residual risk The design and equipment of the truck comply with the standards and directives required for CE conformity. The design and equipment al- so comply with the standards and directives necessary for the UKCA compliance that is required in the United Kingdom. The design and equipment are therefore not part of the required scope of the hazard assessment.

  • Page 68: 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 69 Safety Safety tests The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values...

  • Page 70: 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 71: 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 72: 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 73: 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 74: 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 75 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 76 – Observe the safety regulations for handling the battery. Radiation In accordance with the guide- lines 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. The Laser-Smartfork assistance system (var- iant) is assigned to laser class 1M.

  • Page 77: Overviews

    Overviews...

  • Page 78: Overview

    Overviews Overview Overview 6301_003-020  62 56388011501 EN - 05/2022  -  08...
  • Page 79 Overviews Overview Lift mast Fork carriage Overhead guard Lift cylinder Driver's compartment Rear lighting Battery (in the battery compartment) Battery door Drive axle Steering axle Front lighting Towing device Fork arms Counterweight NOTE The truck equipment may differ from the equipment shown.

  • Page 80: Driver's Compartment

    Overviews Driver's compartment Driver's compartment  64 56388011501 EN - 05/2022  -  08...

  • Page 81: Shelf And Cup Holder

    Emergency off switch This compartment also contains the diag- Key switch nostic connection. Compartment Cup holder for max. 1.5-litre bottles Display/control unit "STILL Easy Control" Driver's seat Operating devices for hydraulic and driving Accelerator pedal functions Brake pedal Signal horn button...

  • Page 82: Operating Devices And Display Elements

    Brightness sensor Right-hand favourites bar "STILL Easy Control" is a third-generation dis- play-operating unit for industrial trucks. It is used as an operating device for the usu- al functions of the truck, such as controlling lighting and windscreen wiper functions and adjusting the driving dynamics.
  • Page 83 – 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 mul- ti-lever operation.

  • Page 84: Lithium-Ion Battery Display

    – Observe the chapter entitled "Display ele- ments" in the STILL "Lithium-ion batteries" operating instructions. Service LED (red) Temperature LED (yellow/red) Charging state LEDs (red/green) Emergency off switch ...

  • Page 85: 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" (variant) NOTE In the dual-pedal version (variant), the drive direction switch (1) is used exclusively to acti-...

  • Page 86: 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  70 56388011501 EN - 05/2022  -  08...
  • Page 87 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 88: 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  72 56388011501 EN - 05/2022  - ...
  • Page 89 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 90: 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"  74 56388011501 EN - 05/2022  - ...
  • Page 91 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 92: 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 93: 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" ing, lowering and sideshift Shift key "F"...

  • Page 94: Travel Direction Selector And Indicator Module (Variant)

    Overviews Operating devices and display elements Travel direction selector and in-  dicator 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 95: Operating

    Operating...

  • Page 96: 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 falling.
  • Page 97 Operating Checks and tasks before daily use Component Course of action Ensure that the attachments are mounted correctly in accordance with the operating instructions from the manufacturer. Attachments (variant) Perform a visual inspection to ensure that the at- tachments are intact and are leak-tight. Perform checks to ensure the attachments are working correctly.
  • Page 98 Operating Checks and tasks before daily use Component Course of action Inspect the battery male connector and the plug connection for moisture or any foreign objects that may have become lodged and remove as necessa- ry, e.g. using compressed air. Battery male connector and plug connec- Visually inspect for sound condition and deforma- tion...

  • Page 99: Climbing Into And Out Of The Truck

    Operating Checks and tasks before daily use Depending on the tyres, the truck may be  fitted with a corona electrode (3). This com- ponent ensures that the truck cannot charge statically. NOTE If the truck is fitted with "non-marking" tyres, the authorised service centre must retrofit a corona electrode.
  • Page 100 Operating Checks and tasks before daily use  CAUTION Components may become damaged through incor- rect use! Truck components, such as the driver's seat, steer- ing wheel etc., are not designed to be used for climb- ing in and out of the truck and may be damaged due to misuse.

  • Page 101: Climbing In And Out Of Trucks When The Driver's Compartment Is Raised (Variant)

    Operating Checks and tasks before daily use Climbing in and out of trucks when the driver's compartment is raised (variant)  WARNING Risk of injury when climbing into and out of the truck due to slipping, striking parts of the truck or becom- ing stuck! If the footwell cover is very dirty or smeared with oil, there is a risk of slipping.

  • Page 102: Adjusting The Driver's Seat And Armrest

    Operating Checks and tasks before daily use For assistance when climbing into and out of  the truck, use the handles (2) and (4) for sup- port. The overhead guard post (1) can also be used for support. Always climb into the truck facing forward: –...

  • Page 103: Adjusting The Steering Column

    Operating Checks and tasks before daily use Adjusting the steering column  – Pull up and hold the lever (2) for steering column adjustment. – Position the steering column (1), then push the lever down again and allow the steering column to engage.  DANGER Risk of accident! –...

  • Page 104: Function Checking Of The Assistance Systems

    Operating Checks and tasks before daily use NOTE If the angle of the display-operating unit changes during driving, tighten the socket head screws. This makes the display-operat- ing unit more secure in the support mounting. Function checking of the assis- tance systems Checking the assistance systems is one of the checks and tasks that must be performed...

  • Page 105: 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. 56388011501 EN - 05/2022  -  08  89...

  • Page 106: 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.  90 56388011501 EN - 05/2022  - ...

  • Page 107: Checking The Emergency Off Function

    Operating Checks and tasks before daily use Checking the emergency off  function  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. – To brake, actuate the service brake. –...

  • Page 108: Driver's Cab

    Operating Checks and tasks before daily use Driver's cab  DANGER Risk of fatal injury in the event of falling from the truck if it tips over! In order to prevent the driver from sliding underneath the truck and being crushed if the truck tips over, a restraint system must be in place and must be used.
  • Page 109 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. – If the brake oil level is lower than it should be or has visibly dropped, contact the au- thorised service centre.

  • Page 110: Checking The Brake System For Correct Function

    Operating Checks and tasks before daily use Checking the brake system for correct 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. – Do not operate the truck if the brake system is faulty.
  • Page 111 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 lorry ramp  DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the truck could run people over.

  • Page 112: 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 113: 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 114: Function Checking Of The Automatic Mast Vertical Positioning Function (Variant)

    Operating Checks and tasks before daily use Function checking of the auto- matic mast vertical positioning function (variant)  CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! – Before using the "automatic mast vertical position- ing"...

  • Page 115: Driver's Seat

    Operating Driver's seat Driver's seat Adjusting the MSG 65 and MSG 75 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 116 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 117 Operating Driver's seat Adjusting the MSG 65/MSG 75 seat  suspension NOTE The MSG 65/MSG 75 driver's seat is de- signed 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 118 Operating Driver's seat The seat automatically adjusts to the driver's weight. Adjusting the longitudinal horizontal  suspension (variant) If the driver's seat is equipped with the "longi- tudinal horizontal suspension" variant, impacts in the drive direction are damped by additional seat suspension.
  • Page 119 Operating Driver's seat Adjusting the backrest extension (var-  iant) – Adjust the backrest extension (7) by pulling it out or pushing it into the desired position. To remove the backrest extension, move it past the end stop by firmly pushing it upwards. 6321_003-040_V3 Switching the seat heater (variant) on ...
  • Page 120 Operating Driver's seat Swivelling the driver's seat to the right  for reverse travel (variant)  WARNING Risk of accident due to the seat swivelling. If the driver's seat swivels while the truck is in mo- tion, the seat position is unstable. –...

  • Page 121: Adjusting The Mgs 95 Driver's Seat

    Operating Driver's seat Adjusting the MGS 95 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. The steering or the operating devices can then be actuated unintentionally.
  • Page 122 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 123 Operating Driver's seat Adjusting the damping of the seat sus-  pension The suspension comfort can be adjusted as desired by the driver. – Turn the adjusting lever (3) until the desired setting is reached. 6301_003-152 Adjusting to the driver's weight and the ...
  • Page 124 Operating Driver's seat Adjusting the longitudinal horizontal  suspension If the driver's seat is equipped with the "longi- tudinal horizontal suspension" variant, impacts in the drive direction are damped by additional seat suspension. The locking lever (5) on the left-hand side of the driver's seat activates and locks the longitudinal horizontal suspension.
  • Page 125 Operating Driver's seat Adjusting the backrest extension  – Adjust the backrest extension (7) by pulling it out or pushing it into the desired position. The engagement can be felt. To remove the backrest extension, move it past the end stop by firmly pushing it upwards. 6301_003-156 Switching the seat heater (variant) on ...
  • Page 126 Operating Driver's seat Adjusting the seat angle  The longitudinal tilt of the seat base can be adjusted individually. – To adjust the seat angle, pull the handle (9) upwards. By simultaneously applying pressure to or re- moving pressure from the front or rear seat base, it tilts into the desired position.

  • Page 127: 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 128 Operating Driver's seat NOTE The buckle has a buckle switch. When the belt was not fastened, the following occurred: The message Close seat belt   ● appears on the display-operating unit. The truck will not drive at speeds faster ● than 4 km/h.
  • Page 129 Operating Driver's seat Special feature for trucks with HSR re- straint systems (variant) If the bracket is not closed, the message   appears Close restraint system in the display. Fastening on a steep slope  The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient.

  • Page 130: Adjusting The Armrest

    Operating Driver's seat Malfunction due to cold – If the buckle or belt retractor are frozen, thaw the buckle or the belt retractor and dry the parts. This prevents the parts from refreezing.  CAUTION The seat belt may be damaged by heat! Do not subject the buckle or belt retractor to exces- sive heat when thawing.
  • Page 131 Operating Driver's seat – Tighten the hand wheel by turning to the right. – Check that the armrest is firmly attached. 56388011501 EN - 05/2022  -  08  115...

  • Page 132: 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 133: 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 (variant)  WARNING All checks and tasks required before daily use must...
  • Page 134 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 ● instructions for FleetManager".  118 56388011501 EN - 05/2022  - ...

  • Page 135: 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 136: 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 137 Operating Display-operating unit When the key switch is switched on, the  input menu ap- Access 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 138: 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...
  • Page 139 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 en- titled "Changing the fleet manager pass- word".
  • Page 140 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 141 Operating Display-operating unit – Press the   softkey.  Service – Press the scroll buttons    until  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 142: 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 While the driver is doing this, the truck func-...

  • Page 143: Process

    The main display contains the message To complete Pre-Shift Check,   press This means that the Pre-Shift Check is still active and the truck functions are restricted. – To acknowledge the message, press the 6219_003-265_en  softkey. – Switch on and check the function to be tes- ted, e.g.

  • Page 144: All Questions

    Operating Pre-Shift Check speed. When the parking brake is applied again, the view returns to Pre-Shift Check. At the end of the check, truck functions are restricted if they have been adjusted as a re- action to a negative test result. The message Pre-Shift Check truck restric- shows that truck functions tions active...

  • Page 145: Defining The Question Sequence

    Operating Pre-Shift Check Is the capacity rating plate present, undamaged, and legible? Is the driver restraint system damaged? Does the horn work? Does the truck lighting work? Do the warning lights work? Is the antistatic belt present and does it have sufficient con- tact with the floor? Is the corona electrode present and clean? Does the parking brake work properly?
  • Page 146 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  130 56388011501 EN - 05/2022  - ...

  • Page 147: Displaying The History

    Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Question sequence 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 148 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  132 56388011501 EN - 05/2022  - ...

  • Page 149: Defining The Shift Start

    Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the softkey. History History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en The Pre-Shift Check display opens.  results This display shows all checks and questions that have been answered with the date and Pre-Shift Check results time.
  • Page 150 Operating Pre-Shift Check NOTE If the truck is equipped with the "FleetManag- er" variant, the shifts are defined on the Fleet- Manager interface. See the relevant operating instructions. – Activate the "Access authorisation for the fleet manager". – Press the  ...
  • Page 151 Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Shift start 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 152 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 153: 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 reverts to the previous menu. There is no activation bar next to this shift.
  • Page 154 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 menu appears.  Pre-Shift Check –...
  • Page 155 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 reverts to the previous Reset the truck restrictions? The entry remains in the history menu.

  • Page 156: 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  softkey is pressed, the main display appears. Hello, 0,0°...
  • Page 157 Operating Driver profiles ped with these variants, drivers must select their profiles manually. NOTE Access to the settings menu is only availa- ble if the truck is at a standstill and the park- ing brake is applied. If the parking brake is released prematurely, the settings menu will close.

  • Page 158: 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 159 Operating Driver profiles – Press the soft-  Driver profiles key  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 160: 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 161 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 162 Operating Driver profiles – Press the  Manage driver pro-  softkey. files Lift height preselection Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Fleet manager 6219_003-296_en – Press the  Rename driver pro-  softkey. files Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en...

  • Page 163: 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 164 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 165: Lighting

    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 166: 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 167: 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 168: 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 169 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 – To switch off the turn indicators, push the lever (1) back to the centre position.

  • Page 170: 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 171: Stvzo Equipment

    This softkey is used to switch off all light- ing devices that are not permitted on roads subject to German traffic regulations (StVO). This relates to the following variants of lighting equipment: STILL SafetyLight and STILL Safety- ● Light 4Plus Warning zone light and warning zone light ●...

  • Page 172: Rotating Beacon

     WARNING Danger of damage to eyes from look- ing into the STILL SafetyLight® and STILL SafetyLight 4Plus®. Do not look into the STILL SafetyLight® or STILL SafetyLight 4Plus®. STILL SafetyLight® and STILL SafetyLight 4Plus® are visual warning units designed to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junctions.

  • Page 173: Warning Zone Light And Warning Zone Light Plus (Variants)

    STILL SafetyLight 4Plus® is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations. Depending on the version, the STILL Safety- Light® projects one or more light-blue light spots in front of or behind the truck and thus warns others about the approaching truck.
  • Page 174 Operating Lighting The warning zone light projects a light bar  next to the truck on both the left-hand side and right-hand side of the truck or even behind the truck. This light bar indicates the danger areas to the sides or rear of the truck while in operation.

  • Page 175: Efficiency And Drive Modes

    Therefore, on distances of up to approx. 40 m, lower speeds are reached than would be the case if the efficiency mode was not activated. As in "STILL Classic" mode, the maximum speed is 20 km/h. Blue-Q 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)  160 56388011501 EN - 05/2022  -  08...

  • 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 display/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: STILL Classic...
  • 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 accident! – 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 different 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 contour and be damaged or torn off. Examples of these components are: An unfolded roof panel in the driver's cab ● Open cab doors ● Condition of the roadways Roadways must be sufficiently firm, level and free from contamination and fallen objects. Drainage channels, level crossings and similar obstacles must be evened out and, if necessa- ry, ramps must be provided so that trucks can...

  • Page 185: Selecting Drive Programmes 1 To 3

    Operating Driving Selecting drive programmes 1 to  The truck has three drive programmes with different preset driving and braking character- istics. The basic principle is that the higher the number of the drive programme selected, the greater the driving dynamics. The drive programme is selected using the display-operating unit under the  ...

  • Page 186: Configuring Drive Programmes A And B

    Operating Driving Selecting drive programme A or  The truck has two driving programmes for personalised handling and braking character- istics. 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 Configuration of the drive programmes using is explained here. drive programme A menu ap-  Setdrive programme A pears. The following parameters can be set: ● Max. speed Determines the maximum speed (varies de- pending on the truck model).

  • 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 direction 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 direction selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 191: Indicator Module Version

    Operating Driving Actuating the drive direction se-  lection lever with the travel direc- tion selector and indicator mod- ule version – 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 Operating Driving Electrical braking recovers energy for the bat- tery. This results in a longer operating time be- tween the charging processes and less wear to the brakes. The truck can also be braked with the service brake by actuating the brake pedal (2). In the first section of the brake pedal's travel, only the regenerative braking takes effect.

  • Page 197: Actuating The Electric Parking Brake

    Operating Driving Actuating the electric parking  brake  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. – Do not leave the truck until the park- ing brake has been applied.
  • Page 198 Operating Driving Releasing the electric parking brake af- ter the truck has been switched on – Press the push button (1) to release the  parking brake. The truck is held in place by the traction mo- tor. Manually actuating the electric parking brake when the truck is stationary Applying the parking brake manually –...
  • Page 199 Operating Driving Cause Effect The electric parking brake is immediately ap- plied with an audible sound. The truck is switched off. The LED (2) will light up briefly with a steady light until the control units switch off. The electric parking brake is immediately ap- The emergency off switch is actuated.
  • Page 200 Operating Driving NOTE If the drive unit fails, the truck can be braked by pressing the push button (1). The truck brakes more strongly if the push button (1) is pressed and held or pressed several times. The electric parking brake cannot be released by actuating the accelerator pedal.

  • Page 201: Malfunctions In The Electric Parking Brake

    A possible cause of the malfunction is that the parking brake cannot determine whether 6219_003-006_V2 the truck is stationary or still in motion. The following section describes how to actuate the parking brake when it is faulty: Actuating a faulty parking brake when the...
  • Page 202 Operating Driving – Press the push button (1) several times in succession so that the push button is actu- ated for a total of five seconds. The parking brake is applied with an audi- ble sound. After the push button is released, the parking brake should not make any fur- ther sounds;...
  • Page 203 Operating Driving Activation and intervention by the "Safe parking" function Cause Effect The following message appears in the display: Parking brake cannot be applied. The driver's seat is vacated. The electric park- - To confirm, press the  softkey. ing brake cannot be applied or previously could A warning signal sounds when the driver's seat not be applied.
  • Page 204 Operating Driving Message: Parking brake cannot be applied If the truck control unit detects a malfunction in  the parking brake, the truck cannot be switch- ed off. The message ● Parking brake can-   appears on the not be applied display-operating unit.

  • 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 Cab Door Is Open

    Operating Driving Speed reduction when the cab door is open  WARNING Risk of accident from sudden deceleration of the truck If the cab door is opened while the truck is in motion, the truck brakes automatically. – Keep the cab door closed when driving. With the "cab"...

  • Page 208: Speed Restriction (Variant)

    Operating Driving Speed restriction (variant)  The speed restriction (variant) is a function that can be configured by the fleet manager. It sets a maximum speed that can either be permanent or be called up by the driver. This function helps the driver to comply with speed restrictions, e.g.
  • Page 209 Operating Driving The menu that opens offers the following func- tions: ● Permanent Enabling this function limits the speed until the fleet manager disables this function. ● By pressing a button If this function is activated, the driver may switch the speed restriction on and off by pressing the ...

  • 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  softkey.  The orange-coloured activation bar next to the 08:20  softkey lights up. The cruise control func- tion is ready. The greyed-out  symbol (1) appears on the display. Taking the cruise control function off standby Pressing the  softkey again takes the func- tion off standby.
  • 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).  196 56388011501 EN - 05/2022  -  08...
  • 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 restriction set to less than 4.5 km/h. ● The truck control unit detects abnormalities, ●...

  • 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 gradients. – 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: Wheel Chock (Variant)

    Operating Parking – In the "push button ignition" variant, press  the button. (1) 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 unless explicit instructions to this effect have been given by the responsible fleet manager.

  • Page 218: 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 219: Operating Devices For The Lifting System

    Operating Lifting Triple 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). Operating devices for the lifting system The method of operating the lifting system de- pends on the operating devices included in the truck's equipment.
  • Page 220 Operating Lifting  WARNING Risk of injury due to delayed response from the truck! If the lifting movements are configured to use low dynamics, the lifting system responds after a delay when the operating device is released, even in an emergency. The fork carriage does not stop immedi- ately upon release.

  • Page 221: Controlling The Lifting System Using Multi-Lever Operation

    Operating Lifting Controlling the lifting system us-  ing 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 222 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). Movements of the lifting system and meanings of the pictograms  Lowering...

  • Page 223: Controlling The Lifting System Using A Double Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 224 Operating Lifting Lifting/lowering the fork carriage To lift the fork carriage: – Move the "lift mast" 360° lever (3) in the direction of the arrow (B). To lower the fork carriage: – Move the "lift mast" 360° lever (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: –...

  • Page 225: Controlling The Lifting System Using A Triple Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 226 Operating Lifting – Move the "lift mast" 360° lever (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the direction of the arrow (C). To tilt the lift mast backwards: –...

  • Page 227: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 228 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 229 Operating Lifting Controlling the lifting system us-  ing 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 230: 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). Movements of the lifting system and meanings of the pictograms  Lowering...
  • Page 231 Operating Lifting 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  To lift the fork carriage: – Pull the Joystick 4Plus (1) backwards (B). To lower the fork carriage: –...

  • Page 232: 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  Lifting...

  • Page 233: 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 234: 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 235: Changing The Fork Arms

    Operating Lifting protection (variant)" in the chapter entitled "Lift height-dependent assistance systems". The lift cylinders have in-built fixed stops to prevent the fork arms from hitting the ground. The lower stop makes inserting the forks into a pallet more comfortable. The driver cannot adjust the fork wear protec- tion manually.
  • Page 236 Operating Lifting NOTE It is recommended that a transport pallet is ● used to supporting the fork arms when they are being installed or removed. The pallet size depends on the size of fork arms in use. It should be large enough that the fork arms do not protrude after being placed on the pallet.

  • Page 237: Fork Extension (Variant)

    Operating Lifting  DANGER There is a risk of fatal injury from a falling load or fork! – Tighten the locking screw (2) each time a fork is changed. – It is not permitted to drive or to transport loads without the locking screw in place. NOTE If the truck is equipped with the "load meas- urement"...
  • Page 238 Operating Lifting NOTE If the truck is equipped with the "load meas- urement" assistance system (variant), the "tare" function must always be run after the fork arms have been changed. Otherwise, cor- rect load measurement cannot be guaranteed. Attaching   DANGER Risk of fatal injury from falling load! At least 60% of the length of the fork extension must...

  • Page 239: Operation With Reversible Fork Arms (Variant)

    Operating Lifting – Insert the securing bolt fully into the fork extension. – Insert the linch pin into the securing bolt and secure. Operation with reversible fork  arms (variant)  DANGER Risk of fatal injury from falling load! Normal fork arms are not structurally designed for reverse operation.

  • Page 240: 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 241: Hydraulic Blocking Function

    Operating Lifting Load chains not under tension  DANGER Danger caused by a falling load! – Make sure that the chain(s) does (do) not become slack when lowering the load. Slack chains can, for instance, result from: Resting the fork carriage or the load on the ●...
  • Page 242 Operating Lifting NOTE Only the emergency steering function remains available.  226 56388011501 EN - 05/2022  -  08...

  • Page 243: 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 244 Operating Handling loads  DANGER Risk of fatal injury from the truck losing stability! Never exceed the load capacity indicated on the capacity rating plate. This applies to compact and homogeneous loads. If these values are exceeded, the stability and rigidity of the fork arms and lift mast cannot be guaranteed.
  • Page 245 Operating Handling loads Basic capacity rating plate 6219_003-337 Basic capacity rating plate Permissible lift height Weight of load to be lifted Distance between the load centre of gravity and the fork back There is always at least one capacity rating plate on the truck: the basic capacity rating plate.
  • Page 246 Operating Handling loads Example of reading the capacity rating plate:  The position numbers in the adjacent graphic correspond to the position numbers on the ba- sic capacity rating plate. Distance between the load centre of 5880 mm gravity and the fork back: 600 mm Permissible lift height: 5880 mm Weight of load to be lifted: 1000 kg The distance between the load centre of grav-...

  • Page 247: Picking Up Loads

    Operating Handling loads A large sideshift enables a strongly off-centre  load position. A large centre offset of the load results in a large reduction in the load capacity of the truck. XZP150 100x40x1200 Since non-integrated attachments can be re- h(mm) placed, multiple residual load capacity rating 6580...

  • Page 248: Danger Area

    Operating Handling loads sufficiently far apart and are positioned as far as possible under the load. If possible, the load should rest on the back of the fork. The load must not protrude too far over the fork tips, nor should the fork tips protrude too far out from the load.

  • Page 249: Transporting Pallets

    Operating Handling loads  DANGER Risk of injury! – Do not step on the fork.  DANGER Risk of injury! – Do not step under the raised forks.  DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position.

  • Page 250: 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, e.g. in Italy. – Contact the relevant authorities. –...

  • Page 251: Picking Up A Load

    Operating Handling loads shift or release unintentionally and cannot be damaged. When transporting suspended loads, suita- ● ble aids (e.g. guy wires or supporting poles) must be available so that accompanying persons can guide suspended loads and prevent the loads from swinging. Take particular care to ensure that there is ●...
  • Page 252 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 253 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 254 Operating Handling loads – Lower the load while maintaining ground  clearance. – Tilt the lift mast backwards.  The load can be transported.  238 56388011501 EN - 05/2022  -  08...

  • Page 255: Determining Visibility Conditions When Driving With A Load

    Operating Handling loads Determining visibility conditions when driving with a load 6301_003-167 Area that is not visible (max. 1085 mm) Load Load height (in driving position) Driver's eye level 4000 mm (distance to the front from the rear corner of the load when it is positioned on the fork carriage in the driving position) The driver's field of vision can be severely limited when driving with a larger load (Y) or...

  • 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  WARNING Risk of accident due to unintentional switch-off of the intermediate lift cut-out. If the truck is also equipped with the "intermediate lift cut-out" variant and the shake function is performed close to an intermediate lift cut-out lift limit, this may inadvertently cancel the lift limit.
  • Page 260 Operating Handling loads Double mini-lever:  – Move the 360° lever (2) back and forth between positions (A) and (B) four times. Then continue to move the component in the same way. Triple mini-lever:  – Move the 360° lever (3) back and forth between positions (A) and (B) four times.

  • Page 261: Setting Down A Load

    Operating Handling loads Fingertip:  – Move the operating lever (5) back and forth four times. Then continue to move the com- ponent in the same way. 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.
  • Page 262 Operating Handling loads – Drive up to the stack with the load lowered  in accordance with regulations. – Set the lift mast to vertical. – Lift the load to the stacking height. – Drive the truck towards the rack carefully. –...

  • Page 263: Driving On Ascending And Descending Gradients

    Operating Handling loads Driving on ascending and de-  scending gradients  DANGER Risk of fatal injury! Driving on ascending and descending gradients car- ries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 264: Driving Onto Lifts

    Operating Handling loads Driving onto lifts  The driver may only use this truck on lifts with a sufficient load capacity and for which the operating company has been granted authori- sation (refer to the section entitled "Definition of responsible persons").  DANGER There is a risk of fatal injury from being crushed or run over by the truck.

  • 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: Lift Height-Dependent Assistance Systems

    Operating Lift height-dependent assistance systems Lift height-dependent assistance systems Optical lift height measuring sys- tem (variant) Design and function  This truck can be fitted with an optical lift height measuring system as a variant. This system is a prerequisite for the assistance systems described in this chapter.
  • Page 267 Operating Lift height-dependent assistance systems Cleaning  It is recommended that the LED sensor glass (2) and the reflector (1) are checked before starting work and, if required, cleaned. The cleaning frequency depends on the appli- cation conditions of the truck. The quality of the light signal may also be reduced as a re- sult of heavy rain or fogging up of the sensor.
  • Page 268 Operating Lift height-dependent assistance systems  CAUTION Risk of damage to the LED lift height sensor through high-pressure cleaning! A high-pressure cleaner can damage the LED lift height sensor due to the penetration of water. This can result in incorrect measurements. –...
  • Page 269 Operating Lift height-dependent assistance systems Emergency operation in the event of malfunctions In the event of a malfunction in the height measurement system, the truck switches to emergency operation. In emergency operation, the assistance sys- tems listed below that are dependent on the lift height are not available: Lift height display ●...

  • Page 270: Lift Height Display (Variant)

    Operating Lift height-dependent assistance systems Lift height display (variant)  If the truck is equipped with the optical lift height measuring system, the current lift height (1) appears permanently in the display- operating unit. The lift height displayed corresponds to the 7,0°...

  • Page 271: Intermediate Lift Cut-Out (Variant)

    Operating Lift height-dependent assistance systems Intermediate lift cut-out (variant)  This function interrupts the lifting process at a set lift height. The intermediate lift cut-out function is useful if the fork carriage is fre- quently lifted to a particular lift height. There are two options when buying the truck: When buying the truck, the lift heights at which the intermediate lift cut-out takes...
  • Page 272 Operating Lift height-dependent assistance systems NOTE The display always displays the next lift limit that is in the path of the current lifting move- ment. The next lift limit at which the function will intervene is highlighted in grey in the display.
  • Page 273 Operating Lift height-dependent assistance systems Option: Lifting beyond the intermediate lift cut-out using the "F button" Optionally, the authorised service centre can configure the function so that the intermedi- ate lift cut-out is suspended by pressing the "F" button on the operating devices for the hydraulic functions.
  • Page 274 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  softkey.  Lift cut-out Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en  258 56388011501 EN - 05/2022  - ...
  • Page 275 Operating Lift height-dependent assistance systems This menu offers three storage locations.  – To configure storage location 1, press Intermediate lift cut-out  softkey. Intermediate lift cut-out 1 Intermediate lift cut-out 2 Intermediate lift cut-out 3 End lift cut-out Fleet manager 6219_003-315_en In this menu, you can define the desired lift ...

  • Page 276: Lift Transition Damping

    Operating Lift height-dependent assistance systems – To deactivate the  intermediate lift , press the cut-out 1 Intermediate  softkey. lift cut-out 1 Intermediate – Press the scroll button  lift cut-out 1 intermediate lift cut-out 1 is deactivated. The orange activation bar goes out.

  • Page 277: End Lift Cut-Out (Variant)

    Operating Lift height-dependent assistance systems End lift cut-out (variant)  This assistance system limits the lift height of the fork carriage. This assistance system does not release the driver from the obligation to observe the "Safety regulations for handling loads". The end lift cut-out is active by default when the truck is switched on.
  • Page 278 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  softkey.  Lift cut-out Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en  262 56388011501 EN - 05/2022  - ...
  • Page 279 Operating Lift height-dependent assistance systems – Press the  softkey.  End lift cut-out Intermediate lift cut-out 1 Intermediate lift cut-out 2 Intermediate lift cut-out 3 End lift cut-out Fleet manager 6219_003-315_en In this menu, you can define the desired lift ...

  • Page 280: Speed Reduction When The Fork Carriage Is Raised (Variant)

    Operating Lift height-dependent assistance systems – To deactivate the  End lift cut-out press the  softkey. End lift cut-out – Press the scroll button  Intermediate is deactivated. lift cut-out 1 End lift cut-out The orange activation bar goes out. Enter desired height 6,892 = Clear = Deactivate...
  • Page 281 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 56388011501 EN - 05/2022  - ...
  • Page 282 Operating Lift height-dependent assistance systems – Press the  softkey.  Lift height Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the desired  height. Speed reduction when NOTE the fork carriage is raised » Lift height The assistance system intervenes automati- cally from 500 mm.
  • Page 283 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 56388011501 EN - 05/2022  - ...
  • Page 284 Operating Lift height-dependent assistance systems – Press the softkey.  Speed restriction Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the maximum  speed. – Enter the speed using softkeys  0 to 9 Speed restriction –...

  • Page 285: Electrical Fork Wear Protection (Variant)

    Operating Lift height-dependent assistance systems Electrical fork wear protection  (variant) This assistance system, in conjunction with the optical height measuring system, ensures that the fork arms do not touch the ground. The correct height for inserting the forks in a pallet can also be configured.
  • Page 286 Operating Lift height-dependent assistance systems NOTE Alternatively, the authorised service centre can parametrise the "F" button to cancel the fork wear protection for the complete lowering of the fork. NOTE When you change fork arms, the fork wear protection must be zeroed. –...
  • Page 287 Operating Lift height-dependent assistance systems – Press the  Fork wear protection softkey. Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en In this menu you can define the desired ...

  • Page 288: Tilt Angle-Dependent Assistance Systems

    Operating Tilt angle-dependent assistance systems Tilt angle-dependent assistance systems Mast tilt angle display (variant)  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 289 Operating Tilt angle-dependent assistance systems positioning reduces wear on various compo- nents, 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- ● tioning" feature Automatic startup of the "Automatic mast ●...
  • Page 290 Operating Tilt angle-dependent assistance systems Function checking of the auto- matic mast vertical positioning function (variant)  CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! – Before using the "automatic mast vertical position- ing"...
  • Page 291 Operating Tilt angle-dependent assistance systems – Drive the truck into an area that is to be used for placing loads into stock and re- moving loads from stock. Once the "automatic mast vertical positioning" assistance system has been calibrated, a pal- let can be stored horizontally in a rack when the truck is standing on a HGV ramp, for ex- ample.
  • Page 292 Operating Tilt angle-dependent assistance systems – Press the scroll keys    until the  Cal- menu appears. ibration – Press the  softkey. Calibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en – Press the  softkey.

  • Page 293: 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 294 Operating Load-dependant assistance systems Configuration by the fleet manager – Activate the "Access authorisation for the fleet manager". – Press the  button. – Press the  softkey. – Press the   softkey.  Truck settings – Press the soft-  Overload detection key.
  • Page 295 Operating Load-dependant assistance systems In this menu you can define the desired  weight. – Enter the weight using softkeys 0 to 9 Overload detection NOTE Only a lower value than the permissible load Enter desired weight capacity of the truck can be entered as an overload.
  • Page 296 Operating Load-dependant assistance systems Dynamic Load Control 1 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria: Lift height ● Load weight ● Load movements which could lead to critical conditions are slowed down if necessary. Dynamic Load Control 1 intervenes in the fol- lowing operating situations: With a telescopic lift mast:...
  • Page 297 Operating Load-dependant assistance systems  WARNING Risk of accident due to the slow response of the lifting system! If the lifting movements are configured to use low dynamics, the lifting system responds after a delay when the operating device is released, even in an emergency.
  • Page 298 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 restriction again. Re- lease the accelerator pedal for a short period to do this. The bar display on the display of the display- ...

  • Page 299: Load Measurement (Variant)

    Operating Load-dependant assistance systems If a sensor belonging to Dynamic Load Con-  trol 2 fails, the level of intervention from the function is increased to a maximum. A cross appears instead of the bar. – If this display appears permanently, contact the authorised service centre.

  • Page 300: Calibrating The Load Measurement

    Operating Load-dependant assistance systems NOTE The load measurement must be calibrated in order to ensure accuracy at all times. The "access authorisation for the fleet manager" is required for the calibration. This access is required: After changing the fork arms, ●...
  • Page 301 Operating Load-dependant assistance systems – Activate the "Access authorisation for the fleet manager". – 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...

  • Page 302: 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 303 Operating Load-dependant assistance systems – Press the  softkey (1).  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 0,0° fork slightly the measurement accuracy in trucks with mul- ti-lever operation.

  • Page 304: Tare Function (Variant)

    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 305 Operating Load-dependant assistance systems – Press the  softkey (1).  The activation bar next to the  symbol lights 0,70 --,-- 0,0° 6219_003-225   prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The message Zero-  ...

  • Page 306: Total Load (Variant)

    Operating Load-dependant assistance systems Total load (variant)  Use the "total load" variant to calculate the total weight of multiple loads. The "total load" is an additional function of the "load meas- urement". It records the individual loads and stores up to three total loads. This allows, for example, three different con- tainers to be laden and their loading weight to be determined.
  • Page 307 Operating Load-dependant assistance systems The first menu level appears. – Press the  softkey. – Press the  softkey. A menu appears with three storage locations  for the total load. The total load is explained here using  0,00 – Press the  softkey.
  • Page 308 Operating Load-dependant assistance systems The message with the prompt  Lower fork   appears. slightly – 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°...

  • Page 309: Zeroing The Assistance Systems

    Operating Zeroing the assistance systems Zeroing the assistance systems Zeroing process The following assistance systems sometimes require zeroing. Load measurement ● When changing fork arms or attachments Lift height display ● When replacing worn tyres For increasingly worn tyres / for new tyres Mast tilt angle display ●...
  • Page 310 Operating Zeroing the assistance systems – Press the softkey.  Zeroing Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Zeroing Fleet manager 6219_003-323_en – Press the softkey for the assistance func-  tion for which the zeroing is to be per- formed, e.g.
  • Page 311 Operating Zeroing the assistance systems The instructions are shown in the display.  Here: Lower forks After the instructions have been followed, Load weight the messages Zeroing successful are displayed. Zeroing failed – If zeroing failed, try again. Lower forks –...

  • Page 312: Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Depressurising the hydraulic system Need to depressurise the hy- draulic 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 313: Wizard For Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Wizard for depressurising the hydraulic 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 314 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, press the softkey.

  • Page 315: Depressurising The Hydraulic System Using Multi-Lever Operation

    Operating Depressurising the hydraulic system The following message appears:  Disen- gage all hydraulic axles, then   switch off the truck – Depressurise the hydraulics, see the rele- vant section for the respective operating de- vices.  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 316: Depressurising The Hydraulic System Using Multi-Lever Operation And The 5Th And 6Th Function

    Operating Depressurising the hydraulic system The hydraulic circuits of the basic functions are now depressurised. 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.

  • Page 317: Depressurising The Hydraulic System Using A Double Mini-Lever

    Operating Depressurising the hydraulic system – Start the "wizard for depressurising the hy- draulic 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.

  • Page 318: 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 319: 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 320: 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 321: 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 322: Depressurising The Hydraulic System Using The Quadruple 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 323: 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 324: 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 325: 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 326: 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 327: 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 328: 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 329: Attachments

    Fitting attachments If the truck is equipped with an integrated at- tachment (variant) at the factory, the specifica- tions in the STILL operating instructions for integrated attachments must be observed. If attachments are fitted at the place of use, the specifications in the operating instructions from the attachment manufacturer must be ob- served.
  • Page 330 Operating Attachments  WARNING Risk of accident due to incorrect labelling! The use of attachments can cause accidents if the labelling is incorrect or missing. If the truck is not fitted with an attachment-specific residual load capacity rating plate, and the operating devices are not marked with the relevant pictograms, the truck must not be used.
  • Page 331 Operating Attachments Plug connectors on the lift mast  – Before fitting the attachment, depressurise the hydraulic system; see the chapter enti- tled "Depressurising the hydraulic system".  CAUTION Risk of damage to components! Open connections on the plug connectors (1) can become dirty.

  • Page 332: General Instructions For Controlling Attachments

    Operating Attachments General instructions for control- ling 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 333: Attachment Example For The Connection Of The Auxiliary Hydraulics

    Operating Attachments NOTE If several hydraulic functions are used at the same time, these functions can influence each other. For example, if the fork carriage is raised and an attachment is operated at the same time, this may change the lifting speed or the operating speed of the attachment.
  • Page 334 Operating Attachments Attachment example for an attachment for ad-  justment of the fork arms Auxiliary hydraulics 1 Auxiliary hydraulics 2 Electrical connection for switch valve 1 (two switch valves are possible) If an attachment is connected to the auxiliary hydraulics 1 (1) and this attachment requires another function, this is referred to as the function of the auxiliary hydraulics 3.
  • Page 335 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 applied. If the parking brake is released pre- maturely, the settings menu will close.
  • Page 336 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 337: Clamp Locking Mechanism (Variant)

    Operating Attachments The return flow is displayed in addition to the  supply flow at full brightness. To adjust the revolution speed, press the  softkey. Auxiliary hydraulics 2 – To save the setting, press the  softkey. Forwards 3 900 1/min The settings are saved.
  • Page 338 Operating Attachments – See the section concerning the relevant op- erating device.  322 56388011501 EN - 05/2022  -  08...

  • Page 339: 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 340 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 341: 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". The central and bottom parts of the picto- grams on each operating lever show the func- tion that is activated by that lever.
  • Page 342 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 343: 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 344 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 345: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operating Attachments Controlling attachments using  the double mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (3) and the cross lever (1) are used to control the "5th function".
  • Page 346 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 extended. If the function key for the "5th function" (3) is actuated and the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork arms open.

  • Page 347: Controlling Attachments Using A Triple Mini-Lever

    Operating Attachments Controlling attachments using a  triple 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 348 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 349: 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 350 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 351: 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 352 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 353: 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 354: 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 355 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 356: 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 1 2 3  the Fingertip and the 5th func- tion NOTE For technical reasons, clamping attachments...
  • Page 357 Operating Attachments Picto- Attachment function gram Move sideshift to the right 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...

  • Page 358: 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 359 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 360: 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". The adhesive label bearing the pictograms for the hydraulic functions (3) for the Joy- stick 4Plus (2) and for the horizontal rocker 6219_003-166_V2...

  • Page 361: 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 362: Auxiliary Equipment

    Operating Auxiliary equipment Auxiliary equipment 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. Shock recognition (variant) The shock recognition is an equipment var- iant of the FleetManager (variant) in which an...
  • Page 363 Operating Auxiliary equipment 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 – To activate the "Intermittent mode" operat- ing stage, press the softkey again. The symbol (2) is shown with an orange back- ground.

  • Page 364: Filling The Washer System

    Operating Auxiliary equipment – To switch this operating stage off, press the softkey repeatedly until the symbol (1) ap- pears again on the display. Roof panel wiper and washer  – To activate the "On" operating stage, press the corresponding softkey  (9).

  • Page 365: Operating The Rear Window Heating

    Operating Auxiliary equipment – Operate the screen washer system until washer fluid is discharged from the spray nozzles. Operating the rear window heat-  – To switch on the rear window heating, push the associated Softkey on the display-oper- ating unit. The rear window heating is switched on.
  • Page 366 Before the truck is able to ac- celerate to the maximum speed permitted for outdoor areas, the speed limitation must still be unlocked. To do this, release the accelerator briefly and then operate the ac- celerator again.
  • Page 367 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 368 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 369 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 370 Operating Auxiliary equipment Sensitivity Range Beam angle 2 m 42° 4 m 33° High (3) 8 m 22.5° 16 m 20° 24 m 15° 2 m 45° 4 m 43° Very high (4) 8 m 30° 16 m 22.5° 24 m 18° – After the adjustment, refit the cover. – Refit the ceiling sensor and connect it. –...

  • Page 371: Optical Assistance Systems

    Operating Optical assistance systems Optical assistance systems Circumferential view camera system (variant) Design Front camera Left-hand camera Right-hand camera Monitor Rear camera The camera system consists of four cameras and a monitor for the camera images. It pro- vides a 360° circumferential view and supports the driver in handling the truck.
  • Page 372 Operating Optical assistance systems system makes it easier to detect other vehi- cles, people and objects in the vicinity of the truck. For safe operation of the camera system, it must be sufficiently bright. The camera sys- tem is not suitable for poorly lit or dark envi- ronments.
  • Page 373 Operating Optical assistance systems  CAUTION Distorted display of the surroundings. Distances and geometric dimensions of obstacles may differ in reali- ty from the representation on the screen. – Regardless of the cameras, always look in the direction you are driving. –...
  • Page 374 Operating Optical assistance systems Rear field of vision The four cameras cover a 360° detection area around the truck. In the hatched areas of the representation above, the fields of vision of the respective adjacent cameras overlap. Monitor The cameras transmit their images to a moni- tor mounted on the top of the right-hand A col- umn via a double joint.
  • Page 375 Operating Optical assistance systems Operation Before attempting to drive, the driver must en- sure that all four cameras are operational and set correctly. – For the right-hand and left-hand cameras, hold one hand out of the right-hand cab window and one hand out of the left-hand cab window.

  • Page 376: Modular Camera System (Variant)

    Operating Optical assistance systems Modular camera system (var- iant) Design The modular camera system consists of the following components: Camera on the right-hand fork arm Front view camera in the lift mast Monitor Rear view camera on the overhead guard These cameras can only be ordered individu- ally or in the following combinations: Front view camera in the lift mast + rear...
  • Page 377 Operating Optical assistance systems The camera system makes it easier to detect other vehicles, people and objects in the vicin- ity of the truck. For safe operation of the camera system, it must be sufficiently bright. The camera sys- tem is not suitable for poorly lit or dark envi- ronments.
  • Page 378 Operating Optical assistance systems  CAUTION Distorted display of the surroundings. Distances and geometric dimensions of obstacles may differ in reali- ty from the representation on the screen. – Regardless of the cameras, always look in the direction you are driving. –...
  • Page 379 The camera angle is chosen in such a ● way that the counterweight is always visible and thus the immediate surroundings of the truck. STILL recommends not changing this setting. The image is displayed the correct way ● round, just like the interior mirror on a car.
  • Page 380 Operating Optical assistance systems  CAUTION When transporting tall loads, the front view camera cannot detect people or obstacles directly in front of the truck. Do not drive for long distances. If necessary, use a guide. Camera on the right-hand fork arm Camera may only be used to place loads ●...

  • Page 381: Laser-Smartfork Assistance System (Variant)

    Operating Optical assistance systems Cleaning – Clean the camera lenses with compressed air or use a small amount of glass cleaner to moisten the lenses. Do not use an ag- gressive cleaning agent or solvents. – Then carefully wipe away with a lint-free cloth.
  • Page 382 Operating Optical assistance systems  DANGER Risk of injury! Looking into the laser beam can damage the eyes, laser radiation (laser class 1M). – If there is a possibility that people are at risk, switch off the laser immediately. – Never look directly into the laser beam. –...
  • Page 383 Operating Optical assistance systems Precautionary measures – There must be no persons stood on the racking levels onto which the laser beam is projected. – If it is possible to see through the rack on- to racks situated behind the relevant rack, people must not stand on the racking lev- els opposite the rack on which the laser is working.
  • Page 384 See the chapter entitled "Config- uring favourites" in the separate operating instructions for the "STILL Easy Control dis- play-operating unit". – Automatic: Switch on the automatic func- tion using the softkey.
  • Page 385 Operating Optical assistance systems – Fully lower the fork carriage before driving any further. – Depending on the variant, switch off the la- ser. Manual: Press the softkey again to switch off the laser. Automatic: The laser switches off automatically if: The "lift/lower"...
  • Page 386 Operating Optical assistance systems  WARNING Possible damage to the laser due to improper clean- ing! – Do not use aggressive cleaning materials or sol- vents. – Do not use high-pressure cleaning equipment. – Never immerse the laser in water or other liquids. –...

  • Page 387: Cab

    Operating Opening and closing the cab  door  CAUTION Risk of component damage. If the cab door opens while driving, there is risk of damage from a collision. – The cab door must be latched securely in the en- gaged position. Opening the cab door from the outside: –...
  • Page 388 Operating Opening and closing the 180° cab door (variant)  WARNING Risk of accident if the restraint system is not used. If the truck has no restraint system other than the cab door and seat belt, it is possible to fall out when driving with the door open.
  • Page 389 Operating – Push in the latch. Push the cab door out- wards. Closing the cab door from the outside: – Take hold of the door by the door han- dle (7). Close the cab door by pushing. Closing the cab door from the inside: –...
  • Page 390 Operating Closing the front door section from the inside: – To release the latch, press the knob (10) in  firmly. – Take hold of the handle (5). – Pull the front door section inwards and close it. 6301_003-165 – Move the locking handle (9) into a vertical ...

  • Page 391: Opening And Closing The Side Window

    Operating Opening and closing the side  window  WARNING There is a risk of crushing between the window frame and side window due to the side windows slip- ping inadvertently during travel. – Make sure that the handle engages securely in the corresponding stop slot.

  • Page 392: Radio (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. Heating system (variant)  DANGER...
  • Page 393 Operating  DANGER Risk of fire due to overheating! The heating system can overheat if the hot air cannot escape from it. The heating system may only be switch- ed on if the blower is running and the heating system is not covered by objects (such as a jacket or cover).
  • Page 394 Operating Selecting blower settings – To select a lower fan output, turn the fan control knob (2) anticlockwise. – To select a high blower output, turn the fan control knob (2) clockwise. Setting heating levels – To set a lower heater power, turn the heat- ing level control knob (1) anticlockwise.
  • Page 395 Operating Adjusting the air distributors  The air distributors for the driver are always supplied with air. It is not necessary to adjust the heating system using the operating devi- ces. – To open the air distributor, push the inden- tation (1) on the disc.

  • Page 396: Clipboard (Variant)

    Operating Switching the air conditioning on and off – Push the on/off switch (5). The LED on the switch lights up red. The air conditioning is switched on. – Press the on/off switch (5) again. The LED on the switch goes out. The air con- ditioning is switched off.

  • Page 397: 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 398: Trailer Operation

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

  • Page 399: Coupling Pin In The Counterweight

    Operating Trailer operation  CAUTION Risk of damage to components! A support load is not permitted. – Do not use trailers with tillers supported by the tow coupling. This truck is suitable for the occasional towing of trailers. If the truck is equipped with a tow- ing device, this occasional towing must not exceed 2% of the daily operating time.
  • Page 400 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 401: Automatic Tow Coupling

    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 402 Operating Trailer operation  DANGER Risk of injury when coupling! People can become trapped between the truck and the trailer. – When coupling, ensure that there are no persons present between the truck and the trailer.  WARNING Risk of crushing when reaching into the coupling. When the coupling pin slams shut, there is a risk of crushing limbs in the coupling.
  • Page 403 Operating Trailer operation  WARNING Risk of component damage if the tiller in the tow coupling is tilted! The tiller should be kept as horizontal as possible when towing. This ensures that the rotation range is sufficient at the top and bottom. The authorised service centre can adjust the assembly height for the tow coupling to the tiller height if necessary.
  • Page 404 Operating Trailer operation NOTE The coupling pin is correctly engaged if the control pin (3) does not protrude out of its guide.  DANGER Risk of accident due to open coupling pin! If the coupling pin drops out during towing, the trailer will work loose.
  • Page 405 Operating Trailer operation The tow coupling is opened. – Slowly drive the truck forwards until the tow- ing eye and towing jaws are disconnected. – 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.

  • Page 406: Towing Trailers

    Operating Trailer operation – Tow the trailer. Uncoupling model RO*245  – Take measures to prevent the trailer from rolling away, e.g. using wheel chocks. – Push the hand lever (5) upwards. – Slowly drive the truck forwards until the tow- ing eye and towing jaws are disconnected.

  • Page 407: 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 408 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 409 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 410 Operating Cold store application – 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. Water top-up systems must not be used at temperatures below 0°C, as this could cause the systems and the water present in the hose lines to freeze.

  • Page 411: Display Messages

    Operating Display messages Display messages Messages Certain truck conditions may cause event-rela- ted messages to be shown on the display of the display-operating unit. There are messages about operation and messages about the truck. If a message about operation appears, the display-operating unit will prompt you to perform an action.
  • Page 412 Operating Display messages Code Shown on display Cause/action This message about the on-board charger is triggered by different causes: A possible fault in the electrical connection be- tween the battery and the on-board charger. The fuse for the on-board charger on the truck  ...
  • Page 413 Operating Display messages Code Shown on display Cause/action If the temperature at the drive units is too high, this message appears. Sprint mode is no longer Acceleration restricted.     available. The truck switches to Classic mode. Temperature Acceleration is restricted. Curve Speed Control reduces the curve speed.
  • Page 414 Operating Display messages Code Shown on display Cause/action The load on the driver's seat is released but the parking brake cannot engage due to a defect. Secure the truck against     - Secure the truck with wedges so that the truck rolling away does not roll away.
  • Page 415 Operating Display messages Code Shown on display Cause/action The truck control unit detects that the braking force of the electric parking brake is reducing.     - Secure the truck with wedges so that the truck Check parking brake does not roll away. - Contact your authorised service centre.
  • Page 416 Operating Display messages Code Shown on display Cause/action This message is not displayed during normal Configuration: Please   operation.   wait - Contact the authorised service centre. If the truck is equipped with an integrated charg- er (variant) and charging is complete, this mes-  ...
  • Page 417 Operating Display messages Code Shown on display Cause/action There is a fault with the charging program. The On-board charger power V7001 charging process is performed with reduced reduction, service re- V7062 power.   quired - Contact the authorised service centre. This message is not displayed during normal  ...
  • Page 418 Operating Display messages Code Shown on display Cause/action If the battery is charged after locking sprint mode or a normal temperature is reached, this     Enable sprint mode message appears. Sprint mode can be used again once the truck has been restarted. If the battery experiences under-voltage or too high a temperature, this message appears.

  • Page 419: Messages About The Truck

    – 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 420: Procedure In Emergencies

    Operating Procedure in emergencies Procedure in emergencies Emergency shutdown   WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch (1) will discon- nect the drives from the power supply. The truck will not be held on a slope by the regenerative brake.

  • Page 421: Procedure If Truck Tips Over

    Operating Procedure in emergencies To decelerate the truck with the mechanical brake, the brake pedal has to be pressed down further No power steering effect; the steering ● forces are increased by the remaining emergency steering function The "Curve Speed Control" system (auto- ●...

  • Page 422: Emergency Hammer

    Operating Procedure in emergencies Emergency hammer  The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazard- ous situation, for example if the truck has top- pled over and the cab door cannot be opened. Single-pane safety glass can be struck rela- tively safely using the emergency hammer in order for the driver to escape or be rescued...

  • Page 423: Emergency Lowering

    Operating Procedure in emergencies The message Emerg. direct. via   drive direction switch pears. The temperature of the display-operating ● unit is too low. This status is shown in the display as fol- lows:   The display-operating unit has failed. ●...
  • Page 424 Operating Procedure in emergencies – Remove the lower lid (1) on the right-hand  side of the footwell panelling next to the accelerator pedal. 6301_003-036 – Remove the hexagon socket wrench (2)  from the compartment on the right next to the driver's seat. 6219_003-260 –...

  • Page 425: Emergency Actuation Of The Electric Parking Brake

    Operating Procedure in emergencies – Re-tighten the emergency lowering screw. – Return the hexagon socket wrench to the support mounting in the compartment. – Refit the lid.  DANGER If the truck is operated while the hydraulic controller is blocked, there is an increased risk of accidents. –...
  • Page 426 Operating Procedure in emergencies 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 427: Towing

    Operating Procedure in emergencies Towing  Safety information  DANGER The brake system on the towing vehicle may fail. Risk of accident! If the brake system of the towing vehicle is not ade- quately sized, the vehicle may not brake safely or the brakes may fail.
  • Page 428 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 429 Operating Procedure in emergencies – Sit in the driver's seat in the truck being towed. Fasten the seat belt. – Use the available restraint systems. – Manually release the parking brake (refer to the previous section entitled "Emergency actuation of the parking brake". The truck is now held in place only by the braking force of the towing vehicle.

  • Page 430: Charging Quick-Access

    Operating Charging quick-access Charging quick-access Charging quick-access in the counterweight (variant) The charging quick-access (variant) is an ad- ditional charger socket behind a lid in the counterweight. This charger socket enables charging of lead-acid batteries and lithium-ion batteries without having to open the battery door.
  • Page 431 Operating Charging quick-access – 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.  DANGER Risk of fire due to overheated connec- tion assemblies! Plugs that are not fully plugged in can produce excessive heat.
  • Page 432 Operating Charging quick-access General NOTE To ensure maximum battery life, always charge lead-acid batteries fully. For intermedi- ate charging during work breaks, use an elec- trolyte circulation pump (variant). Lithium-ion batteries may be charged intermediately as often as required with no restriction to the bat- tery life.
  • Page 433 Operating Charging quick-access – When the charging process is complete, disconnect the charging cable from the charging quick-access (1). 2. Lead-acid battery with truck switched The parking brake is applied automatically or a message appears in the display of the dis- play-operating unit prompting the driver to ap- ply the parking brake.
  • Page 434 Operating Charging quick-access Charging state display in the display-op- erating unit for lithium-ion batteries When charging lithium-ion batteries, the  charging state display (3) appears in the dis- play-operating unit. If the charging state display (3) does not ap- 10:48 pear, there is an error. The charging quick-ac- cess (1) may not recognise the charging ca- ble.

  • Page 435: On-Board Charger

    Operating On-board charger On-board charger General information about the on-board charger (variant) With an on-board charger (variant), there is no need to keep space for a battery charger on company premises. This battery charger is suitable for operation using the public 400-V three-phase supply system with a CEE-16-A socket.

  • Page 436: Changing The Battery Type Used

    Reconfiguration not required: Changing from a lead-acid battery to a ● STILL lithium-ion battery Changing from one STILL lithium-ion bat- ● tery to another STILL lithium-ion battery The battery charger receives all necessary data directly from the lithium-ion battery.

  • Page 437: Configuring The On-Board Charger

    Operating On-board charger Reconfiguration required: Changing from a STILL lithium-ion battery ● to a lead-acid battery Changing from a large lead-acid battery to ● a smaller lead-acid battery with a lower bat- tery capacity or vice versa – Refer to the section entitled "Changing to a different battery type"...
  • Page 438 Operating On-board charger menu  On-board charger The following functions can be configured or switched on: Charging characteristic curve ● Charging characteristic curve ● Charging start time Charging start time ● Charging current limitation ● Maintenance charge Charging current limitation Maintenance charge Fleet manager 6219_003-285_en...
  • Page 439 Operating On-board charger menu  Charging start time – Enter the charging start time using soft- keys  Charging start time – To , press the  button. save – To activate the charging start time, press the scroll button  Enter time to The display reverts to the On-board start charging...
  • Page 440 Operating On-board charger The symbol changes to  (3). The orange  activation bar lights up next to the softkey. The charging state indicator (2) is animated in 10,0 green. Battery charging takes place. The remaining charging time (1) is displayed in the top-left. 75 % 6219_003-289 Charging current limitation...

  • Page 441: Charging The Battery

    Operating On-board charger active, the on-board charger checks the charging state of the battery from time to time and charges it if necessary. – Press the soft- Maintenance charge key. If the maintenance charge is active, the or- ange activation bar lights up next to the soft- key.
  • Page 442 Operating On-board charger  DANGER Risk of explosion due to static charge! If the driver is electrostatically charg- ed, touching the battery may produce sparks. These sparks can ignite oxyhy- drogen gas that has formed. – To dissipate a possible electrostatic charge, touch an earthed component that is situated a long way from the battery.
  • Page 443 Operating On-board charger  DANGER Risk of fire due to arcs! If the charging plug is disconnected dur- ing the charging process (under load), an arc will be produced. This can lead to erosion at the contacts, which consider- ably shortens the service life of the con- tacts and poses a fire hazard.
  • Page 444 Operating On-board charger NOTE To ensure maximum battery life, always charge lead-acid batteries fully. For intermedi- ate charging during work breaks, use an elec- trolyte circulation pump (variant). Lithium-ion batteries may be charged intermediately as often as required with no restriction to the bat- tery life.
  • Page 445 Operating On-board charger – Plug the truck plug (3) of the charging cable  into the charger socket (1) on the truck. – Make sure that the interlock (4) has closed correctly. After a self-test, the battery charger auto- matically begins the charging process. The LED (5) pulses in yellow.
  • Page 446 Operating On-board charger Charging state display on the charger  socket The LED (5) on the charger socket uses dif- ferently coloured flash codes to indicate the current status of the charging process. Only the authorised service centre may rectify mal- functions.
  • Page 447 Operating On-board charger Status Flash code Malfunction without shut-off: charging is continued at lower power   Yellow/red Charging process was aborted or no system voltage present. Overtemperature of the connected battery   Yellow/red Wait for restart after power failure Legend: →...
  • Page 448 Operating On-board charger End of the charging process  When the battery is fully charged, the bat- tery charger automatically stops the charging process. The charging state display (6) on 10:48 the display-operating unit of the truck shows 100% 88 % 6301_003-133 –...
  • Page 449 Operating On-board charger Stopping the charging process manually – Briefly press the charging button (7) on the  truck plug. The charging status display on the display-op- erating unit goes out. The mains plug can now be disconnected. – If the charging process needs to be started again, pull out the truck plug and plug it back in after approx.
  • Page 450 Operating On-board charger Cleaning Check the on-board charger on a regular ba- sis for contamination, particularly in the area of the fans. If significant contamination has accumulated on the battery charger, cooling may be im- paired. The isolation to the truck chassis may also be compromised.

  • Page 451: Compatible Batteries

    – Use only the batteries listed here. In addition to proprietary STILL lithium-ion batteries, only the following batteries may be used: Manufacturer Designation Capacity PzS, TCSM wet battery < 1700 Ah (80 V)

  • Page 452: Performance Data

    Operating On-board charger for gel batteries) is maintained. This produces the maximum battery capacity. If larger batter- ies than specified are charged, over the long term, the batteries can be damaged or may not fully charge. The values shown are for the maximum charging current of 170 A.

  • Page 453: 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  connector – Open the battery door.  CAUTION Risk of component damage! If the battery male connector is connected when the key switch is switched on (under load), a jump spark will be produced.

  • Page 454: Disconnect The Battery Male Connector

    Operating Connecting and disconnecting the battery male connector Disconnect the battery male  connector – Open the battery door.  CAUTION Risk of component damage! If you disconnect the battery male connector while the key switch is switched on (under load), an arc will be produced.

  • Page 455: Handling The Lead-Acid Battery

    Operating Handling the lead-acid battery Handling the lead-acid battery Safety regulations for handling the battery – National statutory provisions for the country of use must be followed when setting up and operating battery charging stations.  CAUTION Possible 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-...
  • Page 456 Operating Handling the lead-acid battery  WARNING Risk of crushing/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 457 Operating Handling the lead-acid battery  DANGER Risk of explosion due to flammable gases! During charging, the battery releases a mixture of oxygen and hydrogen (oxyhy- drogen gas). This gas mixture is explo- sive and must not be ignited. There must be no flammable materi- als or spark-forming operating materials within 2 m of the battery charger and the industrial truck when it is parked for...
  • Page 458 Operating Handling the lead-acid battery Performing battery maintenance The cell covers of the battery must be kept dry and clean. Terminals and cable shoes must be clean, lightly coated with battery grease and screwed on tightly. – Neutralise any spilt battery acid immediate- –...

  • Page 459: Maintaining The Battery

    Operating Handling the lead-acid battery – Do not block the ventilation gaps. – If the battery cover is deformed, contact the authorised service centre. Maintaining the battery  DANGER Danger to life and limb! – Observe the instructions in the chapter entitled "Safety regulations when handling the battery".

  • Page 460: 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 (dilute sulphuric acid) is poisonous and caustic! – Observe safety regulations for han- dling battery acid; see chapter "Bat- tery acid". – Wear personal protective equipment (rubber gloves, apron and protection goggles).

  • Page 461: Checking The Battery Charge Status And Calibrating The Battery Charge Indicator

    Operating Handling the lead-acid battery For a discharged battery, the acid density must be no lower than 1.14 kg/l. Checking the battery charge sta-  tus and calibrating the battery charge indicator  CAUTION Deep discharges shorten the service life of the bat- tery.
  • Page 462 Operating Handling the lead-acid battery calibrated to the newly inserted battery. The stored battery charge history is then deleted in the display-operating unit. – Activate the "Access authorisation for the fleet manager". – Press the  button. – Press the  softkey. –...

  • Page 463: Charging The Lead-Acid Battery

    Operating Handling the lead-acid battery – Press the  Calibrate discharge softkey. indicator After the instruction has been executed, the message Calibrate discharge indicator Calibration successful is dis- Calibration unsuccessful played. – If the calibration failed, try again. – If the calibration fails repeatedly, contact your authorised service centre.
  • Page 464 Operating Handling the lead-acid battery  DANGER Risk of explosion due to old batteries! Old and inadequately maintained batteries can cause excessive gas emissions and excessive heating dur- ing charging. The increased production of explosive gas can lead to an explosion. –...
  • Page 465 Operating Handling the lead-acid battery  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the truck is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens the service life of the contacts.
  • Page 466 Operating Handling the lead-acid battery NOTE Observe the information in the operating in- structions for the battery and the battery charger.  DANGER Risk of explosion! To ensure adequate ventilation, the bat- tery door must be locked in the charging position using the support bracket during the charging process.
  • Page 467 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 468: 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 469 Operating Handling the lead-acid battery 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. – Please refer to the operating instructions from the manufacturer of the battery charg- Ending the equalising charge The equalising charge ends automatically.

  • Page 470: Handling The Lithium-Ion Battery

    Operating Handling the lithium-ion battery Handling the lithium-ion battery Safety regulations for handling the lithium-ion battery First-aid measures  WARNING Risk of injury! Escaping gases can lead to breathing difficulties. Course of action required if gases or liquids escape – Immediately ventilate the area or go out into the fresh air;...
  • Page 471 Operating Handling the lithium-ion battery  WARNING Risk of crushing/shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. If parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed, this could lead to injuries.
  • Page 472 Operating Handling the lithium-ion battery – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire. Battery weight and dimensions  DANGER Risk of tipping due to change in battery weight! The battery weight and dimensions affect the stability of the truck.

  • Page 473: Lithium-Ion Batteries "Ggs Li-Ion 80 V Bg 7"36.2 Kwh And 118.4 Kwh

    Operating Handling the lithium-ion battery Lithium-ion batteries "GGS Li-Ion 80 V BG 7" 36.2 kWh and 118.4 kWh Battery male connector Safety valve Lifting eyes Diagnostic connector Display Maintenance cover for the technology com- partment  WARNING Risk of accident due to weakened lifting eyes. If bent lifting eyes are straightened, they lose their rigidity.

  • Page 474: Regulations For Storing Lithium-Ion Batteries

    Operating Handling the lithium-ion battery Regulations for storing lithium- ion batteries NOTE Lithium-ion batteries are classified as danger- ous goods according to class 9. The following recommendations apply: Wherever possible, store batteries at ● ground level so that they cannot be dam- aged by falling Store the batteries in a segregated area ●...
  • Page 475 Operating Handling the lithium-ion battery – Store in a way that protects the batteries against short circuits – Store batteries at a safe distance from flam- mable materials – Do not store batteries together with metallic objects – Store lithium-ion batteries separately from other types of batteries (no mixed storage) –...

  • Page 476: Checking The Battery Charge State

    Operating Handling the lithium-ion battery Checking the battery charge state The charge state of the lithium-ion battery can be read on the display-operating unit of the truck and on the lithium-ion battery display. Reading on the display-operating unit  – Apply the parking brake. –...
  • Page 477 Operating Handling the lithium-ion battery The truck can no longer be moved. A charge state of > 20% to 30% is indicated ● by yellow bars. A charge state of > 30% to 100% is indica- ● ted by green bars When charging, the charge state LEDs (3) light up green as a chase light.

  • Page 478: Charging The Lithium-Ion Battery

    Operating Handling the lithium-ion battery – If the charge state drops below 15%, drive to the charging station and charge the bat- tery.  WARNING There is no electric brake assistance when the bat- tery is switched off! The drives are de-energised when the battery is au- tomatically switched off.
  • Page 479 Operating Handling the lithium-ion battery To read the battery charge status, see the section entitled "Checking the battery charge status". – Park the truck securely. – Open the battery door completely. – Disconnect the battery male connector. – Keep away from naked flames. Do not smoke.
  • Page 480 Operating Handling the lithium-ion 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 481 Operating Handling the lithium-ion battery – Close the battery door. When doing so, en-  sure that no cables are crushed between the chassis and the battery door. The truck is equipped with a door contact switch for the battery door. If the battery door is not fully closed, the message Close appears on the display of...

  • Page 482: Replacing And Transporting The Battery

    Operating Replacing and transporting the battery Replacing and transporting the battery General information on replacing the battery  CAUTION Risk of components being damaged by the lifting accessory and battery rolling away! The lifting accessory and battery may roll away in an uncontrolled manner if the battery is not removed on a level, smooth floor with sufficient load-bearing capacity.

  • Page 483: Changing To A Different Battery Type

    – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Setting the new battery capacity and the new battery type –...

  • Page 484: Converting To Lithium-Ion Batteries

    The battery male connector and the plug ● connection Adjusting the display-operating unit ● – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Opening and closing the battery  door Opening the battery door –...
  • Page 485 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 486 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 487: Special Notes For Installing The Lithium-Ion Battery

    Operating Replacing and transporting the battery Special notes for installing the  lithium-ion battery With the exception of the following special notes, lithium-ion batteries are replaced in the same way as lead-acid batteries. – Push down the lifting eyes before inserting the battery into the battery compartment.
  • Page 488 Operating Replacing and transporting the battery Removing the battery – Park the truck securely and switch it off. – Open the battery door.  CAUTION Risk of component damage! If you disconnect the battery male connector while the key switch is switched on (under load), an arc will be produced.
  • Page 489 Operating Replacing and transporting the battery  CAUTION Risk of damage! – Lower the battery immediately if it knocks against the chassis above. – Slowly remove the battery from the battery compartment. Transporting and setting down the bat- tery  WARNING Risk of crushing or shearing! The battery must be transported very carefully, i.e.
  • Page 490 Operating Replacing and transporting the battery NOTE Do not straighten any bent lifting eyes; have them replaced by the authorised service cen- tre. – Carefully insert the battery into the battery compartment. When doing so, ensure that Before inserting, the battery cable is posi- ●...
  • Page 491 Operating Replacing and transporting the battery  CAUTION Risk of component damage! If the battery male connector is connected when the key switch is switched on (under load), a jump spark will be produced. This can lead to erosion at the contacts, which considerably shortens the service life of the contacts.

  • Page 492: Replacing The Battery Using A Change Frame (Variant)

    Operating Replacing and transporting the battery 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 493 Operating Replacing and transporting the battery – Disconnect the battery male connector.   WARNING Risk of crushing/shearing! No one must stand directly next to the battery or between the battery and the truck when removing and inserting the battery.  CAUTION Risk of damage! –...
  • Page 494 Operating Replacing and transporting the battery – Position the change frame (3) under the  battery (2) so that the centre of the bat- tery (1) is in line with the recess (4) in the change frame. This alignment ensures that the battery is positioned centrally on the change frame.
  • Page 495 Operating Replacing and transporting the battery The battery (1) can remain on the change  frame (2). The change frame can then be used to set down the battery. – If a substructure (3) is used to set down  the battery (1), ensure that the change frame (2) does not protrude beyond the bat- tery.
  • Page 496 Operating Replacing and transporting the battery NOTE Do not straighten any bent lifting eyes; have them replaced by the authorised service cen- tre. – Carefully insert the battery into the battery compartment. – Ensure that the display on the lithium-ion battery (variant) points towards the battery door.
  • Page 497 Operating Replacing and transporting the battery – Insert the battery male connector fully into  the plug connection on the truck. – Close the battery door. 56388011501 EN - 05/2022  -  08  481...

  • Page 498: Replacing The Battery Using An Electric Battery Carrier (Variant)

    Operating Replacing and transporting the battery Replacing the battery using an electric battery carrier (variant)  DANGER Risk of explosion if the battery is not extended! The battery carrier reduces the space between the battery and the battery hood. During charging, lead- acid batteries generate explosive oxyhydrogen gas.
  • Page 499 Operating Replacing and transporting the battery The driver's seat must not be under load (B) ● The operator must be in the operator's posi- ● tion (2) NOTE If the battery is deeply discharged (less than 10% capacity), it cannot be extended on the battery carrier.
  • Page 500 Operating Replacing and transporting the battery – (C) Open the battery locks as shown by the  direction of the arrows. 6301_003-137 – (D) Ensure that the emergency off switch is  unlocked. This also applies to the emergency off switch on the driver's compartment.
  • Page 501 Operating Replacing and transporting the battery (F) The battery carrier extends.   WARNING Risk of crushing! Never reach under the battery to remove obstacles. – Retract the battery and remove the obstacle. – Make sure that the battery cable is not dam- aged when the battery carrier is extended.
  • Page 502 Operating Replacing and transporting the battery – (I) Position a charged battery securely on  the carrier. – Make sure that the battery does not pro- trude beyond the contours of the carrier. Retracting the battery  CAUTION Potential for damage to the battery male connector! If the battery male connector is connected while the truck is switched on (under load), a transition spark will be produced.

  • Page 503: Transporting The Lead-Acid Battery By Crane

    Operating Replacing and transporting the battery (L) The battery carrier will retract.   WARNING Risk of crushing! Never reach under the battery to remove obstacles. – Extend the battery again. – Lift the battery again using the crane, swivel the battery to the side and remove the obstacle.

  • Page 504: Transporting The Lithium-Ion Battery By Crane

    Operating Replacing and transporting the battery – To avoid short circuits, cover batteries with open terminals or connectors with a rubber mat. – Observe the operating instructions for the lifting gear. – Attach the battery (1) to suitable lifting gear (2).
  • Page 505 Operating Replacing and transporting the battery – Pull out the two lifting eyes (1) on each side  and tilt them towards each other. The lifting eyes are locked in this position. – Observe the operating instructions for the lifting gear. –...

  • Page 506: Cleaning The Truck

    Operating Cleaning the truck Cleaning the truck Cleaning the truck  WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling. Use suitable equipment to reach higher points on the truck.
  • Page 507 Operating Cleaning the truck  CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. – Strictly adhere to the following steps.  CAUTION Possible component damage due to compressed air. – If components are cleaned with compressed air, the air must have a maximum pressure of 0.15 bar.

  • Page 508: Cleaning The Electrical System

    Operating Cleaning the truck – Clean plastics only with cleaning materials intended for plastics. – Clean the truck exterior using water-soluble cleaning materials and water. Cleaning with a water jet, a sponge or a cloth is recom- mended. – Clean all accessible areas. –...

  • Page 509: Cleaning Load Chains

    Operating Cleaning the truck Cleaning load chains   WARNING Risk of accident! Load chains are safety elements. The use of cold/chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden! – Observe the manufacturer's guidelines for working with cleaning materials.

  • Page 510: Cleaning The Windows

    Operating Cleaning the truck Cleaning the windows  Any glass, for example cab windows (variant), must always be kept clean and free of ice. This is the only means of guaranteeing good visibility.  CAUTION Do not damage the rear window heater (inside). –...

  • Page 511: Transporting The Truck

    Operating Transporting the truck Transporting the truck Transport  CAUTION Risk of material damage from overloading! If the truck is driven onto a means of transport, the load capacity of the means of transport, ramps and loading bridges must be greater than the total actual weight of the truck.
  • Page 512 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 513 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 514: 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 transport- ing the complete truck, including the lift mast, for its initial commissioning.

  • Page 515: Decommissioning

    Operating Decommissioning Decommissioning Decommissioning and storing the truck  CAUTION Damage to components due to incorrect storage! Improper storage or decommissioning for a period of more than two months can result in corrosion damage to the truck. If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down.
  • Page 516 Operating Decommissioning  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the truck is switched on (under load), an electric arc will be produced. This can lead to erosion of the contacts, which considerably shortens the service life of the contacts.

  • Page 517: Use After Storage Or Decommissioning

    Operating Decommissioning service centre to find out about additional courses of action. Use after storage or decommis- sioning If the truck has been decommissioned for lon- ger than six months it must be checked care- fully before being used again. As with the annual safety inspection, this inspection must also include all safety-related aspects of the truck.
  • Page 518 Operating Decommissioning  502 56388011501 EN - 05/2022  -  08...

  • Page 519: Maintenance

    Maintenance...

  • Page 520: Safety Regulations For Maintenance

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

  • Page 521: Safety Devices

    Maintenance Safety regulations for maintenance Rings, metal bracelets etc. must be removed before working on electric components. To prevent damage to electronic systems with electronic components, such as an electronic driving regulator or lift control, these compo- nents must be removed from the truck prior to the start of electric welding.

  • Page 522: Working At The Front Of The Truck

    Maintenance Safety regulations for maintenance Working at the front of the truck  DANGER Risk of accident due to an unsecured lift mast. If the lift mast or fork carriage is raised, no work may be performed on the lift mast or at the front of the truck unless the appropriate safety measures are put in place.

  • Page 523: General Maintenance Information

    Maintenance General maintenance information General maintenance infor- mation Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Regu- lar safety checks and checks after unusual incidents must be performed by a competent person. The competent person must conduct their evaluation and assessment from a safety standpoint, unaffected by operational and eco- nomic conditions.
  • Page 524 Maintenance General maintenance information below. This ensures that the truck remains ready for operation and provides optimal per- formance and service life. It is also a precondi- tion for any warranty claims. Maintenance timeframe If maintenance is needed, the message  ...

  • Page 525: Setting Up And Adjusting The Due Date Counter For Maintenance And Safety Checks

    Maintenance General maintenance information The first menu level appears. – Activate the "Access authorisation for the fleet manager". – 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 526 Maintenance General maintenance information Setup and adjustment by the fleet man- ager For the fleet manager, due date counters are also defined for the following checks: Regular testing of the truck for electric ● trucks and IC trucks Battery testing for electric trucks ●...
  • Page 527 Maintenance General maintenance information menu  Safety check – Press the scroll button to activate the input. Safety check – Enter the desired date using softkeys 0 to – To , press the  button. save Enter date Due date counter for individual mainte- 30 .

  • Page 528: 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  ...
  • Page 529 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.
  • Page 530 Maintenance General maintenance information   At operating hours Carried 1000   2000   4000   5000   7000   8000   10000   11000   13000   14000         Check the oil level.     Lift mast  ...
  • Page 531 Maintenance General maintenance information   At operating hours Carried 1000   2000   4000   5000   7000   8000   10000   11000   13000   14000         Read out the error numbers and clear the list.  ...

  • Page 532: 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  ...
  • Page 533 Maintenance General maintenance information lubricity. If a change between different manu- facturers cannot be avoided, drain the old oil thoroughly. Before carrying out lubricating work, filter changes or any work on the hydraulic system, carefully clean the area around the part in- volved.

  • Page 534: Lubrication Plan

    Maintenance General maintenance information Lubrication plan 6331_003-001 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 535: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table General lubrication points Code Unit Operating materials Specifications Dimension   Lubrication High-pressure ID no. 0147873 As required grease Battery Code Unit Operating materials Specifications Dimension   System filling Distilled water   As required Insulation resistance   DIN 43539 For further informa- VDE 0510...
  • Page 536 Maintenance General maintenance information Hydraulic system Code Unit Operating materials Specifications Dimension   System filling Hydraulic oil HVLP 68 DIN 51524, Part 3 42.0 to 58.0 l Hydraulic oil for the NSF H1 depending on the food industry (var- DIN 51524 lift mast and overall iant) height Hydraulic oil for cold...
  • Page 537 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 538: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Lubricating the joints and con-  trols – 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 ●...

  • Page 539: 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 deformed or damaged.
  • Page 540 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 541: Checking The Driver's Seat

    Maintenance Preserving operational readiness Checking the driver's seat   WARNING Risk of injury! – After an accident, check the driver's seat with at- tached restraining belt and fastening. – Check the controls for correct operation. – Check the condition of the seat (e.g. wear on the upholstery) and secure fastening to the hood.
  • Page 542 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 543 Maintenance Preserving operational readiness – Remove any dust and dirt from the fresh-air  inlet (1) beneath the filter mat carrier. 56388011501 EN - 05/2022  -  08  527...

  • Page 544: 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 545 Maintenance Preserving operational readiness Pneumatic tyres (variant)  – Check the tread depth on all four tyres. The tread depth for pneumatic tyres (variant) must be at least 1.6 mm at every point on the tread. If the tread is worn down to the wear mark (2) at any point on the tyre, replace the tyres on one axle.

  • Page 546: Servicing The Steering Axle

    Maintenance Preserving operational readiness Checking wheel fastenings  – Check that the wheel-fastening screws (4) of the drive axle and the steering axle are securely in place and re-tighten as neces- sary. – Observe the torques specified in the "main- tenance data table". 6331_003-005 Servicing the steering axle –...

  • Page 547: Checking The Battery

    Maintenance Preserving operational readiness 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. – Switch the truck on. – Actuate the steering. –...

  • Page 548: Replacing The Fuses

    Maintenance Preserving operational readiness Replacing the fuses  DANGER Danger from electrical current! High voltages are present in the fuse box. There is a risk of electric shock. – Do not open the fuse box. – The fuses must be replaced only by the authorised service centre.
  • Page 549 Maintenance Preserving operational readiness Replace pipes if they display the following ab- normalities: Abrasion ● Deformation and bending ● Leaking ● 56388011501 EN - 05/2022  -  08  533...

  • Page 550: Check The Hydraulic Oil Level

    Maintenance Preserving operational readiness Check the hydraulic oil level  90°  WARNING Hydraulic oils are hazardous to your health. – Observe the safety regulations set out in the sec- tion entitled "Hydraulic fluid". NOTE 90° When changing to a different type of hydraulic oil, the authorised service centre must adjust the parameters of the truck control unit.
  • Page 551 Maintenance Preserving operational readiness ENVIRONMENT NOTE Carefully collect any spilt hydraulic oil. Dis- pose of this hydraulic oil in accordance with environmental regulations. The marks (1), (2) and (3) indicate the mini-  mum filling levels for the different lift mast ver- sions.

  • Page 552: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness Lubricating the lift mast and roll-  er 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 553: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other work that must be carried – Perform all tasks required to maintain full operability; see the chapter entitled "Re- maining ready for operation". Checking the lift cylinders and  connections for leaks  WARNING Risk of injury Observe safety regulations for working on the lift...

  • Page 554: Checking The Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking the fork arms  – 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 555: 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 change- over frame...
  • Page 556 Maintenance 1000-hour maintenance/annual maintenance  540 56388011501 EN - 05/2022  -  08...

  • Page 557: Technical Data

    Technical data...

  • Page 558: 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 559: Dimensions

    Technical data Dimensions Dimensions 6331_003-007 Seat is adjustable ± 90 mm Fork spacing is adjustable 56388011501 EN - 05/2022  -  08  543...
  • Page 560 Technical data Dimensions NOTE Measurements h and b are cus- tomised and can be taken from the order con- firmation.  544 56388011501 EN - 05/2022  -  08...

  • Page 561: Vdi Datasheet Rx60-35 (Plus)/600 Li-Ion

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-35 (Plus)/600 Model Li-Ion Type number 6331 Manufacturer STILL GmbH Drive   Electric Operation   Seat Load capacity/load Q (kg) 3500...
  • Page 562 Technical data VDI datasheet RX60-35 (Plus)/600 Li-Ion RX60-35 (Plus)/600 Model Li-Ion Type number 6331 Tyre size, rear   200/75-9 (21x8-9) Number of front wheels   (x = driven) Number of rear wheels   (x = driven) Track width, front b10 (mm) 1095 Track width, rear b11 (mm)
  • Page 563 Technical data VDI datasheet RX60-35 (Plus)/600 Li-Ion RX60-35 (Plus)/600 Model Li-Ion Type number 6331 Aisle width for pallet 1000 x 1200 crosswise Ast (mm) 4265 Aisle width for pallet 800 x 1200 lengthwise Ast (mm) 4465 Turning radius Wa (mm) 2550 Smallest pivot point distance b13 (mm) Performance data RX60-35 (Plus)/600...
  • Page 564 Technical data VDI datasheet RX60-35 (Plus)/600 Li-Ion RX60-35 (Plus)/600 Model Li-Ion Type number 6331 Acceleration time over 15 m without load (Plus 5.2/5.9 Standard Performance) Service brake Hydraulically actu-   ated multi-disc brake Gradients The values specified in the "Performance da- ta"...
  • Page 565 Technical data VDI datasheet RX60-35 (Plus)/600 Li-Ion Other RX60-35 (Plus)/600 Model Li-Ion Type number 6331 Working pressure for attachments Oil flow for attachments Sound pressure level L (driver's compartment) dB (A) Human vibration: acceleration according to EN 13059 m/s 0.42 Tow coupling, type  ...

  • Page 566: Vdi Data Sheet Rx60-40 (Plus)/Li-Ion And Rx60-40 (Plus)/600 Li-Ion

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-40 (Plus) / Model RX60-40/Li-ion 600 Li-Ion Type number 6332 6333 Manufacturer STILL GmbH STILL GmbH Drive   Electric Electric Operation   Seat Seat Load capacity/load Q (kg)
  • Page 567 Technical data VDI data sheet RX60-40 (Plus)/Li-Ion and RX60-40 (Plus)/600 Li-Ion Model RX60-40 RX60-40/600 Type number 6332 6333 Number of front wheels   (x = driven) Number of rear wheels   (x = driven) Track width, front b10 (mm) 1095 1104 Track width, rear b11 (mm)
  • Page 568 Technical data VDI data sheet RX60-40 (Plus)/Li-Ion and RX60-40 (Plus)/600 Li-Ion Model RX60-40 RX60-40/600 Type number 6332 6333 Aisle width for pallet 800 x 1200 length- Ast (mm) 4465 4465 wise Turning radius Wa (mm) 2550 2550 Smallest pivot point distance b13 (mm) Performance data Model RX60-40...
  • Page 569 Technical data VDI data sheet RX60-40 (Plus)/Li-Ion and RX60-40 (Plus)/600 Li-Ion Gradients The values specified in the "Performance da- ta" table as the maximum climbing capability can be used only to compare the performance of forklift trucks in the same category. The specified values in no way represent the nor- mal daily operating conditions.

  • Page 570: Rx60-40/600

    Technical data VDI data sheet RX60-40 (Plus)/Li-Ion and RX60-40 (Plus)/600 Li-Ion Model RX60-40 RX60-40/600 Type number 6332 6333 Sound pressure level L (driver's com- dB (A) partment) Human vibration: acceleration according to 0.42 0.42 EN 13059 Hitch, Art.   Bolt Bolt Without cab. Values are different with a cab.  554 56388011501 EN - 05/2022  - ...

  • Page 571: Vdi Data Sheet Rx60-45 (Plus) Li-Ion And Rx60-45 (Plus)/600 Li-Ion

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-45 (Plus) / Model RX60-45 Li-Ion 600 Li-Ion Type number 6334 6335 Manufacturer STILL GmbH STILL GmbH Drive   Electric Electric Operation   Seat Seat Load capacity/load...
  • Page 572 Technical data VDI data sheet RX60-45 (Plus) Li-Ion and RX60-45 (Plus)/600 Li-Ion RX60-45 (Plus) / Model RX60-45 Li-Ion 600 Li-Ion Type number 6334 6335 200/75-9 200/75-9 Tyre size, rear   (21x8-9) (21x8-9) Number of front wheels   (x = driven) Number of rear wheels  ...
  • Page 573 Technical data VDI data sheet RX60-45 (Plus) Li-Ion and RX60-45 (Plus)/600 Li-Ion RX60-45 (Plus) / Model RX60-45 Li-Ion 600 Li-Ion Type number 6334 6335 Aisle width for pallet 1000 x 1200 cross- Ast (mm) 4265 4275 wise Aisle width for pallet 800 x 1200 length- Ast (mm) 4465 4475...
  • Page 574 Technical data VDI data sheet RX60-45 (Plus) Li-Ion and RX60-45 (Plus)/600 Li-Ion RX60-45 (Plus) / Model RX60-45 Li-Ion 600 Li-Ion Type number 6334 6335 Acceleration time 15 m without load 5.3/6 5.5/6.1 (plus /standard performance) Service brake Hydr. Operated Hydr. Operated  ...
  • Page 575 Technical data VDI data sheet RX60-45 (Plus) Li-Ion and RX60-45 (Plus)/600 Li-Ion RX60-45 (Plus) / Model RX60-45 Li-Ion 600 Li-Ion Type number 6334 6335 Handling performance (Plus perform- 298/282 298/282 ance /Standard performance) Energy consumption for handling perform- ance (Plus performance /Standard per- kWh/h 10.5/9.6...

  • Page 576: Vdi Data Sheet Rx60-50 (Plus) Li-Ion And Rx60-50 (Plus)/600 Li-Ion

    Different tyres, lift masts, additional units etc. can produce different values. Key data RX60-50 (Plus) / Model RX60-50 Li-Ion 600 Li-Ion Type number 6336 6337 Manufacturer STILL GmbH STILL GmbH Drive   Electric Electric Operation   Seat Seat Load capacity/load...
  • Page 577 Technical data VDI data sheet RX60-50 (Plus) Li-Ion and RX60-50 (Plus)/600 Li-Ion RX60-50 (Plus) / Model RX60-50 Li-Ion 600 Li-Ion Type number 6336 6337 200/75-9 225/75-10 Tyre size, rear   (21x8-9) (23x9-10) Number of front wheels (x = driven)   Number of rear wheels (x = driven)  ...
  • Page 578 Technical data VDI data sheet RX60-50 (Plus) Li-Ion and RX60-50 (Plus)/600 Li-Ion RX60-50 (Plus) / Model RX60-50 Li-Ion 600 Li-Ion Type number 6336 6337 Aisle width for pallet 1000 x 1200 cross- Ast (mm) 4275 4370 wise Aisle width for pallet 800 x 1200 length- Ast (mm) 4475 4570...

  • Page 579: Lift Motor, Power Rating At 15% Ed Kw

    Technical data VDI data sheet RX60-50 (Plus) Li-Ion and RX60-50 (Plus)/600 Li-Ion RX60-50 (Plus) / Model RX60-50 Li-Ion 600 Li-Ion Type number 6336 6337 Acceleration time 15 m without load 5.5/6.1 5.7/6.2 (plus /standard performance) Service brake Hydr. Operated Hydr. Operated  ...

  • Page 580: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Technical data Eco-design requirements for electric motors and variable speed drives RX60-50 (Plus) / Model RX60-50 Li-Ion 600 Li-Ion Type number 6336 6337 Handling performance (Plus perform- 324/315 324/315 ance /Standard performance) Energy consumption for handling perform- ance (Plus performance /Standard per- kWh/h 11.3/10.8...

  • Page 581: Information About The Lead-Acid Battery

    Technical data Information about the lead-acid battery Information about the lead-acid battery  CAUTION The battery weight and the battery dimensions affect the stability of the truck. When replacing the battery, the weight ratios must not be changed. The battery weight must remain within the weight range specified on the nameplate.

  • Page 582: Battery Specifications For X-Line Lithium-Ion Batteries

    Technical data Battery specifications for X-Line lithium-ion batteries Battery specifications for X-Line lithium-ion batteries  CAUTION The battery weight and the battery dimensions affect the stability of the truck. When replacing the battery, the weight ratios must not be changed. The battery weight must remain within the weight range specified on the nameplate.
  • Page 583 Technical data Information on the auxiliary hydraulics   Multi-lever operation Proportional-valve technology Maximum system pressure 280 bar 280 bar "P " Maximum volume flow rate 50 l/min 45 l/min "Q " Trigger of the switch valve 12 V / 2 A 12 V / 2 A 56388011501 EN - 05/2022  - ...
  • Page 584 Technical data Information on the auxiliary hydraulics  568 56388011501 EN - 05/2022  -  08...
  • Page 585 Index   General controlling....316 Information on the auxiliary hydraulics. 566 Access authorisation for the fleet manag- Load capacity....315 er.
  • Page 586 Index   Blue-Q Clean the truck Configuring..... 162 After cleaning....Effects on additional consumers.
  • Page 587 Noise emissions....58 STILL Classic....162 Radiation.
  • Page 588 Index   Hazard assessment....34 Information on the auxiliary hydraulics. . Hazardous areas....168 Information symbols.
  • Page 589 Load measurement....STILL SafetyLight®....Calibrating.....
  • Page 590 Index   Medical equipment....42 On-board charger Messages Changing the battery type..About operation....Charging characteristic curve.
  • Page 591 Index   Replacing the battery General information....Packaging......High Performance variant.
  • Page 592 Index   Safety regulations for working on the lift Starting drive mode....mast......Dual pedal version.
  • Page 593 ..... Speed restriction....192 STILL SafetyLight® and STILL Safety- Variant Light 4Plus®.
  • Page 594 Index   Winter tyres..... . . Working at the front of the truck..506 Warming up the hydraulic oil.
  • Page 596 STILL GmbH 56388011501 EN - 05/2022  -  08...

This manual is also suitable for:

Rx60 35-50/li-ion

Table of Contents