Original instructions Electric forklift truck

Original instructions

Electric forklift truck

RX60-25RX60-25/600RX60-25LRX60-25L/600RX60-30RX60-30LRX60-30L/600RX60-35

6345 6346 6347 6348 63536354 6355 6356

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Prefaceg

Address of manufacturer andcontact detailsSTILL GmbHBerzeliusstraße 1022113 Hamburg, GermanyTel. +49 (0) 40 7339-0Fax: +49 (0) 40 7339-1622Email: [email protected]: http://www.still.de

Rules for the operatingcompany of industrial trucksIn addition to these operating instructions,a code of practice containing additionalinformation for the operating companies ofindustrial trucks is also available.

This guide provides information for handlingindustrial trucks:• Information on how to select suitableindustrial trucks for a particular area ofapplication

• Prerequisites for the safe operation ofindustrial trucks

• Information on the use of industrial trucks• Information on transport, initial commis-sioning and storage of industrial trucks

Internet address and QR codeThe information can be accessed at any timeby pasting the address https://m.still.de/vdmain a web browser or by scanning the QR code.

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Table of contentsg

1 ForewordYour truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Description of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 6Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 11Nameplate of a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Using the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Proper use during towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Parking in temperatures below -10°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Issue date and topicality of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 18Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2 SafetyDefinition of responsible persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Special features when using lithium-ion batteries (variant) . . . . . . . . . . . . . . . . . . . . . . 30Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Changes to the overhead guard and roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Damage, defects andmisuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . . 39Length of the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Special risks associated with using the truck and attachments . . . . . . . . . . . . . . . . . . . 42Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3 OverviewsGeneral view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

General view of driver's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Shelves and cup holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Operating devices and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Display operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Lithium-ion battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Operating devices for hydraulic and traction functions . . . . . . . . . . . . . . . . . . . . . . . . . 64Multi-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4 OperationTesting and activities before daily use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Visual inspections and function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Climbing in and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Adjusting the MSG 65/MSG 75 driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Checking the emergency off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 104Zero adjustment of the load measurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Display-operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 115Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Softkeys for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Switching off additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Setting the drive programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Actuating the drive direction switch, multiple-lever version . . . . . . . . . . . . . . . . . . . . . . 129Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 129

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Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 130Actuate the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 131Starting drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Starting drive mode, dual-pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Actuate the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Malfunctions in the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Reducing speed when turning (Curve Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . 153Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Multi-lever lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 161Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 162Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 163Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 164Controlling the lifting system with the fingertip console . . . . . . . . . . . . . . . . . . . . . . . . . 166Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187Transporting suspended loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Driving on ascending and descending gradients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Controlling attachments using multi-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Operating attachments using multi-lever controls and the 5th function . . . . . . . . . . . . . 207Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 211Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Controlling attachments using the triple mini-lever and the 5th function . . . . . . . . . . . . . 215Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 217Controlling attachments using the quadruple mini-lever and the 5th function . . . . . . . . . 219Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Controlling attachments using the Joystick 4Plus and the 5th function . . . . . . . . . . . . . 222Controlling the attachments with fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Controlling attachments with fingertip and the 5th function . . . . . . . . . . . . . . . . . . . . . . 225Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Switching the lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Switching the working spotlight for reverse travel on and off . . . . . . . . . . . . . . . . . . . . . 233Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Switching direction indicators on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 237STILL SafetyLight (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Shock recognition (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Ceiling sensor (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

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Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252Push-up roof window (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Cold store application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Emergency operation of the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Connecting and disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . 296Connecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Handling the lead-acid battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Checking the battery condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . 303Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Charging the battery with the battery charging flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Equalising charge to prevent a deep discharge of the battery . . . . . . . . . . . . . . . . . . . . 311

Handling the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Safety regulations for handling the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . 313Lithium-ion batteries "GGS Li-ion 80 V" 24.1 kWh and 60 kWh . . . . . . . . . . . . . . . . . . . 316

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Display messages on the display-operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Regulations for storing lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Replacing and transporting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325General information on replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Changing to a different battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Opening/closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Special notes for installing the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Replacing the battery using forklift truck or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . 330Replacing the battery using a change frame (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . 333Replacing the battery with the hydraulic battery carrier . . . . . . . . . . . . . . . . . . . . . . . . . 337Transporting the lead-acid battery by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344Transporting the lithium-ion battery by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Decommissioning and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Returning to service after decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

5 MaintenanceSafety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368Maintenance— 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

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Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 375Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Removing and installing the valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Opening the fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Remaining ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Checking the battery interlock and battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385Checking the driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386Maintaining wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387Servicing the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389Checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Greasing the automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Maintenance for trucks used in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Replacing the heater filter mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

1000-hour maintenance/annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Checking the cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Checking the hydraulic oil level of the hydraulic battery carrier . . . . . . . . . . . . . . . . . . . 403Lubricating the slide elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405Oiling the catch rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 407Checking fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Checking the double pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Checking the battery changeover frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

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6 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

VDI datasheet for RX60-25 and RX60-25/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

VDI datasheet for RX60-25L and RX60-25L/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

VDI datasheet for RX60-30 and RX60-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

VDI datasheet for RX60-30L and RX60-30L/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Information about the lead-acid battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Information about the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Fuse assignment standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Fuse assignment equipment variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

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1

Foreword

1 ForewordYour truck

Your truckDescription of the truck

GeneralThe STILLRX60 25-35 is an electrically drivencounterbalanced truck with a rear swing axle.The truck has a load capacity of 2.5 to 3.5tonnes. Alternatively, a load capacity of up to3.0 tonnes with a load centre of gravity of 600mm is available. The truck can reach speedsof up to 20 km/h without a load.

It is suitable for interior use and for outdooruse.

The display-operating unit manages all func-tions that are not called up by the operatingdevices for drive functions and hydraulic func-tions. All messages and driving conditioninformation are issued via the display. Thedisplay-operating unit uses the current batterycharge state and the selected drive programto calculate the remaining available time untilthe battery has to be recharged and displaysthis information.

The truck supports all functions of FleetMan-ager 4.0 (variant).

Brake system

The brake system of the truck comprises threedifferent brakes:• Service brake• Regenerative brake• Mechanically actuated parking brake• Electrically actuated parking brake (variant)

The service brake is based on a wear-free,oil-immersed multi-disc brake. This multi-discbrake is used as the service brake for heavybraking or emergency braking with the brakepedal. In the normal working mode, theregenerative brake of the electric tractionmotor takes effect. The regenerative brakeconverts the acceleration energy of the truckinto electrical energy. This causes the truck todecelerate as soon as the accelerator pedalis released. Completely removing your footfrom the accelerator pedal causes the truck tobrake until it comes to a standstill. A parking

2 56338011803 EN - 02/2018

Foreword 1Your truck

brake ensures that the truck remains securelyin place when parked.

Hydraulic systemThe steering system and the lift and tilt cylin-ders in the lift mast are supplied with powerby a hydraulic pump operated by an electricmotor.

The proportional valve technology providesparticularly sensitive movements and safehandling of the load. The hydraulic functionscan be parameterised individually by theauthorised service centre.

Up to three hydraulic circuits can be used toactivate attachments (variant). Depending onthe equipment, a hydraulic accumulator is alsoavailable in the lifting circuit for the purpose ofdampening pressure peaks in the hydraulicsystem.

DriveBoth front wheels of the STILL RX60 25-35are driven by a maintenance-free three-phasedrive in the front axle with 80-volt technology.

Lead-acid batteries and lithium-ion batteriesthat can be replaced from the side are avail-able as a power supply source. In both cases,the trucks can be supplied as a cold store vari-ant.

The driver can help to determine the energyconsumption and performance of the truckusing the "Blue-Q" efficiency mode, whichallows the required setting for each currentapplication to be called up via the display-operating unit.

SteeringThe kickback-free, hydraulic rear-wheelsteering with "Curve Speed Control" (CSC)ensures driving stability when cornering,allowing the truck to achieve a small turningcircle and negotiate narrow aisle widths.

56338011803 EN - 02/2018 3


OperationA multi-lever, fingertip switch, mini-lever andthe Joystick 4Plus are available as operatingdevices for the hydraulic functions. Theseoperating devices enable precise operationand smooth control of the lifting speed thanksto directly controlled valves and proportionalvalve technology.

For drive mode, the truck features eithersingle-pedal or dual-pedal operation. Theaccelerator pedal is used to accelerate andbrake (electric brake) the truck. In emergencysituations or when carrying heavy loads, thedriver can also brake the truck using theservice brake by pressing the brake pedal.In dual-pedal operation, the truck has onepedal for the "Forwards" drive direction andone pedal for the "Reverse" drive direction.Acceleration and braking behaviour can beindividually selected from five different driveprogrammes.

The display-operating unit monitors the truckfunctions, including each individual cell in thelithium-ion battery.

GeneralThe truck described in these operating instruc-tions corresponds to the applicable standardsand safety regulations.

If the truck is to be operated on public roads, itmust conform to the existing national regula-tions for the country in which it is being used.The driving permit must be obtained from theappropriate office.

The truck has been fitted with state-of-the-art technology. Following these operatinginstructions will allow the truck to be handledsafely. By complying with the specifications inthese operating instructions, the functionalityand the approved features of the truck will beretained.

Get to know the technology, understand itand use it safely - these operating instructionsprovide the necessary information and help toavoid accidents and to keep the truck ready foroperation beyond the warranty period.

4 56338011803 EN - 02/2018


Therefore:

– Before commissioning the truck, readthe operating instructions and follow theinstructions.

– Always follow all of the safety informationcontained in the operating instructions andon the truck.

CE-Symbol

CE labellingThe manufacturer uses CE labelling to indi-cate that the truck complies with the standardsand regulations valid at the time of marketing.This is confirmed by the issued EC declarationof conformity. The CE labelling is attached tothe nameplate.

An independent structural change or additionto the truck can compromise safety, thusinvalidating the EC declaration of conformity.

The EC declaration of conformity must becarefully stored and made available to theresponsible authorities.

56338011803 EN - 02/2018 5


EC declaration of conformity in accordance with Machinery Directive

Declaration

STILL GmbH

Berzeliusstraße 10

D-22113 Hamburg Germany

We declare that the

Industrial truck according to these operating instructions

Model according to these operating instructions

conforms to the latest version of the Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL GmbH

.

6 56338011803 EN - 02/2018


Accessories• Key for key switch (2 pieces)• Key for cab (variant)• Hexagon socket wrench for emergencylowering

• Battery replacement frame

56338011803 EN - 02/2018 7


Overview

6327_092-001_V11

DANGER

STOP

12

3 4 5

6 7 8

9

10 11

1415

29

16

27

17

28

23

1213

1927247

65

1316

3

1522

122

1

2817

2

48

923

14

18

29

1826

456

7

1011

25

5430 1010 1080 1080 1080

1050 1150 1310

4430 1110 1230 1250 1500

4030 1150 1260 1200 1500

3730 1180 1290 1430 1500

3430 1210 1330 1470 1500

800 700 500600

5030 1270

2

1

3

xx xxxx x xxxxx

1

2

3

4

24

25

26

STILL Hamburg

Berzeliusstr. 10

22113 Hamburg

Tel.: 01804 / 784 55 24

Ihr STILL Service

Nächste Prüfung

7339

06

BATTERIESERVICE

DANGER

Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr

Rated capacityCapacité nominaleNenn-Tragfähigkeit

Battery voltageTension batterieBatteriespannung

Rated drive powerPuissance motr.nom.Nenn-Antriebsleist.

Unladen massMasse à videLeergewicht

max

min.*

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

kg kg

kg

kg

kgkW

V

*

Regelmäßige Prüfung(FEM 4.004)

nach nationalen Vorschriftenbasierend auf den EG-Richtlinien:95/63/EG, 99/92/EG, 2001/45/EG

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung

5634

4391

019

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

20xx

8 56338011803 EN - 02/2018


1 Decal information: Fasten the seat belt2 Decal information: Caution / Read the

operating instructions3 Warning sign: Passengers are not allowed4 Warning sign: Danger due to shearing5 Warning sign: Danger due to high fluid

pressure6 Warning sign: Do not stand underneath the

fork7 Warning sign: Do not stand on the fork8 Warning sign: Risk of short circuit due to

shearing9 Decal information: Do not jump off if the

truck is tipping over / Lean in the oppositedirection to which the truck is tipping

10 Decal information: Parking brake released11 Decal information: Parking brake applied12 Decal information: "Dual pedal operation"13 Warning sign: Danger due to shearing14 Decal information: Lifting gear attachment

point

15 Decal information: Lifting gear attachmentpoint

16 Decal information: Hydraulic oil tank17 Decal information: FEM audit18 Manufacturer's name19 Manufacturer's name22 Manufacturer's name23 Decal information: Unlocking24 Identification plate25 Decal information: Capacity rating plate26 Nameplate27 Decal information: StVZO (Road Traffic

Licensing Regulations) information28 Decal information: Battery service29 Decal information: Caution/Read the oper-

ating instructions/Fasten the seat belt/Ap-ply the parking brake when leaving thetruck/Passengers are not allowed/Do notjump off if the truck is tipping over/Lean inthe opposite direction to which the truck istipping

56338011803 EN - 02/2018 9







maxmin.*


kg kg

kgkg

kgkW

V

*

D-22113 HamburgBerzeliusstr. 10

1 2 3

44

56

7

910

111213

6210_921-003_V3

8

1 Type2 Production number3 Year of manufacture4 Tare weight in kg5 Max. permissible battery weight in kg6 Min. permissible battery weight in kg7 Ballast weight in kg8 Address of manufacturer9 Refer to the technical data listed in these

operating instructions for more detailedinformation

10 CE labelling11 Nominal drive power in kW12 Battery voltage in V13 Rated capacity in kg

NameplateThe truck can be identified from the informa-tion on the nameplate.

The information for the battery weights (5,6) and the ballast weight (7) only applies toelectric forklift trucks.

7090_921-004

xx xxxx x xxxxx

1

2

3

4

Production number

NOTE

The production number is used to identify thetruck. It can be found on the nameplate andmust be referred to in all technical questions.

The production number contains the followingcoded information:

(1) Production location

(2) Model

(3) Year of manufacture

(4) Sequential number

10 56338011803 EN - 02/2018

Foreword 1Using the truck

7094_003-098

1 2

3 45

1 Tare weight (in kg)2 Permitted total weight (in kg)3 Permitted front axle weight (in kg)4 Permitted rear axle weight (in kg)5 Payload (in kg)

StVZO (Road Traffic LicensingRegulations) informationThis label includes information on the weightand load distribution of the truck.

Nameplate of a lithium-ion battery1 Manufacturer2 Nameplate3 Address of manufacturer4 Safety information5 Data matrix code6 Transportation notes7 General operating notes8 CE labelling9 Data/technical data

Using the truckCommissioningCommissioning is the initial intended use ofthe truck.

56338011803 EN - 02/2018 11

1 ForewordUsing the truck

The necessary steps for the commissioningvary depending on the model and equipmentof the truck. These steps require preparatorywork and adjustment work that cannot be per-formed by the operating company. See alsothe chapter entitled "Definition of responsiblepersons".

– To commission the truck, contact theauthorised service centre.

Proper usageThe truck described in these operating in-structions is suitable for lifting, transportingand stacking loads.

The truck may only be used for its properpurpose as set out and described in theseoperating instructions.

If the truck is to be used for purposes otherthan those specified in the operating instruc-tions, the approval of the manufacturer and, ifapplicable, the relevant regulatory authoritiesmust be obtained beforehand to prevent haz-ards.

The maximum load to be lifted is specified onthe capacity rating plate (load diagram) andmust not be exceeded; see also the chapterentitled "Before picking up a load".

Proper use during towingThis truck is suitable for the occasional towingof trailers and is equippedwith a towing devicefor this purpose. This occasional towing maynot exceed 2% of the daily operating time. Ifthe truck is to be used for towing on a moreregular basis, the manufacturer should beconsulted.

The regulations regarding trailer operationmust be observed; see chapter "Traileroperation".

12 56338011803 EN - 02/2018


Impermissible useThe operating company or driver, and not themanufacturer, is liable for any hazards causedby improper use.

NOTE

Please observe the definition of the followingresponsible persons: "operating company"and "driver".

Use for purposes other than those describedin these operating instructions is prohibited.

DANGERThere is a risk of fatal injury from fallingoff the truck while it is moving!– It is prohibited to carry passengers

on the truck.

The truck may not be operated in areas wherethere is a risk of fire, explosion or corrosion, orin areas that are particularly dusty.

Stacking or unstacking is not permissible oninclined surfaces or ramps.

Place of useThe truck can be used both outside and inbuildings. Operation on public roads is onlypermitted if the "StVZO" (GermanRoad TrafficLicensing Regulations) equipment variant isinstalled.

If the truck is to be operated on public roads,the truck must conform to the national regula-tions for the country in which it is being used.

The ground must have an adequate loadcapacity (concrete, asphalt) and a roughsurface. Roadways, working areas and aislewidths must conform to the specifications inthese operating instructions; see the chapterentitled "Roadways".

Driving on upward and downward gradientsis permitted provided the specified data andspecifications are observed, see the "Routes"chapter.

56338011803 EN - 02/2018 13

1 ForewordUsing the truck

The truck is suitable for indoor and outdooruse in countries ranging from the Tropics toNordic regions (temperature range: -20°C to+40°C).

If the truck is to be used in a cold store, it mustbe configured accordingly and, if necessary,approved for such an environment; see thechapter entitled "Cold store application".

CAUTIONBatteries can freeze!If the truck is parked in an ambient temperature ofbelow -10°C for an extended period, the batterieswill cool down. The electrolyte may freeze anddamage the batteries. The truck is then not readyfor operation.– At ambient temperatures of below -10°C, only

park the truck for short periods of time.

The operating company must ensure suitablefire protection for the relevant application inthe truck's surroundings. Depending on theapplication, additional fire protection must beprovided on the truck. If in doubt, contact therelevant authorities.

NOTE

Please observe the definition of the followingresponsible person: "operating company".

Parking in temperatures below -10°C

CAUTIONBatteries can freeze!If the truck is parked in an ambient temperaturebelow -10°C for an extended period, the batterieswill cool down. The electrolyte may freeze anddamage the batteries. The truck is then not readyfor operation.– When the ambient temperature is below -10°C,

only park the truck for short periods of time.

14 56338011803 EN - 02/2018


Using working platforms

WARNINGThe use of working platforms is regulated by na-tional law. The use of working platforms is onlypermitted by virtue of the jurisdiction in the countryof use.– Observe national legislation.– Before using working platforms, consult the

national regulatory authorities.

56338011803 EN - 02/2018 15

1 ForewordInformation about the documentation

Information about the documentationDocumentation scope• Original operating instructions• Original operating instructions for attach-ments (variant)

• Spare parts list• Depending on the truck equipment, "UPA"operating instructionsmay also be provided

NOTE

Refer to the additional information in thesection entitled "Rules for the operatingcompany of industrial trucks".

These operating instructions describe allmeasures necessary for the safe operationand proper maintenance of the truck in allpossible variants available at the time ofprinting. Special versions to meet customerrequirements (UPA) are documented inseparate operating instructions. If you haveany questions, please contact your authorisedservice centre.

Enter the production number and year ofmanufacture from the nameplate in the spaceprovided:

Production number:

Year of manufacture:

Please quote the production number in alltechnical enquiries.

Each truck comes with a set of operatinginstructions. These instructions must bestored carefully and must be available to thedriver and operating company at all times.The storage location is specified in the chapterentitled "Overviews".

If the operating instructions are lost, the op-erating company must obtain a replacementfrom the manufacturer immediately.

The operating instructions are included in thespare parts list and can be reordered as aspare part.

16 56338011803 EN - 02/2018

Foreword 1Information about the documentation

The personnel responsible for operating andmaintaining the equipment must be familiarwith these operating instructions.

The operating company must ensure that allusers have received, read and understoodthese operating instructions.

Safely store the complete documentation andpass on to the subsequent operating companywhen transferring or selling the truck.

NOTE


Thank you for reading and complying withthese operating instructions. If you have anyquestions or suggestions for improvements,or if you have found any errors, please contactthe authorised service centre.

Supplementary documentationThis industrial truck can be fitted with un-planned equipment () that deviates from thestandard equipment and/or the variants.UPA

The UPAmay be, for example:• Special sensors• Special attachments• Towing devices• Customised attachments

In this case, the industrial truck has additionaldocumentation. This may be in the form of aninsert or separate operating instructions.

The original operating instructions for thisindustrial truck are valid for the operationof standard equipment and variants withoutrestriction. The operational and safety infor-mation in the original operating instructionscontinues to be valid in its entirety unless it iscountermanded in this additional documenta-tion.

The requirements for the qualification ofpersonnel as well as the time for maintenance

56338011803 EN - 02/2018 17


may vary. This is defined in the additionaldocumentation.

– If you have any questions, please contactyour authorised service centre.

Issue date and topicality of theoperating instructionsThe issue date of these operating instructionscan be found on the title page.

STILL is constantly engaged in the furtherdevelopment of trucks. These operatinginstructions are subject to change, and anyclaims based on the information and/orillustrations contained in them cannot beasserted.

Please contact your authorised service centrefor technical support relating to your truck.

Copyright and trademark rightsThese instructions must not be reproduced,translated or made accessible to third par-ties—including as excerpts—except with theexpress written approval of the manufacturer.

Explanation of information symbolsused

DANGERIndicates procedures that must be strictly adheredto in order to prevent the risk of fatalities.

WARNINGIndicates procedures that must be strictly adheredto in order to prevent the risk of injuries.

CAUTIONIndicates procedures that must be strictly adheredto in order to prevent material damage and/ordestruction.

18 56338011803 EN - 02/2018


NOTE

For technical requirements that requirespecial attention.

ENVIRONMENT NOTE

To prevent environmental damage.

List of abbreviations

NOTE

This list of abbreviations applies to all typesof operating instructions. Not all of the abbre-viations that are listed here will necessarilyappear in these operating instructions.

Abbrevi-ation

Meaning Explanation

ABE Display operating unit

ArbSchG Arbeitsschutzgesetz German implementation of EU occupa-tional health and safety directives

Betr-SichV

Betriebssicherheitsverordnung German implementation of the EU workingequipment directive

BG Berufsgenossenschaft German insurance company for the com-pany and employees

BGG Berufsgenossenschaftlicher Grundsatz German principles and test specificationsfor occupational health and safety

BGR Berufsgenossenschaftliche Regel German rules and recommendations foroccupational health and safety

DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations

CE Communauté Européenne Confirms conformity with product-specificEuropean directives (CE mark)

CEECommission on the Rules for the Approvalof the Electrical Equipment

International commission on the rules forthe approval of electrical equipment

DC Direct Current Direct current

DFÜ Datenfernübertragung Remote data transmission

DIN Deutsches Institut für Normung German standardisation organisation

EG European Community

EN European standard

FEM Fédération Européene de la Manutention European Federation of Materials Han-dling and Storage Equipment

Fmax maximum Force Maximum power

56338011803 EN - 02/2018 19


Abbrevi-ation

Meaning Explanation

GAA Gewerbeaufsichtsamt

German authority for monitoring/issuingregulations for worker protection, environ-mental protection, and consumer protec-tion

GPRS General Packet Radio Service Transfer of data packets in wirelessnetworks

ID no. ID number

ISO International Organization for Standard-ization

International standardisation organisation

LAN Local Area Network Local area network

KpAUncertainty of measurement of soundpressure levels

LED Light Emitting Diode Light emitting diode

Lp Sound pressure level at the workplace

LpAZAverage continuous sound pressure levelin the driver's compartment

LSP Load centre of gravity Distance of the centre of gravity of the loadfrom the front face of the fork backs

MAK Maximum workplace concentration Maximum permissible air concentrationsof a substance at the workplace

Max. Maximum Highest value of an amount

Min. Minimum Lowest value of an amount

PIN Personal Identification Number Personal identification numberPPE Personal protective equipment

SE Super-Elastic Superelastic tyres (solid rubber tyres)

SIT Snap-In Tyre Tyres for simplified assembly, withoutloose rim parts

StVZO Straßenverkehrs-Zulassungs-Ordnung German regulations for approval of vehi-cles on public roads

TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli-cable in the Federal Republic of Germany

VDE Verband der Elektrotechnik ElektronikInformationstechnik German technical/scientific association

VDI Verein Deutscher Ingenieure German technical/scientific association

VDMAVerband Deutscher Maschinen- undAnlagenbau e.V.

German Mechanical Engineering IndustryAssociation

WLAN Wireless LAN Wireless local area network.

20 56338011803 EN - 02/2018


6210_001-031

4 2

3

1Definition of directionsThe directions "forwards" (1), "backwards" (3),"right" (2) and "left" (4) refer to the installationposition of the parts as seen from the driver'scompartment; the load is to the front.

Schematic views

6210_003-062

View of functions and operationsThis documentation explains the (usuallysequential) chain of certain functions or oper-ations. Schematic diagrams of a counterbal-ance truck are used to illustrate these proce-dures.

NOTE

These schematic diagrams are not represen-tative of the structural state of the documentedtruck. The diagrams are used solely for thepurpose of clarifying procedures.

56338011803 EN - 02/2018 21


View of the display operating unit

NOTE

Views of operating statuses and values inthe display of the display operating unit areexamples and partly dependent on the truckequipment. As a result, the displays shownof the actual operating statuses and valuescan vary. Information that is not relevant fordescriptions is not shown.

22 56338011803 EN - 02/2018

Foreword 1Environmental considerations

Environmental considerationsPackagingDuring delivery of the truck, certain partsare packaged to provide protection duringtransport. This packaging must be removedcompletely prior to initial start-up.

ENVIRONMENT NOTE

The packaging material must be disposed ofproperly after delivery of the truck.

Disposal of components andbatteriesThe truck is composed of different materials. Ifcomponents or batteries need to be replacedand disposed of, they must be:• disposed of,• treated or• recycled in accordance with regional andnational regulations.

NOTE

The documentation provided by the batterymanufacturer must be observed when dispo-sing of batteries.

ENVIRONMENT NOTE

We recommend working with a waste mana-gement company for disposal purposes.

56338011803 EN - 02/2018 23

1 ForewordEnvironmental considerations

24 56338011803 EN - 02/2018

2

Safety

2 SafetyDefinition of responsible persons

Definition of responsible personsOperating companyThe operating company is the natural or legalperson or group who operates the truck or onwhose authority the truck is used.

The operating company must ensure that thetruck is only used for its proper purpose and incompliance with the safety regulations set outin these operating instructions.

The operating company must ensure thatall users read and understand the safetyinformation.

The operating company is responsible for thescheduling and correct performance of regularsafety checks.

We recommend that the national performancespecifications are adhered to.

SpecialistA qualified person is defined as a serviceengineer or a person who fulfils the followingrequirements:• A completed vocational qualification thatdemonstrably proves their professionalexpertise. This proof should consist ofa vocational qualification or a similardocument.

• Professional experience indicating thatthe qualified person has gained practicalexperience of industrial trucks over aproven period during their career Duringthis time, this person has become familiarwith a wide range of symptoms that requirechecks to be carried out, such as basedon the results of a hazard assessment or adaily inspection

• Recent professional involvement in thefield of the industrial truck test in questionand an appropriate further qualificationare essential. The qualified person musthave experience of carrying out the testin question or of carrying out similar tests.Moreover, this person must be aware ofthe latest technological developments

26 56338011803 EN - 02/2018

Safety 2Definition of responsible persons

regarding the industrial truck to be testedand the risk being assessed

DriversThis truck may only be driven by suitable per-sons who are at least 18 years of age, havebeen trained in driving, have demonstratedtheir skills in driving and handling loads tothe operating company or an authorised rep-resentative, and have been specifically in-structed to drive the truck. Specific knowledgeof the truck to be operated is also required.

The training requirements under §3 of theHealth and Safety at Work Act and §9 of theplant safety regulations are deemed to havebeen satisfied if the driver has been trained inaccordance with BGG (General Employers'Liability Insurance Association Act) 925.Observe the national regulations for yourcountry.

Driver rights, duties and rules of be-haviourThe driver must be trained in his rights andduties.

The drivermust be granted the required rights.

The driver must wear protective equipment(protection suit, safety footwear, safetyhelmet, industrial goggles and gloves) thatis appropriate for the conditions, the job andthe load to be lifted. Solid footwear should beworn to ensure safe driving and braking.

The driver must be familiar with the operatinginstructions and have access to them at alltimes.

The driver must:• have read and understood the operatingmanual

• have familiarised himself with safe opera-tion of the truck

• be physically and mentally able to drive thetruck safely

56338011803 EN - 02/2018 27

2 SafetyDefinition of responsible persons

DANGERThe use of drugs, alcohol or medications that affectreactions impair the ability to drive the truck!Individuals under the influence of the aforementio-ned substances are not permitted to perform workof any kind on or with the truck.

Prohibition of use by unauthorisedpersonsThe driver is responsible for the truck duringworking hours. He must not allow unautho-rised persons to operate the truck.

When leaving the truck, the drivermust secureit against unauthorised use, e.g. by pulling outthe key.

28 56338011803 EN - 02/2018

Safety 2Basic principles for safe operation

Basic principles for safe operationInsurance cover on companypremisesIn many cases, company premises arerestricted public traffic areas.

NOTE

The business liability insurance should bereviewed to ensure that, in the event of anydamage caused in restricted public trafficareas, there is insurance cover for the truck inrespect of third parties.

56338011803 EN - 02/2018 29

2 SafetyBasic principles for safe operation

2

1

Special features when using lithium-ion batteries (variant)The following special features apply for theoperating company and drivers when thistruck is equipped with a lithium-ion battery(variant) in place of a conventional lead-acidbattery.

DANGERRisk of fire!Install a class "D" fire extinguisher inareas in which lithium-ion batteriesare used.

DANGERRisk of explosion!Heating to over 80°C, mechanicalstress and incorrect use may causethe battery to explode.

– Never heat the battery to over 80°C orexpose it to naked flames.

– Do not subject the battery to excessivemechanical loads.

– Do not climb on the battery.

– Avoid impacts.

– Do not open the battery.

– Never short-circuit the battery connectors.

– Do not connect the battery with the polarityreversed.

Product-specific dangers of the 24.1 kWh& 60 kWh lithium-ion battery

WARNINGRisk of burns due to hot surfaces!The battery has an integrated brakeresistor that can heat up to over 100°Cduring operation.It can take several hours for thebrake resistor to cool down to a safetemperature.– Do not touch the hot area (1).

30 56338011803 EN - 02/2018


WARNINGRisk of injury!If the safety valve (2) trips, there is a risk of injury!– Exit the area around the battery immediately,

retreating to a minimum distance of 5 m.

NOTE

The installation of the brake resistor (1) mayvary depending on the battery group. Thebuild-up of heat in the area of the brake resistoris harmless. The safety valve (2) opens whenthe battery is subjected to over pressure orcatches fire.

All lithium-ion batteries are essentially associ-atedwith the risk of a fire starting, of the batteryexploding and of the battery causing chemicalburns.

When used as intended, no hazardoussubstances escape from the closed tray andcontact with toxic substances will not occur.There is a risk of contact only in the event ofincorrect use (mechanical, thermal, electrical)that leads to activation of the safety valve (2)or to the housing cracking. As a result, theelectrolyte fluid may leak out, the electrodematerial may react with moisture/water orbattery discharge/a fire/or an explosioncan occur, depending on the surroundingcircumstances.

Touching live components can lead to anelectric shock, which can have thermal orparalysing effects. The latter can cause ven-tricular fibrillation, cardiac arrest or respiratoryparalysis, leading to death.

If a battery combusts, the resulting smoke orvapours can cause irritation of the eyes, skinand respiratory system.

Permissible lithium-ion batteries– Only use lithium-ion batteries that havebeen approved by STILL for use with thistruck.

– Contact the authorised service centreregarding this matter.

56338011803 EN - 02/2018 31


Declaring the use of lithium-ion batteriesWe recommend that the operating companyinforms the local fire brigade of the planneduse of trucks fitted with lithium-ion batteries.

The health and safety representative and theworkforce must also be informed that truckswith lithium-ion batteries are being used.

Hazard assessmentIn accordance with §3 of the German Ordi-nance on Industrial Safety and Health (Betr-SichV), the operating company is obliged toperform a separate hazard assessment in or-der to assess the risks posed to the companyby lithium-ion batteries.

– Observe the national regulations for thecountry in which the truck is being used.

Driver qualification

In addition to the prerequisites set out in thechapter entitled "Definition of responsiblepersons", in the section entitled "Driver",please observe the following:• The driver must be instructed in how tooperate the lithium-ion battery

• Only instructed drivers may drive thesetrucks

Procedure in the event of a fireDamaged lithium-ion batteries pose an in-creased fire hazard. In the event of a fire,large quantities of water are the best option tocool the battery.

– Extinguish the fire itself with class "D"metal-fire extinguishing powder (dry powder) orwith sand.

– A safety zone of 5 m must be establishedaround a burning battery.

– Evacuate the location of the fire as quicklyas possible.

– Ventilate the location of the fire well, asthe resulting combustion gases can causedamage to health if inhaled.

32 56338011803 EN - 02/2018


– Inform the fire brigade that lithium-ionbatteries are affected by the fire.

– Observe the information provided bythe battery manufacturer regarding theprocedure in the event of a fire.

Water can be used to cool down an incipientfire.

TransportIn certain circumstances, transport of thelithium-ion battery outside the premises mayrequire a special transportation reservoir.

– Contact the authorised service centre formore information.

Changes and retrofittingIf the truck is used for work that is not listedin the guidelines or in these instructions andhas to be converted or retrofitted accordingly,you must note that any change to its structuralstate can affect the handling and stability ofthe truck, which in turn can lead to accidents.

You should therefore contact your servicecentre beforehand.

Changes that will adversely affect stability,load capacity and safety systems, amongother things, must not be made without themanufacturer's approval.

The truck can only be converted with writtenapproval from the manufacturer. Approvalfrom the responsible authority must be ob-tained if necessary.

Changes to the brakes, steering, controlelements, circumferential view, equipmentvariants (e.g. attachments) must also not bemade without the prior written approval of themanufacturer.

We warn against the installation and useof restraint systems not approved by themanufacturer.

56338011803 EN - 02/2018 33


DANGERRisk of injury if truck tips over!Even when using an approvedrestraint system, there is someresidual risk that the driver mightbe injured if the truck tips over. Thisrisk of injury can be reduced throughthe combined use of a restraintsystem and the seat belt. In addition,the seat belt protects against theconsequences of rear-end collisionsand falling off a ramp.– Use the seat belt too.

When carrying out welding work on thetruck, it is essential that the battery and allconnections to the electronic control cards aredisconnected. Contact the authorised servicecentre on this matter.

DANGERRiskof explosion fromadditional holesin the battery hood!Explosive gases can escape andlead to potentially fatal injuries if theyexplode. Sealing holes with plugsis not sufficient to prevent gas fromescaping.– Do not drill any holes in the battery

hood.

DANGERRisk of accident from additional holes in the batteryhood!The rigidity of the battery hood is impaired andthe battery hood may fracture. The driver's seatmay collapse, leading to a risk of accident due touncontrolled steering movements whilst driving.– Do not drill any holes in the battery hood.

34 56338011803 EN - 02/2018


DANGERRisk to life from falling load!If the truck is not equipped with an overhead guard,there is a risk to the driver's life, as hemay be struckby a load falling from a lift height of 1800 mm orgreater.Operation of the truck without an overhead guard ata lift height of over 1800 mm is prohibited.– For lift heights of 1800 mm and above, only use

trucks with an overhead guard.

In the event of the manufacturer going intoliquidation and the company not being takenover by another legal person, the operatingcompany can make changes to the truck.

To do so, the operating company must fulfilthe following prerequisites:

Construction documents, test documentsand assembly instructions associated withthe change must be archived and remainaccessible at all times.

Check that the capacity rating plate, decal in-formation, hazard warnings and the operatinginstructions are consistent with regard to thechanges and modify if necessary.

The change must be designed, checkedand implemented by a design office thatspecialises in industrial trucks in accordancewith the standards and directives valid at thetime the changes are made.

Decal information with the following data mustbe permanently affixed to the truck so it isclearly visible:

– Type of change

– Date of change

– Name and address of the company imple-menting the change.

56338011803 EN - 02/2018 35


Changes to the overhead guard androof loads

DANGERIn the event of the overhead guard failing due toa falling load or the truck tipping over, there arepotentially fatal consequences for the driver. Thereis a risk to life!Welding and drilling on the overhead guard chan-ges the material characteristics and the structuraldesign of the overhead guard. Excessive forcescaused by falling loads or the truck tipping overmayresult in buckling of the modified overhead guardand no protection for the driver.– Do not perform welding on the overhead guard.– Do not perform drilling on the overhead guard.

CAUTIONHeavy roof loads damage the overhead guard!To ensure the stability of the overhead guard atall times, a roof load may only be mounted on theoverhead guard if the structural design has beentested and themanufacturer has given approval.– Seek advice from the authorised service centre

for the mounting of roof loads.

Warning regarding non-original partsOriginal parts, attachments and accessoriesare specially designed for this truck. Wespecifically draw your attention to the fact thatparts, attachments and accessories suppliedby other companies have not been tested andapproved by STILL.

CAUTIONInstallation and/or use of such products may there-fore have a negative impact on the design featuresof the truck and thus impair active and/or passivedriving safety.We recommend that you obtain approval from themanufacturer and, if necessary, from the relevantregulatory authorities before installing such parts.The manufacturer accepts no liability for any da-mage caused by the use of non-original parts andaccessories without approval.

36 56338011803 EN - 02/2018


Damage, defects and misuse ofsafety systemsDamage or other defects on the truck orattachment must be reported to the supervisoror responsible fleet manager immediately sothat they can have the defect rectified.

Trucks and attachments that are not functionalor safe to drivemay not be used until they havebeen properly repaired.

Do not remove or deactivate safety systemsand switches.

Fixed set valuesmay only be changedwith theapproval of the manufacturer.

Work on the electrical system (e.g. connectinga radio, additional headlights etc.) is onlypermitted with the manufacturer's writtenapproval. All electrical system interventionsmust be documented.

Even if they are removable, roof panels maynot be removed, as they are designed toprotect against small falling objects.

Tyres

DANGERRisk to stability!Failure to observe the following information andinstructions can lead to a loss of stability. The truckmay tip over, risk of accident!

The following factors can lead to a loss ofstability and are therefore prohibited:• Different tyres on the same axle, e.g.pneumatic tyres and superelastic tyres

• Tyres not approved by the manufacturer• Excessive tyre wear• Tyres of inferior quality• Changing rim wheel parts• Combining rim wheel parts from differentmanufacturers

56338011803 EN - 02/2018 37


The following rules must be observed toensure stability:• Only use tyres with equal and permittedlevels of wear on the same axle

• Only use wheels and tyres of the same typeon the same axle, e.g. only superelastictyres

• Only use wheels and tyres approved by themanufacturer

• Only use high-quality products

Wheels and tyres approved by the manu-facturer can be found on the spare parts list.If other wheels or tyres are to be used, au-thorisation from the manufacturer must beobtained beforehand.

– Contact the authorised service centre onthis matter.

When changing wheels or tyres, alwaysensure that this does not cause the truck totilt to one side (e.g. always replace right-hand and left-hand wheels at the sametime). Changes must only be made followingconsultation with the manufacturer.

If the type of tyre used on an axle is changed,for example from superelastic tyres to pneu-matic tyres, the loaddiagrammust be changedaccordingly.


Medical equipment

WARNINGElectromagnetic interferencemayoccur onmedicaldevices!Only use equipment that is sufficiently protectedagainst electromagnetic interference.

Medical equipment, such as pacemakers orhearing aids, may not work properly when thetruck is in operation.

– Ask your doctor or the manufacturer ofthe medical equipment to confirm that themedical equipment is sufficiently protectedagainst electromagnetic interference.

38 56338011803 EN - 02/2018


Exercise caution when handling gassprings and accumulators

WARNINGGas springs are under high pressure. Improperremoval results in an elevated risk of injury.For ease of operation, various functions on thetruck can be supported by gas springs. Gas springsare complex components that are subject to highinternal pressures (up to 300 bar). They may underno circumstances be opened unless instructed todo so, and may be installed only when not underpressure. If required, the authorised service centrewill depressurise the gas spring in accordance withthe regulations before removal. Gas springs mustbe depressurised before recycling.– Avoid damage, lateral forces, buckling, tempe-

ratures over 80°C and heavy contamination.– Damaged or defective gas springs must be

changed immediately.– Contact the authorised service centre.

WARNINGAccumulators are under high pressure. Improperinstallation of an accumulator results in an elevatedrisk of injury.Before starting work on the accumulator it must bedepressurised.– Contact the authorised service centre.

Length of the fork arms

DANGERRisk of accident due to the incorrect selection offork arms!– The fork armsmust match the depth of the load.

If the fork arms are too short, the load mayfall off the arms after it has been picked up.In addition, be aware that the load centre ofgravity may shift as a result of dynamic forces,such as braking. A load that is otherwiseresting safely on the fork arms may moveforwards and fall.

If the fork arms are too long, they can catchon loading units behind the load that is to be

56338011803 EN - 02/2018 39


picked up. These other loading units then fallover when the load is raised.

– For helpwith selecting the correct fork arms,contact the authorised service centre.

40 56338011803 EN - 02/2018

Safety 2Residual risk

Residual riskResidual dangers, residual risksDespite careful working and compliance withstandards and regulations, the occurrenceof other risks when using the truck cannot beentirely excluded.

The truck and all other system componentscomply with current safety requirements.Nevertheless, even when the truck is usedfor its proper purpose and all instructionsare followed, some residual risk cannot beexcluded.

Even beyond the narrow danger areas of thetruck itself, a residual risk cannot be excluded.Persons in this area around the truck mustexercise a heightened degree of awareness,so that they can react immediately in the eventof any malfunction, incident or breakdown etc.

WARNINGAll persons that are in the vicinity of the truckmust be instructed regarding these risks that arisethrough use of the truck.In addition, we draw attention to the safety regulati-ons in these operating instructions.

Risks can include:• Escape of consumables due to leakages,rupture of lines and containers etc.

• Risk of accident when driving over difficultground such as gradients, smooth orirregular surfaces, or with poor visibilityetc.

• Falling, tripping etc. when moving onthe truck, especially in wet weather, withleaking consumables or on icy surfaces

• Fire and explosion risks due to batteries andelectrical voltages

• Human error resulting from failure toobserve the safety regulations,

• Unrepaired damage or defective and worncomponents,

• Insufficient maintenance and testing• Use of incorrect consumables• Exceeding test intervals

56338011803 EN - 02/2018 41

2 SafetyResidual risk

The manufacturer is not held responsible foraccidents involving the truck caused by thefailure of the operating company to complywith these regulations either intentionally orcarelessly.

StabilityThe stability of the truck has been tested to thelatest technological standards and is guaran-teed provided that the truck is used properlyand according to its intended purpose. Thesestandards only take into account the dynamicand static tipping forces that can arise duringspecified use in accordance with the operat-ing rules and intended purpose. However, thedanger of exceeding the moment of tilt due toimproper use or incorrect operation and losingstability can never be excluded.

The loss of stability can be avoided or min-imised by the following actions:

– Always secure the load against slipping,e.g. by lashing.

– Always transport unstable loads in suitablecontainers.

– Always drive slowly when cornering.

– Drive with the load lowered.

– Even with sideshifts, align the load ascentrally as possible with the truck andtransport in this position.

– Avoid turning and diagonally driving acrossslopes or gradients.

– Never have the load facing downhill whentravelling on slopes or gradients.

– Pick up only loads of the approved width.

– Always take great care when transportingsuspended loads.

– Do not drive over ramp edges or steps.

Special risks associated with usingthe truck and attachmentsApproval from the manufacturer and attach-ment manufacturer must be obtained each

42 56338011803 EN - 02/2018


time the truck is used in a manner that fallsoutside the scope of normal use, and in caseswhere the driver is not certain that he can usethe truck correctly and without the risk of acci-dents.

56338011803 EN - 02/2018 43


Overview of hazards and counter-measures

NOTE

This table is intended to help evaluate thehazards in your facility and applies to all drivetypes. It does not claim to be complete.

– Observe the national regulations for thecountry in which the truck is being used.

Hazard Measure Check note√ Complete- Not applicable

Notes

Truck equipment doesnot comply with localregulations

Test O If in doubt, consultcompetent factoryinspectorate oremployers' liabilityinsurance association

Lack of skills andqualification of driver

Driver training (sit-onand stand-on)

O BGG 925VDI 3313 driver permit

Usage by unauthorisedpersons

Access with key onlyfor authorised persons

O

Truck not in a safecondition

Recurrent testing andrectification of defects

O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Risk of falling whenusing workingplatforms

Compliance withnational regulations(different national laws)

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employer's liabilityinsurance associations

Impaired visibility dueto load

Resource planning O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Assessment of dieselexhaust gases

O Technical Regulationsfor HazardousSubstances (TRGS)554 and the GermanOrdinance on IndustrialSafety and Health(BetrSichV)

Contamination ofrespiratory air

Assessment of LPGexhaust gases

O German threshold limitvalues list (MAK-Liste)and the GermanOrdinance on IndustrialSafety and Health(BetrSichV)

44 56338011803 EN - 02/2018



Notes

Issuing of operatinginstructions

O German Ordinance onIndustrial Safety andHealth (BetrSichV) andGerman Health andlabour protection law(ArbSchG)

Written notice ofinstruction to driver

O German Ordinance onIndustrial Safety andHealth (BetrSichV) andGerman Health andlabour protection law(ArbSchG)

Impermissible usage(improper usage)

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

When fuelling

a) Diesel Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

b) LPG Note German SocialAccident Insurance(DGUV) regulationD34, the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

56338011803 EN - 02/2018 45



Notes

When charging thetraction battery

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O Association forElectrical, Electronicand InformationTechnologies (VDE)regulation 0510: Inparticular- Ensure adequateventilation- Insulation value withinthe permissible range

When using batterychargers

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),employers' liabilityinsurance associationregulation 104 and theoperating instructions

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employers' liabilityinsurance associationregulation 104

When parking LPGtrucks

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),employers' liabilityinsurance associationregulation 104 and theoperating instructions

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employers' liabilityinsurance associationregulation 104

With driverless transport systems

Roadway qualityinadequate

Clean/clear driveways O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Load carrierincorrect/slipped

Reattach load to pallet O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Drive behaviourunpredictable

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Driveways blocked Mark drivewaysKeep driveways clear


Driveways intersect Announce right-of-wayrule


No person detectionduring depositing andretrieval

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

.

46 56338011803 EN - 02/2018


Danger to employeesAccording to the GermanOrdinance on Indus-trial Safety and Health (BetrSichV) and labourprotection law (ArbSchG), the operating com-pany must determine and assess hazardsduring operation, and establish the labourprotection measures required for employ-ees (BetrSichVO). The operating companymust therefore draw up appropriate operatinginstructions (§ 6 ArbSchG) and make themavailable to the driver. A responsible personmust be appointed.

NOTE


The construction and equipment of thetruck correspond to the Machinery Directive2006/42/EC and are therefore marked withCE labelling. These elements are thereforenot included in the hazard assessment. At-tachments possess their own CE labelling andlikewise are not included for that reason. Theoperating company must, however, select thetype and equipment of the trucks so as to com-ply with the local provisions for deployment.

The result must be documented (§ 6 Arb-SchG). In the case of truck applications involv-ing similar hazard situations, the results maybe summarised. This overview (see chapter"Overview of hazards and countermeasures")provides help on complying with this regula-tion. The overview specifies the main hazardsthat are the most frequent cause of accidentsin the event of non-compliance. If other majoroperational hazards are involved, they mustalso be taken into consideration.

The conditions of use for trucks are broadlysimilar in many plants, so the hazards canbe summarised in one overview. Observethe information provided by the relevantemployers' liability insurance association onthis subject.

56338011803 EN - 02/2018 47

2 SafetySafety tests

Safety testsRegular safety inspection of the truck

Safety inspection based on time andextraordinary incidentsThe operating company must ensure that thetruck is checked by a specialist at least once ayear or after particular incidents.

As part of this inspection, a complete checkof the technical condition of the truck must beperformed with regard to accident safety.In addition, the truck must be thoroughlychecked for damage that could potentiallyhave been caused by improper use. A testlog must be created. The results from theinspection must be retained until a further twoinspections have been carried out.

The inspection date is indicated by an adhe-sive label on the truck.

– Arrange for the service centre to performperiodic safety inspections on the truck.

– Observe guidelines for checks carried outon the truck in accordance with FEM 4.004.

The operator is responsible for ensuring anydefects are remedied without delay.

– Contact your service centre.

NOTE

Observe the national regulations for yourcountry!

Insulation testingThe insulation of the truckmust have sufficientinsulation resistance. For this reason, insula-tion testing in accordance with DIN EN 1175and DIN 43539, VDE 0117 and VDE 0510must be conducted at least once yearly as partof the FEM testing.

The insulation testing results must be at leastthe test values given in the following twotables.

– For insulation testing, contact the autho-rised service centre.

48 56338011803 EN - 02/2018

Safety 2Safety tests

The exact procedure for this insulation testingis described in the workshop manual for thistruck.

NOTE

The truck's electrical system and drive batte-ries must be checked separately.

Test values for the drive battery

Component Recommendedtest voltage Measurements Nominal voltage

UBattTest values

50 VDC 24 volts > 1200 Ω

100 VDC 48 volts > 2400 ΩBattery

100 VDC

Batt+Batt-

Battery tray

80 volts > 4000 Ω.

Test values for the entire truck

Nominal voltage Test voltage Test values for new trucks Minimum values over theduration of the service life

24 volts 50 VDC Min. 50 kΩ > 24 kΩ

48 volts 100 VDC Min. 100 kΩ > 48 kΩ

80 volts 100 VDC Min. 200 kΩ > 80 kΩ.

56338011803 EN - 02/2018 49

2 SafetySafety regulations for handling consumables

Safety regulations for handling consumablesPermissible consumables

DANGERFailure to observe the safety regulations relating toconsumables may result in a risk of injury, death ordamage to the environment.– Observe the safety regulations when handling

such materials.

Refer to the maintenance data table for thepermissible substances that are necessary foroperation (see ⇒ Chapter "Maintenance datatable", P. 5-378).

Oils

DANGEROils are flammable!– Follow the statutory regulations.– Do not allow oils to come into

contact with hot engine parts.– No smoking, fires or naked flames!

DANGEROils are toxic!– Avoid contact and consumption.– If vapour or fumes are inhaled,

move to fresh air immediately.– In the event of contact with the

eyes, rinse thoroughly (for at least10 minutes) with water and thenconsult an eye specialist.

– If swallowed, do not inducevomiting. Seek immediate medicalattention.

50 56338011803 EN - 02/2018

Safety 2Safety regulations for handling consumables

WARNINGProlonged intensive contact with theskin can result in dryness and irritatethe skin!– Avoid contact and consumption.– Wear protective gloves.– After any contact, wash the skin

with soap andwater, and then applya skin care product.

– Immediately change soakedclothing and shoes.

WARNINGThere is a risk of slipping on spilled oil, particularlywhen combined with water!– Spilt oil should be removed immediately with

oil-binding agents and disposed of according tothe regulations.

ENVIRONMENT NOTE

Oil is a water-polluting substance!• Always store oil in containers that complywith the applicable regulations.

• Avoid spilling oils.• Spilt oil should be removed immediatelywith oil-binding agents and disposed ofaccording to the regulations.

• Dispose of old oils according to the regula-tions.

Hydraulic fluid

WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous to your health.– Do not spill the fluids.– Follow the statutory regulations.– Do not allow the fluids to come into

contact with hot engine parts.

56338011803 EN - 02/2018 51

2 SafetySafety regulations for handling consumables

WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous to your health.– Do not allow the fluids to come into

contact with the skin.– Avoid inhaling spray.– Penetration of pressurised fluids

into the skin is particularly danger-ous if these fluids escape at highpressure due to leaks in the hydrau-lic system. In case of such injury,immediate medical assistance isrequired.

– To avoid injury, use appropriatepersonal protective equipment(e.g. protective gloves, industrialgoggles, skin protection and skincare products).

ENVIRONMENT NOTE

Hydraulic fluid is a water-polluting substance.• Always store hydraulic fluid in containersthat comply with regulations

• Avoid spills• Spilt hydraulic fluid should be removedimmediately with oil-binding agents anddisposed of according to the regulations

• Dispose of old hydraulic fluid according tothe regulations

Battery acid

WARNINGBattery acid contains dissolvedsulphuric acid. This is toxic.– Avoid touching or swallowing the

battery acid at all costs.– In case of injury, seek medical

advice immediately.

52 56338011803 EN - 02/2018

Safety 2Safety regulations for handling consumables

WARNINGBattery acid contains dissolvedsulphuric acid. This is corrosive.– When working with battery acid,

use appropriate PSA (rubbergloves, apron, protection goggles).

– When working with battery acid,never wear a watch or jewellery.

– Do not allow any acid to getonto clothing or skin or into theeyes. If this does happen, rinseimmediately with plenty of cleanwater.

– In case of injury, seek medicaladvice immediately.

– Immediately rinse away spiltbattery acid with plenty of water.

– Follow the statutory regulations.

ENVIRONMENT NOTE

– Dispose of used battery acid in line with theapplicable regulations.

Disposal of consumables

ENVIRONMENT NOTE

Materials that accumulate during repair,maintenance and cleaning must be collectedproperly and disposed of in accordance withthe national regulations for the country inwhich the truck is being used. Work mustonly be carried out in areas designated for thatpurpose. Care must be taken to minimise anyenvironmental pollution.

– Soak up any spilt fluids such as hydraulicoil or gearbox oil immediately using anoil-binding agent.

– Neutralise any spilt battery acid immedi-ately.

– Always observe national regulations con-cerning the disposal of used oil.

56338011803 EN - 02/2018 53

2 SafetyEmissions

EmissionsThe values specified apply to a standard truck(compare the specifications in the "Technicaldata" chapter). Different tyres, lift masts,additional units etc. may produce differentvalues.

Noise emissionsThe values were determined based onmeasuring procedures from the standardEN 12053 "Safety of industrial trucks. Testmethods for measuring noise emissions",based on EN 12001 and EN ISO 3744 and therequirements of EN ISO 4871.

This machine emits the following soundpressure level:

Continuous sound pressure level in thedriver's compartment

LpAZMeasurementuncertainty KpA

< 70.0 dB(A) 4 dB(A)

The values were determined in the test cycleon an identical machine from the weightedvalues for operating statuses and idling.

Time proportions:• Lifting 18%• Idling 58%• Driving 24%

However, the indicated noise levels at thetruck cannot be used to determine the noiseemissions atworkplacesaccording to themostrecent version of Directive 2003/10/EC (dailypersonal noise pollution). If required, thesenoise emissions must be determined directlyat the workplaces under the actual conditionspresent (further sources of noise, particularapplication conditions, sound reflections) bythe operating company.

NOTE


54 56338011803 EN - 02/2018

Safety 2Emissions

VibrationsThe vibrations of the machine have beendetermined on an identical machine in ac-cordance with the standards DIN EN 13059"Safety of industrial trucks - Test methodsfor measuring vibration" and DIN EN 12096"Mechanical vibration - Declaration and verifi-cation of vibration emission values".

Frequency-weighted effective value of accel-eration on the seat

MSG 65 driver's seatMeasurementuncertainty

< 0.7 m/s2 0.21 m/s2

Tests have indicated that the amplitude of thehand and arm vibrations on the steering wheelor the operating devices in trucks is less than2.5 m/s2. There are therefore no measure-ment guidelines for these measurements.

The individual vibration load on the driverover the course of a working day must bedetermined by the operating company inaccordance with Directive 2002/44/EC at theactual place of use, to ensure that all additionalfactors, such as the driving route, intensity ofuse etc., are considered.

NOTE


56338011803 EN - 02/2018 55

2 SafetyEmissions

Battery

DANGERRisk of explosion due to flammablegases!During charging, the lead-acid batteryreleases a mixture of oxygen andhydrogen (oxyhydrogen gas). Thisgas mixture is explosive and must notbe ignited.– Make sure that there is always

sufficient ventilation in workingareas that are entirely or partiallyenclosed.

– Keep away from open flames andflying sparks.

– Do not smoke.– Observe the instructions in the

chapter entitled Safety regulationswhen handling the battery.

RadiationAccording to the guide-lines DIN EN 62471:2009-03(VDE 0837-471:2009-03), the STILL Safety-Light (variant) is assigned to risk group 2 dueto its photobiological hazard potential.

56 56338011803 EN - 02/2018

3

Overviews

3 OverviewsGeneral view

General view

6321_003-073_V2

56

7

8

9

12

3

4

1 Lift mast2 Overhead guard3 Driver's compartment4 Traction electronics5 Steering axle

6 Battery7 Drive axle with traction motor8 Fork carriage9 Fork arms

58 56338011803 EN - 02/2018

Overviews 3General view

56338011803 EN - 02/2018 59

3 OverviewsGeneral view of driver's compartment

General view of driver's compartment

8

9

6

72

0

13

5

%75

h

2

234,7

12:15

1 2 3 4

5

6

7

89

10

11

12

13

14

6321_003-132_V3

60 56338011803 EN - 02/2018

Overviews 3Shelves and cup holders

1 Parking brake lever2 Steering wheel3 Key switch4 Display operating unit5 Operating devices for hydraulic and traction

functions6 Emergency off switch (only in this position in

multi-lever operation)7 Storage compartment

8 Cup holder for max. 1-l bottles9 Compartment and storage location for

operating instructions10 Driver's seat11 Accelerator pedal12 Brake pedal13 Alarm horn foot switch14 Steering column adjustment lever

NOTE

The truck equipment may differ from theequipment shown.

7321_003-125

1

2

3

Shelves and cup holders

WARNINGObjects may fall into the footwell and obstruct thepedals, which poses a risk of accident!Objects to be stored must be of the correct size sothat they cannot fall from the shelf (1) or out of thecup holder (2). Objects that fall into the footwellduring travel as a result of steering or braking mayslip between the pedals (3) and prevent them fromworking correctly. It may then not be possible tobrake the truck when necessary.– Bottles of 1 l or smaller may be stored in the cup

holder.– Make sure that stored objects cannot fall from

the shelves when the truck is started up, steeredor braked.

56338011803 EN - 02/2018 61

3 OverviewsOperating devices and display elements

Operating devices and display elementsDisplay operating unit

6210_003-082_V3

12

3 4 5 6 7 8 9 10 11

12

13

14

1516

1718192021222324

25

26

1 Hazard warning system button2 Front windscreen wiper button3 Working spotlight button4 Drive programme selector button5 Lighting button6 Lighting symbol7 Not assigned8 Battery charge display9 Drive programme display (numerical)10 Left direction indicator light11 Forward travel display12 Right direction indicator light13 Malfunction display

14 Reverse travel display15 Power rating display16 Time display (digital)17 Not assigned18 Rotating beacon display19 Interior light display20 Rear window heating display21 Interior light/rotating beacon button22 Rear window heating button23 Menu change button24 Lighting button25 Blue-Q button26 Rear window wiper button

NOTE

The buttons (5, 21, 22) and the correspondingindicators (6, 7, 18, 19, 20) are assignedaccording to the auxiliary equipment installed.

The assignment shown here is an exampleand may differ from the assignment actuallyprogrammed on the truck. Buttons may beassigned multiple functions that are calledup according to the menu navigation. Forfurther information, see the section entitled"Operating the display and operating unit".


62 56338011803 EN - 02/2018

Overviews 3Operating devices and display elements

6209_003-002

1

23

1 Service LED (red)2 Temperature LED (yellow/red)3 Charging state LEDs (red/green)

Lithium-ion battery displayThe lithium-ion battery display is located onthe side of the battery tray. In addition tothe display operating unit, it also shows thecharging status and information relating to thelithium-ion battery.

– Refer to the chapter entitled "Display" inthe operating instructions of the batterymanufacturer, "BMZ".

56338011803 EN - 02/2018 63


Operating devices for hydraulic andtraction functionsDifferent versions of the operating devices areavailable for operating the truck's hydraulicand traction functions.

The truck can be equipped with the followingoperating devices:• Multiple-lever• Double mini-lever• Triple mini-lever• Quadruple mini-lever• Joystick 4Plus• Fingertip• Mini-console

64 56338011803 EN - 02/2018


Multi-lever

5060_003-168

1 2 3 4

5

6

1 "Lift/lower" operating lever2 "Tilt" operating lever3 Operating lever for attachment (variant)4 Operating lever for attachments with 5th

function (variant)5 "5th function" function switch (variant)6 Drive direction switch

NOTE

In the dual-pedal version (variant), the truck isequipped with a signal horn button instead ofthe drive direction switch.

56338011803 EN - 02/2018 65


Double mini-lever

F1 F2

7312_003-002

1

23 4

5

6

7

8

1 "Lift mast" 360° lever2 Function key F13 Function key F24 "Drive direction / turn indicator" cross lever

5 Function key "5th function"6 "Attachments" cross lever7 Emergency stop switch8 Signal horn button

NOTE

Depending on the specification, variouselectric attachment parts can be controlledvia function keys (2) and (3). Changes mustonly bemade by the authorised service centre.

66 56338011803 EN - 02/2018


Three-way mini-lever

1

2

3 45

6

7

89

5060_003-089

1 "Lift mast" 360° lever2 Function key F13 Function key F24 "Drive direction / turn indicator" cross lever5 Function key "5th function"

6 "Auxiliary hydraulics 1" operating lever7 "Auxiliary hydraulics 2" operating lever8 Emergency stop switch9 Signal horn button

NOTE


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Four-way mini-lever

5060_003-088

1

2

34 5

6

7

8

910

1 "Lift/lower" operating lever2 "Tilt" operating lever3 Function key F14 Function key F25 "Drive direction / turn indicator" cross lever

6 Function key "5th function"7 "Auxiliary hydraulics 1" operating lever8 "Auxiliary hydraulics 2" operating lever9 Emergency stop switch10 Signal horn button

NOTE


68 56338011803 EN - 02/2018


Joystick 4Plus

1

2

3

4

5

9

8

7

6

6210_003-087

1 Horizontal rocker button for "3rd hydraulicfunction", tilt the lift mast

2 Pictograms for the basic hydraulic functions3 Pictograms for the 5th hydraulic function and

the clamp locking mechanism (variant)4 Pictograms for the 3rd & 4th hydraulic

functions

5 LED for clamp locking mechanism (variant)6 Slider for the "4th hydraulic function", e.g.

reach frame forwards/backwards7 Vertical rocker button for the "drive direction"8 Shift key "F"9 Signal horn button

56338011803 EN - 02/2018 69


Fingertip

F1F1 F2F2

6321_003-004

1 2 3 4 5 6 7

89101112

1 Function key F12 Function key F23 Left-hand turn indicator button4 Signal horn button5 Right-hand turn indicator button6 Button for 5th function

7 Emergency stop switch8 "Attachments" operating lever9 "Attachments" operating lever10 "Tilt" operating lever11 "Lift/lower" operating lever12 Travel direction switch

NOTE


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7311_003-0561

2

1 Travel direction switch2 Direction indicator switch

Mini consoleThe mini console is located on the steeringcolumn below the steering wheel.

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4

Operation

4 OperationTesting and activities before daily use

Testing and activities before daily use

1

2

6210_000-002

Load lift system unit

Visual inspections and functionchecking

DANGERRisk of explosion if hydrogen builds upin the cab!If the truck is equipped with a cab,hydrogen from the battery compart-ment can penetrate the cab throughunsealed bores in the battery hood. Abuild-up of hydrogen can lead to ex-plosions.There must be no unsealed bores inthe battery hood. Sealing bores withplugs is not sufficient to prevent gasfrom escaping.– Have unused bores in the battery

hood sealed by the authorisedservice centre.

WARNINGRisk of accident due to damage or other defects onthe truck or on the attachment (variant)!Damage to the truck or the attachment (variant) canlead to unpredictable and dangerous situations.If damage or other defects are identified on thetruck or attachment (variant) during the followinginspections, the truck must not be used until it hasbeen properly repaired.– Do not remove or deactivate safety systems or

switches.– Do not change any predefined set values.– Do not use the truck until it has been properly

repaired.

WARNINGRisk of falling when working on high parts of thetruck.– Use only the steps provided on the truck.– Do not use any truck components as mounting

aids or platforms.– Use suitable equipment.

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Operation 4Testing and activities before daily use

CAUTIONRisk of component damage!A deformed or damaged battery male connectorcan cause overheating and the related consequen-tial damage.– Check the battery male connector for damage.– If necessary, have the battery male connector

replaced by the authorised service centre.

To be able to operate the truck safely, visualinspections and function checking must becarried out before daily use. The componentsthat must be checked and their checkpointsare listed in the following table. If damageor other defects are identified on the truck orthe attachment (variant) during the followingchecks, do not use the truck until it has beenrepaired properly. Damage or other defectsmust be reported to the supervisor or theresponsible fleet manager immediately sothat repairs to be performed by the authorisedservice centre can be arranged.

Ensure that the truck is safe for operation each day before it is used:

Component Course of action

Fork arms, general lifting accessories

Performa visual inspection for deformation andwear(for example, bent, broken, significant wear).Check the condition and function of safety devices(1) to prevent lifting and shifting.

Roller tracks (2) Make sure that there is a film of grease.

Load chainsPerform a visual inspection to ensure that the chainsare intact and have adequate and even tension.

Attachments (variant)

Ensure correct mounting in accordance with theoperating instructions of the manufacturer.Perform a visual inspection to ensure the attach-ments are intact and not leaking.Perform checks to ensure the attachments areworking correctly.

Lift and tilt cylinders, tank, valve block,hoses, pipes, connections

Perform a visual inspection for damage and leaks.Have damaged components replaced by the autho-rised service centre.

Underside Check the area under the truck for leaking consum-ables.

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Wheels, tyres

Perform a visual inspection for wear and damage.Make sure that only rims of the same type from thesamemanufacturer are fitted.In the event of uneven tyre wear, replace both tyres.Observe the safety regulations in the chapter entitled"Tyres".

Axle Make sure that no consumables are escaping fromthe axle.

Overhead guard, guard grille (variant) Perform a visual inspection for integrity.Check for secure mounting.

Steps Make sure they are clean (free of ice, not slippery).

Panes of glass (variant) Perform a visual inspection for integrity.Make sure they are clean (also free of ice).

Handholds Check for secure mounting.

Maintenance lids Check the close function and close the lids.

Battery hood Make sure that there are no unused bores in thebattery hood.

Battery cover

Perform a visual inspection for integrity and defor-mation.Check that the lock is in good condition and isworking correctly.Check the close function.Close.

BatteryCheck that the lock is in good condition and isworking correctly.Lock the battery.

Battery male connector

Perform a visual inspection for integrity and defor-mation.Check the contacts.Have damaged batterymale connectors replaced bythe authorised service centre.

Coupling pin, tow coupling (variant)

Performa visual inspection for deformation andwear(for example, bent, torn, broken).Check the securing bush in the counterweight forintegrity and that it is working correctly.Check that the linchpin is present and workingcorrectly (chain, rope, split pin).

Labelling, adhesive label

Check that labels are present and intact/legible.Replace damaged or missing adhesive labels inaccordance with the chapter entitled "Labellingpoints".

Driver's seat, seat belt Check the integrity and function.

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Lighting, warning units Check the integrity and function.

Antistatic belt (3), corona electrode (4)(See the following illustration.)

Perform a visual inspection for integrity.Ensure cleanliness.Make sure that the antistatic belt (3) is still longenough to touch the ground.The discharge wires of the corona electrode (4)must not touch the ground. The wires discharge theenergy to the air.

Antistatic belt and corona electrode

Depending on the tyres used, the truck is fittedwith one ormore antistatic belts (3) and/or witha corona electrode (4). These componentsensure that the truck cannot charge statically.

– Do not use the truck if there is any damageor defects.

– In this case, contact your authorised servicecentre.

Any other necessary tasks are summarisedunder their own headings, e.g. adjusting thedriver's seat.

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Climbing in and out of the truck

WARNINGRisk of injury when climbing into and out of thetruck due to slipping, striking parts of the truck orbecoming stuck!If the footwell cover is very dirty or smeared with oil,there is a risk of slipping. There is a risk of hittingyour head on the post of the overhead guard or ofyour clothes becoming stuck when climbing out ofthe truck.– Ensure that the footwell cover is non-slip.– Do not jump into or out of the truck.– Ensure that you have a secure grip on the truck.

WARNINGRisk of injury when jumping out of the truck!If your clothing or jewellery (e.g. watch, ring etc.)become stuck on a component while you arejumping out of the truck, this can lead to seriousinjuries (e.g. from falling, loss of fingers etc.). It isforbidden to jump out of the truck.– Do not jump out of the truck.– Do not wear jewellery at work.– Do not wear loose-fitting workwear.

CAUTIONComponents may become damaged throughincorrect use!Truck components, such as the driver's seat,steering wheel, parking brake lever etc., are notdesigned to be used for climbing in and out of thetruck and can be damaged due to misuse.– Only use the fittings specifically designed for the

purpose of climbing into and out of the truck.

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6321_003-140

1

5

4

3

2Toassistwith climbing into andout of the truck,the footwell must be used as a step (4) and thehandle (1) must be used for support. The postof the overhead guard (5) can also be used forsupport.

Always climb into the truck in a forwardsmotion:

– Grip the handle (1) with your left hand andhold on.

– Put your left foot on the step (3).

– Enter the truck with your right foot first andsit down on the driver's seat (2).

Always climb out of the truck backwards:

– Grip the handle (1) with your left hand andhold on.

– Stand up from the driver's seat and placeyour left foot on the step (3).

– Climb out of the truck right foot first.

Adjusting the MSG 65/MSG 75driver's seat

DANGERThere is a risk of accident if the seat or seat backrestshifts suddenly, which could cause the driver tomove in an uncontrolled manner. This may result inunintentional actuation of the steering or operatingdevices and thus cause the truck or load to move inan uncontrolled fashion.– Do not adjust the seat or seat backrest while

driving– Adjust the seat and the seat backrest so that all

operating devices can be actuated safely– Ensure that the seat and seat backrest are

securely engaged

WARNINGOn some equipment variants, theamount of head clearance on the truckmay be restricted.On these specific equipment variants,the distance between the head andthe lower edge of the roofing sheetmust be at least 40 mm.

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NOTE

If there are separate operating instructions forthe seat, they must be followed.

WARNINGTo obtain optimum seat cushioning, you must ad-just the seat suspension to your own body weight.This is better for your back and protects your health.– To prevent injury, make sure that there are no

objects within the swivel area of the seat

7094_003-0061

Moving the driver's seat– Lift and hold the lever (1)

– Push the driver's seat into the desiredposition.

– Release the lever.

– Ensure that the driver's seat is securelyengaged.

7094_003-008

2

Adjusting the seat backrestDo not put pressure on the seat backrest whileengaging it.

– Lift and hold the lever (2)

– Push the seat backrest into the desiredposition.

– Release the lever.

– Ensure that the seat backrest is securelyengaged.

NOTE

The backwards tilt angle of the seat backrestcan be restricted by the structural condition ofthe truck.

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6321_003-038

3

4

Adjusting the seat suspension

NOTE

The driver's seat can be adjusted to suit theweight of the individual driver. In order toachieve the best seat suspension setting, thedriver should perform the adjustment whilstsitting in the seat.

NOTE

The driver's seatMSG 65/MSG 75 is designedfor people weighing between 45 kg and170 kg.

NOTE

The MSG 75 seat is equipped with electric airsuspension that is activated using an electricswitch instead of the lever (3).

– Fully extend the weight-adjusting lever (3)

– Pump it up or down to set the driver'sweight.

– Return the weight adjusting lever to thecentral initial position before each new lift(audible click).

– Fully fold in the weight adjusting lever onceadjustment is complete.

NOTE

The driver's weight has been selected cor-rectly when the arrow (4) is in the centre of theinspection window. If the seat does not moveany further when you pump the weight adju-sting lever, the minimum or maximum weightsetting has been reached.

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6321_003-039

5

Adjusting the lumbar support (variant)

NOTE

The lumbar support can be adjusted to suitthe contours of the individual driver's spine.Adjusting the lumbar support moves a convexsupport cushion into the upper or lower part ofthe backrest.

– Turn the turning knob (5) up or down untilthe lumbar support is in the desired position

6321_003-040

6Adjusting the backrest extension(variant)– Adjust the backrest extension (6) by pullingit out or pushing it into the desired position.

To remove the backrest extension, move itpast the end stop by jolting it upwards.

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6321_003-041

7

Switching the seat heater (variant) onand off

NOTE

The seat heater only functions if the seatcontact switch is active, i.e. when the driver issitting on the driver's seat.

– Switch the seat heater (7) on or off using theswitch.

Seat belt

DANGEREven when using an approvedrestraint system, there is someresidual risk that the driver might beinjured if the truck tips over.This risk of injury can be reducedthrough the combined use of therestraint system and the seat belt.In addition, the seat belt protectsagainst the consequences of rear-endcollisions and falling off a ramp.– We therefore recommend that you

also use the seat belt.

DANGEROnly bracket doors (variant) or the driver's cab(variant) with closed, fixed doors constitute a driverrestraint system. Plastic doors (weather protection)do not constitute a restraint system!If you need to open or remove the doors, you mustuse an alternative suitable restraint system (e.g. aseat belt).

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7311_003-048

1

23

Fastening the seat belt

DANGERRisk to life when driving without a seat belt!If the truck tips over or crashes into an obstacleand the driver is not wearing the seat belt, the drivermay be thrown from the truck. The driver could slideunder the truck or collide with an obstacle.There is a risk of fatal injury!– Fasten the seat belt before every trip.– Do not twist the seat belt when fastening it.– Only use the seat belt to secure one person.– Have any malfunctions repaired by the authori-

sed service centre.

NOTE

The buckle has a buckle switch (variant). Inthe event of an operating error or malfunction,the message SAFETY BELT appears in thedisplay and operating unit, see the chapterentitled "Display messages".

– Pull the seat belt (3) out of the belt retractorwithout jerking and fasten closely aroundthe body over the thighs.

NOTE

Sit as far back as possible so that your backis leaning against the seat backrest. Theautomatic blocking mechanism permitssufficient freedom of movement on the seat.

– Click the belt tongue (2) into buckle (1).

– Check tension of the seat belt. It should beclose to the body.

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6210_342-005

Fastening on a steep slopeThe automatic blocking mechanism preventsthe belt from being extended whenever thetruck is on a steep gradient. It is not possibleto pull the seat belt any further out of the beltretractor.

– Move away carefully on the slope.

– Fasten the seat belt.

Releasing the seat belt

7090_342-0051

4

– Push the red button (4) on the buckle (1).

– Manually guide the belt tongue slowly backto the retractor.

NOTE

Do not allow the seat belt to retract too quickly.The automatic blocking mechanism may betriggered if the belt tongue strikes the housing.It will then no longer be possible to pull the seatbelt out with the usual force.

– Using increased force, pull the seat beltaround 10-15 mm out of the retractor todisengage the blocking mechanism.

– Slowly allow the seat belt to retract again.

– Protect the seat belt from dirt (for example,by covering it).

Malfunction due to cold– If the buckle or belt retractor is frozen, thawthemout anddry them thoroughly to preventrecurrence.

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CAUTIONThe seat belt may be damaged by heat!Do not subject the buckle or belt retractor to exces-sive heat when thawing.– Do not use air warmer than 60°C when thawing.

Adjusting the armrest

DANGERThere is a risk of accident if the armrest lowers sud-denly, causing the driver tomove in an uncontrolledmanner. This can result in unintentional actuationof the steering or the operating devices and thuscause uncontrolled movements of the truck or load.– Do not adjust the armrest while driving.– Adjust the armrest so that all operating devices

can be actuated safely.– Ensure that the armrest is securely tightened.

7331_342-001

3 1 2

Adjusting the length of the armrest– Release the star-grip handle (1) by turningit anti-clockwise.

– Shift the armrest (2) into the desired posi-tion.

– Tighten the star-grip handle by turning itclockwise.

– Check that the armrest is firmly attached.

Adjusting the height of the armrest– Release hand wheel (3) by turning it anti-clockwise.

– Shift the armrest (2) into the desired posi-tion.

– Tighten the hand wheel by turning it clock-wise.

– Check that the armrest is firmly attached.

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6210_424-001

1

2

Adjusting the steering column

DANGERRisk of accidents!Adjusting the steering column during travel maycause the truck to career out of control.– Adjust the steering column only when the truck is

at a standstill.– Ensure that the steering column is engaged.

– Press down and hold the lever (2) forsteering column adjustment.

– Position the steering column (1) and releasethe lever.

When the steering column engages, the leversnaps back to the initial position.

– Gently push and pull on the steering columnto make sure that the steering column isengaged.

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Unlocking the emergency off switch

6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

– Pull out/turn the emergency off switch (1)until it unlocks.

Switching on the key switch

WARNINGBefore switching on the key switch, all tests andoperations prior to commissioning must be perfor-med without any defects being detected.– Carry out checks and operations before commis-

sioning.– Do not operate the truck if defects have been

detected; contact the authorised service centre.

NOTE

When the truck is switched on, the maximumdriving speed is restricted. The driving speedlimitation is disabled as soon as the truck issteered out of cornering to drive in a straight

88 56338011803 EN - 02/2018


line. To do this, rotate the steering wheel byapproximately half a turn.

I

1

0

5060_003-029_V2

– Insert switch key (1) into the key switch andturn to position "I".

7312_003-085

This initiates a self-test. All lamps in the drivedirection and turn indicator displays light upbriefly.

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When the key switch is switched on, thedisplay shows the welcome screen in theset language until the truck controller has fullystarted up.

If the truck is ready for operation, the standarddisplays are shown.

If the truck is equipped with the "accessauthorisation with PIN code" variant, thedisplay initially changes to the input menufor access authorisation.

1 2

346341_003-006_V3

Standard display elements1 Battery charge

The available battery capacity is shownin the display field.

2 Drive programThe current traction program (1–5)appears on the display.

3 Power ratingThe average power consumption andconsumption trends are shown in thedisplay field.

4 TimeThe current time appears in the displayfield.

NOTE

After connecting the battery, the correctcharging state may not be displayed untilthe battery is placed under load in the form ofdriving or lifting operations.

Additional information may appear on thedisplay.

– If malfunctions occur, refer to the informa-tion in the chapter entitled "Display mes-sages".

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Access authorisation with PIN code(variant)

DescriptionTrucks equipped with the "Access authori-sation with PIN code" variant are protectedagainst unauthorised use by a five-digit driverPIN. Up to fifty different driver PINs can bedefined so that the same truck can be usedby different drivers, each with their own driverPIN.

NOTE

The driver PINs are defined in a truck controlunit menu that can only be accessed bypersons with the corresponding accessauthorisation, e.g. fleet managers.

Once the key switch has been switched on,the input menu for the driver PIN appearson the display and operating unit screen. Allof the truck's functions (driving, hydraulics,additional electrical installations and thedisplay and operating unit displays) areblocked. The function of the hazard warningsystem (variant) is guaranteed. Enter the five-digit driver PIN (possible entries from 00000 to99999) to enable the blocked functions. Oncethe correct driver PIN has been entered, thestandard displays are shown. All of the truckfunctions are available.

The access authorisation can be configuredin such a way that the driver PIN has to bere-entered each time the driver steps off thetruck, in order for the truck to be operatedagain.


The first driver PIN is preset to "11111" at thefactory. All others are preset to "0xFFF" buthave no function as the highest valid driverPIN is "99999". Persons with the appropriateaccessauthorisation, e.g. fleetmanagers, canchange the driver PINs in the correspondingmenu.

56338011803 EN - 02/2018 91


NOTE

When first commissioning the truck, we re-commend you change the access authorisa-tion set at the factory. This is the only way toguarantee that the driver PIN is only known topersons with corresponding access authori-sation.

The driver PINs are stored in the truck controlunit. These are still available if the displayand operating unit has been changed. Theauthorised service centre can use a diagnosticdevice to read out the driver PIN and, ifnecessary, restore the factory default driverPIN.

ACCESS CODE input menuThe driver enters the five-digit driver PIN(00000 to 99999) in this input menu.

The driver PIN is entered using the buttons orSoftkeys (1). The digits entered for the driverPIN (2) are not visible but are represented bycircles instead. If the driver PIN entered iscorrect, the familiar screen appears with thestandard display, and all truck functions areavailable.

8

9

6

7

4

2

0

1

3

5

BQ_023_en_V2

If an incorrect driver PIN is entered, themessage INVALID appears for a short time.When the message goes out, the driver PINcan be re-entered.

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8

9

6

7

4

2

0

1

3

5

BQ_024_en_V2

After three invalid entry attempts, the mes-sage CODE DENIED appears. The input isthen locked for five minutes before anotherattempt can be made.

Blue-Q_029_V2

1

2

Defining the driver PIN

NOTE

The driver PINs can be defined only by per-sons with the appropriate access authorisa-tion, e.g. fleet managers. To set the driverPIN, the fleet manager must access the con-figuration menu. The configuration menu ispassword-protected. After entering the pass-word, the fleet manager can configure generalsettings for the truck. To change the pass-word, see the chapter entitled "Changing thepassword".

– Push the drive program selection button (1)and themenu change button (2) at the sametime.

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8

9

6

7

4

2

0

1

3

5

1

2

BQ_030_en_V2

1

2

6

7

3

4

5

ESC

PASSWORD appears in the display.

– Enter the four-digit password (factorydefault: 2777) using the buttons (1).

– Confirm the input using Softkey (2).

8

9

6

7

4

2

0

1

3

5

BQ_31_en

1

3 2

CONFIGURATION appears in the display.

– Use the drive program selection button (1)and the menu change button (3) to selectthe ACCESS CODEmenu.

– Confirm your selection using Soft-key (2).

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8

9

6

7

4

2

0

1

3

5

BQ_025_en_V3

1

34 2

Selecting the driver PINIn the ACCESS CODEmenu, there are fiftypossible driver PINs to choose from.

The digit sequences can be set or changed inthe NEW CODE submenu.

Once the ACCESS CODEmenu has been ac-cessed, the CODE selection field (2) containsthe number 1. The first of the fifty driver PINscan now be defined.

– Use the drive program selection button (1)and the menu change button (4) to selectthe desired driver PIN (1 to 50).


NEW CODE appears in the display.

– Enter the desired driver PIN using thebuttons or Softkeys (5).

Thedigits entered do not appear in the display.Instead they are represented by circles in theNEW CODE field (6).

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9

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0

1

3

5

7

8

1

2

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7

3

4

5

8

9

0

BQ_026_en

CONFIRM appears in the display.

The CONFIRM submenu is used to confirmthe new driver PIN.

– Enter the new driver PIN for a second timein the CONFIRM field (8) using the buttonsor Softkeys (7).

If the entry matches the new driver PINpreviously entered, the system will acceptthe new driver PIN once the last digit hasbeen entered. The display switches back tothe ACCESS CODEmenu.

Another driver PIN can be defined here.

8

9

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0

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3

5

BQ_023_en_V2

If the driver PIN entered in the CONFIRM sub-menu does not match the driver PIN enteredpreviously in the NEW CODE submenu, themessage INVALIDwill appear.

The message will then disappear after a shorttime. The new driver PIN can be entered inthe CONFIRM submenu for further confirma-tion.

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9

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7

4

2

0

1

3

5

BQ_024_en_V2

After three incorrect entries, the CODE DE-NIEDmessage appears.

The display switches back to the ACCESSCODEmenu. The desired driver PIN must bere-defined.

Blue-Q_029_V2

1

2

Changing the passwordIt is recommended that you change the factorydefault password.

NOTE

The password can only be changed when theparking brake is applied.

– Push the drive program selection button (1)and themenu change button (2) at the sametime.

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7

4

2

0

1

3

5

1

2

BQ_030_en_V2

1

2

6

7

3

4

5

ESC

PASSWORD appears in the display.

– Enter the current password using thebuttons (1).

– Confirm the input using Softkey (2).

8

9

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7

4

2

0

1

3

5

1

23

BQ_032_en

CONFIGURATION appears in the display.

– Use the drive program selection button (1)and the menu change button (3) to selectthe PASSWORDmenu.


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9

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1

34

BQ_033_en

2

1

PASSWORD/PASSWORD LEVEL appears inthe display.

– Use the drive program selection button (1)and the menu change button (4) to selectthe desired PASSWORD LEVEL (2).


8

9

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5

ESC

BQ_034_en_V2

1 2 3

4

NEW CODE appears in the display.

The four-digit password can be entered usingthe buttons (1).

CAUTIONDo not enter the password 1777!If this password is entered, the configuration op-tions for the fleet manager are restricted to driverauthorisations and cannot be reset independently.The authorisations can only be reset by the autho-rised service centre!

– Enter the new desired password using thebuttons (1).

The digits entered are shown in plain text inthe NEW CODE field (4).


In the NEW CODE field, -??- appears briefly.The new password is confirmed.

– Press Softkey (2) to correct the newpassword.

The display switches back to PASS-WORD/PASSWORD LEVEL.

– Repeat the process steps from PASS-WORD/PASSWORD LEVEL.

– To exit the configuration menu, pressSoftkey (2) repeatedly until the standarddisplay appears.

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F1F1 F2F2

6210_003-095

1

1

1

1

1

Operating the signal horn– Push the signal horn button (1).

The signal horn sounds.

NOTE

The signal horn is used to warn people againstimminent danger or to announce your intentionto overtake.

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6321_003-094

Driver's cab

DANGERRisk of fatal injury in the event of falling from thetruck if it tips over!In order to prevent the driver from sliding under-neath the truck and being crushed if the truck tipsover, a restraint systemmust be in place and mustbe used. The restraint system prevents the driverfrom being thrown from the truck if it tips over. Thedriver's cab constitutes a driver restraint systemonly if the cab door is sturdy and closed. Fabric-co-vered cabs (variant) with doors made of plastic orcanvas do not constitute a driver restraint systemand offer no protection from the consequences ofthe truck tipping over!– Close the cab door before operation– If the door is open or has been removed, use a

comparably secure restraint system– We recommend that you always use the seat belt

1

5060_003-015

Checking the brake system forcorrect function

DANGERIf the brake system fails, the truck is insufficientlybraked or not braked at all, so there is a risk ofaccident!– Do not commission trucks with a defective brake

system.

Checking the foot brake– Release the parking brake.

– Depress the brake pedal (1).

There must be a slight pedal clearance andthen a noticeable brake pressure point.

– Accelerate the unladen truck in a clear area.

– Press the brake pedal firmly.

The truck must decelerate noticeably.

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6210_342-005

Checking the parking brake

DANGERIf the truck rolls away, there is a risk of being runover and therefore a danger to life!– The truck must not be parked on a slope.– In emergencies, secure with wedges on the side

facing downhill.– Only leave the truck when the parking brake is

applied.

– Actuate the parking brake at walking speedor on a steep gradient.

The truck must stop and remain stationary.

– If the truck continues to roll despite theparking brake being applied, notify theauthorised service centre.

5060_003-031

1Checking the steering system forcorrect function

DANGERIf the hydraulics fail, there is a risk of accident as thesteering characteristics have changed.– Do not operate the truck if it has a defective

steering system.

– Operate steering wheel (1). The steeringplay while stationary must not be more thantwo finger widths.

NOTE

If the truck is switched on with the steeringwheel turned, the maximum driving speed islimited. Travel speed limitation is removedas soon as the steering wheel is moved outof a cornering position into the straight-aheadposition. This requires a change in steeringangle of about half a revolution.

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6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

I Mini-lever versionII Multiple-lever versionIII Joystick 4Plus versionIV Fingertip version

Checking the emergency off function

WARNINGNoelectric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply.– To brake, actuate the service brake.

– Slowly drive the truck forwards.

– Press the emergency off switch (1).

The truck will coast.

The display and operating unit shows themessage EMERGENCY OFF SWITCH period-ically.

– Brake the truck to a standstill by actuatingthe brake pedal.

NOTE

In trucks with an electric parking brake, theelectric parking brake will be applied as soonas the truck comes to a stop.

– Pull out/turn the emergency off switch (1).

The truck performs an internal self-test and isthen ready for operation again.

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6210_003-067_V2

21

Checking the vertical lift mastposition (variant) for correct function

NOTE

The function check of the lift mast verticalposition (variant) must be carried out everytime a truck is commissioned.

– Press the Softkey (1).

The comfort feature "lift mast vertical posi-tion" is switched on. The symbol (2) isdisplayed.

– Tilt the lift mast backwards.

The lift mast must tilt back fully and movegently as far as the end stop.

– Tilt the lift mast forward.

The lift mast must tilt forwards and stop in thevertical position.

– Release the operating device to tilt andactuate again.

The lift mast must tilt forwards fully and movegently as far as the end stop.

Zero adjustment of the load mea-surement (variant)

NOTE

A zero adjustment must be carried out inorder to guarantee the accuracy of the loadmeasurement (variant) at all times. Zeroadjustment is required• Before daily use• after changing the fork arms• after fitting or changing attachments.

NOTE

Accurate zero adjustment is only possible ifthe fork is not carrying a load. Do not take up aload yet.

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NOTE

Accurate zero adjustment is only possiblewithin the first lifting stage of the lift mast.When carrying out the zero adjustment, do notraise the fork more than 800 mm above theground.

NOTE

Theway in which the lifting system is operateddepends on the operating devices included inthe truck's equipment; see the chapter entitled"Lifting system operating devices".

– Set lift mast to vertical.

– Raise the fork to a height of 300-800 mm.

6210_003-071_V2

21

– Press the Softkey (1).

The zero adjustment of the loadmeasurementis switched on. The symbol is displayed.The message LOWER FORKS appears on thedisplay.

NOTE

During the following process, the fork carriagemust be lowered slightly and then stoppedabruptly. While doing so, the fork mustnot touch the ground, otherwise the zeroadjustment will not be accurate. To stopthe lowering procedure quickly, release theoperating device for lowering so that it jumpsinto the zero position.

– Lower the fork carriage slightly and releasethe operating device.

When the zero adjustment has been carriedout correctly, the value "0 kg" appears on thedisplay.

– The zero adjustment of the load measure-ment is completed. The symbol (2) isdisplayed.

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4 OperationDisplay-operating unit

Display-operating unitIndicators

1 2

346341_003-006_V3

Standard displays

In the factory setting, the following indicatorscan be seen in the display and operating unit:1 Battery charge

Displays the available battery capacityas a segmented bar graph in 10%increments.Approx. every 10 seconds, the displayswitches fromshowing thebattery chargeto the remaining operating time.If a different drive program or a differentdrive mode (e.g. Blue-Q) is selected,the system immediately recalculates theremaining operating time and indicatesfor how long the truck can be driven if theoperating situation of the last 30 minutesis maintained.

2 Drive programDisplays the number of the selected driveprogram. To change the drive program,refer to the section entitled "Setting thedrive program".The Blue-Q icon appears when theBlue-Q function is switched on; refer tothe section entitled "Blue-Q efficiencymode".

3 Power ratingThe power rating indicator shows theaverage energy consumption over thelast 30 minutes in kilowatts (kW).Trends relating to the current energyconsumption are displayed as a verticalbar graph . The percentage changein each bar is shown in the table under"Power trends indicator" below.

4 TimeDisplays the current time digitally in hoursand minutes. The time can be adjusted;see the chapter entitled "Setting thetime".

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Operation 4Display-operating unit

CAUTIONDeep discharges shorten the service life of thebattery.If no bar is shown (0% of the available batterycapacity, i.e. around 20% of the nominal capacity),deep discharge begins.– Deep discharge (no bar on the display) must be

avoided.– Cease work with the truck immediately.– Charge the batteries immediately.

NOTE

To prevent deep discharge, certain restric-tions (variant) can be activated (e.g. slowlifting). Consult the authorised service centreon this matter.

Power trends indicatorSymbol Energy consumption trend

Significant increase (> 50%)

Increase (up to 50%)

Slight increase (up to 30%)

No change

Slight decrease (up to -30%)

Decrease (up to -50%)

Significant decrease (> -50%).

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7312_003-106_V2

6

89

75

Additional indicators5 Menu change button

When the menu change button ispressed, the following additional indi-cators appear:

6 "Service in" displayDisplays the remaining time in operatinghours until the next maintenance opera-tion is due according to the maintenanceschedule in the maintenance instruc-tions. Contact the authorised servicecentre in good time.

7 Operating hoursDisplays the total operating hourscompleted by the truck. The hour meterstarts running as soon as the truck isdriven or the working hydraulics areactuated.

8 Total distanceDisplays the total distance driven inkilometres.

9 Daily kilometresDisplays the kilometres driven for theday.

NOTE

Ask the authorised service centre about thespeed driven indicator.

NOTE

Have all repair and maintenance work perfor-med by an authorised service centre. This isthe only way to permanently correct defects.

– Inform the authorised service centre whenthe maintenance interval is reached.

Adjusting the displays

NOTE

The parking brake must always be engagedwhen you adjust the displays. The displayscannot be adjusted if the parking brake is notengaged.

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NOTE

When adjusting the displays, do not actuatethe hydraulic system operating devices. If youdo, entry is interrupted and the display returnsto the operating display.

The displays are adjusted in the CONFIGU-RATIONmenu.

– Turn the key switch to position "I".

Blue-Q_029_V2

1

2

– Press the drive program button (1) and themenu change button (2) at the same time.

8

9

6

7

4

2

0

1

3

5

1

2

BQ_030_en_V2

1

2

6

7

3

4

5

ESC

The display changes to thePASSWORDmenu.

NOTE

It may be necessary to enter a password inorder to configure the displays. This dependson the configuration of the display-operatingunit.• For configuration of the display-operatingunit, contact the authorised service centre

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7312_003-056_en_V3

ESC

1 2 3– Press the Softkey (3).

The display changes to the CONFIGURA-TIONmenu.

The following settings are possible and can befound in the corresponding chapter:• Setting the date and time• Resetting the daily kilometres and dailyoperating hours

• Setting the language• Configure Blue-Q

Symbols in the display

MessagesTo show operating messages, warningmessages or error messages in the display,text messages and symbols are used.

Symbols for operating messages

Description Symbol

Empty field No display

Please wait

Service required

Lift limitation

Reference cycle

Battery charging

Drive program

Hour meter

Odometer

Daily hour meter

Daily odometer

Speed

Steering angle

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Description Symbol

Load

Time

Hydraulic system

Exh.gas purifier

Coolant temperature

Fuel level

Blue-Q

Power rating (average)

Power rating (trend).

Symbols for warning messages

Description Symbol

Parking brake

Actuate seat switch

Safety belt

Battery acid level

Neutral warning message

Are you sure?

Oil pressure.

Symbols for error messages

Description Symbol

Brake system malfunction

Overheating of the engine

Overheating

Malfunction in the electrical system

General malfunction.

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Symbols for softkey functions of auxiliaryequipmentThe following symbols for softkey functionsare used on the left of the display for auxiliaryequipment:

Description Symbol


General function OFF

General function ON

Rear working spotlight OFF

Rear working spotlight ON

Front working spotlight OFF

Front working spotlight ON

Windscreen heating OFF

Windscreen heating ON

Rear window heating OFF

Rear window heating ON

Interior lighting OFF

Interior lighting ON

Roof wiper/washer OFF

Roof wiper/washer ON

Heater blower OFF

Heater blower ON

Rotating beacon OFF

Rotating beacon ON

Seat heater OFF

Seat heater ON

Signal horn OFF

Signal horn ON

Cruise control OFF

Cruise control ON

Automatic mast vertical positioning OFF

Automatic mast vertical positioning ON

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Description Symbol

Load measurement zero adjustment OFF

Load measurement zero adjustment ON

Load measurement OFF

Load measurement ON.

Symbols for softkey functions for menunavigation and for acknowledgingmessagesThe following symbols for the softkey functionsare used on the left of the display for menunavigation and to acknowledge messages:

Description Symbol


Cancel input

Confirm input

Confirm information

Reset

Back by one menu level

Back to the previous edit field

Scroll up

Scroll down

Count up

Count down.

Status LEDs of the function keys foradditional electrical installationsThe current switch status of a button is indi-cated with LEDs next to the relevant functionkey for the additional electrical installation.

Description LED

Function off LED OFF

Function on LED ON.

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Symbols for numeric keypadThe buttons and Softkeys that can be used toenter numbers and to cancel or confirm inputvalues are shown in the display.

BQ_037

1

2

6

7

3

4

5

ESC

Screen for entering the fleet manager pass-word:

1

2

6

7

3

4

5

8

9

0

BQ_038

Screen for entering the driver PIN (accesscode):

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8

9

0

6

7

4

3

5

7312_003-054_en_V3

1 2 3 4Setting the date or time– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the Drive programme button (1) orthe Menu change button (2) repeatedly untilthe TIME option appears.

– Confirm your selection using the Soft-key (4).

The TIMEmenu appears.

– Press and hold down the Drive programmebutton (1) or Menu change button (2) untilthe desired time appears on the display.

As the buttons are held down for longer, thescrolling speed increases in three levels.

– Confirm the set time using Softkey (4).

– Use the Softkey (3) to exit themenu andreturn to the next level up.

NOTE

The date is set in a similar manner.

8

9

0

6

7

4

3

5

7312_003-055_en_V4

1 2 3 4Resetting the daily kilometres anddaily operating hoursThe daily number of kilometres and dailyoperating hours displays can be reset to zero:

– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the Drive programme button (1) orthe Menu change button (2) repeatedly untilthe DAY KM option appears.


The DAY KMmenu appears.

– Reset the displayed mileage using Soft-key (4).


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NOTE

The daily operating hours are reset in thesamemanner.

8

9

0

6

7

4

3

5

7312_003-058_en_V4

1 2 3 4Setting the languageThe displays can be shown in additionallanguages:

– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the drive programme button (1) or themenu change button (2) repeatedly until theLANGUAGE option appears.


The LANGUAGEmenu appears.

– Press drive program button (1) or menuchangebutton (2) until the desired languageappears in the display.



Softkeys for operating variousequipment variantsAdditional functions can be displayed on thedisplay-operating unit. These additionalfunctions, e.g. a rotating beacon, can beswitched on and off using Softkeys.

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1 2 3

ABE_Softkeytasten_V2

Changing the Softkey functions:

A grey bar (3) highlights the Softkey column.This is the right-hand column in the exampleshown here. These additional functionscan now be switched on and off via thecorresponding Softkeys (2). The right-handcolumn is only populated with additionalfunctions if the truck has more than threeequipment variants that can be switched onand off using Softkeys.

In this case, proceed as follows to switchbetween the two columns:

– Briefly press the Menu change button (1).

The grey bar jumps to the left-hand col-umn. These additional functions can nowbe switched on and off via the correspondingSoftkeys (2).

NOTE

Press the Menu change button (1) for approx.1 second to switch between the individualmenus on the display-operating unit.

NOTE

The additional functions depend on theindividual equipment of the truck and mayvary from those shown here.

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4 OperationBlue-Q efficiency mode

Blue-Q efficiency modeFunctional descriptionThe Blue-Q efficiency mode affects both thedrive unit and the activation of the additionalconsumers, and reduces the truck's energyconsumption.

If the efficiency mode has been activated, theacceleration behaviour of the truck changes tomake acceleration more moderate.

When travelling at low speeds—normallywhen manoeuvring—no reduction is notice-able despite the activated efficiency mode.For moderate speeds of at least approx.7 km/h, acceleration is gentler. Therefore,on distances of up to approx. 40 m, lowerspeeds are reached than would be the case ifthe efficiency mode was not activated.

Blue-Q has no influence on:• Maximum speed• Climbing capability• Traction• Braking characteristics

NOTE

The Blue-Q efficiency mode can be swit-ched on and off in the STANDARD and FI-XED-FLEX operating modes. If the FIXEDoperating mode is configured in the displayoperating unit, the Blue-Q button has no func-tion and the Blue-Q efficiency mode is swit-ched on permanently; see also chapter "Con-figuring Blue-Q efficiency mode".

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Operation 4Blue-Q efficiency mode

Switching off additional consumersIf the Blue-Q efficiency mode is activated,the controller switches off various additionalconsumers after a few seconds in certain con-ditions. The additional consumers availabledepend on the truck equipment. The followingtable shows the conditions that cause addi-tional consumers to be switched off. Only oneof the conditions listed must be met.

ConditionAdditional consumers

Seat switch notactuated

Truck stopped Truck is in motion

Front workingspotlights X X Backwards > 3 km/h

Rearworking spotlights X X ForwardsTop double workingspotlight X X > 3 km/h

Headlights X X -

Front wiper X X Backwards > 3 km/h

Rear wiper X X Forwards

Seat heater X - -

Cab heating X - -

NOTE

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment, theBlue-Q efficiency mode does not switch offthe lighting devices headlights and workingspotlights, side lights, rear lights and licenseplate lamps.

Switching efficiencymode Blue-Q onand off

NOTE

The Blue-Q efficiency mode can be swit-ched on and off in the STANDARD and FI-XED-FLEX operating modes. If the FI-XED operating mode is configured in thedisplay-operating unit, the Blue-Q button isdisabled and the Blue-Q efficiency mode isswitched on permanently. For information on

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4 OperationBlue-Q efficiency mode

configuring the Blue-Q operating modes, seethe "Configuring Blue-Q efficiency mode" sec-tion.

2

2

1

3

– Press the Blue-Q button (2) to switch onBlue-Q.

The Blue-Q symbol (1) is displayed. TheLED (3) illuminates in blue. Blue-Q efficiencymode is switched on.

– To switch it off, press the Blue-Q button (2)again.

The Blue-Q symbol (1) and the LEDs (3) goout. Blue-Q efficiency mode is switched off.

Configuring Blue-Q efficiency modeThe following operating modes can be se-lected to activate the Blue-Q efficiency mode:

STANDARD

• Blue-Q is turned off whenever the truckis commissioned. The driver can use theBlue-Q button to switch efficiency mode onand off at any time while the truck is beingoperated

FIXED

• Blue-Q is switched on permanently when-ever the truck is commissioned and duringtruck operation. The driver cannot turn effi-ciency mode off

FIXED-FLEX

• Blue-Q is turned on whenever the truckis commissioned. The driver can use theBlue-Q button to switch efficiency mode onand off at any time while the truck is beingoperated

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Operation 4Blue-Q efficiency mode

8

9

0

6

7

4

3

5

7312_003-179_en

1 2 3 4– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Keep pressing the drive programme button(1) or the menu change button (2) until op-tion BLUE Q CONFIGURATION appears.

– Confirm your selection with Softkey (4).

The BLUE-Q CONFIGURATION menuappears.

– Press drive program button (1) or menuchange button (2) until the desired effi-ciency mode appears in the display.

– Confirm the set efficiency mode usingSoftkey (4).


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TractionSafety regulations when driving

Driving conductThe driver must follow the public rules of theroad when driving in company traffic.

The speed must be appropriate to the localconditions.

For example, the driver must drive slowlyaround corners, in tight passageways, whendriving through swing-doors, at blind spots, oron uneven surfaces.

The driver must always maintain a safebraking distance from vehicles and persons infront, and must always have the truck undercontrol. Stopping suddenly, turning quicklyand overtaking at dangerous or blind spotsmust be avoided.

– Initial driving practice must be carried out inan empty space or on a clear roadway.

The following are forbidden during driving:• Allowing arms and legs to hang outside thetruck

• Leaning the body over the outer contour ofthe truck

• Climbing out of the truck• Moving the driver's seat• Adjusting the steering column• Releasing the seat belt• Disabling the restraint system• Raising the load higher than 300 mmabove the ground (with the exceptionof manoeuvring processes during theplacement into stock/removal from stockof loads)

• Using electronic devices, for exampleradios, mobile phones etc.

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Operation 4Traction

WARNINGThe use of multimedia and communication equip-ment as well as playing these devices at an exces-sive volume during travel or when handling loadscan affect the operator's attention. There is a risk ofaccident!– Do not use devices during travel or when hand-

ling loads.– Set the volume so that warning signals can still

be heard.

WARNINGIn areas where use of mobile phones is prohibited,use of a mobile phone or radio telephone is notpermitted.– Switch off the devices.

Visibility when drivingThe driver must look in the drive direction andhave a sufficient view of the driving lane.

Particularly for reverse travel, the driver mustbe sure that the driving lane is clear.

When transporting goods that impair visibility,the driver must drive the truck in reverse.

If this is not possible, a second person actingas a guide must walk in front of the truck.

In this case the driver must only move atwalking pace and with extra care. The truckmust be stopped immediately if eye contactwith the guide is lost.

Rear-view mirrors are only to be used forobserving the road area behind the truck andnot for reverse travel. If visual aids (mirror,monitor) are necessary to achieve sufficientvisibility, it is necessary to practise using them.For reverse travel using visual aids, extra careshould be taken.

When using attachments, special conditionsapply; see the chapter entitled "Fitting attach-ments".

Any glass (variant, e.g. windscreen) andmirrors must always be clean and free of ice.

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4 OperationTraction

Roadways

Dimensions of roadways andaislewidthsThe following dimensions and aisle widthrequirements apply under the specifiedconditions to ensure safe manoeuvring. Ineach case, it must be checked whether alarger aisle width is necessary, e.g. in thecase of different load dimensions.

Within the EU, Directive 89/654/EEC (mini-mum safety and health requirements for theworkplace) must be observed. The respectivenational guidelines apply for areas outside ofthe EU.

The required aisle widths depend on thedimensions of the load.

The aisle widths for pallets are as follows:

Aisle width [mm]

Model Type With pallet1000 x 1200crosswise

With pallet800 x 1200lengthwise

RX60-25 6345 3678 3877

RX60-25/600 6346 3683* 3882

RX60-25L 6347 3830 4030

RX60-25L/600 6348 3835* 4035

RX60-30 6353 3760 3960

RX60-30L 6354 3850 4050

RX60-30L/600 6355 3850* 4050

RX60-35 6356 3879 4079

* Without taking protruding fork arms into account.

The truck may only be used on roadwaysthat do not have excessively sharp bends,excessively steep gradients or excessivelynarrow or low entrances.

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Operation 4Traction

Driving on ascending and descendinggradients

WARNINGRisk of accident due to the drive unit switching off!Driving up and down longer gradients may causethe drive unit to overheat and switch off. The truckwill then no longer decelerate when the acceleratorpedal is released and will coast.Driving up and down longer gradients greater than15% is not permitted due to the minimum specifiedbraking values. The climbing capability valuesgiven below only apply to overcoming obstacles onthe roadway and to short differences in level, e.g.ramps.– Before driving on long ascending and descen-

ding gradients greater than 15%, consult theauthorised service centre.

CAUTIONRisk of component damage due to reduced groundclearance with a hydraulic battery carrier (variant)!Trucks fitted with a hydraulic battery carrier (va-riant) have a reduced ground clearance, and thepermitted climbing capability is therefore reduced.The ground clearance with standard tyres is redu-ced to 62.5 mm. It may be the case that the maxi-mumwear limit of the tyres is not reached.– Check the angle of ramps!

NOTE

The values specified in the "Maximum clim-bing capability" table can be used only to com-pare the performance of forklift trucks in thesame category. The specified values in noway represent the normal daily operating con-ditions.

Trucks can theoretically be driven on theascending and descending gradients in thefollowing table.

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4 OperationTraction

Maximum climbing capability

Maximum climbing capability [%]Model Type

With load Without load With batterycarrier

RX60-25 6345 25.5 29.7

RX60-25/600 6346 24.0 28.3

RX60-25L 6347 24.2 30.2

RX60-25L/600 6348 24.0 30.0

RX60-30 6353 21.7 29.0

RX60-30L 6354 21.9 30.6

RX60-30L/600 6355 20.9 29.3

RX60-35 6356 19.1 29.2

8.0

The upwards and downwards slopes must notexceed the gradients listed above and musthave a rough surface.

The top and bottom of the gradient mustfeature smooth and gradual transitions toprevent the load from falling to the ground orthe truck being damaged.

Warning in the event that componentsprotrude beyond the truck contour

Trucks are often required to drive through verynarrow or very low spaces such as aisles orcontainers. The dimensions of the trucks aredesigned for this purpose. However, movablecomponents may protrude beyond the truckcontour andbedamagedor torn off. Examplesof these components are:• An unfolded roof panel in the driver's cab• Open cab doors

Condition of the roadwaysRoadways must be sufficiently firm, level andfree from dirt and fallen objects.

Drainage channels, level crossings andsimilar obstacles must be evened out and,if necessary, ramps must be provided so thattrucks can drive over these obstacles with asfew bumps as possible.

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Operation 4Traction

Note the load capacity of manhole covers,drain covers etc.

There must be sufficient distance between thehighest points of the truck or the load and thefixed elements of the surrounding area. Theheight is based on the overall height of the liftmast and the dimensions of the load; see thechapter entitled "Technical data".

Rules for roadways and the working areaIt is only permitted to drive on routes autho-rised for traffic by the operating company or itsrepresentatives. Traffic routes must be freeof obstacles. The load may only be set downand stored in the designated locations. Theoperating company and its representativesmust ensure that unauthorised third parties donot enter the working area.

NOTE


Hazard areasHazard areas on roadways must be markedby standard traffic signs or, if necessary, byadditional warning signs.

Setting the drive programmeThe driving and braking characteristics of thedrive can be set on the display and operatingunit.

– Push the drive programme button (1)repeatedly until the number of the requireddrive programme appears on the display(2).

Drive programs 1–5 are available.

Essentially, the higher the number of the driveprogramme, the greater the driving dynamics.

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4 OperationTraction

The following drive programs are available:

Drive programme 1 2 3 4 5

Speed (km/h) 16 16 16 16 16

Acceleration (%) (forwards/backwards) 80 90 100 110 120

Deceleration (%) (forwards/backwards) 80 90 100 110 120

Reversing (%) (forwards/backwards) 80 90 100 110 120

Brake retardation (%) (electric brake booster) 60 70 80 90 100.

5060_003-082

1

2

Selecting the drive directionThe desired drive direction of the truck mustbe selected using the drive direction switchbefore attempting to drive. Actuation of thedrive direction switch depends on whichoperating devices are fitted on the truck.

Possible equipment variants include:• Multiple-lever• Mini-lever• Joystick 4Plus• Fingertip• Mini-console

NOTE

Thedrivedirection canalso be changedduringtravel. Your foot can remain on the acceleratorpedal while doing so. The truck deceleratesand is then accelerated again in the oppositedirection (reversing).The indicator for the selected drive direction("forwards" (1) or "reverse" (2)) lights up on thedisplay and operating unit.

Neutral positionIf the truck is stopped for an extended period,select the neutral position to prevent the truckfrom suddenly starting if the accelerator pedalis pressed inadvertently.

– Briefly select the drive direction switchfor the direction opposite to the currentdirection.

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Operation 4Traction

The drive direction indicator on the display andoperating unit goes out.

NOTE

When the seat is vacated, the drive directionswitch is set to "Neutral". To drive, the drivedirection switch must be actuated again.

1

5060_003-095

Actuating the drive direction switch,multiple-lever version

NOTE

Before actuating the drive direction switch,see the notes about choosing the drivedirection; see ⇒ Chapter "Selecting the drivedirection", P. 4-128.

– For the "forwards" drive direction, push thedrive direction switch (1) downwards

– For the "backwards" drive direction, pushthe drive direction switch upwards

5060_003-096

F1 F2

1

Actuating the drive direction switch,mini-lever version– For the "forwards" drive direction, push thecross lever (1) forwards

– For the "backwards" drive direction, pushthe cross lever backwards

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4 OperationTraction

1

6210_003-101

A

B

Actuating the vertical rockerswitch for the "drive direction", joy-stick 4Plus version– For the "forwards" drive direction, pushthe vertical rocker button for the "drivedirection"(1) upwards (A).

– For the "reverse" drive direction, pushthe vertical rocker button for the "drivedirection"(1) downwards (B).

F1F1 F2F2

5060_003-097

1

Actuate the drive direction switch,fingertip version– For the "forwards" drive direction, push thedrive direction switch (1) forwards.

– For the "backwards" drive direction, pushthe drive direction switch backwards.

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Operation 4Traction

5060_003-005

1

Actuating the drive direction switch,mini-console version– For the "forwards" drive direction, push thedrive direction switch (1) forwards.

– For the "backwards" drive direction, pushthe drive direction switch to the rear.

NOTE

Alternatively, the drive direction can also beselected using the drive direction switches onthe operating devices.

Starting drive mode

DANGERBeing trapped under a rolling or tipping truck couldcause fatal injuries!– Sit down on the driver's seat.– Fasten the seat belt.– Activate the available restraint systems.

Observe the information in the chapter entitled"Safety regulations when driving".

The driver's seat is equipped with a seatswitch. This checks whether the driver's seatis occupied. If it is not occupied or in the caseof malfunction of the seat switch, the truckcannot be moved and all lift functions arelocked out. In such a case, the messageSEAT SWITCH appears in the operatingunit display; see the chapter entitled "SEATSWITCHmessage".

– Lift the fork carriage until the necessaryground clearance is achieved.


– Release the parking brake.

– Select the desired drive direction.

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4 OperationTraction

5060_003-082

1

2

The indicator for the selected drive direction("forwards" (1) or "backwards" (2)) lights up onthe display and operating unit.

NOTE

Depending on the equipment, an acousticsignal (variant) may sound a warning duringreverse travel, the warning light (variant) maylight up or the hazard warning system (variant)may flash.

3

5060_003-084

– Actuate the accelerator pedal (3).

The truck will travel in the selected drive direc-tion. The speed is controlled by the accelera-tor pedal position. When the accelerator pedalis released, the truck decelerates.

NOTE

The truck can briefly be stopped on upwardor downward gradients without actuatingthe parking brake (electric brake). The truckbegins to creep downwards slowly.

DANGERRisk of accident due to brake failure!The electric brake only functions while the keyswitch is switched on, the emergency off switchhas not been actuated and the parking brake isreleased.– Use the brake pedal if the electric brakemalfunc-

tions.– Do not leave the truck without applying the

parking brake!

Changing the drive direction– Remove foot from accelerator pedal.


– Actuate the accelerator pedal.

The truck will travel in the selected drivedirection.

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NOTE

Thedrive direction canalsobechangedduringtravel. Your foot can remain on the acceleratorpedal while doing so. The truck deceleratesand is then accelerated again in the oppositedirection (reversing).

NOTE

In the event of an electrical fault with theaccelerator the drive unit is shut down. Theelectrical brake (service brake) causes thetruck to decelerate. The truck cannot be drivenagain until the accelerator pedal has beenreleased and then actuated again, providedthe electrical fault has been corrected. If thetruck still cannot be operated, park it securelyand contact your authorised service centre.

Starting drive mode, dual-pedalversion (variant)

DANGERBeing trapped under a rolling or tipping truck couldcause fatal injuries.– Sit down on the driver's seat.– Fasten the seat belt.– Activate the available restraint systems.

Observe the information in the chapter entitledSafety regulations when driving.

The driver's seat is equipped with a seatswitch. This checks whether the driver'sseat is occupied. If it is not occupied or inthe case of malfunction of the seat switch, thetruck cannot be moved and all lifting functionsare locked. In this situation, the messageSEAT SWITCH appears on the operating unitdisplay.

– Lift the fork carriage until the necessaryground clearance is achieved.



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– Press the right accelerator pedal (1) to drive"forwards" and press the left acceleratorpedal (2) to drive "backwards".

NOTE

In the dual pedal version, any drive directionswitches on the operating devices will notfunction.

5060_003-083

3

4

The indicator for the selected drive direction("forwards" (3) or "backwards" (4)) lights up onthe display and operating unit.

NOTE

Depending on the equipment, an acousticsignal (variant) may sound a warning duringreverse travel, the warning light (variant) maylight up or the hazard warning system (variant)may flash.

The truck will travel in the selected drive direc-tion. The speed is controlled by the accelera-tor pedal position. When the accelerator pedalis released, the truck decelerates.

NOTE

The truck can be stopped briefly on upwardor downward gradients without actuating theparking brake (electric brake). The truck willthen begin to creep downhill slowly.

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DANGERRisk of accident due to brake failure!The electric brake only functions while the keyswitch is switched on, the emergency off switchhas not been actuated and the parking brake isreleased.– Use the brake pedal if the electric brakemalfunc-

tions.– Do not leave the truck without applying the

parking brake!

Changing the drive direction– Remove foot from actuated acceleratorpedal.

– Actuate the accelerator pedal for theopposite direction.

The truck will travel in the selected drivedirection.

NOTE

In the event of an electrical fault with theaccelerator the drive unit is shut down. Theelectric brake (service brake) causes the truckto decelerate. The truck cannot be drivenagain until the accelerator pedal has beenreleased and then actuated again, providedthat the electrical fault has been corrected.If the truck still cannot be operated, park itsecurely and contact your authorised servicecentre.

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2

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Operating the service brakeThe electric brake converts the accelerationenergy of the truck into electrical energy. Thiscauses the truck to decelerate.

Electrical braking recovers energy for thebattery. This results in a longer operating timebetween charging operations and less wear tothe brakes.

The truck can also be brakedwith themechan-ical brake by actuating the brake pedal (2). Inthe first section of the brake pedal's travel, onlythe electric brake takes effect. As the pedal isdepressed further, the mechanical brake isalso activated and acts on the drive wheels

DANGERIf the service brake fails, the truck cannot brakesufficiently. There is a risk of accident!If the driver notices that the electrical braking effecthas reduced by 50% and that the drive torque hasdecreased to 50% of the normal level, a componentfailure may have occurred.– Bring the truck to a standstill using the brakes.

Use the parking brake if necessary to assist inthis process.

– Notify the authorised service centre.– Do not operate the truck again until the service

brake has been repaired.

DANGERAt speeds that are too high, there is a danger thatthe truck could slip or overturn!The braking distance of the truck depends on theweather conditions and the level of contaminationon the roadway. Note that the basic braking di-stance increases with the square of the speed.– Adapt your driving and braking style to suit the

weather conditions and the level of contamina-tion on the roadway.

– Always choose a driving speed that will providea sufficient stopping distance.

– Brake the truck by releasing the acceleratorpedal (1).

– If the braking effect is inadequate, usethe brake pedal (2) as well to apply themechanical brake.

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Parking brakeOperation of the parking brake depends onwhich parking brake the truck is fitted with.

Possible equipment variants are as follows:• Mechanical parking brake; see ⇒ Chap-ter "Actuating the mechanical parkingbrake", P. 4-137

• Electric parking brake; see ⇒ Chapter "Ac-tuate the electric parking brake", P. 4-139

Actuating the mechanical parkingbrake

DANGERThere is a risk of being run over if the truck rollsaway, and therefore a danger to life.– The truck must not be parked on a slope.– In emergencies, secure with wedges on the side

facing downhill.– Only leave the truck when the parking brake is

applied.

NOTE

Once the parking brake is released, thepreviously selected drive direction is retainedand is shown on the drive direction indicator.

NOTE

If you operate the accelerator pedal while theparking brake is applied and a drive directionis selected, the message PARKING BRAKEappears in the display.

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9

6

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0

13

5

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h

2

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Apply the parking brake– Pull the parking brake lever (1) down fullyand release.

The parking brake lever swivels back half thedistance into the middle position automati-cally.

The parking brake is engaged and the wheelsare blocked. Driving is no longer possible.The drive direction indicator (2) on the displayand operating unit goes out.

6210_494-002

Releasing the parking brake– Pull the parking brake lever (1) down fullyout of the middle position.

– In the lower lever position, pull out the leverknob and then guide the parking brake leverup fully.

NOTE

The parking brake lever swivels to the upperposition automatically by means of springforce and should be guided only lightly byhand. If the adjustment is stiff, notify theauthorised service centre.

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Actuate the electric parking brakeThe electric parking brake is intended forworking cycles that require the driver to leavethe truck frequently. The parking brake doesnot need to be applied or released manually.Despite these automatic aids, the driveris always responsible for parking the trucksafely. The safety information about parkingthe truck safely applies.

DANGERThere is a risk of fatal injury from being run over ifthe truck rolls away.– Do not park the truck on gradients.– Use wedges to secure the truck on the downhill-

facing side.– Only leave the truck when the parking brake is

applied.

NOTE

The electric parking brake can be activated orreleased only if the batterymale connector hasbeen connected and the key switch is switchedon. The LED(2.) lights up as soon as the truckis switched on. Only the display-operating unitindicates that the parking brake is applied.

– Stop the truck.

As soon as the driver leaves the seat, the seatswitch is released and the parking brake isapplied. The LED (2) in the push button for theparking brake lights up continuously.

The electric parking brake is applied automat-ically in the following situations:

Cause Effect

When the driver leaves the driver's seat:After a short waiting period, you will hearthe parking brake engage and the LED (2)illuminates with a steady light.

When the driver takes his foot off the acceleratorpedal:

After a short waiting period, you will hearthe parking brake engage and the LED (2)illuminates with a steady light. The truck isheld by the traction motor on a gradient untilthe parking brake is applied.

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Cause Effect

When the key switch is turned off:You will hear the parking brake engage imme-diately and the LED (2) illuminates briefly with asteady light until the control units switch off.

If the emergency off switch is actuated, followingthe emergency off function: The parking brake is applied.

6311_003-031_en_V2

If the electric parking brake has been applied,the PARKING BRAKE ACTIVEmessageappears on the display for five seconds.

NOTE

In order to protect the brake cable for theparking brake, the parking brake is not alwaysfully applied. However under the followingcircumstances the parking brake is alwaysfully applied:• The truck is stationary on a slope andcan roll away easily. The parking brakeis automatically applied fully

• The driver wishes to fully apply parkingbrake and does so by pressing the pushbutton for the parking brake

• The driver switches off the truck via the keyswitch

– To release the parking brake again, thedriver must sit down on the driver's seat.


– Press the accelerator pedal.

The parking brake audibly releases and theLED (2) in the push button for the parkingbrake goes out.

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If the parking brake has not been appliedby the accelerator pedal being released orthe driver's seat being vacated, then it is notpossible to drive the truck until the parkingbrake has been released by pressing thebutton. The RELEASE PARKING BRAKEmessage appears in the display.

Releasing the electric parking brake afterthe truck has been switched on.

NOTE

The LED(2.) lights up as soon as the truck isswitched on. Only the display-operating unitindicates that the parking brake is applied.

The parking brake cannot be released bypressing the accelerator pedal immediatelyafter switching on the truck.

6210_003-050_V421

– Press the push button (1) to release theelectric parking brake.

The parking brake is then released as normalduring operation by pressing the acceleratorpedal.

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Actuating the parking brake when thetruck is stationaryApplying the parking brake manually

– Press the push button (1).

The parking brake will make a noise when it isapplied and the LED (2) lights up continuously.

The parking brake is applied automatically

6311_003-031_en_V2

If the electric parking brake is applied, thePARKING BRAKE ACTIVEmessage ap-pears in the display for 5 seconds.

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Releasing the parking brake manually

NOTE

When the truck is ready for operation, theelectric parking brake can be released at anytime by pressing the button.

– Sit down on the driver's seat.


You will hear the parking brake being releasedand the LED (2) goes out.

NOTE

Release of the electric parking brake bystarting to drive is only available if the electricparking brake is applied automatically by thedriver taking his foot off the accelerator pedalor vacating the driver's seat.

6210_003-050_V421

Functions when the truck is movingActuation by the driver


The truck is braked moderately. Dependingon the situation, driving is possible again afterthe button has been released. If the truck isat a standstill, you will hear the parking brakeengage and the LED (2) illuminates with asteady light.

Actuation triggered automatically

Cause Effect

When the driver leaves the driver's seat:

After a short wait, the truck rolls to a stop ordecelerates moderately. If the truck is at astandstill, the parking brake audibly engagesand the LED (2) illuminates with a steady light.

When the key switch is turned off:

The truck will roll to a stop. If the truck is ata standstill, you will hear the parking brakeengage and the LED (2) illuminates with asteady light until the control units switch off.

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Cause Effect

If the emergency off switch is actuated, followingthe emergency off function:

The truck will roll to a stop. If the truck is ata standstill, you will hear the parking brakeengage and the LED (2) illuminates briefly witha steady light.

Automatic braking:

With the drive deactivated and the seat notoccupied or the truck being accelerated heavily,the parking brake is applied with moderatebraking force.

.

"Safe parking" functionThe "safe parking" function alerts the driverif he/she leaves the driver's seat or triesto switch off the truck without applying theparking brake. This function also prevents thetruck from being switched off when the parkingbrake is not applied.

The function is activated if the parking brakehas been applied but has not been appliedcorrectly as a result of a malfunction.

In both cases the function intervenes asfollows:

The function intervenes as follows:• If the driver tries to switch off the truckwhen the parking brake is not applied orthe parking brake is faulty, the PARKINGBRAKE: APPLY HANDBRAKE!messageappears on the display-operating unit.

• If the driver now leaves the truck withoutapplying the parking brake, a continuouswarning sound will also be emitted. Thewarning sound will stop if the driver returnsto his/her position in the truck or if the driverapplies the parking brake.

• If the parking brake cannot be applied, thetruck also cannot be switched off withouttaking other measures.

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DANGERRisk of fatal injury from being run over if the truckrolls away!If the parking brake is faulty, the truck must beparked safely and secured so that it cannot rollaway. To do this, strictly adhere to the followinginstructions:– Apply the parking brake manually. See the

section entitled "Emergency operation of theelectric parking brake".

– If necessary, use wheel chocks to prevent thetruck from rolling away.

– Have the parking brake repaired by an authori-sed service centre.

NOTE

If it is necessary to switch off a truck with afaulty parking brake, the "Switching off a truckwith a faulty electrical parking brake" sectionmust be observed. It is essential to secure thetruck to prevent it from rolling away.

Malfunctions in the electric parkingbrakeBefore leaving the truck, the driver must makesure that the electric parking brake is appliedproperly.

If the controller detects a malfunction in theelectric parking brake, the truck cannot beswitched off.

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Possible malfunctions

Error indication Effect Remedy

LED (2) in the push button (1)flashes.

Parking brake malfunction.It cannot be guaranteed that theparking brake has been appliedproperly.It may still be possible toactuate the parking brake bypressing the push button (1).

Park the truck safely.Notify the authorised servicecentre.

LED (2) in push button (1) doesnot light up when the brake isactuated.

It cannot be guaranteed that theparking brake has been appliedproperly.


The actuation noise is clearlydifferent to the normal noise orthere is no noise at all.



A warning signal is issued fromsignal horn or another acousticwarning unit in the truck.



The truck rolls even thoughthe parking brake has beenapplied.



Display and operating unit:Symbol: "Parking brake"Display: APPLY HAND-BRAKE!

LED flashes.Parking brake is not appliedautomatically.

Press and hold the push button(1) for five seconds and thenrelease the push button.The parking brake will make anoise when it is applied.

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Display and operating unit:Symbol: "Parking brakemalfunction"Display: PARKING BRAKEError number: X6511

The LED (2) in the push button(1) flashes.The parking brake fails torelease.The drive unit is locked.The error message flashesevery 30 seconds for fiveseconds.

Try again to release the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe service centre.If the truck needs to be movedbecause it is in the way,release the parking brakemanually. See the chapterentitled "Emergency operationof the electric parking brake".Then park the truck safely in adifferent location and notify theservice centre.


The LED (2) in the push button(1) flashes.The parking brake is notapplied.The maximum speed is limitedto 5 km/h.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe authorised service centre.Apply the parking brakemanually. See the chapterentitled "Emergency operationof the electric parking brake".

Symbol: "Service required"Display: PARKING BRAKEError number: X6501

The LED (2) in the push button(1) flashes.Maintenance time reached.The error message flashesevery 30 seconds for fiveseconds.



Control problemThe drive unit remains active aslong as the contactor is closed.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe service centre.Apply the parking brakemanually if necessary. See thechapter entitled "Emergencyoperation of the electric parkingbrake".

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Display and operating unit:Symbol: "Temperature"Display: PARKING BRAKEError number: X6502

Application of the parking brakeis delayed.The system switches off in theevent of over-temperature.The error message flashesevery 30 seconds for fiveseconds.

Allow the parking brake to cooldown. If the warning appearsagain, notify the authorisedservice centre


Malfunction in the parkingbrake.The drive unit remains active aslong as the contactor is closed.Creep mode is possible oncethe parking brake has beenreleased.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe authorised service centre.Apply the parking brakemanually if necessary. See thechapter entitled "Emergencyoperation of the electric parkingbrake".

.

Actuating a faulty electric parking brake

6210_003-050_V421

If the electric parking brake is faulty, the LED(2) in the push button (1) will flash and themessage APPLY HANDBRAKE! will appearon the display and operating unit. A possiblecause of the malfunction is that the parkingbrake cannot determine whether the truck isstationary or still in motion. The brake can bethen be applied via the push button (1). Thefollowing section describes how to actuate theparking brake when it is faulty:

Actuating a faulty parking brake when thetruck is stationary

Apply the parking brake:

– Press and hold the push button (1) for atleast five seconds and then release thepush button.

The parking brake will make a noise when it isapplied. After the push button is released, theparking brake will not make any further noise;if you hear the parking brake release again itmeans that the push button was pressed forless than five seconds. In this case, press thepush button again to apply the parking brakeagain. Repeat this process up to four times ifnecessary.

Releasing the parking brake:

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– Press the push button (1) then release thepush button.

The parking brake will make a noise when itis released. If the malfunction in the parkingbrake persists, it will not be possible to releasethe parking brake.

Actuating a faulty parking brake when thetruck is in motion

– Press push button.

The parking brake is applied.

NOTE

The truck will brake more sharply if the pushbutton (1) is pressed and held for a long periodor if the push button is pressed multiple times.

Switching off the truck when the electricparking brake is faultyIf the electric parking brake cannot be appliedand the driver tries to switch off the truck,the truck will not switch off at first. Instead,the truck responds with the following errormessages:

The red lamp (1) in the multifunction displaybegins to flash.

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The LED (2) in the push button for the electricparking brake flashes.

The message PARKING BRAKE APPLYHANDBRAKE! appears on the display andoperating unit.

If the driver now leaves the truck, a warningsound will be emitted and will stop only whenthe driver has resumed his/her seat in thetruck. To switch off the truck despite theparking brake being faulty (e.g. in order totow the truck) proceed as follows:

– Switch off the key switch again.

The message APPLY HANDBRAKE! willappear on the display and operating unit.

– Press the ESC (3) soft key.

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– The message SWITCH OFF TRUCK? willappear on the display and operating unit.To continue switching off the truck, pressthe soft key (4). To abort the process forswitching off the truck, press the ESC (5)soft key.

– ThemessageARE YOU SURE? appears onthe display and operating unit. To continueswitching off the truck, press the soft key(6). The truck will now switch off. To abortthe process for switching off the truck, pressthe ESC (7) soft key.

If switching off the truck was continued, thetruck will now be switched off and the parkingbrake will not have been applied. The truckcan now be towed. If the truck is not goingto the towed, the truck must be secured withwheel chocks to prevent it from rolling away.

DANGERRisk of fatal injury from the truck rolling away!The truck is not secured against rolling away be-cause the parking brake is not applied.– Use wheel chocks to prevent the truck from

rolling away.– Notify the authorised service centre so that it can

repair the parking brake.

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A

A B

A B

B

5060_003-007

1

Steering

DANGERIf the hydraulics fail, there is a risk of accident as thesteering characteristics have changed.– Do not operate the truck if it has a defective

steering system.

– Steer the truck by turning the steering wheel(1) accordingly.

Turning the steering wheel in the direction ofarrow (A) steers the truck in drive direction (A).

Turning the steering wheel in the direction ofarrow (B) steers the truck in drive direction (B).

For turning radius information, see ⇒ Chap-ter "Technical data", P. 411.

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6327_003-006

Reducing speed when turning(Curve Speed Control)This function reduces the speed of the truck asthe steering angle increases, regardless of theamount to which the accelerator has been ac-tuated. If the steering angle is reduced againupon exiting the curve, the truck accelerates inline with how far the accelerator is depressed.

However, the function does not release thedriver from the duty to approach a curve at aspeed according to the following factors:• The carried load• The roadway conditions• The radius of the curve

DANGERThe Curve Speed Control function cannot overridethe 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 steeringcharacteristics of the truck.

DANGERIncreased risk of tipping if the Curve Speed Controlfunction is disabled! If the controller fails while thetruck is in motion or if the controller is disabled,the truck will no longer automatically brake whensteering.– Do not turn off the key switch while driving.– Actuate the emergency stop switch only in

emergencies.– Always adapt your driving style to the conditions.

Despite the Curve Speed Control function, thetruckmay overturn in extreme cases within thefollowing situations:• Cornering too fast on uneven or inclinedroadways.

• Turning the steering wheel sharply whiledriving.

• Cornering with an inadequately securedload.

• Cornering too fast on a smooth or wetroadway.

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7321_003-052_en_V2

Reducing speed with a raised load(variant)This function (variant) reduces the speed ofthe truck with a raised load.

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Operation 4Parking

ParkingParking the truck securely andswitching it off

DANGERThere is a risk of fatal injury from beingrun over if the truck rolls away.– The truck must not be parked on a

slope.– In emergencies, secure with

wedges on the side facing downhill.– Do not leave the truck until the

parking brake has been applied.

DANGERThere is a risk to life caused by a falling load or iftruck components are being lowered.– Lower the load fully before leaving the truck.

CAUTIONBatteries may freeze!If the truck is parked in an ambient temperature ofbelow -10°C for an extended period, the batterieswill cool down. The electrolyte may freeze anddamage the batteries. The truck is then not readyfor operation.– At ambient temperatures of below -10°C, only

park the truck for short periods of time.

– Apply parking brake.

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5060_003-130

– Lower the fork carriage to the ground.

– Tilt the lift mast forwards until the tips of thefork arms rest on the ground.

– If attachments (variant) are fitted, retractthe working cylinders; see the chapterentitled "General instructions for controllingattachments".

– Turn the switch key to the left and remove it.

NOTE

Switch keys, FleetManager cards (variant),FleetManager transponder chips (variant) andthe PIN code for access authorisation (variant)must not be handed over to other personsunless explicit instructions to this effect havebeen given.

7321_003-039_V2

2

1

1

Wheel chock (variant)The wheel chock (variant) is used to preventthe truck from rolling away on a slope.

– Lift handle (2) on the support mounting.

– Remove wheel chock (1) from the supportmounting.

– Push the wheel chock under a front axlewheel on the side facing the downhill slope.

NOTE

After use, return the wheel chock to thesupport mounting and press the handle (2)down again.

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LiftingLifting system variantsThe movement of the fork carriage and thelift mast heavily depends on the followingequipment:• The lift mast with which the truck isequipped, see ⇒ Chapter "Types of liftmast", P. 4-157

• The operating device with which thehydraulic functions are controlled, see⇒ Chapter "Lifting system operating de-vices", P. 4-158

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 4-180.

Types of lift mastOne of the following lift masts may be installedin the truck:

6210_810-001

1

Telescopic mastDuring lifting, the lift mast rises over the outerlift cylinders, bringing the fork carriage with itvia the chains (fork carriage rises twice as fastas the inner lift mast). The top edge (1) of theinner lift mast can therefore be higher than thefork carriage.

DANGERRisk of accident due to collision of the lift mast orload with low ceilings or entrances.– Note that the inner lift mast or loadmay be higher

than the fork carriage.– Note the heights of ceilings and entrances.

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6210_810-002

2

3

Hi-Lo lift mast (variant)During lifting, the inner lift cylinder moves upto free lift (3), and then the outer lift cylindersraise the inner lift mast up to the max. height(2).

NOTE

When lifting above the free lift, the fork car-riage always remains at the upper edge of theextending lift mast.



6210_810-002

2

3

Triplex lift mast (variant)During lifting, the inner lift cylinder moves upto free lift (3), and then the outer lift cylindersraise the inner lift mast up to the max. height(2).



Lifting system operating devicesThe operation of the lifting system dependson the operating devices that are fitted on thetruck.

Possible equipment variants include:• Multiple-lever• Double mini-lever• Triple mini-lever• Quadruple mini-lever

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• Joystick 4Plus• Fingertip

– The following informationmust be observedregardless of the equipment variant:

DANGERReaching into or climbing between moving partsof the truck (e.g. lift mast, sideshifts, workingequipment, load carrying devices etc.) can lead toserious injury or death and is therefore prohibited.– Observe the safety regulations for handling

loads.– Only operate the lifting system from the driver's

seat.

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B

C

D

7312_003-022_V2

DC

B

A

Multi-lever lifting system

DANGERReaching or climbing between moving parts of thetruck (e.g. lift mast, sideshifts, working equipment,load carryingdevices etc.) can lead to serious injuryor death and is therefore prohibited.– Always observe the safety regulations for hand-

ling loads; see ⇒ Chapter "Safety regulationswhen handing loads", P. 4-180.

– Only operate the lifting system from the driver'sseat.

Lifting/lowering the fork carriageTo lift fork carriage:

– Move the "lift-lower" operating lever (1) inthe direction of the arrow (B).

To lower fork carriage:

– Move the "lift-lower" operating lever (1) inthe direction of the arrow (A).

Tilting the lift mastTo tilt the lift mast forwards:

– Move the "tilt" operating lever (2) in thedirection of the arrow (C).

To tilt the lift mast backwards:

– Move the "tilt" operating lever (2) in thedirection of the arrow (D).

NOTE

The symbols on the operating levers show thedirection of movement of the lift mast or forkcarriage when the operating lever is moved.

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F1 F2

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A

C

D

B

1

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using adouble mini-lever



seat.


– Move the "lift mast" 360° lever (1) in thedirection of arrow (B).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (A).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (C).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (D).

NOTE

The symbols on the 360° lever show thedirection of movement of the lift mast and thefork carriage when the 360° lever is moved.

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5060_003-105

A

C

D

B

1

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using atriple mini-lever



seat.


– Move the "lift mast" 360° lever (1) in thedirection of arrow (B).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (A).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (C).


– Move the "lift mast" 360° lever (1) in thedirection of arrow (D).

NOTE

The symbols on the 360° lever show thedirection of movement of the lift mast and thefork carriage when the 360° lever is moved.

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5060_003-106

1 C

D

2

A

B

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using aquadruple mini-lever



seat.


– Move the "lift mast" operating lever (1) in thedirection of the arrow (A).


– Move the "lift mast" operating lever (1) in thedirection of the arrow (B).


– Move the "lift-lower" operating lever (2) inthe direction of arrow (D).


– Move the "lift-lower" operating lever (2) inthe direction of arrow (C).

NOTE


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4 OperationLifting

Controlling the lifting system usingthe joystick 4Plus



seat.

6210_003-089

1

A

B

Lifting/lowering the fork carriageTo lift the fork carriage:

– Pull the joystick 4Plus (1) backwards (B).

To lower the fork carriage:

– Push the joystick 4Plus (1) forwards (A).

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Operation 4Lifting

6210_003-090

DC

2

7312_003-022_V2

DC

B

A


– Tilt the horizontal rocker button (2) to the left(C).


– Tilt the horizontal rocker button (2) to theright (D).

1

6210_003-091

E

F

Fork-carriage sideshiftTo move the fork carriage to the left.

– Push the joystick 4Plus (1) to the left (E).

To move the fork carriage to the right:

– Push the joystick 4Plus (1) to the right (F).

NOTE

The symbols on the joystick 4Plus indicate thedirection of movement of the lift mast or thefork carriage.

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4 OperationLifting

F1F1 F2F2

6321_003-011

1

2

1 2

6210_003-043

6210_713-002_V2

2

1

Controlling the lifting system with thefingertip console



seat.


– Pull the "lift/lower" operating lever (1)backwards.


– Push the "lift/lower" operating lever (1)forwards.


– Push the "tilt" operating lever (2) forwards.


– Pull the "tilt" operating lever (2) backwards.

NOTE


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Operation 4Lifting

Changing the fork arms

DANGERRisk of fatal injury from being run over if the truckrolls away!– Do not park the truck on a gradient.– Apply the parking brake.– Change the fork arms in a separate, safe location

on a level surface.

WARNINGThere is a risk of injury when changing the forkarms; the weight of the fork arms could cause themto fall on your legs, feet or knees. The space to theleft and right of the fork is a danger area.– Always wear protective gloves and safety

footwear when changing the fork arms.– Ensure that no one stands in the danger area!– Do not pull on the fork arms.– The fork arms must always be carried by two

people; if necessary, use a hoist.

NOTE

• For installation and removal, a transportpallet is recommended for supportingthe fork arms. The pallet size dependson the fork arm size used and should bedimensioned such that the fork arms do notprotrude after being placed on the pallet.This means the fork arms can be safelyplaced down and transported.

• Both fork arms can be pushed over to thesame side. It is possible to choose the sidevia which the forks are removed

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4 OperationLifting

1

2

6210_003-027

Removal– Select a pallet corresponding to the fork armsize.

– Set down the pallet next to the fork carriageon the side chosen for removal.

– Lift the fork carriage until the fork arms areapprox. 3 cm above the pallet.

– Apply the parking brake.

– Remove the switch key.

– Unscrew the locking screw (2) on the sidechosen for removal.

– Pull up the locking lever (1) and push thefork arms onto the pallet one after the other.

Installation– Make sure that the locking screw is un-screwed on the side chosen for installation.

– Place the fork arms on a pallet next tothe fork carriage on the side chosen forinstallation.

– Pull up the locking lever (1) and push thefork arms onto the fork carriage one afterthe other.

– Place the fork arms in the required positionand push down the locking lever. Ensurethat the locking lever snaps into place.

– Screw in and tighten the locking screw (2).

DANGERThere is a risk of fatal injury from a falling load orfork!– Tighten the locking screw each time a fork is

changed.– Driving and moving loads without the locking

screw is prohibited.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustment ofthe load measurement" must always be per-formed after the fork arms have been chan-

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Operation 4Lifting

ged. Otherwise, correct load measurementcannot be guaranteed.

Fork extension (variant)

DANGERThere is a risk of being run over if the truck rollsaway and therefore a danger to life.– Do not park the truck on a slope.– Apply the parking brake.– Change the fork extension in a separate, safe

location on a level surface.

WARNINGThere is a risk of crushing!Theweight of the fork extension can cause crushingor cuts on sharp edges or burrs.– Always wear protective gloves and safety

footwear.

WARNINGThere is a risk of tipping!The weight and dimensions of the fork extensionaffect the stability of the truck. The permissibleweights stated on the capacity rating plate must bereduced in proportion to the actual load distance.The truck is equipped with a fork extension exworks, the capacity rating plate is already adjustedaccordingly.– Observe load capacity, see the "Before picking

up a load" chapter.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustment ofthe load measurement" must always be per-formed after the fork extensions have beenchanged. Otherwise, correct load measure-ment cannot be guaranteed.

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4 OperationLifting

7071_003-104_V2

1

2

3

Attachment

DANGERRisk to life from falling load!At least 60% of the length of the fork extensionmustlie on the fork arm. Amaximum 40% overhang overthe fork arm end is permissible. The fork extensionmust also be secured against slipping from the forkarm.If the fork extension (1) is not secured with a secu-ring bolt (2) and linch pin (3), the load with the forkextension may fall.– Push the fork extension completely to the back

of the fork.– Make sure that 60% of the length of the fork

extension is on the fork arm.– Always secure the fork extension with a securing

bolt.– Always secure the securing bolt with a linch pin.

– Remove the linch pin (3) from the securingbolt (2).

– Remove the securing bolt from the forkextension (1).

– Push the fork extension onto the fork armsuntil it is flush with the fork back.

– Insert the securing bolts located behind thefork back fully into the fork extension.

– Insert the linch pin into the securing bolt andsecure.

Removal– Remove the linch pin (3) from the securingbolt (2).

– Remove the securing bolt from the forkextension (1).

– Pull the fork extension from the fork arms.

– Insert the securing bolt fully into the forkextension.

– Insert the linch pin into the securing bolt andsecure.

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Operation with reversible fork arms(variant)

DANGERRisk to life from falling load!Standard fork arms are not structurally designed forreverseoperation. If this instruction is not observed,it can lead to material failure and the load falling.– Only work in reverse operation using reversible

fork arms (1)

WARNINGRisk of accident from slipping load!Loadsmay slip on the reversible fork arms if there isno load support. A fork extension (variant) cannotbe secured against slipping.– Do not use a fork extension (variant)

WARNINGRisk of accident from the truck tipping over.When driving, the centre of gravity of the load (2)must not be higher than 600 mm above the ground.The truck may tip forwards when driving or braking.– Only drive with a load centre of gravity up to a

max. of 600 mm above the ground

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustmentof the load measurement" must always beperformed after the reversible fork arms havebeen changed. Otherwise, correct load mea-surement cannot be guaranteed.

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4 OperationLifting

6341_862-001

Reversible fork arms (1) can be used to reachan additional lift height. The reversible forkarms are installed on the fork carriage in thesame manner as standard fork arms. Loadsmay be lifted on and beneath the reversiblefork arms. The mast is lifted and tilted in thesamemanner.

– Only work in reverse operation usingreversible fork arms

– Do not use a fork extension (variant)

– If the "load measurement" comfort featureis available, perform a "zero adjustment ofthe load measurement"

– To drive, raise the load centre of gravity (2)to a max. of 600 mm above the ground

– Observe the information in the sectionentitled "Transporting suspended loads"

Malfunctions during lifting mode

Incorrect extension sequence

DANGERRisk of accidents!In the case of Hi-Lo lift masts (variant) and triplex liftmasts (variant), an incorrect extension sequencemay occur, i.e. the inner lift mast may extendbefore the free lift is complete. As a result, theoverall height is exceeded and damagemay occurin passageways or from low ceilings.

An incorrect extension sequence may, forinstance, result from:• The hydraulic oil temperature being too low.• Blocking of the fork carriage in the inner liftmast.

• Blocking of the free lift cylinder.• Blocking of the chain roller on the free liftcylinder.

– If the hydraulic oil temperature is too low,slowly actuate the lift mast functions severaltimes in order to raise the oil temperature.

In the event that the fork carriage is blockedin the inner lift mast, or the free lift cylinderor chain roller are blocked, the cause of the

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Operation 4Lifting

blockage must be eliminated before resumingwork.

– Notify your service centre

Load chains not under tension

DANGERDanger 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 theracking.

• Fork carriage rollers blocking in the lift mastdue to contamination.

– If the fork carriage or the load comes to anunexpected stop, lift the fork carriage untilthe chains are under tension again andlower the load at another suitable location.

– If the fork carriage rollers in the lift mastbecome blocked due to contamination, liftthe fork carriage until the chains are undertension again. Remove the contaminationbefore resuming work.

WARNINGRisk of injury!– Observe the safety regulations for working on

the lift mast, see the chapter entitled "Working atthe front of the truck".

Hydraulic blocking functionThe hydraulic blocking function ensures thatall the functions of the working hydraulicsare disabled whenever the seat switch in thedriver's seat is unloaded.

If the driver stands up from the driver's seat,the blocking function prevents the hydraulicfunctions that:• Lift the load• Lower the load• Tilt the lift mast• Additional functions

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Releasing the block on the hydraulicsProceed as follows to release the block on thehydraulics:

– Sit down on the driver's seat.

All the relevant functions of the workinghydraulics will be available again.

NOTE

If it is not possible to release the block on thehydraulics when the load is raised becauseof a technical fault, the load must be loweredusing the "emergency lowering" mechanismbefore any further action is taken. Do notoperate the truck again until the fault has beenrectified by the authorised service centre.

Automatic lift cut out (variant)

Description:The automatic lift cut out (variant) means thatthe load cannot be lifted above a preset height.This function uses a sensor that is welded onat the factory at the required lift mast limitheight. Once attached, the height cannot beeasily changed.

Application:• If the ceiling of the building is lower thanthe maximum lift height of the truck, thisvariant can prevent the lift mast fromaccidentally hitting the ceiling, which canresult in damage.

• If the truck is frequently used at a particularheight, the work is simplified by the auto-matic lift cut out at this height.

NOTE

If a load is lifted very quickly, the fork carriageand load are moved approximately 15 cmabove the position of the sensor due toinertia. This deviation is already taken intoconsideration at the factory when determiningthe position of the sensor.

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Operation 4Lifting

Overriding and reactivating the auto-matic lift cut outIf a load needs to be lifted to the truck'smaximum lift height and the automatic liftcut out function is not required, it is possibleto override the lift cut out. It is automaticallyreactivated when the truck is switched off andback on again.

To override the automatic lift cut out:

F1

1

7312_003-160_V3

– Press Softkey (1).

Automatic lift cut out is switched off.The symbol is displayed. Loads can belifted to the maximum lift height for the truck.

To switch the automatic lift cut out back on:


Automatic lift cut out is switched on.The symbol is displayed. Loads can belifted only to the set lift height for the truck.

Lift mast vertical position (variant)

DescriptionIf the truck is equipped with the "lift mastvertical position" comfort feature (variant),the driver can put down goods, such as paperrolls, vertically with precision and thus avoiddamage when unloading. The tilt cylindersrun into the end stops gently to prevent hardvibrations and impacts. Oscillating motions ofthe truck are minimised, thus increasing worksafety. The lift mast vertical position reduceswear on various components and thereforereduces maintenance costs.

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4 OperationLifting

CAUTIONRisk of damage to property due to the lift mastcolliding with racks or other objects!– Before using the "lift mast vertical position"

comfort feature, position the truck at a sufficientdistance from racks and other objects.

The "lift mast vertical position" comfort featureconsists of the following individual functions:• Display of the "lift mast vertical position"• Automatic approach towards the "lift mastvertical position"

• Gentle running-in to the end stops

F1F1 F2F2

F1 F2

6210_003-092

1

2

4 5

3

The "lift mast vertical position" comfort featureis only available as a variant if the truck isequipped with one of the following operatingdevices:

• Double mini-lever (1)• Triple mini-lever (2)• Quadruple mini-lever (3)• Fingertip (4)• Joystick 4Plus (5)

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Operation 4Lifting

6210_003-069_en_V2

1

Display of the "lift mast vertical position"The driver can see the mast tilt on the displayand operating unit screen. The bar in thedisplay shows the current mast tilt relativeto the "lift mast vertical position". The arrowabove the barmarks the vertical position of thelift mast.

Automatic approach towards the "liftmast vertical position"

6210_003-067_V2

21

– Switch on the "lift mast vertical position"comfort feature via the button (1) on thedisplay and operating unit.

– Tilt the lift mast forwards using the corre-sponding operating device. The lift maststops automatically as soon as the prese-lected setting is reached for the "lift mastvertical position".

If the comfort feature is switched off, the liftmast tilts forwards past the "lift mast verticalposition" without stopping.

If the lift mast is tilted backwards, it movespast the "lift mast vertical position" withoutstopping, regardless of whether the comfortfeature is switched on or not.

Gentle running-in to the end stops

The lift mast is braked gently at the end of thetilt range. This prevents the lift mast fromstopping harshly in the end position andreduces severe oscillating motions of thetruck.

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4 OperationLifting

Tilting the lift mast forwards with the "liftmast vertical position"

6210_003-067_V2

21

– Actuate the button (1) to switch on the "liftmast vertical position" comfort feature; thefunction display (2) in the display shows theactivated status.

– Tilt the lift mast forwards.

NOTE

The way in which the lifting system is operateddepends on the operating devices included inthe truck's equipment; see the chapter entitled"Lifting system operating devices".

6210_003-069_en_V2

1

The lift mast is tilted forwards and stops assoon as the vertical position is reached. Thearrow above the bar shown on the screen ofthe display and operating unit represents the"lift mast vertical position".

Tilting the lift mast forwards beyond thevertical position:

– Release the operating device for tilting andactuate again.

The lift mast is tilted beyond the verticalposition up to the end stop. The current masttilt is shown in the display and operating unit.

– To deactivate the "liftmast vertical position",actuate the button (1) again.

Tilting the lift mast backwards with the"lift mast vertical position"– Tilt the lift mast backwards.

The lift mast is tilted backwards withoutstopping in the vertical position.

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Operation 4Lifting

Possible restrictions on the "lift mastvertical position"

In some circumstances, the lift mast cannotmove exactly into the preset vertical position.Possible causes include:• Uneven ground• Bent fork• Bent attachment• Worn tyres• Severely deformed lift mast

The vertical position can be corrected by tiltingthe lift mast using the relevant operatingdevice. If the vertical position has to becorrected frequently, the "lift mast verticalposition" should be calibrated.

6210_003-070_en_V2

12

3

Calibrating the "lift mast vertical position"– Set the lift mast to the required position.

– Press and hold the button (1) for the "liftmast vertical position" for at least fiveseconds.

The message "? VERTICAL POSITION"will appear on the display.

Storing the mast position:

– Press the drive program selection button(3).

The current mast position is stored.

Cancelling calibration:

– Press the menu change button (2).

The calibration is cancelled.

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4 OperationHandling loads

Handling loads

6210_003-030

Safety regulations when handingloadsThe safety regulations for handling loads areshown in the following sections.

DANGERThere is a risk to life caused by falling loads or ifparts of the truck are being lowered.– Never walk or stand underneath suspended

loads or raised fork arms.– Never exceed the maximum load indicated on

the capacity rating plate. Otherwise stabilitycannot be guaranteed!

DANGERRisk of accident from falling or crushing!– Do not step onto the forks.– Do not lift people.– Never grab or climb on moving parts of the truck.

DANGERRisk of accident from a falling load!– When transporting small items, attach a load

safety guard (variant) to prevent the load fromfalling on the driver.

– Use a closed roof covering (variant) in addition.

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Operation 4Handling loads

Before taking up load

2

1

780

9101310

93012306801500

95012606901500

970860710150010008807301500

600500

6401080

4830

4630

4230

3830

kg

3

5051_003-006

800

800 5030660

5230

500

880

Load capacityThe load capacity indicated for the truck on thecapacity rating plate may not be exceeded.The load capacity is influenced by the loadcentre of gravity and the lift height as well asby the tyres, if applicable.

The position of the capacity rating plate canbe found in the chapter entitled "Identificationpoints".

WARNINGThe figures show examples.Only the capacity rating plateson the truckare valid!

The attachment of additional weights toincrease load capacity is prohibited.

DANGERRisk to life from the truck losing stability!Never exceed the maximum loads shown! Thesevalues apply to compact and homogenous loads.Otherwise, the stability as well as the rigidity of thefork arms and lift mast cannot be guaranteed.Improper or incorrect operation or the placement ofpersons to increase load capacity is prohibited.

56338011803 EN - 02/2018 181


5051_003-007

3

5230

500

2

880 Kg

1

ExampleWeight of load to be lifted: 880 kg (3)

Load distance from fork back: 500 mm (1)

Permitted lift height: 5230 mm (2)

WARNINGRisk of accident from the truck losing stability!The permissible load of the attachments (variant)and the reduced lifting capacity of the combinationof truck and attachment must not be exceeded.– Observe the special capacity rating plate infor-

mation shown on the truck and the attachment.

Load measurement (variant)

DescriptionKnowing the weight of the load to be trans-ported gives the driver greater security. Ifthe truck is equipped with the "load measure-ment" (variant) comfort feature, the weight ofthe lifted load can be measured and shown inthe display and operating unit.

Load measurement is possible only when thetruck is at a standstill. Before performing aload measurement, the load must be raised toa height of 300-800 mm above the ground.

182 56338011803 EN - 02/2018


The load measurement has an accuracy of+/-3% of the rated capacity of the truck.

NOTE

In order to ensure accuracy at all times, a zeroadjustment of the load measurement must becarried out. Zero adjustment is required.• as part of daily commissioning• after changing the fork arms• after fitting or changing attachments.

Performing the load measurement

DANGERRisk of accident from a falling load!The loadmay fall if the load centre of gravity has notbeen taken into account or the load has not beenpicked up securely.– Pick up the load securely; see the chapter

entitled "Picking up loads".

CAUTIONIf the weight determined by a load measurementexceeds the permissible residual load capacity ofthe truck, the truck cannot be operated safely.– Set down and reduce load immediately.– If necessary, use another truck with sufficient

load-bearing capacity.

NOTE

Accurate load measurement is only possibleunder the following conditions:• The hydraulic oil is at normal operatingtemperature

• The load is at rest at the beginning of theload measurement

• The load corresponds to at least 10% of thenominal load capacity in trucks with a loadcapacity of up to 2.5 t

• The load corresponds to at least 5% of thenominal load capacity in trucks with a loadcapacity of 3 t and over

• The lift mast is in the vertical position• The fork is not raised to more than 800 mmabove the ground

56338011803 EN - 02/2018 183


NOTE

The method of operating the lifting systemdepends on the operating devices included inthe truck's equipment.

– Ensure that the truck has been in operationfor a period of time before carrying out theload measurement.


– Raise the fork to a height of 300–800 mm.

– Ensure that the load is at rest.

6210_003-072_V2

21


Load measurement is switched on.The (2) symbol is displayed.

NOTE

If the truck is equipped with mini-levers orfingertip operation, the F1 button can also bepressed as an alternative.

NOTE

During the following process, the fork carriagemust be lowered slightly and then stoppedabruptly. While doing so, the fork mustnot touch the ground, otherwise the loadmeasurement will not be accurate. To stopthe lowering procedure quickly, release theoperating device for lowering so that it jumpsinto the zero position.

– Lower the fork carriage slightly and releasethe operating device.

NOTE

When stopping the lowering process theload must be cushioned in order to create ameasurable impulse.

184 56338011803 EN - 02/2018


6210_003-073_en

3

When loadmeasurement has been performedcorrectly, the determined load weight (3) isshown on the display.

NOTE

If the load measurement is invalid, the value"-9999 kg" is displayed in the operating unit.

Picking up loadsTo make sure that the load is securely sup-ported, it must be ensured that the fork armsare sufficiently far apart and are positioned asfar as possible under the load.

If possible, the load should rest on the back ofthe fork.

The load must not protrude too far over thefork tips, nor should the fork tips protrude toofar out from the load.

Loads are to be picked up and transported asclose to the middle as possible.

DANGERRisk of accident from a falling load!When transporting small items, attach a load safetyguard (variant) to prevent the load from falling onthe driver.A closed roof covering (variant) should also beused.Removable roof panels may not be removed.

56338011803 EN - 02/2018 185


1

6210_842-001

Adjusting the fork– Lift the locking lever (1) and move the forkarms to the desired position.

– Allow the locking lever to snap back intoplace.

The load centre of gravity must be midwaybetween the fork arms.

– Only actuate the fork prong positioner(variant) when the fork is not carrying aload.

Danger areaThe danger area is the area in which peopleare at risk due to the movements of the truck,its working equipment, its load-carryingequipment (e.g. attachments) or the load.Also included are the areas where loadscould fall or working equipment could fall orbe lowered.

DANGERRisk of injury!– Do not step on the fork.

DANGERRisk of injury!– Do not step under the raised forks.

DANGERPeople may be injured in the danger area of thetruck!The danger area of the truck must be completelyclear of all personnel, except the driver in hisnormal operating position. If persons fail to leavethe danger area despite warnings:– Cease work with the truck immediately.– Secure the truck against use by unauthorised

parties.

186 56338011803 EN - 02/2018


DANGERDanger of death from falling loads!– Never walk or stand underneath

suspended loads.

6327_003-009

Transporting palletsAsa rule, loads (e.g. pallets)must be transpor-ted individually. Transporting multiple loads atthe same time is only permitted:• when instructed by the supervisor and• when the technical requirements have beenmet.

The driver must ensure proper condition ofthe load. Only safely and carefully positionedloads may be transported.

6210_001-007

Transporting suspended loadsBefore transporting suspended loads, con-sult the national regulatory authorities (inGermany, the employer's liability insuranceassociations).

National regulations may place restrictionson these operations. Contact the relevantauthorities.

DANGERSuspended loads that begin to swing can result inthe following risks:

• Impaired braking and steering action• Tipping over the loadwheels or drivewheels• Tipping the truck at right angles to thedirection of travel

• Risk of crushing of guide persons• Reduced visibility.

56338011803 EN - 02/2018 187


DANGERLoss of stability.Slipping or swinging suspended loads can lead to aloss of stability and cause the truck to tip over.– When transporting suspended loads, observe

the following instructions

Instructions for transporting suspended loads:• Swinging loads must be prevented by usingthe proper driving speed and driving style(careful steering, braking)

• Hanging loads must be hooked on to thetruck in such a way that the harness cannotshift or release unintentionally and cannotbe damaged

• When transporting suspended loads, suit-able devices (e.g. guy wires or supportingpoles) must be available so that accompa-nying persons can guide suspended loadsand prevent the loads from swinging

• Take particular care to ensure that there isno one in the drive direction in the drivinglane

• If, despite this, the load begins to swing,ensure that no person is placed at risk

DANGERRisk of accidents!When transporting hanging loads, never perform orend driving and load movements abruptly.Never drive on slopes with a suspended load.Transporting containers holding fluids as hangingloads is not permitted.

Load pick up

DANGERThere is a risk to life caused by a falling load or ifparts of the truck are being lowered.– Never walk or stand underneath suspended

loads or raised fork arms.– Never exceed the maximum load values spe-

cified on the capacity rating plate. Otherwise,stability cannot be guaranteed.

– Only store pallets which do not exceed thespecified maximum size. Damaged loading

188 56338011803 EN - 02/2018


equipment and incorrectly formed loadsmust not be stored.

– Attach or secure the load to the load-carrying equipment so that the load cannotmove or fall.

– Store the load so that the specified aislewidth is not reduced by protruding parts.

6210_800-005

– Approach the racking carefully, brake gentlyand stop just in front of the racking.

6210_800-006

– Position the forks.


– Lift the fork carriage to the stacking height.

CAUTIONComponent damage possible!When inserting the fork into the racking, ensure thatthe racking and load are not damaged.

56338011803 EN - 02/2018 189


6210_800-007

– Insert the fork as far under the load aspossible. Stop the truck as soon as thefork back is resting on the load. The centreof gravity of the load must be positionedbetween the fork arms in the middle.

6210_800-008

– Lift the fork carriage until the load is restingentirely on the forks.

DANGERRisk of accidents!– Beware of any people in the danger area.– Ensure that the roadway behind you is clear.

DANGERNever tilt the lift mast with a raised load due to therisk of tipping!– Lower the load before tilting the lift mast.

– Move backwards carefully and slowly untilthe load is clear of the racking. Brake gently.

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5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

56338011803 EN - 02/2018 191


6210_800-011

Transporting loads

NOTE

Observe the information in the chapter entitled"Safety regulations when driving".

DANGERThe higher a load is lifted, the less stable it beco-mes. The truck can tip over or the load can fall,increasing the risk of accident!Driving with a raised load and the lift mast tiltedforward is not permitted.– Only drive with the load lowered.– Lower the load until ground clearance is reached

(not over 300 mm).– Only drive with the lift mast tilted backwards.

6210_800-013

– Drive slowly and carefully round corners!

NOTE

Observe the information in the chapter entitled"Steering".

– Always accelerate and brake gently!

NOTE

Observe the information in the chapter entitled"Operating the service brake".

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6210_800-014

– Never drive with a load protruding to theside (e.g. with the sideshift)!

Setting down loads

DANGERRisk of accident due to changed moment of tilt!The load centre of gravity and the moment of tiltmove due to tilting the lift mast forwards with araised load or due to the load slipping. The truckmay tip forwards.– Only tilt the lift mast forwards with a raised lifting

accessory when it is directly above the stack.– When the lift mast is tilted forwards, take parti-

cular care to ensure that the truck does not tipforwards and that the load does not slip.

WARNINGRisk of accident from a falling load!If the fork or the load remains suspended duringlowering, the load may fall.– When removing from stock, move the truck far

enough back so that the load and the fork can belowered freely.

56338011803 EN - 02/2018 193


6210_800-015

– Drive up to the stack with the load loweredin accordance with regulations.


– Lift the load to the stacking height.

– Drive the truck towards the rack carefully.

6210_800-016

– Lower the load until it rests securely on therack.

DANGERRisk of accident!– Beware of any people in the danger area.– Ensure that the roadway behind you is clear.

– Move the truck back until the fork arms canbe lowered without touching the stack.

– Lower the fork while maintaining groundclearance.

– Tilt the lift mast backwards and drive away.

194 56338011803 EN - 02/2018


6210_001-008

Driving on ascending and descend-ing gradients

DANGERDanger to life!Driving on ascending and descending gradientscarries special dangers!– Always follow the instructions below.

– On ascending and descending gradients,the load must be carried facing uphill.

– It is only permitted to drive on ascendingand descending gradients that are markedas traffic routes and that can be used safely.

– Ensure that the ground to be traversed isclean and provides a good grip.

– Do not turn on ascending and descendinggradients.

– Do not drive onto or along ascending anddescending gradients at an angle.

– Do not park the truck on ascending ordescending gradients.

– In case of emergency, secure the truck withwedges so that the truck does not roll away.

– Reduce the driving speed on descendinggradients.

It is not permitted to drive on long ascendingand descending gradients greater than 15%due to the specified minimum braking andstability values.

– Before driving on ascending and descend-ing gradients greater than 15%, consult theauthorised service centre.

The process of placing loads into stockand removing loads from stock while onan ascending or descending gradient is notpermitted!

– Always place loads into stock and removeloads from stock on a horizontal plane.

56338011803 EN - 02/2018 195


5060_003-071

Driving on liftsThe driver is only allowed to use this truckon lifts with a sufficient load capacity and forwhich the operating company (see ⇒ Chap-ter "Definition of responsible persons", P. 26)has been granted authorisation.

DANGERThere is a risk to life from being crushed or run overby the truck.– There must be no personnel already in the lift

when the truck is driven into the lift.– Personnel are only permitted to enter the lift once

the truck is secure, and must exit the lift beforethe truck is driven out.






max

min.*

kg kg

kg

kg

kgkW

V

*



1

3

2

Determining the actual total weight– Park the truck securely, see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 4-155.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate and, ifnecessary, by weighing the load to be lifted.

– Add the determined unit weights to obtainthe actual total weight of the truck:

Tare weight (1)

+ Max. permissible battery weight (2)

+ Ballast weight (variant) (3)

+ Net weight of attachment (variant)

+ Weight of the load to be lifted

+ 100 kg allowance for the driver

= Actual total weight

– Drive the truck with the forks forwards intothe lift without touching the shaft walls.

– Park the truck securely in the lift, see⇒ Chapter "Parking the truck securelyand switching it off", P. 4-155, to preventuncontrolled movements of the load or thetruck.

196 56338011803 EN - 02/2018


6210_001-010

Driving on loading bridges

DANGERRisk of accident from the truck crashing!Steering movements can cause the tail end to veeroff the loading bridge towards the edge. This maycause the truck to crashThe lorry driver and the truck driver must agree onthe lorry's departure time.– Establish the departure time of the lorry.– Determine the total actual weight of the truck.– Before driving across a loading bridge, ensure

that it is properly attached and secured and hasa sufficient load capacity (lorry, bridge etc.).

– Ensure that the vehicle onto which you will bedriving is secured to prevent it from shifting andthat it can support the load of the truck.






max

min.*

kg kg

kg

kg

kgkW

V

*



1

3

2

Determining the total actual weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate and, ifnecessary, by weighing the load to be lifted.

– Add the determined unit weights to obtainthe total actual weight of the truck:

Tare weight (1)



+ Attachment net weight (variant)

+ Weight of the load to be lifted

+ 100 kg allowance for driver

= Total actual weight

– Drive slowly and carefully on the loadingbridge.

56338011803 EN - 02/2018 197

4 OperationAttachments

AttachmentsFitting attachmentsIf the truck is equipped with an integratedattachment (variant) at the factory, the specifi-cations in the STILL operating instructions forintegrated attachments must be observed.

If attachments are fitted at the place of use,the specifications in the operating instructionsof the attachment manufacturer must beobserved.

If an attachment is not delivered togetherwith the forklift truck, the specifications andoperating instructions of the attachmentmanufacturer must be observed.

Before initial commissioning, the functionof the attachment and the visibility from thedriver's position with and without a load mustbe checked by a competent person. If thevisibility is deemed insufficient, visual aidssuch asmirrors, a camera/monitor system etc.must be used.

In addition, it is essential that the warningsbelow are observed.

CAUTIONAttachments must be CE-certified. If the truck isnot fitted with an attachment-specific residual loadcapacity rating plate and the operating devices arenot marked with corresponding pictograms, thetruck must not be used.– Order the residual load capacity rating plate and

pictograms from your authorised service centrein good time.

– The authorised service centre must adapt thehydraulic system to the requirements of theattachment (e.g. by adjusting the pump motorspeed).

198 56338011803 EN - 02/2018

Operation 4Attachments

DANGERThere is risk to life caused by a falling load!Attachments that hold the load by exerting pressureon it (e.g. clamps)must be controlled additionally bya second operating function (lock) that is actuatedto prevent an unintentional release of the load.If such an attachment is retrofitted, a second opera-ting function for actuation must also be retrofitted.– Make sure that the additional clamp locking

mechanism function is available.

DANGERThere is risk to life caused by a falling load!During installation of a clamp with integral sideshift,ensure that the clamp does not open when thesideshift is actuated.– Notify your authorised service centre before

installation.– Never grab or climb on moving parts of the truck.

7090_900-001

Hydraulic connection– Before installing the attachment, releasethe pressure from the hydraulic system.

CAUTIONRisk of damage to components!Open connections of plug connectors can becomedirty. The plug connectors can become stiff and dirtcan enter the hydraulic system.– Once the attachment has been disassembled,

attach theprotective caps to the plug connectors.

Mounting attachmentsMounting an attachment and connectingthe energy supply for an attachment mustonly be performed by competent persons inaccordance with the information providedby the manufacturer and supplier of theattachment. After each installation, theattachment must be checked for correctfunction prior to initial commissioning.

NOTE

Please observe the definition of the followingresponsible person: "competent person".

56338011803 EN - 02/2018 199


Load capacity with attachmentThe permissible load capacity of the attach-ment and the allowable load (load capacityand load moment) of the truck must not be ex-ceeded by the combination of attachment andpayload. The specifications of the manufac-turer and supplier of the attachment must becomplied with.

– Observe the residual load capacity ratingplate, see the chapter entitled "Taking up aload using attachments".

7090_900-001

Releasing the pressure from thehydraulic system

WARNINGThe movements of the load lift system present arisk of crushing.During the process described below, the forkcarriage or the lift mast can only be moved slightly.– Do not reach into or stand below the components

of the load lift system.

Non-clamping attachments are connectedto the third hydraulic circuit via the plugconnectors on the fork carriage and arecontrolled via the "5th hydraulic function".

– Before fitting attachments, the pressuremust be released from the plug connectors(arrows) and the other hydraulic circuits.

Attachments must only be installed by compe-tent persons. The specifications provided bythe manufacturer and supplier of the attach-ments must be observed during installation ofthe attachments.

– Before each use of the attachment, checkand ensure the functions of the installedattachment.

200 56338011803 EN - 02/2018


1

2

Procedure for multi-lever operation– Switch on the key switch.

– Lower the fork carriage to the ground.

– Tilt the lift mast backwards to the stop.

– Switch off the key switch.

– Actuate the operating lever (1) severaltimes in the direction of the arrow until theend position is reached.

The hydraulic circuits of the first four hydraulicfunctions are depressurised.

– Switch on the key switch.

– Lower the fork carriage.

– Switch on the hazard warning system(variant).

NOTE

Press the button for switching on the hazardwarning system even if the truck is not equip-ped with a hazard warning system. Switchingon the hazard warning system prevents theelectrical system from being switched off,even if the key switch is subsequently swit-ched off.


The message KEY SWITCH appears in thedisplay.

– Press and hold the horizontal rocker buttonfor the 5th function (2).

– While holding down the button, actuatethe operating lever several times in thedifferent directions of the arrows until theend position is reached.

– Press and hold the horizontal rocker buttonfor the 5th function(2) in the other switchsetting.

– While holding down the push button,actuate the operating lever several timesin the different directions of the arrows untilthe end position is reached.

56338011803 EN - 02/2018 201


The hydraulic circuit of the 5th hydraulicfunction is depressurised. The connectionson the lift mast are depressurised.

NOTE

The number of operating levers shown maydiffer from the truck's equipment.

WARNINGUnintended movement of the lift mast presents arisk of injury.The hydraulic pump is inactive. If an operatingdevice for the hydraulic functions is accidentallyactuated, it may still cause unintended movementsof the lift mast.– Do not touch the operating devices.

202 56338011803 EN - 02/2018


1

F1F1 F2F2

1

1

F1 F2

1

1

+ F

2

2

2 2

2

Procedure for mini-lever, fingertip andJoystick 4Plus operation

NOTE

In trucks with the "FleetManager" or "accessauthorisation with PIN code" equipment va-riants, access authorisation must be enabled.


– Lower the fork carriage.

– Switch on the hazard warning system(variant).

NOTE

Press the button for switching on the hazardwarning system even if the truck is not equip-ped with a hazard warning system. Switchingon the hazard warning system prevents theelectrical system from being switched off,even if the key switch is subsequently swit-ched off.


The message KEY SWITCH appears in thedisplay.

– Actuate the operating lever (1) severaltimes in the direction of the arrow until theend position is reached.

The hydraulic circuits of the first four hydraulicfunctions are depressurised.

– Press and hold the 5. Funktion (2) functionkey.

– While holding down the button, actuate therelevant operating lever (1) several timesin the different directions of the arrows untilthe end position is reached.

The hydraulic circuit of the 5th hydraulicfunction is depressurised. The connectionson the lift mast are depressurised.

– Release the function key (2).

56338011803 EN - 02/2018 203


General instructions for controllingattachmentsThe way in which attachments (variant) arecontrolled depends on the operating devicesincluded in the truck's equipment.

Essentially, a distinction is drawn between:• Multiple-lever• Multiple-lever with a 5th function (variant)• Double mini-lever• Double mini-lever with a 5th function(variant)

• Triple mini-lever• Triplemini-lever with a 5th function (variant)• Quadruple mini-lever• Quadruple mini-lever with a 5th function(variant)

• Joystick 4Plus• Joystick 4Plus with a 5th function (variant)• Fingertip• Fingertip with a 5th function (variant)

– For information on controlling attachmentswith the respective operating devices, seethe relevant sections in this chapter.

WARNINGUse of attachments can give rise to additionalhazards such as a change in the centre of gravity,additional danger areas etc.Attachments must only be used for their intendedpurpose as described in the relevant operatinginstructions. Drivers must be taught how to operatethe attachments.Loads may only be picked up and transportedwith attachments if they are securely grasped andattached. Where necessary, loads must also besecured against slipping, rolling away, falling over,swinging or tipping over. Note that any change tothe position of the load centre of gravity will affectthe stability of the truck.– Refer to the capacity rating plate for the attach-

ments being used.

NOTE

Further variants and functions are available inaddition to the functions described below. The

204 56338011803 EN - 02/2018


directions of movement can be seen on thepictograms on the operating devices.

NOTE

All the attachments described fall into thecategory of equipment variants. Pleasesee the respective operating instructionsfor an exact description of the respectivemovements/actions of the attachment fitted.

56338011803 EN - 02/2018 205


2060_003-019

1

Controlling attachments usingmulti-lever operationIn this equipment, the attachments (variant)are controlled via the operating lever (1).

The pictograms on the operating lever showthe functions that are activated by this lever.

The meanings are as follows:

– Move operating lever (1) forwards.

The attachment moves in the direction shownin the upper part of the pictogram.

– Move operating lever (1) backwards.

The attachment moves in the direction shownin the lower part of the pictogram.

7311_862-001

2 3

6

4

7

9 10

5

8

– Note the following attachment functions andpictograms.

2 Move side shift frame or fork for-wards/backwards

3 Move sideshift to the left/right

4 Adjust fork arms: open/close

5 Swivel lift mast or fork to the left/right

6 Release/clamp load retainer

7 Push off/pull in load

8 Open/close clamps

9 Turn to the left/right

10 Tip shovel over/tip shovel back

NOTE

The pictograms shown correspond to theattachments fitted to this truck at the factory. Ifan attachment with other functions is fitted, thepictograms must be checked for the correctrepresentation and changed if necessary.

– Contact the authorised service centre ifrequired.

206 56338011803 EN - 02/2018


5060_003-040_V2

21

1

3

5060_003-041

Operating attachments using multi-lever controls and the 5th function

NOTE

For technical reasons, clamping attachmentsmust not be controlled via the 5th function.

The attachments (variant) are controlled inthis version using operating levers (1) and (2).

On the operating lever (1) you can, with theaid of switch (3), initiate a function changeoverso that this operating lever then controls the"5th function".

NOTE

The "5th function" designation refers to thefact that the four operating levers controlfour functions, while the "5th function" canbe controlled by switching functions.

The central and bottomparts of the pictogramson the operating levers always show thefunction that is activated by that lever. Thetop part of the pictogram shows that theattachment is equippedwith the "5th function".

This essentially involves the following:

– Move the operating lever forwards.

The attachment moves in the direction ofmovement shown in the centre part of thepictogram.

– Move the operating lever backwards.

The attachment moves in the direction ofmovement shown in the lower part of thepictogram.

– Actuate the switch

The additional function of the attachment isactivated and can be controlled as the "5thfunction" with the operating lever.

NOTE

Please see the operating instructions of thefitted attachment for the movements/actionsresulting from using this "5th function".

56338011803 EN - 02/2018 207


6210_862-011

2 3

6

4

7

9

5

8


2 Move sideshift frame or fork for-wards/backwards








NOTE



208 56338011803 EN - 02/2018


5060_003-113

A

C B

D

1

5060_003-112_V2

A

C B D

Controlling attachments using adouble mini-leverThe attachments (variants) are controlled inthis version using the "attachments" crosslever (1).

The pictograms on the "attachments" crosslever show the respective functions that areactivated by this lever.


– Move the "attachments"(1) cross lever inthe direction of the arrow (A) .

The attachment moves in accordance with thepictogram in position (A).

– Move the "attachments"(1) cross lever inthe direction of the arrow (B) .

The attachment moves in accordance with thepictogram in position (B).

– Move the "attachments"(1) cross lever inthe direction of the arrow (C) .

The attachment moves in accordance with thepictogram in position (C).

– Move the "attachments"(1) cross lever inthe direction of the arrow (D) .

The attachment moves in accordance with thepictogram in position (D).

56338011803 EN - 02/2018 209


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8


3 Move sideshift frame or fork forwards

4 Move sideshift frame or fork back-wards

5 Move sideshift to the left

6 Move sideshift to the right

7 Adjust fork arms: open

8 Adjust fork arms: close

9 Swivel lift mast or fork to the left

10 Swivel lift mast or fork to the right

11 Release load retainer

12 Clamp load retainer

13 Push off the load

14 Pull in the load

15 Open clamps

16 Close clamps

17 Rotate to the left

18 Rotate to the right

19 Tip shovel over

20 Tip shovel back

NOTE



210 56338011803 EN - 02/2018


2

E

F

13

7312_003-113_V2

E F

Controlling attachments usingthe double mini-lever and the 5thfunction

NOTE


NOTE

The "lift mast" 360° lever (3) and the "attach-ments" cross lever (2) control four hydraulicfunctions. The designation "5th function" re-fers to the fact that the 5th hydraulic functioncan be controlled with the cross lever by swit-ching the functions using the "5th function"function key (1).

The pictograms on the "attachments" crosslever (2) show the respective functions thatare activated by this lever.


– Actuate the "5th function" function key (1)and move the "attachments" cross lever (2)in the direction of arrow (E).

The attachment moves in accordance with thepictogram in position (E).

– Actuate the "5th function" function key (1)and move the "attachments" cross lever (2)in the direction of arrow (F).

The attachment moves in accordance with thepictogram in position (F).

NOTE

The pictograms are attached dependingon the pre-assembled attachment. If anattachment with other functions is fitted, thepictograms must be checked for the correctrepresentation and changed if necessary.


56338011803 EN - 02/2018 211


3 5

11

7

4 6

13

15 17

9

12 1410

16 18

8













14 Pull in the load



17 Tip shovel over

18 Tip shovel back.

212 56338011803 EN - 02/2018


5060_003-108

1

2

AC

BD

5060_003-109_V2

A C

B D

Controlling attachments using atriple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective functions that are activated bythese levers.


– Move the operating lever (1) towards (A)

The attachment moves in accordance with thepictogram in position (A).

– Move the operating lever (1) towards (B)

The attachment moves in accordance with thepictogram in position (B).

– Move the operating lever (2) towards (C)

The attachment moves in accordance with thepictogram in position (C).

– Move the operating lever (2) towards (D)

The attachment moves in accordance with thepictogram in position (D).

56338011803 EN - 02/2018 213


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8













14 Pull in the load

15 Open clamps

16 Close clamps



19 Tip shovel over

20 Tip shovel back

NOTE



214 56338011803 EN - 02/2018


5060_003-121

E

F

2

1

3

5060_003-120_V2

E

F

Controlling attachments using thetriple mini-lever and the 5th function

NOTE


NOTE

The "lift mast" 360° lever and operating levers(1) and (2) control four hydraulic functions.The designation "5th function" refers to thefact that the 5th hydraulic function can becontrolled with the operating lever (1) byswitching the functions using the function key(3).



– Actuate the "5th function" function key (3)and move operating lever (1) towards (E).


– Actuate the "5th function" function key (3)and move operating lever (1) towards (F).


56338011803 EN - 02/2018 215


5060_003-122

3

4

1

2






NOTE



216 56338011803 EN - 02/2018


5060_003-110

1

2

AC

BD

5060_003-109_V2

A C

B D

Controlling attachments using aquadruple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective function that is activated bythese levers.


– Move the operating lever (1) towards (A)

The attachment moves in the direction shownin pictogram (A).

– Move the operating lever (1) towards (B)

The attachment moves in the direction shownin pictogram (B).

– Move the operating lever (2) towards (C)

The attachment moves in the direction shownin pictogram (C).

– Move the operating lever (2) towards (D)

The attachment moves in the direction shownin pictogram (D).

56338011803 EN - 02/2018 217


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8













14 Pull in the load

15 Open clamps

16 Close clamps



19 Tip shovel over

20 Tip shovel back

NOTE



218 56338011803 EN - 02/2018


5060_003-119

4

1

25

3

E

F

5060_003-120_V2

E

F

Controlling attachments using thequadruple mini-lever and the 5thfunction

NOTE


NOTE

Operating levers (1) to (4) are used to controlfour hydraulic functions. The designation "5thfunction" refers to the fact that the 5th hydraulicfunction can be controlled with the operatinglever (3) by switching the functions using the"5th function" function key (5).



– Actuate the "5th function" function key (5)and move operating lever (3) towards (E).


– Actuate the "5th function" function key (5)and move operating lever (3) towards (F).


56338011803 EN - 02/2018 219


5060_003-122

3

4

1

2






NOTE



220 56338011803 EN - 02/2018


Controlling attachments via thejoystick 4PlusIn this equipment, the attachments (variant)are controlled via the joystick 4Plus (1) and theslider (2).

The pictograms on the decal informationabout operation of the joystick 4Plus showthe respective functions that are activatedby the individual operating devices of thejoystick 4Plus.

6210_003-098

1

4

2

5

3


Operating device Function of theattachment

1 Joystick 4Plus Move sideshift to theleft/right

2 Joystick 4Plus orslider

Adjust fork arms:open/close

3 SliderMove side shift frameor fork carriageforwards/backwards

4 Joystick 4Plus orslider

Rotate attachmentleft/right

5 Slider Tip shovel over/tipshovel back

NOTE

The pictograms on the joystick 4Plus areapplied according to the attachments fitted tothis truck at the factory. If an attachment withother functions is fitted, the pictograms mustbe checked for the correct representation andchanged if necessary.


56338011803 EN - 02/2018 221


Controlling attachments using theJoystick 4Plus and the 5th function– Note the following attachment functions andpictograms.

NOTE

For technical reasons, clamping attachmentsmust not be controlled via the "5th function".

Operating device Function of theattachment

1Joystick 4Plus &shift key "F"

Adjust fork arms:close/open

2Horizontal rockerbutton & shiftkey "F"

Adjust fork:backwards/forwards


Swivel lift mast orfork: left/right


Additional forkcarriage: lift/lower

NOTE

The 5th hydraulic function can be used tocontrol an attachment. The pictograms onthe Joystick 4Plus show which attachmentfunctions can be controlled using the "5thfunction".

2

1

6210_003-086

For attachments that are controlled usingthe 5th hydraulic function, the procedures foroperation are as follows:

– Press and hold shift key "F" (1) on theJoystick 4Plus.

– At the same time, actuate the horizontalrocker switch (2) in the direction shown inthe pictogram so that the attachmentmovesaccordingly.

NOTE

The pictograms on the Joystick 4Plus areapplied according to the attachments fitted tothis truck at the factory. If an attachment withother functions is fitted, the pictograms must

222 56338011803 EN - 02/2018


be checked for the correct representation andchanged if necessary.


56338011803 EN - 02/2018 223


F1F1 F2F2

6321_003-013

1

Controlling the attachments withfingertipThe attachments (variant) are controlled inthis version using the operating levers (1).

Thepictogramson theoperating levers alwaysshow the functions that are activated by thatlever.

– Move operating lever (1) forwards.

The attachment moves in the direction ofmovement shown in the upper part of thepictogram.

– Move operating lever (1) backwards.


6210_003-031

2 3

6

4

7

9 10

5

8


2 Move side shift frame or forksforwards/backwards

3 Move sideshift to the left/to the right


5Swivel lift mast or forks to the left/tothe right



8 Open/close clamps

9 Turn to the left/to the right


NOTE



224 56338011803 EN - 02/2018


F1F1 F2F2

6210_003-032

13

2Controlling attachments with finger-tip and the 5th function

NOTE


NOTE

The designation "5th function" refers to thefact that the four operating levers controlfour functions, while the "5th function" canbe controlled by switching functions.

The attachments (variant) are controlled usingthe operating levers (1).

You can also use the switch (2) to switchfunctions, in which case the correspondingoperating lever controls the "5th function".

The pictogram (3) behind the operatinglever shows in the upper and lower parts thefunction that is activated with this lever.

The meanings are as follows:

– Move operating lever forwards.

The attachment moves in the direction ofmovement shown in the upper part of thepictogram.

– Move operating lever back.


– Actuate the switch (2).

The additional function of the attachment isactivated/deactivated and can be controlledas the "5th function" using the operating lever.

56338011803 EN - 02/2018 225


F1F1 F2F2

6210_003-033

4

5

6

– Press the function key (4).

NOTE

The arrow (5) under the function key indicateswhich operating lever is equipped with the "5thfunction".

The "5th function" is switched to the 3rdoperating lever; see adhesive label (6).

F1F1 F2F2

6210_003-034

7

8

9

– Press the function key (7).

NOTE

The arrow (8) under the function key indicateswhich operating lever is equipped with the "5thfunction".

The "5th function" is switched to the 4thoperating lever; see adhesive label (9).

NOTE

The movement/action of this "5th function"can be found in the operating instructions ofthe fitted attachment.

NOTE

The pictograms are applied depending on thepre-assembled attachment. If an attachmentwith other functions is fitted, the pictogramsmust be checked for the correct representationand changed if necessary.


226 56338011803 EN - 02/2018


6210_003-035

10 11

14

12

15

17

13

16


10 Move side shift frame or fork for-wards/backwards







17 Tip shovel over/tip shovel back.

Clamp locking mechanism (variant)This truck can be fitted with a clamp lockingmechanism as a variant. This clamp lockingmechanism prevents the clamp from openingunintentionally if the operating function isinadvertently triggered.

DANGERThere is a risk of fatal injury from falling loads if thecorrect function of the clamp locking mechanism isnot guaranteed!If other attachments are used on this truck in addi-tion to the clamp, make sure that the clamp lockingmechanism function is reassigned to the corre-sponding operating device every time the clamp isreassembled; see the chapter entitled "Fitting at-tachments".– Make sure that the additional clamp locking

mechanism function is available.

56338011803 EN - 02/2018 227


6210_003-076

1

2

Multi-lever– Press and hold the (2) button to release theclamp locking mechanism.

NOTE

The hydraulic function for opening the clampis only available if the button is pressed.After releasing the button, the clamp lockingmechanism is automatically reactivated.

– To release the clamp locking mechanism,push the operating lever (1) forwards.

It is not necessary to release the clamp lockingmechanism in order to close the clamp.

– To close the clamp, pull the operating lever(1) backwards.

F1 F2

6210_003-077

1

2

Double mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.

The LED for button "F2" (2) lights up as longas the clamp locking mechanism is released.

NOTE

The hydraulic function for opening the clampis available for one second after the clamplocking mechanism is released. After onesecond, the clamp locking mechanism isautomatically reactivated.

– To open the clamp, push the operating lever(1) forwards again.



228 56338011803 EN - 02/2018


6210_003-078

1

2

Triple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





6210_003-079

2

1

Quadruple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





56338011803 EN - 02/2018 229


+ F

+ F

1

3

2

Joystick 4Plus– To open the clamp locking mechanism,press and hold the shift button "F"(3).

– While doing so, move the horizontal rockerbutton (1) to the left.

– Keep the shift button "F" (3) pressed downand move the horizontal rocker button (1)back to the neutral position.

The LED (2) lights up.

– While holding down the shift button "F",move the horizontal rocker button (1) to theleft again within 1 second.

The LED (2) lights up as long as the clamplocking mechanism is released.

NOTE



– To close the clamp locking mechanism,press and hold the shift button"F"(3).

– While doing so, move the horizontal rockerbutton (1) to the right.

The clamp closes.

230 56338011803 EN - 02/2018


6210_003-080

F1F1 F2F2

1

2Fingertip switch– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





1

2

3

7090_860-002

Taking up a load using attachments

WARNINGRisk of accidents!Attachments may only be used for their intendedpurpose as described in the relevant operatinginstructions.Drivers must be instructed in the handling of theattachments.

WARNINGRisk of accidents!Loads may only be picked up and transported withattachments if they are securely attached. Wherenecessary, loads should also be secured againstslipping, rolling, falling over, swinging or tippingover. Note that any change to the position of theload's centre of gravity will affect the stability of theforklift truck.Check the capacity rating plates for theattachmentsor combination of attachments.

– The rating plates show the permissiblevalues for:

56338011803 EN - 02/2018 231

4 OperationAuxiliary equipment

• Load capacity Q (kg) (1)• Lift height h (mm) (2)• Load distance C (mm) (3)

Auxiliary equipmentSwitching the lighting on and off

Driving lights

Blue-Q_039

1

– To switch on the parking light, press thebutton (1).

The front sidelights and the rear lights light up.

– To switch on the headlights, press thebutton (1) again.

The headlights light up in addition to theparking light.

– To switch off the driving lights, press thebutton (1) again.

The driving lights go out.

Working spotlights

Blue-Q_008_V3

1

– To switch on the working spotlights (frontand rear), press the button (1).

The working spotlights light up.

– To switch off the working spotlights, pressthe button (1) again.

The working spotlights go out.

NOTE

When the working spotlights are switched onin trucks with StVZO (German Road TrafficLicensing Regulations) equipment (variant),the following lighting devices on the truck arealso activated:• Rear lights• Sidelights

232 56338011803 EN - 02/2018

Operation 4Auxiliary equipment

Switching the working spotlight forreverse travel on and offThe working spotlight for reverse travel isattached to the overhead guard at the rear. Itprovides optimal illumination of the roadway ifthe truck is travelling in reverse.

21

– Press the softkey (1).

The symbol (2) is displayed. The rearworking spotlight does not yet illuminate.

– Set the drive direction to "Reverse".

The rear working spotlight illuminates.

NOTE

If the drive direction is set to "Forwards", therear working spotlight goes out.

Switching the rotating beacon on andoff

5060_003-045_V2

21

– Press the Softkey (1) to switch on therotating beacon.

The rotating beacon is switched on. Thesymbol is displayed.

– To switch off the rotating beacon, press theSoftkey .

The rotating beacon goes out. The symbol(2) is displayed.

56338011803 EN - 02/2018 233


5060_003-011_V2

1

2

Switching the hazard warningsystem on and off– To switch on the hazard warning system,press the button (1).

All direction indicators and indicatorlights (2) flash.

– To switch off the hazard warning system,press the button (1) again.

The hazard warning system goes out.

NOTE

The hazard warning system can also beswitched on without the key switch beingswitched on. To do this, press and hold thebutton for three seconds.

Switching direction indicators on andoff

Mini-lever version

5060_003-096

F1 F2

1

– Switch on the direction indicators bymovingthe corresponding drive direction/turnindicator cross lever (1) to the left or right.

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2 3

5060_003-012_V2

The direction indicators and the correspon-ding direction indicator lights (2) or (3) flash.

– Switch off the direction indicators bymovingthe cross lever to the centre position.

Fingertip version

F1F1 F2F2

5060_003-100

1– Switch on the direction indicators bymovingthe corresponding turn indicator button (1)to the left or to the right.

– Turn off the direction indicators by pushingthe other turn indicator button.

56338011803 EN - 02/2018 235


Mini-console version

5060_003-046

1

– Switch on the direction indicators bymovingthe turn indicator switch (1) to the left or tothe right.

2 3

5060_003-012_V2

The direction indicators and the correspon-ding turn indicator displays (2) or (3) flash.

– Switch off the direction indicators bymovingthe turn indicator switch to the centreposition.

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6210_003-060

2

3

Switching the double workingspotlights on and off.The double working spotlights are fitted up onthe front right and left on the overhead guard.Each double working spotlight consists ofan upper working spotlight (2) and a lowerworking spotlight (3). The upper workingspotlight illuminates the working area atgreat lift heights, the lower working spotlightilluminates the working area directly in front ofthe truck.

Depending on the equipment, the upperworking spotlights can be switched on/offautomatically or manually.

Switching the upper working spotlightson/off manually

NOTE

The upper working spotlights can be switchedon/off independently of the lower workingspotlights. For information about switching onthe lower working spotlights, see the sectionentitled "Switching the lighting on and off".

NOTE

This function is not available if the truck isequipped with rear window heating.


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6311_003-030_V3

1

– Press Softkey (1) to switch on theworking spotlights.

The working spotlights are switched on. Thesymbol is displayed.

– Press Softkey to switch off the workingspotlights.

The working spotlights are switched off. Thesymbol is displayed.

Switching the upper working spotlightson/off automatically– Turn the key switch to position "I".

– For information about switching on theworking spotlights, see the chapter entitled"Switching the lighting on and off".

The lower working spotlights light up.

The upper working spotlights are switched onautomatically when the lift mast is lifted for aperiod of at least two seconds.

NOTE

During these two seconds, a maximum of twolifts can be executed to prevent the workingspotlights from switching on each time aprecise adjustment is made. If more lifts arecarried out during this time, the upper workingspotlights will remain switched off.

NOTE

The upper working spotlights are switchedoff automatically when the truck is driven forlonger than one second at a speed faster than2.1 km/h.

Lift-height-controlled switching on/off ofthe upper working spotlights

NOTE

This equipment is available only if a proximityswitch is fitted to the lift mast to record aparticular lift height of the fork carriage onthe lift mast.


238 56338011803 EN - 02/2018


– Switch on the working spotlights.

The lower working spotlights light up.

The upper working spotlights are switched onby the proximity switch when the fork carriagereaches or exceeds the preset lift height.

The upper working spotlights are switched offby the proximity switch when the fork carriagefalls below the preset lift height again.

CAUTIONPossible component damage caused by collision ifthe proximity switch is set incorrectly.– The proximity switch may be adjusted by trained

personnel.– If necessary, inform the authorised service

centre.

STILL SafetyLight (variant)

WARNINGDanger of damage to eyes fromlooking into the STILL SafetyLight.Do not look into theSTILLSafetyLight.

The STILL SafetyLight is a visual warning unitdesigned to enable early detection of trucksin driving areas with low visibility (such asdrive lanes, high racks), as well as at blindjunctions. The STILL SafetyLight is mountedon a support on the overhead guard suchthat it is not affected by jolts and vibrations.The STILL SafetyLight projects one or morelight-blue light spots in front of or behindthe truck and thus warns others about theapproaching truck. Several light spots areprojected as a chase light. The chase lightindicates the location of the truck with itsdirection of travel.

Depending on the configuration of the truck,the STILL SafetyLight automatically switchesitself on when the truck is moving. TheSTILL SafetyLight can also be switched onand off on the display-operating unit.

– To do so, press the corresponding button.

56338011803 EN - 02/2018 239


NOTE

If the truck is to be operated on public roads,the STILL SafetyLight must be switched off.

Operating the windscreenwiper/washer

7312_003-171_V3

1

2

– Push button (1) to actuate the front wind-screen wiper/washer (variant)

– Push button (2) to actuate the rear wind-screen wiper/washer (variant)

Repeated pressing of the respective buttonswitches between the operating stages in thesequence specified shown below.

Button actuation Operating stage

Off

1st time on

2nd time Interval

3rd time + hold Washer

4th time Off.

1

26327_003-008

Filling the washer system– Open the filler cap (1) of the washer system(variant).

– Fill the washer reservoir (2) with washerfluid containing anti-freeze, according tothe maintenance data table; see ⇒ Chap-ter "Maintenance data table", P. 5-378.

CAUTIONComponents may become damaged due to theeffects of frost!Water expands when it freezes. If there is no anti-freeze in the washer system (variant), the systemmay become damaged due to the accumulation ofice in freezing conditions.– Always use washer fluid containing anti-freeze.

– Close the filler cap.

– Operate washer system until washer fluid isdischarged from the spray nozzles.

240 56338011803 EN - 02/2018


FleetManager (variant)FleetManager is an equipment variant andcan be fitted to the truck in different versions.The description and operation information canbe found in the separate operating instructionsfor the corresponding FleetManager versions.

Shock recognition (variant)The shock recognition is an equipment variantof the FleetManager (variant) in which anacceleration sensor is installed in the truck.The acceleration sensor records data arisingfrom rapid accelerations or decelerations ofthe truck, e.g. in the event of an accident.This data can be electronically read out andevaluated.


Driver restraint systems (variants)Different driver restraint systems are availableas variants for this truck. The description andoperation for these systems can be foundin the separate "Driver restraint systems"operating instructions.

56338011803 EN - 02/2018 241


Ceiling sensor (variant)

Description

1

The ceiling sensor (1) on the overhead guardis an assistance system that automaticallyreduces the driving speed of the truck withinhalls. However, this assistance system doesnot release the driver from the responsibilityof observing the speed limits on companypremises.

Depending on the system setting, the ceilingsensor can detect overhead structures abovethe truck at a height of 2 m to 24 m above thesensor.

Operating the ceiling sensor systemThe drivers are to be instructed on the useof the ceiling sensor system by the operatingcompany.

When the driver enters a hall for the firsttime after starting work, he must be certainthat the ceiling sensor system is functioningcorrectly. Despite the ceiling sensor systembeing installed, the driver must also check thespeed indicator on the display-operating uniton a regular basis to ensure that he does notexceed the maximum speed permitted for theenvironment.

• Entering a hallThe ceiling detector system automaticallydetects whether the truck enters a hall. Thesystem then automatically slows the truck tothe maximum speed that is set for the hall.

• Leaving a hallIf the truck leaves the hall again, the ceilingdetector system enables the maximumspeed set for areas outside the hall. Dueto the range of the sensor, this may nothappen until the truck is a few metres awayfrom the hall exit. Before the truck is able toaccelerate to themaximumspeed permittedfor outdoor areas, the speed limitation muststill be unlocked. To do this, release the

242 56338011803 EN - 02/2018


accelerator briefly and then operate theaccelerator again.

• Switching on the truck in a hallIf the truck is switched on inside a hall, theceiling detector system detects the hallceiling and reduces the driving speed to themaximum speed that is set for halls.

Possible limitations for object recognition• If the truck moves under larger overheadstructures outdoors, e.g. a pedestrianbridge, the ceiling sensor system mayinterpret this overhead structure to be a hallceiling and reduce the maximum speed.

• In rare cases, it may occur that the ceilingsensor system does not recognize a ceilingand does not then reduce the speed. Thiscan happen if the signals from the ceilingsensor are insufficiently reflected due to theceiling geometry; for example, if there arelarge window areas at a 45° angle.

In these cases, the sensitivity and the range ofthe ceiling sensor system must be adjusted.Formore information, refer to the next chapter.

Changing the sensor settingsThe ceiling sensor system is supplied bySTILL with the following factory settings:

Sensitivity: High

Ceiling height: 24 m

– Pull out the connecting cable from thesensor.

56338011803 EN - 02/2018 243


1

– On the underside of the assembly baseplateon the overhead guard, loosen the four nuts(1) on the sensor.

– Carefully remove the sensor.

2

– Using the supplied key (2), open the sensorhousing to gain access to the DIP switches.

244 56338011803 EN - 02/2018


1 2 3 4 5 6 7 8

3

– Using the DIP switches "1" to "5" (3), adjustthe range and the sensitivity of the sensor.The DIP switches can be adjusted using asmall screwdriver.

CAUTIONThe settings for DIP switches "6" to "8" are thefactory settings of the manufacturer.They must not be changed!

Factory settings of the manufacturer - do notchange

DIP switch

6 7 8

1 1 0

The possible settings for DIP switches "1" to"5" are shown in the following tables:

DIP switch

1 2 3 Range

0 0 0 2 m

0 0 1 3 m

0 1 0 4 m

0 1 1 6 m

1 0 0 8 m

1 0 1 12 m

1 1 0 16 m

1 1 1 24 m

4 5 Sensitivity

0 0 Very high

0 1 High

1 0 Medium

1 1 Low

The sensor has different beam angles de-pending on the combination of range and

56338011803 EN - 02/2018 245


sensitivity that has been set. See the followingtable:

Sensitivity Range Beam angle

2 m 22.5°

4 m 22.5°

8 m 20°

16 m 15°

Low (1)

24 m 5°

2 m 35°

4 m 30°

8 m 25°

16 m 22.5°

Medium (2)

24 m 10°

Sensitivity Range Beam angle

2 m 42°

4 m 33°

8 m 22.5°

16 m 20°

High (3)

24 m 15°

2 m 45°

4 m 43°

8 m 30°

16 m 22.5°

Very high (4)

24 m 18°

246 56338011803 EN - 02/2018


2 3 41234

Representation of the beam angle dependingon the sensitivity of the sensor that has beenset, from (1)"low" to (4)"very high".

Additional labellingAdhesive label next to the display-operatingunit

56338011803 EN - 02/2018 247

4 OperationCab

CabOpening the cab door

DANGERThere is a risk of damage through collision if the cabdoor opens while driving.– The cab door must be latched securely in the

engaged position.

Opening the cab door from the outside:

6321_003-061_V345

2 13

– Insert the key in the door lock (5), unlockand remove the key.

– Pull the door handle (4) and release thedoor lock.

– Open the cab door (3) by pulling outwards.

Opening the cab door from the inside:– Take hold of the handlebar (2) and latch (1).

– Press the latch in and push the cab dooroutwards.

248 56338011803 EN - 02/2018

Operation 4Cab

Closing the cab door

DANGERThere is a risk of damage caused by collision if thecab door opens while driving.– The cab door must be latched securely in the

engaged position.

6321_003-141_V2

3

1 2

Opening the side windows

WARNINGThere is a risk of crushing between the windowframe and side window from the side windowsslipping inadvertently during travel.– Make sure that the handle engages securely in

the corresponding stop slot.

Opening the rear side window:– Press the handle (3) together and slide therear side window (2) forwards.

Opening the front side window:The front sidewindow (1) can be opened in thesame way as the rear side window.

6321_003-141_V2

3

1 2

Closing the side windows

WARNINGThere is a risk of crushing between the windowframe and side window from the side windowsslipping inadvertently during travel.– Make sure that the handle engages securely in

the corresponding stop slot.

Closing the rear side window:– Press the handle (3) together and pull therear side window (2) to the rear.

Closing the front side window:The front side window (1) can be closed in thesame way as the rear side window.

56338011803 EN - 02/2018 249

4 OperationCab

7312_003-013

7 8Operating the interior lighting

6311_003-013_V2

21

– Switch the interior lighting (7) on or off usingthe switch (8) or button (1).

The "interior lighting" symbol (2) appears inthe display.

250 56338011803 EN - 02/2018

Operation 4Cab

Operating the rear window heating

6311_003-014_V2

21

– Press Softkey (1) to switch on the rearwindow heating.

Rear window heating is switched on.The symbol is displayed.

– Press Softkey (1) to switch off the rearwindow heating.

Rear window heating is switched off.The (2) symbol is displayed.

NOTE

Rear window heating will switch off automati-cally after approximately 10 minutes.

6321_003-015

1

2

Radio (variant)The radio (1) and the loudspeakers (2) are anequipment variant. If the truck is equippedwitha radio and loudspeakers, they are integratedinto the roof lining.

The description and operation can be foundin the separate operating instructions for theradio.

WARNINGThe driver's attention is adversely affected byoperating the radio or listening to excessive volumewhile driving or handling loads. There is a risk ofaccident!– Do not use the radio when driving or when

handling loads.– Set the radio volume so that you can still hear

warning signals.

56338011803 EN - 02/2018 251

4 OperationCab

Heating system (variant)

Switching on the blower and heatingsystem

DANGERBy taking in heavily polluted surroun-ding air into the closed cab there is adanger of poisoning!The heater must not be operated inthe vicinity of storage areas or the likein which fuel vapours or fine dust (e.g.coal, wood or grain dust) can form.

DANGERThere is a risk of explosion due togases being given off or igniting as aresult of heat.– Do not expose spray cans or gas

cartridges to the flow of hot air.

0 1

2

3

0 1

2

3

1

2

6210_345-001

– Rotate the blower switch (1) clockwise tothe desired blower position.

The blower is in operation and runs at thespeed level selected by the blower switch (1) .

DANGERThe heating system overheats if thehot air cannot escape from it. There isa risk of fire!The heating system may only beswitched on if the blower is runningand the heating system is not coveredby objects (such as a jacket or cover).– Always switch the blower on first.– Do not switch the heating system

on until the blower is switched on.– Remove existing objects away from

the heating system or air outlets.

DANGERThe heating system housing canbecome very hot when the heatingsystem is operating. There is a risk ofburns if it is touched!– Do not touch the heating system

housing during operation.– Only touch the switches provided.

252 56338011803 EN - 02/2018

Operation 4Cab

– Rotate the heating level switch (2) clock-wise to the desired heating level.

The heating system is in operation. The airis heated up to the heating level set by theheating level switch (2).

Selecting blower settingsSetting blower to low:

– Set blower switch (1) to level 1.

Setting blower to medium:


Setting blower to high:


Setting heating levelsSet heating system to low (50%):

– Set heating level switch (2) to level 1.

Set heating system to medium (75%):


Set heating system to high (100%):


Turn off the heating system and blower

DANGERThe heating system overheats if thehot air cannot escape from it. There isa risk of fire!The blower may only be turned off ifthe heating system is turned off.– Always turn the heating system off

first.– Only turn the blower off when the

heating system is switched off.

– Rotate the heating level switch (2) anticlock-wise to heating level 0.

The heating system is out of order.

– Rotate the blower switch (1) anticlockwiseto blower position 0.

The blower is out of order.

56338011803 EN - 02/2018 253

4 OperationCab

Change fuses

DANGERUsing the wrong fuses can result inshort circuits. There is a risk of fire!– Only use fuses with the prescri-

bed nominal current; see ⇒ Chap-ter "Replacing fuses", P. 5-393.

6210_003-105_V2

1

2

3

3

Push-up roof window (variant)

WARNINGRisk of crushing!– When closing the roof window, do not reach

between the roof window and the overheadguard.

– Do not reach in to touch components as they arebeing closed.

The push-up roof window (1) is an equipmentvariant.

– To unlock and open the roof window, rotatethe handle (2) in an anti-clockwise directionand use it to push the roof window upwards.

The roof window is held in the open position bymeans of gas springs (3).

– To close and lock the roof window, pullthe roof window downwards using thehandle and rotate the handle in a clockwisedirection

254 56338011803 EN - 02/2018

Operation 4Cab

6210_003-107

21

Clipboard (variant)The clipboard (1) with reading lamp (2) is anequipment variant.

56338011803 EN - 02/2018 255

4 OperationTrailer operation

Trailer operation

6210_313-001

Towed load

DANGERThere is an increased risk of accident when using atrailer.Using a trailer changes the truck handling charac-teristics. When towing, operate the truck such thatthe trailer train can be safely driven and braked atall times. The maximum permissible speed whentowing is 5 km/h.– Do not exceed the permissible speed of 5 km/h.– Do not couple the truck in front of rail vehicles.– The truck must not be used to push any kind of

trolley.– It must be possible to drive and brake at all times.

CAUTIONRisk of damage to components!The maximum towed load for occasional towingis the rated capacity specified on the nameplate.Overloading can lead to component damage on thetruck. The sum of the actual towed load and theactual load on the fork must not exceed the ratedcapacity. If the existing towed load correspondsto the rated capacity of the truck, no load may betransported on the fork at the same time. The loadcan be distributed between the fork and the trailer.– Check the load distribution and adjust it to

correspond to the rated capacity.– Observe the permissible rigidity value of the tow

coupling.

CAUTIONRisk of damage to components!Themaximum towed load only applies when towingunbraked trailers on a level surface (maximumdeviation +/- 1%) and on firm ground. The towedload must be reduced if towing on gradients. Ifnecessary, notify the authorised service centre ofthe application conditions. The service centre willprovide the required data.– Inform the authorised service centre.

256 56338011803 EN - 02/2018

Operation 4Trailer operation

CAUTIONRisk 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 towingof trailers. If the truck is equipped with atowing device, this occasional towing mustnot exceed 2% of the daily operating time. Ifthe truck is to be used for towing on a moreregular basis, the manufacturer should beconsulted.

Coupling pin in the counterweight

Coupling the trailer

DANGERIf you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

1 7090_900-008

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

56338011803 EN - 02/2018 257


6321_003-116

2

3

– Push the coupling pin (2) down, turn 90°and pull out.

– Adjust tiller height.

DANGERPeople can become trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

– Slowly move the truck back.

– Bymoving the truck back, introduce the tillerinto the recess (3) in the counterweight.

DANGERIf the coupling pin or securing bush are lost ordestroyed during towing, the trailer will work looseand become uncontrollable. This causes a risk ofaccident!– Use only original coupling pins that have been

checked carefully.– Ensure that the coupling pin is correctly inserted

and secured.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

– Remove any items used to prevent thetrailer from rolling away.

Uncoupling the trailer– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

258 56338011803 EN - 02/2018


6321_003-116

2

3

– Push the coupling pin (2) down, turn 90°and pull out.

– Slowly move the truck forwards and guidethe tow-bar eye completely out of thecounterweight.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

Automatic tow coupling

DANGERPeople may be trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

DANGERNever jack up the truck on the tow coupling or useit for crane lifting. The tow coupling is not designedfor this and could be deformed or damaged. Thiscould cause the truck to fall, with potentially fatalconsequences!– Use the tow coupling only for towing.– For jacking up and crane loading, use only the

designated lifting points.

DANGERThe tow coupling is not designed to support loadsand could become deformed or destroyed. Thiscould cause the supported load to fall, with poten-tially fatal consequences!– The tow coupling should be subjected only to

horizontal loads, i.e. the tiller must be horizontal.

56338011803 EN - 02/2018 259


DANGERIf you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

WARNINGNever reach between the coupling pins and thetowing jaws. If the component moves suddenlythere is a risk of injury!– To release the coupling pin, actuate the corre-

sponding lever or use a suitable device (e.g.assembly lever).

– When not in use, close the automatic towcoupling.

WARNINGRisk of damage due to component collision.A truck with tow coupling needs more room formanoeuvring due to its overhang. The tow couplingcan damage the racking or the tow coupling itselfwhen manoeuvring. If there is a collision with thetow coupling, test the tow coupling for damagesuch as cracks. A damaged tow coupling must notbe used again.– Always manoeuvre carefully and with sufficient

room.– In the case of a collision, test the tow coupling for

damage.– Replace tow coupling if damaged, if necessary

contact the authorised service centre.

WARNINGRisk of damage to the tow bar eye or tiller!Due to the truck's rear wheel steering, the sideslewing angle of the tiller may not be adequate. Thecoupling or the tiller may be damaged! The tow bareye of the tiller must fit the tow coupling in terms ofshape and size.– Ensure that the tow bar eye and tiller fit correctly.– Avoid sharp cornering.– Exercise care when travelling and manoeuvring

in reverse.

260 56338011803 EN - 02/2018


WARNINGRisk of component damage if the tiller in the towcoupling is tilted!The tiller should be kept as horizontal as possiblewhen towing. This ensures that the rotation rangeis sufficient at the top and bottom. The authorisedservice centre can adjust the assembly height forthe tow coupling to the tiller height if necessary.– Make sure that the tiller is level.– To change the coupling height, contact the

authorised service centre.

1 7090_900-008

Coupling model RO*243

NOTE

Tow coupling RO 243 is intended for a tow-bareye in accordance with DIN 74054 (borediameter: 40 mm).

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

– Adjust the tow bar eye of the tiller so that it isat the centre of the towing jaws.

3

7321_003-064

2

– Pull out the safety handle (3).

– Push the hand lever (2) upwards.

DANGERPersons may become trapped between the truckand trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTIONWhen being coupled, the tow-bar eye must engagein the middle of the coupling jaw. Failure to followthese instructions could result in damage to thecoupling jaw or to the tow-bar eye!– Ensure that the tow-bar eye enters the coupling

jaw centrally.


56338011803 EN - 02/2018 261


DANGERIf thecoupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Ensure that the safety handle is flush with the

securing bush.– If the safety handle protrudes, repeat the coup-

ling process.


– Tow the trailer.

Closing model RO*243 by hand

DANGERRisk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, use only a suitable device to close the towcoupling (e.g. assembly lever).

– Use a suitable device (e.g. assembly lever)to push the coupling pin up.

The coupling pin is released from the latch andthe tow coupling then closes automatically.

3

7321_003-064

2

Uncoupling model RO*243– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

– Pull out the safety handle (3).


– Slowly drive the truck forwards until the tow-bar eye and towing jaws are disconnected.

– Close the tow coupling by hand.

262 56338011803 EN - 02/2018


Coupling model RO*244 A

NOTE

Trailer coupling RO 244 is intended for a towbar eye in accordance with DIN 74054 (borediameter 40 mm) or DIN 8454 (bore diameter35 mm).

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.


– Push the hand lever (2) upwards until itsnaps into place.

The tow coupling is opened.

DANGERPeople can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.


jaw centrally.

– Move the truck back slowly until the tow bareye is inserted centrally into the couplingjaw of the tow coupling and the coupling pinengages.

NOTE

The coupling pin is correctly engaged if thecontrol pin (3) does not protrude out of itsguide.

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DANGERIf thecoupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!The control pin (3)must not protrude out of its guide.– Ensure that the coupling pin is engaged cor-

rectly.If the coupling pin is not correctly engaged:– Remove any items used to prevent the trailer

from rolling away.– Move the truck with the trailer forwards approx.

1 m and then move it back slightly.– On the coupling pin, check again that the control

pin does not protrude out of its guide.



Closing model RO*244 A by hand

DANGERRisk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, only actuate the tow coupling via theclosing lever (1).

– Press the closing lever (1) downwards asfar as it will go.

The tow coupling is closed.

Uncoupling model RO*244 A– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.


The tow coupling is opened.


– Close the tow coupling by actuating theclosing lever (1).

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NOTE

To protect the lower coupling pin bush againstcontamination, always keep the tow couplingclosed.

7321_003-066_V2

57

6


NOTE

Trailer coupling RO 245 is intended for atow-bar eye in accordance with DIN 74054(bore diameter 40 mm) or DIN 8454 (borediameter 35 mm).




– The tow coupling is opened.

DANGERPeople can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.


DANGERIf the coupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Make sure that the control pin does not protrude

from the control bush.– Repeat the coupling process if necessary.



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7321_003-066_V2

57

6




– Push the closing lever (7) on the left side ofthe tow coupling down as far as it will go.

The tow coupling is closed.

7

8

7321_003-067


NOTE

Tow coupling RO 841 is intended for a tow-bareye in accordance with DIN 74054 (borediameter 40 mm).



DANGERPeople may be trapped between truck and trailer.When hooking up, ensure that no one is betweenthe truck and trailer.


jaw centrally.


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DANGERIf the coupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Make sure that the control pin does not protrude

from the control bush.– Repeat the coupling process if necessary.






– Close the tow coupling.

7090_900-011Towing trailers– Drivers who are towing a trailer for the firsttime must practise driving with a trailer in asuitable area.

– When passing through narrow road areas(entrances, gates etc.), observe the dimen-sions of the trailer and load.

– When towing multiple trailers, ensurea sufficient minimum distance to fixedinstallations when turning and cornering.

The permissible length of the trailer trainsdepends on the roadways to be driven andmay need to be determined during the testdrive.

It is the responsibility of the operating com-pany to instruct the drivers regarding thepermissible number of trailers and, whererequired, any additional speed reductions onindividual sections of the route.

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NOTE


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Operation 4Cold store application

6210_900-002

Cold store applicationThe truck features cold store equipment(variant), making it suitable for use in coldstores.

It is equipped for two different types of applica-tion and marked with the cold store symbol.

The display-operating unit is heated in thisvariant.

As another variant, the truck can be equippedwith a driver's cab with a heating system.

Types of application

There are two different types of cold storeapplication for the truck, distinguished by twodifferent temperature ranges.1 Constant deployment in temperature

range -5°C, brief deployment down to-10°C.

2 Alternating between indoor use down to-32°C and outdoor use to +25°C, brieflyup to +40°C.

Operation

CAUTIONChanging from a cold internal temperature toa warm outside temperature may result in theformation of condensation water. This water mayfreeze on re-entry to the cold store, blockingmovingparts of the truck.It is essential that close attention is paid to theduration of deployment in the different temperatureranges for both types of application.Before being used in the cold store, the truck mustbe dry and warmed up.The truck must not leave the cold store area formore than 10 minutes. By adhering to this rule,condensation water will not have time to form.If the truck stays outside for more than 10 minutes,it must remain there at least until the condensationwater has drained away and the truck has dried off.Depending on the weather, this will take at least30 minutes.

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4 OperationCold store application

WARNINGRisk of injury!If condensation water freezes in the cold store, donot try to free parts that have become stuck withyour hands.

– To ensure operational safety, drive the truckfor approximately 5minutes and actuate thebrake several times.

– Actuate all hydraulic lifting functions severaltimes.

This warm-up phase is necessary to ensurethat the oil reaches the operating temperature.

– Always park the truck outside the cold store.

CAUTIONRisk of component damage!The lead-acid batteries must not be left in the coldstore overnight without power uptake or charging.

– Charge the battery outside the cold store.Operate the truck using a replacementbattery.

Using batteries in the cold storeTo compensate for the reduction in capacityat low temperatures, it is advisable to uselead-acid batteries with the maximum nominalcapacity in the respective battery dimensionsfor the truck series.

Electric trucks must not be parked in a coldarea for any longer than necessary. This alsoapplies to unused batteries. The chargingstation and the parking area for trucks andbatteries must be at normal room temperature(not below 10°C). Charging is extremely slowat low temperatures. At temperatures below10°C, the battery cannot be fully charged withthe usual charging parameters.

– Charge the battery fully before each shift.

– During the gassing phase, always top upwith distilled water.

To prevent the distilled water from freezing, itmust be mixed with the battery acid.

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Operation 4Cold store application

Water top-up systems must not be used attemperatures below 0°C, as this could causethe systems and the water present in the hoselines to freeze.

The battery voltage when discharged is thusgenerally lower at low temperatures. Thefinal discharged voltage is reached earlier,meaning the capacity of the battery is lower.

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4 OperationDisplay messages

Display messages

8

9

0

6

7

4

2

1

3

5

7312_003-157

2 3 4

1

Display contentOn the display of the display-operating unit,event-related messages may appear due tocertain truck conditions.

The following types of message may appearindividually or in combination:• A graphic symbol (2)• The message (3)• An error code (4) consisting of a letter and afour-digit number

NOTE

Each time a message appears, the "Malfunc-tion" display (1) also lights up.

Messages are always shown repeatedly andfor a certain period of time, according to theevent.

In the case of successive events, the respec-tivemessages are displayed one after anotheron the display.

After a few seconds, the display will alternatebetween the last shown operating display andthe message.

The frequency of alternation depends on thetype of event.

– If a message appears, follow these operat-ing instructions.

Once the event is remedied, the message willdisappear.

If a malfunction continues to occur, themessage will continue to appear.

– Park the truck safely.

– Inform the authorised service centre.

Error code tableThe table gives an overview of possibledisplays. The "Comment" column containsinformation on how to proceed if any of thesemessages are displayed.

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Operation 4Display messages

Message text (English)/Error code

Comment

OVERHEATINGA5022

Traction motor(s) is/are too hot.1st phase: regulation of acceleration and speed.2nd phase: limitation of phase current in converter (emer-gency driving function is retained).The error automatically disappears as soon as the tempera-ture is below the limit.If the fault occurs frequently, contact your service centre.

OVERHEATINGA5364

Pump converter is too hot.Contact your service centre.

ACCELERATORA3002A3003A3004A3005A3006A3007A3505

Sensor fault, truck cannot be driven.Contact your service centre.

ACCELERATORA3008

Accelerator voltages (for dual pedal) do not match; truckcannot be driven.Contact your service centre.

ACCELERATORA3811

Accelerator configuration is invalid. Truck cannot be driven.Contact your service centre.

BRAKE SENSORA3016A3017

Sensor fault; truck can only be driven at emergency modespeed.Contact your service centre.

CONFIGURATIONA2111A3801A3812

Parameterisation error; drive unit and hydraulic drive notfunctioning.Contact your service centre.

SEAT SWITCHA302

Seat switch has not been actuated for approx. 8 hours.Truck may possibly only permit driving at a reduced speedand with reduced lifting capacity.Stand up briefly and then sit down again.If this does not resolve the problem, contact your servicecentre.

STEERINGA3215A3216A3570

Sensor fault; truck moves at emergency mode speed.Contact your service centre.

DIRECTION SWITCHA3020

Switch error; no or limited drive unit function.Contact your service centre.

LIFTINGA3102A3103

Sensor fault; no or limited hydraulic drive function.Contact your service centre.

56338011803 EN - 02/2018 273



Comment

TILTINGA3107A3108


MAST VERTICALA3130A3131A3132

No hydraulic function.Turn off "lift mast vertical position".Contact your service centre.

MAST VERTICAL ERRORA3135

No hydraulic function.Turn off "lift mast vertical position".Contact your service centre.

EXT1A3112A3113


EXT2A3117A3118


POWER SUPPLYA2242

Transmitter power supply short circuit. Truck cannot bedriven.Contact your service centre.

SURVEILLANCEA2801A2802A2808A2809A2810A2815

Drive unit not functioning.Release accelerator pedal.If this error occurs sporadically, it can be tolerated. If usabilityis impaired, contact your service centre.

SURVEILLANCEA2803A2806

Drive direction is set to neutral.Reselect the drive direction.If this error occurs sporadically, it can be tolerated. If usabilityis impaired, contact your service centre.

SURVEILLANCEA2817

Truck is not ready for operation.Turn the key switch to the zero position and restart.If this error occurs sporadically, it can be tolerated. If usabilityis impaired, contact your service centre.

SURVEILLANCEA2804A2805A2807A2811A2812A2813A2814A2816A2818

No or limited drive unit function.Contact your service centre.

SURVEILLANCEA2295

No or limited function of drive unit and hydraulic drive.Contact your service centre.

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Comment

DRIVEA5031A5041A5046A5301A5331A5361

Temperature sensor fault.Contact your service centre.

BATTERY CHANGERA5910

The support roller for the hydraulic battery carrier is not fullyextended.Contact your service centre.


Hydraulic pump for the hydraulic battery carrier is overheat-ing.Allow the truck to cool down for one hour.


Button errorContact your service centre.


Plausibility error with potentiometer for hydraulic batterycarrier.Contact your service centre.

CONTROL UNITA3305

CIO not functioning.Contact your service centre.

PARKING BRAKE OIL PRES-SUREA3043

Parking brake oil pressure too low; the drive unit is locked.Contact your service centre.

PARKING BRAKE OIL PRES-SUREA3049

Parking brake oil pressure low; truck only moves at emer-gency mode speed.Contact your service centre.

SERVICE REQUIREDS5950

Lithium-ion battery requires servicing.Contact your service centre.

LITHIUM BATTERYS5951

No CAN communication with the lithium-ion battery.Switch off the truck.Check the battery male connector and re-insert.Switch the truck on again.If the fault occurs frequently, contact your service centre.


Lithium-ion battery overtemperature.Allow the truck to cool down.The error automatically disappears as soon as the tempera-ture is below the limit.If the fault occurs frequently, contact your service centre.


Lithium-ion battery temperature too low.Allow the truck to acclimatise.The error automatically disappears as soon as the tempera-ture is above the limit.If the fault occurs frequently, contact your service centre.

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Comment


Lithium-ion battery shock event.Contact your service centre.


Internal error in the lithium-ion battery.Contact your service centre.

.

General messages

NOTE

Some of the following messages are equip-ment-specific and may not appear on thedisplay and operating unit of every truck. Thefollowing messages are therefore intendedonly as a reference.

SERVICE BRAKEmessageIf the message SERVICE BRAKE appearson the display, notify the authorised servicecentre.

– Park the truck securely for checking by theauthorised service centre.

– If multi-disc brakes in the drive wheel unitsare blocked, tow the truck.

APPLY HANDBRAKEmessage

DANGERRisk of fatal injury from being run over if the truckrolls away!Parking the truck without the parking brake appliedis dangerous and is not permitted.– The truck must not be parked on a slope.– Only leave the truck when the parking brake has

been applied.– In emergencies, secure the truck using wedges

on the side facing downhill.

NOTE

The truck is equipped with a negative spring-operated brake. Switching off the truck willblock the multi-disc brakes in the drive wheelunits after a few minutes. However, the truckcan still roll until the drive wheel units are

276 56338011803 EN - 02/2018


blocked. For this reason, the parking brakemust always be applied before you leave thetruck!

If you park the truck without applying theparking brake and then vacate the driver'sseat, the APPLY HANDBRAKEmessage willappear in the display (variant). An optionalsignal tone sounds.


The APPLY HANDBRAKEmessage disap-pears.

If the truck moves even though the parkingbrake is applied:

– Drive the truck onto level ground and park itsafely. Secure it with wedges if necessary.

– Notify the authorised service centre.

BRAKE SENSORmessageIf the BRAKE SENSORmessage appears inthe display, themaximum driving speedwill bereduced. The brake sensor in the brake pedalmust be checked.


CODE DENIEDmessageIf the message CODE DENIED appears onthe display, the driver PIN has been enteredincorrectly three times. The input is thenlocked for five minutes before another attemptcan be made.

– Enter the driver PINagain after fiveminutes.

ACCELERATORmessageIf the ACCELERATORmessage appears onthe display, the truck will remain stationary.The accelerator must be checked.


SWITCHOFF TRUCK?messageIf the message SWITCH OFF THE TRUCK?appears on the display, the switching-off of thetruck is verified.

56338011803 EN - 02/2018 277


– Press the corresponding softkey on thedisplay and operating unit to switch off thetruck or cancel the operation.

PARKING BRAKE ACTIVEmessageIf the electric parking brake is applied, thePARKING BRAKE ACTIVEmessage ap-pears on the display for 5 seconds.

– Release the parking brake to enable drivingmode.

RELEASE PARKING BRAKEmessageIf the message RELEASE PARKING BRAKEappears on the display, driving mode cannotbe enabled until the parking brake has beenreleased by pressing the button.

– Release the parking brake by pressing thebutton.

PARKING BRAKE: APPLY HAND-BRAKE! messageIf the message PARKING BRAKE: APPLYHANDBRAKE! appears on the display, theelectric parking brake is faulty.

– Release the parking brake by pressing thebutton.

LOWER FORKSmessage

DANGERThere is a risk of fatal injury from a falling load orparts of the truck being lowered!Parking the truck with the load lifted is dangerousand is not permitted under any circumstances! Theincreased safety provided by this function must notbe misused in order to take safety risks.– Lower the load fully before leaving the truck.

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7312_003-071_en_V2

The fork is not lowered.

If the fork is above the height sensor, the keyswitch is turned off and the seat vacated,the LOWER FORKS message appears inthe display (variant). An optional signal tonesounds.

– Lower the fork to the ground.

The message LOWER FORKS disappears.

STEERINGmessageIf the STEERINGmessage appears in thedisplay, the truck will only move at emergencymode speed. The steering angle sensor mustbe checked.


TILTING SPEEDmessageIf the message TILTING SPEED appearson the display after the welcome screen, thetilting speed of the lift mast on this truck issignificantly higher than on previous trucks inthis family.

EMERGENCY SWITCHmessage

WARNINGNoelectric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply.– To brake, actuate the service brake.

The truck is equipped with an emergency offswitch. When this switch is actuated, thedriving functions and the functions of theworking hydraulics are blocked.

TheEMERGENCYSWITCHmessageappearsperiodically when the following criteria aremet:• The key switch is set to stage "I"• The emergency off switch is actuated• An operating device is actuated

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? VERTICAL POSITIONIf the message ? VERTICAL POSITIONappears on the display, calibration of the"vertical lift mast position" has been activated.

– Save the mast position or cancel thecalibration.

7312_003-072_en_V3

REFERENCE CYCLEmessageIf the fork was lowered after the truck wasswitched off, the control electronics do notknow the position of the fork when the truckis restarted. The truck will only travel at areduced driving speed. Depending on thepositionof the fork, themessageREFERENCECYCLE (variant)may appear in the display. Toalign the position with the control electronics,the fork must be raised.


The truck will only travel at a reduced drivingspeed. The message REFERENCE CYCLEmay appear in the display.

– Raise the fork.

The message REFERENCE CYCLE goes out,or now appears in the display for the first timeand then goes out.

– To drive again, lower the fork to a maximumof 300 mm above the ground.

The truck can now be driven again with nospeed limitation.

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7325_003-056_en_V2

F1 F2

SAFETY BELTmessage

DANGERRisk of fatal injury in the event of fallingfrom the truck if it tips over!If the truck tips over, the driver is at riskof injury even if a restraint system isused. The risk of injury canbe reducedby using a combination of a restraintsystem and a seat belt. In addition,the seat belt protects against theconsequences of rear-end collisionsand falling off ramps.– We recommend that you always

use the seat belt.

This device (variant) ensures that if theseat belt is not being used or is being usedincorrectly, the truck will only drive slowly or(optionally) will not drive at all.

Depending on the configuration selected, theworking hydraulics functions (lifting/tilting) areeither available as normal, slowed down or notavailable at all.

The SAFETY BELTmessage with the restric-ted driving and lifting functions is triggered bythe following circumstances:• Seat belt not worn and driver's seat occu-pied

• The seat belt is constantly fastened but thedriver's seat is only occupied afterwards

• The seat belt is not fastened until after thekey switch has been switched on

• The seat belt is unfastened while driving

– If the SAFETY BELTmessage appears,fasten the seat belt in accordance with theregulations.

The truck can again be operated withoutrestrictions.

If the seat belt is released while driving, thetruck will be limited to low driving speeds or willbe braked to a halt.

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DANGERRisk of accident!– The speed must be adjusted to suit the driving

situation!The increased safety provided by this functionmustnot be misused in order to take safety risks.

ARE YOU SURE ?messageIf the message ARE YOU SURE ? appears onthe display, a prior prompt is verified.

– Press the corresponding softkey on thedisplay and operating unit to continue or tocancel the operation.

SEAT SWITCHmessageThe truck is equipped with a seat switch.

If the SEAT SWITCHmessage appears, thedriving functions and the working hydraulicsare blocked.

The SEAT SWITCHmessage is triggered bythe following situations:• The seat switch is not actuated while theaccelerator pedal or steering wheel isactuated

• The seat switch is not actuated while theoperating device for the working hydraulicsis actuated

• The shift time has been exceeded• The operating time has been exceeded

NOTE

The operating devices shown in the followingillustrations are only examples and may differfrom the equipment in your truck.

282 56338011803 EN - 02/2018


7312_003-066_en_V2

The seat switch is not actuated while the ac-celerator pedal or steering wheel is actuated

The accelerator pedal or the steering wheel isactuated, even though no one is sitting in thedriver's seat. The message SEAT SWITCHappears on the display. The truck will notmove.

– Sit in the driver's seat and fasten the seatbelt.

The truck can be driven again without restric-tions.

7325_003-054_en_V2

F1 F2

The seat switch is not actuated while theoperating device for the working hydraulicsis actuated

An operating device for the working hydraulicsis actuated, even though no one is sittingin the driver's seat. The message SEATSWITCH appears on the display. The workinghydraulics functions cannot be executed.

– Sit in the driver's seat and fasten the seatbelt.

The working hydraulics can be operatedagain.

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7325_003-054_en_V2

F1 F2

The shift time has been exceeded

NOTE

The shift time is adjustable.

If the key switch is switched on and the driverdoes not leave the seat before the set shifttime is exceeded, SEAT SWITCH appearson the display. This is also the case if anoperating device for the working hydraulics orthe accelerator pedal is actuated. Dependingon the configuration, the working hydraulicfunctions can be executed normally, onlyslowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


7325_003-055_en_V3

F1 F2

The operating time has been exceeded

NOTE

The operating time is adjustable.

If the key switch is switched on, the parkingbrake is released and the driver does notleave the seat before the set operating time isexceeded, and if neither the operating devicesfor the working hydraulics nor the acceleratorpedal are actuated during this time, SEATSWITCHappears on the display. The truckwillnotmove. Depending on the configuration, theworking hydraulic functions can be executednormally, only slowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


OVERHEATINGmessageIf the message OVERHEATING appearson the display, the traction motors haveoverheated. The acceleration and the speedof the truck are reduced.

– Allow the truck to cool down.

– If the error persists, contact your authorisedservice centre.

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SURVEILLANCEmessageIf the SURVEILLANCE message appearsin the display, there is a fault in the processmonitoring.

This shuts off the drive unit.

– Switch the key switch to the "0" position andthen back to the "I" position.

– Start the engine.

– Release accelerator pedal.

– Select the drive direction again.

NOTE

If this error occurs sporadically, it can be tole-rated. If the operational capacity is impaired,notify your authorised service centre.

NOT VALID messageIf the message NOT VALID appears on thedisplay, an incorrect driver PIN has beenentered when entering the access code.

– Once the message goes out, enter thedriver PIN again.

Drive-specific messages

Message ! PARKING BRAKE OILPRESSUREIf the followingmessageappears in the displaywhen the accelerator pedal is actuated:! PARKING BRAKE OIL PRESSURE, theservice brake of the truck is not ready for use.

The driving speed is limited to 5 km/h.

When the service brake is ready for operation,themessagedisappears. The speed limitationis cancelled.

MOT/GEN.-TEMP. messageIf the MOT/GEN.-TEMP.message appears,the traction motor or the generator is over-heated or a cable is broken.

56338011803 EN - 02/2018 285


– Interrupt work and allow the truck to cooldown. Do not switch off the key switch.

NOTE

If the operational capacity is impaired, notifyyour authorised service centre.

OVERHEATINGmessageIf the message OVERHEATING appearsin the display, the traction motors haveoverheated. The acceleration and the speedof the truck are reduced.

– Allow the truck to cool down.

– If the error persists, contact your authorisedservice centre.

CLOSE THE DOORmessageIf the message CLOSE THE DOOR (variant)appears in the display, the battery door is notshut correctly. The truck will not move.

– Close the battery door.

LIFT HEIGHTmessageSpeed limitation with a raised load (variant)

This function makes sure that the truck canonly move slowly when a load is lifted.

DANGERRisk of accident!Before using this function, familiarise yourself withthe altered driving characteristics of the truck!Optionally, the truck can have altered accelerationbehaviour and/or braking characteristics.

DANGERRisk of accident!Driving with a lifted load is prohibited, because thetruck can overturn due to the high centre of gravity.Because the limits determined by physics cannotbe altered, the increased safety provided by thisfunction must not bemisused in order to take safetyrisks.

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If the fork is raised above a certain height, thefollowing happens:

6210_003-054-en_V3

Lifting the load at a standstill

The key switch is switched on. The driver sitson the seat with the belt fastened. The load islifted. The display briefly shows the flashingmessage LIFT HEIGHT. The truck will onlytravel at a reduced driving speed.

– Lower the fork (load) to just above theground.


6210_003-055_en_V3

Lifting the load while driving

If you are travelling with the load during astacking/unstacking operation and lift the loadwhile travelling, the flashing message LIFTHEIGHT appears briefly in the display. Thetruck will travel slowly or will be braked.

– Lower the fork (load) to just above theground.


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4 OperationProcedure in emergencies

Procedure in emergencies

6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

2

5060_003-054

Emergency shutdown

WARNINGNo electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply. The truck will notbe held on a slope by the electric brake.– To brake, actuate the service brake.

CAUTIONActuating the emergency off switch (1) or discon-necting the battery male connector (2) shuts downthe electrical functions of the truck.– Only use this safety system in the event of an

emergency.

CAUTIONRisk of component damage!If you disconnect the battery male connector whilethe key switch is switched on (under load), an arcwill be produced. This can lead to erosion at thecontacts, which considerably shortens their servicelife.– Switch off the key switch before disconnecting

the battery male connector.– Do not disconnect the battery male connector

while the key switch is switched on, except in anemergency.

In an emergency, all functions of the truck canbe shut down:

– Press the emergency off switch (1) ordisconnect the battery male connector (2).

Pressing the emergency off switch has thefollowing effect in drive mode:• No reduction in truck speed when theaccelerator pedal is released, accordingto the drive program selected. The truck willcoast

• In trucks with an electric parking brake(variant), the electric parking brake isapplied as soon as the truck comes to astop

• The electric brake does not function duringthe first part of brake pedal travel. To brake

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Operation 4Procedure in emergencies

the truck using the mechanical brake, thebrake pedal must be pushed down further

• The truck can only be held on a slope usingthemechanical brake, not the electric brake

• No power steering effect; the steeringforces are increased by the remainingemergency steering function

• The "Curve Speed Control" system (auto-matic reduction in truck speed when cor-nering) does not function The truck must bedecelerated with the mechanical brake bypressing the brake pedal

• No hydraulic functions are available

7090_001-005

Procedure if truck tips over

DANGERIf the truck tips over, the driver could fall out andslide under the truck with potentially fatal conse-quences. There is a risk to life.Failure to comply with the limits specified in theseoperating instructions, e.g. driving on unacceptablysteep gradients or failing to adjust speed whencornering, can cause the truck to tip over. If thetruck starts to tip over, do not leave the truck underany circumstances. This increases the danger ofbeing hit by the truck.– Do not release your seat belt.– Never jump off the truck.– You must adhere to the rules of behaviour if the

truck tips over.

Rules of behaviour if truck tips over:

– Hold onto the steering wheel with yourhands.

– Brace your feet in the footwell.

– Bend your upper body over the steeringwheel.

– Bend your body against the direction of thefall.

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6321_003-097_V3

1

Emergency hammerThe emergency hammer is used to rescue thedriver if he is shut inside the cab in a hazardoussituation, for example if the truck has toppledover and the cab door cannot be opened.

Single-pane safety glass can be struck rela-tively safely using the emergency hammer inorder for the driver to escape or be rescuedfrom the danger area.

Using the emergency hammer

WARNINGWhen glass is smashed there is a risk of injurycaused by glass splinters!When the cab glass is smashed, splinters of glasscan shoot into the face and cause damage to skinand eyes through cuts. When a pane of glass issmashed, the face should be turned away andcovered with the crook of the free arm.– Protect the face when smashing a pane of glass.

– Pull the emergency hammer out of itssupport mounting at the handle.

– Using one of the two metal tips on the headof the emergency hammer, hit the pane ofglass with force until it breaks.

Emergency loweringIf the hydraulic controller fails whilst a loadis raised, emergency lowering can be per-formed. An emergency lowering screw for thispurpose is located on the valve block.

DANGERThere is a risk of fatal injury fromfalling loads or parts of the truck beinglowered.– Do not walk beneath the raised

load.– Adhere to the following steps.

– Remove the valve cover.

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6210_003-108_V2

1– Remove the hexagon socket wrench (1)from the compartment on the right next tothe driver's seat.

NOTE

In this procedure, a distinction is made be-tween the types of operating devices.

6210_003-100_V2

2

4

3

5

A

B

A Joystick 4Plus version and mini-leverversion:

B Multiple-lever version

For the Joystick 4Plus version and the mini-lever version (A):

– Using the hexagon socket wrench, turn theemergency lowering screw (2) on the valveblock (5) a maximum of 1.5 revolutions toloosen it.

For the multiple-lever version (B):

– Using the hexagon socket wrench (1),turn the emergency lowering screw (4)on the valve block (3) a maximum of 1.5revolutions to loosen it.

WARNINGThe load is lowered!The lowering speed is regulated by unscrewing theemergency lowering screw.– Note the following list.

For both versions:• Tightening torque:max. 2.5 Nm

• When unscrewed a little:The load lowers slowly

• When unscrewed a lot:The load lowers quickly

After lowering:

– Screw the emergency lowering screw forthe load back in.

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– Return the hexagon socket wrench to thesupport mounting in the compartment.

– Install the valve cover.

DANGERIf the truck is operated with the hydraulic controllerblocked, there is an increased risk of accidents!– After the emergency lowering procedure, have

the malfunction rectified.– Notify the authorised service centre.

3

6210_003-051_V3

Emergency operation of the electricparking brake

WARNINGThe truck can roll away when the parking brake isreleased!Emergency operation of the parking brake can beinitiated only when the fork is lowered and the truckis switched off.

In emergency operation or during transportwithout a battery, the electric parking brakecan be operated manually via the hand wheel.

– Lower the forks to the ground.


– Lift cover (3) and move it to the side.

6210_003-053_V2

4

– Remove hand wheel (4) and place upsidedown on the tappet.

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656210_003-052_V3

5551

4391

001

1.2.

– Place the hand wheel with the tappet lugs(5) on the tappet (6) and press down againstthe spring force.

NOTE

Do not rotate the hand wheel to the stop,because this will trigger the relubricationdevice.

– To apply the parking brake rotate the handwheel clockwise until the force neededincreases markedly and the truck is heldsecurely. The effort required is not great.

– To release the parking brake rotate thehand wheel anticlockwise a maximum of5 revolutions until the hand wheel can beturned easily.

After manual operation, the hand wheel is tobe returned to its latch position and the coverto its normal position.

6036Ba-0265060_003-070

Towing

DANGERThe brake system on the towing vehicle may fail.There is a risk of accident!If the brake system of the towing vehicle is notadequately sized, the vehicle may not brake safelyor the brakes may fail. The towing vehicle must beable to absorb the pulling and braking forces fromthe unbraked towed load (total actual weight of thetruck).– Check the pulling and braking forces of the

towing vehicle.

DANGERThe truck could drive into the towing vehicle whenthe towing vehicle brakes. There is a risk of acci-dent!If a rigid connection has not been used for powertransmission in two directions during towing, thetruck may drive into the towing vehicle when thetowing vehicle brakes. For safety reasons, only atested tow bar may be used.– Use a tested tow bar.

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CAUTIONIf the drive of the truck between the drive motor andthe drive axle is not interrupted, the drive may bedamaged.– Place the drive direction switch in the neutral

position.

CAUTIONRisk of component damage!If you remove the battery male connector with thekey switch switched on (under load), an arc willbe produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Do not disconnect the battery male connector

while the key switch is switched on.

DANGERPeople can be crushed between the truck andtowing vehicle during manoeuvring. There isdanger of death!The towing vehicle may only be manoeuvred andthe tow bar may only be attached using a secondperson as a guide. This ensures that the driver ofthe towing vehicle and the mechanic attaching thetow bar are aware of possible risks.– Only manoeuvre with a guide.

CAUTIONSteering is stiff! There is no power steering if thehydraulics fail!– The selected towing speed must allow the truck

and towing vehicle to be effectively braked andcontrolled at all times.

CAUTIONIf the truck is not steered while it is being towed, itmay veer out in an uncontrolled manner!– The truck being towedmust also be steered by a

driver.– The driver of the truck being towed must sit in

the driver's seat and fasten the seat belt beforetowing.

– Where possible, activate the restraint systemsprovided.

– Set down load and lower fork arms close tothe ground.

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– Place the drive direction switch in theneutral position.



– Disconnect the battery male connector.

– Check the pulling and braking forces of thetowing vehicle.

– With the help of a guide, attach the towingvehicle to the truck.

– Secure the tow bar to the tow coupling of thetowing vehicle and the truck.

– Sit in the driver's seat in the truck to betowed, and fasten the safety belt.

– Where possible, activate the restraintsystems provided.


– Select a towing speed that allows the truckand towing vehicle to be effectively brakedand controlled at all times.

– Tow the truck.

– After towing, secure the truck from rollingaway (e.g. by applying the parking brake orusing chocks).

– Remove the tow bar.

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4 OperationConnecting and disconnecting the battery male connector

Connecting and disconnecting the battery male connector

6327_600-001_V4

1

Connecting the batterymale connec-tor– Open the battery cover.

CAUTIONComponent damage possible!If you connect the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can cause the contacts to weld,which considerably shortens their service life.– Do not connect battery male connector with key

switch switched on.– Make sure that the key switch is switched off

before connecting the battery male connector.

– Insert the battery male connector (1) fullyinto the plug connection on the truck.

CAUTIONThere is a risk of short circuit if thecables are damaged.The battery cablemust not be crushedwhen closing the battery cover.– Make sure that the battery cable

does not collide with the batterycover.

– Close the battery cover.

Disconnecting the battery maleconnector

CAUTIONRisk of component damage!If you remove the battery male connector when thekey switch is switched on (under load), an arcwill beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Switch off the key switch before the battery male

connector is disconnected.– Only disconnect the battery male connector with

the key switch switched on in an emergency.

– Open the battery cover.

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Operation 4Connecting and disconnecting the battery male connector

1

5060_003-051

– Disconnect the battery male connector (1)by pulling in the direction of the arrow at theplug connection.

– Place the battery male connector on thebattery.

CAUTIONThere is a risk of short circuit if thecables are damaged.Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing the batterycover.– Check the connecting cable for

damage.– Ensure that the battery cable does

not come into contact with thebattery cover.


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4 OperationHandling the lead-acid battery

Handling the lead-acid batterySafety regulations when handlingthe battery– National statutory provisions for the countryof usemust be followedwhen setting up andoperating battery charging stations.

CAUTIONRisk of component damage!Incorrect connection or operation ofthe charging station or battery chargermay result in damage to components.– Follow the operating instructions

for the charging station or batterycharger and for the battery.

– The following safety regulations must beobserved when maintaining, charging andchanging the battery.

Maintenance personnelBatteries may be charged, maintained orchanged only by properly trained personnelin accordance with the instructions of themanufacturer of the battery, battery charger ortruck.

– The handling instructions for the battery andthe operating instructions for the batterycharger must be followed.

WARNINGRisk of crushing/shearing!The battery is very heavy. There is arisk of serious injury if any parts of thebody are caught under the battery.If parts of the body are wedgedbetween the battery cover and theedge of the chassis when the batterycover is closed, this could lead toinjuries.– Always wear safety shoes when

replacing the battery.– Only close the battery cover if there

is no part of the body between thebattery cover and the edge of thechassis.

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Operation 4Handling the lead-acid battery

The battery must only be replaced in accor-dance with the directions in these operatinginstructions.

– When charging andmaintaining the battery,observe the manufacturer's maintenanceinstructions for the battery and batterycharger.

Fire protection measures

DANGERRisk of explosion due to flammablegases!During charging, the battery releasesa mixture of oxygen and hydrogen(oxyhydrogen gas). This gas mixtureis explosive andmust not be ignited.Theremust be no flammablematerialsor spark-forming operating materialswithin 2 m of either the truck when itis parked for charging or the batterycharger.– When working with batteries, take

the following security precautions.

– Keep away from open flames and do notsmoke.

– Ensure that work areas are adequatelyventilated.

– Disconnect the battery male connectorbefore charging and only when the truckand battery charger are switched off.

– The battery cover must remain open duringcharging.

– Expose the surfaces of the battery cells.

– Do not place any metal objects on thebattery.

– Open any protective structures fully (e.g.fabric-covered cab).

– Have fire extinguishing equipment ready.

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Battery weight and dimensions

DANGERRisk of tipping due to change in battery weight!The battery weight and dimensions affect the sta-bility of the truck. When replacing the battery, theweight ratios must not be changed. The batteryweight must remain within the weight range speci-fied on the nameplate.– Do not remove or change the position of ballast

weights.– Note the battery weight.

Maintaining the batteryThe cell covers of the battery must be kept dryand clean.

Terminals and cable shoes must be clean,lightly coated with battery grease and tightlyscrewed.

– Neutralise any spilt battery acid immedi-ately.

– Observe the safety regulations for handlingbattery acid; see the chapter entitled"Battery acid".

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6210_600-001

Damage to cables and battery maleconnectors

CAUTIONThere is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.– Check the battery cable for da-

mage.– When removing and reinstalling

the battery, ensure that the batterycables are not damaged.

– Ensure that the battery cable doesnot come into contact with thebattery cover.

CAUTIONPotential for damage to themale battery connector!If the battery male connector is disconnectedor connected while the key switch is switchedon or the battery charger is under load, an arcwill be produced at the battery male connector.This can lead to erosion at the contacts, and canconsiderably shorten the service life of the contacts.– Switch off the key switch or battery charger be-

fore the battery male connector is disconnectedor connected.

– Do not disconnect the battery male connectorwhile under load, except in an emergency.

Maintaining the battery

DANGERRisk to life!– Observe the chapter "Safety regulations for

handling the battery".

WARNINGBattery acid is toxic and corrosive!– Observe the safety regulations in the "Battery

acid" chapter.

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer's opera-

56338011803 EN - 02/2018 301


ting instructions! The operating instructionsfor the battery charger must also be followed.Only the instructions that camewith the batterycharger are valid. If any of these instructionsare not available, please request them fromthe dealer.

The battery maintenance is composed of thefollowing sections "Checking the battery con-dition, acid level and acid density", "Checkingthe battery charge status", "Charging the bat-tery" and "Equalising charge to prevent a deepdischarge of the battery" together.

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Checking the battery condition, acidlevel and acid density

WARNINGThe electrolyte (dilute sulphuric acid)is poisonous and caustic!– Observe safety regulations for

handling battery acid; see chapter"Battery acid".

– Wear personal protective equip-ment (rubber gloves, apron andprotection goggles).

– Rinse away spilt battery acidimmediately with plenty of water!

CAUTIONRisk of damage!– Heed the information in the operating instructi-

ons for the battery.

– Remove the battery from the truck.

– Inspect battery for cracked housing, raisedplate sand acid leaks.

– Have defective batteries repaired by theauthorised service centre.

6321_003-126

1

2

– Open filler cap (1) and check the acid level.

For batteries with "caged cell plugs", the liquidmust reach the bottom of the cage.

For batteries without "caged cell plugs", theliquid must reach a height of approx. 10 to 15mm above the lead plates.

– Topupmissing fluidwith distilledwater only.

– Clean the battery cell cover and dry ifnecessary.

– Remove any oxidation residues on thebattery terminals and then apply acid-freegrease to the terminals.

– Tighten the battery-terminal clips (2) to atorque of 22–25 Nm (depending on the sizeof the terminal screws used).

– Check acid density with an acid siphon.

After charging, the acid density must bebetween 1.28 and 1.30 kg/l.

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For a discharged battery, the acid densitymust be no lower than 1.14 kg/l.

6311_003-011_V2

1Checking the battery charge status

CAUTIONDeep discharges shorten the service life of thebattery.If no bar is shown in the battery charge display (1)(0% of the available battery capacity, i.e. around20% of the nominal capacity), deep dischargebegins.– Avoid deep discharges (no bar on the display)

(see the section entitled "Equalising charge toprevent a deep discharge of the battery").

– Cease work with the truck immediately.– Charge the batteries immediately.– Do not leave batteries in a discharged or partly

discharged state.



– Read the charge state (1) from the display.

– Charge a discharged or partly dischargedbattery.

NOTE

The battery charge display shows the avai-lable battery capacity as a segmented bargraph in 10% increments. Approx. every 10seconds, the display switches between thebattery charge and the remaining period.

Charging the battery

DANGERDanger to life and limb!– Observe the instructions in the chapter entitled

"Safety regulations when handling the battery".

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WARNINGBattery acid is toxic and corrosive!– Observe the safety regulations in the chapter

entitled "Battery acid".

CAUTIONRisk of component damage!Incorrect connection or operation ofthe charging station or battery chargermay result in damage to components!– Follow the operating instructions

for the charging station or batterycharger and for the battery.

CAUTIONPossibility of damaging the battery male connec-tors!Ensure that the key switch or battery charger isswitched off before the battery male connectors aredisconnected or connected.

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer's opera-ting instructions! The operating instructionsfor the battery charger must also be followed.Only the instructions that camewith the batterycharger are valid. If any of these instructionsare missing, please request them from thedealer.

To read the battery charging state, see thesection entitled "Checking the battery chargestatus".

– Park the truck securely.

– Open any protective structures fully (e.g.fabric-covered cab).

– Open battery cover completely.

– Do not place any metal objects or tools onthe battery.

– Keep away from open flames and do notsmoke.

– Check the battery cable and the chargingcable for damage, and have them replaced

56338011803 EN - 02/2018 305


by the authorised service centre if neces-sary.

6327_003-036_V2

2

– Disconnect the battery male connector (2)by pulling the handle.

DANGERExplosive gases are generated duringcharging!– Ensure that work areas are

adequately ventilated.– For trucks with a cab (including

fabric-covered cabs), ensureadequate ventilation in the cab(variant).

6321_003-127

3

– Attach the battery male connector (3) to thebattery charger connector.

NOTE

Follow the information in the operating instruc-tions for your battery and the battery charger(equalising charge).

– Start the battery charger.

– The ventilation gaps between the cover andchassis must not be blocked.

DANGERRisk of explosion!The battery cover must be kept openduring charging to ensure adequateventilation.

After charging

– Switch off the battery charger.

– Disconnect the batterymale connector fromthe battery charger plug.

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6327_600-001_V4

1

– Insert the battery male connector (1) fullyinto the plug connection on the truck.

CAUTIONThere is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable does


6210_600-001

– Close the battery cover completely. Whendoing so, ensure that no cables are crushedbetween the chassis and the cover.

The battery cover must be locked, otherwisethe CLOSE THE DOOR error message willappear in the display and the truck will notdrive.

Charging the battery with the batterycharging flap

DANGERRisk of explosion!– Observe the safety regulations when handling

the battery; see chapter "Safety regulationswhen handling the battery".

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer's opera-

56338011803 EN - 02/2018 307


ting instructions! The operating instructionsfor the battery charger must also be followed.Only the instructions that camewith the batterycharger are valid. If any of these instructionsare not available, please request them fromthe dealer.

6321_003-103

1

2

Battery charging flap (variant)– Park the truck securely.

– Press the release buttons (1).

The release buttons pop out.

– Turn the release buttons (1).

The release buttons unlock the battery charg-ing flap (2).

– Open the battery charging flap (2) com-pletely.




308 56338011803 EN - 02/2018


6321_003-101_V3

3

– Disconnect the battery male connector (3)from the truck.

DANGERExplosive gases are generated duringcharging!– Always ensure adequate ventila-

tion in the vicinity.– Ensure adequate ventilation in the

cab (variant) for trucks with a cab(including fabric-covered cabs).

DANGERThere is a risk of damage, short circuiting andexplosions!– Do not place any metallic objects or tools on the

battery.– Keep away from open flames and do not smoke.

WARNINGThe electrolyte (dilute sulphuric acid) is poisonousand caustic!– Observe safety regulations for handling battery

acid; see chapter "Battery acid".– Rinse away spilt battery acid immediately with

plenty of water!

– Before charging, check the battery cableand the charging cable for damage, andhave the cables replaced by the authorisedservice centre if necessary.

CAUTIONRisk of component damage!If you connect the charging cable while the batterycharger is switched on (under load), an arc will beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Switch off the battery charger before the char-

ging cable is connected.

56338011803 EN - 02/2018 309


6321_003-105

4

3

– Connect the battery male connector (3) tothe battery charger plug (4).


NOTE

Follow the information in the operating instruc-tions for your battery and the battery charger(equalising charge).

DANGERRisk of explosion!The battery charging flap must bekept open during charging to ensureadequate ventilation.

– The ventilation gaps between the cover andchassis must not be blocked.

Upon completion of charging:

– Turn off the battery charger.

CAUTIONRisk of component damage!If you disconnect the charging cable while the bat-tery charger is switched on, an arc will be produced.This can lead to erosion at the contacts, which con-siderably shortens their service life.– Switch off the battery charger before the char-

ging cable is disconnected.

WARNINGRisk of explosion!The plug may only be disconnectedfrom the socket when the truck andbattery charger are switched off.


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6321_003-101_V3

3

– Reattach the battery male connector (3) tothe plug on the truck.

CAUTIONThere is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable does


6210_600-001

– Close the battery cover completely. Whendoing so, ensure that no cable is crushedbetween the chassis and the cover.

Equalising charge to prevent a deepdischarge of the batteryLead-acid batteries must be charged at leastonce per week for equalisation purposes. Thisis to ensure that all battery cells are evenlycharged. This prevents a deep discharge ofthe battery and extends its life span.

NOTE

Dependent on the battery charger used, theequalising charge might not begin until 24hours have elapsed. Therefore, a periodwhen

56338011803 EN - 02/2018 311


no shifts are running, such as the weekend, isideal for performing the equalising charge.

– Observe the information in the operatinginstructions of the charger regarding how toperform an equalising charge.

Starting the equalising charge– Charge the battery.

– After charging, leave the battery in thecharger.

The battery charger remains switched on.Depending on the battery charger used, theequalising charge starts after between 6 and24 hours. The equalising charge takes up to2 hours.

– Please refer to the operating instruc-tions from the manufacturer of the batterycharger.

Ending the equalising chargeThe equalising charge ends automatically.If the battery is required during this process,you can interrupt the equalising charge bypressing the "stop button" on the batterycharger.

– Please refer to the operating instruc-tions from the manufacturer of the batterycharger.

CAUTIONRisk of component damage!If the plug for the battery charger is disconnectedfrom the battery male connector while the batterycharger is switched on, an arc is produced. This canlead to erosion at the contacts, which considerablyshortens their service life.– Switch off the battery charger before disconnec-

ting the charging cable.

– Switch off the battery charger.


– Insert the battery male connector fully intothe plug connection on the truck.

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Operation 4Handling the lithium-ion battery

Handling the lithium-ion batterySafety regulations for handling thelithium-ion battery

First-aid measures

WARNINGRisk of injury!Escaping gases can lead to breathing difficulties.

Course of action required if gases or liquidsescape

– Immediately ventilate the area or go out intothe fresh air; in more serious cases, call adoctor immediately.

Skin irritation can occur in the event of contactwith the skin.

– Thoroughly wash the skin with soap andwater.

Eye irritation can occur in the event of contactwith the eyes.

– Immediately rinse eyes thoroughly withwater for 15 minutes, then consult a doctor.

Maintenance personnelThe lithium-ion battery is virtually mainte-nance-free and can be charged by the driver.


– Follow the handling instructions for thebattery and the operating instructions forthe battery charger.

– Observe the following safety regulationswhen maintaining, charging and changingthe battery.

56338011803 EN - 02/2018 313

4 OperationHandling the lithium-ion battery

WARNINGRisk of crushing/shearing!The battery is very heavy. There is arisk of serious injury if any parts of thebody are caught under the battery.If parts of the body are wedgedbetween the battery door and the edgeof the chassis when the battery door isclosed, this could lead to injuries.– Always wear safety shoes when

replacing the battery.– Only close the battery door if there

is no part of the body between thebattery door and the edge of thechassis.

The battery must only be replaced in accor-dance with the directions in these operatinginstructions.

– When charging andmaintaining the battery,observe the manufacturer's maintenanceinstructions for the battery and batterycharger.

Fire protection measures

DANGERThere is a risk of damage, short circuiting andexplosion!– Do not place any metal objects or tools on the

battery.– Keepaway fromnaked flamesanddonot smoke.

DANGERIncreased risk of fire!Damaged lithium-ion batteries posean increased fire hazard.In the event of a fire, large quantitiesof water are the best option to cool thebattery.

– Extinguish the fire yourself using sand or aclass "D" metal-fire extinguishing powder.

– A safety zone of 5 m must be establishedaround a burning battery.

– Evacuate the location of the fire as quicklyas possible.

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– Ventilate the location of the fire well, asthe resulting combustion gases can causedamage to health if inhaled.

– Inform the fire brigade that lithium-ionbatteries are affected by the fire.

– Observe the information provided bythe battery manufacturer regarding theprocedure in the event of a fire.

Battery weight and dimensions

DANGERRisk of tipping due to change in battery weight!The battery weight and dimensions affect the sta-bility of the truck. When replacing the battery, theweight ratios must not be changed. The batteryweight must remain within the weight range speci-fied on the nameplate.

– Do not remove or change the position ofballast weights.

– Observe the battery weight.

General safety regulations for lithium-ionbatteriesThe following safety regulations generallyapply to operating lithium-ion batteries.

– Comply with the specifications statedin the safety data sheets of the batterymanufacturer.

– Protect the battery against mechanicaldamage to prevent internal short circuits.

– If batteries have the slightest externaldamage, dispose of them in accordancewith national regulations for the country inwhich they are being used.

– Do not expose batteries directly to contin-uously high temperatures or heat sources,such as direct sunlight.

– Train employees in how to handle lithium-ion batteries correctly.

– Place class "D" fire extinguishers in theareas in which trucks fitted with lithium-ionbatteries are operated.

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Lithium-ion batteries "GGS Li-ion 80 V"24.1 kWh and 60 kWh

6301_003-023

1 Battery male connector2 Lifting eyes3 Display

4 Technology compartment5 Safety valve6 Diagnostic connector

WARNINGRisk of accident due to weakened lifting eyes.If bent lifting eyes are straightened, they lose theirrigidity. The lifting eyes are then no longer able tosupport the weight of the battery. The battery mayfall.– Do not straighten bent lifting eyes.– Have bent lifting eyes replaced by the authorised

service centre.

NOTE

When switching to lithium-ion batteries,have the truck electronics adapted by theauthorised service centre.

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Display messages on the display-operating unit

The following table describes the messages that appear on the display-operating unit for thelithium-ion battery:

Message Meaning Remedy/reaction

LITHIUM BATTERYTEMPERATURE

The battery temperatureis lower than −15°C orhigher than 60°C.If the temperaturerises above 60°C, thetemperature LED flashesin the battery display.If the temperaturerises above 65°C, thetemperature LED lights upin the battery display andthe truck switches off.

Temperature < −15°C:allow the truck toacclimatise in a warmerarea.Temperature > 60°C:allow the truck to cooldown.

LITHIUM BATTERYRESTRICTION

The truck performance isgradually reduced.The truck goes intoemergency operation.

Switch off the truck andthen switch it on again.If the error occursfrequently, notify yourauthorised service centre.

LITHIUM BATTERYERROR

The battery has an errorand reports it to the truckcontrol unit.The truck switches offafter five seconds androlls to a stop. Withinthis five-second period,the truck slows downaccording to the selectedgear.The service LED lights upin the battery display.

Notify the authorisedservice centre.

.

Regulations for storing lithium-ionbatteries

NOTE

Lithium-ion batteries are classified as danger-ous goods according to class 9.

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The following recommendations apply:• Store batteries at a height between 60 cmand 120 cm so that they are not damaged ifthey fall

• Store the batteries in a segregated areasuitable for fire protection (container orsafety cabinet)

• Store the batteries at a temperature be-tween +15°C and +30°C and air humidityfrom 0% to 80%

Observe the following regulations for safestorage of the batteries:

– Store batteries fixed onto pallets andsecured against overturning.

– Observe the floor load capacity of thestorage area; refer to the manufacturer'sspecifications regarding battery weight

– To protect batteries against moisture, donot store them directly on the floor

– Due to the fire risk, store batteries outsidebuildings

– Store in a cool, dry and well-ventilated area

– Never subject the battery to temperaturesbelow -35°C and above 80°C.

Long-term storage below -10°Cor above 50°Chas a negative impact on the service life of thebattery.

– After twelve months, check the chargingstate of the battery and recharge if neces-sary

– Cordon off the warehouse area

– Only persons who are aware of the risksand safety regulationsmay access this area

– Protect against direct sunlight

– Protect against precipitation

– Store in a way that protects the batteriesagainst short circuits

– Store batteries at a safe distance fromflammable materials

– Do not store batteries together with metallicobjects

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– Store lithium-ion batteries separately fromother types of batteries (no mixed storage).

– Maintain a safety margin of at least 2.5 m toother goods

– To avoid a deep discharge, observe thespecifications of the battery manufacturerregarding the maximum permissible stor-age period


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Checking the battery charge statusThe charge state of the lithium-ion batterycan be read on the display-operating unit ofthe truck and on the display of the lithium-ionbattery.

6311_003-011_V2

1Reading the display operating unit– Apply the parking brake.


– Read the charge state (1) from the display.

– Charge a discharged or partly dischargedbattery.

NOTE

The battery charge display shows the avai-lable battery capacity as a segmented bargraph in 10% increments. Approx. every 10seconds, the display switches between thebattery charge and the remaining period.

Meaning of the bar graph on the display• The remaining two bars flash:The charge state is < 30%.The battery must be recharged soon.

• No bars are displayed:The charge state is < 15 %.Charge the battery.The "Lifting" hydraulic function is sloweddown.The maximum driving speed is limited. Thisspeed can be parameterised individually bythe authorised service centre.

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6209_003-002

1

23

1 Service LED (red)2 Temperature LED (yellow/red)3 Charging state LEDs (red/green)

Reading from the battery indicatorThe battery indicator is located at the side ofthe battery tray. Like the display-operatingunit, the battery indicator shows the chargestate of the lithium-ion battery. Warnings areissued only on this battery indicator.


Charging state LEDs

When the battery is connected to the truckand the truck is switched on, the charge stateLEDs (3) display the charge state in 10%increments. The charge state LEDs can lightup in green and red.• A charge state of 0% to 20% is indicated bya red bar.If this bar flashes, the charge state is < 2%.The truck can no longer be moved.

• A charge state of > 20% to 30% is indicatedby yellow bars.

• A charge state of > 30% to 100% is indicatedby green bars

When charging, the charging state LEDs (3)light up green as a chase light.

Service LEDThe service LED (1) lights up red if the batteryfunction is significantly restricted or operationis not possible.

– Contact the authorised service centre.

Temperature LEDThe temperature LED (2) indicates an in-creased temperature. The power of the bat-tery is reduced. The LED is illuminated un-til the temperature falls to within the normalrange. The LED goes out as soon as the tem-perature drops into the normal range.

56338011803 EN - 02/2018 321


LEDcolour Cause Consequence

Flash-ingyellow

Slightlyincreasedtemperature(> 60°C)

Power reduction

Solidyellow

Increasedtemperature(> 65°C)

Shut-off

Flash-ing red

Greatlyincreasedtemperature(> 70°C)

Shut-off

Solidred

Greatlyincreasedtemperature(> 75°C)

Shut-off

.

Procedure if a lithium-ion battery has alow charge stateTo prevent deep discharge of the lithium-ionbattery, performance limitations are imposedonce the charge state of the battery is ≤ 10%.

– If the charge state drops below15%, drive tothe charging station and charge the battery.

WARNINGNo electric brake assistance when the battery isswitched off!The drives are de-energised when the battery isautomatically switched off.The truck will not be held on a slope by the electricbrake.– To brake, actuate the service brake.

– If the battery switches off, tow the truck tothe charging station.

– Charge the battery.

322 56338011803 EN - 02/2018


Charging the battery

CAUTIONRisk of component damage!Incorrect connection or incorrect operation of thecharging station or battery charger may result indamage to components!– Follow the operating instructions for the charging

station or battery charger and for the battery.

CAUTIONRisk of component damage!Battery male connectors and battery chargerconnectors from different manufacturers are notcompatible and may cause damage.– Usebatterymale connectors andbattery charger

connectors produced by the samemanufacturer.– If the connectors are from different manufac-

turers, please contact your authorised servicecentre.

NOTE

To prevent deep discharge of the lithium-ionbattery, performance limitations are imposedonce the charge state of the battery drops toa certain level. The battery must be chargedbefore the charge state drops below 15%.

To read the battery charge state; see thesection entitled "Checking the battery chargestatus".

– Park the truck safely.

– Fully open any protective structures (e.g.fabric-covered cab).

– Open the battery cover fully.

– Disconnect the battery male connector bypulling the handle.

– Do not place any metal objects or tools onthe battery.

– Keep away from naked flames and do notsmoke.

– Check the battery cables for damage.If necessary, have the battery cablesreplaced by the authorised service centre.

56338011803 EN - 02/2018 323


DANGERThere is a risk of damage, short circuiting andexplosion!– Do not place any metal objects or tools on the

battery.– Keep away from naked flames.– Do not smoke.

– Connect the battery male connector to theplug on the battery charger.


The charging process starts automatically.The display signals the charging process byilluminating the LEDS as a chase light.

The charger indicates when the battery is fullycharged. Only disconnect the battery from thecharger if there is no current is flowing.

The battery has no memory effect. Therefore,it can be charged in any charge state withoutthe capacity of the battery being impaired.

At ambient temperatures below 0°C, thecharging process will take much longer.

– Observe the information in the operatinginstructions for the battery and the batterycharger.

After chargingThe battery charger will stop automatically.

– Disconnect the batterymale connector fromthe plug for the battery charger.

– Insert the battery male connector fully intothe plug connection on the truck.

CAUTIONThere is a risk of short circuit if thecables are damaged.Do not crush the charging cable whenclosing the battery cover.– Make sure that the charging cable

does not come into contact with thebattery cover.

324 56338011803 EN - 02/2018

Operation 4Replacing and transporting the battery

6210_600-001

– Close the battery cover. When doing so,ensure that no cables are crushed betweenthe chassis and the battery cover.

The truck is equipped with a door contactswitch for the battery cover. If the batterycover is not fully closed, the message CLOSETHE DOOR appears on the display of thedisplay-operating unit. The truck will notmove.

Replacing and transporting the batteryGeneral information on replacing thebattery

CAUTIONRisk of components being damaged by the liftingaccessory and battery rolling away!The lifting accessory andbatterymay roll away in anuncontrolled manner if the battery is not removedon a level, smooth floor with sufficient load-bearingcapacity.– Follow the operating instructions for the lifting

accessories used.– Always remove the battery on a level, smooth

floor with sufficient load-bearing capacity.

The battery can be removed using the follo-wing lifting accessories:• Truck• Change frame (variant)• Hydraulic drive

The load capacity of the lifting accessory usedmust at least match the battery weight (seebattery identification plate).

56338011803 EN - 02/2018 325

4 OperationReplacing and transporting the battery

Changing to a different battery typeThe authorised service centre can convert thetruck to a different battery type and capacity.

Note the following points:• The new battery capacity and new batterytype must be set in the display-operatingunit.If this is not done, the actual battery dis-charge status cannot be determined. Thebattery charge level is not displayed cor-rectly.In the worst case, the battery may bedamaged by a deep discharge.

• When changing to TENSOR® batteries, themaximum speed of the truckmust be limitedto 17 km/h for technical reasons.

– Contact the authorised service centre in thissituation.

– Only use lithium-ion batteries that havebeen approved by STILL with this truck.

6327_600-010

1

Opening/closing the battery cover

Opening the battery cover

CAUTIONThe outside mirror (1) is in the movement range ofthe battery cover. When opening the battery cover,a collision can cause components to be damaged.– Fold outside mirror forwards.– Ensure that there is sufficient lateral distance (at

least 100 mm) from the battery cover.

326 56338011803 EN - 02/2018


6327_003-010

2

A

– Pull on the interlock (2) of the battery coverand lift battery cover at (A) grip position.

The cover catch snaps into place.

Closing the battery cover

WARNINGWhen closing the battery cover, limbs could be-come trapped— risk of crushing!When closing the battery cover, nothing shouldcome between the battery cover and the edge ofthe chassis.– Close the battery cover carefully.– Only close the battery cover if there are no parts

of the body in the way.

WARNINGWhen closing the battery cover, there is a risk oftrapping the battery cable. If the cable is crushed orsheared off, there is a risk of short circuit!When closing the battery cover, nothing shouldcome between the battery cover and the edge ofthe chassis.– Close the battery cover carefully.– Only close the battery cover if the battery cable

is not in the way.

– Pull the cover catch (3) slightly out andpull the battery cover at the grip positiondownwards at the same time(B)until thecover catch is unlocked.

6327_600-009

B 3

– Release the latch.

56338011803 EN - 02/2018 327


6321_003-085

5

4– Before closing the battery cover, close thebattery safety catches (5) until they lock intoplace.

DANGERIf the battery is not locked correctly, the batterycan slide out of the truck, with potentially fatalconsequences!– Ensure that the battery safety catch (5) is locked

as far as it will go.

NOTE

If the battery safety catch (5) is difficult tomove, use the coupling pin (4) to help.

– Allow the battery cover lock to snap intoplace.

6327_600-005_V4

6

The battery cover interlock must snap intoplace properly or the built-in sensor (6) willgenerate the error message CLOSE THEDOOR on the display and the truck will notdrive.

328 56338011803 EN - 02/2018


6210_600-002

NOTE

The apertures in the flap (arrowed) are ne-cessary for forced ventilation and must not beblocked.

Special notes for installing thelithium-ion batteryWith the exception of the following specialnotes, lithium-ion batteries are replaced in thesame way as lead-acid batteries.

– Push down the lifting eyes before insertingthe battery into the battery compartment.Make sure that the lifting eyes do notprotrude.

The lifting eyes may bend in the event of acollision with the truck chassis.

– Install the lithium-ion batterywith the displayfacing the outside of the truck so that it canbe read when the battery door or batterycover is open.

– Lay the battery cable on the battery. Makesure that the cable does not come intocontact with the truck chassis duringinstallation.

56338011803 EN - 02/2018 329


Replacing the battery using forklifttruck or pallet truck

CAUTIONRisk of damage!The battery must only be removed on a level andsmooth floor in accordance with the operatinginstructions of the truck or lift truck used.

Preparation– Park the truck safely.





330 56338011803 EN - 02/2018


6327_600-001_V4

1

– Disconnect the battery male connector (1).

CAUTIONThere is a risk of short circuit if thecables are damaged!Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing the batterycover.– Check the connecting cables for



WARNINGRisk of crushing and shearing!Personnel must not stand directlynext to the battery or between thebattery and the forklift truck whenremoving and inserting the batterywith the forklift truck or lift truck.

WARNINGRisk of accident!The load capacity of the truck in use must at leastmatch the battery weight (see battery identificationplate).

6210_606-011

A

B

– Before picking up the battery, the fork armsmust be adjusted to match the openingin the chassis (A). Push the fork armstogether. Maintain the maximum possibledistance between the fork arms.

Taking up the battery

CAUTIONRisk of component damage!– The fork arms must not be moved underneath

the battery beyond the length of the opening inthe chassis.

NOTE

It is helpful if this measurement (B), measuredfrom the fork tips, is marked on the fork arms.

56338011803 EN - 02/2018 331


6321_003-086

2

– Fold the battery safety catches (2) to theside.

– Move the fork arms carefully underneaththe battery.

– Carefully lift the battery up and out of thetruck. Pay attention to the distance to thechassis.

WARNINGRisk of crushing and shearing!The battery must be transported very carefully, i.e.at a low speed, using slow steeringmovements andcareful braking.– Do not use the methods described above to

transport the battery over long distances.

– Carefully remove the battery from the truck.

6321_003-002

– Set the battery down on a stable base sothat it is secure. Position the battery againstthe stops on the base.

– Pick up the new battery and transport it tothe truck.

– Position the battery cable on the batteryso that it will not become trapped when thebattery is inserted.

– Position the battery at a right angle to thetruck.

– Carefully insert the battery into the batterycompartment.

Once the battery is positioned correctlyin the battery compartment:– Carefully lower the battery.

– Carefully move the lifting accessory outfrom under the battery.

– Close the battery safety catches until theylock into place.

332 56338011803 EN - 02/2018


6327_600-001_V4

1

– Insert the battery male connector (1).

CAUTIONThere is a risk of short circuit if thecables are damaged!Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable does



Replacing the battery using a changeframe (variant)

CAUTIONRisk of damage!Place the battery change frame along with the trac-tion battery only onto a firm surface with sufficientload-bearing capacity.Do not place the battery change frame with thetraction battery onto a soft surface or in a rack.

The battery change frame (variant) featuresan advantageous design that allows a truckor pallet stacker to pick up the battery quickly.The battery along with the change frame canbe set down and charged. The change framefits between the battery holding fixtures in thebattery compartment of the truck. Once thebattery has been set down onto its holdingfixtures, the change frame is moved back outof the truck.

Preparation– Park the truck securely.


56338011803 EN - 02/2018 333


CAUTIONRisk of component damage!If you disconnect the battery male connector whilethe key switch is switched on (under load), an arcwill be produced. This can lead to erosion at thecontacts, which considerably shortens their servicelife.– Switch off the key switch before the battery male

connector is disconnected.– Do not disconnect the battery male connector


6327_600-001_V4

1

– Disconnect the battery male connector (1).

CAUTIONThere is a risk of a short circuitoccurring if the cables are damaged!Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing the batterycover.– Check the connection cable for



WARNINGRisk of crushing/shearing!Personnel must not stand directly nextto the battery or between the batteryand the truck when removing andinserting the battery with the truck orlift truck.

WARNINGRisk of accident!The load capacity of the truck/lift truck in use mustat least match the battery weight (see batteryidentification plate).

– Ensure that the maximum load capacity ofthe change frame is not exceeded.

The maximum load capacity of the changeframe is specified on the identification plate.

– Before picking up the change frame, adjustthe fork arm distance.

334 56338011803 EN - 02/2018


– Position the change frame (3) under thebattery (2) so that the centre of the battery(1) is in line with the recess (4) in the changeframe.

This alignment ensures that the battery ispositioned centrally on the change frame. Thebattery must be positioned centrally on thechange frame in order for the change frame tobe moved into the truck and to reduce the riskof the battery tipping over when being moved.If multiple batteries are used, it is advisable topermanently mark the centre of the battery (1)(e.g. using a strip of adhesive tape).

Picking up the battery

CAUTIONRisk of component damage!– Move the change frame under the battery only

up to the edge of the stop.

6321_003-086

2

– Fold the battery safety catches (2) to theside.

– Carefully move the change frame under thebattery.

– Carefully lift the battery up and out of thetruck. Pay attention to the distance to thechassis.

WARNINGRisk of crushing/shearing!The battery must be transported very carefully, i.e.at a low speed, using slow steeringmovements andcareful braking.– Do not use the methods described above to

transport the battery over long distances.

– Carefully remove the battery from the truck.

56338011803 EN - 02/2018 335


The battery (1) can remain on the changeframe (2). The change frame can then beused to set the battery down.

– If a substructure (3) is used to set down thebattery (1), ensure that the change frame(2) does not protrude beyond the battery.

– Set the battery down on a stable base sothat it is secure. Position the battery againstthe stops on the base.

– Move the change frame out from under thebattery.

– Pick up the new battery using the changeframe and transport the new battery to thetruck.

– Position the battery cable on the batteryso that it will not become trapped when thebattery is inserted.

– Position the battery at a right angle to thetruck.

– Carefully insert the battery into the batterycompartment.

Once the battery is positioned correctlyin the battery compartment:– Carefully place the battery onto the batteryholding fixtures.

– Carefully move the change frame out fromunder the battery.

336 56338011803 EN - 02/2018


– Close the battery safety catches (2) untilthey latch into place.

– Plug in the battery male connector (1)

CAUTIONThere is a risk of a short circuitoccurring if the cables are damaged!Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable does



Replacing the battery with thehydraulic battery carrier

PreconditionsThe following preconditions apply whenchanging a battery using the hydraulic batterycarrier:

• The extension area must be free of obsta-cles

• The ground must be stable, clean and even

NOTE

When the battery is fully discharged, it is notpossible to use the battery carrier.

56338011803 EN - 02/2018 337


1

6321_003-016

Emergency stop when moving thebatteryWhen working with the hydraulic batterycarrier, it may not be possible to reach theemergency off switch. In an emergency,disconnect the battery male connector (1).

CAUTIONComponent damage possible!If you remove the battery male connector when thekey switch is switched on (under load), an arcwill beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Turn off the key switch before the battery male



6321_003-074

Extending the battery hydraulically– Apply the parking brake.

338 56338011803 EN - 02/2018


6321_003-075

– Make sure that there is no load on thedriver's seat.

– Open the battery cover fully.

6321_003-076

– Open the battery safety catches.

WARNINGRisk of crushing/shearing!When extending the battery carrier, there must beno personnel in the extension area. There is a riskof crushing and shearing when the battery carrierextends.The battery male connector must remain in reachas an emergency off mechanism.– Place it beside the counterweight and outside

the extension area.

56338011803 EN - 02/2018 339


6321_003-077

– Press the extend push button until thecarriage has reached its end position.

During the extension procedure the supportalso extends automatically.

CAUTIONComponent damage possible!When extending the carriage, the battery cablemaycollide with components and become damaged.– Make sure that the battery cable does not

become stuck or crushed.– In the event of a malfunction, release the exten-

sion button and correct the malfunction.

DANGER DANGER

6321_003-078

– Ensure that the battery cable is not dam-aged when the carriage is extended.

NOTE

If the movement of the carriage is restrictedby obstacles, release the push button. Thecarriage can only be retracted. If the pushbutton is actuated continuously, the driveswitches off after 50 seconds.

WARNINGRisk of crushing!Never reach under the battery to remove obstacles.– Retract the battery again and remove obstacle.

NOTE

If the motor protection function is triggered:The motor protection function is controlled bya counter. After retracting and extending fivetimes, the hydraulic battery carrier is disabledfor 60 minutes. The counter is reset whenthe motor has been running for less thanfive minutes and there is no actuation for 15minutes.

340 56338011803 EN - 02/2018


6321_003-079

After extending the battery fully:– To avoid short-circuits, place a rubbermat on the battery with open terminals orconnectors.

CAUTIONComponent damage possible!If you remove the battery male connector when thekey switch is switched on (under load), an arcwill beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Turn off the key switch before the battery male




– Disconnect the battery male connector andplace it on the battery.

– Attach the battery to suitable lifting gear.Observe the operating instructions for thelifting gear.

6327_003-046

– Lift the battery sideways out of the truck.Ensure that there is sufficient distance fromthe battery cover.

CAUTIONComponent damage possible!– Do not allow slack lifting gear to fall onto the

battery cells.

DANGERRisk of death from suspended loads!– Never walk or stand underneath

suspended loads.

– Lift the battery out of the battery tray and setit down carefully.

– Ensure that there is sufficient distancewhen setting down so that the truck is notdamaged when the crane is used.

– Before inserting the battery, check that thebattery tray is free of objects.

– Carefully insert the replacement battery intothe battery tray.

56338011803 EN - 02/2018 341


6321_003-081

After inserting the battery into the batterytray:

CAUTIONComponent damage possible!If you connect the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Switch off the key switch before the battery male

connector is connected.– Do not connect the battery male connector

while the key switch is switched on, except inan emergency.

– Connect the battery male connector.


WARNINGRisk of injury!– Personnel must stand beside the counterweight

outside the retraction area.

CAUTIONComponent damage possible!When retracting the carriage, the battery cable maycollide with components and become damaged.– Make sure that the battery cable does not

become stuck or crushed.– In the event of a malfunction, release the retrac-

tion button and correct the malfunction.

DANGER DANGER

6321_003-083

– Make sure that the battery cable is notdamaged when the carriage is retracted.

WARNINGRisk of crushing!Do not reach into the battery compartment while thebattery carrier is being operated.

342 56338011803 EN - 02/2018


6321_003-082

– Press the retract push button until thecarriage has reached its end position.

– Release the push button.

NOTE

If the movement of the carriage is restricted byobstacles, release the push button.

WARNINGRisk of crushing!Never reach under the battery to remove obstacles.– Extend the carriage again.– Lift the battery with the crane again, swivel the

battery to the side and remove the obstacle.

CAUTIONRisk of damage!If the drive system overheats, the battery carrier isswitched off automatically. After a cooling-downperiod of about 60 minutes, the battery carrier canbe reactivated.– Notify the authorised service centre if the battery

carrier is blocked.

6321_003-084

– Close the battery safety catches.


56338011803 EN - 02/2018 343


Messages and errors during use of the hydraulic battery carrier

Error code Cause Remedy

5920 The unit is overheated. Allow the truck to cool down forone hour.

5910

5930

5931

Notify authorised service centre

Message Cause Remedy

BATTERY CHANGER The battery support is not fullyretracted

Press the "Retract battery"push button until the supportis fully retracted. Notify theauthorised service centre if thisstep is not successful.

CLOSE THE DOORThe battery cover is notcorrectly closed. Close the battery cover.

.

6210_003-012

1

2Transporting the lead-acid battery bycrane

DANGERThere is risk of fatal injury from beingstruck by falling loads!– Never walk or stand underneath

suspended loads.

The tray for the lead-acid battery (1) isequipped with four lifting eyes. The batterymay only be transported by crane using a lift-ing gear and bridge piece (2) that are suitablein terms in size and load capacity.

– To avoid short circuits, cover batteries withopen terminals or connectors with a rubbermat.

– Observe the operating instructions for thelifting gear.

– Attach the battery (1) to suitable lifting gear(2).

– Lift the battery carefully and ensure that ithangs straight on the lifting gear.

344 56338011803 EN - 02/2018


The lifting gearmust be vertical when lifting, sothat no lateral pressure is applied to the tray.

– Set the battery down carefully.

– Remove the lifting gear after the battery hasbeen set down.

– Do not place slack lifting gear on the batterycells or allow it to fall on the battery cells.

6210_003-012

1

2Transporting the lithium-ion batteryby crane

DANGERThere is risk of fatal injury from beingstruck by falling loads!– Never walk or stand underneath

suspended loads.

WARNINGRisk of accident due to weakened lifting eyes.If bent lifting eyes are straightened, they lose theirrigidity. The lifting eyes are then no longer able tosupport the weight of the battery. The battery mayfall.– Do not straighten bent lifting eyes.

– Have bent lifting eyes replaced by the authorisedservice centre.

The lithium-ion battery (1) is equipped withfour extendable lifting eyes. The battery mayonly be transported by crane using a liftinggear and bridge piece (2) that are suitable interms in size and load capacity.

56338011803 EN - 02/2018 345


– Pull out the two lifting eyes (1) on each sideand tilt them towards each other.

The lifting eyes are locked in this position.

– Observe the operating instructions for thelifting gear.

– Attach the lifting gear to the four lifting eyes.

– Lift the battery carefully and ensure that ithangs straight on the lifting gear.

The lifting gearmust be vertical when lifting, sothat no lateral pressure is applied to the tray.

– Set the battery down carefully.

– Remove the lifting gear after the battery hasbeen set down. Lift up and release the liftingeyes to lower them.

346 56338011803 EN - 02/2018

Operation 4Cleaning the truck

Cleaning the truckCleaning the truck– Park the truck securely.

CAUTIONRisk of component damage!If you remove the battery male connector with thekey switch switched on (under load), an arc willbe produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Switch off the key switch before the battery male




WARNINGThere is a risk of injury due to fallingwhen climbing onto the truck!When climbing onto the truck, youcan get stuck or slip on componentsand fall. Higher points on the truckshould only be accessed using theappropriate equipment.– Adhere strictly to the following

steps.

– Use only the steps provided to climb ontothe truck.

– Use equipment such as stepladders orplatforms to reach inaccessible areas.

Preparing the truck for cleaning

CAUTIONIf water penetrates the electrical system, there is arisk of short circuit!– Adhere strictly to the following steps.

– Switch the electrical system off beforecleaning.

– Do not spray electric motors and otherelectrical components or their coversdirectly with water.

56338011803 EN - 02/2018 347

4 OperationCleaning the truck

CAUTIONExcessive water pressure or water and steam thatare too hot can damage truck components.– Adhere strictly to the following steps.

– Only use high-pressure cleaners with amaximum output power of 50 bar and at amaximum temperature of 85°C.

– When using high-pressure cleaners, makesure there is a distance of at least 20 cmbetween the nozzle and the object beingcleaned.

– Do not aim the cleaning jet directly atadhesive labels or decal information.

DANGERRisk of fire!Deposits/accumulations of combusti-ble materials may ignite in the vicinityof hot components (e.g. drive units).– Adhere strictly to the following

steps.

– Regularly remove all deposits/accumula-tions of foreign materials in the vicinity ofhot components.

DANGERFlammable fluids can be ignited by hotcomponents on the truck, causing arisk of fire!– Adhere strictly to the following

steps.

– Do not use flammable fluids for cleaning.

– Note the manufacturer's guidelines forworking with cleaning materials.

CAUTIONAbrasive cleaning materials can damage compo-nent surfaces!Using abrasive cleaning materials that are unsuita-ble for plastics may dissolve plastic parts or makethem brittle. The screen on the display operatingunit may become cloudy.– Adhere strictly to the following steps.

348 56338011803 EN - 02/2018


– Only clean plastic parts with plastic cleaningmaterials.

– Note the manufacturer's guidelines forworking with cleaning materials.

Washing the truck exterior– Clean the truck exterior with water-solublecleaning materials and water (water jet,sponge, cloth).

– Clean all walk-in areas, the oil filling open-ings and their surroundings, and the lubri-cating nipples before lubricating.

NOTE

Please note: The more often the truck iscleaned, the more frequently it must belubricated.

6210_600-005

Cleaning the electrical system

WARNINGDanger of electric shocks due to residual capacity!– Never reach into the electrical system with your

bare hands.

CAUTIONCleaning electrical system partswith water can damage the electricalsystem.Cleaning electrical system parts withwater is forbidden!– Do not remove covers etc.– Use only dry cleaning materials in

accordance with the manufactu-rer's specifications.

– Clean the electrical system parts with ametal-free brush and blow the dust off withlow-pressure compressed air.

56338011803 EN - 02/2018 349

4 OperationCleaning the truck

6321_003-020

Cleaning load chains

WARNINGRisk of accident!Load chains are safety elements.The use of cold cleaning solvents, chemical clea-ners or fluids that are corrosive or contain acid orchlorine can damage the chains; use of these itemsis forbidden!– Observe the manufacturer's guidelines for

working with cleaning materials.

– Place a collection vessel under the lift mast.

– Clean with paraffin derivatives, such asbenzine.

– When using a steam jet, do not use addi-tional cleaning agents.

– Remove any water in the chain links usingcompressed air immediately after cleaning.Move the chain several times during thisprocedure.

– Immediately after drying the chain, spray itwith chain spray. Move the chain severaltimes during this procedure.

ENVIRONMENT NOTE

Dispose of any fluid that has been spilledor collected in the collection vessel in anenvironmentally friendly manner.

– Observe the national regulations for thecountry of use.

350 56338011803 EN - 02/2018


6321_003-089

1

Cleaning the windowsAny panes of glass, e.g. cab windows (vari-ant), must always be kept clean and free of ice.This is the only means of guaranteeing goodvisibility.

CAUTIONDo not damage the rear window heater (inside).– Take great care when cleaning the rear window

(1) and do not use any objects with sharp edges.

– Clean the windows.

NOTE

Cleaning can be done using a commerciallyavailable glass cleaner.

6210_001-029

After washing– Carefully dry truck (e.g. with compressedair).

– Sit on the driver's seat and start up the truckin accordance with regulations.

CAUTIONDanger of short-circuits!– If any moisture has penetrated into the motors

despite the precautionary measures taken, thismust first be dried with compressed air.

– The truck must then be started up to preventpossible corrosion damage.

56338011803 EN - 02/2018 351

4 OperationTransporting the truck

Transporting the truckTransport

CAUTIONDanger of material damage from overloading!If the truck is driven onto a means of transport,the load capacity of the means of transport, theramps and loading bridges must be greater thanthe actual total weight of the truck. Componentsmay become permanently deformed or damageddue to overloading.– Determine the actual total weight of the truck.– Only load the truck if the load capacity of the

means of transport, the ramps and loadingbridges is greater than the actual total weightof the truck.






max

min.*

kg kg

kg

kg

kgkW

V

*



1

3

2

Determining the actual total weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate.

– Add the determined unit weights to obtainthe actual total weight of the truck:

Tare weight (1)




+ 100 kg allowance for driver

= Actual total weight

352 56338011803 EN - 02/2018

Operation 4Transporting the truck

DANGERRisk of accident from the truck crashing!Steering movements can cause the tail end to veeroff the loading bridge towards the edge. This maycause the truck to crash.– Before driving over a loading bridge, ensure that

it is installed and secured properly.– Ensure that the transport vehicle to be driven

onto has been sufficiently secured againstmoving.

– Maintain a safety distance from edges, loadingbridges, ramps, working platforms etc.

– Drive slowly and carefully onto the transportvehicle.

6210_001-012_V3

Setting chocks– Secure the truck from rolling away byplacing a wheel chock in front of each frontwheel and behind each back wheel (1).

– Park the truck securely.




– Ensure that the key switch is switched off.


NOTE

If the electric parking brake (variant) cannot betriggered electrically, it must be applied ma-nually; see the chapter entitled "Emergencyoperation of the electric parking brake".

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Lashing

CAUTIONAbrasive lashing straps can rub against the surfaceof the truck and cause damage.– Position slip-resistant pads beneath the lifting

points (e.g. rubber mats or foam).

6321_003-104

1

– Attach lashing straps (1) to both sides of thetruck and lash the truck to the rear.

6210_003-048_V2

2

1

– Attach lashing straps (1) to the coupling pin(2) or loop around the coupling pin and lashthe truck to the side.

DANGERShifting of the load caused by the lashing strapsslipping!The truck must be lashed securely so that it cannotmove during transportation.– Make sure that the lashing straps are tightened

securely and that the pads cannot slip off.

Crane loadingCrane loading is only intended for transportingthe complete truck, including the lift mast,for its initial commissioning. For applicationconditions that require frequent loading or

354 56338011803 EN - 02/2018


that are not dealt with here, please contactthe manufacturer with regard to specialequipment variants.

Trucks may only be laden by persons withsufficient experience in the suitable harnessesand hoists.






max

min.*

kg kg

kg

kg

kgkW

V

*



1

3

2

Determining the loading weight– Park the truck securely; see chapter "Park-ing the truck securely".

– Determine the unit weights by reading themoff the truck nameplate and, if necessary,the attachment (variant) nameplate.

– Add the determined unit weights to obtainthe loading weight of the truck:

Tare weight (1)




= Loading weight.

Hooking on the lifting straps

CAUTIONHarnesses may damage the truck's paintwork!Harnesses may damage paintwork by chafing andpressing on the surface of the truck. Particularlyhard or sharp-edged harnesses, such as wires orchains, can quickly damage the surface.– Use textile harnesses, e.g. lifting straps, with

edge protectors or similar protective devices ifnecessary.

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DANGERIf the hoists and harnesses failand cause the truck to fall, theconsequences are potentially fatal!– Use only hoists and harnesses

with sufficient load capacity for thedetermined loading weight.

– Only use the truck's designatedlifting points.

– Make sure that harnesses such ashooks, shackles, belts etc. are onlyused in the indicated load direction.

– The harnesses must not bedamaged by truck parts.

NOTE

The attachment points are indicated by a hooksymbol.

4

6321_003-069– Loop the lifting straps around the maintraverse (4) on the outer mast of the liftmast.

356 56338011803 EN - 02/2018


6321_003-070

5

– Loop the lifting straps around the counter-weight (5) as shown.

– Determine the truck's centre of gravity, see"Dimensions" chapter.

6321_003-071

7 6– Adjust the length of the harnesses so thatthe lifting eye (6) is vertically above thetruck's centre of gravity.

This ensures that the truck hangs level whenlifting it.

– Connect the lifting straps to the lifting eyeand insert the safety device (7).

CAUTIONIncorrectly fitted harnesses may damage attach-ment parts!Pressure from the harnesses can damage ordestroy attachment parts when the truck is lifted.If attachment parts are in the way (e.g. lighting, rearwindow, trademark emblem etc.), these must beremoved before loading.– Secure harnesses in such a way that they do not

touch any attachment parts.

– Check that harnesses cannot collide withattachment parts.

56338011803 EN - 02/2018 357

4 OperationDecommissioning

Loading the truck

DANGERIf the raised truck swings in anuncontrolled fashion, it may crushpeople. There is a risk to life!– Never walk or stand underneath

suspended loads.– Do not allow the truck to bump into

anything whilst it is being lifted, orallow it to move in an uncontrolledway.

– If necessary, hold the truck usingguide ropes.

– Carefully lift the truck and set it down at theintended location.

DecommissioningDecommissioning and storing thetruck

CAUTIONComponent damage through incorrect storage!Improper storage or decommissioning for a periodof more than two months can result in corrosiondamage to the truck. If the truck is parked in an am-bient temperature of below -10°C for an extendedperiod, the batteries will cool down. The electrolytemay freeze and damage the batteries.– Store the truck in a dry, clean, frost-free and

well-ventilated environment.– Implement the following measures before

decommissioning.

Measures to be implemented beforedecommissioning– Clean the truck thoroughly, see the chapterentitled "Cleaning the truck".

– Lift the fork carriage to the stop severaltimes.

– Tilt the lift mast forwards and backwardsseveral times and, if fitted, move the attach-ment repeatedly.

358 56338011803 EN - 02/2018

Operation 4Decommissioning

– To relieve the strain on the load chains,lower the fork onto a suitable supportingsurface, e.g. a pallet.

– Check the hydraulic oil level. Top the oil upif necessary.

– Apply a thin layer of oil or grease to alluncoated moving parts.

– Lubricate the truck.

– Lubricate the joints and controls.

– Lubricate the slide elements and guides ofthe hydraulic battery carrier (variant); seethe section entitled "Lubricating the slideelements" in the chapter entitled "1000-hourmaintenance/annual maintenance".

– Lubricate the catch rail of the hydraulicbattery carrier (variant); see the sectionentitled "Oiling the catch rails" in the chapterentitled "1000-hour maintenance/annualmaintenance".

– Lubricate the battery interlock and thebattery cover; see the section entitled"Checking the battery interlock and batterycover" in the chapter entitled "Remainingready for operation".

CAUTIONRisk of component damage!If you remove the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can cause the contacts to erode,which considerably shortens their service life.– Switch off the key switch before disconnecting

the battery male connector.– Do not disconnect the battery male connector



– Check the battery condition, acid level andacid density.

– Service the battery.

NOTE

Store only fully charged batteries.

56338011803 EN - 02/2018 359


– Apply a suitable contact spray to all exposedelectrical contacts.

CAUTIONTyre deformation as a result of continuous loadingon one side!Have the truck raised and jacked up by the autho-rised service centre so that all wheels are off theground. This prevents permanent deformation ofthe tyres.– Only have the truck raised and jacked up by the

authorised service centre.

CAUTIONRisk of damage from corrosion due to condensationon the truck!Many plastic films and synthetic materials arewatertight. Condensation water on the truck cannotescape through these covers.– Do not use plastic film as this facilitates the

formation of condensation water.– Cover with vapour-permeable material, e.g.

cotton.

– Cover the truck to protect it from dust.

– If the truck is to be shut down for evenlonger periods, contact the authorisedservice centre to find out about additionalmeasures.

Returning to service after decommis-sioningIf the truck has been decommissioned forlonger than six months, it must be carefullychecked before being re-commissioned. Aswith the annual safety inspection, this checkshould also include all safety-related aspectsof the truck.

– Clean the truck thoroughly, see the chapterentitled "Cleaning the truck".

– Lubricate the joints and controls.

– Lubricate the slide elements and guides ofthe hydraulic battery carrier (variant); seethe section entitled "Lubricating the slideelements" in the chapter entitled "1000-hourmaintenance/annual maintenance".

360 56338011803 EN - 02/2018

Operation 4Decommissioning

– Lubricate the catch rail of the hydraulicbattery carrier (variant); see the sectionentitled "Oiling the catch rails" in the chapterentitled "1000-hour maintenance/annualmaintenance".

– Check the battery condition, acid level andacid density.

– Check the hydraulic oil for condensationwater. Change the hydraulic oil if neces-sary.

– Carry out the checks and tasks that are to beperformed before the first commissioning.

– Perform "visual inspections and functionchecking".

The following points must be checked inparticular:• Drive, control, steering• Brakes (service brake, parking brake)• Lifting system (lifting accessories, loadchains, mounting)

NOTE

For further information, see the workshopmanual for the truck or contact the authorisedservice centre.

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362 56338011803 EN - 02/2018

5

Maintenance

5 MaintenanceSafety regulations for maintenance

Safety regulations for maintenanceGeneral informationTo prevent accidents during maintenance andrepair work, all necessary safety measuresmust be taken, e.g.:


– Turn off the key switch and remove the key.


– Ensure that the truck cannot move uninten-tionally or start up inadvertently.

– If required, have the truck jacked up by theauthorised service centre.

– Have the raised fork carriage or the ex-tended lift mast secured against accidentallowering by the authorised service centre.

– Insert an appropriately sized wooden beamas an abutment between the lift mast andthe cab, and secure the lift mast to preventit tilting backwards unintentionally.

– Observe the maximum lift height of the liftmast, and compare the dimensions fromthe technical data with the dimensions ofthe hall into which the truck is to be driven.These steps are taken to prevent a collisionwith the ceiling of the hall and to avoid anydamage caused as a result.

Working on the hydraulic equipmentThe hydraulic systemmust be depressurisedprior to all work on the system.

Working on the electrical equipmentWork may only be performed on the electricalequipment of the truck when it is in a voltage-free state. Function checks, inspectionsand adjustments on energised parts mustonly be performed by trained and authorisedpersons, taking the necessary precautionsinto account. Rings, metal bracelets etc.must be removed before working on electriccomponents.

364 56338011803 EN - 02/2018

Maintenance 5Safety regulations for maintenance

To prevent damage to electronic systemswith electronic components, such as anelectronic driving regulator or lift control, thesecomponents must be removed from the truckprior to the start of electric welding.

Work on the electrical system (e.g. connectinga radio, additional headlights etc.) is onlypermitted with approval from the authorisedservice centre.

Safety devicesAfter maintenance and repair work, all safetydevices must be reinstalled and tested foroperational reliability.

Set valuesThe device-dependent set values must beobserved when making repairs and whenchanging hydraulic and electrical compo-nents. These are listed in the appropriatesections.

Lifting and jacking up

DANGERThere is a risk to life if the truck tips over!If not raised and jacked up properly, the truck maytip over and fall off. Only the hoists specified in theworkshop manual for this truck are allowed and aretested for the necessary safety and load capacity.– Only have the truck raised and jacked up by the

authorised service centre.– Only jack the truck up at the points specified in

the workshop manual.

The truck must be raised and jacked up forvarious types of maintenance work. Theauthorised service centre must be informedthat this is to take place. Safe handling ofthe truck and the corresponding hoists isdescribed in the truck's workshop manual.

56338011803 EN - 02/2018 365

5 MaintenanceSafety regulations for maintenance

Working at the front of the truck

DANGERRisk of accident!If the lift mast or fork carriage is raised, no workmay be performed on the lift mast or at the front ofthe truck unless the following safety measures areobserved.– When securing, only use chains with sufficient

load-bearing capacity.– Contact the authorised service centre.

CAUTIONPossibility of damage to the ceiling!– Note the maximum lift height of the lift mast.

Securing the lift mast against tiltingbackwardsA hardwood beam with a cross-section of120 x 120 mm is required. The length ofthe hardwood beam must approximatelycorrespond to the width of the fork carriage(b3). To avoid impact injuries, the hardwoodbeam must not protrude beyond the outercontour of the truck. A maximum lengthmatching the total width (b1) of the truck isrecommended.

– Obtain the dimensions (b1) and (b3) fromthe corresponding VDI datasheet.

366 56338011803 EN - 02/2018

Maintenance 5Safety regulations for maintenance

1 2

3

6210_001-030_V3

– Clamp the hardwood beam (1) between thedriver protection structure (2) and the liftmast (3).

Removing the lift mast

DANGERRisk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

remove the lift mast.

Securing the lift mast against falling off

DANGERRisk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

secure the lift mast.

56338011803 EN - 02/2018 367

5 MaintenanceGeneral maintenance information

General maintenance informationPersonnel qualificationsOnly qualified and authorised personnel areallowed to perform maintenance work. Reg-ular safety checks and checks after unusualincidents must be performed by a competentperson. The competent person must conducttheir evaluation and assessment from a safetystandpoint, unaffected by operational andeconomic conditions. The competent personmust have sufficient knowledge and experi-ence to be able to assess the condition of atruck and the effectiveness of the protectivedevices in accordance with technical conven-tions and the principles for testing trucks.

Maintenance personnel for batteriesBatteries may only be charged, serviced, andreplaced by personnel who have receivedappropriate training in accordance with theinstructions from the manufacturers of thebattery, battery charger and truck.

– Follow the handling instructions for thebattery and the operating instructions forthe battery charger.

Maintenance work without specialqualificationsSimple maintenance work, such as checkingthe hydraulic oil level, may be carried out byuntrained personnel. A qualification suchas those held by a competent person is notrequired to carry out this work. The requiredtasks are described in the chapter entitled"Remaining ready for operation".

Information for carrying out mainte-nanceThis section contains all information requiredto determine when the truck needs mainte-nance. Carry out maintenance work within thetime limits according to the hour meter andusing the following maintenance check lists.This is the only way to ensure that the truckremains ready for operation and provides op-

368 56338011803 EN - 02/2018

Maintenance 5General maintenance information

timal performance and service life. It is also aprecondition for any warranty claims.

7312_003-156_V2

1Maintenance timeframe– Carry out maintenance work on the truck inaccordance with the "Service in" display (1).

– The maintenance check lists indicate themaintenance work that is due.

The intervals are defined for standard use.Shorter maintenance intervals can be definedin consultation with the operating company,depending on the application conditions of thetruck.

The following factors may necessitate shortermaintenance intervals:• Contaminated, poor quality roads• Dusty or salty air• High levels of air humidity• Extremely high or low ambient tempera-tures, or extreme changes in temperature

• Multi-shift operation with a high duty cycle• Specific national regulations for the truck orindividual components

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370 56338011803 EN - 02/2018


Maintenance— 1000 hours/annuallyAt operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Chassis, bodywork and fittings

Check chassis for cracks

Check overhead guard/cab and panes of glass for damage

Check controls, switches and joints for damage, and apply grease and oil

Check driver's seat for correct function and for damage

Check driver restraint system for correct function and for damage, and clean.

Check the signal horn

Variant: Check the dual-pedal variant for damage and correct function, and lubricate

Tyres and wheels

Check tyres for wear and check the air pressure if necessary

Check wheels for damage and check the tightening torques

Power unit

Drive axle: Check mounting, check for leaks, and clean cooling fins

Drive wheel unit and multi-disc brake: Check the oil level

Change the gearbox oil (once after the first 1000 hours)

Steering

Check steering system for correct function and for leaksCheck that the steering wheel is firmly attached and check the turning handle fordamageSteering axle: Check that it is firmly attached, check for leaks, and apply grease

Check steering stop

Brake

Check all mechanical brake parts for condition and correct function

Carry out brake test

Variant: Check the electric parking brake variant for damage and correct function

Variant: Electric parking brake: Check the relubrication device

Electrical system

Check all power cable connections

Check main contactor contacts

56338011803 EN - 02/2018 371


At operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Test switches, transmitters and sensors for correct function

Check lighting and indicator lights

Battery and accessoriesCheck the lead-acid battery for damage and check the acid density; observe themanufacturer's maintenance instructionsVariant: Lead-acid battery with electrolyte circulation: Replace the non-return valve

Variant: Lithium-ion battery: Observe the manufacturer's maintenance instructions

Check the appliance plug and truck harness for damage

Check the battery male connector and battery harness for damage

Battery compartmentCheck that the battery door, and the sensor if necessary, is working correctly andcheck for damage.Check the battery lock for damage.Variant: Hydraulic battery carrier: Check all moving parts for wear, and oil or lubri-cate. Observe the special maintenance scheduleVariant: Hydraulic battery carrier: Check the oil level and check for leaks

Hydraulics

Check hydraulic system for condition, correct function and leaks

Check the hydraulics blocking function (ISO valve)

Check oil level

Lift mast

Check mast bearings for damage, and lubricate. Check the tightening torque

Check mast profiles for damage and wear, and lubricate

Check load chains for damage and wear, adjust and lubricate

Check lift cylinders and connections for damage and leaks

Check guide pulleys for damage and wear

Check support rollers and chain rollers for damage and wear

Check the play between the fork carriage stop and run-out barrier

Check tilt cylinders and connections for damage and leaks

Check fork carriage for damage and wear

Check fork arm interlock for damage and correct function

372 56338011803 EN - 02/2018


At operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Check fork arms for wear and deformation

Check that there is a safety screw on the fork carriage or on the attachment

Special equipment

Check the condition of the antistatic belt or antistatic electrode.Check heating system for damage; observe manufacturer's maintenance instructi-onsCheck attachments for wear and damage; observe manufacturer's maintenanceinstructionsCheck trailer coupling for wear and damage; observe manufacturer's maintenanceinstructionsGeneral

Read out error numbers and delete list

Reset maintenance interval

Check labelling for completeness

Test drive the truck

56338011803 EN - 02/2018 373


374 56338011803 EN - 02/2018


Maintenance - 3000 hours/every two yearsAt operating hours Carried out

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work

Power unit

Drive wheel unit and multi-disc brake: Change the gearbox oil

Replace the bleeder screws on the drive wheel units

Brake

Variant: Electric parking brake: Replace the actuation push button

Hydraulics

Renew the hydraulic oil

Replace the return line filter and breather filter

Variant: Replace the high-pressure filter

For RX60-50 LSP600 (6330) only: Replace the accumulator

Ordering spare parts and wearingpartsSpare parts are provided by our spare partsservice department. The information requiredfor ordering parts can be found in the spareparts list.

Only use spare parts as per the manufac-turer's instructions. The use of unapprovedspare parts can result in an increased risk ofaccidents due to insufficient quality or incor-rect assignment. Anyone using unapprovedspare parts shall assume unlimited liability inthe event of damage or harm.

Quality and quantity of the requiredoperating materialsOnly the operating materials specified in themaintenance data table may be used.

– The required consumables and lubricantscan be found in themaintenance data table.

56338011803 EN - 02/2018 375


Oil and grease types of a different qualitymust not be mixed. This negatively affectsthe lubricity. If a change between differentmanufacturers cannot be avoided, drain theold oil thoroughly.

Before carrying out lubricating work, filterchanges or any work on the hydraulic system,carefully clean the area around the partinvolved.

When topping up working materials, use onlyclean containers!

Lubrication plan

376 56338011803 EN - 02/2018


Code1 Lubrication point

(A) Four lubricating nipples on each side of the steering axle for the axle stub bearing andtrack rod arm

(B) Sliding surfaces on the lift mast

(C) Load chains

(D) One lubricating nipple on each of the two lift mast bearings1See the following chapter, "Maintenance data table", under this Code. for the respective lubri-cant specification.

.

56338011803 EN - 02/2018 377


Maintenance data table

General lubrication points

Code Unit Operating materials Specifications AmountLubrication High-pressure

greaseID no. 0147873 As required

Battery

Code Unit Operating materials Specifications AmountSystem filling Distilled water As required

Insulation resistance DIN 43539VDE 0510

For furtherinformation, referto the workshop

manual for the truckin question.

Electrical system

Code Unit Operating materials Specifications AmountInsulation resistance DIN EN 1175

VDE 0117For further

information, referto the workshop

manual for the truckin question.

Controls/joints

Code Unit Operating materials Specifications AmountHigh-pressuregrease

ID no. 0147873 As requiredLubrication

Oil SAE 80MIL-L2105API-GL4

As required

Dual-pedaloperation

High-pressuregrease

ID no. 0147873 As required

378 56338011803 EN - 02/2018


Hydraulic system

Code Unit Operating materials Specifications AmountHydraulic oil HVLP 68

DIN 51524 Part 3Hydraulic oil for thefood industry (variant)

USDA H1DIN 51524

Hydraulic oil,fire-retardant

HFC/HFDU

Hydraulic oil,biological

HEES

System filling

Hydraulic oil for coldstore application

HVLP 68DIN 51524 Part 3

Max. 32.5 l

Hydraulic battery carrier

Code Unit Operating materials Specifications AmountCatch rail Multi-purpose oil,

acid-free, resin-freeRivolta TRS PlusID no. 0149847

As required

Slide elements andguide rails

High-pressuregrease


System filling Hydraulic oil HVLP 68DIN 51524 Part 3

Max. 2 l

Tyres

Code Unit Operating materials Specifications AmountSuperelastic tyres Wear limit To wear mark

Solid rubber tyres Wear limit To wear mark

Pneumatic tyres Minimum tread depth Air pressure: seeinformation on the

truckMin. tread depth:

1.6 mm

Steering axle

Code Unit Operating materials Specifications Amount(A) Axle stub bearing,

spherical bearingHigh-pressuregrease


Wheel nuts/screws Torque wrench 220 Nm

Axle stub nut Torque wrench 310 Nm

56338011803 EN - 02/2018 379


Drive axleCode Unit Operating materials Specifications Amount

Wheel nuts/screws Torque wrench 640 Nm

Wheel gear Gearbox oil Fuchs TITAN GearHyp LDSAE 80W-90API-GL5

Lift mastCode Unit Operating materials Specifications Amount(B) Lubrication High-pressure

greaseID no. 0147873 As required

Stop Play Min. 2 mm

(D)Lift mast bearing Grease Aralub 4320

DIN 51825-KPF2N20ID no. 0148659

Fill with grease until asmall amount of fresh

grease escapesScrews for the liftmast bearing

Torque wrench 310 Nm

Load chainsCode Unit Operating materials Specifications Amount(C) Lubrication High-load chain

sprayFully syntheticTemperature range:-35°C to +250°CID no. 0156428

As required

Washer system

Code Unit Operating materials Specifications AmountSystem filling Washer fluid Winter, ID no. 172566 As required

.

380 56338011803 EN - 02/2018

Maintenance 5Providing access to maintenance points

Providing access to maintenance pointsRemoving and installing the valvecover

2

223

6210_762-002

Removing the valve cover– For trucks with a heating system (variant),unscrew five screws (2).

– Remove the heating system panelling (3).

– If the cover (6) is in place, remove it by liftingit with your finger.

– Unscrew the four screws (5).

5

5

6

4

– Lift up the valve cover (4) and remove it.

Fitting the valve cover– Refit the valve cover (4).

– Refit the cover (6).

– Refit the heating system panelling (3).

Opening the fuse boxTo access the fuse box and other componentsin the electronic control unit, you need toremove the cover sheet (1).

56338011803 EN - 02/2018 381

5 MaintenanceProviding access to maintenance points

22

1

3

Removing the cover sheet– Park the truck safely and switch it off.

– Open the battery door or battery cover.

Beneath it there is a screw.

– Remove the hexagon socket wrench fromthe compartment.

– Loosen two screws (2) but do not removethem completely.

The cover sheet is held in place by clamps atthe sides.

– Unscrew two screws (3).

– Remove the cover sheet (1).

– To fit the cover sheet, slide it into the clampsat the sides.

– Tighten all screws.

4

5

5Opening the fuse box– Unscrew the screws (5).

The screw at the side can be accessedthrough the open battery door or battery cover.

– Remove the fuse box cover (4).

– To fit the cover, screw in and tighten thescrews again.

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Maintenance 5Remaining ready for operation

Remaining ready for operation

6210_606-030_V2

1Lubricating the joints and controls– Oil or grease bearings and joints accordingto the "maintenance data table".

• Driver's seat guide• Cab door hinges (variant)• Battery-door hinges or battery-cover hinges• Actuating rod (1) for valves (with multi-leveroperation)

Checking the battery interlock andbattery cover

DANGERAmalfunction of the battery interlock and batterycover can cause the battery cover to open and thebattery could possibly fall out when the truck is tiltedor during sharp deceleration. If the battery falls outthere is a danger of being crushed.– If the interlock is deformed, damaged or difficult

to move, inform STILL Service immediately. Donot operate the truck.

– Check that the interlocks function correctly.– Interlocks must be greased and move easily.– Always check the interlock after an accident.

NOTE

The interval for greasing is influenced signi-ficantly by the application conditions and en-vironmental conditions affecting the truck.Every 1000 hours and as necessary visuallyinspect and check the function of the interlockand all of its moving parts.

– Open the battery cover; see ⇒ Chap-ter "Opening/closing the batterycover", P. 4-326.

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5 MaintenanceRemaining ready for operation

6321_003-137

1

– Check that the battery lock (1) moves easilyand that it is not deformed or damaged.

6321_003-136

2

3

– Check that the battery cover lock (3) moveseasily and that it is not deformed or dam-aged.

– Check that the rest plate (2) of the batterycover lock is seated correctly, and that it isnot deformed or damaged.

– Grease the lock mechanisms.

– Close the battery cover again.

384 56338011803 EN - 02/2018


Maintaining the seat belt

DANGERThere is a risk to life if the seat belt fails during anaccident!If the seat belt is faulty, it may tear or open duringan accident and no longer keep the driver in thedriver's seat. The driver may therefore be hurledagainst the truck components or out of the truck.– Ensure operational reliability by continually

testing.– Do not use a truck with a defective seat belt.– Only have a defective belt replaced by your

service centre.– Only use genuine spare parts.– Do not make any changes to the belt.

NOTE

Carry out the following checks on a regularbasis (monthly). In the case of significantstrain, a daily check is necessary.

Checking the seat belt

6327_342-009

1

23

– Pull out the belt (3) completely and checkfor wear.

The belt must not be frayed or cut. Thestitching must not be loose.

– Check whether the belt is dirty.

– Check whether parts are worn or damaged,including the attachment points.

– Check the buckle (1) to ensure that it locksin properly.

When the belt tongue (2) is inserted, the beltmust be held securely.

56338011803 EN - 02/2018 385


7090_342-0051

4

– The belt tongue (2) must release when thered button (4) is pressed.

– The automatic blocking mechanism mustbe tested at least once a year:

– Park the forklift truck on level ground.

– Pull out the belt with a jerk.

The automatic blocking mechanism mustblock extension of the belt.

– Tilt the seat at least 30 ° (if necessary,remove the seat).

– Slowly extend the belt.

The automatic blocking mechanism mustblock extension of the belt.

Cleaning the seat belt

– Clean the seat belt as necessary, butwithout using chemical cleaning materials(a brush will suffice).

Replacement after an accidentAs a rule, the seat belt must be changed afteran accident.

6327_342-010

Checking the driver's seat

WARNINGRisk of injury!– After an accident, check the driver's seat with

attached restraining belt and fastening.

– Check the controls for correct operation.

– Check the condition of the seat (e.g. wearon the upholstery) and secure fastening tothe hood.

WARNINGRisk of injury!– Have the seat repaired by the service centre if

you identify any damage during the checks.

386 56338011803 EN - 02/2018


Maintaining wheels and tyres

WARNINGRisk of accident!Uneven wear reduces the stability of the truck andincreases the braking distance.– Change worn or damaged tyres without delay.

WARNINGRisk of tipping!Tyre quality affects the stability of the truck.If you wish to use a different type of tyre on the truckfrom the tyres approved by the truck manufacturer,or tyres fromadifferentmanufacturer, youmust firstobtain approval from the truck manufacturer.

WARNINGRisk to stability!When using pneumatic tyres or solid rubber tyres,rim wheel parts must never be changed and rimwheel parts from different manufacturers must notbe mixed.

6311_003-004

Checking the condition and wear of thetyres

WARNINGTyre quality affects the stability and handling of thetruck.Changes can only be made after consultation withthe manufacturer.When changingwheels or tyres, always ensure thatthis does not cause the truck to tilt to one side (e.g.always replace right-hand and left-hand wheels atthe same time).

56338011803 EN - 02/2018 387


21

6311_003-005

– If necessary, remove any foreign bodiesimbedded in the tyre profile (1).

NOTE

The wear of the tyres on an axle must beapproximately the same.• Super elastic tyres and solid rubber tyrescan be worn down to the wear mark (2)

6210_460-004

3

Checking wheel fastenings– Check wheel fastening nuts (3) and boltsfor secure positioning, and retighten asnecessary.

– Observe the torques; see the "maintenancedata table".

388 56338011803 EN - 02/2018


Servicing the steering axle– Park the truck securely.

Checking the steering axle– Check the condition and wear of the rubberparts of the axle swivel bearings.

– Check the stub axle bearing (1) and tie rodjoint (2) for play and wear.

– Check the steering cylinder (3) for leaktight-ness (traces of oil).

NOTE

In the case of excessive play or wear, haveyour service centre change the relevant parts.

Lubricating the steering axle

ENVIRONMENT NOTE

Dispose of old grease and contaminateddevices in accordance with the nationalregulations for the country in which the truck isbeing used.

56338011803 EN - 02/2018 389


– At the lubricating nipples (4), lubricate theaxle stub bearing and the steering leverbearingswith grease in accordancewith the"maintenance data table".

If, after a few strokes, there is no longer anyold grease escaping, actuate the steering.

WARNINGRisk of crushing!Do not actuate the steering during lubrication.

– Switch on the truck.

– Actuate the steering.

– Park the truck securely again.

– Repeat the lubrication procedure.

NOTE

Please note: the more often the truck iscleaned, the more frequently it must belubricated.

Checking the lines for leaks– Retighten leaky connections.

NOTE

Have faulty lines replaced by your authorisedservice centre.

– After repairs, force out any trapped air byturning the steering wheel from stop to stopseveral times.

Checking the tightening torque of theaxle stub nuts– Set steering to end stop.

– Park the truck securely again.

390 56338011803 EN - 02/2018


– Check the tightening torque of the axle stubnut (5) in accordancewith the "maintenancedata table" and tighten the axle stub nut asnecessary.

Checking the battery– For information on checking the battery, seethe chapter entitled "Checking the batterycondition, acid level and acid density".

Checking the fuses

DANGERHazard from electrical current!Take care when handling; residualcapacity may be present.Before starting the following mainten-ance work:– Park the truck securely.– Disconnect the battery male

connector.

56338011803 EN - 02/2018 391





1

Fuses for standard equipment and equipmentvariants are located in the rear part of thecontrol electronics (1).

– Open the cover.

– Remove the cover from the control electron-ics.

392 56338011803 EN - 02/2018


2 3 4 5

79 8

6

6210_600-004

– Check the condition of the main fuse (2) (nodamage to the porcelain body) and checkthat it is securely positioned; tighten theclamping screws if necessary.

– Check the condition of fuses (3) to (3),check that the cable connections are secureand check for oxidation residues. Clean ifnecessary.(9)

NOTE

Depending on the specification, not all fuseswill be present in the truck.

CAUTIONWater in the electrical system cancause damage to components!In order to protect theelectrical systemagainst ingress of water, the covermust be closed.– Refit the cover after these tasks

have been completed.


– Carry out a functional test.

Replacing fuses

DANGERHazard from electrical current!Take care when handling; there maybe residual capacity present.Before starting the following mainten-ance work:– Park the truck securely.– Disconnect the battery male

connector.

56338011803 EN - 02/2018 393





DANGERRisk of fire!Using the wrong fuses can result inshort circuits.– Only use fuses with the prescribed

nominal current.

NOTE

Depending on the equipment, not all fuses willbe present in the truck.

1

Fuses for standard equipment and equipmentvariants are located in the rear part of thecontrol electronics (1).

– Open the cover.

– Remove the cover from the control electron-ics.

– Replace the blown fuse; see the sectionentitled "Fuse assignment".

CAUTIONWater in the electrical system cancause damage to components!In order to protect theelectrical systemagainst ingress of water, the covermust be closed.– Refit the cover after these tasks

have been completed.


– Carry out a functional test.

394 56338011803 EN - 02/2018


Checking the hydraulic oil level– Park the truck securely.





– Remove maintenance lid or bottom plate.

CAUTIONHydraulic oils are hazardous to your health and areunder pressure during operation.– Note the safety regulations in the "Hydraulic

fluid" chapter.

CAUTIONRisk of damage to components!Remove connector for drive unit.

1

2

6210_700-002

– Unscrew breather filter (1).

– Check the oil level on the oil dipstick. The oillevel must be between the markings (2).

– If the oil level is too low, pour hydraulic oil ofthe correct specification as specified in themaintenance data table into the filler neck.

– Fill the hydraulic oil no higher than the uppermarking on the oil dipstick.

NOTE

Use a funnel.

ENVIRONMENT NOTE

Carefully collect up any spilled oil and disposeof it in an environmentally friendly manner.

– Screw in the breather filter with oil dipstick.

– Close maintenance lid or bottom plate.

56338011803 EN - 02/2018 395



Checking the hydraulic system forleaks

WARNINGHydraulic oil under pressure canescape from leaking lines and causeinjuries to the skin.Wear suitable protective gloves,industrial goggles etc.

WARNINGHydraulic hoses become brittle!Hydraulic hoses should not be used longer than 6years.The specifications of BGR 237 should be compliedwith. Deviating national laws are to be taken intoaccount.

– Check pipe and hose connection screwjoints for leaks (traces of oil).

Hose lines must be changed if:• The outer layer has been breached orbecomes brittle with tears

• They are leaking• There are unnatural deformations (e.g.bubble formation or buckling)

• A fitting is detached from the hose• A fitting is badly damaged or corroded

Pipes must be changed if:• There is abrasion with the loss of material• There are unnatural deformations anddetectable bending stress

• They are leaking

396 56338011803 EN - 02/2018


16210_800-020

Lubricating the lift mast and rollertrack– Remove dirt and lubricant residue from theroller track.

– Lubricate the roller tracks (1) of the outside,middle, and inside mast with a super-pressure adhesion lubricant to reducewear. See ⇒ Chapter "Maintenance datatable", P. 5-378.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

Greasing the automatic tow coupling

NOTE

Wear to moving parts can be significantlyreduced by appropriate servicing and regularlubrication of the coupling.

– Avoid over-greasing!

NOTE

Close the coupling before cleaning witha high-pressure cleaner. After cleaning,lubricate the coupling pin, tow bar eye andits supporting surface again.

56338011803 EN - 02/2018 397


3

7321_003-091

21

Model RO*243– Pull out the safety handle (3).


– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 5-378.

– Close the coupling by raising the couplingpin with a suitable tool.

– For journeys with a rigid drawbar trailer,lubricate the underside of the tow bar eyeand the supporting surface on the coupling.

7321_003-092

– Determine the wear on the coupling pin.

The diameter of the spherical part must not beless than 36.5 mm.

Model RO*244 A– Open coupling.

Wartung_Rockinger 244 A

1– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 5-378.

– Grease coupling pin, tow bar eye and itssupporting surface.

398 56338011803 EN - 02/2018


7321_003-094

Model RO*245– Lubricate via the points provided for thispurpose (lubricating nipple, opened cou-pling) in accordance with the maintenancedata table; see ⇒ Chapter "Maintenancedata table", P. 5-378.

– Grease the supporting surface for thetow-bar eye.

7321_003-095

Model RO*841– Lubricate via the points provided for thispurpose (lubricating nipple, opened cou-pling) in accordance with the maintenancedata table; see ⇒ Chapter "Maintenancedata table", P. 5-378.

– Grease the supporting surface for thetow-bar eye.

56338011803 EN - 02/2018 399


6210_900-002

Maintenance for trucks used in coldstores– On trucks used in cold stores (variant),check all rollers and chains in the lift mastfor ease of movement once a week.

Replacing the heater filter mat

DANGERDanger of death from electric shock!The heater housing contains liveparts. These live parts can cause anelectric shock while the battery maleconnector is connected.– Do not reach into the heater if the

truck is connected to the battery.– Park the truck safely. Disconnect

the battery male connector.

6321_003-091

1

2

– Loosen the mounting screw (1).

– Remove the cover (2).

400 56338011803 EN - 02/2018


4

3

6345_003-006

– Loosen the screw of the housing cover (3).

– Remove the housing cover (4).

6345_003-007

7

5

6

– Pull out the filter mat carrier (5).

– Check the filter mat (6) for contamination. Ifthe filter mat is grey in colour, replace it.

NOTE

Change the filter mat at least every twomonths.

– Remove any dust and dirt from the fresh-airinlet (7) beneath the filter mat carrier.

56338011803 EN - 02/2018 401


402 56338011803 EN - 02/2018

Maintenance 51000-hour maintenance/annual maintenance

1000-hour maintenance/annual maintenanceOther tasks– Perform all tasks required to maintainfull operability; see the chapter entitled"Remaining ready for operation".

6321_003-030

1

2

Checking the cable connections– Check that the pump motor feed cable(1) and traction motor feed cable (2) aresecurely attached, in good condition andinsulated.

NOTE

Oxidised connections and brittle cables resultin voltage drops and cause malfunctions.

– Remove oxidised connections and replacebrittle cables.

6327_003-045

1

Checking the hydraulic oil level of thehydraulic battery carrier

WARNINGHydraulic oils are hazardous to your health and areunder pressure during operation.– Note safety regulations for working with hydrau-

lic oils; see ⇒ Chapter "Hydraulic fluid", P. 2-51.

Checking the hydraulic oil level– Park the forklift truck on level ground.

– Remove the battery (see ⇒ Chapter "Re-placing the battery with the hydraulic bat-tery carrier", P. 4-337) and place it next tothe truck so that the battery male connectorcan be inserted again.

The minimum distance between the batteryand the truck should be > 0.5 m. This is to

56338011803 EN - 02/2018 403

5 Maintenance1000-hour maintenance/annual maintenance

ensure that the hydraulic battery carrier pushbuttons can be accessed.

– Connect the battery plug.

WARNINGIf the battery carrier is not at a sufficient safetydistance from mechanical components when it isactuated hands or feet can be crushed. There isrisk of injury!– Actuating beyond the carrier is prohibited.– It is not permitted to walk on the battery holder

plate.

– Retract the hydraulic battery carrier.

– Withdraw sealing plug (1) through theopening in the mounting plate.

The oil level must lie between 65 and 70mm when measured from the base of thecontainer.

– If the oil level is below the required level,top up the hydraulic oil via the filler neckaccording to the maintenance data table(see ⇒ Chapter "Maintenance data ta-ble", P. 5-378).

NOTE

Use a funnel.

– Screw sealing plugs (1) back in.

– Reinstall the battery.

ENVIRONMENT NOTE

Carefully collect up any spilled oil and disposeof it in an environmentally friendly manner.

404 56338011803 EN - 02/2018


Lubricating the slide elements

2

6321_003-124

6321_003-125

3

Lubricating the slide elements– Extend the battery with the hydraulicbattery carrier and remove the battery, see⇒ Chapter "Replacing the battery with thehydraulic battery carrier", P. 4-337.

– Remove dirt and contaminated lubricantresidues.

– Lubricate the slide elements and guide rails(2) and (3) in accordance with the mainte-nance data table (see ⇒ Chapter "Mainte-nance data table", P. 5-378.

– Reinstall the battery.

Oiling the catch rails

WARNINGRisk of injury!If the battery carrier is not at a sufficiently safetydistance from mechanical components when it isactuated, hands or feet may be crushed.– Actuating beyond the battery carrier is prohibi-

ted.– It is not permitted to walk on the battery holder

plate.

56338011803 EN - 02/2018 405


WARNINGRisk of injury!If the battery carrier is actuated while maintenancework is being carried out, hands or feet may becrushed.– De-energise the truck before performing mai-

ntenance work.

WARNINGRisk of crushing!If the support rollers swing away when the batteryis inserted, the battery carrier with the battery canland on feet.If the catch rails are not clean and are insufficientlyoiled, there is no guarantee that the support rollerswill lock correctly.Toensure that theoil is evenly distributedand to testthe functionality, fully retract and then fully extendthe battery carrier once after the oiling is complete.The support rollers must be swung out fully andlocked in position after lubrication.

NOTE

The catch rails of the support rollers are loca-ted beneath the battery carrier. If necessaryuse a mirror to gain a better view.

– Park the forklift truck on level ground.

6210_003-007

– Remove the battery, see "Replacing thebattery with the hydraulic battery carrier".

– Place the battery next to the truck so that thebattery male connector can be reinserted.

The minimum distance between the batteryand the truck must be > 0.5 m. This distanceensures that the hydraulic battery carrieractuation buttons can be accessed.


– Retract the battery carrier until the sup-port rollers are directly underneath (thebattery carrier is then extended by approx.300 mm).

– Pull out the switch key.

– Push the emergency off switch.


406 56338011803 EN - 02/2018


– Remove any dirt from the catch rails.

6210_003-049_V2

– Lubricate the catch rails with oil accordingto the maintenance data table - do not usegrease!


– Pull the emergency off switch.


– Retract the battery carrier fully and thenextend again.

WARNINGRisk of crushing!The support rollers must be swung out fully andlocked in position after lubrication.

– Check that the support rollers are swung allthe way out and are locked in position.

– If the support rollers are fully swung out andlocked, reinstall the battery.

– If the support rollers do not swing outcorrectly or are not in the locked position,inform your authorised service centre.

6321_003-020

Checking the lift cylinders andconnections for leaks

WARNINGRisk of injury!Observe safety regulations for working on the liftmast, see the "Working at the front of the truck"chapter.

– Check hydraulic connections and lift cylin-ders for leaks (visual inspection).

– Have leaking screw joints or leaking hy-draulic cylinders repaired by the authorisedservice centre.

56338011803 EN - 02/2018 407


6210_842-002

1

23

Checking fork arms– Inspect the fork arms (1) for any visibledeformation. The wear must not amount tomore than 10% of the original thickness.

CAUTIONWorn fork arms should always be replaced in pairs.

– Check the securing mechanism (3) forproper operation.

– The locking screw (2) that prevents dislodg-ing must be present.

Checking the reversible fork arms

NOTE

This check is only required for reversible forkarms (variant).

– Check the outside of the fork bend (1) forcracks. Contact your service centre.

408 56338011803 EN - 02/2018


6327_003-026

Checking the double pedal– Remove the floorplate.

– Check that the support and springs of thedouble pedal mechanism are securelypositioned.

– Check that all screws are sealed withlocking varnish.

Checking the battery changeoverframe– The screw joints and welded seams ofthe battery changeover frame must besubjected to a visual inspection.

56338011803 EN - 02/2018 409


410 56338011803 EN - 02/2018

6

Technical data

6 Technical dataDimensions

Dimensions

1 Seat is adjustable ±90 mm 2 Fork spacing is adjustable

412 56338011803 EN - 02/2018

Technical data 6Dimensions

NOTE

Measurements h1, h3, h4, h6 and b1 arecustomised and can be taken from the orderconfirmation.

Centre of gravity "S" (distance measuredfrom the front axle)

RX60-25 (6345) 774 mm

RX60-25/600 (6346) 774 mm

RX60-25L (6347) 842 mm

RX60-25L/600 (6348) 842 mm

RX60-30 (6353) 823 mm

RX60-30L (6354) 830 mm

RX60-30L/600 (6355) 830 mm

RX60-35 (6356) 892 mm

NOTE

The specified centre of gravity "S" relatesto trucks with standard equipment. If, forexample, the truck is equipped with a differentlift mast, attachment or driver protectionstructure, this value is only a guide value. Ifnecessary, the centre of gravity "S" must bedetermined on an individual basis for eachtruck.

56338011803 EN - 02/2018 413

6 Technical dataVDI datasheet for RX60-25 and RX60-25/600

VDI datasheet for RX60-25and RX60-25/600

NOTE

This VDI datasheet specifies only the techni-cal values of the truck version with standardequipment. Different tyres, lift masts, additio-nal units etc. may produce different values.

Characteristics

Model RX60-25 RX60-25/600

Type number 6345 6346

Manufacturer STILL GmbH STILL GmbH

Drive Electric Electric

Operation Seated Seated

Rated capacity/load Q (kg) 2500 2500

Load centre of gravity distance c (mm) 500 600

Load distance x (mm) 445 450

Wheelbase y (mm) 1595 1595

Weights

Model RX60-25 RX60-25/600


Net weight including battery kg 4585 4840

Axle load with front load kg 6287 6502

Axle load with rear load kg 798 838

Axle load without front load kg 2306 2356

Axle load without rear load kg 2279 2484.

Wheels, chassis frame

Model RX60-25 RX60-25/600


Tyres SE SE

Front tyre size 225/75-10(23x9-10)

225/75-10(23x9-10)

414 56338011803 EN - 02/2018

Technical data 6VDI datasheet for RX60-25 and RX60-25/600

Model RX60-25 RX60-25/600


Rear tyre size 180/70-8(18x7-8)

180/70-8(18x7-8)

Number of front wheels (x = driven) 2x 2x

Number of rear wheels (x = driven) 2 2

Front track width b10 (mm) 992 992

Rear track width b11 (mm) 900 900.

Basic dimensions

Model RX60-25 RX60-25/600


Tilt of lift mast/fork carriage, forwards Degrees 5 5

Tilt of lift mast/fork carriage, backwards1 Degrees 7 7

Height with lift mast retracted h1 (mm) 2200 2200

Free lift h2 (mm) 160 160

Lift2 h3 (mm) 3020 3020

Height with lift mast extended h4 (mm) 3650 3800

Height above overhead guard h6 (mm) 2210 2210

Seat height in relation to SIP h7 (mm) 1262 1262

Coupling height h10 (mm) 485 / 365 485 / 365

Total length l1 (mm) 3353 3558

Length including fork back l2 (mm) 2353 2358

Total width b1 (mm) 1199 1199

Fork arm thickness s (mm) 40 45

Fork arm width e (mm) 100 100

Fork arm length l (mm) 1000 1200

Fork carriage Standard;class; form ISO 2328 III A ISO 2328 III A

Fork carriage width b3 (mm) 1150 1150

Ground clearance with load under lift mast m1 (mm) 125 125

1 Applies to telescopic, NiHo and triple masts.2 The specified nominal lift takes into account the tyre deflection and tolerances of the tyre diameter.

56338011803 EN - 02/2018 415

6 Technical dataVDI datasheet for RX60-25 and RX60-25/600

Model RX60-25 RX60-25/600


Ground clearance at centre of wheelbase m2 (mm) 125 125Aisle width for pallet 1000 x 1200 cross-wise3

Ast (mm) 3678 36834

Aisle width for pallet 800 x 1200 length-wise5

Ast (mm) 3877 3882

Turning radius Wa (mm) 2032 2032

Smallest pivot point distance b13 (mm) 539 539.

Performance data

Model RX60-25 RX60-25/600


Driving speed with load km/h 19 19

Driving speed without load km/h 20 20

Lifting speed with load m/s 0.53 0.52

Lifting speed without load m/s 0.55 0.55

Lowering speed with load m/s 0.54 0.54

Lowering speed without load m/s 0.45 0.45

Tractive force with load kg 8000 7950

Tractive force without load kg 8110 8060

Max. tractive force with load kg 17,440 17,420

Max. tractive force without load kg 17,220 17,090

Climbing capability with load % 21.3 20.4

Climbing capability without load % 29.5 29.1

Max. climbing capability with load % 25.5 24.0

Max. climbing capability without load % 29.7 28.3

Acceleration time with load s 4.5 4.6

Acceleration time without load s 4.2 4.2Service brake Electr./mech. Electr./mech.

.

3 Applies to telescopic, NiHo and triple masts.4 Does not take the protruding fork arms into consideration.5 Applies to telescopic, NiHo and triple masts.

416 56338011803 EN - 02/2018

Technical data 6VDI datasheet for RX60-25 and RX60-25/600

Ascending gradientsThe values specified in the "Performancedata" table as the maximum climbing capa-bility can be used only to compare the perfor-mance of forklift trucks in the same category.The specified values in no way represent thenormal daily operating conditions.

WARNINGTo use the truck safely – with or without a load –the maximum ascending or descending gradientpermitted for travel is 15%.– If you have any questions, contact your authori-

sed service centre.

Electric motor

Model RX60-25 RX60-25/600


Traction motor, power rating S3 60 min kW 15 15

Lift motor, power rating at 15% ED kW 16.3 16.3

Battery Standard;circuit DIN 43536 A DIN 43536 A

Battery voltage U (V) 80 80

Nominal capacity K5 K5 (Ah) 560 - 620 560 - 620

Battery weight kg 1558 1558Energy consumption: 60 VDI workingcycles/hour kWh/h 6.7 6.9

.

Other

Model RX60-25 RX60-25/600


Working pressure for attachments bar 250 250

Oil flow for attachments l/min 30 30Sound pressure level LpAZ (driver's com-partment)6 dB (A) < 70 < 70

Human vibration: acceleration in accor-dance with EN 13059 m/s2 < 0.7 < 0.7

Tow coupling, DIN type/model Bolt Bolt.

6 Without cab. Values with cab differ.

56338011803 EN - 02/2018 417

6 Technical dataVDI datasheet for RX60-25L and RX60-25L/600

VDI datasheet for RX60-25Land RX60-25L/600

NOTE


Key data

Model RX60-25L RX60-25L/600








Wheelbase y (mm) 1740 1740.

Weight











Tyres SE SE

Front tyre size 225/75-10(23x9-10)

225/75-10(23x9-10)

418 56338011803 EN - 02/2018

Technical data 6VDI datasheet for RX60-25L and RX60-25L/600




180/70-8(18x7-8)





Basic dimensions



Tilt of lift mast/fork carriage, forwards Degree 5 5

Tilt of lift mast/fork carriage, backwards7 Degree 7 7



Lift8 h3 (mm) 3020 3020















56338011803 EN - 02/2018 419





Ast (mm) 3830 383510


Ast (mm) 4030 4035



Performance data











Max. tractive force with load kg 17390 17420

Max. tractive force without load kg 17210 17130






Acceleration time without load s 4.2 4.2Service brake electr./mech. electr./mech.

.


420 56338011803 EN - 02/2018




sed service centre.

Electric motor









.

Other








56338011803 EN - 02/2018 421

6 Technical dataVDI datasheet for RX60-30 and RX60-35

VDI datasheet for RX60-30and RX60-35

NOTE


Characteristics

Model RX60-30 RX60-35









Weights











Tyres SE SE

Front tyre size 250/60-12(23x10-12) 315/45-12

422 56338011803 EN - 02/2018

Technical data 6VDI datasheet for RX60-30 and RX60-35




180/70-8(18x7-8)





Basic dimensions







Lift14 h3 (mm) 3020 3020















56338011803 EN - 02/2018 423

6 Technical dataVDI datasheet for RX60-30 and RX60-35




Ast (mm) 3760 3879


Ast (mm) 3960 4079



Performance data



















.

15 Applies to telescopic, NiHo and triple masts.16 Applies to telescopic, NiHo and triple masts.

424 56338011803 EN - 02/2018

Technical data 6VDI datasheet for RX60-30 and RX60-35



sed service centre.

Electric motor









.

Other








56338011803 EN - 02/2018 425


VDI datasheet for RX60-30Land RX60-30L/600

NOTE


Characteristics










Weights











Tyres SE SE

Front tyre size 250/60-12(23x10-12) 315/45-12

426 56338011803 EN - 02/2018





180/70-8(18x7-8)





Basic dimensions







Lift19 h3 (mm) 3020 3020















56338011803 EN - 02/2018 427





Ast (mm) 3850 385021


Ast (mm) 4050 4050



Performance data



















.


428 56338011803 EN - 02/2018




sed service centre.

Electric motor









.

Other








56338011803 EN - 02/2018 429

6 Technical dataErgonomic dimensions

0000_003-002

40 mm

Ergonomic dimensions

WARNINGDanger of impact injuries to the head!If the head of the operator is located too close to theunderside of the roof, the suspension of the driver'sseat or an accidentmay cause the head to strike theoverhead guard.To avoid head injuries, a minimum distance of40 mmmust be ensured between the underside ofthe roof and the head of the tallest operator.To determine the actual head clearance, the opera-tor must sit in the driver's seat and the seat suspen-sion must be set to this driver's requirements.Due to the individual nature of height and bodyweight aswell as thewide variety of types of driver'sseat and overhead guard, the minimum headclearance must be ensured in every truck.

The driver's compartment has been designedtaking ergonomics in the workplace intoaccount and in accordance with EN ISO 3411.In general, from the seat position, the operatorhas sufficient space to reach the operatingdevices safely, to operate the truck and to viewthe outline of the truck. Operators whose bodysize deviates from the specified dimensionson which EN ISO 3411 is based must beindividually considered by the operatingcompany.

430 56338011803 EN - 02/2018

Technical data 6Information about the lead-acid battery

Information about thelead-acid battery

CAUTIONThe battery weight and the battery dimensionsaffect the stability of the truck.When replacing the battery, the weight ratiosmust not be changed. The battery weight mustremain within the weight range specified on thenameplate. The location of ballast weightsmust notbe changed. The bottom of the battery tray must beclosed.

– Use batteries that meet DIN standards.

– Do not change the position of ballastweights.

– Check the battery weight against theinformation on the nameplate.

– Only use a battery tray that is closed at thebottom.

– The battery weight can be found on thenameplate of the battery.

NOTE

Battery specifications according toDIN 43536;cells in accordance with DIN EN 60254-2,80-V circuit B.

RX60-25 (6345), RX60-25/600 (6346), RX60-30 (6353)

Battery compartment dimensions [mm]Batterydesignation

Capacity[Ah] Depth Width Height

Tray

4 PzV 480 4804 PzW 560HAWKER®

wf 200plus560

4 PzS 560 560

4 PzS 620 620

4 CSM 640 640TENSOR®

TCSM 1235 640

1028 711 784 234

.

56338011803 EN - 02/2018 431

6 Technical dataInformation about the lead-acid battery

RX60-25L (6347), RX60-25L/600 (6348), RX60-30L (6354), RX60-30L/600 (6355),RX60-35 (6356)

Battery compartment dimensions [mm]Batterydesignation


Tray


wf 200plus560

4 PzS 560 560

4 PzS 620 620

4 CSM 640 640

1028 711 784 234


wf 200plus700

5 PzS 700 700

5 PzS 775 775

5 CSM 800 800TENSOR®

TCSM 1620 840

1028 855 784 235

NOTE

When converting to TENSOR® batteries, themaximum speed of the truck must be limitedto 17 km/h for technical reasons. Contactthe authorised service centre regarding thismatter.

432 56338011803 EN - 02/2018

Technical data 6Information about the lithium-ion battery

Information about thelithium-ion battery

CAUTIONThe battery weight and the battery dimensionsaffect the stability of the truck.When replacing the battery, the weight ratios mustnot be changed. The battery weight must remainwithin the weight range specified on the nameplate.The bottom of the battery tray must be closed.

– Use batteries that meet DIN standards.

– Check the battery weight against theinformation on the nameplate.

– Only use a battery tray that is closed at thebottom.

– The battery weight can be found on thenameplate of the battery.

– For more information, please refer to thenameplate and the operating instructionsfor the lithium-ion battery.

GGS Li-Ion 80 V BG6Battery compartment dimensions [mm]Battery

designationand nominalenergy [kW/h]


Tray

24.1 268

60.3 6701028 711 687 234

– Contact the authorised service centre forfurther technical data.

56338011803 EN - 02/2018 433

6 Technical dataFuse assignment

Fuse assignment

12 3 4 5 6 7 8

910

111213

14

6210_604-002

Fuse assignment standard equip-ment

1 Main fuse F01 400 A

2 Heating system F22 50 A

3 Voltage converter F21 20 A

4 CPP rear F24 10 A

5 Option board, solenoid valve on the attachment F23 10 A

6 CPP/RPP roof F26 25 A

7 CPP/RPP seat F27 25 A

8 MMS option board F29 15 A

9 CPP/RPP front F28 10 A

10 Proportional technology F25 10 A

11 U4 voltage converter F15 10 A

Solenoid valve on attachment F15 10 A

12 U1 voltage converter F14 15 A

U1/U2 voltage converter F14 30 A

48 V working spotlight F14 15 A

13 SU/MCU F11 10 A

14 Horn F12 10 A.

434 56338011803 EN - 02/2018

Technical data 6Fuse assignment

8

9

0

6

7

4

2

13

5

F1 F2

7312_003-042

%75

h

2

234,7

12:15

12 3

Fuse assignment equipment vari-ants

1 5th hydraulic function 24/48 V F1 10 A

2 Variant (e.g. MMS) F3 10 A

3 Variant (e.g. light) F2 10 A.

56338011803 EN - 02/2018 435

6 Technical dataFuse assignment

436 56338011803 EN - 02/2018

Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 97Defining the driver PIN . . . . . . . . . . . . 93Entering the access code . . . . . . . . . 92Selecting the driver PIN . . . . . . . . . . . 95

Access authorisation with PIN code . . . . 91Accessories . . . . . . . . . . . . . . . . . . . . . . . 7Actuate the parking brake

when the truck is moving . . . . . . . . . 143Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 130Joystick 4Plus version . . . . . . . . . . 130Mini-console version . . . . . . . . . . . . 131Mini-lever version . . . . . . . . . . . . . . 129Multiple-lever version . . . . . . . . . . . 129

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 86Adjusting the fork . . . . . . . . . . . . . . . . . 186Adjusting the steering column . . . . . . . . . 87After washing . . . . . . . . . . . . . . . . . . . . 351

AttachmentsAssembly . . . . . . . . . . . . . . . . . . . . 198Controlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 209Controlling using multi-lever

operation . . . . . . . . . . . . . . . . . . 206Controlling using the double

mini-lever and the 5th function . . 211Controlling using the joystick 4Plus . 221Controlling using the quadruple

mini-lever and the 5th function . . 219Controlling using the triple

mini-lever and the 5th function . . 215Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 217Controlling with a triple mini-lever . . . 213Controlling with fingertip . . . . . . . . . 224Controlling with fingertip and

5th function . . . . . . . . . . . . . . . . 225General controlling . . . . . . . . . . . . . 204Mounting . . . . . . . . . . . . . . . . . . . . 199Operating with multi-lever controls

and the 5th function . . . . . . . . . . 207Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 200Special risks . . . . . . . . . . . . . . . . . . . 42Taking up a load . . . . . . . . . . . . . . . 231

Automatic lift cut out . . . . . . . . . . . . . . . 174Automatic tow coupling . . . . . . . . . . . . 259

Coupling RO*243 . . . . . . . . . . . . . . 261Coupling RO*244 A . . . . . . . . . . . . . 263Coupling RO*245 . . . . . . . . . . . . . . 265Coupling RO*841 . . . . . . . . . . . . . . 266Uncoupling RO*243 . . . . . . . . . . . . 262Uncoupling RO*244 A . . . . . . . . . . . 264Uncoupling RO*245 . . . . . . . . . . . . 266Uncoupling RO*841 . . . . . . . . . . . . 267

Axle stub nutsChecking the tightening torque . . . . 390

56338011803 EN - 02/2018 437

Indexg

BBattery

Changing the battery type . . . . . . . . 326Charging . . . . . . . . . . . . . . . . . . . . . 304Charging to equalise . . . . . . . . . . . . 311Charging with the battery charging

flap . . . . . . . . . . . . . . . . . . . . . . 307Check interlock . . . . . . . . . . . . . . . . 383Checking . . . . . . . . . . . . . . . . . . . . 391Checking condition, acid level and

acid density . . . . . . . . . . . . . . . . 303Checking the changeover frame . . . 409Checking the charge state . . . . . . . . 304Disposal . . . . . . . . . . . . . . . . . . . . . . 23Information . . . . . . . . . . . . . . . . . . . 431Maintaining . . . . . . . . . . . . . . . . . . . 301Safety regulations . . . . . . . . . . . . . . 298

Battery acid . . . . . . . . . . . . . . . . . . . . . . 52Battery cover

Check interlock . . . . . . . . . . . . . . . . 383Battery specifications

Lead-acid battery . . . . . . . . . . . . . . 431Lithium-ion battery . . . . . . . . . . . . . 433

Before taking up load . . . . . . . . . . . . . . 181Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 120Functional description . . . . . . . . . . . 118Switching off . . . . . . . . . . . . . . . . . . 119Switching off additional consumers . 119Switching on . . . . . . . . . . . . . . . . . . 119

CCab

Open door . . . . . . . . . . . . . . . . . . . 248Opening the side windows . . . . . . . . 249Operating the interior lighting . . . . . . 250Operating the rear window heating . . 251

CE labelling . . . . . . . . . . . . . . . . . . . . . . . 5Ceiling sensor . . . . . . . . . . . . . . . . . . . 242Changes to the truck . . . . . . . . . . . . . . . 33Changing the drive direction . . . . . . . . . 132

Dual-pedal version . . . . . . . . . . . . . 135

Changing the fork arms . . . . . . . . . . . . 167Changing the password . . . . . . . . . . . . . 97Charging the lithium-ion battery . . . . . . 323Checking fork arms . . . . . . . . . . . . . . . 408Checking the cable connections . . . . . . 403Checking the charge state of the

lead-acid battery . . . . . . . . . . . . 304Checking the charge status of the

lithium-ion battery . . . . . . . . . . . . 320Checking the double pedal . . . . . . . . . . 409Checking the driver's seat . . . . . . . . . . . 386Checking the emergency off function . . 103Checking the lift cylinders and

connections for leaks . . . . . . . . . 407Checking wheel fastenings . . . . . . . . . . 388Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 227Cleaning the electrical system . . . . . . . 349Cleaning the truck . . . . . . . . . . . . . . . . 347Cleaning the windows . . . . . . . . . . . . . 351Climbing into the truck . . . . . . . . . . . . . . 78Climbing out of the truck . . . . . . . . . . . . . 78Clipboard . . . . . . . . . . . . . . . . . . . . . . . 255Closing the cab door . . . . . . . . . . . . . . . 249Closing the side windows . . . . . . . . . . . 249Cold store application . . . . . . . . . . . . . . 269

Batteries . . . . . . . . . . . . . . . . . . . . . 270Operation . . . . . . . . . . . . . . . . . . . . 269Types of application . . . . . . . . . . . . 269

Commissioning . . . . . . . . . . . . . . . . . . . 11Condition of the roadways . . . . . . . . . . 126Connecting the batterymale connector . 296Consumables . . . . . . . . . . . . . . . . . . . . 50

Disposal . . . . . . . . . . . . . . . . . . . . . . 53Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 52Safety information for handling oils . . . 50Safety information for hydraulic fluid . . 51

Contact details . . . . . . . . . . . . . . . . . . . . . ICopyright and trademark rights . . . . . . . . 18Coupling pin in the counterweight . . . . . 257

438 56338011803 EN - 02/2018

Indexg

Cover sheet on the counterweightFitting . . . . . . . . . . . . . . . . . . . . . . . 382Removing . . . . . . . . . . . . . . . . . . . . 382

Crane loading . . . . . . . . . . . . . . . . . . . 354Determining the loading weight . . . . 355Hooking on the lifting straps . . . . . . . 355

Curve Speed Control . . . . . . . . . . . . . . 153

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 37Danger area . . . . . . . . . . . . . . . . . . . . 186Danger areas of lithium ion batteries . . . . 30Danger to employees . . . . . . . . . . . . . . . 47Declaration of conformity . . . . . . . . . . . . . 6Declaring the use of lithium-ion batteries . 32Decommissioning the truck . . . . . . . . . 358Defects . . . . . . . . . . . . . . . . . . . . . . . . . 37Defining the driver PIN . . . . . . . . . . . . . . 93Definition of directions . . . . . . . . . . . . . . 21Description of the truck . . . . . . . . . . . . . . . 2Dimensions . . . . . . . . . . . . . . . . . . . . . 412Dimensions of roadways . . . . . . . . . . . 124Direction indicators . . . . . . . . . . . . . . . 234

Fingertip version . . . . . . . . . . . . . . . 235Mini-console version . . . . . . . . . . . . 236Mini-lever version . . . . . . . . . . . . . . 234

Disconnecting the battery maleconnector . . . . . . . . . . . . . . . . . 296

Display and operating unitAdditional indicators . . . . . . . . . . . . 108Adjusting the displays . . . . . . . . . . . 108Configure Blue Q . . . . . . . . . . . . . . . 120Indicators . . . . . . . . . . . . . . . . . . . . 106

Display messagesDisplay content . . . . . . . . . . . . . . . . 272Drive-specific . . . . . . . . . . . . . 285, 317General . . . . . . . . . . . . . . . . . . . . . 276

Display operating unit . . . . . . . . . . . . . . . 62Resetting the daily kilometres . . . . . 115Setting the date . . . . . . . . . . . . . . . . 115Setting the language . . . . . . . . . . . . 116Setting the time . . . . . . . . . . . . . . . . 115Standard displays . . . . . . . . . . . . . . 106

Display symbols . . . . . . . . . . . . . . . . . . 110Auxiliary equipment softkey

functions . . . . . . . . . . . . . . . . . . 112Error messages . . . . . . . . . . . . . . . 111Menu navigation softkey functions . . 113Numeric keypad . . . . . . . . . . . . . . . 114Operating messages . . . . . . . . . . . . 110Status LEDs . . . . . . . . . . . . . . . . . . 113Warning messages . . . . . . . . . . . . . 111

Display-operating unitStandard display elements . . . . . . . . 90

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 23Components . . . . . . . . . . . . . . . . . . . 23

Documentation scope . . . . . . . . . . . . . . 16Double mini-lever . . . . . . . . . . . . . . . . . . 66

Lifting/lowering the fork carriage . . . 161Tilting the lift mast . . . . . . . . . . . . . . 161

Driver qualification for using lithium-ionbatteries . . . . . . . . . . . . . . . . . . . 32

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 27

Driver's cabUse . . . . . . . . . . . . . . . . . . . . . . . . 101

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 27Driving

Ascending gradients . . . . . . . . . . . . 195Descending gradients . . . . . . . . . . . 195

Driving lightsSwitching on and off . . . . . . . . . . . . 232

Driving on lifts . . . . . . . . . . . . . . . . . . . 196Driving on loading bridges . . . . . . . . . . 197

EEC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 6

56338011803 EN - 02/2018 439

Indexg

Electric parking brakeEmergency operation . . . . . . . . . . . 292Malfunctions . . . . . . . . . . . . . . . . . . 145

EmergenciesEmergency operation of the electric

parking brake . . . . . . . . . . . . . . . 292Truck tipping over . . . . . . . . . . . . . . 289Using the emergency hammer . . . . . 290

Emergency hammer . . . . . . . . . . . . . . . 290Emergency lowering . . . . . . . . . . . . . . 290Emergency shutdown . . . . . . . . . . . . . 288Emissions . . . . . . . . . . . . . . . . . . . . . . . 54

Battery . . . . . . . . . . . . . . . . . . . . . . . 56Noise emissions . . . . . . . . . . . . . . . . 54Radiation . . . . . . . . . . . . . . . . . . . . . 56Vibrations . . . . . . . . . . . . . . . . . . . . . 55

Entering the access code . . . . . . . . . . . . 92Ergonomic dimensions . . . . . . . . . . . . . 430Error code table . . . . . . . . . . . . . . . . . . 272Example . . . . . . . . . . . . . . . . . . . . . . . 182

FFilling the washer system . . . . . . . . . . . 240Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 70

Lifting/lowering the fork carriage . . . 166Tilting the lift mast . . . . . . . . . . . . . . 166

First-aid measures for working withlithium-ion batteries

Maintenance personnel . . . . . . . . . . 313Fitting attachments . . . . . . . . . . . . . . . 198FleetManager . . . . . . . . . . . . . . . . . . . 241

Shock recognition . . . . . . . . . . . . . . 241Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 39Fork extension . . . . . . . . . . . . . . . . . . . 169Four-way mini-lever . . . . . . . . . . . . . . . . 68

Lifting/lowering the fork carriage . . . 163Function checking . . . . . . . . . . . . . . . . . 74Fuse assignment

Equipment variants . . . . . . . . . . . . . 435Standard equipment . . . . . . . . . . . . 434

Fuse boxClosing . . . . . . . . . . . . . . . . . . . . . . 382Opening . . . . . . . . . . . . . . . . . . . . . 382

FusesChecking . . . . . . . . . . . . . . . . . . . . 391Replacing . . . . . . . . . . . . . . . . . . . . 393

GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 4General view . . . . . . . . . . . . . . . . . . . . . 58

Driver's compartment . . . . . . . . . . . . 60

HHandling gas springs and accumulators . 39Hazard areas . . . . . . . . . . . . . . . . . . . . 127Hazard assessment . . . . . . . . . . . . . . . . 32Hazard warning system . . . . . . . . . . . . 234Hazards and countermeasures . . . . . . . . 44Heating system . . . . . . . . . . . . . . . . . . 252Hydraulic battery carrier

Checking the oil level . . . . . . . . . . . . 403Lubricating the slide elements . . . . . 405Oiling the catch rails . . . . . . . . . . . . 405

Hydraulic blocking function . . . . . . . . . . 173Releasing . . . . . . . . . . . . . . . . . . . . 174

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 51Hydraulic system

Checking for leaks . . . . . . . . . . . . . . 396Checking the oil level . . . . . . . . . . . . 395

IIllustration of lithium-ion batteries . . . . . 316Impermissible use . . . . . . . . . . . . . . . . . 13Information for carrying out mainte-

nance . . . . . . . . . . . . . . . . . . . . 368Maintenance timeframe . . . . . . . . . . 369

Information symbols . . . . . . . . . . . . . . . . 18Insulation testing . . . . . . . . . . . . . . . . . . 48

Drive battery test values . . . . . . . . . . 49Test values for the truck . . . . . . . . . . . 49

Insurance cover on company premises . . 29Interior lighting . . . . . . . . . . . . . . . . . . . 250

440 56338011803 EN - 02/2018

Indexg

Issue date of the operating instructions . . 18

JJacking up . . . . . . . . . . . . . . . . . . . . . . 365Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 69

Fork-carriage sideshift . . . . . . . . . . . 165Lifting/lowering the fork carriage . . . 164Tilting the lift mast . . . . . . . . . . . . . . 165

LLashing . . . . . . . . . . . . . . . . . . . . . . . . 354Lift cut out

Automatic . . . . . . . . . . . . . . . . . . . . 174Lift mast

Lubricating the roller track . . . . . . . . 397Removing . . . . . . . . . . . . . . . . . . . . 367Securing against falling off . . . . . . . . 367Securing against tilting backwards . . 366

Lift mast versionsHi-Lo lift mast . . . . . . . . . . . . . . . . . 158Triplex lift mast . . . . . . . . . . . . . . . . 158

Lift mast vertical position . . . . . . . . . . . 175Automatic approach . . . . . . . . . . . . 177Calibrating . . . . . . . . . . . . . . . . . . . 179Description . . . . . . . . . . . . . . . . . . . 175Display . . . . . . . . . . . . . . . . . . . . . . 177Possible restrictions . . . . . . . . . . . . 179Run-in to end stops . . . . . . . . . . . . . 177Tilting the lift mast backwards . . . . . 178Tilting the lift mast forwards . . . . . . . 178

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 365Lifting system

Controlling using a doublemini-lever . . . . . . . . . . . . . . . . . . 161

Controlling using a quadruplemini-lever . . . . . . . . . . . . . . . . . . 163

Controlling using a triple mini-lever . . 162Controlling using the joystick 4Plus . 164Controlling with the fingertip

console . . . . . . . . . . . . . . . . . . . 166Multi-lever . . . . . . . . . . . . . . . . . . . . 160Operating devices . . . . . . . . . . . . . . 158

LightingSTILL SafetyLight . . . . . . . . . . . . . . 239Switching on and off . . . . . . . . . . . . 232

List of abbreviations . . . . . . . . . . . . . . . . 19Lithium-ion batteries

Battery weight and dimensions . . . . 315Changing the battery type . . . . . . . . 326Charging . . . . . . . . . . . . . . . . . . . . . 323Checking the charge status . . . . . . . 320Danger areas . . . . . . . . . . . . . . . . . . 30Declaring the use of . . . . . . . . . . . . . . 32Display . . . . . . . . . . . . . . . . . . . . . . . 63Display messages . . . . . . . . . . . . . . 317Driver qualification . . . . . . . . . . . . . . 32Fire protection measures . . . . . . . . . 314First-aid measures . . . . . . . . . . . . . 313Hazard assessment . . . . . . . . . . . . . 32Illustration . . . . . . . . . . . . . . . . . . . . 316Information . . . . . . . . . . . . . . . . . . . 433Installing . . . . . . . . . . . . . . . . . . . . . 329Maintenance personnel . . . . . . . . . . 313Nameplate . . . . . . . . . . . . . . . . . . . . 11Permissible batteries . . . . . . . . . . . . . 31Procedure in the event of a fire . . . . . . 32Product-specific dangers . . . . . . . . . . 30Regulations for storing . . . . . . . . . . 317Safety regulations . . . . . . . . . . 313, 315Special features . . . . . . . . . . . . . . . . 30Transport outside the premises . . . . . 33

Lithium-ion battery display . . . . . . . . . . . 63Load

Picking up . . . . . . . . . . . . . . . . . . . . 188Setting down . . . . . . . . . . . . . . . . . . 193transporting . . . . . . . . . . . . . . . . . . 192

Load capacity . . . . . . . . . . . . . . . . . . . 181Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 350Load measurement . . . . . . . . . . . . . . . 182

Description . . . . . . . . . . . . . . . . . . . 182Execution . . . . . . . . . . . . . . . . . . . . 183Zero adjustment . . . . . . . . . . . . . . . 104

Lubricating the joints and controls . . . . . 383

56338011803 EN - 02/2018 441

Indexg

MMaintenance data table . . . . . . . . . . . . 378

Battery . . . . . . . . . . . . . . . . . . . . . . 378Controls/joints . . . . . . . . . . . . . . . . . 378Drive axle . . . . . . . . . . . . . . . . . . . . 380Electrical system . . . . . . . . . . . . . . . 378General lubrication points . . . . . . . . 378Hydraulic battery carrier . . . . . . . . . 379Hydraulic system . . . . . . . . . . . . . . 379Lift mast . . . . . . . . . . . . . . . . . . . . . 380Load chains . . . . . . . . . . . . . . . . . . 380Steering axle . . . . . . . . . . . . . . . . . . 379Tyres . . . . . . . . . . . . . . . . . . . . . . . 379Washer system . . . . . . . . . . . . . . . . 380

Maintenance for trucks used in coldstores . . . . . . . . . . . . . . . . . . . . 400

Maintenance personnel for batteries . . . 368Maintenance work without special

qualifications . . . . . . . . . . . . . . . 368Malfunctions during lifting mode . . . . . . 172Malfunctions in the electric parking

brake . . . . . . . . . . . . . . . . . . . . . 145Manual tow coupling

Coupling . . . . . . . . . . . . . . . . . . . . . 257Uncoupling . . . . . . . . . . . . . . . . . . . 258

Medical equipment . . . . . . . . . . . . . . . . . 38

Message! PARKING BRAKE OIL PRES-

SURE . . . . . . . . . . . . . . . . . . . . 285? VERTICAL POSITION . . . . . . . . . 280ACCELERATOR . . . . . . . . . . . . . . . 277APPLY HANDBRAKE . . . . . . . . . . . 276ARE YOU SURE ? . . . . . . . . . . . . . 282BRAKE SENSOR . . . . . . . . . . . . . . 277CLOSE THEDOOR . . . . . . . . . . . . 286CODE DENIED . . . . . . . . . . . . . . . . 277EMERGENCY SWITCH . . . . . . . . . 279LIFT HEIGHT . . . . . . . . . . . . . . . . . 286LITHIUM BATTERY ERROR . . . . . . 317LITHIUM BATTERY RESTRIC-

TION . . . . . . . . . . . . . . . . . . . . . 317LITHIUM BATTERY TEMPERA-

TURE . . . . . . . . . . . . . . . . . . . . 317LOWER FORKS . . . . . . . . . . . . . . . 278MOT/GEN. TEMP. . . . . . . . . . . . . . 285NOT VALID . . . . . . . . . . . . . . . . . . . 285OVERHEATING . . . . . . . . . . . 284, 286PARKING BRAKE ACTIVE . . . . . . . 278PARKING BRAKE: APPLY

HANDBRAKE! . . . . . . . . . . . . . . 278REFERENCE CYCLE . . . . . . . . . . . 280RELEASE PARKING BRAKE . . . . . 278SAFETY BELT . . . . . . . . . . . . . . . . 281SEAT SWITCH . . . . . . . . . . . . . . . . 282SERVICE BRAKE . . . . . . . . . . . . . . 276STEERING . . . . . . . . . . . . . . . . . . . 279SURVEILLANCE . . . . . . . . . . . . . . 285SWITCHOFF TRUCK? . . . . . . . . . . 277TILTING SPEED . . . . . . . . . . . . . . . 279

MessagesGeneral . . . . . . . . . . . . . . . . . . . . . 276

Mini console . . . . . . . . . . . . . . . . . . . . . . 71Misuse of safety systems . . . . . . . . . . . . 37

442 56338011803 EN - 02/2018

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MSG 65/MSG 75 driver's seatAdjusting . . . . . . . . . . . . . . . . . . . . . 79Adjusting the backrest extension . . . . 82Adjusting the lumbar support . . . . . . . 82Adjusting the seat backrest . . . . . . . . 80Adjusting the seat suspension . . . . . . 81Moving . . . . . . . . . . . . . . . . . . . . . . . 80Switching the seat heater on and off . . 83

Multi-lever . . . . . . . . . . . . . . . . . . . . . . . 65Lifting/lowering the fork carriage . . . 160Tilting the lift mast . . . . . . . . . . . . . . 160

NNameplate . . . . . . . . . . . . . . . . . . . . . . . 10Nameplate of a lithium-ion battery . . . . . . 11Neutral position . . . . . . . . . . . . . . . . . . 128

OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Opening the cab door . . . . . . . . . . . . . . 248Opening the side windows . . . . . . . . . . 249Opening/closing the battery cover . . . . . 326Operating company . . . . . . . . . . . . . . . . 26Operating devices for hydraulic and

traction functions . . . . . . . . . . . . . 64Operating materials

Quality and quantity . . . . . . . . . . . . 375Operating procedures . . . . . . . . . . . . . . 21Operating the service brake . . . . . . . . . 136Operating the signal horn . . . . . . . . . . . 100Ordering spare parts andwearing parts . 375Overhead guard

Drilling . . . . . . . . . . . . . . . . . . . . . . . 36Roof loads . . . . . . . . . . . . . . . . . . . . 36Welding . . . . . . . . . . . . . . . . . . . . . . 36

OverviewAccessories . . . . . . . . . . . . . . . . . . . . 7Identification points . . . . . . . . . . . . . . . 8

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 23

Parking brake . . . . . . . . . . . . . . . . . . . 137Electric parking brake . . . . . . . . . . . 139Mechanical parking brake . . . . . . . . 137

Parking the truck securely . . . . . . . . . . 155Permissible lithium-ion batteries . . . . . . . 31Personnel qualifications . . . . . . . . . . . . 368Picking up loads . . . . . . . . . . . . . . . . . . 185Place of use . . . . . . . . . . . . . . . . . . . . . . 13Procedure if truck tips over . . . . . . . . . . 289Procedure in the event of a fire when

using lithium-ion batteries . . . . . . . 32Product-specific dangers of lithium-ion

batteries . . . . . . . . . . . . . . . . . . . 30Production number . . . . . . . . . . . . . . . . 10Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 28Proper usage . . . . . . . . . . . . . . . . . . . . . 12Push-up roof window . . . . . . . . . . . . . . 254

QQuadruple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 163

RRadio . . . . . . . . . . . . . . . . . . . . . . . . . 251Rear window heating . . . . . . . . . . . . . . 251Reducing speed when turning . . . . . . . 153Reducing speed with a raised load . . . . 154Regulations for storing lithium-ion

batteries . . . . . . . . . . . . . . . . . . 317Replacing the battery

General information . . . . . . . . . . . . 325Lithium-ion battery . . . . . . . . . . . . . 329Using a change frame . . . . . . . . . . . 333using a forklift truck . . . . . . . . . . . . . 330with the hydraulic battery carrier . . . . 337

Replacing the filter mat . . . . . . . . . . . . . 400Resetting the daily kilometres . . . . . . . . 115Resetting the daily operating hours . . . . 115Residual dangers . . . . . . . . . . . . . . . . . . 41Residual risks . . . . . . . . . . . . . . . . . . . . 41Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 33

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Returning to service after decommis-sioning . . . . . . . . . . . . . . . . . . . . 360

Reversible fork armChecking . . . . . . . . . . . . . . . . . . . . 408

Reversible fork arms . . . . . . . . . . . . . . 171Roadways . . . . . . . . . . . . . . 124, 126 – 127

Aisle widths . . . . . . . . . . . . . . . . . . . 124Ascending gradients . . . . . . . . . . . . 125Components protruding beyond the

truck contour . . . . . . . . . . . . . . . 126Descending gradients . . . . . . . . . . . 125

Rotating beacon . . . . . . . . . . . . . . . . . . 233Rules for roadways and the working

area . . . . . . . . . . . . . . . . . . . . . . 127

SSafety devices . . . . . . . . . . . . . . . . . . . 365Safety inspection . . . . . . . . . . . . . . . . . . 48Safety regulations for handling

lithium-ion batteries . . . . . . . . . . 313Battery weight and dimensions . . . . 315Fire protection measures . . . . . . . . . 314Maintenance personnel . . . . . . . . . . 313

Safety regulations for handling thebattery

Damage to cables and battery maleconnectors . . . . . . . . . . . . . . . . . 301

Safety regulations for maintenanceGeneral information . . . . . . . . . . . . 364Safety devices . . . . . . . . . . . . . . . . 365Set values . . . . . . . . . . . . . . . . . . . . 365Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 364Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 364Safety regulations for working on the lift

mast . . . . . . . . . . . . . . . . . . . . . 366Safety regulations for working with

lithium-ion batteries . . . . . . . . . . 315Safety regulations when driving . . . . . . 122Safety regulations when handing loads . 180

Safety regulations when handling thebattery . . . . . . . . . . . . . . . . . . . . 298

Battery weight and dimensions . . . . 300Fire protection measures . . . . . . . . . 299Maintaining the battery . . . . . . . . . . 300Maintenance personnel . . . . . . . . . . 298

Schematic views . . . . . . . . . . . . . . . . . . 21Scope of the documentation

UPA solutions . . . . . . . . . . . . . . . . . . 17Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 83

Checking . . . . . . . . . . . . . . . . . . . . 385Cleaning . . . . . . . . . . . . . . . . . . . . . 386Fastening . . . . . . . . . . . . . . . . . . . . . 84Fastening on a steep slope . . . . . . . . 85Maintaining . . . . . . . . . . . . . . . . . . . 385Malfunction due to cold . . . . . . . . . . . 85Releasing . . . . . . . . . . . . . . . . . . . . . 85Replacement after an accident . . . . 386

Selecting the drive direction . . . . . . . . . 128Selecting the driver PIN . . . . . . . . . . . . . 95Servicing the heater . . . . . . . . . . . . . . . 400Set values . . . . . . . . . . . . . . . . . . . . . . 365Setting chocks . . . . . . . . . . . . . . . . . . . 353Setting the date . . . . . . . . . . . . . . . . . . 115Setting the drive programme . . . . . . . . . 127Setting the language . . . . . . . . . . . . . . 116Setting the time . . . . . . . . . . . . . . . . . . 115Shock recognition . . . . . . . . . . . . . . . . 241Special risks . . . . . . . . . . . . . . . . . . . . . 42Stability . . . . . . . . . . . . . . . . . . . . . . . . . 42Standard display elements . . . . . . . . . . . 90Starting drive mode . . . . . . . . . . . . . . . 131

Dual-pedal version . . . . . . . . . . . . . 133Status LEDs . . . . . . . . . . . . . . . . . . . . 113Steering . . . . . . . . . . . . . . . . . . . . . . . . 152Steering axle

Checking . . . . . . . . . . . . . . . . . . . . 389Checking the lines for leaks . . . . . . . 390Lubrication . . . . . . . . . . . . . . . . . . . 389Servicing . . . . . . . . . . . . . . . . . . . . 389

Steering systemChecking for correct function . . . . . . 102

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Storing the truck . . . . . . . . . . . . . . . . . . 358StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 11Switching off the truck . . . . . . . . . . . . . 155Switching on the key switch . . . . . . . . . . 88

TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 412Three-waymini-lever . . . . . . . . . . . . . . . 67

Lifting/lowering the fork carriage . . . 162Topicality of the operating instructions . . 18Towed load . . . . . . . . . . . . . . . . . . . . . 256Towing . . . . . . . . . . . . . . . . . . . . . . . . 293

Proper use . . . . . . . . . . . . . . . . . . . . 12Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 267Transport . . . . . . . . . . . . . . . . . . . . . . . 352Transporting pallets . . . . . . . . . . . . . . . 187Transporting suspended loads . . . . . . . 187Transporting the battery by crane

Lead-acid battery . . . . . . . . . . . . . . 344Lithium-ion battery . . . . . . . . . . . . . 345

Transporting the lithium-ion battery . . . . . 33Triple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 162Types of lift mast . . . . . . . . . . . . . . . . . 157

Telescopic mast . . . . . . . . . . . . . . . 157Tyres

Safety principles . . . . . . . . . . . . . . . . 37

UUnlocking the emergency off switch . . . . 88Using working platforms . . . . . . . . . . . . . 15

VValve cover

Installing . . . . . . . . . . . . . . . . . . . . . 381Removing . . . . . . . . . . . . . . . . . . . . 381

VariantCeiling sensor . . . . . . . . . . . . . . . . . 242

VariantsAccess authorisation with PIN code . . 91Automatic lift cut out . . . . . . . . . . . . 174Clamp locking mechanism . . . . . . . . 227Clipboard . . . . . . . . . . . . . . . . . . . . 255FleetManager . . . . . . . . . . . . . . . . . 241Fork extension . . . . . . . . . . . . . . . . 169Heating system . . . . . . . . . . . . . . . . 252Hi-Lo lift mast . . . . . . . . . . . . . . . . . 158Lift mast vertical position . . . . . . . . . 175Lifting systems . . . . . . . . . . . . . . . . 157Load measurement . . . . . . . . . . . . . 182Push-up roof window . . . . . . . . . . . . 254Radio . . . . . . . . . . . . . . . . . . . . . . . 251Reducing speed with a raised load . . 154Reversible fork arms . . . . . . . . . . . . 171Shock recognition . . . . . . . . . . . . . . 241Triplex lift mast . . . . . . . . . . . . . . . . 158Wheel chock . . . . . . . . . . . . . . . . . . 156Windscreen wiper/washer . . . . . . . . 240

VDI datasheetRX60-25 . . . . . . . . . . . . . . . . . . . . . 414RX60-25/600 . . . . . . . . . . . . . . . . . 414RX60-25L . . . . . . . . . . . . . . . . . . . . 418RX60-25L/600 . . . . . . . . . . . . . . . . 418RX60-30 . . . . . . . . . . . . . . . . . . . . . 422RX60-30L . . . . . . . . . . . . . . . . . . . . 426RX60-30L/600 . . . . . . . . . . . . . . . . 426RX60-35 . . . . . . . . . . . . . . . . . . . . . 422

Vertical lift mast positionChecking for correct function . . . . . . 104

View of functions and operations . . . . . . . 21View of operating procedures . . . . . . . . . 21Views of the display operating unit . . . . . 22Visual inspections . . . . . . . . . . . . . . . . . 74

WWarning regarding non-original parts . . . 36Wheel chock . . . . . . . . . . . . . . . . . . . . 156

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Wheels and tyresChecking the condition and wear of

the tyres . . . . . . . . . . . . . . . . . . . 387Checking wheel fastenings . . . . . . . 388Maintaining . . . . . . . . . . . . . . . . . . . 387

Windscreen wiper/washer . . . . . . . . . . 240Working at the front of the truck . . . . . . . 366Working on the electrical equipment . . . 364Working on the hydraulic equipment . . . 364Working spotlight for reverse travel

Switching on and off . . . . . . . . . . . . 233

Working spotlightsAutomatically switching on/off . . . . . 238Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 238Manually switching on/off . . . . . . . . 237Switching on and off . . . . . . . . 232, 237

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 104

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Original instructions Electric forklift truck

Documents

Transcript of Original instructions Electric forklift truck