RX60-60 RX60-70 RX60-80 · Preface g Addressofmanufacturerand contactdetails STILLGmbH Berzeliusstraße10 22113Hamburg,Germany Tel.+49(0)407339-0 Fax:+49(0)407339-1622 Email:[email protected]

Original instructions

Electric forklift truck

RX60-60RX60-70RX60-80

6341 6342 6343 6344

56358042501 EN - 10/2016

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

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Table of contentsg

1 ForewordYour truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 3Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Issue date and topicality of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 IntroductionUsing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Proper use during towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Parking in temperatures below -10°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Special risks associated with using the truck and attachments . . . . . . . . . . . . . . . . . . . 20Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3 SafetyDefinition of responsible persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Changes to the overhead guard and roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Damage, defects andmisuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . . 37Length of the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Coolant and cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 OverviewsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Overview of the driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Display operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Operating devices for hydraulic and driving functions . . . . . . . . . . . . . . . . . . . . . . . . . . 53Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Identification points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 63

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5 OperationChecks and tasks to be carried out prior to commissioning . . . . . . . . . . . . . . . . . . . . . . 66Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Checking the condition of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Adjusting the MSG 65/MSG 75 driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Climbing into and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Connecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Using the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Checking the emergency off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Zero adjustment of the load measurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 102

Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Setting the drive programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 110Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 110Actuate the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 111Starting drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Starting drive mode, dual pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Reducing speed when turning (Curve Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . 121Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 132Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 133Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 134Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 135Controlling the lifting system with the fingertip console . . . . . . . . . . . . . . . . . . . . . . . . . 137Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Transporting suspended loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Driving on ascending and descending slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Working with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 170Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Controlling attachments using the three-waymini-lever and the 5th function . . . . . . . . . 174Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 176Controlling attachments using the four-way mini-lever and the 5th function . . . . . . . . . . 178Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180Controlling attachments using the joystick 4Plus and the 5th function . . . . . . . . . . . . . . 181Controlling the attachments with fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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Controlling attachments with fingertip and the 5th function . . . . . . . . . . . . . . . . . . . . . . 183Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Operating auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190Switching the lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Switching the direction indicators on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 194Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Accident recorder (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Cab operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Push-up roof window (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Operating the display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 225Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Soft key button for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . 226

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Effects on additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Operating in special operating situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Releasing the spring-operated brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Changing to a different battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267Opening and closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Equalising charge to prevent a deep discharge of the battery . . . . . . . . . . . . . . . . . . . . 275Replacing the battery using a truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

PowerPlusLife battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283PowerPlusLife® battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283PowerPlusLife® temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284PowerPlusLife® error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Re-commissioning after shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

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6 MaintenanceGeneral maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Maintenance - 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 304Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Removing and attachingthe left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Installing and removing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Opening/closing the front right cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316Removing and attaching the rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Cleaning the radiator and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Topping up cooling fluid and checking coolant content . . . . . . . . . . . . . . . . . . . . . . . . . 319Servicing wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Replacing the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323Checking the battery condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . 326Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Changing the heating system fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Replacing the recirculated air filter for the heating system . . . . . . . . . . . . . . . . . . . . . . 330

1000-hour maintenance/annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Checking the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Checking the door latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 334Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

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Checking the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Greasing the automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

7 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

VDI datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Battery specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

X 56358042501 EN - 10/2016

1

Foreword

1 ForewordYour truck

Your truckGeneralThe 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 trucks have been fitted with state-of-the-art technology. All that remains is to handlethe truck safely and maintain its functionality.

These operating instructions provide thenecessary information to do this. Read andobserve the information provided beforecommissioning the truck. This will preventaccidents and ensure that the warrantyremains valid.

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.

2 56358042501 EN - 10/2016

Foreword 1Your truck

EC declaration of conformity in accordance with Machinery Directive

Declaration

STILL GmbH

Berzeliusstraße 10

D-22113 Hamburg Germany

We declare that the

Industrial truck according to these operating instructions

Model according to these operating instructions

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

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL GmbH

.

56358042501 EN - 10/2016 3

1 ForewordYour truck

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

4 56358042501 EN - 10/2016

Foreword 1Information about the documentation

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

• Spare parts list• VDMA rules for the proper use of industrialtrucks

These operating instructions describe all mea-sures necessary for the safe operation andproper maintenance of your truck in all pos-sible variants available at the time of printing.Special versions to meet customer require-ments are documented in separate operatinginstructions. If you have any questions, pleasecontact your authorised service centre.

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

Production number...............................................

Year of manufacture...................................................

Please quote the production number during alltechnical enquiries.

Each truck comes with a set of operatinginstructions. These instructions must bestored carefully and must be available to thedriver andoperating companyat any time. Thestorage location is specified in the "Overviews"chapter.

If the operating instructions are lost, theoperator must obtain a replacement from themanufacturer immediately.

The operating instructions are included in thespare parts list and can be reordered there asa spare part.

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.

56358042501 EN - 10/2016 5

1 ForewordInformation about the documentation

NOTE

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

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.

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

DANGER

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

WARNING

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

6 56358042501 EN - 10/2016


CAUTION

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

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

Arb-SchG

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

Betr-SichV

Betriebssicherheitsverordnung German implementation of the EU work-ing equipment directive

BG Berufsgenossenschaft German insurance company for thecompany 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 (CEmark)

CEECommission on theRules for theApprovalof 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

56358042501 EN - 10/2016 7


Abbrevi-ation

Meaning Explanation

EN European standard

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

Fmax maximum Force Maximum power

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 Maximumworkplace 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 ofvehicles 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

8 56358042501 EN - 10/2016


Abbrevi-ation

Meaning Explanation

VDI Verein Deutscher Ingenieure German technical/scientific association

VDMAVerband Deutscher Maschinen- undAnlagenbau e.V.

GermanMechanical Engineering IndustryAssociation

WLAN Wireless LAN Wireless local area network.

56358042501 EN - 10/2016 9


Units

Unit symbol Unit name Explanation

°C Degree Celsius Unit of temperature

°F Degree Fahrenheit Unit of temperature

A Ampere Unit of electrical current

Ah Ampere hour Unit of electrical charge storage capacity (nominalcapacity)

dB Decibel Unit of sound intensity

cm Centimetre Unit of length (1 cm = 10 mm)

cm3 Cubic centimetres Unit of volume

g Gram Unit of mass

h/d Hours per day Hours driven per day

kg Kilogram Unit of mass (1 kg = 1000 g)

kg/m3 Kilograms per cubicmetre

Unit of density (ratio of the mass of a body to itsvolume)

km/h Kilometres per hour Unit of speed

kN Kilonewton Unit of force (1 kN = 1000 N)

kW Kilowatt Unit of electrical power

kWh/h Kilowatt hour/hour Energy consumption

l Litre Unit of volume

l/h Litres per hour Unit of consumption

l/min Litres per minute Unit of consumption

m Metre Unit of length (1 m = 100 cm)

m/s2Metres per secondsquared Unit of acceleration

min Minute Unit of time (1 min. = 60 s)rpm Revolution(s) per minute Unit of revolution speedmm Millimetre Unit of length (1 mm = 10-3 m)

N Newton Unit of force (1 N = 10-3 kN)

Nm Newton metre Unit of torque

s Second Base unit for time

10 56358042501 EN - 10/2016


Unit symbol Unit name Explanation

t Tonne Unit of mass (1 t = 1000 kg)

V Volt Unit of electrical voltage

W Watt Unit of electrical powerW/kg Watt/kilogram Performance by mass (power density)

Wh Watt-hours Unit of electrical work (nominal energy)Wh/kg Watt-hours/kilogram Stored energy per kilogram of mass (energy density)

.

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.

56358042501 EN - 10/2016 11


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.

12 56358042501 EN - 10/2016

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.

56358042501 EN - 10/2016 13

1 ForewordEnvironmental considerations

14 56358042501 EN - 10/2016

2

Introduction

2 IntroductionUsing the truck

Using the truckProper 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".

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

NOTE


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

16 56358042501 EN - 10/2016

Introduction 2Using the truck

DANGER

There is a risk of fatal injury fromfalling off the truck while it is moving!– It is prohibited to carry passengerson 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 outdoors andin buildings. 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,it must conform to the national regulations forthe country in which it is being used.

The ground must have an adequate loadcapacity (concrete, asphalt) and a roughsurface. Routes, work areas and aisle widthsmust conform to the specifications in theseoperating instructions, see the "Routes"chapter.

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

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

This truck is not designed to be operated incold stores.

56358042501 EN - 10/2016 17

2 IntroductionUsing the truck

CAUTION

Batteries 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 will then not beready for operation.– When the ambient temperature is 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 note the definition of "operating com-pany" in the sense of responsible persons!

Parking in temperatures below -10°C

CAUTION

Batteries 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.

Using working platforms

WARNING

The 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.

18 56358042501 EN - 10/2016

Introduction 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.

WARNING

All 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

56358042501 EN - 10/2016 19

2 IntroductionResidual 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

20 56358042501 EN - 10/2016


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.

56358042501 EN - 10/2016 21


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 unautho-rised persons

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 nationallaws)

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employer’sliability insuranceassociations

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 onIndustrial Safety andHealth (BetrSichV)

Contamination ofrespiratory air

Assessment of LPGexhaust gases

O German thresholdlimit values list(MAK-Liste) and theGerman Ordinance onIndustrial Safety andHealth (BetrSichV)

22 56358042501 EN - 10/2016



Notes

Issuing of operatinginstructions

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and German Healthand labour protectionlaw (ArbSchG)

Written notice ofinstruction to driver

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and German Healthand labour protectionlaw (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

56358042501 EN - 10/2016 23



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 valuewithin the permissiblerange

When using batterychargers

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

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employers’liability insuranceassociation regulation104

When parking LPGtrucks

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

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employers’liability insuranceassociation regulation104

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


24 56358042501 EN - 10/2016



Notes

Driveways intersect Announce right-of-way rule


No person detectionduring depositing andretrieval

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

.

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 major

56358042501 EN - 10/2016 25


operational 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.

26 56358042501 EN - 10/2016

3

Safety

3 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

28 56358042501 EN - 10/2016

Safety 3Definition 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

56358042501 EN - 10/2016 29

3 SafetyDefinition of responsible persons

DANGER

The 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.

30 56358042501 EN - 10/2016

Safety 3Basic 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.

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.

56358042501 EN - 10/2016 31

3 SafetyBasic principles for safe operation

DANGER

Risk 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.

DANGER

Risk of explosion from additionalholes in 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 batteryhood.

DANGER

Risk 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.

32 56358042501 EN - 10/2016


DANGER

Risk to life from falling load!If the truck is not equipped with an overhead guard,there is a risk to the driver’s life, as 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.

56358042501 EN - 10/2016 33


Changes to the overhead guard androof loads

DANGER

In 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.

CAUTION

Heavy 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.

CAUTION

Installation 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.

34 56358042501 EN - 10/2016


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

DANGER

Risk 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

56358042501 EN - 10/2016 35


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

WARNING

Electromagnetic 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.

36 56358042501 EN - 10/2016


Exercise caution when handling gassprings and accumulators

WARNING

Gas 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.

WARNING

Accumulators 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

DANGER

Risk 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

56358042501 EN - 10/2016 37


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.

38 56358042501 EN - 10/2016

Safety 3Safety 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 a year as partof the FEM testing.

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

56358042501 EN - 10/2016 39

3 SafetySafety tests

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

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

Nominalvoltage UBatt

Test values

50 VDC 24 V > 1200

100 VDC 48 V > 2400Battery

100 VDC

Batt+Batt-

Battery tray

80 V > 4000.

Test values for the entire truck

Nominalvoltage Test voltage Test values for new trucks Minimum values over the

duration of the service life24 V 50 VDC Min. 50 k > 24 k

48 V 100 VDC Min. 100 k > 48 k

80 V 100 VDC Min. 200 k > 80 k.

40 56358042501 EN - 10/2016

Safety 3Safety regulations for handling consumables

Safety regulations for handling consumablesPermissible consumables

DANGER

Failure 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. 6-307).

Oils

DANGER

Oils are flammable!– Follow the statutory regulations.– Do not allow oils to come intocontact with hot engine parts.

– No smoking, fires or naked flames!

DANGER

Oils are toxic!– Avoid contact and consumption.– If vapour or fumes are inhaled,move to fresh air immediately.

– In the event of contact with theeyes, rinse thoroughly (for at least10 minutes) with water and thenconsult an eye specialist.

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

56358042501 EN - 10/2016 41

3 SafetySafety regulations for handling consumables

WARNING

Prolonged intensive contact with theskin can result in dryness and irritatethe skin!– Avoid contact and consumption.– Wear protective gloves.– After any contact, wash the skinwith soap and water, and thenapply a skin care product.

– Immediately change soakedclothing and shoes.

WARNING

There 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

WARNING

These fluids are pressurised duringoperation of the truck and arehazardous to your health.– Do not spill the fluids.– Follow the statutory regulations.– Do not allow the fluids to come intocontact with hot engine parts.

42 56358042501 EN - 10/2016


WARNING

These fluids are pressurised duringoperation of the truck and arehazardous to your health.– Do not allow the fluids to come intocontact with the skin.

– Avoid inhaling spray.– Penetration of pressurisedfluids into the skin is particularlydangerous if these fluids escapeat high pressure due to leaks inthe hydraulic system. In case ofsuch injury, immediate medicalassistance is required.

– 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

WARNING

Battery acid contains dissolvedsulphuric acid. This is toxic.– Avoid touching or swallowing thebattery acid at all costs.

– In case of injury, seek medicaladvice immediately.

56358042501 EN - 10/2016 43

3 SafetySafety regulations for handling consumables

WARNING

Battery 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.

Coolant and cooling fluid

WARNING

Coolant and cooling fluid can behazardous to your health and theenvironment!Coolants are chemical corrosioninhibitors and cooling systemprotecting agents such as Glysantin.Cooling fluid is an appropriatemixture ofwater and coolant. Coolantin both concentrated and dilute formcan be hazardous to your healthif swallowed, or hazardous to theenvironment if spilled.– Store coolant and cooling fluidonly in their original containers anddo not spill them.

– Never store coolant or cooling fluidin empty food containers, bottlesor other containers.

– Observe the national regulationsfor the country of use.

ENVIRONMENT NOTE

44 56358042501 EN - 10/2016


– Soak up any spilt coolant or cooling fluidimmediately using an oil binding agent anddispose of it in accordance with the nationalregulations for the country of use.

– Dispose of old coolant or cooling fluid inaccordance with the national regulations forthe country of use.

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.

56358042501 EN - 10/2016 45

3 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, EN ISO 3744 and therequirements of EN ISO 4871.

This machine emits the following soundpressure level:

Continuous sound pressure level in thedriver’s compartment

LpAZ Measurementuncertainty KpA

< 70 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 noise levels indicated on thetruck cannot be used to determine the noiseemissions atworkplacesaccording to themostrecent version of Directive 2003/10/EC (dailypersonal noise pollution). If necessary, thesenoise emissions should be determined by theoperating company directly at the workplaceunder the actual conditions there (additionalnoise sources, special application conditions,sound reflections).

NOTE


46 56358042501 EN - 10/2016

Safety 3Emissions

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

0.31 m/s2 0.093 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 personal vibration load on the driver overa working day must be determined by theoperating company at the actual place of usein accordance with Directive 2002/44/EC, inorder to consider all additional influences,such as driving route, intensity of use etc.

NOTE


56358042501 EN - 10/2016 47

3 SafetyEmissions

Battery

DANGER

Risk 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.– Make sure that there is alwayssufficient ventilation in workingareas that are entirely or partiallyenclosed.

– Keep away from open flames andflying sparks.

– Do not smoke.– Observe the safety regulations forhandling the battery.

48 56358042501 EN - 10/2016

4

Overviews

4 OverviewsOverview

Overview

1 2 3

4

5

678

9

10

6341_003-019_V2

1 Lift mast2 Driver’s compartment3 Overhead guard4 Left side cover5 Steering axle

6 Drive axle7 Tilt cylinder8 Fork arms9 Fork carriage10 Lift cylinder

50 56358042501 EN - 10/2016

Overviews 4Overview of the driver’s compartment

Overview of the driver’s compartment

9

0

7

8

5

3

1

24

6

100 % +-

5

12890

15:23

F1 F2

1 2 4

6

814

15

6341_003-020

7

911 10

3 5

12

16

13

1 Parking brake lever2 Steering wheel3 Key switch4 Display and operating unit5 Document holder6 Operating devices for hydraulic and traction

functions7 Emergency off switch8 Compartment

9 Bottle holder for max. 1.5 l bottles10 Driver’s seat11 Compartment and potential storage location

for operating instructions12 Compartment13 Filler cap for windscreen washer reservoir14 Accelerator pedal15 Brake pedal16 Steering column adjustment

NOTE

The truck equipment may differ from theequipment shown.

56358042501 EN - 10/2016 51

4 OverviewsOperating and display elements

Operating 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".

52 56358042501 EN - 10/2016

Overviews 4Operating and display elements

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

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

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

56358042501 EN - 10/2016 53


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.

54 56358042501 EN - 10/2016


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


56358042501 EN - 10/2016 55


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


56 56358042501 EN - 10/2016


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

56358042501 EN - 10/2016 57


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


58 56358042501 EN - 10/2016


7311_003-0561

2

1 Travel direction switch2 Direction indicator switch

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

56358042501 EN - 10/2016 59

4 OverviewsIdentification points

Identification pointsOverview

7

8

DANGER

DANGER

3

2

19

1

9

11

12

21

6341_003-018_V3

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

*

DANGER

DANGER

54305430 10101010 10801080 10801080 10801080

10501050 11501150 13101310

44304430 11101110 12301230 12501250 15001500

40304030 11501150 12601260 12001200 15001500

37303730 11801180 12901290 14301430 15001500

34303430 12101210 13301330 14701470 15001500

800800 700700 500500600

5030 1270

2

1

3

20xx

5

4

6

13

15

16

14

STILL Hamburg

Berzeliusstr. 10

22113 Hamburg

Tel.: 01804 / 784 55 24

Ihr STILL Service

Nächste Prüfung

7339

06

BATTERIESERVICE

10 bar

13 18

1 2 19

12

37

14 515

154

1716117

8

13

9

20

DANGER

DANGER

DANGER

17

20

17

20

21

1

106

Regelmäßige Prüfung(FEM 4.004)

nach nationalen Vorschriftenbasierend auf den EG-Richtlinien:2009/104/EG, 99/92/EG

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung56

3443

9101

9

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

60 56358042501 EN - 10/2016

Overviews 4Identification points

1 Decal information: Caution/read the operat-ing instructions

2 Warning sign: Danger due to shearing3 Decal information: Battery service4 Warning sign: Do not stand underneath the

fork/Do not stand on the fork/Danger due toshearing/Danger due to high fluid pressure

5 Decal information: Hydraulic oil tank6 Decal information: Attachment capacity

rating plate7 Decal information: Inspection sticker8 Decal information: FEM test9 Decal information: Caution/Read the op-

erating instructions/Fasten seat belt/Applyparking brake when leaving the truck/Pas-sengers are not allowed/Do not jump off ifthe truck is tipping over/Lean in the oppositedirection to which the truck is tipping

10 Manufacturer’s label text

11 Decal information: Nameplate12 Decal information: Capacity rating plate13 Decal information: Lifting gear attachment

point14 Warning sign: Actuate accumulator/brake

pedal 30x/Read operating instructions15 Decal information: Tyre filling pressure16 Decal information: StVZO (German Road

Traffic Licensing Regulations) information(variant)

17 Warning sign: Danger due to shearing/Dan-ger due to high fluid pressure

18 Manufacturer’s label text19 Warning sign: Risk of short circuit due to

shearing20 Warning sign: Do not stand underneath the

fork/Do not stand on the fork21 Decal information: To unlock, turn 90° to the

right/to lock, turn 90° to the left

56358042501 EN - 10/2016 61







max

min.*


kg kg

kg

kg

kgkW

V

*

1 2 3

4

5

6

7

89

10

11

12

6210_921-003_V2

1 Type2 Production number3 Year of manufacture4 Tare weight in kg5 Max. permissible battery weight in kg (for

electric forklift trucks only)6 Min. permissible battery weight in kg (for

electric forklift trucks only)7 Ballast weight in kg (for electric forklift trucks

only)8 Refer to the technical data listed in these

operating instructions for more detailedinformation

9 CE labelling10 Nominal drive power in kW11 Battery voltage in V12 Rated capacity in kg

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

62 56358042501 EN - 10/2016

Overviews 4Identification points

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

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.

56358042501 EN - 10/2016 63


64 56358042501 EN - 10/2016

5

Operation

5 OperationChecks and tasks to be carried out prior to commissioning

Checks and tasks to be carried out prior to commissioningVisual inspections

WARNING

Risk 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.

WARNING

There is a risk of falling when working on high partsof the truck.– Use only the steps provided on the truck.– Do not stand on truck components or use them

to help you climb onto the truck.– Use suitable equipment.

1

2

6210_000-002

Prior to commissioning, ensure that the truckis safe to be operated:

• The fork arms must be secured againstlifting and shifting

• The locking devices (1) of the fork armsmust not be damaged or deformed

• Fork arms and other lifting accessoriesmust not show any noticeable damage (e.g.bends, cracks, significant wear)

• The roller tracks (2) must be lubricated witha visible grease film

• The chains must not be damaged and mustbe evenly and adequately tensioned

• Check the area under the truck for leakingconsumables

• The guard grille (variant) and overheadguard must be undamaged and securelymounted

66 56358042501 EN - 10/2016

Operation 5Checks and tasks to be carried out prior to commissioning

• Attachments (variant) must be properlymounted and function according to theoperating instructions

• All decal information signs must be inplace and legible. Replace damaged ormissing adhesive labels in accordance withthe overview in the "Identification points"chapter.

• Anywarning units (e.g. signal horn)must bein perfect condition and function correctly

• Check the visible areas of the hydraulicsystem and hydraulic oil tank for damageand leaks. Damaged hoses must bereplaced

• The battery must be positioned securely inthe battery tray.

• Check the battery male connector fordamage (e.g. cracks, breaks or deformationof the housing, and whether the contactsare bent or damaged). If necessary, havethe battery male connector replaced by theauthorised service centre

• The battery cover must be securely closed• The battery lock and the indexing bolt for thebattery base framemust not be damaged ordeformed

• The battery base frame, battery tray andbattery cover must not be damaged ordeformed

• The maintenance lids must be closed• Steps must be clean and free of ice• Any panes of glass (variant, e.g. wind-screen) must be clean and free of ice

• Depending on the tyres, the truck may befitted with an antistatic belt. The antistaticbelt must not be damaged. It must also beclean and long enough to touch the ground

• The coupling pin in the counterweight mustshow no noticeable damage (e.g. bends,cracks or breaks). The securing bush in thecounterweight must be present

• A tow coupling (variant) must show nonoticeable damage (e.g. coupling pinbent, cracks or breaks). Every removablecoupling pin must be secured against losswith a securing device (e.g. a chain, a splitpin or a rope)

56358042501 EN - 10/2016 67


• The exhaust air grille on the cover of therear weight must not be covered. It must bekept free of debris such as leaves or similardeposits

• Damage or other defects on the truck orattachment (variant) must be reported tothe supervisor or responsible fleet managerimmediately so that arrangements can bemade for the defect to be rectified

WARNING

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

replaced by the authorised service centre.

DANGER

Risk of explosion if hydrogen buildsup in the cab!If the truck is equipped with acab, hydrogen from the batterycompartment can penetrate the cabthrough unsealed bores in the batteryhood. A build-up of hydrogen canlead to explosions.There must be no unsealed bores inthe battery hood. Sealing bores withplugs is not sufficient to prevent gasfrom escaping.– Have unused bores in the batteryhood sealed by the authorisedservice centre.

Filling the washer system

CAUTION

Components may become damaged due to theeffects of frost!Water expands when it freezes. If there is noanti-freeze in the washer system, the system maybe damaged due to the build up of ice in freezingconditions.– Always use washer fluid containing anti-freeze.

68 56358042501 EN - 10/2016


The windscreen washer reservoir is under thecompartment behind the driver’s seat. Thesight glass (1) displays the fill level.

7331_341-001

2

1

– Open filler cap (2) for the windscreenwasher reservoir.

– Fill the windscreen washer reservoir withwasher fluid and anti-freeze in accor-dance with the maintenance data table;see ⇒ Chapter "Maintenance data ta-ble", P. 6-307.

– Close lid.

– Operate washer system until washer fluid isdischarged from the spray nozzles.

Checking the condition of the wheelsand tyres

WARNING

Risk of accidents! With uneven wear or incorrect airpressure, the stability of the forklift truck decreasesand the braking distance increases.– Change worn or damaged tyres without delay.

WARNING

Risk of tipping!Tyre quality affects the stability of the truck.If you wish to use a different type of tyre on the truckfrom the tyres approved by the truck manufacturer,or tyres fromadifferentmanufacturer, youmust firstobtain approval from the truck manufacturer.

WARNING

Risk 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.

56358042501 EN - 10/2016 69


NOTE

Only approved types of tyre may be used; seechapter entitled "Tyres".

12

7321_003-003

– Check tyres (1) for wear or damage.

Tyres must not be damaged or excessivelyworn. They must be worn evenly on bothsides.

– In the case of pneumatic tyres, check the airpressure. The air pressure indicated on theadhesive labels (2) must be observed.

NOTE

Observe the safety principles outlined in thechapter entitled "Tyres".

Checking the coolant level

WARNING

Risk of scalding due to hot coolant!The cooling system is pressurised! When you openthe coolant reservoir, hot coolant can leak out. Onlyopen the coolant reservoir when the cooling systemis cold.– Switch off the truck and allow it to cool down.– Donot open the coolant reservoir until the engine

has cooled down.

CAUTION

Risk of component damage due to overheating!The power electronics and the hydraulic oil areprotected from overheating by a cooling system.Loss of coolant from leaking coolant hoses or fromthe radiator reduces the cooling capacity and cancause components to overheat. If the coolant levelis low, this indicates a leak in the cooling system.– Check the cooling system for leaks.

– Remove the left side cover.

70 56358042501 EN - 10/2016


6341_003-023

2

1

– Pull the locking pin (1) on the coolantreservoir (2) upwards.

– Pull out the coolant reservoir under the rearcover.

– Check the coolant level.

min

max

6341_003-024

3

4

5

2

1

The coolant level should bebetween the uppermark (4) and the lower mark (5).

– Top up the coolant to the uppermark, but nofurther, if necessary.

– Make sure that the reservoir cap (3) isscrewed on and tightly sealed.

– Push the coolant reservoir (2) back in untilthe locking pin (1) engages.

– Attach the left side cover.

56358042501 EN - 10/2016 71


Adjusting the MSG 65/MSG 75driver’s seat

DANGER

There 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

WARNING

On some equipment variants, theamount of head clearance on thetruck may be restricted.On these specific equipment va-riants, the distance between the headand the lower edge of the roofingsheet must be at least 40 mm.

NOTE

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

WARNING

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

objects within the swivel area of the seat

72 56358042501 EN - 10/2016


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.

56358042501 EN - 10/2016 73


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/MSG75 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 upor 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.

74 56358042501 EN - 10/2016


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.

56358042501 EN - 10/2016 75


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.

Adjusting the armrest

DANGER

There 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.

76 56358042501 EN - 10/2016


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

– Check that the armrest is firmly attached.

6210_424-001

1

2

Adjusting the steering column– Press down the steering column adjustmentlever (2).

– Position the steering column (1) and pull thelever up again.

DANGER

Risk of accidents!– Ensure that the steering column is secure.The steering columnmust click into place.Never adjust the steering column while driving.

56358042501 EN - 10/2016 77

5 OperationCommissioning

CommissioningClimbing into and out of the truck

WARNING

Risk 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 overhead guard post or of yourclothes becoming stuck when climbing out of thetruck.– 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.

WARNING

Risk of injury when jumping out of the truck!If your clothing or jewellery (e.g. watch, ring etc.)becomes 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.

CAUTION

Components 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 may be damaged due to misuse.– Only use the fittings specifically designed for the

purpose of climbing into and out of the truck.

NOTE

The foot that the driver starts with whenclimbing into and out of the truck is crucial inensuring this action is carried out safely. Thiswill depend on the number of steps. Truckswith a single wheel on the front axle featuretwo steps. Trucks with two wheels on the frontaxle feature three steps.

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Operation 5Commissioning

Climbing in and out of trucks featuring asingle wheel and two steps

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When climbing into and out of the truck, usethe handles (2) and (4) for support. Theoverhead guard post (1) can also be usedfor support.

Always climb into the truck facing forwards:

– Grip handle (2) with your left hand and holdon.

– Grip handle (4) with your right hand andhold on.

– Place your right foot on the bottom step (5).

– Place your left foot on the top step (6).

– Place your right foot into the footwell (7).

– Enter the truck and sit down on the driver’sseat (3).

Always climb out of the truck backwards:


– Stand up from the driver’s seat and placeyour left foot on the top step (6).

– Grip the handle (4) with your right hand andhold on.

– Place your right foot on the bottom step (5).

– Place your left foot on the ground and climbdown from the truck.

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Climbing in and out of trucks featuringtwo wheels and three steps

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When climbing into and out of the truck, usethe handles (2) and (4) for support. Theoverhead guard post (1) can also be usedfor support.

Always climb into the truck facing forwards:


– Grip handle (4) with your right hand andhold on.

– Place your left foot on the bottom step (5).

– Place your right foot on themiddle step (6).

– Place your left foot on the top step (7).

– Place your right foot into the footwell (8).

– Enter the truck and sit down on the driver’sseat (3).

Always climb out of the truck backwards:


– Stand up from the driver’s seat and placeyour left foot on the top step (7).

– Grip the handle (4) with your right hand andhold on.

– Place your right foot on themiddle step (6).

– Place your left foot on the bottom step (5).

– Place your right foot on the ground andclimb down from the truck.

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Connecting the batterymale connec-tor

CAUTION

Risk of component damage!If you connect 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 connect the battery male connector while

the key switch is switched on.

CAUTION

There is a risk of short circuit if thecables are damaged.The battery cable must not becrushed when closing the batterycover.

– Ensure that the key switch is switched off.

– Open the battery cover.

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2– Hold the battery male connector (2) bythe handle (1) and insert the battery maleconnector into the plug connection on thetruck.

– Push the fastener (3) completely to the rightto retract the batterymale connector into theplug connection and to secure the batterymale connector in position.

– Ensure that the battery cable cannot comeinto contact with the battery cover.

– Close the battery cover.

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Unlocking the emergency off switch– Pull the emergency off switch (1) until it isunlocked.

Switching on the key switch

WARNING

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

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– 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.

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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 functionas the highest valid driverPINis "99999". Persons with the correspondingaccessauthorisation, e.g. fleetmanagers, canchange the driver PINs in the correspondingmenu.

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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 (1).The digits entered for the driver PIN (2) are notvisible, instead being represented by circles.If the driver PIN entered is correct, the familiardisplay appears with the standard display, andall truck functions are available.

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

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Defining the driver PIN

NOTE

The driver PIN can only be defined by personswith the corresponding access authorisation,e.g. fleet managers. In order for the fleetmanager to define the driver PIN, the confi-guration menu must be accessed. The confi-guration menu is password-protected. Afterentering the password, the fleet manager canconfigure general settings for the truck. Tochange the password, see the chapter entitled"Changing the password".

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

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ESC

PASSWORD appears in the display.

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

– Confirm the entry by pressing the ENTER

button (2).

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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 by pressing theENTER button (2).

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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).


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NEW CODE appears in the display.

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

The digits entered donot appear in the display.Instead they are represented by circles in theNEW CODE field (6).

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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 buttons(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.

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

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

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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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ESC

PASSWORD appears in the display.

– Enter the current password using thebuttons (1).

– Confirm the entry by pressing the ENTER

button (2).

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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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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).


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NEW CODE appears in the display.

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

CAUTION

Do not enter the password 1777!If this password is entered, the configuration op-tions for the fleet manager are restricted to 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.

– To correct the newpassword, push the ESC

button (2).

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

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

– To exit the configuration menu, push theESC button repeatedly until the standarddisplays appear.

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F1F1 F2F2

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Operating the signal horn

NOTE

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

– Push the signal horn button (1).

The signal horn sounds.

Seat belt

DANGER

Even when using an approvedrestraint system, there is someresidual risk that the driver mightbe injured 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-end collisions and falling off a ramp.– We therefore recommend that youalso use the seat belt.

DANGER

Only 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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Fastening the seat belt

DANGER

Risk 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

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– 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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CAUTION

The 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.

7331_341-002

Using the driver’s cab

DANGER

Risk 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. This will prevent the driver from falling outof the truck if it tips over. The driver’s cab constitu-tes a driver restraint system only if the cab door issturdy and closed. Fabric-covered cabs (variant)with doors made of plastic or canvas do not consti-tute a driver restraint system and offer no protectionfrom the consequences of the 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.

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Checking the brake system forcorrect function

DANGER

If 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– Check pedal clearance:

There must be a distance of at least 60 mmbetween the pressure point and the pedalstop.

– Accelerate the truck without a load in a cleararea; see "Driving" chapter.

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– Press the brake pedal (1) firmly.

The truck must decelerate noticeably.

6210_342-005

Checking the parking brake

DANGER

If 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.

– Check the function of the parking brake atwalking speed or on a steep gradient byapplying the parking brake.

The truck must remain stationary on thegradient with the parking brake applied. Ifthe truck rolls in spite of an actuated parkingbrake, contact your service centre.

5060_003-031

1Checking the steering system forcorrect function

DANGER

If 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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Checking the emergency off function

WARNING

There is no electric braking assistance when theemergency off switch is actuated!Actuating the emergency off switch will de-energisethe entire electrical system. The truck will not beheld on a slope by the electric brake.– Brake the truck by depressing the brake pedal.

CAUTION

There is no power steering when the emergency offswitch is actuated!The truck is equipped with a hydraulic power stee-ring system. When the emergency off switch isactuated, the hydraulic system is completely shutdown. Steering forces are increased by the remai-ning emergency steering function.– Steer with a higher level of force.

– Slowly drive the truck forwards.

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– Press the emergency off switch (1).

The truck will roll to a stop.

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

– Pull out the emergency off switch (1).

The knob is unlocked and pops out. The truckperforms an internal self-test and is then readyfor operation again.

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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• as part of daily commissioning• 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.

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

Operation of the lifting system depends onwhich operating devices the truck is fittedwith; see ⇒ Chapter "Lifting system operatingdevices", P. 5-131.

– Set lift mast to vertical.

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

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– Keep button (1) for the "zero adjustment"pressed for at least four seconds; the "zeroadjustment"(2)symbol will appear in 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 in theoperating unit display.

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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.

– Actuate function key (1) to switch on thecomfort feature "lift mast vertical position".

Function display (2) must appear in thedisplay.

– 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.

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Operation 5Traction

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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5 OperationTraction

WARNING

The 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.

WARNING

In 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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Operation 5Traction

Roadways

Dimensions of roadwaysandaislewidthsThe 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.

For pallets, these are:

Aisle width [mm]

Model Type With pallet1000 x 1200crosswise

With pallet800 x 1200lengthwise

RX60-60 6341

RX60-70 6342

RX60-80 6343

4907 5107

RX60–80(LSP 900) 6344 4999 5199

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

Driving on gradients

WARNING

Driving up and down longer gradients may causethe drive unit to overheat and switch off.It is not permitted to drive up and down longergradients due to the minimum specified brakingvalues. The climbing capability values given belowonly apply to overcoming obstacles on the roadwayand to short differences in level, e.g. ramps.

The truck may be driven on the followingupwards or downwards gradients:

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5 OperationTraction

Maximum gradient [%]Model Type

With load Without loadRX60-60(LSP 600) 6341 16.3 25.0

RX60-70(LSP 600) 6342 15.5 25.3

RX60-80(LSP 600) 6343 14.0 23.4

RX60–80(LSP 900) 6344 12.0 18.3

LSP = load centre of gravity

The upwards and downwards slopes must notexceed the above gradient and should have arough surface.

Smooth and gradual transitions at the top andbottom of the gradient should prevent the loadfrom falling to the ground or the truck beingdamaged.

Warning: Components may projectbeyond 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, movableparts may project beyond the truck contourand be damaged or torn off. Examples of suchcomponents include:• A folding roof panel in the driver’s cab• Cab doors• LPG cylinders that can be swung out

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

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

Ensure manhole covers and similar covershave adequate load capacity.

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Operation 5Traction

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.

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6311_003-028_V2

1

1 2

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

Drive programs 1–5 are available.

Essentially, the higher the drive programnumber is, the greater the driving dynamics.

The following drive programmes are available:

Drive programmeDrive values1

1 2 3 4 5

Maximum speed (km/h) 19 19 19 19 19

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

NOTE

The maximum speed pre-set in the driveprogramme is technically dependent on thebattery used. Depending on the battery typeused, the preset maximum speed must beadapted by the authorised service centre. Ifthemaximum speed is not adapted, it can leadto technical faults in drive mode.• Contact your authorised service centre.

Battery designation Maximum speed (km/h)

7 PzS 1085 PowerPlusLife® 20

8 PzS 1120 19

1 Values applicable to the standard device. Values for variants may deviate from this data.

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Operation 5Traction

Battery designation Maximum speed (km/h)

8 PzS 1240 19

TENSOR® TCSM 2545 17.

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. The method ofactuating the drive direction switch dependson the operating devices included in the truck’sequipment.

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

NOTE

The drive direction can also be changedduring travel. Your foot can remain on theaccelerator pedal while doing so. The truck isthen decelerated and accelerated again in theopposite direction (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 inadvertently pressed.

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

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

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NOTE

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

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

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).

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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.

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

DANGER

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

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

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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,the truck cannot be moved and all liftingfunctions are locked. In such a case, themessage SEAT SWITCH appears in thedisplay-operating unit; see the chapter entitled"General messages".

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


– Release the parking brake.

– Select the desired drive direction.

5060_003-082

1

2

The indicator for the selected drive direction("forwards" (1) or "reverse" (2)) lights up on thedisplay-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.

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3

5060_003-084

– Press 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

If the followingmessageappears in the displaywhen the accelerator pedal is actuated:! PARKING BRAKE OIL PRESSURE, theservice brake of the truck is not yet ready foruse.• The driving speed is limited to 5 km/h.• When the service brake is ready for opera-tion, the message disappears. The speedlimitation is cancelled.

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.

DANGER

Risk 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 your foot from the acceleratorpedal.

– Select the desired drive direction.

– Actuate the accelerator pedal.

The truck will travel in the selected drivedirection.

NOTE

The drive direction can also be changedduring travel. Your foot can remain on the

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accelerator pedal while doing so. The truck isthen decelerated and accelerated again in theopposite direction (reversing).

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.

Starting drive mode, dual pedalversion (variant)

DANGER

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


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,the truck cannot be moved and all liftingfunctions are locked. In such a case, themessage SEAT SWITCH appears in thedisplay-operating unit; see the chapter entitled"General messages".

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



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5060_003-085

2 1

– 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 "reverse" (4)) lights up on thedisplay-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

If the followingmessageappears in the displaywhen the accelerator pedal is actuated:! PARKING BRAKE OIL PRESSURE, theservice brake of the truck is not yet ready foruse.• The driving speed is limited to 5 km/h.• When the service brake is ready for opera-tion, the message disappears. The speedlimitation is cancelled.

NOTE

The truck can be stopped briefly on upwardor downward gradients without actuating the

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parking brake (electric brake). The truck willthen begin to creep downhill slowly.

DANGER

Risk 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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1

2

5060_003-006

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

DANGER

If 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.

DANGER

At 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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Actuating the mechanical parkingbrake

DANGER

There 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.

8

9

6

72

0

13

5

%75

h

2

234,7

12:15

1 2

7312_003-044_V2

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.

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Operation 5Traction

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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5 OperationTraction

A

A B

A B

B

5060_003-007

1

Steering

DANGER

If 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. 339.

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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

DANGER

The 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.

DANGER

Increased 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 5Lifting

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. 5-128

• The operating device with which thehydraulic functions are controlled, see⇒ Chapter "Lifting system operating de-vices", P. 5-131

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 5-144.

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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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 the "F1"(1) button on the displayoperating unit. The automatic lift cut out isnow overridden and a load can be lifted tothe truck’s maximum lift height.

To switch the automatic lift cut out back on:

– Press the "F1"(1) button again.

Lift mast vertical position (variant)

DescriptionIf the truck is equipped with the "lift mastvertical position" comfort feature (variant),the driver can put goods, such as paper rolls,down 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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CAUTION

Risk 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

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.

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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.

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".

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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".

Tilt the lift mast forwards beyond the verticalposition:

– 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 "lift mast 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.

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.

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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 button (3).

The current mast position is stored.

Cancelling calibration:

– Press the menu change button (2).

The calibration is cancelled.

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.

DANGER

Risk 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

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).

DANGER

Risk 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.

Malfunctions during lifting mode

Incorrect extension sequence

DANGER

Risk of accidents!With triple masts (variant), an incorrect extensionsequence may occur, i.e. the inner lift mast mayextend before the free lift has finished. As a result,the overall height is exceeded and damage mayoccur in passageways or from low ceilings.

An incorrect extension sequence may, forinstance, result from:• The hydraulic oil temperature being too low.• The fork carriage becoming blocked in theinner lift mast.

• Blocking of the free lift cylinder.• The chain roller becoming blocked at thefree lift cylinder.

– 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 theblockage must be eliminated before resumingwork.

– Notify your service centre

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Load chains not under tension

DANGER

Danger caused by a falling load!– Make sure that the chain(s) does (do) not

become slack when lowering the load.

Slack chains can, for instance, result from:• Resting the fork carriage or the load on theracking.

• Fork carriage rollers becoming blocked inthe lift mast due 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.

WARNING

Risk of injury!– Observe the safety regulations for working on lift

masts; see ⇒Chapter "Working at the front of thetruck", P. 6-312.

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

Releasing the block on the hydraulicsProceed as follows to release the block on thehydraulics:

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Operation 5Lifting

– 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.

Lifting system operating devicesThe method of operating the lifting systemdepends on the operating devices included inthe truck’s equipment.

Possible equipment variants include:• Double mini-lever• Triple mini-lever• Quadruple mini-lever• Joystick 4Plus• Fingertip switch

– The following informationmust be observedregardless of the equipment variant:

DANGER

Reaching 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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F1 F2

5060_003-038

A

C

D

B

1

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using adouble mini-lever

DANGER



seat.

Lifting/lowering the fork carriageTo lift fork carriage:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (B).

To lower fork carriage:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (A).

Tilting the lift mastTo tilt the lift mast forwards:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (C).

To tilt the lift mast backwards:

– 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

DANGER



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

DANGER



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

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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Controlling the lifting system usingthe joystick 4Plus

DANGER



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).

6210_003-090

DC

2


– Tilt the horizontal rocker button (2) to the left(C).


– Tilt the horizontal rocker button (2) to theright (D).

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1

6210_003-091

E

F

7312_003-022_V2

DC

B

A

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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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

DANGER



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

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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Changing the fork arms

DANGER

There is a risk of being run over if the truck rollsaway, and therefore a danger to life.– 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.

WARNING

There is a risk of injury when changing the forkarms; the fork arms’ weight could cause them to fallon your legs, feet or knees. The space to the leftand 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 onto oneside.

138 56358042501 EN - 10/2016

Operation 5Lifting

1

2

6210_003-027

Removal– Select a pallet corresponding to the fork armsize.

– Position the pallet to the left or right of thefork carriage.

– Raise the fork carriage until the lower edgesof the fork arms are approx.3 cmhigher thanthe height of the pallet.

– Actuate the parking brake and make sure itis applied securely.

– Turn the switch key to the left and remove it.

– Undo the locking screw (2) on the right orleft.

– Pull the locking lever (1) upwards and pushthe fork arms outwards onto the pallet.

Installation– Position the fork arms to the left or right ofthe fork carriage on a pallet.

– Push the fork arms onto the fork carriagefrom the outside towards the centre.

– Pull the locking lever (1) upwards and pushthe fork arms into the required position.Ensure that the locking lever snaps intoplace.

– Fit and tighten the locking screw (2).

DANGER

There is a risk to life caused by a falling load or fork!– Tighten the locking screw after every fork

replacement.– It is not permitted to drive or transport loads

without the locking screw.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, then a "zero adjust-ment of the load measurement" is imperativeafter the fork arms have been changed; see⇒ Chapter "Zero adjustment of the load mea-surement (variant)", P. 5-101. Otherwisecorrect measurement of the load cannot beguaranteed.

56358042501 EN - 10/2016 139

5 OperationLifting

Fork extension (variant)

DANGER

There 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.

WARNING

There 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.

WARNING

There 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.– 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 adjustmentof the load measurement" is imperative afterthe fork extension has been changed; see the"Zero adjustment of the load measurement"chapter. Otherwise, correct load measure-ment cannot be guaranteed.

140 56358042501 EN - 10/2016

Operation 5Lifting

7071_003-104_V2

1

2

3

Attachment

DANGER

Risk 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.

56358042501 EN - 10/2016 141

5 OperationLifting

Operation with reversible fork arms(variant)

DANGER

Risk 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)

WARNING

Risk 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)

WARNING

Risk 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.

142 56358042501 EN - 10/2016

Operation 5Lifting

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 thesame manner.

– 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"

56358042501 EN - 10/2016 143

5 OperationHandling loads

Handling loads

6210_003-030

Safety regulations when handingloadsThe safety regulations for handling loads areshown in the following sections.

DANGER

There 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!

DANGER

Risk 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.

DANGER

Risk 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.

144 56358042501 EN - 10/2016

Operation 5Handling 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".

WARNING

The figures show examples.Only the capacity rating plateson the truckare valid!

The attachment of additional weights toincrease load capacity is prohibited.

DANGER

Risk 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.

56358042501 EN - 10/2016 145


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)

WARNING

Risk 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.

146 56358042501 EN - 10/2016


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

DANGER

Risk 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".

CAUTION

If 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

56358042501 EN - 10/2016 147


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

– Press button (1) for "load measurement";the "load measurement" symbol (2) ap-pears on the display highlighted in black.

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.

148 56358042501 EN - 10/2016


6210_003-073_en

3

If load measurement has been carried outcorrectly, the determined load weight (3) isshown on the display of the display-operatingunit.

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.

DANGER

Risk 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.

56358042501 EN - 10/2016 149


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.

DANGER

Risk of injury!– Do not step on the fork.

DANGER

Risk of injury!– Do not step under the raised forks.

DANGER

People may be injured in the danger area of 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.

150 56358042501 EN - 10/2016


DANGER

Danger of death from falling loads!– Never walk or stand underneathsuspended 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.

DANGER

Suspended 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.

56358042501 EN - 10/2016 151


DANGER

Loss 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

DANGER

Risk 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

DANGER

There 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.

152 56358042501 EN - 10/2016


– Only store pallets which do not exceed thespecified maximum size. Damaged loadingequipment 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.

CAUTION

Component damage possible!When inserting the fork into the racking, ensure thatthe racking and load are not damaged.

56358042501 EN - 10/2016 153


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.

DANGER

Risk of accidents!– Beware of any people in the danger area.

CAUTION

Component damage possible!– Ensure that the roadway behind you is clear.

– Move backwards carefully and slowly untilthe load is clear of the racking. Brake gently.

DANGER

Never tilt the lift mast with a raised load due to therisk of tipping!– Lower the load before tilting the lift mast.

154 56358042501 EN - 10/2016


5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

56358042501 EN - 10/2016 155


6210_800-011

Transporting loads

NOTE


DANGER

The higher a load is lifted, the less stable it beco-mes. The truck can tip over or the load can fall,increasing the risk of accident!Driving with a raised load and the lift mast 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".

156 56358042501 EN - 10/2016


6210_800-014

– Never drive with a load protruding to theside (e.g. with the sideshift)!

Setting down loads

DANGER

Risk of accident due to changed moment of tilt!Pleasenote that the liftmast canbe tilted far enoughforward with a raised load to cause the truck to tipover.The load centre of gravity and the moment of tiltboth change when the load slips. The truck may tipforwards.– Only tilt the lift mast forwards with a raised lifting

accessory when it is directly above the stack.– When the lift mast is tilted forward, take particular

care to ensure that the truck does not tip forwardsand that the load does not slip.

WARNING

Risk 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.

NOTE

If the truck is to be used to store a raised loadwith the lift mast tilted forwards, e.g. in a rackwith sloping racking channels, an additional

56358042501 EN - 10/2016 157


load capacity diagrammust be created as thestability will be affected.• Contact the authorised service centre onthis matter.

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.

DANGER

Risk of accident!– Beware of any people in the danger area.– Ensure that the roadway behind you is clear.

– Move the truck back until the fork arms canbe lowered without touching the stack.

– Lower the fork while maintaining groundclearance.

– Tilt the lift mast backwards and drive away.

158 56358042501 EN - 10/2016


6210_001-008

Driving on ascending and descend-ing slopes

DANGER

Danger to life!Onascending and descending slopes the loadmustbe carried facing uphill.It is only permitted to drive on ascending anddescending slopes if they are marked as trafficroutes and can be used safely.The driver must check that the ground is clean witha good grip.It is not permitted to perform turns on ascendingslopes, to approach them diagonally or to park thetruck on them.Drive at a reduced speed on descending slopes.It is not permitted to put items into stock or toremove them from stock while on an ascendingor descending slope.The forklift truck should not be parked on a slope.– In case of emergency, secure the truck with

chocks.

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. 28)has been granted authorisation.

DANGER

There 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.

56358042501 EN - 10/2016 159







max

min.*


kg kg

kg

kg

kgkW

V

*

1

3

2

6210_001-016_V2

Determining the actual total weight– Park the truck securely, see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 5-286.

– 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. 5-286, to preventuncontrolled movements of the load or thetruck.

160 56358042501 EN - 10/2016


6210_001-010

Driving on loading bridges

DANGER

Risk 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

6210_001-016_V2

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.

56358042501 EN - 10/2016 161

5 OperationWorking with attachments

Working with 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.

NOTE

Please note the definition of "competentperson" in the sense of responsible persons!

CAUTION

Attachments must be CE-certified. If the truck isnot fitted with an attachment-specific residual loadcapacity rating plate, and the operating devices arenot marked with the relevant pictograms, the truckmust 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).

162 56358042501 EN - 10/2016

Operation 5Working with attachments

DANGER

There is risk to life caused by a falling load!Attachments that hold the load by exerting pressureon it (e.g. clamps)must beadditionally controlled 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.

DANGER

There 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.

7341_003-019

Hydraulic connection– Before fitting the attachment, release thepressure from the hydraulic system.

CAUTION

Risk 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 attachments have been disassembled,

attach theprotective caps to the plug connectors.

Mounting attachmentsMounting the attachment and connecting theenergy supply for power-driven attachmentsmust only be performed by authorised per-sonnel in accordance with the informationprovided by the manufacturer and supplier ofthe attachment. After each assembly, the at-tachmentmust be checked for correct functionprior to initial commissioning.

NOTE

Please note the definition of "competentperson" in the sense of responsible persons!

56358042501 EN - 10/2016 163


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 in 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 "Picking up aload using attachments".

7341_003-019

Releasing the pressure from thehydraulic systemPrior to assembling attachments, the pressuremust be released from the plug connectors(arrows).

Attachments must only be assembled byauthorised personnel in accordance with theinformation provided by the manufacturerand supplier of the attachments. After eachassembly, the attachment must be checkedfor proper functioning prior to being put intooperation for the first time.

NOTE

The pressure release procedure is dependenton the operating devices for controlling thehydraulic functions; see the chapter entitled"Lifting system operating devices".

164 56358042501 EN - 10/2016


1

F1F1 F2F2

1

1

F1 F2

1

16311_003-034_V2

Releasing the pressure

NOTE

In trucks with the "FleetManager" or "accessauthorisation with PIN code" equipment va-riants, access authorisation must be enabled.

– Switch on the key switch.

– Lower the fork carriage.

– Switch on the hazard warning system(variant).

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.

– Switch off the key switch.

– Actuate the operating lever (1) for control-ling the hydraulic functions repeatedly inthe direction of the arrow, as far as the endposition.

The valves open and the hydraulic system isdepressurised.

56358042501 EN - 10/2016 165


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:• 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 switch• Fingertip with a 5th function (variant)

– For information on controlling attachmentswith the respective operating devices, seethe relevant sections in this chapter.

WARNING

Use 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 transported withattachments if the loads 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. Thedirections of movement can be seen on thepictograms on the operating devices.

166 56358042501 EN - 10/2016


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.

56358042501 EN - 10/2016 167


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.

This essentially involves the following:

– 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).

168 56358042501 EN - 10/2016


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8

– Note the following attachment functions andpictograms.

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

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.

56358042501 EN - 10/2016 169


7312_003-112

12E

F

7312_003-113_V2

E F

Controlling attachments usingthe double mini-lever and the 5thfunction

NOTE

The "lift mast" 360° lever and the "attach-ments" cross lever control four hydraulic func-tions. The "5th function" designation refersto the fact that switching functions using the"5th function" function key (1) control the 5thhydraulic function via the cross lever.

The pictograms on the "attachments" crosslever show the respective functions that areactivated by this lever.


– Actuate the "5th function"(1) function keyand move the "attachments"(2)cross leverin 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"(2) cross leverin the direction of the arrow (F).

The attachment moves in accordance with thepictogram in position (F).

170 56358042501 EN - 10/2016


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



56358042501 EN - 10/2016 171


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).

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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



56358042501 EN - 10/2016 173


5060_003-121

E

F

2

1

3

5060_003-120_V2

E

F

Controlling attachments using thethree-way mini-lever and the 5thfunction

NOTE

Four hydraulic functions are controlled usingthe "lift mast" 360° lever and operating levers(1) and (2). The designation "5th function"refers to the fact that the function change-overuses the function key (3) , which then allowsthe 5th hydraulic function to be controlled withthe operating lever (1).


The meanings are as follows:

– Actuate the "5th function" function key (3)and move operating lever (1) towards (E).


– Actuate the "5th function" function key(3) and move the operating lever (1) to-wards(F).

The attachment moves in accordance with thepictogram in position (F) .

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5060_003-122

3

4

1

2






NOTE



56358042501 EN - 10/2016 175


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).

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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



56358042501 EN - 10/2016 177


5060_003-119

4

1

25

3

E

F

5060_003-120_V2

E

F

Controlling attachments using thefour-way mini-lever and the 5thfunction

NOTE

Operating levers (1) to (4) are used to control4 hydraulic functions. The designation "5thfunction" refers to the fact that the functionchange-over uses the "5th function" functionkey (5), which then allows the 5th hydraulicfunction to be controlled using the operatinglever (3).



– 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).

The attachment moves in accordance with thepictogram in position (F).

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5060_003-122

3

4

1

2






NOTE



56358042501 EN - 10/2016 179


1

6210_003-085

Controlling attachments via thejoystick 4PlusIn this equipment, the attachments (variant)are controlled via the joystick 4Plus (1).

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


Operatingdevice

Function of theattachment

1 Joystick 4Plus Move sideshift to theleft/right

2 Joystick 4Plus orslider

Adjust fork arms:open/close

3 SliderMove reach 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 areattached 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.


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Controlling attachments using thejoystick 4Plus and the 5th function

6210_003-096

1– Note the following attachment functions andpictograms.

Operatingdevice

Function of theattachment

1Horizontalrocker button+ shift button "F"

Release/open clamp

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.

– Simultaneously actuate the horizontalrocker switch (2) in the direction shown inthe pictogram so that the attachmentmovesaccordingly.

NOTE

The pictograms on the joystick 4Plus areattached 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.


56358042501 EN - 10/2016 181


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.

The attachment moves in the direction ofmovement shown in the lower part of thepictogram.

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

4 Adjust fork arms: open/close

5Swivel lift mast or forks to the left/tothe right

6 Release/clamp load retainer

7 Push off/pull in load

8 Open/close clamps

9 Turn to the left/to the right

10 Tip shovel over/tip shovel back

NOTE



182 56358042501 EN - 10/2016


F1F1 F2F2

6210_003-032

13

2Controlling attachments with finger-tip and the 5th function

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.


– Move operating lever forwards.

The attachment moves in the direction ofmovement shown in the upper part of thepictogram.

– Move operating lever back.

The attachment moves in the direction ofmovement shown in the lower part of thepictogram.

– Actuate the switch (2).

The additional function of the attachment isactivated/deactivated and can be controlledas the "5th function" using the operating lever.

56358042501 EN - 10/2016 183


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.

184 56358042501 EN - 10/2016


6210_003-035

10 11

14

12

15

17 18

13

16


10 Move side shift frame or fork for-wards/backwards

11 Move sideshift to the left/right

12 Adjust fork arms: open/close

13 Swivel lift mast or fork to the left/right

14 Release/clamp load retainer

15 Push off/pull in load

16 Open/close clamps

17 Turn to the left/right

18 Tip shovel over/tip shovel back

NOTE



Clamp locking mechanism (variant)This truck can be fitted with a clamp lockingmechanism as a variant. This prevents theclamp from opening unintentionally if theoperating function is inadvertently triggered.

DANGER

There 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.

56358042501 EN - 10/2016 185


F1 F2

6210_003-077

1

2

Double mini-lever– To release the clamp locking mechanism,push the cross lever (1) forwards.

The LED for button F2 (2) lights up as long asthe 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 cross lever (1)forwards again.

It is not necessary to release the clamp lockingmechanism in order to close the clamp.

– To close the clamp, pull the cross lever (1)back.

– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the double mini-lever and the 5thfunction".

6210_003-078

1

2

Triple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE


– To open the clamp, push the operating lever(1) forwards again.


– To close the clamp, pull the operating lever(1) back.

186 56358042501 EN - 10/2016


– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the triple mini-lever and the 5thfunction".

6210_003-079

2

1

Quadruple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the quadruple mini-lever and the 5thfunction".

56358042501 EN - 10/2016 187


1

3

2

6210_003-097

Joystick 4Plus– To release the clamp locking mechanism,press and hold shift key "F"(3) andmove thehorizontal rocker button (1) to the right.

– Keep shift key "F"(3) pressed and movethe horizontal rocker button (1) back to theneutral position.

The LED (2) lights up as long as the clamplocking mechanism is released.

– To open the clamp, press and hold shiftkey "F"(3) and move the horizontal rockerbutton (1) to the right.

NOTE



– To close the clamp, press and hold shift keyF (3) and move the horizontal rocker button(1) to the left.

– To operate the clamping attachments, seethe section entitled "Controlling attach-ments using the joystick 4Plus and the 5thfunction".

188 56358042501 EN - 10/2016


6210_003-080

F1F1 F2F2

1

2Fingertip– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





– To operate the clamping attachments; seethe section entitled "Controlling attach-ments using the fingertip and the 5th func-tion".

1

2

3

7090_860-002

Taking up a load using attachments

WARNING

Risk 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.

WARNING

Risk 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.

56358042501 EN - 10/2016 189

5 OperationOperating auxiliary equipment

– The rating plates show the permissiblevalues for:

• Load capacity Q (kg) (1)• Lift height h (mm) (2)• Load distance C (mm) (3)

Operating 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 lightup. On the variant with StVZO (German RoadTraffic Licensing Regulations) equipment, thelicence plate lamp also lights 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.

NOTE

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment, theparking light and the licence plate lamp canbe switched on without the key switch beingswitched on.

190 56358042501 EN - 10/2016

Operation 5Operating auxiliary equipment

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

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment,the parking light and the licence plate lampare switched on by switching on the workingspotlights.

Switching the rotating beacon on andoff

5060_003-045_V2

21

– Push the button (1) for switching on therotating beacon.

The rotating beacon symbol (2) appears onthe display. The rotating beacon is switchedon.

NOTE

Pushing the button again switches the rotatingbeacon off again.

56358042501 EN - 10/2016 191


5060_003-011_V2

1

2

Switching the hazard warningsystem on and off– Push the button (1) to switch on the hazardwarning system.

All direction indicators and indicatorlights (2) flash.

NOTE

Pushing the button again switches the hazardwarning system off again.

NOTE

The hazard warning system can also beswitched on without the key switch beingswitched on.

Switching the direction indicators onand off

5060_003-096

F1 F2

1

Mini-lever version– Switch on the direction indicators bymovingthe drive direction/turn indicator cross lever(1) to the left or right.

192 56358042501 EN - 10/2016


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

5060_003-046

1

Mini-console version– Switch on the direction indicators bymovingthe turn indicator switch (1) to the left or tothe right.

56358042501 EN - 10/2016 193


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 turn indicator switch to the centreposition

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 on switchingthe lower working spotlights on, see the"Switching lighting on and off" chapter.

NOTE

This function is not available if the truck isequipped with rear window heating.

194 56358042501 EN - 10/2016


– Turn the key switch to position "I".

6311_003-030_V3

1

– Press button (1).

NOTE

Pressing the button again switches the work-ing spotlights off again.

Switching the upper working spotlightson/off automatically– Turn the key switch to position "I".

– For information on switching on workingspotlights, see the "Switching lighting onand off" chapter.

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

In these two seconds, a maximum of two liftscan take place so that the working spotlightsdo not switch on each time a precise adjust-ment is made. If more lifts are carried outduring this time, the upper working spotlightswill remain switched off.

NOTE

The upper working spotlights are switchedoff automatically when the truck is driven forlonger than one second and faster than 2.1km/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.


– Switch on the working spotlights.

56358042501 EN - 10/2016 195


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.

CAUTION

Possible component damage caused by collision ifthe proximity switch is set incorrectly.– The proximity switch may be adjusted by trained

personnel.– Inform the relevant service centre.

Operating the windscreenwiper/washer

7312_003-171_V3

1

2

– Press the button (1) to activate the frontwiper/washer (variant) and the roof panelwiper (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 shown below.

Button actuation Operating stage

Off

1st time On

2nd time Interval

3rd time + hold Washer

4th time Off.

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.

196 56358042501 EN - 10/2016

Operation 5Cab operation

Accident recorder (variant)The accident recorder is an equipment variantto the FleetManager (variant), which is in-stalled in the truck’s acceleration sensor. Theacceleration sensor records data in the eventof an accident. This data can be electronicallyread out and evaluated. For further informa-tion, contact your STILL service centre.

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.

Cab operation

7331_341-0034 5

2

1

3

Opening the cab door

DANGER

There 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.

Opening the cab door from the outside:– Insert the key in the door lock (1), unlockand remove the key.

– Pull the door handle (2) and release thedoor lock.

– Open the cab door (3) by pulling outwards.

Opening the cab door from the inside:– Take hold of the handlebar (4) and latch (5).

– Press the latch in and push the cab dooroutwards.

56358042501 EN - 10/2016 197

5 OperationCab operation

Closing the cab door

DANGER

There 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.

7331_341-007

4

2

1

3

Opening the side windows

WARNING

There 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 (2) together and slide therear side window (1) forwards.

– Make sure that the handle engages in thestop slot (3).

Opening the front side window:The front side window (4) can be opened in thesame way as the rear side window.

198 56358042501 EN - 10/2016


7331_341-007

4

2

1

3

Closing the side windows

WARNING

There 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 (2) together and pull therear side window (1) to the rear.

– Make sure that the handle engages in thestop slot (3).

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

56358042501 EN - 10/2016 199


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.

200 56358042501 EN - 10/2016


Operating the rear window heating

6311_003-014_V2

21

– Switch the rear window heating on or offwith button (1).

The "rear window heating" symbol (2) appearsin the display.

NOTE

The rear window heating will switch off au-tomatically after approx. 10 minutes or afterpressing the switch again.

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.

WARNING

The 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.

56358042501 EN - 10/2016 201


Heating system (variant)

DANGER

Risk of explosion!There is a risk of explosion if theheater is operated in the vicinity ofstorage areas or similar areas wherefuel vapours or coal dust, wood dustand crop dust can accumulate.– Do not expose spray cans or gascartridges to the flow of hot air.

– Do not operate the heater inhazardous areas.

DANGER

Risk of fire as a result of heat buildingup in the heating element!Heat may build up if the air intakeopening is blocked or the heatingelement collects dust. The heatingelement may overheat or short-circuit.– Do not cover the air intakeopening.

– Do not operate the heating systemwithout a fresh air filter andrecirculated air filter fitted.

DANGER

Risk of burns!When the heating system is ope-rated, the heating system housingbecomes hot and can burn the skin ifit is touched.– Do not touch the heating systemhousing during operation.

CAUTION

Risk of blower malfunction!The fresh air filter and recirculated air filter collectdust and dirt particles from the intake air. If the filterelements are not fitted, dust and dirt particles mayblock the blower.– Do not operate the blower without a fresh air filter

and recirculated air filter fitted.

202 56358042501 EN - 10/2016


Switching on the blower

2

6341_003-021

1

– To switch on the blower, turn on the blowerswitch (1).

The blower runs at the speed level set at theswitch.

Switching on the heating system

NOTE

The heating system only heats up when theblower is switched on. If the blower switchis switched off, the heating system will notfunction, regardless of the position of theheater switch.

– To switch the heating system on, firstswitch on the blower switch (1) and thenthe heating switch (2).

The heating system is in operation. The air isheated up to the heat output level set at theheating switch (2).

Adjusting the air flow

7331_345-002

4

3

– Adjust the air flow at the front outlet vents(3) and at the outlet vent in the footwell (4).

56358042501 EN - 10/2016 203


6210_003-105_V2

1

2

3

3

Push-up roof window (variant)

WARNING

Risk 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

6210_003-107

21

Clipboard (variant)The clipboard (1) with reading lamp (2) is anequipment variant.

204 56358042501 EN - 10/2016

Operation 5Trailer operation

Trailer operation

6210_313-001

Towed load

DANGER

There 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.

CAUTION

Risk 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 towed load present corresponds tothe rated capacity of the truck, it is not permitted totransport a load on the fork at the same time. Theload can be distributed between the fork and thetrailer.– Check the load distribution and adjust to corre-

spond to the rated capacity.– Observe the permissible rigidity value of the tow

coupling.

CAUTION

Risk 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 centreof the application conditions. The service centreprovides the required data.– Inform the authorised service centre.

56358042501 EN - 10/2016 205

5 OperationTrailer operation

CAUTION

Damage to the tow coupling due to overloading!Tow couplings RO*243 and RO*244 must beindividually checked to ensure that they are suitablefor the planned towing operation. The permissiblerigidity value of the tow coupling must always betaken into account. The authorised service centrecan check and/or confirm the maximum towed loadfor the planned towing operation.– Observe the operating instructions for the tow

coupling.– Inform the authorised service centre.

CAUTION

Risk of damage to components!A support load is not permitted.– Do not use trailers with tillers supported by the

tow coupling.

This truck is suitable for the occasional towingof trailers. If the truck is equipped with atowing device, this occasional towing mustnot exceed 2%of the daily operating time. Themanufacturer must be consulted if the truck isto be used for towing on a more regular basis.

Coupling pin in the counterweight

Coupling the trailer

DANGER

Danger to life! If you briefly leave the truck to coupleor uncouple the trailer, there is a risk of being runover by the truck rolling away.– Apply the parking brake.– Lower the fork to the ground.– Turn off the key switch and remove the key.

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1 7090_900-008

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

2 36341_003-012

– Push the coupling pin (2) down, turn 90°and pull out.

– Adjust the tiller height.

DANGER

People can become trapped between the truck andtrailer.When coupling, ensure that there are no personspresent between the truck and the trailer.

– Slowly move the truck backwards.

– Bymoving the truck back, introduce the tillerinto the recess (3) in the counterweight.

DANGER

If the coupling pin or securing bush are lost ordestroyed during towing, the trailer will work looseand become uncontrollable. This poses a risk ofaccident!– Only use genuine coupling bolts that have been

checked.– 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.

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Uncoupling the trailer– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

2 36341_003-012

– 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

DANGER

Persons may become trapped between the truckand trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

DANGER

Never jack up or crane load the truck on the towcoupling. The tow coupling is not designed for thisand could be deformed or destroyed. The truckcould fall off, with potentially fatal consequences!– Use the tow coupling only for towing.– For jacking up and crane loading, use only the

designated lifting points.

DANGER

The tow coupling is not designed for support loadsand could be deformed or destroyed. This couldcause the supported load to fall, with potentiallyfatal consequences!– The tow coupling should be subjected only to

horizontal loads, i.e. the tiller must be horizontal.

208 56358042501 EN - 10/2016


DANGER

If you briefly leave the truck to couple or uncouple,there is a risk to life caused by the truck rolling awayand running you over.– Apply the parking brake.– Lower the fork to the ground.– Turn off the key switch and remove the key.

WARNING

Never 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.

CAUTION

Risk 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, check 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, check the tow coupling

for damage.– Replace tow coupling if damaged, if necessary

contact the authorised service centre.

CAUTION

Risk 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.

56358042501 EN - 10/2016 209


CAUTION

Risk of component damage if the tiller in the towcoupling is tilted!The tiller should if possible be kept horizontal whentowing. This ensures a sufficient rotation range atthe top and bottom. The authorised service centrecan adjust the assembly height for the tow couplingto 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

CAUTION



NOTE

TowcouplingRO*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.

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3

7321_003-064

2

– Pull out the safety handle (3).

– Push the hand lever (2) upwards.

DANGER

Persons may become trapped between the truckand trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTION

When 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.

– Slowly move the truck back.

DANGER

If 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.– 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

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area with yourhand. If, for example, a tow rope is to be secured inthe tow coupling, use only a suitable device to closethe tow coupling (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 andthen closes the tow coupling automatically.

56358042501 EN - 10/2016 211


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.

Coupling model RO*244 A

CAUTION



NOTE

Tow coupling RO*244 A is intended for atow-bar eye in accordance with DIN 74054(bore diameter 40 mm) or DIN 8454 (borediameter 35 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.

212 56358042501 EN - 10/2016


DANGER

Persons may become trapped between the truckand trailer!When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTION

When 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.

– 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) doesnot protrude out of itsguide.

DANGER

If the coupling 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.



56358042501 EN - 10/2016 213


Closing model RO*244 A by hand

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area with yourhand. If, for example, a tow rope is to be secured inthe tow coupling, only actuate the tow coupling viathe closing 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.

– Push the hand lever (2) upwards until itsnaps into place.



– Close the tow coupling by actuating theclosing lever (1).

NOTE

To protect the lower coupling pin bush againstcontamination, always keep the tow couplingclosed.

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7321_003-066_V2

57

6

Coupling model RO*245

NOTE

Tow coupling RO 245 is intended for a tow-bareye 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.




DANGER

Persons may become trapped between the truckand trailer!When hooking up, ensure that no one is betweenthe truck and trailer.

– Slowly move the truck back.

DANGER

If 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

Uncoupling model RO*245– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.



– Push the closing lever (7) on the left side ofthe tow coupling down as far as it will go.

The tow coupling is closed.

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.

NOTE


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Operation 5Operating the display and operating unit

Operating the display and 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 the battery 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".

56358042501 EN - 10/2016 217

5 OperationOperating the display and operating unit

CAUTION

Deep 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%).

218 56358042501 EN - 10/2016


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.

56358042501 EN - 10/2016 219


7312_003-056_en_V3

ESC

1 2 3Adjusting the displays

NOTE

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

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.


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

The display changes to thePASSWORDmenu.

– Press the return key (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• Configuring Blue Q

Symbols in the display

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

220 56358042501 EN - 10/2016


Symbols for operating messages

Description Symbol

Empty field No display

Please wait

Service required

Lift limitation

Reference cycle

Battery charging

Drive program

Hour meter

Odometer

Daily hour meter

Daily odometer

Speed

Steering angle

Load

Time

Hydraulic system

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

56358042501 EN - 10/2016 221


Description Symbol

Are you sure?

Oil pressure.

Symbols for error messages

Description Symbol

Brake system malfunction

Overheating of the engine

Overheating

Malfunction in the electrical system

General malfunction.

Symbols for auxiliary equipment soft keyfunctionsFor the auxiliary equipment, the followingsymbols for the soft key functions are used onthe left in the display:

Description Symbol


General function key OFF

General function key 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

222 56358042501 EN - 10/2016


Description Symbol

Heater blower OFF

Heater blower ON

Rotating beacon OFF

Rotating beacon ON

Seat heater OFF

Seat heater ON

Signal horn OFF

Signal horn ON.

Symbols for the soft key functions formenu navigation and for acknowledgingmessagesFor menu navigation and to acknowledgemessages, the following symbols for thesoft key functions are used on the left of thedisplay:

Description Symbol


ESC button to return to the main menu

ENTER button to confirm

OK button to confirm

RES button to reset

Button to return to the main menu

Button to return to the previous edit field

Scroll button to scroll up

Scroll button to scroll downScroll button to count up

Scroll button to 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.

56358042501 EN - 10/2016 223


Description LED

Function off LED OFF

Function on LED ON.

Symbols for numeric keypadThe available inputs and the positions of thekeys are shown for inputting digits, ESC andENTER .

BQ_037

1

2

6

7

3

4

5

ESC

Keys for the digits 1 to 7 and the ESC andENTER keys for inputting the fleet managerpassword

1

2

6

7

3

4

5

8

9

0

BQ_038

Keys for digits 0 to 9 for inputting the driver PIN(access code)

224 56358042501 EN - 10/2016


8

9

0

6

7

4

3

5

7312_003-054_en_V3

1 2 3 4Setting the date or time– Switch to the "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-220.

– Press the drive program key (1) or menuselection key (2) until the option TIMEappears.Confirm your selection by pressingthe Return key (4).

The "TIME" menu appears.

– Press the drive program button (1) or themenu change button (2) until the desiredtime appears in the display.

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

– Confirm the time set by pressing the Returnkey (4).

– Use the arrow key (3) to exit the menu andreturn to the next higher level.

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 "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-220.

– Press drive program button (1) or menuselection button (2) until the DAY-KMoption appears. Confirm your selectionby pressing the Return key.

The "DAY KM" menu appears.

– Reset the values by pressing the RES (4)button.

– Use the arrow key (3) to exit the menu andreturn to the next higher level.

56358042501 EN - 10/2016 225


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 "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-220.

– Press drive program button (1) or menuselection button (2) until the LANGUAGEoption appears. Confirm your selection bypressing Return key(4).

The "LANGUAGE" menu appears.

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

– Confirm your selection by pressing theReturn key (4).

– Use arrow key (3) to exit the menu andreturn to the next higher level.

Soft key button for operating variousequipment variantsThere are two soft key columns available onthe display operating unit. With these softkey columns, you can switch the additionalfunctions on and off, e.g. a rotating beacon.The second soft key column is only availableif the truck has more than three additionalfunctions.

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1 2 3

ABE_Softkeytasten_V2

A grey bar (3) highlights the active soft keycolumn, i.e. the soft keys in this column can beoperated. To change the soft key column:

– Briefly press the "Menu change button"(1).The grey bar jumps to the other soft keycolumn. The required soft keys are nowactive and the functions assigned to themcan be switched on and off using thecorresponding soft key buttons (2).

NOTE

In order to shift between the individual menusof the display operating unit, press the "Menuchange button" (1) for approx. 1 second.

NOTE

The functions of the two soft key columnsdepend on the individual equipment of thetruck. Therefore, the soft keys on your displayoperating unit may vary to those shown here.

56358042501 EN - 10/2016 227

5 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".

Effects on additional consumersThe following table shows the specific condi-tions that cause certain auxiliary devices toshutdown when Blue Q is activated. The aux-iliary devices available depend on the truckequipment.

228 56358042501 EN - 10/2016

Operation 5Blue-Q efficiency mode

Shut-off Seat switch Truck stopped Drive directionFront workingspotlight* X X Backwards > 3 km/h

Rear workingspotlight* X X Forwards

Top double workingspotlight* X X > 3 km/h

Headlight* X X -

Side light - - -

Front wiper X X Backwards > 3 km/h

Rear wiper X X Forwards

Seat heater X - -

Cab heating X - -

*No shutdown for StVZO (Road Traffic Licensing Regulations) equipment..

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 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. For information onconfiguring the Blue-Q operating modes, seechapter "Configuring Blue Q efficiency mode".

56358042501 EN - 10/2016 229

5 OperationBlue-Q efficiency mode

2

6210_003-065_V3

1 2

– Press the Blue-Q button (1).

The Blue-Q symbol (2) appears next to thedrive programme symbol in the display andoperating unit, which means that the Blue-Qefficiency mode is activated.

Pressing the Blue-Q button once again turnsthe Blue-Q efficiency mode off again.

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

230 56358042501 EN - 10/2016

Operation 5Blue-Q efficiency mode

8

9

0

6

7

4

3

5

7312_003-179_en

1 2 3 4– Switch to the CONFIGURATIONmenu;see ⇒ Chapter "Adjusting the dis-plays", P. 5-220

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

– Confirm your selection by pressing theReturn key (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 with Returnbutton (4).

– Use arrow key (3) to exit the menu andreturn to the next higher level.

56358042501 EN - 10/2016 231

5 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. In the "Comment" column you willfind information on how to proceed should anyof these messages appear.

232 56358042501 EN - 10/2016

Operation 5Display 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 error occurs more frequently, notify your authorisedservice centre.

OVERHEATINGA5364

Pump converter is too hot.Notify your authorised service centre.

ACCELERATORA3002A3003A3004A3005A3006A3007A3505

Sensor fault, truck cannot be driven.Notify your authorised service centre.

ACCELERATORA3008

Accelerator voltages (for dual pedal) do not match; truckcannot be driven.Notify your authorised service centre.

ACCELERATORA3811

Accelerator configuration is invalid. Truck cannot be driven.Notify your authorised service centre.

BRAKE SENSORA3016A3017

Sensor fault; truck can only be driven at emergency modespeed.Notify your authorised service centre.

CONFIGURATIONA2111A3801A3812

Parameterisation error; drive unit and hydraulic drive notfunctioning.Notify your authorised service centre.

SEAT SWITCHA302

Seat switch has not been actuated for approx. 8 hours.Truck may still drive at a reduced speed and with reducedlifting capacity.Stand up briefly and then sit down again.If this does not resolve the problem, contact your authorisedservice centre.

STEERINGA3215A3216A3570

Sensor fault; truck moves at emergency mode speed.Notify your authorised service centre.

DRIVE DIRECTIONA3020

Switch error; no or limited drive unit function.Notify your authorised service centre.

LIFTINGA3102A3103

Sensor fault; no or limited hydraulic drive function.Notify your authorised service centre.

56358042501 EN - 10/2016 233



Comment

TILTINGA3107A3108


MAST VERTICALA3130A3131A3132

No hydraulic function.Turn off "lift mast vertical position".Notify your authorised service centre.

MAST VERTICALA3135

No hydraulic function.Turn off "lift mast vertical position".Notify your authorised service centre.

EXT1A3112A3113


EXT2A3117A3118


POWER SUPPLYA2242

Transmitter power supply short circuit. Truck cannot bedriven.Notify your authorised service centre.

SURVEILLANCEA2801A2802A2808A2809A2810A2815

Drive unit not functioning.Release accelerator pedal.If this error occurs sporadically, it can be tolerated. If theoperational capacity is impaired, notify your authorisedservice centre.

SURVEILLANCEA2803A2806

Drive direction is set to neutral.Reselect the drive direction.If this error occurs sporadically, it can be tolerated. If theoperational capacity is impaired, notify your authorisedservice 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 theoperational capacity is impaired, notify your authorisedservice centre.

SURVEILLANCEA2804A2805A2807A2811A2812A2813A2814A2816A2818

No or limited drive unit function.Notify your authorised service centre.

234 56358042501 EN - 10/2016



Comment

SURVEILLANCEA2295

No or limited function of drive unit and hydraulic drive.Notify your authorised service centre.

DRIVEA5031A5041A5046A5301A5331A5361

Temperature sensor faultNotify your authorised service centre.

BATTERY CHANGERA5910

The support roller for the hydraulic battery carrier is not fullyextendedNotify your authorised service centre.


Hydraulic pump of the hydraulic battery carrier is overheat-ing.Allow the truck to cool down for 1 hour.


Button errorNotify your authorised service centre.


Plausibility error with potentiometer for hydraulic batterycarrierNotify your authorised service centre.

CONTROL UNITA3305

CIO not functioning.Notify your authorised service centre.

PARKING BRAKE OILPRESSUREA3043

Parking brake oil pressure too low; the drive unit is locked.If this message remains permanently displayed, notify yourauthorised service centre.

PARKING BRAKE OILPRESSUREA3049

Parking brake oil pressure low; truck only moves at emer-gency mode speed.If this message remains permanently displayed, notify yourauthorised 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.

56358042501 EN - 10/2016 235


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

DANGER

Risk 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 areblocked. 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.

– Apply the parking brake.

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.

236 56358042501 EN - 10/2016


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.

– 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.

56358042501 EN - 10/2016 237


– 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

DANGER

There 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.

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 STEERING message 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.

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EMERGENCY SWITCHmessage

WARNING

Noelectric 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

? 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

REFERENCECYCLEmessageIf 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 theposition of the fork, themessageREFERENCECYCLE (variant)mayappear 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.

56358042501 EN - 10/2016 239


– To drive again, lower the fork to a maximumof 300 mm above the ground.

The truck can now be driven again with nospeed limitation.

7325_003-056_en_V2

F1 F2

SAFETY BELTmessage

DANGER

Risk of fatal injury in the event offalling from the truck if it tips over!If the truck tips over, the driver is atrisk of injury even if a restraint systemis used. The risk of injury can bereduced by using a combinationof a restraint system and a seatbelt. In addition, the seat beltprotects against the consequencesof rear-end collisions and falling offramps.– We recommend that you alwaysuse 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.

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If the seat belt is released while driving, thetruck will be limited to low driving speeds or willbe braked to a halt.

DANGER

Risk 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.

56358042501 EN - 10/2016 241


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 thedisplay. 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 SURVEILLANCEmessage 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 followingmessage appears 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.

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– 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.

DANGER

Risk 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.

DANGER

Risk 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.

56358042501 EN - 10/2016 245


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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Operation 5Operating in special operating situations

Operating in special operating situationsTransportation

CAUTION

Risk of material damage from overloading!If the truck is driven onto a means of transport,the load capacity of the means of transport, theramps and loading bridges must be greater thanthe total actual weight of the truck. Componentsmay become permanently deformed or damageddue to overloading.– Determine the total actual 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 total actual weightof the truck.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

3

2

6210_001-016_V2

Determining the total actual 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 total actual weight of the truck:

Tare weight (1)




+ 100 kg allowance for driver

= Total actual weight

56358042501 EN - 10/2016 247

5 OperationOperating in special operating situations

DANGER

Risk 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 across a loading bridge, ensure

that it is properly attached and secured.– Ensure that the transport vehicle onto which the

truck is to be driven has been sufficiently securedagainst moving.

– Maintain a safe distance from edges, loadingbridges, ramps, working platforms etc.

– Drive slowly and carefully onto the transportvehicle.

7331_003-002

Inserting wedges– Secure the truck from rolling away byplacing a wheel chock (1) in front of eachfront wheel and behind each back wheel.

– Park the truck securely.

CAUTION

Risk of component damage!If you remove the battery male connector whilethe key switch is switched on (under load), an arcwill be 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.


– Disconnect the battery male connector.

Lashing down

CAUTION

Abrasive 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).

248 56358042501 EN - 10/2016


7341_003-026_V2

1

– Attach lashing straps (1) to both sides of thetruck and lash the truck to the rear.

7341_003-027_V2

2

1

– Attach lashing straps (1) to the coupling pin(2) or loops around the coupling pin andlash the truck to the side.

DANGER

The truck may slip if the lashing straps slip!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.

56358042501 EN - 10/2016 249


6036Ba-0265060_003-070

Towing

DANGER

The brake system on the towing vehicle may fail.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 tractive and braking forces fromthe unbraked towed load (total actual weight of thetruck).– Check the tractive and braking forces of the

towing vehicle.

DANGER

The truck could drive into the towing vehicle whenthe towing vehicle brakes. Risk of accident!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.

CAUTION

If the truck drive between the drive motor andthe drive axle is not interrupted, the drive may bedamaged.– Place the drive direction switch in the neutral

position.

CAUTION

Risk 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.– Do not disconnect the battery male connector


250 56358042501 EN - 10/2016


DANGER

People can be crushed between the truck andtowing vehicle during manoeuvring. There is a riskof fatal injury!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.

CAUTION

Steering 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.

CAUTION

If 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.

CAUTION

Component damage as a result of blocked brakes!The truck is equipped with a negative spring-operated brake. As a result, when you switch offthe truck, the multi-disc brakes in the drive wheelunits block. For towing, the brake must be releasedat the brake valve. Otherwise, the truck is towedwith the wheels blocked.Once the spring-operated brake is released, pres-sure builds up gradually again in the brake hydrau-lics and the brakes can block again. Note the towingtimewhen the key switch is switchedoff. The towingprocess must be interrupted in each case and thebrake released again.– Releasing the spring-operated brake– Note the towing time and release the spring-

operated brake again as necessary.

– Set down the load and lower the fork armsclose to the ground.

56358042501 EN - 10/2016 251


– Place the drive direction switch in theneutral position.




– Check the tractive and braking forces of thetowing vehicle.

– With the help of a guide, move the towingvehicle to the truck.

– Secure the tow bar to the tow coupling onthe towing vehicle and the truck.

– Release the spring-operated brake

– Sit in the driver’s seat in the truck to betowed and fasten the seat 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.

– Note the towing time (refer to the tablein the section entitled "Releasing thespring-operated brake") and release thespring-operated brake again as necessary.

– After towing, secure the truck against rollingaway (e.g. by applying the parking brake orusing wedges).

– Remove the tow bar.

Crane loadingCrane loading is only intended for transportingthe complete truck, including the lift mast,for its initial commissioning. For applicationconditions that require frequent loading orthat are not dealt with here, please contactthe manufacturer with regard to specialequipment variants.

252 56358042501 EN - 10/2016


Trucks may only be laden by persons with suf-ficient experience with the suitable harnessesand hoists.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

3

2

6210_001-016_V2

Determining the loading weight– Park the truck securely; see the chapterentitled "Parking 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:

Unladen weight (1)




= Loading weight.

Hooking on the lifting straps

CAUTION

Harnesses may damage the truck’s paintwork!Harnesses may damage paintwork by rubbing 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 deviceswhere necessary.

56358042501 EN - 10/2016 253


DANGER

There is a risk of fatal injury if thehoists and harnesses fail and causethe truck to fall!– Only use hoists and harnesseswith sufficient load capacity for thedetermined loading weight.

– Only use the truck’s designatedlifting points.

– Make sure that harness partssuch as hooks, shackles, beltsand similar items are only used inthe indicated load direction.

– The harnesses must not bedamaged by truck parts.

NOTE

The lifting points are indicated by a hooksymbol.

7341_003-028

3

– Loop the lifting straps around the maintraverse (3) on the outer mast of the liftmast as shown.

254 56358042501 EN - 10/2016


7341_003-029_V2

4

– Loop the lifting straps around the counter-weight (4) as shown.

– Determine the truck’s centre of gravity, seechapter entitled "Dimensions".

7321_003-013

5 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 whenlifted.

– Attach the lifting straps to the lifting eye andinsert the safety device (5).

CAUTION

Incorrectly 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 come intocontact with attachment parts.

56358042501 EN - 10/2016 255


Loading the truck

DANGER

If the raised truck swings in anuncontrolled manner, it may crushpeople. There is a risk of fatal injury!– Never walk or stand underneathsuspended loads.

– Do not allow the truck to bump intoanything whilst it is being lifted, orallow it to move in an uncontrolledmanner.

– If necessary, hold the truck usingguide ropes.

– Carefully lift the truck and set it down at theintended location.

256 56358042501 EN - 10/2016

Operation 5Procedure in emergencies

Procedure in emergencies

7312_003-183

F1F1 F2F2

1

1

1

Emergency shutdown

WARNING

There is no electric braking assistance when theemergency off switch is actuated!Actuating the emergency off switch will de-energisethe entire electrical system.– To brake, actuate the service brake.

CAUTION

Actuating the emergency off switch (1) or discon-necting the battery male connector (3) shuts downthe electrical functions of the truck.This safety system must only be used in an emer-gency or to safely park the truck.

CAUTION

Risk of component damage!If you remove the battery male connector whilethe key switch is switched on (under load), an arcwill be produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Switch off the key switch before the battery male

connector is disconnected.– Only disconnect the battery male connector

while the key switch is switched on in an emer-gency.

In an emergency, all functions of the truck canbe shut down:

56358042501 EN - 10/2016 257

5 OperationProcedure in emergencies

6341_003-013_V2

2

4

3– Press the emergency off switch (1) oropen the fastener (4) of the battery maleconnector (3) by pulling the fastener to theleft. Disconnect the battery male connector(3) from the plug connection by pulling thehandle (2) in the direction of the arrow.

In drive mode, this has the following effect:• No reduction in truck speed when theaccelerator pedal is released, accordingto the drive program selected. The truck willroll to a stop

• The electric brake does not function duringthe first part of brake pedal depression.To brake the truck using the mechanicalbrake, the brake pedal must be pusheddown 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 of truck speedwhen corner-ing) 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

DANGER

If 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:

258 56358042501 EN - 10/2016


– 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.

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

WARNING

When 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 control block.

56358042501 EN - 10/2016 259


DANGER

There is a risk of fatal injury fromfalling loadsor parts of the truck beinglowered.– Do not walk beneath the raisedload.

– Follow the steps described below.

NOTE

A hexagon socket wrench is located beneaththe bottomplate on the brake valve for carryingout the steps detailed below. This hexagonsocket wrench must remain in the truck at alltimes.

– Remove the bottom plate.

17341_003-014

– Take the hexagon socket wrench (1) out ofthe support mounting.

– Open the front right cover.

260 56358042501 EN - 10/2016


6341_003-0142 3

– Loosen the emergency lowering screw (3)on the control block (2) by a maximum of1.5 revolutions using the hexagon socketwrench.

– Screw the emergency lowering screw backin after the load is lowered.

– Return the hexagon socket wrench to thesupport mounting provided.

– Install the bottom plate.

– Close the front right cover.

WARNING

The load is lowered!The lowering speed is regulated by unscrewing theemergency lowering screw.– Note the following list.

Remember the following:• Tightening torque:max. 2.5 Nm

• When unscrewed a little:The load lowers slowly

• When unscrewed a lot:The load lowers quickly

DANGER

If 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.

Releasing the spring-operated brake

CAUTION

Component damage as a result of blocked brakes!In order to tow the truck, the multi-disc brakes mustnot be blocked in the drive wheel units.– Repeatedly release the spring-operated brake

during the towing process, in accordance withthe table below.

The truck is equipped with a negative spring-operated brake. Switching off the truck will

56358042501 EN - 10/2016 261


block the multi-disc brakes in the drive wheelunits after a few minutes. However, the truckcan still be moved until the drive wheel unitsare blocked. In order to tow the truck, thespring-operated brake must be released byactuating the brake valve. Otherwise, thetruck is towed with the wheels blocked.

NOTE

The brake valve is installed in front of thedriver’s seat beneath the bottom plate.

The coupling pin from the counterweightcan be used as an aid to actuate the brakevalve. If there is no removable coupling pinavailable on the truck, for example, if the truckis equipped with an automatic tow coupling(variant), the bottom plate must be raisedcompletely in order to access the brake valve.

Once the spring-operated brake is released,the pressure gradually drops again in thebrake hydraulics and the brakes can blockagain. The towing process must be inter-rupted at certain times and the spring-oper-ated brake released again, in accordance withthe table below.

Hydraulic oiltemperature

Period after releasing thespring-operated brake untilit is blocked once again

°C Minutes Seconds

-20 190 0

20 7 40

50 2 50

95 1 50

Actuate the brake valve by means of a cou-pling pin:

– Take the coupling pin out of the counter-weight.

262 56358042501 EN - 10/2016


6341_003-034

– Grip the rubber tab in the rubber mat usingthe finger opening and pull up the tab.

6341_003-036

1

2

– Insert the coupling pin (1) into the bore (2)on the bottom plate until the pin noticeablyrests on the brake valve plate beneath.

– Repeatedly press the coupling pin downvertically.

The spring-operated brake is released.

NOTE

To fully release the spring-operated brake,press down on the brake valve plate at least30 times. The pressure that builds up in thebrake hydraulics as a result releases thespring-operated brake.

– Once the spring-operated brake is re-leased, fold the rubber tab in the rubbermat back down.

– Insert the coupling pin in the counterweight.

Actuate the brake valvewithout a coupling pin:

– Remove the rubber mat.

– Remove the bottom plate.

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7341_003-030

3

– Press the brake valve plate (3) downrepeatedly.

The spring-operated brake is released.

NOTE

To fully release the spring-operated brake,press down on the brake valve plate at least30 times. The pressure that builds up in thebrake hydraulics as a result releases thespring-operated brake.

– After releasing the spring-operated brake,re-install the bottom plate and the rubbermat.

WARNING

Risk of injury through falling or slipping!

If the bottom plate is not inserted, there is a dangerof footwear getting stuck, causing you to fall. Evenwhen the bottom plate is installed, there is still adanger of slipping and injury if the rubber mat is notused.– Install the bottom plate and rubber mat.

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Operation 5Handling the battery

Handling the batterySafety regulations when handlingthe battery

Maintenance personnel

DANGER WARNING

Risk 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.– Alwayswear safety footwearwhenreplacing the battery.

– Only close the battery coverif there is no part of the bodybetween the battery cover andthe edge of the chassis.

The battery must only be replaced in accor-dance with the directions in these operatinginstructions.

When charging and maintaining the battery,observe the manufacturer’s maintenance in-structions for the battery and battery charger.

Fire protection measures

DANGER

Risk of explosion due to flammablegases!During charging, the battery releasesa mixture of oxygen and hydrogen(oxyhydrogen gas). This gas mixtureis explosive and must not be ignited.No flammable materials or spark-forming operating materials may bewithin 2 m of either the truck when itis parked for charging or the batterycharger.When working with batteries, takethe following security precautions.

– Keep away from open flames and do notsmoke.

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5 OperationHandling the battery

– Always ensure adequate ventilation in thevicinity.

– Disconnect the battery male connectorbefore charging and only when the truckand battery charger are switched off.

– 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.

Lifting accessory

The battery can be removed using the follo-wing lifting accessories:• For trucks, see chapter entitled "Replacinga battery using a truck"

DANGER

Risk of accident!The battery could fall from the lifting accessoryor the lifting accessory could tip over or becomedamaged. If this happens, there is a risk to life.The battery must only be removed when the truckis on level, smooth ground with sufficient loadcapacity. The load capacity of the lifting accessoryused (see operating instructions or nameplate)must at least match the battery weight (see batteryidentification plate).– Ensure the load capacity of the lifting accessory.– Remove the battery on suitable ground.

Battery weight and dimensions

DANGER

Risk of tipping due to change in battery weight!The battery weight and dimensions affect the sta-bility of the truck. When replacing the battery, 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.

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6210_600-001

Damage to cables and battery maleconnectors

CAUTION

There is a risk of short circuit if thecables are damaged.The battery cable must not becrushed when closing the batterycover.– Check the battery cable fordamage.

– When removing and reinstallingthe battery, ensure that the batterycables are not damaged.

– Ensure that the battery cable doesnot come into contact with thebattery cover.

CAUTION

Possible damage to the battery male connector!If the battery male connector is disconnected orconnected while the key switch is switched onor the battery charger is under load, an arc willbe produced at the battery male connector. Thiscan lead to corrosion 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.

– Only disconnect the battery male connectorwhile under load in an emergency.

Changing to a different battery typeIt is generally possible for a truck to be con-verted to a different battery type and a differentcapacity by the authorised service centre.

Note the following points:• The display-operating unit must be adjustedto the new battery capacity.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.

– Contact your authorised service centre.

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NOTE

When converting to PowerPlusLife® batteries,the maximum speed of the truck can beincreased to 20 km/h.• Contact your authorised service centre.

NOTE

When converting from PowerPlusLife® batte-ries to other batteries, the maximum speed ofthe truck must be limited to 17 km/h for techni-cal reasons.• Contact your authorised service centre.

Opening and closing the batterycover

6341_003-016_V3

1Opening the battery cover

WARNING

Risk of injury from the battery cover lowering!The battery cover (1) is equipped with gas springsthat hold it in the opened position. When additionalload is present, for example through heavy objects,strong wind or other persons, the battery cover canlower suddenly. Cold weather and ageing can alsoreduce the performance of the gas springs andcause the cover to lower.– Make sure that the battery cover is not being

pushed down by strong winds or other persons.– If the gas springs no longer hold the battery cover

independently, notify your authorised servicecentre.

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6341_003-033

1 2

3

4

– Unlock the quick release clamp (1) with a1/4 turn in a clockwise direction.

– Open the battery cover lock (3) using thekey.

– To release the battery cover, pull thehandle (4) and at the same time use theother handle (2) to swivel the battery coverupwards.

NOTE

Beneath the battery cover, there is a latch thatengages in the upper position of the batterycover and prevents accidental closing.

6341_003-015_V2

1 2– Make sure that the safety hook (1) engagesin the gap on the bracket (2).

Closing the battery cover

CAUTION

When 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.– Do not grasp any edges. Always close the

battery cover by grasping one of the handlesin each hand.

– Close the battery cover carefully.– Only close the battery cover if there are no parts

of the body in the way.

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6341_003-033

1 2

3

4

– To close the battery cover, take hold of thehandles (2) and (4) at the same time andpull down firmly.

– Make sure that the battery cover lockengages when you close it.

– Lock the battery cover lock (3) using thekey.

– Lock the quick release clamp (1) with a 1/4turn in an anti-clockwise direction.

NOTE

The battery cover is only correctly locked if thetop section of the handle (4) closes flush withthe cover.

Disconnecting the battery maleconnector

CAUTION



CAUTION

There is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.



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6341_003-013_V2

2

4

3– Open the fastener (4) for the battery maleconnector (3) by pulling the fastener to theleft.

– Disconnect the battery male connector (3)from the plug connection by pulling thehandle (2) in the direction of the arrow.

– Check the battery cable for damage.

6341_003-039

3

1– Hang the battery male connector (3) on thefront edge of the battery tray (1).

CAUTION

When closing the battery cover, there is a risk ofdamage to the battery male connector!When closing the battery cover, the battery covermay collide with the battery male connector thathas been hung on the battery tray. As a result, thebattery male connector may become damaged. Ifthis is the case, the battery male connector mustthen be replaced.– Leave the battery cover open.

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6311_003-011_V2

1Checking the battery charge status

CAUTION

Deep discharges shorten the service life of thebattery.If there are no bars on the battery charge display (1)(0% of the available battery capacity, i.e. around20% of the nominal capacity), it indicates the startof deep discharge.– Avoid deep discharge (no bar on the display).– Cease work with the truck immediately.– Charge the batteries immediately.– Do not leave batteries in a discharged or partly

discharged state.



– Read the battery charge (1) on the display.

– Charge a discharged or partly dischargedbattery.

NOTE

The battery charge displays 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 operatingtime.

Charging the battery

DANGER

Risk to life!– Observe the chapter entitled "Safety regulations

for handling the battery" without fail.

WARNING

Battery acid is toxic and corrosive!– Observe the safety regulations in the "Battery

acid" chapter.

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CAUTION

Risk of component damage!Incorrect connection or operationof the charging station or batterycharger may result in damage tocomponents!– Follow the operating instructionsfor the charging station or batterycharger and for the battery.

CAUTION

Possible damage to the male battery connector!– Ensure that the key switch or battery charger is

switched off before the battery male connector isdisconnected 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 not available, please request them fromthe dealer.

NOTE

A 640-A battery male connector/230-A batterycharger plug adaptor cable is available as anaccessory from the authorised service centre.




– Open any protective structures fully (e.g.fabric-covered cab).


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6341_003-013_V2

2

4



– Do not place any metal objects or tools onthe battery.


– Inspect the battery cables and chargingcables for damage; change if necessary.

6341_003-040

61

2

3 4 5– Use the handle (4) to hang the batterycharger plug (5) on the front edge of thebattery tray (1).

– Hold the battery male connector (3) bythe handle (2) and insert the battery maleconnector into the battery charger plug (5).

– Push the fastener (6) for the battery chargerplug completely to the right to retract thebattery male connector into the batterycharger plug and to secure the battery maleconnector in position.

NOTE

Follow the information in the operating instruc-tions for your battery and the battery charger(equalising charge).

CAUTION

When using PowerPlusLife® batteries, ensuregood circulation of cooling air.The cooling air inlet and cooling air outlet must notbe covered. Otherwise, the air cannot circulatethrough the air ducts and the battery will heat up toomuch.– Make sure that no cloths or rags etc. cover the

cooling air inlet and cooling air outlet.

– Start the battery charger.

Once the charging process is complete:

– Switch off the battery charger.

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6341_003-041

61

2

3 4 5– Open the fastener (6) for the battery chargerplug (5) by pulling the fastener to the left.

– Disconnect the battery male connector (3)from the battery charger plug by pulling thehandle (2) in the direction of the arrow.

– Pick up the battery charger plug using thehandle (4) and remove the battery chargerplug from the battery tray (1).

6341_003-005_V2

1

3



– Ensure that the battery cable does not comeinto contact with the battery cover.

– 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

56358042501 EN - 10/2016 275


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.

CAUTION

Risk 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.

– Disconnect the batterymale connector fromthe battery charger plug.

– Insert the battery male connector fully intothe plug connection on the truck.

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Replacing the battery using a truck

DANGER


for handling the battery" without fail.

PreparationThe load capacity of the truck used must atleast match the battery weight (see batteryidentification plate).

– Check the load capacity of the truck.

– Make sure that the floor is suitable forbattery removal.



CAUTION

Do not disconnect the battery male connector whilethe key switch is switched on!– Ensure that the key switch is switched off.

6341_003-013_V2

2

4



– Check the battery cable for damage.

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6341_003-039

3

1– Hang the battery male connector (3) on thefront edge of the battery tray (1).

– When removing the battery cable, makesure that it does not come into contact withany components.

6341_003-009_V2

A

1– Adjust the distance (A) between the forkarms of the truck to match the distance (A)between the forked fittings in the batterybase frame.

– Swivel the battery lock (1) upwards.

The battery lock is held in the raised positionby means of the tension spring. The batterycan be accessed as required.

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6210_606-011

A

B

Taking up the battery

DANGER WARNING

Risk of crushing/shearing!Personnel must not stand directlynext to the battery or between thebattery and the truck when removingand inserting the battery with thetruck.

– Determine the length of the battery baseframe and, starting from the fork tip, markone of the fork arms; dimension (B).

– Move the fork arms carefully up to the markin the forked fittings in the battery baseframe.

– Carefully lift the battery and battery baseframe up and out of the truck. When doingso, pay attention to the distance to thechassis.

– Carefully remove the battery and the batterybase frame from the truck, i.e. at a lowspeed, using slow steering movements andbraking carefully.

6341_003-032_V2

– Set thebattery andbattery base framedowncarefully.

The battery always remains on the batterybase frame.

Installing the battery

CAUTION

Damage to the battery possible!If the battery is not used in the truck in conjunctionwith the battery base frame, the battery cannot besecurely positioned in the battery compartment.The battery can tip over in the battery compartment.Thismay cause damage to the battery and the truckcomponents.– Always use the battery in conjunction with the

battery base frame.

– Pick up the new battery along with thebattery base frame and carefully transport itto the truck.

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6341_003-039

3

1– Make sure to hang the batterymale connec-tor (3) on the front edge of the battery tray(1), and ensure that the battery cable doesnot become trapped during installation.

– Position the battery at a right angle to thetruck.

6341_003-010_V4

1 22

3

The slide rail (1) serves as an installation aidand guides the battery base frame at a rightangle into the battery compartment.

The impact protection (2) protects the flapsupport from damage during insertion of thebattery.

The detent cams (3) must engage in the bat-tery base frame when the battery is lowered.When the detent cams are engaged, the bat-tery is prevented from slipping sideways out ofthe battery compartment.

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6341_003-008_V3

3

– Carefully insert the battery into the batterycompartment. When doing so, take note ofthe adjustment and entry aids (3) on the leftof the battery compartment.

NOTE

The batterymust be guided in flush against theadjustment and entry aids (3). This will helpthe driver to insert the battery without it gettingstuck on the truck.

6341_003-035

1

2

Once the battery is positioned correctly in thebattery compartment:

– Carefully lower the battery.

– Check that the detent cams (2) are fullyengaged in the bores (1) and that the batteryis level.

– If the battery is not positioned correctly,repeat this process.

– Carefully move the fork arms out from thebattery base frame.

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6341_003-038

1

– Swivel the battery lock (1) downwards.

6341_003-005_V2

1

3



– Ensure that the battery cable cannot comeinto contact with the battery cover.

– Close the battery cover.

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Operation 5PowerPlusLife battery

PowerPlusLife battery

1 Battery male connector2 Battery tray3 Battery rack4 Temperature monitoring5 Battery management

PowerPlusLife® batteryThe PowerPlusLife® battery is an air-cooledlead-acid battery. The self-cooling featuregives this battery significant advantages overconventional lead-acid batteries which heatup during operation and whilst charging, andstay hot for a long time.

The PowerPlusLife® battery is a protectedin-house development by STILL GmbH.

Advantages of the PowerPlusLife® battery:• Higher driving speeds and greater handlingperformance

• Longer battery life, even under severeconditions

• Continuous temperature-controlled self-cooling, even when removed from the truckand not connected to a battery charger

• Ready for use again more quickly aftercharging

• Less heat radiated into the driver’s compart-ment

NOTE

When converting to PowerPlusLife® batteries,the maximum speed of the truck can beincreased to 20 km/h.• Contact your authorised service centre.

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5 OperationPowerPlusLife battery

1

2

6341_003-045

1 Intake opening2 Air distributors

Cooling air flow

CAUTION

If the cooling air flow is low, the cooling of the batterymalfunctions.Do not cover the intake openings (1) and air distri-butors (2) on the battery. Otherwise, the coolingair flow cannot circulate through the air ducts. Thebattery will then heat up too much.– Make sure that the intake openings and air

distributors stay open.– When installing and removing the battery, check

the intake openings and air distributors for dirt.

1 Red LED "not ready for use"2 Yellow LED "cooling active"3 Green LED "ready for use"

PowerPlusLife® temperaturemonitoringThe control unit detects the core temperatureof the battery and adjusts the fan control forcooling. The LEDs continuously indicate thecooling state of the battery.

If the red LED (1) is illuminated, the batterytemperature is high and cooling is active.

If the yellow LED (2) is illuminated, batterycooling is active.

If the green LED (3) is illuminated, the batteryis ready for use.

Especially when PowerPlusLife® batteries areused for mixed applications, the temperaturemonitoring function makes it clear whetherthe battery has cooled down sufficiently aftercharging and is now ready for use.

– If the red LED (1) is illuminated, allow thebattery to cool down further until the redLED goes out.

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Operation 5PowerPlusLife battery

1 Red LED2 Yellow LED3 Green LED

PowerPlusLife® error messagesOne of the three LEDs is always lit up to indi-cate the cooling status of the PowerPlusLife®battery. If an LED changes from being perma-nently illuminated to flashing, it indicates thatan error message has been generated. Theerror message is independent of the colour ofthe LED. In the event of a fault, it is always theLED that is currently illuminated that flashes.

The following error messages are indicated bya flashing LED:

Fluid levelThe fluid level in the PowerPlusLife® battery ischecked by a sensor.

If anLEDslowly flashesalternately, it indicatesthat the fluid level is too low.

– Top up the fluid; see the chapter entitled"Servicing the battery".

1

6341_003-046

1 Diagnostic connector

Internal errorIf an LED flashes at frequent intervals, itindicates the presence of an internal fault.

The error can be read using the diagnosticsfunction. The diagnostic connector (1) islocated on the battery management device,on the right alongside the LEDs.

– Contact your authorised service centre.

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5 OperationDecommissioning

DecommissioningParking the truck securely andswitching it off

DANGER

Risk of fatal injury frombeing run overif the truck rolls away!– The truck must not be parked on aslope.

– In emergencies, secure with wed-ges on the side facing downhill.

– Only leave the truck when theparking brake has been applied.

DANGER

There is a risk of fatal injury from a falling load orparts of the truck being lowered!– Lower the load fully before leaving the truck.

CAUTION

Batteries 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 will then not beready for operation.– At ambient temperatures of below -10°C, only

park the truck for short periods of time.


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Operation 5Decommissioning

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.

7312_003-183

F1F1 F2F2

1

1

1

– Press the emergency off switch (1).

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.

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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.

Shutting down and storing the truck

CAUTION

Component damage due to incorrect storage!If the truck is stored or shut down in an impropermanner formore than twomonths, it may suffer cor-rosion damage. If the truck is parked in an ambienttemperature of below -10°C for an extended period,the batteries will cool down. The electrolyte mayfreeze and damage the batteries.– Implement the following measures before

shutting down.

CAUTION



288 56358042501 EN - 10/2016


CAUTION

Tyre 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 will prevent permanent deformation ofthe tyres.

CAUTION

Danger of damage from corrosion due to conden-sation on 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.

NOTE

Only store batteries that are fully charged.

Measures to be implemented beforeshutdown– Store the truck in a dry, clean, frost-free andwell-ventilated environment.

– Clean the truck thoroughly; see the chapterentitled "Cleaning".

– Lift the fork carriage to the stop severaltimes.

– Tilt the lift mast forwards and backwardsseveral timesand, if fitted,moveattachmentrepeatedly.

– To relieve the strain on the load chains,lower the fork onto a suitable supportingsurface, e.g. a pallet.

– Check the hydraulic oil level and top up ifrequired.

– Apply a thin layer of oil or grease to alluntreated moving parts.

– Grease the truck.

– Lubricate the joints and controls.

– Lubricate the battery cover interlock.

– Ensure that the key switch is switched off,then disconnect the batterymale connector.

56358042501 EN - 10/2016 289


– Check the battery condition, acid level andacid density.

– Service the battery.

– Spray all exposed electrical contacts with asuitable contact spray.

– Only have the truck raised and jacked up bythe authorised service centre.

– Cover the truck with vapour-permeablematerials, such as cotton, in order to protectagainst dust.

– If the truck is to be shut down for evenlonger periods, contact your authorisedservice centre to find out about additionalmeasures.

Re-commissioning after shutdownIf the truck has been shut down for longer thansixmonths, itmust be carefully checkedbeforebeing re-commissioned. As in the annualinspection, this check should also include allsafety items for the truck.

– Clean the truck thoroughly; see the chapterentitled "Cleaning".

– Oil joints and controls.

– Check the battery condition and aciddensity, and recharge if necessary.

– Check the hydraulic oil for condensationwater and replace if necessary.

– Carry out checks and operations before thefirst commissioning.

– Put the truck into operation.

During commissioning, the following must bechecked in particular:• Drive, controller, steering• Brakes (service brake, parking brake)• Lifting system (lifting accessories, loadchains, mounting)

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NOTE

For further information, see the truck work-shopmanual or contact the authorised servicecentre.

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5 OperationCleaning

CleaningCleaning the truck– Park the truck securely.

CAUTION

Risk 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

connector is disconnected.– Only disconnect the battery male connector with

the key switch switched on in an emergency.


WARNING

There 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 followingsteps.

– Use only the steps provided to climb ontothe truck.

– Use equipment such as stepladders orplatforms to reach inaccessible areas.

Preparing the truck for cleaning

CAUTION

If 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.

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Operation 5Cleaning

CAUTION

Excessive 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.

DANGER

Risk of fire!Deposits/accumulations of combusti-ble materials may ignite in the vicinityof hot components (e.g. drive units).– Adhere strictly to the followingsteps.

– Regularly remove all deposits/accumula-tions of foreign materials in the vicinity ofhot components.

DANGER

Flammable fluids can be ignited byhot components on the truck, causinga risk of fire!– Adhere strictly to the followingsteps.

– Do not use flammable fluids for cleaning.

– Note the manufacturer’s guidelines forworking with cleaning materials.

CAUTION

Abrasive 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.

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5 OperationCleaning

– 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

WARNING

Danger of electric shocks due to residual capacity!– Never reach into the electrical system with your

bare hands.

CAUTION

Cleaning 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 inaccordance with the manufactu-rer’s specifications.

– Clean the electrical system parts with ametal-free brush and blow the dust off withlow-pressure compressed air.

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Operation 5Cleaning

6210_810-004

Cleaning load chains

WARNING

Risk of accident!Load chains are safety elements.The use of cold/chemical cleaners or fluids that arecorrosive or contain acid or chlorine can damagethe chains and is 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.

For chain spray specifications, see the "Main-tenance data table" chapter.

ENVIRONMENT NOTE

Dispose of any fluid that has been spilledor collected in the collection vessel in anenvironmentally friendly manner. Follow thestatutory regulations.

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.

CAUTION

Do not damage the rear window heater (inside)!– Take great care when cleaning the rear window

and do not use any objects with sharp edges.

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5 OperationCleaning

– Clean the windows 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.

CAUTION

Danger 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.

296 56358042501 EN - 10/2016

6

Maintenance

6 MaintenanceGeneral maintenance information

General maintenance informationPersonnel qualificationsOnly qualified and authorised personnelare allowed to perform maintenance work.The annual testing must be carried out bya qualified person. The examination andassessment of the qualified person mustbe unaffected by operational and economicconditions and must be conducted solelyfrom a safety perspective. He/she must havesufficient knowledge and experience to beable to assess the condition of a truck andthe effectiveness of the protective devices inaccordance with technical conventions andthe principles for testing trucks.

Maintenance personnel for batteriesBatteries may only be charged, maintainedor changed by properly trained personnelin accordance with the instructions from themanufacturers of the battery, battery chargerand truck. The handling instructions for thebattery and the operating instructions for thebattery charger must be followed.

Maintenance work without specialqualificationsSimple maintenance work, e.g. checkingthe hydraulic oil level, may be carried out byuntrained personnel. A qualification, like thatof a specialist, is not required to carry out thiswork. The required operations are describedin sufficient detail in the corresponding placesin these operating instructions.

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-

298 56358042501 EN - 10/2016

Maintenance 6General 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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300 56358042501 EN - 10/2016


Maintenance - 1000 hours/annuallyAt operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Chassis, bodywork and fittings

Check the chassis for cracks

Check the overhead guard/cab and panes of glass for damage

Check the controls, switches and joints for damage, and apply grease and oil

Check the driver’s seat for correct function and for damage

Check the driver restraint system for correct function and for damage, and clean

Check the battery cover and interlock for correct function and for damage

Check the battery lock for correct function and for damage

Check the indexing bolt for the battery pallet lock for damage

Check the dual pedal (variant) for correct function and for damage, and lubricate

Tyres and wheels

Check tyres for wear. If pneumatic tyres are fitted, check the air pressure

Check the wheels for damage and check the tightening torques.

Power unit

Drive axle: Check mounting, check for leaks, clean cooling fins

Check the gearbox oil level

Change gearbox oil (once after 1000 hours)

Steering

Check the steering system for correct function and for leaksCheck that the steering wheel is securely attached and check the turning handle fordamageSteering axle: Check that the steering axle is securely attached, check for leaks andapply greaseCheck the steering stop

Brake

Check the condition of all mechanical brake parts and check for correct function

Check the brake valve for correct function and leaks

Check the service brake for correct function

Check the parking brake for correct function

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Electrical system

Check all power cable connections

Check the contacts of the main contactors.

Check the switches, transmitters and sensors for correct function

Check the lighting and indicator lights

Cooling system (power electronics and hydraulics)

Check the cooling fluid level and coolant content

Check for correct function and leaks

Clean the radiator, radiator grilles, exhaust air funnel and water outlet

Battery and accessoriesCheck battery for damage and acid density; observe manufacturer’s maintenanceinstructionsElectrolyte circulation: replace the non-return valve

Check the battery pallet for damage.

Check the interlock and indexing bolts in the chassis for damage.

Check the appliance plug and truck harness for damage.

Check the battery male connector and battery harness for damage

HydraulicsCheck the condition of the hydraulic system, and check for correct function andleaksCheck the hydraulics blocking function (ISO valve)

Check the oil level

Lift mastCheck the mast bearings for damage, lubricate them, and check the tighteningtorqueCheck the mast profiles for damage and wear. Lubricate the mast profiles

Check the load chains for damage and wear. Adjust and lubricate the load chains

Check the lift cylinders and connections for damage and leaks

Check the guide pulleys for damage and wear

Check the support rollers and chain rollers for damage and wear

Check the play between the fork carriage stop and the run-out barrier

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check the tilt cylinders and connections for damage and leaks

Check the fork carriage for damage and wear

Check the fork arm interlock for damage and correct function

Check the fork arms for wear and deformation

Check that there is a safety screw on the fork carriage or on the attachment

Check the auxiliary hydraulics hoses for damage

Special equipment

Heating system: Replace the fresh air filter

Heating system: Replace the recirculated air filterCheck the heating system for damage; observe the manufacturer’s maintenanceinstructionsCheck the attachments for wear and damage; observe themanufacturer’s mainten-ance instructionsCheck the trailer coupling for wear and damage; observe the manufacturer’s mai-ntenance instructionsGeneral

Read out the error numbers and delete the list

Reset the maintenance interval

Check the labelling to ensure it is complete

Perform a test drive

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Maintenance - 3000 hours/every two years

At operating hours Carriedout

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work.

Power unit

Change the gearbox oil

Cooling system (power electronics and hydraulics)

Change the cooling fluid (every 2 years)

Hydraulics

Change the hydraulic oil

Change the return line filter, breather filter and high-pressure filter

Replace the accumulator (variant)

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.

Oil and grease types of a different qualitymust not be mixed. This negatively affects

304 56358042501 EN - 10/2016


the 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!

56358042501 EN - 10/2016 305


Lubrication plan

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 lubricant specificationThis lubrication plan describes the series-productiontruck with standard equipment. For maintenance points on variant trucks, see the relevant chap-ter and/or instructions provided by the manufacturer.

.

306 56358042501 EN - 10/2016


Maintenance data table

General lubrication points

Code Unit Operating material Specifications MeasurementLubrication High-pressure

greaseID no. 0147873 As required

Battery

Code Unit Operating material Specifications MeasurementSystem contents Distilled water As required

Insulationresistance

DIN 43539VDE 0510

For furtherinformation, referto the workshop

manual for the truckin question.

Electrical system

Code Unit Operating material Specifications MeasurementInsulationresistance

DIN EN 1175VDE 0117

For furtherinformation, referto the workshop

manual for the truckin question.

Controls/joints

Code Unit Operating material Specifications MeasurementHigh-pressuregrease

ID no. 0147873 As requiredLubrication

Oil SAE 80MIL-L2105API-GL4

As required

Dual pedaloperation

High-pressuregrease

ID no. 0147873 As required

Hydraulic system

Code Unit Operating material Specifications MeasurementHydraulic oil HVLP 68 or

ISO VG 68DIN 51524, part 2

System contents

Hydraulic oil forthe food industry(variant)

USDA H1DIN 51524

Max. 125 l

56358042501 EN - 10/2016 307


Tyres

Code Unit Operating material Specifications MeasurementMinimum treaddepth

Min. 1.6 mmSuperelastic tyres

Wear limit To wear mark

AL80-01 steering axle

Code Unit Operating material Specifications MeasurementWheel nuts/screws Torque wrench DIN 74361-A 20-10

A2C640 Nm

(A) Axle stub bearing,spherical bearing

Grease Aralub 4320DIN 51825-KPF2N20ID no. 0148659

Fill with grease untila small amountof fresh grease

escapes(A) Wheel bearing,

wheel bearing rotaryshaft seal

Grease DIN 51825-KP2K-30, lithium-saponifiedID no. 0163488

Fill with grease

AE80-02 drive axleCode Unit Operating material Specifications Measurement

SAE 80W-90API-GL4

System contentsincl. service brake

Gearbox oil

ARAL EP Plus80W-90BP Energear HT80W-90Castrol SyntraxUniversal 80W-90

For further infor-mation, refer to theworkshopmanual forthe truck in question.

Wheel nuts/screws Torque wrench DIN 74361-A 20-10A2C

640 Nm

Lift mastCode Unit Operating material Specifications Measurement(B) Lubrication High-pressure

greaseID no. 0147873 As required

Stop Play Min. 2 mm

Screws for the liftmast bearing

Torque wrench Cylinder headbolt M24x90-12.9ISO 4762

1100 Nm

(D) Lift mast bearing Grease Aralub 4320DIN 51825-KPF2N20ID no. 0148659

Fill with grease untila small amountof fresh grease

escapes

308 56358042501 EN - 10/2016


Load chainsCode Unit Operating material Specifications Measurement(C) Lubrication High-load chain

sprayFully syntheticTemperature range:-35°C to +250°CID no. 0156428

As required

Cooling system (power electronics/hydraulic oil)

Code Unit Operating material Specifications MeasurementSystem contents Corrosion inhibitor

and coolingsystem protectingagent/water

40% coolant/60%water, for frostprotection down to-25 CVWG12plus (violet)TL-VW 774 F

Approx. 4.5 l

Washer system

Code Unit Operating material Specifications MeasurementSystem contents Washer fluid Winter, ID

no. 172566As required

.

56358042501 EN - 10/2016 309

6 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.

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Maintenance 6Safety 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

DANGER

There 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.

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6 MaintenanceSafety regulations for maintenance

Working at the front of the truck

DANGER

Risk 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.

CAUTION

Possibility 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.

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Maintenance 6Safety 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

DANGER

Risk 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

DANGER

Risk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

secure the lift mast.

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6 MaintenanceProviding access to maintenance points

Providing access to maintenance pointsRemoving and attachingthe left side cover

1

2

7341_003-006_V2

Removing the cover– Release the quick release clamps (1) with a1/4 revolution.

– Remove the cover (2) and put carefullyaside.

Attaching the cover– Carefully position the cover (2).

– Lock the quick release clamps (1) with a1/4 turn.

Installing and removing the bottomplate

Removing the bottom plate.

CAUTION

Risk of short circuit if cables are damaged!– Check the connecting cables for damage.– When removing and reinstalling the bottom

plate, make sure that the connecting cablesare not damaged.

NOTE

The bottom plate has a recess that the ope-rator can insert his fingers into to lift it. Therecess is beneath the rubber mat.

NOTE

The accelerator pedal is attached to thebottom plate and is removed with this also.The connecting plug for the accelerator islocated underneath the bottom plate.

– Remove the rubber mat.

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Maintenance 6Providing access to maintenance points

1 2

3

7341_003-013

– Grasp the recess (3) in the bottom plate (2).

– Lift up the bottom plate.

7341_003-018

1

– Disconnect the plug connector (1) on theaccelerator pedal.

– Lift bottomplate and place in a safe location.

Installing the bottom plate

WARNING

Risk of crushing between bottom plate and frameedge!If limbs or objects are between the bottom plate andframe edge when the bottom plate is closed, theycan be crushed.– Make sure that when you close the bottom plate,

there is nothing between the cover and the frameedge.

– Position the bottom plate at the front.

– Connect the connection assembly to theaccelerator pedal.

– Carefully guide the bottom plate down andclose.

– Insert the rubber mat.

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6 MaintenanceProviding access to maintenance points

Opening/closing the front right cover

Opening the cover

WARNING

Risk of injury through crushing if the cover fallsdown!The cover is equipped with a gas spring that holdsthe cover in the open position unless there is anyother load on it, e.g. heavy objects, strong winds orother persons.– There must be no objects on the cover when you

open it.– Make sure that the cover is not being pushed

down by strong winds or other persons.

2

3

7341_003-007

– Release the quick release clamp (3) with a1/4 revolution.

– Swivel the cover (2) upwards.

The cover is held in the opened position by thegas spring.

Closing the cover

WARNING

Risk of crushing between cover and frame edge!If limbs or objects are between the cover andframe edge when the cover is closed, they canbe crushed.– Make sure when you close the cover that there is

nothing between the cover and the frame edge.

2

3

7341_003-007

– Swivel the cover (2) downwards.

– Lock the quick release clamp (3) with a1/4 revolution.

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Maintenance 6Providing access to maintenance points

12 3

36341_003-025

Removing and attaching the rearcover

CAUTION

Risk of component damage!If a load is placed on the exhaust air grille (2), thiscan lead to deformation or cause the exhaust airgrille to come away.– Do not lean or step on the exhaust air grille.– Do not place any objects on the exhaust air grille.

Removing the rear cover– Unscrew five screws (3) from the rear cover(1).

– Remove the rear cover (1).

Attaching the rear cover– Make sure that the top rubber seal of theexhaust air funnel is properly secured.

– Attach the rear cover (1).

– Screw the rear cover into place with fivescrews (3).

56358042501 EN - 10/2016 317

6 MaintenanceServicing

ServicingCleaning the radiator and checkingfor leaks

WARNING

Risk of burns due to hot components!Cooling system components can be so hot thatdirect contact may burn the skin.– Make sure that the cooling system has cooled

down.– Do not grasp or touch hot components.– In the event of burns, seek first aid immediately.

CAUTION

Risk of component damage due to overheating!A cooling system protects the power electronicsand hydraulic oil against overheating. Loss ofcooling fluid from leaking cooling fluid hoses orfrom the radiator reduces the cooling capacity andcan cause components to overheat. If the coolingfluid level is low, this indicates a leak in the coolingsystem.– Check the cooling system for leaks.



– Check the cooling fluid level.

– Remove the rear cover and clean theexhaust grille.

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Maintenance 6Servicing

6341_003-029

2

3

1

4

5– Clean the radiator grille (1), exhaust airfunnel (2) and water drain (3) using asuitable brush and blow them out usingcompressed air (max. 2 bar) if necessary.

– Unscrew the radiator grille (1) at the screwjoints (5) and dismantle it to clean theradiator (4) behind.

– Clean the radiator fins.

– Check the radiator and cooling fluid hosesfor leaks.

– Tighten clips at leaking hose connections.

– Check whether the leakage has beeneliminated. If not, notify the authorisedservice centre.

– Attach the radiator grille and screw it firmlyinto position.

NOTE

Make sure that the radiator grille is screwedtightly into place.

– Attach the rear cover.


Topping up cooling fluid and check-ing coolant content

WARNING

Risk of scalding due to hot cooling fluid!The cooling system is pressurised! Opening thecooling fluid tank may result in hot coolant leakingout. Only open the cooling fluid tank when thecooling system is cool.– Switch off the truck and leave it to cool down.– Do not open the cooling fluid tank until the truck

has cooled down.

WARNING

Coolant and cooling fluid can pose a hazard tohealth and the environment!– Observe the safety regulations set out in the

chapter entitled "Coolant and cooling fluid".


56358042501 EN - 10/2016 319


6341_003-023

2

1

– Pull up the locking pin (1) on the cooling fluidtank (2).

– Pull out the cooling fluid tank from under therear cover.

– Slowly open the tank cap (3) and releasethe over pressure.

– Check the concentration of the coolant.

Concentration of the coolant

CAUTION

Risk of corrosion!The percentage of coolant must always be atleast 40%, even if frost protection is not neededin warmer climates.If greater frost protection is required for climatic rea-sons, the percentage of coolant can be increasedto up to 60%.

The percentage of coolant must not exceed 60%,otherwise the frost protection is reduced. In addi-tion, the cooling effect is also reduced.– Only use clean, softened water for the water

percentage.

CAUTION

Coolant with a different specification must not bemixed in!– Only use coolant as set out in the maintenance

data table to top up the tank.

Frost protectionup to °C

Water percentage%

Coolant percentage%

-25 60 40

-30 55 45

-35 50 50

-40 40 60

For details of the filling quantity in the coolingsystem, see the chapter entitled "Maintenancedata table".

320 56358042501 EN - 10/2016


min

max

6341_003-024

3

4

5

2

1

The cooling fluid level should be between theupper marking (4) and the lower marking (5).

– Check the cooling fluid level.

– Top the cooling fluid up to the uppermarkingif necessary.

– Screw the tank cap (3) back on tightly.

– Slide the coolant tank (2) back into positionuntil the locking pin (1) engages.


12

7321_003-003

Servicing wheels and tyres

WARNING

Risk of accident!Uneven wear reduces the stability of the truck andincreases the braking distance.– Worn or damaged tyres (left or right) must be

replaced immediately.

WARNING

Risk 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.

WARNING

Risk 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.

Checking air pressure– Check the air pressure of all four tyres;adjust if necessary.

56358042501 EN - 10/2016 321


NOTE

The correct air pressure for pneumatic tyres(variant) is determined by the type of tyresused. Observe the information on the adhe-sive labels (2) on the truck.

7081_003-059

3Checking condition and wear of the tyres

WARNING

Tyre quality affects the stability and handling of thetruck.Changes can only be made in consultation with themanufacturer.When changingwheels or tyres, always ensure thatthis does not cause the truck to tilt to one side (e.g.always change right and left wheels at the sametime).

NOTE

The wear of the tyres on an axle must beapproximately the same.• The tread depth (1) for pneumatic tyresmust be at least 1.6 mm at every point onthe tread.

• Super-elastic tyres (variant) can be worndown to the wear mark (3).

– Check the tread depth on all four tyres.

– Check distance between the tyre tread andthe wear mark.

– Remove any foreign bodies imbedded inthe tyre tread.

Checking wheel fastenings– Check that the wheel fastening (4) is se-curely fastened and retighten as necessary.

322 56358042501 EN - 10/2016


47321_003-112

– Observe the torques; see the "maintenancedata table".

Replacing the fuses

DANGER

Risk of fire and risk of injury!The truck must be de-energised before any workis carried out on the electrical system. Electricshocks can result in injuries and cause fires in theelectrical system. There is also a risk of fire if fusesare bridged or repaired. Fuses with the wrongnominal current can cause short circuits.– Park the truck securely and de-energise.– Do not bridge or repair fuses.– Use only fuses with the prescribed nominal cur-

rent, see the chapter entitled "Fuse assignment".– See the chapter entitled "Working on the electri-

cal equipment".

NOTE

The electrical fuses for the truck are located intwo separate fuse boxes.

56358042501 EN - 10/2016 323


6341_003-030

1Front fuse boxPower distribution unit and 80-V technol-ogyThe fuses for the power distribution unit andthe 80-V consumers are located in the frontfuse box (1).

– De-energise the truck.

– Determine the cause of the short circuitor overload and eliminate it. Notify theauthorised service centre as necessary.

– Open the front right cover.

1 1

117311_003-021

– Open the cover fastenings (1) and removethe cover.

– Replace the defective fuse with nominalcurrent according to "Fuse assignment -front fuse box".

– Close the cover to secure the fuse box.

– Close the front right cover.

– Perform a function check. If the errorpersists or if the fuse is still defective, notifyyour authorised service centre.

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6341_003-031

1

Rear fuse box12-V technologyThe fuses for the 12-V consumers are locatedin the rear fuse box (1).

– De-energise the truck.

– Determine the cause of the short circuitor overload and eliminate it. Notify theauthorised service centre as necessary.


1 1

117311_003-021

– Open the cover fastenings (1) and removethe cover.

– Replace the defective fuse with nominalcurrent according to "Fuse assignment -rear fuse box".

– Close the cover to secure the fuse box.


– Perform a function check. If the errorpersists or if the fuse is still defective, notifyyour authorised service centre.

56358042501 EN - 10/2016 325


Checking the battery condition, acidlevel and acid density– Remove the battery from the truck.

DANGER


when handling the battery".

WARNING

Battery acid is toxic and corrosive!– Observe the safety regulations inthe chapter entitled "Battery acid".

CAUTION

Damage to the battery possible!– Follow the information in the operating instructi-

ons for the battery.

The battery must be removed for servicing; ifnecessary, change the truck battery.



– Expose the surfaces of the battery cells.

– Do not place any metal objects on thebattery.

– Inspect battery for cracked housing, raisedplates and acid leaks.

– Have defective batteries repaired by theauthorised service centre.

326 56358042501 EN - 10/2016


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.

– Top up low fluid with distilled water only.

– Immediately rinse away any spilled batteryacid with plenty of water.

– Clean the battery cell cover and dry ifnecessary.

– Remove any oxidation residue on thebattery terminals and battery terminal clipsand grease them with acid-free grease.

– Tighten the battery-terminal clips (2) to atorque of 22 - 25 Nm (depending on the sizeof the terminal screws used).

– Check theacid density usinganacid siphon.

After charging, this value must lie between1.28 - 1.30 kg/l.

For a discharged battery, the acid densitymust not be less than 1.14 kg/l.

– Close the filler cap (1) again.

When using PowerPlusLife® batteries:

– Make sure thatwhen cleaning orwhen fillingupwith liquid none of the liquid flows into thecooling channels.

– Check the cooling air inlet and cooling airoutlet for dirt and remove any dirt that ispresent.

Checking the hydraulic oil level

CAUTION

Hydraulic oils are hazardous to your health and areunder pressure during operation.– Note the safety regulations in the "Hydraulic

fluid" chapter.



56358042501 EN - 10/2016 327


7341_003-051_V2

1

– Unscrew breather filter (1).

7094_700-002

1

2

– Check the oil level on the oil dipstick. The oillevel must be at least up to the mark (2) onthe dipstick.

– If the oil level is too low, pour hydraulic oil ofthe corresponding specification accordingto the maintenance data table into the fillerneck.

– Pour hydraulic oil up to the upper end of themarking (2) on the oil dipstick (maximum).

NOTE

Use a funnel.

ENVIRONMENT NOTE

Carefully collect any spilled oil and dispose ofit in an environmentally friendly manner.

– Screw in the breather filter with oil dipstick.


Changing the heating system freshair filterThe fresh air filter for the heating system is onthe right on the exterior of the cab.

328 56358042501 EN - 10/2016


7341_003-0471

2

– Loosen the quick-release clamp (1) byturning it and remove the cover (2).

7341_003-048

3 4– Grasp the filter insert (3) at the fingeropening (4) and remove it completely fromthe filter housing.

– Check the filter insert for contamination andbeat out.

NOTE

Replace the filter insert when it is clearly grey,but at least every two months.

– Remove pollution present in the filterhousing and fresh-air inlet.

– Insert the filter insert back into the filterhousing.

– Ensure that the filter insert sits correctly andprecisely in the filter housing.

– Attach the cover and lock the quick-releaseclamp.

56358042501 EN - 10/2016 329


6341_003-037

2

1

2

3

Replacing the recirculated air filterfor the heating systemThe recirculated air filter for the heatingsystem is located on the right-hand side of thecab, underneath the heating system panelling(1).

– Unscrew the screws (2) and remove theheating system panelling.

– Completely remove the filter mat (3) fromthe filter housing.

– Check the filter mat for contamination andbeat out.

NOTE

Replace the filter mat when it is clearly grey,but at least every two months.

– Remove any dirt that has collected in thefilter housing and recirculated-air inlet.

– Re-insert the filtermat into the filter housing.

– Make sure that the filter mat sits correctlyand accurately in the filter housing.

– Attach the heating system panelling andsecure tightly in place using the screws.

330 56358042501 EN - 10/2016

Maintenance 61000-hour maintenance/annual maintenance

1000-hour maintenance/annual maintenanceOther tasks– Perform all maintenance work; see the"Maintenance" chapter.

6327_342-010

Checking the driver’s seat

WARNING

Risk 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.

WARNING

Risk of injury!– Have the seat repaired by the service centre if

you identify any damage during the checks.

Maintaining the seat belt

DANGER

There 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.

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6 Maintenance1000-hour maintenance/annual maintenance

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.

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.

332 56358042501 EN - 10/2016


Checking the door latch– Inspect the condition of the catch bolt andcheck for wear.

– Check the lock mechanism for easy opera-tion.

Lubricating the joints and controls– Oil or grease other bearings and jointsaccording to the maintenance data table.

• Driver’s seat guide• In the cab, lubricate door hinges at thelubricating nipple (variant)

• Battery door hinges or battery cover hinges• Lubricate shafts and joints in dual-pedaloperation (variant)

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. 6-307.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

56358042501 EN - 10/2016 333


7341_003-053

Checking the lift cylinders andconnections for leaks

WARNING

Risk 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.

Checking the hydraulic system forleaks

WARNING

Hydraulic oil under pressure canescape from leaking lines and causeinjuries to the skin.Wear suitable protective gloves,industrial goggles etc.

WARNING

Hydraulic 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

334 56358042501 EN - 10/2016


Pipes must be changed if:• There is abrasion with the loss of material• There are unnatural deformations anddetectable bending stress

• They are leaking

1 2 3

7094_842-001

Checking the fork arms– Check the fork arms (1) for visible deforma-tion and excessive wear.

Wear must not amount to more than 10% ofthe original thickness.

– Check the fork latch (3) for correct opera-tion.

– Check that the locking screw (2) is securedand cannot fall out of the fork arms.

– Replace any worn or deformed fork arms.

CAUTION

Fork arms must not be uneven!– Always replace both fork arms.

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.

56358042501 EN - 10/2016 335


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.

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. 6-307.

– 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.

336 56358042501 EN - 10/2016


Wartung_Rockinger 244 A

1– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-307.

– Grease coupling pin, tow bar eye and itssupporting surface.

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. 6-307.

– Grease the supporting surface for thetow-bar eye.

56358042501 EN - 10/2016 337


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. 6-307.

– Grease the supporting surface for thetow-bar eye.

338 56358042501 EN - 10/2016

7

Technical data

7 Technical dataDimensions

Dimensions

1 Fork spacing is adjustable

NOTE

Measurements h1, h3, h4, h6 and b1 arecustomised and can be taken from the orderconfirmation.

340 56358042501 EN - 10/2016

Technical data 7Dimensions

Centre of gravity "S" (distance measuredfrom the front axle)

RX60-60 1006 mm

RX60-70 1006 mm

RX60-80 1006 mm

RX60-80 (LSP 900) 1006 mm

NOTE

The specified centre of gravity "S" 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.

56358042501 EN - 10/2016 341

7 Technical dataVDI datasheet

VDI datasheetNOTE

Values are valid for the standard device.Variants may deviate from them.

Characteristics

Model RX60-60 RX60-70 RX60-80 RX60-80LSP 900

Type carrier 6341 6342 6343 6344

Manufacturer STILLGmbH

STILLGmbH

STILLGmbH

STILLGmbH

Drive: electric, diesel, petrol,LPG, mains electric Electric Electric Electric Electric

Operation: manual, accom-panied, standing, seated,order picker

Seated Seated Seated Seated

Rated capacity/load Q (kg) 6000 7000 8000 8000Load centre of gravitydistance

c (mm) 600 600 600 900

Load distance x (mm) 710 720 720 750

Wheelbase y (mm) 2285 2285 2285 2285.

Weights


Net weight kg 11,996 12,512 13,369 15,915

Axle load with front load kg 15,842 17,751 19,355 21,549

Axle load with rear load kg 2154 1761 2015 2366

Axle load without front load kg 6413 6591 6627 7097

Axle load without rear load kg 5619 5823 6655 8333.

342 56358042501 EN - 10/2016

Technical data 7VDI datasheet

Wheels, chassis frame


Tyres: superelastic (SE),solid rubber (V), pneu-matic (L)

SE SE SE SE

Front wheel size 355/50-20 8.25-15 315/70-15 315/70-15

Rear wheel size 250-15 250-15 250-15 28x12.5–15Number of front wheels(x = driven) 2x 4x 4x 4x

Number of rear wheels(x = driven) 2 2 2 2

Front track width, single tyre 1364 - - -

Front track width, twin tyres

b10(mm)

- 1510 1561 1561

Rear track widthb11(mm) 1358 1358 1358 1432

.

Basic dimensions


Lift mast/fork carriage tilt,forwards

Degree 5 5 5 5

Lift mast/fork carriage tilt,backwards

Degree 8 8 8 8

Height with lift mast retracted h1 (mm) 2710 2710 2710 2710

Free lift h2 (mm) 150 150 150 150

Lift height h3 (mm) 3550 3150 3150 2750

Height with lift mast extended h4 (mm) 4440 4240 4140 4140Height above overheadguard h6 (mm) 2697 2697 2697 2697

Seat height in relation toSIP/standing height h7 (mm) 1719 1719 1719 1719

Coupling height h10(mm) 520/670 520/670 520/670 520/670

Total length l1 (mm) 4640 4660 4660 5335

Length including fork back l2 (mm) 3440 3460 3460 3535

Total width b1 1679 1996 1996 2141

56358042501 EN - 10/2016 343

7 Technical dataVDI datasheet


Fork arm thickness s (mm) 70 70 70 70

Fork arm width e (mm) 150 150 150 200

Fork arm length l (mm) 1200 1200 1200 1200Fork carriage, class/form A,B ISO IV A ISO IV A ISO IV A ISO IV A

Fork carriage width b3 (mm) 1600 1800 1800 2180Ground clearance with loadunder lift mast

m1 (mm) 220 220 220 220

Ground clearance at centreof wheelbase

m2 (mm) 210 210 210 210

Aisle width for pallets 1000 x1200 crosswise

Ast(mm) 4907 4907 4907 4999

Aisle width for pallets 800 x1200 lengthwise

Ast(mm) 5107 5107 5107 5199

Turning radius Wa(mm) 3007 3007 3007 3049

Smallest pivot point distance b13(mm) 877 877 877 877

.

Performance data


Driving speed with load km/h 14 14 14 14

Driving speed without load km/h 17 17 17 17

Lifting speed with load m/s 0.36 0.30 0.28 0.28

Lifting speed without load m/s 0.48 0.37 0.37 0.37

Lowering speed with load m/s 0.56 0.53 0.53 0.53

Lowering speed without load m/s 0.52 0.42 0.42 0.42

Tractive force with load N 28788 28674 28468 27997

Tractive force without load N 29023 28936 28767 28295

Climbing capability with load % 16.3 16.1 16.0 15.5Climbing capability withoutload % 25.0 24.1 23.0 >22.5

Acceleration time with load(15 m) s 5.7 5.8 5.8 6.0

Acceleration time withoutload (15 m) s 5.0 5.1 5.1 5.2

Service brake Mech./hydr. Mech./hydr. Mech./hydr. Mech./hydr..

344 56358042501 EN - 10/2016

Technical data 7VDI datasheet

Electric motor


Traction motor, power ratingS3 60 min kW 2x10.5 2x10.5 2x10.5 2x10.5

Lift motor, power rating at15% ED kW 2x21.0 2x21.0 2x21.0 2x21.0

Battery in accordance withDIN 43531/35/36 A, B, C

DIN43536 A

DIN43536 A

DIN43536 A

DIN43536 A

Battery voltage U (V) 80 80 80 80

Battery capacity K5 Ah 1240 1240 1240 1240

Battery weight kg 2824 2824 2824 2824Energy consumption: 45 VDIworking cycles/hour kWh/h 12.6 14.5 16.0 17.7

Handling performance t/h 348.4 376.1 411.4 420.0Energy consumption versushandling performance kWh/h 15.4 17.5 19.2 19.8

.

Other


Working pressure forattachments bar 250 250 250 250

Oil flow for attachments l/min 60 60 60 60

Sound pressure level LpAZ dB (A) 66.4 66.4 66.4 66.4

Sound power level LwAZ dB (A) 86.6 86.6 86.6 86.6Human vibrations accelera-tion 2) as per EN 13059 m/s2 < 0.38 < 0.38 < 0.38 < 0.38

Tow coupling, type/model Bolt Bolt Bolt Bolt

2) Depending on the driver’s seat, see chapter entitled "Emissions"..

56358042501 EN - 10/2016 345

7 Technical dataErgonomic dimensions

0000_003-002

40 mm

Ergonomic dimensions

WARNING

Danger 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.

346 56358042501 EN - 10/2016

Technical data 7Battery specifications

Battery specifications

CAUTION

The battery weight and dimensions affect thestability 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 ballast weights.– Check the battery weight against the information

on the nameplate.– Only use a battery tray that is closed at the

bottom.

Lead-acid batteries

NOTE

Battery specifications to DIN 43536; cells toDIN EN 60254-2, 80 V circuit A.

– The battery weight can be found on thenameplate of the battery.

Battery compartmentdimensions (mm)

Battery designation Capacity(Ah)

Depth Width Height

Tray

7 PzS 1085 PowerPlusLife® 1085 1037 1287 784 238

8 PzS 1120 1120 1037 1287 784 238

8 PzS 1240 1240 1037 1287 784 238

TENSOR® TCSM 2545 1320 1037 1287 784 238

NOTE

When determining the weight, add the weightof the battery base frame (65 kg) to the batteryweight.

NOTE

The maximum speed pre-set in the driveprogramme is technically dependent on thebattery used. Depending on the battery typeused, the preset maximum speed must beadapted by the authorised service centre. If

56358042501 EN - 10/2016 347

7 Technical dataBattery specifications

themaximum speed is not adapted, it can leadto technical faults in drive mode.• Contact your authorised service centre.

348 56358042501 EN - 10/2016

Technical data 7Fuse assignment

Fuse assignment

NOTE

The electrical fuses for the truck are located intwo separate fuse boxes. Depending on thespecification, not all fuses will be present inthe truck.

Fuse assignment - Front fuse boxPower Distribution Unit and 80-V technology

F11 SU control unit/MCU control unit (10 A)9F5 Not assigned9F16 Heating system (30 A)F10 Reserve (20 A)

F14 Not assignedF15 Voltage transformer U1 (10 A)9F17 Voltage transformers U2 and U3 (15 A)9F18 Voltage transformers U4 and U5 (15 A)

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7 Technical dataFuse assignment

Fuse assignment - rear fuse box12-V technology

1F16 Proportional technology (10 A)9F03 Option board (10 A)5F12 Front CPP - control unit (20 A)9F32 Not assigned9F33 Not assigned

5F11 Roof CPP - control unit (30 A)5F13 Seat CPP - control unit (30 A)1F10 Cooling pump (10 A)4F01 Signal horn (10 A)9F34 Cooling fan (20 A)

350 56358042501 EN - 10/2016

Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 92Defining the driver PIN . . . . . . . . . . . . 88Entering the access code . . . . . . . . . 86Selecting the driver PIN . . . . . . . . . . . 89

Access authorisation with PIN code . . . . 85Accessories . . . . . . . . . . . . . . . . . . . . . . . 4Accident recorder . . . . . . . . . . . . . . . . . 197Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 111Joystick 4Plus version . . . . . . . . . . 110Mini-console version . . . . . . . . . . . . 111Mini-lever version . . . . . . . . . . . . . . 110

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 76Adjusting the fork . . . . . . . . . . . . . . . . . 150Adjusting the steering column . . . . . . . . . 77After washing . . . . . . . . . . . . . . . . . . . . 296Attachments

Controlling using a doublemini-lever . . . . . . . . . . . . . . . . . . 168

Controlling using the doublemini-lever and the 5th function . . 170

Controlling using the four-waymini-lever and the 5th function . . 178

Controlling using the three-waymini-lever and the 5th function . . 174

Controlling via the joystick 4Plus . . . 180Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 176Controlling with a triple mini-lever . . . 172Controlling with fingertip . . . . . . . . . 182Controlling with fingertip and

5th function . . . . . . . . . . . . . . . . 183Fitting . . . . . . . . . . . . . . . . . . . . . . . 162General controlling . . . . . . . . . . . . . 166Mounting . . . . . . . . . . . . . . . . . . . . 163Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 164Special risks . . . . . . . . . . . . . . . . . . . 20Taking up a load . . . . . . . . . . . . . . . 189

Automatic lift cut out . . . . . . . . . . . . . . . 123

Automatic tow coupling . . . . . . . . . . . . 208Coupling RO*243 . . . . . . . . . . . . . . 210Coupling RO*244 A . . . . . . . . . . . . . 212Coupling RO*245 . . . . . . . . . . . . . . 215Uncoupling RO*243 . . . . . . . . . . . . 212Uncoupling RO*244 A . . . . . . . . . . . 214Uncoupling RO*245 . . . . . . . . . . . . 216

BBattery

Changing the battery type . . . . . . . . 267Charging . . . . . . . . . . . . . . . . . . . . . 272Charging to equalise . . . . . . . . . . . . 275Checking the acid density . . . . . . . . 326Checking the acid level . . . . . . . . . . 326Checking the charge status . . . . . . . 272Checking the condition . . . . . . . . . . 326Disposal . . . . . . . . . . . . . . . . . . . . . . 13PowerPlusLife . . . . . . . . . . . . . . . . 283Safety regulations . . . . . . . . . . . . . . 265

Battery acid . . . . . . . . . . . . . . . . . . . . . . 43Battery cover

Closing . . . . . . . . . . . . . . . . . . . . . . 269Opening . . . . . . . . . . . . . . . . . . . . . 268

Battery male connectorConnecting . . . . . . . . . . . . . . . . . . . . 81Disconnecting . . . . . . . . . . . . . . . . . 270

Battery specifications . . . . . . . . . . . . . . 347Before taking up load . . . . . . . . . . . . . . 145Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 230Functional description . . . . . . . . . . . 228Switching off . . . . . . . . . . . . . . . . . . 229Switching on . . . . . . . . . . . . . . . . . . 229

Bottom plateInstalling . . . . . . . . . . . . . . . . . . . . . 315Removing . . . . . . . . . . . . . . . . . . . . 314

CCab

Operating the interior lighting . . . . . . 200Operating the rear window heating . . 201

56358042501 EN - 10/2016 351

Indexg

CE labelling . . . . . . . . . . . . . . . . . . . . . . . 2Changes to the truck . . . . . . . . . . . . . . . 31Changing the drive direction . . . . . . . . . 113

Dual pedal version . . . . . . . . . . . . . 116Changing the fork arms . . . . . . . . . . . . 138Changing the heating system fresh air

filter . . . . . . . . . . . . . . . . . . . . . . 328Changing the password . . . . . . . . . . . . . 92Checking coolant content . . . . . . . . . . . 319Checking the door latch . . . . . . . . . . . . 333Checking the driver’s seat . . . . . . . . . . 331Checking the emergency off function . . 100Checking the fork arms . . . . . . . . . . . . . 335Checking the lift cylinders and

connections for leaks . . . . . . . . . 334Checking wheel fastenings . . . . . . . . . . 322Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 185Cleaning the electrical system . . . . . . . 294Cleaning the truck . . . . . . . . . . . . . . . . 292Cleaning the windows . . . . . . . . . . . . . 295Climbing into the truck . . . . . . . . . . . . . . 78Climbing out of the truck . . . . . . . . . . . . . 78Clipboard . . . . . . . . . . . . . . . . . . . . . . . 204Closing the cab door . . . . . . . . . . . . . . . 198Closing the side windows . . . . . . . . . . . 199Condition of roadways . . . . . . . . . . . . . 106Consumables . . . . . . . . . . . . . . . . . . . . 41

Coolant and cooling fluid safetyinformation . . . . . . . . . . . . . . . . . . 44

Disposal . . . . . . . . . . . . . . . . . . . . . . 45Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 43Safety information for handling oils . . . 41Safety information for hydraulic fluid . . 42

Contact details . . . . . . . . . . . . . . . . . . . . . ICoolant

Checking the level . . . . . . . . . . . . . . . 70Coolant and cooling fluid . . . . . . . . . . . . 44Cooling fluid . . . . . . . . . . . . . . . . . . . . . 319

Topping up . . . . . . . . . . . . . . . . . . . 319Copyright and trademark rights . . . . . . . . . 6Coupling pin in the counterweight . . . . . 206

Crane loading . . . . . . . . . . . . . . . . . . . 252Determining the loading weight . . . . 253Hooking on the lifting straps . . . . . . . 253

Curve Speed Control . . . . . . . . . . . . . . 121

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 35Danger area . . . . . . . . . . . . . . . . . . . . 150Danger to employees . . . . . . . . . . . . . . . 25Declaration of conformity . . . . . . . . . . . . . 3Defects . . . . . . . . . . . . . . . . . . . . . . . . . 35Defining the driver PIN . . . . . . . . . . . . . . 88Definition of directions . . . . . . . . . . . . . . 11Dimensions . . . . . . . . . . . . . . . . . . . . . 340Dimensions of roadways . . . . . . . . . . . 105Direction indicators . . . . . . . . . . . . . . . 192

Mini-console version . . . . . . . . . . . . 193Mini-lever version . . . . . . . . . . . . . . 192

Display and operating unitAdditional indicators . . . . . . . . . . . . 219Adjusting the displays . . . . . . . . . . . 220Configure Blue Q . . . . . . . . . . . . . . . 230Indicators . . . . . . . . . . . . . . . . . . . . 217

Display messagesDisplay content . . . . . . . . . . . . . . . . 232Drive-specific . . . . . . . . . . . . . . . . . 244General . . . . . . . . . . . . . . . . . . . . . 235

Display operating unit . . . . . . . . . . . . . . . 52Resetting the daily kilometres . . . . . 225Setting the date . . . . . . . . . . . . . . . . 225Setting the language . . . . . . . . . . . . 226Setting the time . . . . . . . . . . . . . . . . 225Standard displays . . . . . . . . . . . . . . 217

Display symbols . . . . . . . . . . . . . . . . . . 220Auxiliary equipment soft key

functions . . . . . . . . . . . . . . . . . . 222Error messages . . . . . . . . . . . . . . . 222Menu navigation soft key functions . . 223Numeric keypad . . . . . . . . . . . . . . . 224Operating messages . . . . . . . . . . . . 221Status LEDs . . . . . . . . . . . . . . . . . . 223Warning messages . . . . . . . . . . . . . 221

352 56358042501 EN - 10/2016

Indexg

Display-operating unitStandard display elements . . . . . . . . 84

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 13Components . . . . . . . . . . . . . . . . . . . 13

Documentation scope . . . . . . . . . . . . . . . 5Double mini-lever . . . . . . . . . . . . . . . . . . 54

Lifting/lowering the fork carriage . . . 132Tilting the lift mast . . . . . . . . . . . . . . 132

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 29

Driver’s cabUse . . . . . . . . . . . . . . . . . . . . . . . . . 98

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 29Driving

on ascending and descendingslopes . . . . . . . . . . . . . . . . . . . . 159

Driving lightsSwitching on and off . . . . . . . . . . . . 190

Driving on gradients . . . . . . . . . . . . . . . 105Driving on lifts . . . . . . . . . . . . . . . . . . . 159Driving on loading bridges . . . . . . . . . . 161

EEC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 3

Effects on additional consumers . . . . . . 228Emergencies

Truck tipping over . . . . . . . . . . . . . . 258Using the emergency hammer . . . . . 259

Emergency hammer . . . . . . . . . . . . . . . 259Emergency lowering . . . . . . . . . . . . . . 259Emergency shutdown . . . . . . . . . . . . . 257Emissions . . . . . . . . . . . . . . . . . . . . . . . 46

Battery . . . . . . . . . . . . . . . . . . . . . . . 48Noise emissions . . . . . . . . . . . . . . . . 46Vibrations . . . . . . . . . . . . . . . . . . . . . 47

Entering the access code . . . . . . . . . . . . 86Ergonomic dimensions . . . . . . . . . . . . . 346Error code table . . . . . . . . . . . . . . . . . . 232Example . . . . . . . . . . . . . . . . . . . . . . . 146

FFilling the washer system . . . . . . . . . . . . 68Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 58

Lifting/lowering the fork carriage . . . 137Tilting the lift mast . . . . . . . . . . . . . . 137

Fitting attachments . . . . . . . . . . . . . . . 162FleetManager . . . . . . . . . . . . . . . . . . . 196

Accident recorder . . . . . . . . . . . . . . 197Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 37Fork extension . . . . . . . . . . . . . . . . . . . 140Four-way mini-lever . . . . . . . . . . . . . . . . 56

Lifting/lowering the fork carriage . . . 134Front right cover

Closing . . . . . . . . . . . . . . . . . . . . . . 316Opening . . . . . . . . . . . . . . . . . . . . . 316

Fuse assignment . . . . . . . . . . . . . . . . . 34912-V technology . . . . . . . . . . . . . . . 35080-V technology . . . . . . . . . . . . . . . 349Front fuse box . . . . . . . . . . . . . . . . . 349Power distribution unit . . . . . . . . . . . 349Rear fuse box . . . . . . . . . . . . . . . . . 350

Fuse boxFront . . . . . . . . . . . . . . . . . . . . . . . 324Rear . . . . . . . . . . . . . . . . . . . . . . . . 325

GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HHandling gas springs and accumulators . 37Hazard areas . . . . . . . . . . . . . . . . . . . . 107Hazard warning system . . . . . . . . . . . . 192Hazards and countermeasures . . . . . . . . 22Heating system . . . . . . . . . . . . . . . . . . 202

Adjusting the air flow . . . . . . . . . . . . 203Switching on . . . . . . . . . . . . . . . . . . 203Switching on the blower . . . . . . . . . . 203

Hydraulic blocking function . . . . . . . . . . 130Releasing . . . . . . . . . . . . . . . . . . . . 130

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 42

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Hydraulic systemChecking for leaks . . . . . . . . . . . . . . 334Checking the oil level . . . . . . . . . . . . 327

IIdentification points

Overview . . . . . . . . . . . . . . . . . . . . . 60Impermissible use . . . . . . . . . . . . . . . . . 16Information for carrying out mainte-

nance . . . . . . . . . . . . . . . . . . . . 298Maintenance timeframe . . . . . . . . . . 299

Information symbols . . . . . . . . . . . . . . . . . 6Inserting wedges . . . . . . . . . . . . . . . . . 248Insulation testing . . . . . . . . . . . . . . . . . . 39

Drive battery test values . . . . . . . . . . 40Truck test values . . . . . . . . . . . . . . . . 40

Insurance cover on company premises . . 31Interior lighting . . . . . . . . . . . . . . . . . . . 200Issue date of the operating instructions . . . 6

JJacking up . . . . . . . . . . . . . . . . . . . . . . 311Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 57

Fork-carriage sideshift . . . . . . . . . . . 136Lifting/lowering the fork carriage . . . 135Tilting the lift mast . . . . . . . . . . . . . . 135

LLashing down . . . . . . . . . . . . . . . . . . . 248Left side cover . . . . . . . . . . . . . . . . . . . 314

Attaching . . . . . . . . . . . . . . . . . . . . 314Removing . . . . . . . . . . . . . . . . . . . . 314

Lift cut outAutomatic . . . . . . . . . . . . . . . . . . . . 123

Lift mastLubricating the roller track . . . . . . . . 333Removing . . . . . . . . . . . . . . . . . . . . 313Securing against falling off . . . . . . . . 313Securing against tilting backwards . . 312

Lift mast versionsTriplex lift mast . . . . . . . . . . . . . . . . 129

Lift mast vertical position . . . . . . . . . . . 124Automatic approach . . . . . . . . . . . . 126Calibrating . . . . . . . . . . . . . . . . . . . 128Description . . . . . . . . . . . . . . . . . . . 124Display . . . . . . . . . . . . . . . . . . . . . . 126Possible restrictions . . . . . . . . . . . . 127Run-in to end stops . . . . . . . . . . . . . 126Tilting the lift mast backwards . . . . . 127Tilting the lift mast forwards . . . . . . . 126

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 311Lifting system

Controlling using a doublemini-lever . . . . . . . . . . . . . . . . . . 132

Controlling using a quadruplemini-lever . . . . . . . . . . . . . . . . . . 134

Controlling using a triple mini-lever . . 133Controlling using the joystick 4Plus . 135Controlling with the fingertip

console . . . . . . . . . . . . . . . . . . . 137Operating devices . . . . . . . . . . . . . . 131

LightingSwitching on and off . . . . . . . . . . . . 190

List of abbreviations . . . . . . . . . . . . . . . . . 7Lithium-ion batteries

Changing the battery type . . . . . . . . 267Load

Picking up . . . . . . . . . . . . . . . . . . . . 152Setting down . . . . . . . . . . . . . . . . . . 157transporting . . . . . . . . . . . . . . . . . . 156

Load capacity . . . . . . . . . . . . . . . . . . . 145Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 295Load measurement . . . . . . . . . . . . . . . 146

Description . . . . . . . . . . . . . . . . . . . 146Execution . . . . . . . . . . . . . . . . . . . . 147Zero adjustment . . . . . . . . . . . . . . . 101

Lubricating the joints and controls . . . . . 333

MMaintenance

Removing and attaching the rearcover . . . . . . . . . . . . . . . . . . . . . 317

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Maintenance data table . . . . . . . . . . . . 307Battery . . . . . . . . . . . . . . . . . . . . . . 307Controls/joints . . . . . . . . . . . . . . . . . 307Cooling system (power electron-

ics/hydraulic oil) . . . . . . . . . . . . . 309Drive axle . . . . . . . . . . . . . . . . . . . . 308Electrical system . . . . . . . . . . . . . . . 307General lubrication points . . . . . . . . 307Hydraulic system . . . . . . . . . . . . . . 307Lift mast . . . . . . . . . . . . . . . . . . . . . 308Load chains . . . . . . . . . . . . . . . . . . 309Steering axle . . . . . . . . . . . . . . . . . . 308Tyres . . . . . . . . . . . . . . . . . . . . . . . 308Washer system . . . . . . . . . . . . . . . . 309

Maintenance personnel for batteries . . . 298Maintenance work without special

qualifications . . . . . . . . . . . . . . . 298Malfunctions during lifting mode . . . . . . 129Manual tow coupling

Coupling . . . . . . . . . . . . . . . . . . . . . 206Uncoupling . . . . . . . . . . . . . . . . . . . 208

Medical equipment . . . . . . . . . . . . . . . . . 36

Message! PARKING BRAKE OIL PRES-

SURE . . . . . . . . . . . . . . . . . . . . 244? VERTICAL POSITION . . . . . . . . . 239ACCELERATOR . . . . . . . . . . . . . . . 237APPLY HANDBRAKE . . . . . . . . . . . 236ARE YOU SURE ? . . . . . . . . . . . . . 241BRAKE SENSOR . . . . . . . . . . . . . . 237CLOSE THEDOOR . . . . . . . . . . . . 245CODEDENIED . . . . . . . . . . . . . . . . 237EMERGENCY SWITCH . . . . . . . . . 239LIFT HEIGHT . . . . . . . . . . . . . . . . . 245LOWER FORKS . . . . . . . . . . . . . . . 238MOT/GEN. TEMP. . . . . . . . . . . . . . 244NOT VALID . . . . . . . . . . . . . . . . . . . 244OVERHEATING . . . . . . . . . . . 243, 245PARKING BRAKE ACTIVE . . . . . . . 237PARKING BRAKE: APPLY

HANDBRAKE! . . . . . . . . . . . . . . 238REFERENCECYCLE . . . . . . . . . . . 239RELEASE PARKING BRAKE . . . . . 237SAFETY BELT . . . . . . . . . . . . . . . . 240SEAT SWITCH . . . . . . . . . . . . . . . . 241SERVICE BRAKE . . . . . . . . . . . . . . 236STEERING . . . . . . . . . . . . . . . . . . . 238SURVEILLANCE . . . . . . . . . . . . . . 244SWITCHOFF TRUCK? . . . . . . . . . . 237TILTING SPEED . . . . . . . . . . . . . . . 238

MessagesGeneral . . . . . . . . . . . . . . . . . . . . . 235

Mini console . . . . . . . . . . . . . . . . . . . . . . 59Misuse of safety systems . . . . . . . . . . . . 35MSG 65/MSG 75 driver’s seat

Adjusting . . . . . . . . . . . . . . . . . . . . . 72Adjusting the backrest extension . . . . 75Adjusting the lumbar support . . . . . . . 75Adjusting the seat backrest . . . . . . . . 73Adjusting the seat suspension . . . . . . 74Moving . . . . . . . . . . . . . . . . . . . . . . . 73Switching the seat heater on and off . . 76

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NNameplate . . . . . . . . . . . . . . . . . . . . . . . 62Neutral position . . . . . . . . . . . . . . . . . . 109

OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Opening the cab door . . . . . . . . . . . . . . 197Opening the side windows . . . . . . . . . . 198Operating company . . . . . . . . . . . . . . . . 28Operating devices for hydraulic and

driving functions . . . . . . . . . . . . . . 53Operating materials

Quality and quantity . . . . . . . . . . . . 304Operating procedures . . . . . . . . . . . . . . 11Operating the service brake . . . . . . . . . 117Operating the signal horn . . . . . . . . . . . . 95Ordering spare parts andwearing parts . 304Overhead guard

Drilling . . . . . . . . . . . . . . . . . . . . . . . 34Roof loads . . . . . . . . . . . . . . . . . . . . 34Welding . . . . . . . . . . . . . . . . . . . . . . 34

OverviewDriver’s compartment . . . . . . . . . . . . 51

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 13Parking brake

Mechanical parking brake . . . . . . . . 118Parking the truck securely

Switching off the truck . . . . . . . . . . . 286Personnel qualifications . . . . . . . . . . . . 298Picking up loads . . . . . . . . . . . . . . . . . . 149Place of use . . . . . . . . . . . . . . . . . . . . . . 17PowerPlusLife

Cooling air flow . . . . . . . . . . . . . . . . 284Diagnostic connector . . . . . . . . . . . . 285Error messages . . . . . . . . . . . . . . . 285Fluid level . . . . . . . . . . . . . . . . . . . . 285Internal error . . . . . . . . . . . . . . . . . . 285Temperature monitoring . . . . . . . . . 284

PowerPlusLife battery . . . . . . . . . . . . . 283Procedure if truck tips over . . . . . . . . . . 258

Production number . . . . . . . . . . . . . . . . 63Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 30Proper usage . . . . . . . . . . . . . . . . . . . . . 16Push-up roof window . . . . . . . . . . . . . . 204

QQuadruple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 134

RRadiator

Checking for leaks . . . . . . . . . . . . . . 318Cleaning . . . . . . . . . . . . . . . . . . . . . 318

Radio . . . . . . . . . . . . . . . . . . . . . . . . . 201Re-commissioning after shutdown . . . . 290Rear cover

Attaching . . . . . . . . . . . . . . . . . . . . 317Removing . . . . . . . . . . . . . . . . . . . . 317

Rear window heating . . . . . . . . . . . . . . 201Reducing speed when turning . . . . . . . 121Reducing speed with a raised load . . . . 122Replacing the battery

using a truck . . . . . . . . . . . . . . . . . . 277Replacing the fuses . . . . . . . . . . . . . . . 323

12-V technology . . . . . . . . . . . . . . . 32580-V technology . . . . . . . . . . . . . . . 324Front fuse box . . . . . . . . . . . . . . . . . 324Power distribution unit . . . . . . . . . . . 324Rear fuse box . . . . . . . . . . . . . . . . . 325

Replacing the recirculated air filter forthe heating system . . . . . . . . . . . 330

Resetting the daily kilometres . . . . . . . . 225Resetting the daily operating hours . . . . 225Residual dangers . . . . . . . . . . . . . . . . . . 19Residual risks . . . . . . . . . . . . . . . . . . . . 19Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 31Reversible fork arm

Checking . . . . . . . . . . . . . . . . . . . . 335Reversible fork arms . . . . . . . . . . . . . . 142Roadways . . . . . . . . . . . . . . . . . . 105 – 107Rotating beacon . . . . . . . . . . . . . . . . . . 191

356 56358042501 EN - 10/2016

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Rules for roadways and the workingarea . . . . . . . . . . . . . . . . . . . . . . 107

SSafety devices . . . . . . . . . . . . . . . . . . . 311Safety inspection . . . . . . . . . . . . . . . . . . 39Safety regulations for maintenance

General information . . . . . . . . . . . . 310Safety devices . . . . . . . . . . . . . . . . 311Set values . . . . . . . . . . . . . . . . . . . . 311Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 310Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 310Safety regulations for working on the lift

mast . . . . . . . . . . . . . . . . . . . . . 312Safety regulations when driving . . . . . . 103Safety regulations when handing loads . 144Safety regulations when handling the

battery . . . . . . . . . . . . . . . . . . . . 265Battery weight and dimensions . . . . 266Damage to cables and battery male

connectors . . . . . . . . . . . . . . . . . 267Fire protection measures . . . . . . . . . 265Lifting accessory . . . . . . . . . . . . . . . 266Maintenance personnel . . . . . . . . . . 265

Schematic views . . . . . . . . . . . . . . . . . . 11Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 95

Checking . . . . . . . . . . . . . . . . . . . . 332Cleaning . . . . . . . . . . . . . . . . . . . . . 332Fastening . . . . . . . . . . . . . . . . . . . . . 96Fastening on a steep slope . . . . . . . . 97Maintaining . . . . . . . . . . . . . . . . . . . 331Malfunction due to cold . . . . . . . . . . . 97Releasing . . . . . . . . . . . . . . . . . . . . . 97Replacement after an accident . . . . 332

Selecting the drive direction . . . . . . . . . 109Selecting the driver PIN . . . . . . . . . . . . . 89Set values . . . . . . . . . . . . . . . . . . . . . . 311Setting the date . . . . . . . . . . . . . . . . . . 225Setting the drive programme . . . . . . . . . 107Setting the language . . . . . . . . . . . . . . 226

Setting the time . . . . . . . . . . . . . . . . . . 225Shutdown

Re-commissioning . . . . . . . . . . . . . 290Shutting down the truck . . . . . . . . . . . . 288Special risks . . . . . . . . . . . . . . . . . . . . . 20Spring-operated brake

Releasing . . . . . . . . . . . . . . . . . . . . 261Stability . . . . . . . . . . . . . . . . . . . . . . . . . 20Standard display elements . . . . . . . . . . . 84Starting drive mode . . . . . . . . . . . . . . . 111

Dual pedal version . . . . . . . . . . . . . 114Status LEDs . . . . . . . . . . . . . . . . . . . . 223Steering . . . . . . . . . . . . . . . . . . . . . . . . 120Steering system

Checking for correct function . . . . . . . 99Storing the truck . . . . . . . . . . . . . . . . . . 288StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 63Switching on the key switch . . . . . . . . . . 82

TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 340VDI datasheet . . . . . . . . . . . . . . . . . 342

Three-waymini-lever . . . . . . . . . . . . . . . 55Lifting/lowering the fork carriage . . . 133

Topicality of the operating instructions . . . 6Towed load . . . . . . . . . . . . . . . . . . . . . 205Towing . . . . . . . . . . . . . . . . . . . . . . . . 250

Proper use . . . . . . . . . . . . . . . . . . . . 16Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 216Transportation . . . . . . . . . . . . . . . . . . . 247Transporting pallets . . . . . . . . . . . . . . . 151Transporting suspended loads . . . . . . . 151Triple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 133Types of lift mast . . . . . . . . . . . . . . . . . 128

Telescopic mast . . . . . . . . . . . . . . . 128Tyres

Safety principles . . . . . . . . . . . . . . . . 35

56358042501 EN - 10/2016 357

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UUnits . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Unlocking the emergency off switch . . . . 82Using working platforms . . . . . . . . . . . . . 18

VVariants

Access authorisation with PIN code . . 85Accident recorder . . . . . . . . . . . . . . 197Automatic lift cut out . . . . . . . . . . . . 123Clamp locking mechanism . . . . . . . . 185Clipboard . . . . . . . . . . . . . . . . . . . . 204FleetManager . . . . . . . . . . . . . . . . . 196Fork extension . . . . . . . . . . . . . . . . 140Heating system . . . . . . . . . . . . . . . . 202Lift mast vertical position . . . . . . . . . 124Lifting systems . . . . . . . . . . . . . . . . 123Load measurement . . . . . . . . . . . . . 146Push-up roof window . . . . . . . . . . . . 204Radio . . . . . . . . . . . . . . . . . . . . . . . 201Reducing speed with a raised load . . 122Reversible fork arms . . . . . . . . . . . . 142Triplex lift mast . . . . . . . . . . . . . . . . 129Wheel chock . . . . . . . . . . . . . . . . . . 288Windscreen wiper/washer . . . . . . . . 196

VDI datasheet . . . . . . . . . . . . . . . . . . . 342Vertical lift mast position

Checking for correct function . . . . . . 102

View of functions and operations . . . . . . . 11View of operating procedures . . . . . . . . . 11Views of the display operating unit . . . . . 12Visual inspections . . . . . . . . . . . . . . . . . 66

WWarning regarding non-original parts . . . 34Wheel chock . . . . . . . . . . . . . . . . . . . . 288Wheels and tyres

Checking air pressure . . . . . . . . . . . 321Checking condition and wear of the

tyres . . . . . . . . . . . . . . . . . . . . . 322Checking wheel fastenings . . . . . . . 322Servicing . . . . . . . . . . . . . . . . . . . . 321

Windscreen wiper/washer . . . . . . . . . . 196Working at the front of the truck . . . . . . . 312Working on the electrical equipment . . . 310Working on the hydraulic equipment . . . 310Working spotlights

Automatically switching on/off . . . . . 195Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 195Manually switching on/off . . . . . . . . 194Switching on and off . . . . . . . . 191, 194

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 101

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Documents

RX60-60 RX60-70 RX60-80 · Preface g Addressofmanufacturerand contactdetails STILLGmbH Berzeliusstraße10 22113Hamburg,Germany Tel.+49(0)407339-0 Fax:+49(0)407339-1622 Email:[email protected]