Originalinstructions Electricforklifttruck

Original instructions

Electric forklift truck

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

6345 6346 6347 6348 63536354 6355 6356

56338011803 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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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 IntroductionUsing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Proper use during towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Parking in temperatures below -10°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Special risks associated with using the truck and attachments . . . . . . . . . . . . . . . . . . . 18Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

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

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Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Changes to the overhead guard and roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Damage, defects andmisuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . . 35Length of the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 OverviewsGeneral view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

General view of driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Operating devices and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Display operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Operating devices for hydraulic and traction functions . . . . . . . . . . . . . . . . . . . . . . . . . 54Multi-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Identification points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 65

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5 OperationChecks and tasks to be carried out prior to commissioning . . . . . . . . . . . . . . . . . . . . . . 68Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Checking the condition of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Adjusting the MSG 65/MSG 75 driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Climbing in and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Connecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Shelves and cup holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Driver’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) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 102

Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Setting the drive programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Actuating the drive direction switch, multiple-lever version . . . . . . . . . . . . . . . . . . . . . . 110Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 111Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 111Actuate the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 112Starting drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Starting drive mode, dual-pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Actuate the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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Reducing speed when turning (Curve Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . 128

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Multi-lever lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 140Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 141Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 142Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 143Controlling the lifting system with the fingertip console . . . . . . . . . . . . . . . . . . . . . . . . . 145Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Transporting suspended loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Driving on ascending and descending slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Working with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Controlling attachments using multi-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 176Controlling attachments using multi-lever operation and the 5th function . . . . . . . . . . . 177Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 181Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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Controlling attachments using the three-way mini-lever and the 5th function . . . . . . . . . 185Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 187Controlling attachments using the four-way mini-lever and the 5th function . . . . . . . . . . 189Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Controlling attachments using the joystick 4Plus and the 5th function . . . . . . . . . . . . . . 192Controlling the attachments with fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Controlling attachments with fingertip and the 5th function . . . . . . . . . . . . . . . . . . . . . . 194Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Operating auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Switching the lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Switching direction indicators on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Accident recorder (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Cab operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Push-up roof window (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Use in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Operating the display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

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Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 240Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Soft key button for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . 241

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Effects on additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Operating in special operating situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Emergency operation of the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Opening/closing the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Checking the battery condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . 286Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Equalising charge to prevent a deep discharge of the battery . . . . . . . . . . . . . . . . . . . . 290Changing to a different battery type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292General information on replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Replacing the battery using forklift truck or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . 293Battery transport with crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296Replacing the battery using a change frame (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . 296Replacing the battery with the hydraulic battery carrier . . . . . . . . . . . . . . . . . . . . . . . . . 301Charging the battery with the battery charging flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

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Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Recommissioning after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

6 MaintenanceGeneral maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Maintenance— 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 333Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Removing/installing the valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344Checking the battery interlock and battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Checking the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Maintaining wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Servicing the steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

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Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Greasing the automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Maintenance for trucks used in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361Maintaining the heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

1000-hour maintenance/annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363Checking the cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363Checking the function of the battery cover sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363Checking the hydraulic oil level of the hydraulic battery carrier . . . . . . . . . . . . . . . . . . . 364Lubricating the slide elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366Oiling the catch rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 368Checking fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369Checking the double pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370Checking the battery changeover frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

7 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

VDI datasheet for RX60-25 and RX60-25/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

VDI datasheet for RX60-25L and RX60-25L/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

VDI datasheet for RX60-30 and RX60-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

VDI datasheet for RX60-30L and RX60-30L/600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Battery specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Fuse assignment standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Fuse assignment equipment variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

X 56338011803 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 56338011803 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

.

56338011803 EN - 10/2016 3

1 ForewordYour truck

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

• Battery replacement frame

4 56338011803 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.

56338011803 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 56338011803 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

56338011803 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 56338011803 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.

6210_001-031

4 2

3

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

Schematic views

6210_003-062

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

NOTE

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

56338011803 EN - 10/2016 9


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.

10 56338011803 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.

56338011803 EN - 10/2016 11

1 ForewordEnvironmental considerations

12 56338011803 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.

14 56338011803 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 outside and inbuildings. Operation on public roads is onlypermitted if the "StVZO" (GermanRoad TrafficLicensing Regulations) equipment variant isinstalled.

If the truck is to be operated on public roads, itmust conform to the existing national regula-tions for the 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 forklift truck is suitable for indoor andoutdoor use in countries ranging from theTropics to Nordic regions (temperature range:-20°C to +40°C).

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

56338011803 EN - 10/2016 15

2 IntroductionUsing the truck

CAUTION

Batteries can freeze!If the truck is parked in an ambient temperature ofbelow –10 °C for an extended period, the batteriescool down. The electrolytemay freeze and damagethe batteries. The truck is then not ready for opera-tion.– In an ambient temperature of below –10 °C, only

park the truck for short periods.

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

NOTE

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

Parking in temperatures below -10°C

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.

16 56338011803 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

56338011803 EN - 10/2016 17

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

18 56338011803 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.

56338011803 EN - 10/2016 19


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)

20 56338011803 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

56338011803 EN - 10/2016 21



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


22 56338011803 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

56338011803 EN - 10/2016 23


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.

24 56338011803 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

26 56338011803 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

56338011803 EN - 10/2016 27

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.

28 56338011803 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.

56338011803 EN - 10/2016 29

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.

30 56338011803 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.

56338011803 EN - 10/2016 31


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.

32 56338011803 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

56338011803 EN - 10/2016 33


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.

34 56338011803 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

56338011803 EN - 10/2016 35


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.

36 56338011803 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.

56338011803 EN - 10/2016 37

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.

38 56338011803 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. 6-336).

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.

56338011803 EN - 10/2016 39

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.

40 56338011803 EN - 10/2016

Safety 3Safety regulations for handling consumables

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.

56338011803 EN - 10/2016 41

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.

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.

42 56338011803 EN - 10/2016

Safety 3Emissions

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

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

This machine emits the following soundpressure level:

Continuous sound pressure level in thedriver’s compartment

LpAZMeasurementuncertainty KpA

< 70.0 dB(A) 4 dB(A)

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

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

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

NOTE


56338011803 EN - 10/2016 43

3 SafetyEmissions

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

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

MSG 65 driver’s seatMeasurementuncertainty

< 0.7 m/s2 0.21 m/s2

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

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

NOTE


44 56338011803 EN - 10/2016

Safety 3Emissions

Battery

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.– 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.

56338011803 EN - 10/2016 45

3 SafetyEmissions

46 56338011803 EN - 10/2016

4

Overviews

4 OverviewsGeneral view

General view

6321_003-073_V2

56

7

8

9

12

3

4

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

6 Battery7 Drive axle with traction motor8 Fork carriage9 Fork arms

48 56338011803 EN - 10/2016

Overviews 4General view

56338011803 EN - 10/2016 49

4 OverviewsGeneral view of driver’s compartment

General view of driver’s compartment

8

9

6

72

0

13

5

%75

h

2

234,7

12:15

1 2 3 4

5

6

7

89

10

11

12

13

14

6321_003-132_V3

50 56338011803 EN - 10/2016

Overviews 4General view of driver’s compartment

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

functions6 Emergency off switch (only in multiple-lever

version)7 Storage compartment

8 Bottle holder for max. 0.5 l bottles9 Compartment and storage location for

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

NOTE

The truck equipment may differ from theequipment shown.

56338011803 EN - 10/2016 51

4 OverviewsOperating devices and display elements

Operating devices and display elementsDisplay operating unit

6210_003-082_V3

12

3 4 5 6 7 8 9 10 11

12

13

14

1516

1718192021222324

25

26

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

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

NOTE

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

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

52 56338011803 EN - 10/2016

Overviews 4Operating devices and display elements

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

56338011803 EN - 10/2016 53


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

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

54 56338011803 EN - 10/2016


Multi-lever

5060_003-107

1 2 3 4

5

6

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

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

NOTE

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

NOTE

If the truck is equipped with a clamping attach-ment, the "5th function" function switch is usedto actuate the clamp locking mechanism.

56338011803 EN - 10/2016 55


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.

56 56338011803 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


56338011803 EN - 10/2016 57


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


58 56338011803 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

56338011803 EN - 10/2016 59


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


60 56338011803 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.

56338011803 EN - 10/2016 61

4 OverviewsIdentification points

Identification pointsOverview

6327_092-001_V11

DANGER

STOP

12

3 4 5

6 7 8

9

10 11

1415

29

16

27

17

28

23

1213

1927247

65

1316

3

1522

122

1

2817

2

48

923

14

18

29

1826

456

7

1011

25

5430 1010 1080 1080 1080

1050 1150 1310

4430 1110 1230 1250 1500

4030 1150 1260 1200 1500

3730 1180 1290 1430 1500

3430 1210 1330 1470 1500

800 700 500600

5030 1270

2

1

3

xx xxxx x xxxxx

1

2

3

4

24

25

26

STILL Hamburg

Berzeliusstr. 10

22113 Hamburg

Tel.: 01804 / 784 55 24

Ihr STILL Service

Nächste Prüfung

7339

06

BATTERIESERVICE

DANGER

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

Rated capacityCapacité nominaleNenn-Tragfähigkeit

Battery voltageTension batterieBatteriespannung

Rated drive powerPuissance motr.nom.Nenn-Antriebsleist.

Unladen massMasse à videLeergewicht

max

min.*

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

kg kg

kg

kg

kgkW

V

*

Regelmäßige Prüfung(FEM 4.004)

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

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung

5634

4391

019

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

20xx

62 56338011803 EN - 10/2016

Overviews 4Identification points

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

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

pressure6 Warning sign: Do not stand underneath the

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

shearing9 Decal information: Do not jump off if the

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

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

point

15 Decal information: Lifting gear attachmentpoint

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

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

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

56338011803 EN - 10/2016 63







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.

64 56338011803 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.

56338011803 EN - 10/2016 65


66 56338011803 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 in a safe condition:

• The fork arms must be secured againstlifting and shifting.

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

• Fork armsandother lifting accessoriesmustnot feature any noticeable signs of damage(e.g. deformation, cracks, significant wear)

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

• The chains must not be damaged and theymust be evenly and adequately tensioned.

• Check the area under the truck for leakingconsumables.

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

68 56338011803 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 by the authorised service centre

• The battery must be securely locked.• Check the battery male connector for dam-age (e.g. cracks, breaks or deformation ofthe housing, bent or damaged contacts). Ifnecessary, have the batterymale connectorreplaced by the authorised service centre

• The battery cover must be securely closed.• The latches of the battery interlock 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)

• Damage or other defects on the truck orattachment (variant) must be reported tothe supervisor or responsible fleet managerimmediately so that they can arrange for thedefect to be rectified.

56338011803 EN - 10/2016 69


WARNING

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

replaced by the authorised service centre.

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.

1

26327_003-008

Filling the washer system– Open the filler cap (1) of the washer system(variant).

– Fill the washer reservoir (2) with washerfluid containing anti-freeze, according tothe maintenance data table; see ⇒ Chap-ter "Maintenance data table", P. 6-336.

CAUTION

Components may become damaged due to theeffects of frost!Water expands when it freezes. If there is no anti-freeze in the washer system (variant), the systemmay become damaged due to the accumulation ofice in freezing conditions.– Always use washer fluid containing anti-freeze.

– Close the filler cap.

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

70 56338011803 EN - 10/2016


Checking the condition of the wheelsand tyres

WARNING

Risk of accident!Uneven wear reduces the stability of the truck andincreases the braking distance.– Renew left and right 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.

NOTE

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

5051_460-004

1– Check tyres (1) for wear or damage.

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

NOTE

Observe the safety regulations in the chapterentitled "Tyres".

56338011803 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 56338011803 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.

56338011803 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 56338011803 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.

56338011803 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 56338011803 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.

56338011803 EN - 10/2016 77

5 OperationCommissioning

CommissioningClimbing in 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 post of the overhead guard or ofyour clothes becoming stuck when climbing out ofthe truck.– Ensure that the footwell cover is non-slip.– Do not jump into or out of the truck.– Ensure that you have a secure grip on the truck.

WARNING

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

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

purpose of climbing into and out of the truck.

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Operation 5Commissioning

6321_003-140

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3

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

Always climb into the truck in a forwardsmotion:

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

– Put your left foot on the step (3).

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

Always climb out of the truck backwards:

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

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

– Climb out of the truck right foot first.

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6327_600-001

1

Connecting the batterymale connec-tor– Open the battery cover.

CAUTION

Component damage possible!If you connect the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can cause the contacts to weld,which considerably shortens their service life.– Do not connect battery male connector with key

switch switched on.– Make sure that the key switch is switched off

before connecting the battery male connector.

– Insert the battery male connector (1) fullyinto the plug connection on the truck.

CAUTION

There is a risk of short circuit if thecables are damaged.The battery cable must not becrushed when closing the batterycover.– Make sure that the battery cabledoes not collide with the batterycover.

– Close the battery cover.

7321_003-125

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Shelves and cup holders

WARNING

Objects may fall into the footwell and obstruct thepedals, which poses a risk of accident!Objects to be stored must be of the correct size sothat they cannot fall from the shelf (1) or out of thecup holder (2). Objects that fall into the footwellduring travel as a result of steering or braking mayslip between the pedals (3) and prevent them fromworking correctly. The truck may subsequently notbe able to be braked when necessary.– Bottles of max. 0.5 l may be stored in the cup

holder– Make sure that stored objects cannot fall from

the shelves when the truck is started up, steeredand braked

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Unlocking the emergency off switch

6321_003-145

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

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 straight

56338011803 EN - 10/2016 81


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

I

1

0

5060_003-029_V2

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

7312_003-085

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

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

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

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

1 2

346341_003-006_V3

Standard display elements1 Battery charge

The available battery capacity is shownin the display field.

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

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

4 TimeThe current time appears in the displayfield.

NOTE

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

Additional information may appear on thedisplay.

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

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Access authorisation with PIN code(variant)

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

NOTE

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

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

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


The first driver PIN is preset to "11111" at thefactory. All others are preset to "0xFFF" buthaveno function as 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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BQ_023_en_V2

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

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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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Blue-Q_029_V2

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2

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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BQ_030_en_V2

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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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BQ_31_en

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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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BQ_025_en_V3

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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).

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

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BQ_026_en

CONFIRM appears in the display.

The CONFIRM submenu is used to confirmthe new driver PIN.

– Enter the new driver PIN for a second timein the CONFIRM field (8) using the 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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BQ_023_en_V2

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

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

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BQ_024_en_V2

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

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

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Blue-Q_029_V2

1

2

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

NOTE

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

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

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BQ_030_en_V2

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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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BQ_032_en

CONFIGURATION appears in the display.

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


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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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ESC

BQ_034_en_V2

1 2 3

4

NEW CODE appears in the display.

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

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 new password, 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.

56338011803 EN - 10/2016 93


F1F1 F2F2

6210_003-095

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

The signal horn sounds.

NOTE

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

94 56338011803 EN - 10/2016


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).

7311_003-048

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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".

56338011803 EN - 10/2016 95


– 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.

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.

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Releasing the seat belt

7090_342-0051

4

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

– Manually guide the belt tongue slowly backto the retractor.

NOTE

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

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

– Slowly allow the seat belt to retract again.

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

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

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.

56338011803 EN - 10/2016 97


6321_003-094

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. The restraint system prevents the driverfrom being thrown from the truck if it tips over. Thedriver’s cab constitutes a driver restraint systemonly if the cab door is sturdy and closed. Fabric-co-vered cabs (variant) with doors made of plastic orcanvas do not constitute a driver restraint systemand offer no protection from the consequences ofthe truck tipping over!– Close the cab door before operation– If the door is open or has been removed, use a

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

1

5060_003-015

Checking the brake system forcorrect function

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.

– Press the brake pedal (1) firmly.

The truck must decelerate noticeably.

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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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6321_003-145

F1F1 F2F2

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F1 F2

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

Checking the emergency off function

WARNING

No electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply.– To brake, actuate the service brake.

– Slowly drive the truck forwards.

– Press the emergency off switch (1).

The truck will coast.

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

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

NOTE

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

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

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

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.

100 56338011803 EN - 10/2016


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. 5-137.

– Set lift mast to vertical.

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

6210_003-071_V2

21

– 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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6210_003-067_V2

21

Checking the vertical lift mastposition (variant) for correct function

NOTE

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

– 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

RX60-25 6345 3678 3877

RX60-25/600 6346 3683* 3882

RX60-25L 6347 3830 4030

RX60-25L/600 6348 3835* 4035

RX60-30 6353 3760 3960

RX60-30L 6354 3850 4050

RX60-30L/600 6355 3850* 4050

RX60-35 6356 3879 4079

* Without taking protruding fork arms into account.

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

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5 OperationTraction

Driving on gradients

WARNING

Driving up and down longer gradients may causethe drive unit to overheat and switch off.Driving up and down longer gradients is not permit-ted due to the minimum specified braking values.The climbing capability values given below only ap-ply to overcoming obstacles on the roadway and toshort differences in level, e.g. ramps.

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

Maximum gradient [%]Model Type

With load Without load With batterycarrier

RX60-25 6345 25.5 29.7

RX60-25/600 6346 24.0 28.3

RX60-25L 6347 24.2 30.2

RX60-25L/600 6348 24.0 30.0

RX60-30 6353 21.7 29.0

RX60-30L 6354 21.9 30.6

RX60-30L/600 6355 20.9 29.3

RX60-35 6356 19.1 29.2

8.0

CAUTION

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

The upwards and downwards gradients mustnot exceed themaximum gradients above andmust feature a rough surface.

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

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Operation 5Traction

Warning in case components projectbeyond the truck contour

Trucks are often required to drive throughvery narrow or very low spaces such as aislesor containers. The trucks are dimensionedfor this purpose. However, movable partsmay project beyond the truck contour andbe damaged or torn off. Examples of suchcomponents include:• A folding roof panel in the driver’s cab• Cab doors• Folding LPG cylinders

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

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

Ensure sufficient load capacity of manholes,drain covers and the like.

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


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5 OperationTraction

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

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

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

Drive programs 1–5 are available.

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

The following drive programs are available:

Drive programme 1 2 3 4 5

Speed (km/h) 16 16 16 16 16

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

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

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

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

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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.

5060_003-082

1

2

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

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

NOTE

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

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

Neutral positionIf the truck is stopped for an extended period,select the neutral position to prevent the truck

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5 OperationTraction

from suddenly starting if the accelerator pedalis pressed inadvertently.

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

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

NOTE

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

1

5060_003-095

Actuating the drive direction switch,multiple-lever version

NOTE

Before actuating the drive direction switch,see the notes about choosing the drivedirection; see ⇒ Chapter "Selecting the drivedirection", P. 5-109.

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

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

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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 down on the driver’s seat.– Fasten the seat belt.– Activate the available restraint systems.

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

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

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


– Release the parking brake.

– Select the desired drive direction.

5060_003-082

1

2

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

NOTE

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

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3

5060_003-084

– Actuate the accelerator pedal (3).

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

NOTE

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

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 accelerator pedal.

– Select the desired drive direction.

– Actuate the accelerator pedal.

The truck will travel in the selected drivedirection.

NOTE

Thedrivedirection canalso be changedduringtravel. Your foot can remain on the acceleratorpedal while doing so. The truck deceleratesand is then accelerated again in the oppositedirection (reversing).

NOTE

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

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truck still cannot be operated, park it securelyand contact your authorised service centre.

Starting drive mode, dual-pedalversion (variant)

DANGER

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

Observe the information in the chapter entitledSafety regulations when driving.

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

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



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.

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5060_003-083

3

4

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

NOTE

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

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

NOTE

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

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 been

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Operation 5Traction

released 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.

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.

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5 OperationTraction

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

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

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

Possible equipment variants are as follows:• Mechanical parking brake; see ⇒ Chap-ter "Actuating the mechanical parkingbrake", P. 5-118

• Electric parking brake; see ⇒ Chapter "Ac-tuate the electric parking brake", P. 5-120

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.

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8

9

6

72

0

13

5

%75

h

2

234,712:15

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.

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

6210_003-050_V421

Actuate the electric parking brakeThe electric parking brake is intended forworking cycles that require the driver toleave the truck frequently. The driver doesnot need to manually apply or release theparking brake. Despite these automatic aids,the driver is always responsible for parkingthe truck safely. The safety information aboutparking the truck safely applies.

DANGER

There is a risk of being run over ifthe truck rolls away and therefore adanger to life.– The truck should not be parked ona slope.

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

– Only leave the truck if the parkingbrake is applied.

NOTE

The electric parking brake can be activatedor released only if the battery male connectorhas been connected and the key switch isswitched on.

– Stop the truck. As soon as the driver leavesthe seat, the seat switch is released and theparking brake is applied. The LED (2) in thepush button for the parking brake lights upcontinuously.

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

Cause Effect

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

When the driver takes his foot off the accelera-tor pedal:

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

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Cause Effect

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

If the emergency off switch is actuated, follow-ing the emergency off function: The parking brake is applied.

6311_003-031_en_V2

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

NOTE

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

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

• The driver switches off the truck via the keyswitch

– To release the parking brake again, thedriver must sit down again on the driver’sseat and press the accelerator pedal. Theparking brake will make a noise when it isreleased and the LED (2) in the push buttonfor the parking brake will go out.

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6311_003-032_en_V2

If the parking brake was not applied by the ac-celerator pedal being released or the driver’sseat being vacated, then drive operation is notpossible until the parking brake has been re-leased by pressing the button. The messageRELEASE PARKING BRAKE appears in thedisplay.

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

6210_003-050_V421

– The parking brake cannot be released bypressing the accelerator pedal immediatelyafter switching on the truck. The electricparking brake must be released using thepush button (1). The parking brake is thenreleased as normal during operation bypressing the accelerator pedal.

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6210_003-050_V421

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

– Press push button (1).

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

The parking brake is applied automatically

6311_003-031_en_V2

If the electric parking brake is applied, themessage PARKING BRAKE ACTIVE ap-pears in the display for 5 seconds.

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6210_003-050_V421

Releasing the parking brake manually

NOTE

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

– Sit down on the driver’s seat.


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

NOTE

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

6210_003-050_V421

Functions for when the truck is movingActuation by the driver


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

Actuation triggered automatically

Cause Effect

When the driver leaves the driver’s seat:

After a short wait the truck rolls away or decel-erates moderately. If the truck is at a standstill,you will hear the parking brake engage and theLED (2) illuminates with a steady light.

When the key switch is turned off:

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

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Cause Effect

If the emergency off switch is actuated, follow-ing the emergency off function:

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

Automatic braking:

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

.

"Safe parking" functionThe "safe parking" function alerts the driverif he/she leaves the driver’s seat or tries toswitches off the truck without applying theparking brake. This function also preventsthe truck being switched off when the parkingbrake is not applied.

This function is active in the following situati-ons:• The electric parking brake has not beenapplied

• The electric parking brake has been appliedbut has not been applied correctly as aresult of a malfunction

In both cases the function intervenes asfollows:

– If the driver tries to switch off the truckwhen the parking brake is not applied orthe parking brake is faulty, the "PARKINGBRAKE: APPLY HANDBRAKE!" warningmessage appears on the display andoperating unit.

– If the driver now leaves the truck withoutapplying the parking brake, a continuouswarning tone will also sound. The warningtone will stop if the driver resumes his/herposition in the truck or if the driver appliesthe parking brake.

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

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DANGER

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

chapter entitled "Emergency operation of theelectric parking brake".

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

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

NOTE

If it is necessary to switch off a truck with afaulty parking brake, see the chapter entitled"Switching off a truck with a faulty electricalparking brake". It is essential that wheelchocks are used to prevent the truck fromrolling away.

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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 steeringwheel(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. 371.

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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 caseswithin 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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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. 5-134

• The operating device with which thehydraulic functions are controlled, see⇒ Chapter "Lifting system operating de-vices", P. 5-137

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 5-152.

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 down goods, such as paperrolls, vertically with precision and thus avoiddamage when unloading. The tilt cylindersrun into the end stops gently to prevent hardvibrations and impacts. Oscillating motions ofthe truck are minimised, thus increasing worksafety. The lift mast vertical position reduceswear on various components and thereforereduces maintenance costs.

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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

F1F1 F2F2

F1 F2

6210_003-092

1

2

4 5

3

The "lift mast vertical position" comfort featureis only available as a variant if the truck isequipped with one of the following operatingdevices:

• Double mini-lever (1)• Triple mini-lever (2)• Quadruple mini-lever (3)• Fingertip (4)• Joystick 4Plus (5)

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6210_003-069_en_V2

1

Display of the "lift mast vertical position"The driver can see the mast tilt on the displayand operating unit screen. The bar in thedisplay shows the current mast tilt relativeto the "lift mast vertical position". The arrowabove the barmarks the vertical position of thelift mast.

Automatic approach towards the "liftmast vertical position"

6210_003-067_V2

21

– Switch on the "lift mast vertical position"comfort feature via the button (1) on thedisplay and operating unit.

– Tilt the lift mast forwards using the corre-sponding operating device. The lift maststops automatically as soon as the prese-lected setting is reached for the "lift mastvertical position".

If the comfort feature is switched off, the liftmast tilts forwards past the "lift mast verticalposition" without stopping.

If the lift mast is tilted backwards, it movespast the "lift mast vertical position" withoutstopping, regardless of whether the comfortfeature is switched on or not.

Gentle running-in to the end stops

The lift mast is braked gently at the end of thetilt range. This prevents the lift mast fromstopping harshly in the end position andreduces severe oscillating motions of thetruck.

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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

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

6210_003-069_en_V2

1

The lift mast is tilted forwards and stops assoon as the vertical position is reached. Thearrow above the bar shown on the screen ofthe display and operating unit represents the"lift mast vertical position".

Tilting the lift mast forwards beyond thevertical position:

– Release the operating device for tilting andactuate again.

The lift mast is tilted beyond the verticalposition up to the end stop. The current masttilt is shown in the display and operating unit.

– To deactivate the "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.

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Possible restrictions on the "lift mastvertical position"

In some circumstances, the lift mast cannotmove exactly into the preset vertical position.Possible causes include:• Uneven ground• Bent fork• Bent attachment• Worn tyres• Severely deformed lift mast

The vertical position can be corrected by tiltingthe lift mast using the relevant operatingdevice. If the vertical position has to becorrected frequently, the "lift mast verticalposition" should be calibrated.

6210_003-070_en_V2

12

3

Calibrating the "lift mast vertical position"– Set the lift mast to the required position.

– Press and hold the button (1) for the "liftmast vertical position" for at least fiveseconds.

The message "? VERTICAL POSITION"will appear on the display.

Storing the mast position:

– Press the drive program selection button(3).

The current mast position is stored.

Cancelling calibration:

– Press the menu change button (2).

The calibration is cancelled.

Types of lift mastOne of the following lift masts may be installedin the truck:

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Operation 5Lifting

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.

6210_810-002

2

3

Hi-Lo lift mast (variant)During lifting, the inner lift cylinder moves upto free lift (3), and then the outer lift cylindersraise the inner lift mast up to the max. height(2).

NOTE

When lifting above the free lift, the fork car-riage always remains at the upper edge of theextending lift mast.

DANGER



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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



Malfunctions during lifting mode

Incorrect extension sequence

DANGER

Risk of accidents!In the case of Hi-Lo lift masts (variant) and triplex liftmasts (variant), an incorrect extension sequencemay occur, i.e. the inner lift mast may extendbefore the free lift is complete. As a result, theoverall height is exceeded and damagemay occurin passageways or from low ceilings.

An incorrect extension sequence may, forinstance, result from:• The hydraulic oil temperature being too low.• Blocking of the fork carriage in the inner liftmast.

• Blocking of the free lift cylinder.• Blocking of the chain roller on the free liftcylinder.

– If the hydraulic oil temperature is too low,slowly actuate the lift mast functions severaltimes in order to raise the oil temperature.

In the event that the fork carriage is blockedin the inner lift mast, or the free lift cylinderor chain roller are blocked, the cause of 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 blocking in the lift mastdue to contamination.

– If the fork carriage or the load comes to anunexpected stop, lift the fork carriage untilthe chains are under tension again andlower the load at another suitable location.

– If the fork carriage rollers in the lift mastbecome blocked due to contamination, liftthe fork carriage until the chains are undertension again. Remove the contaminationbefore resuming work.

WARNING

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

the lift mast, see the chapter entitled "Working atthe front of the truck".

Lifting system operating devicesThe operation of the lifting system dependson the operating devices that are fitted on thetruck.

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

– The following informationmust be observedregardless of the equipment variant:

56338011803 EN - 10/2016 137

5 OperationLifting

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.

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:

– 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.

138 56338011803 EN - 10/2016

Operation 5Lifting

5060_003-099

1 2A

B

C

D

7312_003-022_V2

DC

B

A

Multi-lever lifting system

DANGER

Reaching or climbing between moving parts of thetruck (e.g. lift mast, sideshifts, working equipment,load carrying devicesetc.) can lead to serious injuryor death and is therefore prohibited.– Always observe the safety regulations for hand-

ling loads; see ⇒ Chapter "Safety regulationswhen handing loads", P. 5-152.

– Only operate the lifting system from the driver’sseat.

Lifting/lowering the fork carriageTo lift fork carriage:

– Move the "lift-lower" operating lever (1) inthe direction of the arrow (B).

To lower fork carriage:

– Move the "lift-lower" operating lever (1) inthe direction of the arrow (A).

Tilting the lift mastTo tilt the lift mast forwards:

– Move the "tilt" operating lever (2) in thedirection of the arrow (C).

To tilt the lift mast backwards:

– Move the "tilt" operating lever (2) in thedirection of the arrow (D).

NOTE

The symbols on the operating levers show thedirection of movement of the lift mast or forkcarriage when the operating lever is moved.

56338011803 EN - 10/2016 139

5 OperationLifting

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.


– 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.

140 56338011803 EN - 10/2016

Operation 5Lifting

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.

56338011803 EN - 10/2016 141

5 OperationLifting

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


142 56338011803 EN - 10/2016

Operation 5Lifting

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).

56338011803 EN - 10/2016 143

5 OperationLifting

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.

144 56338011803 EN - 10/2016

Operation 5Lifting

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


56338011803 EN - 10/2016 145

5 OperationLifting

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.

146 56338011803 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. 5-100. Otherwisecorrect measurement of the load cannot beguaranteed.

56338011803 EN - 10/2016 147

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.

148 56338011803 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.

56338011803 EN - 10/2016 149

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.

150 56338011803 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"

56338011803 EN - 10/2016 151

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.

152 56338011803 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.

56338011803 EN - 10/2016 153


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.

154 56338011803 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

56338011803 EN - 10/2016 155


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.

156 56338011803 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.

56338011803 EN - 10/2016 157


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.

158 56338011803 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.

56338011803 EN - 10/2016 159


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.

160 56338011803 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.

56338011803 EN - 10/2016 161


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.

162 56338011803 EN - 10/2016


5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

56338011803 EN - 10/2016 163


6210_800-011

Transporting loads

NOTE

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

DANGER

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

164 56338011803 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

56338011803 EN - 10/2016 165


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.

166 56338011803 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. 26)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.

56338011803 EN - 10/2016 167







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. 5-313.

– 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. 5-313, to preventuncontrolled movements of the load or thetruck.

168 56338011803 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.

56338011803 EN - 10/2016 169

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.

In addition, it is essential that the warningsbelow are observed.

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 corresponding pictograms, thetruck must not be used.– Order the residual load capacity rating plate and

pictograms from your authorised service centrein good time.

– The authorised service centre must adapt thehydraulic system to the requirements of theattachment (e.g. by adjusting the pump motorspeed).

170 56338011803 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 be controlled additionally bya second operating function (lock) that is actuatedto prevent an unintentional release of the load.If such an attachment is retrofitted, a second opera-ting function for actuation must also be retrofitted.– Make sure that the additional clamp locking

mechanism function is available.

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.

7090_900-001

Hydraulic connection– Before installing the attachment, releasethe pressure 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 attachment has been disassembled,

attach theprotective caps to the plug connectors.

Mounting attachmentsMounting an attachment and connectingthe energy supply for an attachment mustonly be performed by competent persons inaccordance with the information providedby the manufacturer and supplier of theattachment. After each installation, theattachment must be checked for correctfunction prior to initial commissioning.

NOTE

Please observe the definition of the followingresponsible person: "competent person".

56338011803 EN - 10/2016 171


Load capacity with attachmentThe permissible load capacity of the attach-ment and the allowable load (load capacityand load moment) of the truck must not be ex-ceeded by the combination of attachment andpayload. The specifications of the manufac-turer and supplier of the attachment must becomplied with.

– Observe the residual load capacity ratingplate, see the chapter entitled "Taking up aload using attachments".

7090_900-001

Releasing the pressure from thehydraulic systemPrior to assembling attachments, the plugconnectors must be depressurised.

Attachments must only be installed by au-thorised personnel in accordance with theinformation provided by the manufacturer andsupplier of the attachments. After each instal-lation, the attachment must be checked forcorrect function prior to initial commissioning.

NOTE

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

2060_003-018

Depressurisation, multi-lever– Switch on the key switch.

– Lower the fork carriage to the ground.

– Tilt the lift mast back to the stop

– Switch off the key switch.

– Actuate the operating lever for controllingthe hydraulic functions repeatedly in thedirection of the arrow as far as the endposition

NOTE

The number of operating levers shown maydiffer from the truck’s equipment.

172 56338011803 EN - 10/2016


1

F1F1 F2F2

1

1

F1 F2

1

16311_003-034_V2

Releasing pressure, joystick 4Plus,mini-lever and fingertip switch

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.


– 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.

56338011803 EN - 10/2016 173


General instructions for controllingattachmentsThe way in which attachments (variant) arecontrolled depends on the operating devicesincluded in the truck’s equipment.

Essentially, a distinction is drawn between:• Multiple-lever• Multiple-lever with a 5th function (variant)• Double mini-lever• Double mini-lever with a 5th function(variant)

• Triple mini-lever• Triplemini-lever with a 5th function (variant)• Quadruple mini-lever• Quadruple mini-lever with a 5th function(variant)

• Joystick 4Plus• Joystick 4Plus with a 5th function (variant)• Fingertip• Fingertip with a 5th function (variant)

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

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 transportedwith attachments if they are securely grasped andattached. Where necessary, loads must also besecured against slipping, rolling away, falling over,swinging or tipping over. Note that any change tothe position of the load centre of gravity will affectthe stability of the truck.– Refer to the capacity rating plate for the attach-

ments being used.

NOTE

Further variants and functions are available inaddition to the functions described below. The

174 56338011803 EN - 10/2016


directions of movement can be seen on thepictograms on the operating devices.

NOTE

All the attachments described fall into thecategory of equipment variants. Pleasesee the respective operating instructionsfor an exact description of the respectivemovements/actions of the attachment fitted.

56338011803 EN - 10/2016 175


2060_003-019

1

Controlling attachments usingmulti-lever operationIn this equipment, the attachments (variant)are controlled via the operating lever (1).

The pictograms on the operating lever showthe functions that are activated by this lever.

The meanings are as follows:

– Move operating lever (1) forwards.

The attachment moves in the direction shownin the upper part of the pictogram.

– Move operating lever (1) backwards.

The attachment moves in the direction shownin the lower part of the pictogram.

7311_862-001

2 3

6

4

7

9 10

5

8

– Note the following attachment functions andpictograms.

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

3 Move sideshift to the left/right

4 Adjust fork arms: open/close

5 Swivel lift mast or fork to the left/right

6 Release/clamp load retainer

7 Push off/pull in load

8 Open/close clamps

9 Turn to the left/right

10 Tip shovel over/tip shovel back

NOTE

The pictograms shown correspond to theattachments fitted to this truck at the factory. Ifan attachment with other functions is fitted, thepictograms must be checked for the correctrepresentation and changed if necessary.

– Contact the authorised service centre ifrequired.

176 56338011803 EN - 10/2016


5060_003-040_V2

21

1

3

5060_003-041

Controlling attachments usingmulti-lever operation and the5th functionThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

On the operating lever (1) you can, with theaid of switch (3), initiate a function changeoverso that this operating lever then controls the"5th function".

NOTE

The designation "5th function" refers to thefact that the four operating levers controlfour functions, while the "5th function" canbe controlled by switching functions.

The central and bottomparts of the pictogramson the operating levers always show thefunction that is activated by that lever. Thetop part of the pictogram shows that theattachment is equippedwith the "5th function".


– Move the operating lever forwards

The attachment moves in the direction shownin the centre part of the pictogram.

– Move the operating lever backwards

The attachment moves in the direction shownin the lower part of the pictogram.

– Actuate the switch

The additional function of the attachment isactivated and can be controlled as the "5thfunction" with the operating lever.

NOTE

Please see the operating instructions of theattachment that is fitted for themovements/ac-tions resulting from use of this "5th function".

56338011803 EN - 10/2016 177


6210_862-011

2 3

6

4

7

9 10

5

8










10 Open/close clamps

NOTE



178 56338011803 EN - 10/2016


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).

56338011803 EN - 10/2016 179


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8


3 Move sideshift frame or fork forwards

4 Move sideshift frame or fork back-wards

5 Move sideshift to the left

6 Move sideshift to the right

7 Adjust fork arms: open

8 Adjust fork arms: close

9 Swivel lift mast or fork to the left

10 Swivel lift mast or fork to the right

11 Release load retainer

12 Clamp load retainer

13 Push off the load

14 Pull in the load

15 Open clamps

16 Close clamps

17 Rotate to the left

18 Rotate to the right

19 Tip shovel over

20 Tip shovel back

NOTE



180 56338011803 EN - 10/2016


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).

56338011803 EN - 10/2016 181


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



182 56338011803 EN - 10/2016


5060_003-108

1

2

AC

BD

5060_003-109_V2

A C

B D

Controlling attachments using atriple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective functions that are activated bythese levers.


– Move the operating lever (1) towards (A)

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

– Move the operating lever (1) towards (B)

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

– Move the operating lever (2) towards (C)

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

– Move the operating lever (2) towards (D)

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

56338011803 EN - 10/2016 183


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



184 56338011803 EN - 10/2016


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).



– 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) .

56338011803 EN - 10/2016 185


5060_003-122

3

4

1

2






NOTE



186 56338011803 EN - 10/2016


5060_003-110

1

2

AC

BD

5060_003-109_V2

A C

B D

Controlling attachments using aquadruple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective function that is activated bythese levers.


– Move the operating lever (1) towards (A)

The attachment moves in the direction shownin pictogram (A).

– Move the operating lever (1) towards (B)

The attachment moves in the direction shownin pictogram (B).

– Move the operating lever (2) towards (C)

The attachment moves in the direction shownin pictogram (C).

– Move the operating lever (2) towards (D)

The attachment moves in the direction shownin pictogram (D).

56338011803 EN - 10/2016 187


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



188 56338011803 EN - 10/2016


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).

56338011803 EN - 10/2016 189


5060_003-122

3

4

1

2






NOTE



190 56338011803 EN - 10/2016


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.


56338011803 EN - 10/2016 191


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.


192 56338011803 EN - 10/2016


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


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



8 Open/close clamps

9 Turn to the left/to the right


NOTE



56338011803 EN - 10/2016 193


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.

194 56338011803 EN - 10/2016


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 equippedwith 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 equippedwith 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.

56338011803 EN - 10/2016 195


6210_003-035

10 11

14

12

15

17 18

13

16








16 Open/close clamps



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.

196 56338011803 EN - 10/2016


6210_003-076

1

2

Multi-lever– Press and hold the (2) button to release theclamp locking mechanism.

NOTE

The hydraulic function for opening the clampis only available if the button is pressed.After releasing the button, the clamp lockingmechanism is automatically reactivated.

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

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

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

– To operate the clamping attachments, seethe section entitled "Controlling attach-ments using multi-lever operation and the5th function".

F1 F2

6210_003-077

1

2

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

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



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

56338011803 EN - 10/2016 197


6210_003-078

1

2

Triple 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 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





198 56338011803 EN - 10/2016


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

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.

– The rating plates show the permissiblevalues for:

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

56338011803 EN - 10/2016 199

5 OperationOperating auxiliary equipment

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.

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.

200 56338011803 EN - 10/2016

Operation 5Operating auxiliary equipment

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.

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.

56338011803 EN - 10/2016 201


Switching direction indicators on andoff

Mini-lever version

5060_003-096

F1 F2

1

– Switch on the direction indicators bymovingthe corresponding drive direction/turnindicator cross lever (1) to the left or right.

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.

202 56338011803 EN - 10/2016


Fingertip version

F1F1 F2F2

5060_003-100

1– Switch on the direction indicators bymovingthe corresponding turn indicator button (1)to the left or to the right.

– Turn off the direction indicators by pushingthe other turn indicator button.

Mini-console version

5060_003-046

1

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

56338011803 EN - 10/2016 203


2 3

5060_003-012_V2

The direction indicators and the correspon-ding turn indicator displays (2) or (3) flash.

– Switch off the direction indicators bymovingthe turn indicator switch to the centreposition.

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.

204 56338011803 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.

56338011803 EN - 10/2016 205


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

– Push button (1) to actuate the front wind-screen wiper/washer (variant)

– Push button (2) to actuate the rear wind-screen wiper/washer (variant)

Repeated pressing of the respective buttonswitches between the operating stages in thesequence specified shown below.

Button actuation Operating stage

Off

1st time on

2nd time Interval

3rd time + hold Washer

4th time Off.

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.

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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.

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5 OperationCab operation

Cab operationOpening the cab door

DANGER

There is a risk of damage through collision if the cabdoor opens while driving.– The cab door must be latched securely in the

engaged position.

Opening the cab door from the outside:

6321_003-061_V345

2 13

– Insert the key in the door lock (5), unlockand remove the key.

– Pull the door handle (4) and release thedoor lock.

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

Opening the cab door from the inside:– Take hold of the handlebar (2) and latch (1).

– Press the latch in and push the cab dooroutwards.

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Operation 5Cab 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.

6321_003-141_V2

3

1 2

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 (3) together and slide therear side window (2) forwards.

Opening the front side window:The front sidewindow (1) can be opened in thesame way as the rear side window.

6321_003-141_V2

3

1 2

Closing the side windows

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

Closing the front side window:The front side window (1) can be closed in thesame way as the rear side window.

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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.

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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.

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Heating system (variant)

Switching on the blower and heatingsystem

DANGER

By taking in heavily polluted surroun-ding air into the closed cab there is adanger of poisoning!The heater must not be operated inthe vicinity of storage areas or the likeinwhich fuel vapours or fine dust (e.g.coal, wood or grain dust) can form.

DANGER

There is a risk of explosion due togases being given off or igniting as aresult of heat.– Do not expose spray cans or gascartridges to the flow of hot air.

0 1

2

3

0 1

2

3

1

2

6210_345-001

– Rotate the blower switch (1) clockwise tothe desired blower position.

The blower is in operation and runs at thespeed level selected by the blower switch (1) .

DANGER

The heating system overheats if thehot air cannot escape from it. Thereis a risk of fire!The heating system may only beswitched on if the blower is runningand the heating system is notcovered by objects (such as a jacketor cover).– Always switch the blower on first.– Do not switch the heating systemon until the blower is switched on.

– Remove existing objects awayfrom the heating system or airoutlets.

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DANGER

The heating system housing canbecome very hot when the heatingsystem is operating. There is a risk ofburns if it is touched!– Do not touch the heating systemhousing during operation.

– Only touch the switches provided.

– Rotate the heating level switch (2) clock-wise to the desired heating level.

The heating system is in operation. The airis heated up to the heating level set by theheating level switch (2).

Selecting blower settingsSetting blower to low:

– Set blower switch (1) to level 1.

Setting blower to medium:


Setting blower to high:


Setting heating levelsSet heating system to low (50%):

– Set heating level switch (2) to level 1.

Set heating system to medium (75%):


Set heating system to high (100%):


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Turn off the heating system and blower

DANGER

The heating system overheats if thehot air cannot escape from it. Thereis a risk of fire!The blower may only be turned off ifthe heating system is turned off.– Always turn the heating system offfirst.

– Only turn the blower off when theheating system is switched off.

– Rotate the heating level switch (2) anticlock-wise to heating level 0.

The heating system is out of order.

– Rotate the blower switch (1) anticlockwiseto blower position 0.

The blower is out of order.

Change fuses

DANGER

Using the wrong fuses can result inshort circuits. There is a risk of fire!– Only use fuses with the prescri-bed nominal current; see ⇒ Chap-ter "Replacing fuses", P. 6-354.

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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.

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5 OperationTrailer 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 existing towed load correspondsto the rated capacity of the truck, no load may betransported on the fork at the same time. The loadcan be distributed between the fork and the trailer.– Check the load distribution and adjust it to

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

coupling.

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 centre ofthe application conditions. The service centre willprovide the required data.– Inform the authorised service centre.

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Operation 5Trailer operation

CAUTION

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

tow coupling.

This truck is suitable for the occasional towingof trailers. If the truck is equipped with atowing device, this occasional towing mustnot exceed 2% of the daily operating time. Ifthe truck is to be used for towing on a moreregular basis, the manufacturer should beconsulted.

Coupling pin in the counterweight

Coupling the trailer

DANGER

If you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

1 7090_900-008

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

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6321_003-116

2

3

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

– Adjust tiller height.

DANGER

People can become trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

– Slowly move the truck back.

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

DANGER

If the coupling pin or securing bush are lost ordestroyed during towing, the trailer will work looseand become uncontrollable. This causes a risk ofaccident!– Use only original coupling pins that have been

checked carefully.– Ensure that the coupling pin is correctly inserted

and secured.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

– Remove any items used to prevent thetrailer from rolling away.

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

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6321_003-116

2

3

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

– Slowly move the truck forwards and guidethe tow-bar eye completely out of thecounterweight.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

Automatic tow coupling

DANGER

People may be trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

DANGER

Never jack up the truck on the tow coupling or useit for crane lifting. The tow coupling is not designedfor this and could be deformed or damaged. Thiscould cause the truck to fall, with potentially fatalconsequences!– Use the tow coupling only for towing.– For jacking up and crane loading, use only the

designated lifting points.

DANGER

The tow coupling is not designed to support loadsand could become deformed or destroyed. Thiscould cause the supported load to fall, with poten-tially fatal consequences!– The tow coupling should be subjected only to

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

56338011803 EN - 10/2016 219


DANGER

If you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

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.

WARNING

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, test the tow coupling for damagesuch as cracks. A damaged tow coupling must notbe used again.– Always manoeuvre carefully and with sufficient

room.– In the case of a collision, test the tow coupling for

damage.– Replace tow coupling if damaged, if necessary

contact the authorised service centre.

WARNING

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.

220 56338011803 EN - 10/2016


WARNING

Risk of component damage if the tiller in the towcoupling is tilted!The tiller should be kept as horizontal as possiblewhen towing. This ensures that the rotation rangeis sufficient at the top and bottom. The authorisedservice centre can adjust the assembly height forthe tow coupling to the tiller height if necessary.– Make sure that the tiller is level.– To change the coupling height, contact the

authorised service centre.

1 7090_900-008

Coupling model RO*243

NOTE

Tow coupling RO 243 is intended for a tow-bareye in accordance with DIN 74054 (borediameter: 40 mm).

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

– Adjust the tow bar eye of the tiller so that it isat the centre of the towing jaws.

3

7321_003-064

2

– Pull out the safety handle (3).

– Push the hand lever (2) upwards.

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.


56338011803 EN - 10/2016 221


DANGER

If thecoupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Ensure that the safety handle is flush with the

securing bush.– If the safety handle protrudes, repeat the coup-

ling process.


– Tow the trailer.

Closing model RO*243 by hand

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, use only a suitable device to close the towcoupling (e.g. assembly lever).

– Use a suitable device (e.g. assembly lever)to push the coupling pin up.

The coupling pin is released from the latch andthe tow coupling then closes automatically.

3

7321_003-064

2

Uncoupling model RO*243– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

– Pull out the safety handle (3).


– Slowly drive the truck forwards until the tow-bar eye and towing jaws are disconnected.

– Close the tow coupling by hand.

222 56338011803 EN - 10/2016


Coupling model RO*244 A

NOTE

Trailer coupling RO 244 is intended for a towbar eye in accordance with DIN 74054 (borediameter 40 mm) or DIN 8454 (bore diameter35 mm).

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


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

The tow coupling is opened.

DANGER

People can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTION


jaw centrally.

– Move the truck back slowly until the tow bareye is inserted centrally into the couplingjaw of the tow coupling and the coupling pinengages.

NOTE

The coupling pin is correctly engaged if thecontrol pin (3) does not protrude out of itsguide.

56338011803 EN - 10/2016 223


DANGER

If thecoupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!The control pin (3)must not protrude out of its guide.– Ensure that the coupling pin is engaged cor-

rectly.If the coupling pin is not correctly engaged:– Remove any items used to prevent the trailer

from rolling away.– Move the truck with the trailer forwards approx.

1 m and then move it back slightly.– On the coupling pin, check again that the control

pin does not protrude out of its guide.



Closing model RO*244 A by hand

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, only actuate the tow coupling via theclosing lever (1).

– Press the closing lever (1) downwards asfar as it will go.

The tow coupling is closed.

Uncoupling model RO*244 A– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.


The tow coupling is opened.


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

224 56338011803 EN - 10/2016


NOTE

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

7321_003-066_V2

57

6


NOTE

Trailer coupling RO 245 is intended for atow-bar eye in accordance with DIN 74054(bore diameter 40 mm) or DIN 8454 (borediameter 35 mm).




– The tow coupling is opened.

DANGER

People can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.


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




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

The tow coupling is closed.

7

8

7321_003-067


NOTE

Tow coupling RO 841 is intended for a tow-bareye in accordance with DIN 74054 (borediameter 40 mm).



DANGER

People may be trapped between truck and trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTION


jaw centrally.


226 56338011803 EN - 10/2016


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.






– Close the tow coupling.

7090_900-011Towing trailers– Drivers who are towing a trailer for the firsttime must practise driving with a trailer in asuitable area.

– When passing through narrow road areas(entrances, gates etc.), observe the dimen-sions of the trailer and load.

– When towing multiple trailers, ensurea sufficient minimum distance to fixedinstallations when turning and cornering.

The permissible length of the trailer trainsdepends on the roadways to be driven andmay need to be determined during the testdrive.

It is the responsibility of the operating com-pany to instruct the drivers regarding thepermissible number of trailers and, whererequired, any additional speed reductions onindividual sections of the route.

56338011803 EN - 10/2016 227


NOTE


228 56338011803 EN - 10/2016

Operation 5Use in cold stores

6210_900-002

Use in cold storesThe truck features cold store equipment(variant), making it suitable for use in coldstores.

It is equipped for two different types of applica-tion and marked with the cold store symbol.

Cold store-compatible oils (for hydraulicsand the gearbox) and greases (for movingparts, gearing and chains) are used withthe cold store equipment. Furthermore, thedisplay-operating unit is heated.

As another variant, the truck can be equippedwith a driver’s cab with a heating system.

Types of applicationThere are two different types of cold storeapplication for the truck, distinguished by twodifferent temperature ranges.

Type of application1 Constant deployment in temperature

range −5 °C, brief deployment down to−10 °C.

2 Alternating between indoor use down to−32 °C and outdoor use to +25 °C, brieflyup to +40 °C.Use hydraulic oil suitable for use incold stores in accordance with the"maintenance data table".

56338011803 EN - 10/2016 229

5 OperationUse in cold stores

Operation

CAUTION

Changing from a cold inside temperature to a warmoutside temperature may result in the formationof water condensation. This water may freeze onre-entering the cold store, blocking moving parts ofthe truck.It is essential that close attention is paid to theduration of deployment in the different temperatureranges for both types of application.Before being used in the cold store, the truck mustbe dry and warmed up.The truck must not leave the cold store area formore than 10 minutes. By adhering to this rule,condensation water will not have time to form.If the truck stays outside for more than 10 minutes,it must remain there as a minimum until such timeas the condensation water has drained off and thetruck has dried off. Depending on the weather, thiswill take at least 30 minutes.

WARNING

Risk of injury!If water condensation freezes in the cold store, donot try to free blocked parts with your hands.

– Drive the truck for approx. 5 minutes andactuate the brake several times to ensureoperational safety.

– Actuate all hydraulic lifting functions severaltimes.

This warm-up phase is necessary to ensurethat the oil reaches the operating temperature.

– Always park the truck outside the cold store.

CAUTION

Risk of component damage!Batteries should not be left in the cold store over-night without power uptake or charging.

– Charge the battery outside the cold storeand operate the truck using a replacementbattery.

Using batteries in the cold storeTo compensate for the reduction in capacityat low temperatures, it is advisable to use

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Operation 5Use in cold stores

batteries with the maximum nominal capacityin the respective battery dimensions for therange.

Electric forklift trucks must not be parked forany longer than necessary in a cold area. Thisalso applies to unused batteries. The chargingstation and the parking area for trucks andbatteries must be at normal room temperature(not below 10 °C). Charging is extremely slowat low temperatures. At temperatures below10 °C, the battery cannot be fully charged withthe usual charging parameters.

– Charge the battery fully before each shift.

– During the gassing phase, always top upwith distilled water.

The distilledwater will mix with the battery acidso that it does not freeze.

Water top-up systems must not be used attemperatures below 0 °C, as this could causethe systems and the water present in the hoselines to freeze.

The battery voltage when discharged isgenerally lower at low temperatures, and thefinal discharged voltage is reached earlier, i.e.the capacity of the battery is lower.

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5 OperationOperating 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 thebattery chargeto the remaining operating time.If a different drive program or a differentdrive mode (e.g. Blue-Q) is selected,the system immediately recalculates theremaining operating time and indicatesfor how long the truck can be driven if theoperating situation of the last 30 minutesis maintained.

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

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

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

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Operation 5Operating 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%).

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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.

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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.

56338011803 EN - 10/2016 235


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

236 56338011803 EN - 10/2016


Description Symbol

Are you sure?

Oil pressure.

Symbols for error messages

Description Symbol

Brake systemmalfunction

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

56338011803 EN - 10/2016 237


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.

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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)

56338011803 EN - 10/2016 239


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. 5-235.

– 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. 5-235.

– 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.

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NOTE

The daily operating hours are reset in thesame manner.

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. 5-235.

– 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.

56338011803 EN - 10/2016 241


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.

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Operation 5Blue-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.

56338011803 EN - 10/2016 243

5 OperationBlue-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".

244 56338011803 EN - 10/2016

Operation 5Blue-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

56338011803 EN - 10/2016 245

5 OperationBlue-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. 5-235

– 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.

246 56338011803 EN - 10/2016

Operation 5Display 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.

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5 OperationDisplay 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.

248 56338011803 EN - 10/2016



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.

56338011803 EN - 10/2016 249



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.

250 56338011803 EN - 10/2016


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.

56338011803 EN - 10/2016 251


BRAKE SENSORmessageIf the BRAKE SENSORmessage appears inthe display, themaximumdriving 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 fiveminutes before another attemptcan be made.

– Enter the driverPIN again 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.

252 56338011803 EN - 10/2016


– 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 STEERINGmessage appears in thedisplay, the truck will only move at emergencymode speed. The steering angle sensor mustbe checked.


TILTING SPEEDmessageIf the message TILTING SPEED appearson the display after the welcome screen, thetilting speed of the lift mast on this truck issignificantly higher than on previous trucks inthis family.

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EMERGENCY SWITCHmessage

WARNING

No electric 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

REFERENCE CYCLEmessageIf the fork was lowered after the truck wasswitched off, the control electronics do notknow the position of the fork when the truckis restarted. The truck will only travel at areduced driving speed. Depending on thepositionof the fork, themessageREFERENCECYCLE (variant)may appear in the display. Toalign the position with the control electronics,the fork must be raised.


The truck will only travel at a reduced drivingspeed. The message REFERENCE CYCLEmay appear in the display.

– Raise the fork.

The message REFERENCE CYCLE goes out,or now appears in the display for the first timeand then goes out.

254 56338011803 EN - 10/2016


– 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.

256 56338011803 EN - 10/2016


7312_003-066_en_V2

The seat switch is not actuated while the ac-celerator pedal or steering wheel is actuated

The accelerator pedal or the steering wheel isactuated, even though no one is sitting in thedriver’s seat. The message SEAT SWITCHappears on the display. The truck will notmove.

– Sit in the driver’s seat and fasten the seatbelt.

The truck can be driven again without restric-tions.

7325_003-054_en_V2

F1 F2

The seat switch is not actuated while theoperating device for the working hydraulicsis actuated

An operating device for the working hydraulicsis actuated, even though no one is sittingin the driver’s seat. The message SEATSWITCH appears on the display. The workinghydraulics functions cannot be executed.

– Sit in the driver’s seat and fasten the seatbelt.

The working hydraulics can be operatedagain.

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7325_003-054_en_V2

F1 F2

The shift time has been exceeded

NOTE

The shift time is adjustable.

If the key switch is switched on and the driverdoes not leave the seat before the set shifttime is exceeded, SEAT SWITCH appearson the display. This is also the case if anoperating device for the working hydraulics orthe accelerator pedal is actuated. Dependingon the configuration, the working hydraulicfunctions can be executed normally, onlyslowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


7325_003-055_en_V3

F1 F2

The operating time has been exceeded

NOTE

The operating time is adjustable.

If the key switch is switched on, the parkingbrake is released and the driver does notleave the seat before the set operating time isexceeded, and if neither the operating devicesfor the working hydraulics nor the acceleratorpedal are actuated during this time, SEATSWITCHappears on the display. The truckwillnotmove. Depending on the configuration, theworking hydraulic functions can be executednormally, only slowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


OVERHEATINGmessageIf the message OVERHEATING appearson the display, the traction motors haveoverheated. The acceleration and the speedof the truck are reduced.

– Allow the truck to cool down.

– If the error persists, contact your authorisedservice centre.

258 56338011803 EN - 10/2016


SURVEILLANCEmessageIf the SURVEILLANCE message appearsin the display, there is a fault in the processmonitoring.

This shuts off the drive unit.

– Switch the key switch to the "0" position andthen back to the "I" position.

– Start the engine.

– Release accelerator pedal.

– Select the drive direction again.

NOTE

If this error occurs sporadically, it can be tole-rated. If the operational capacity is impaired,notify your authorised service centre.

NOT VALID messageIf the message NOT VALID appears on thedisplay, an incorrect driver PIN has beenentered when entering the access code.

– Once the message goes out, enter thedriver PIN again.

Drive-specific messages

Message ! PARKING BRAKE OILPRESSUREIf the followingmessageappears in the displaywhen the accelerator pedal is actuated:! PARKING BRAKE OIL PRESSURE, theservice brake of the truck is not ready for use.

The driving speed is limited to 5 km/h.

When the service brake is ready for operation,themessagedisappears. The speed limitationis cancelled.

MOT/GEN.-TEMP. messageIf the MOT/GEN.-TEMP.message appears,the traction motor or the generator is over-heated or a cable is broken.

56338011803 EN - 10/2016 259


– 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.

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If the fork is raised above a certain height, thefollowing happens:

6210_003-054-en_V3

Lifting the load at a standstill

The key switch is switched on. The driver sitson the seat with the belt fastened. The load islifted. The display briefly shows the flashingmessage LIFT HEIGHT. The truck will onlytravel at a reduced driving speed.

– Lower the fork (load) to just above theground.


6210_003-055_en_V3

Lifting the load while driving

If you are travelling with the load during astacking/unstacking operation and lift the loadwhile travelling, the flashing message LIFTHEIGHT appears briefly in the display. Thetruck will travel slowly or will be braked.

– Lower the fork (load) to just above theground.


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5 OperationOperating in special operating situations

Operating in special operating situationsTransport

CAUTION

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

means of transport, the ramps and loadingbridges is greater than the actual total weightof the truck.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

3

2

6210_001-016_V2

Determining the actual total weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate.

– Add the determined unit weights to obtainthe actual total weight of the truck:

Tare weight (1)




+ 100 kg allowance for driver

= Actual total weight

262 56338011803 EN - 10/2016

Operation 5Operating 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 over a loading bridge, ensure that

it is installed and secured properly.– Ensure that the transport vehicle to be driven

onto has been sufficiently secured againstmoving.

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

– Drive slowly and carefully onto the transportvehicle.

6210_001-012_V3

Setting chocks– Secure the truck from rolling away byplacing a wheel chock in front of each frontwheel and behind each back wheel (1).

– Park the truck securely.

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.– 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.

– Ensure that the key switch is switched off.

– Disconnect the battery male connector.

NOTE

If the electric parking brake (variant) cannot betriggered electrically, it must be applied ma-nually; see the chapter entitled "Emergencyoperation of the electric parking brake".

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Lashing

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).

6321_003-104

1

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

6210_003-048_V2

2

1

– Attach lashing straps (1) to the coupling pin(2) or loop around the coupling pin and lashthe truck to the side.

DANGER

Shifting of the load caused by the lashing strapsslipping!The truck must be lashed securely so that it cannotmove during transportation.– Make sure that the lashing straps are tightened

securely and that the pads cannot slip off.

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6036Ba-0265060_003-070

Towing

DANGER

The brake system on the towing vehicle may fail.There is a risk of accident!If the brake system of the towing vehicle is notadequately sized, the vehicle may not brake safelyor the brakes may fail. The towing vehicle must beable to absorb the pulling and braking forces fromthe unbraked towed load (total actual weight of thetruck).– Check the pulling and braking forces of the

towing vehicle.

DANGER

The truck could drive into the towing vehicle whenthe towing vehicle brakes. There is a risk of acci-dent!If a rigid connection has not been used for powertransmission in two directions during towing, thetruck may drive into the towing vehicle when thetowing vehicle brakes. For safety reasons, only atested tow bar may be used.– Use a tested tow bar.

CAUTION

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

position.

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.– Do not disconnect the battery male connector

while the key switch is switched on.

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DANGER

People can be crushed between the truck andtowing vehicle during manoeuvring. There isdanger of death!The towing vehicle may only be manoeuvred andthe tow bar may only be attached using a secondperson as a guide. This ensures that the driver ofthe towing vehicle and the mechanic attaching thetow bar are aware of possible risks.– Only manoeuvre with a guide.

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.

– Set down load and lower fork arms close tothe ground.

– Place the drive direction switch in theneutral position.




– Check the pulling and braking forces of thetowing vehicle.

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

– Secure the tow bar to the tow coupling of thetowing vehicle and the truck.

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

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– Where possible, activate the restraintsystems provided.


– Select a towing speed that allows the truckand towing vehicle to be effectively brakedand controlled at all times.

– Tow the truck.

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

– Remove the tow bar.

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.

Trucks may only be laden by persons withsufficient experience in the suitable harnessesand hoists.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

3

2

6210_001-016_V2

Determining the loading weight– Park the truck securely; see chapter "Park-ing the truck securely".

– Determine the unit weights by reading themoff the truck nameplate and, if necessary,the attachment (variant) nameplate.

– Add the determined unit weights to obtainthe loading weight of the truck:

Tare weight (1)




= Loading weight.

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Hooking on the lifting straps

CAUTION

Harnesses may damage the truck’s paintwork!Harnesses may damage paintwork by chafing andpressing on the surface of the truck. Particularlyhard or sharp-edged harnesses, such as wires orchains, can quickly damage the surface.– Use textile harnesses, e.g. lifting straps, with

edge protectors or similar protective devices ifnecessary.

DANGER

If the hoists and harnesses failand cause the truck to fall, theconsequences are potentially fatal!– Use only hoists and harnesseswith sufficient load capacity for thedetermined loading weight.

– Only use the truck’s designatedlifting points.

– Make sure that harnesses suchas hooks, shackles, belts etc. areonly used in the indicated loaddirection.

– The harnesses must not bedamaged by truck parts.

NOTE

The attachment points are indicated by a hooksymbol.

4

6321_003-069– Loop the lifting straps around the maintraverse (4) on the outer mast of the liftmast.

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6321_003-070

5

– Loop the lifting straps around the counter-weight (5) as shown.

– Determine the truck’s centre of gravity, see"Dimensions" chapter.

6321_003-071

7 6– Adjust the length of the harnesses so thatthe lifting eye (6) is vertically above thetruck’s centre of gravity.

This ensures that the truck hangs level whenlifting it.

– Connect the lifting straps to the lifting eyeand insert the safety device (7).

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 collide withattachment parts.

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5 OperationProcedure in emergencies

Loading the truck

DANGER

If the raised truck swings in anuncontrolled fashion, it may crushpeople. There is a risk to life!– 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 uncontrolledway.

– If necessary, hold the truck usingguide ropes.

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

Procedure in emergencies

6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

Emergency shutdown

WARNING

No electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply. The truck will notbe held on a slope by the electric brake.– To brake, actuate the service brake.

CAUTION

Actuating the emergency off switch (1) or discon-necting the battery male connector (2) shuts downthe electrical functions of the truck.– Only use this safety feature in an emergency or

in order to safely park the truck.

CAUTION

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

connector is disconnected.– Do not disconnect the battery male connector

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Operation 5Procedure in emergencies

2

5060_003-054

while the key switch is switched on, except in anemergency.

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

– Press the emergency off switch (1) ordisconnect the battery male connector (2).

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 willcoast

• In trucks with an electric parking brake(variant), the electric parking brake isapplied as soon as the truck comes to astop

• The electric brake does not function duringthe first part of brake pedal travel. To brakethe truck using the mechanical brake, thebrake pedal must be pushed down further

• The truck can only be held on a slope usingthemechanical brake, not the electric brake

• No power steering effect; the steeringforces are increased by the remainingemergency steering function

• The "Curve Speed Control" system (auto-matic reduction in truck speed when cor-nering) does not function The truck must bedecelerated with the mechanical brake bypressing the brake pedal

• No hydraulic functions are available

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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:

– Hold onto the steering wheel with yourhands.

– Brace your feet in the footwell.

– Bend your upper body over the steeringwheel.

– Bend your body against the direction of thefall.

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6321_003-097_V3

1

Emergency hammerThe emergency hammer is used to rescue thedriver if he is shut inside the cab in a hazardoussituation, for example if the truck has toppledover and the cab door cannot be opened.

Single-pane safety glass can be struck rela-tively safely using the emergency hammer inorder for the driver to escape or be rescuedfrom the danger area.

Using the emergency hammer

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 valve block.

DANGER

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

– Adhere to the following steps.

– Remove the valve cover.

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6210_003-108_V2

1– Remove the hexagon socket wrench (1)from the compartment on the right next tothe driver’s seat.

NOTE

In this procedure, a distinction is made be-tween the types of operating devices.

6210_003-100_V2

2

4

3

5

A

B

A Joystick 4Plus version and mini-leverversion:

B Multiple-lever version

For the Joystick 4Plus version and the mini-lever version (A):

– Using the hexagon socket wrench, turn theemergency lowering screw (2) on the valveblock (5) a maximum of 1.5 revolutions toloosen it.

For the multiple-lever version (B):

– Using the hexagon socket wrench (1),turn the emergency lowering screw (4)on the valve block (3) a maximum of 1.5revolutions to loosen it.

WARNING

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

For both versions:• Tightening torque:max. 2.5 Nm

• When unscrewed a little:The load lowers slowly

• When unscrewed a lot:The load lowers quickly

After lowering:

– Screw the emergency lowering screw forthe load back in.

274 56338011803 EN - 10/2016


– Return the hexagon socket wrench to thesupport mounting in the compartment.

– Install the valve cover.

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.

3

6210_003-051_V3

Emergency operation of the electricparking brake

WARNING

The truck can roll away when the parking brake isreleased!Emergency operation of the parking brake can beinitiated only when the fork is lowered and the truckis switched off.

In emergency operation or during transportwithout a battery, the electric parking brakecan be operatedmanually via the hand wheel.

– Lower the forks to the ground.


– Lift cover (3) and move it to the side.

6210_003-053_V2

4

– Remove hand wheel (4) and place upsidedown on the tappet.

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656210_003-052_V3

5551

4391

001

1.2.

– Place the hand wheel with the tappet lugs(5) on the tappet (6) and press down againstthe spring force.

NOTE

Do not rotate the hand wheel to the stop,because this will trigger the relubricationdevice.

– To apply the parking brake rotate the handwheel clockwise until the force neededincreases markedly and the truck is heldsecurely. The effort required is not great.

– To release the parking brake rotate thehand wheel anticlockwise a maximum of5 revolutions until the hand wheel can beturned easily.

After manual operation, the hand wheel is tobe returned to its latch position and the coverto its normal position.

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Operation 5Handling the battery

Handling the batterySafety regulations when handlingthe battery– National statutory provisions for the countryof usemust be followedwhen setting up andoperating battery charging stations.

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.

– The following safety regulations must beobserved when maintaining, charging andchanging the battery.

Maintenance personnelBatteries may be charged, maintained orchanged only by properly trained personnelin accordance with the instructions of themanufacturer of the battery, battery charger ortruck.

– The handling instructions for the battery andthe operating instructions for the batterycharger must be followed.

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.– Always wear safety shoes whenreplacing the battery.

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

56338011803 EN - 10/2016 277

5 OperationHandling the battery

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

– When charging andmaintaining the battery,observe the manufacturer’s maintenanceinstructions for the battery and batterycharger.

Fire protection measures

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.There must be no flammable mate-rials or spark-forming operating ma-terials within 2 m of either the truckwhen it is parked for charging or thebattery charger.– When working with batteries, takethe following security precautions.

– Keep away from open flames and do notsmoke.

– Ensure that work areas are adequatelyventilated.

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

– The battery cover must remain open duringcharging.

– Expose the surfaces of the battery cells.

– Do not place any metal objects on thebattery.

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

– Have fire extinguishing equipment ready.

278 56338011803 EN - 10/2016


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.

Maintaining the batteryThe cell covers of the battery must be kept dryand clean.

Terminals and cable shoes must be clean,lightly coated with battery grease and tightlyscrewed.

– Neutralise any spilt battery acid immedi-ately.

– Observe the safety regulations for handlingbattery acid; see the chapter entitled"Battery acid".

6210_600-001

Damage to cables and battery maleconnectors

CAUTION

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

56338011803 EN - 10/2016 279


CAUTION

Potential for damage to themale battery connector!If the battery male connector is disconnectedor connected while the key switch is switchedon or the battery charger is under load, an arcwill be produced at the battery male connector.This can lead to erosion at the contacts, and canconsiderably shorten the service life of the contacts.– Switch off the key switch or battery charger be-

fore the battery male connector is disconnectedor connected.

– Do not disconnect the battery male connectorwhile under load, except in an emergency.

6327_600-010

1

Opening/closing the battery cover

Opening the battery cover

CAUTION

The outside mirror (1) is in the movement range ofthe battery cover. When opening the battery cover,a collision can cause components to be damaged.– Fold outside mirror forwards.– Ensure that there is sufficient lateral distance (at

least 100 mm) from the battery cover.

280 56338011803 EN - 10/2016


6327_003-010

2

A

– Pull on the interlock (2) of the battery coverand lift battery cover at (A) grip position.

The cover catch snaps into place.

Closing the battery cover

WARNING

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

of the body in the way.

WARNING

When closing the battery cover, there is a risk oftrapping the battery cable. If the cable is crushed orsheared off, there is a risk of short circuit!When closing the battery cover, nothing shouldcome between the battery cover and the edge ofthe chassis.– Close the battery cover carefully.– Only close the battery cover if the battery cable

is not in the way.

– Pull the cover catch (3) slightly out andpull the battery cover at the grip positiondownwards at the same time(B)until thecover catch is unlocked.

6327_600-009

B 3

– Release the latch.

56338011803 EN - 10/2016 281


6321_003-085

5

4– Before closing the battery cover, close thebattery safety catches (5) until they lock intoplace.

DANGER

If the battery is not locked correctly, the batterycan slide out of the truck, with potentially fatalconsequences!– Ensure that the battery safety catch (5) is locked

as far as it will go.

NOTE

If the battery safety catch (5) is difficult tomove, use the coupling pin (4) to help.

– Allow the battery cover lock to snap intoplace.

6327_600-005

6

The battery cover interlock must snap intoplace properly or the built-in sensor (6) willgenerate the error message CLOSE THEDOOR on the display and the truck will notdrive.

282 56338011803 EN - 10/2016


6210_600-002

NOTE

The apertures in the flap (arrowed) are ne-cessary for forced ventilation and must not beblocked.

Disconnecting the battery maleconnector

CAUTION




– Open the battery cover.

56338011803 EN - 10/2016 283


1

5060_003-051

– Disconnect the battery male connector (1)by pulling in the direction of the arrow at theplug connection.

– Place the battery male connector on thebattery.

CAUTION

There is a risk of short circuit if thecables are damaged.Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing thebattery cover.– Check the connecting cable fordamage.



Maintaining the battery

DANGER

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

handling the battery".

WARNING

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

acid" chapter.

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer’s opera-ting instructions! The operating instructionsfor the battery charger must also be followed.Only the instructions that camewith the batterycharger are valid. If any of these instructionsare not available, please request them fromthe dealer.

The battery maintenance is composed of thefollowing sections "Checking the battery con-

284 56338011803 EN - 10/2016


dition, acid level and acid density", "Checkingthe battery charge status", "Charging the bat-tery" and "Equalising charge to prevent a deepdischarge of the battery" together.

56338011803 EN - 10/2016 285


Checking the battery condition, acidlevel and acid density

WARNING

The electrolyte (dilute sulphuric acid)is poisonous and caustic!– Observe safety regulations forhandling battery acid; see chapter"Battery acid".

– Wear personal protective equip-ment (rubber gloves, apron andprotection goggles).

– Rinse away spilt battery acidimmediately with plenty of water!

CAUTION

Risk of damage!– Heed the information in the operating instructi-

ons for the battery.

– Remove the battery from the truck.

– Inspect battery for cracked housing, raisedplate sand acid leaks.

– Have defective batteries repaired by theauthorised service centre.

6321_003-126

1

2

– Open filler cap (1) and check the acid level.

For batteries with "caged cell plugs", the liquidmust reach the bottom of the cage.

For batteries without "caged cell plugs", theliquid must reach a height of approx. 10 to 15mm above the lead plates.

– Topupmissing fluidwith distilledwater only.

– Clean the battery cell cover and dry ifnecessary.

– Remove any oxidation residues on thebattery terminals and then apply acid-freegrease to the terminals.

– Tighten the battery-terminal clips (2) to atorque of 22–25 Nm (depending on the sizeof the terminal screws used).

– Check acid density with an acid siphon.

After charging, the acid density must bebetween 1.28 and 1.30 kg/l.

286 56338011803 EN - 10/2016


For a discharged battery, the acid densitymust be no lower than 1.14 kg/l.

6311_003-011_V2

1Checking the battery charge status

CAUTION

Deep discharges shorten the service life of thebattery.If no bar is shown in the battery charge display (1)(0% of the available battery capacity, i.e. around20% of the nominal capacity), deep dischargebegins.– Avoid deep discharges (no bar on the display)

(see the section entitled "Equalising charge toprevent a deep discharge of the battery").

– Cease work with the truck immediately.– Charge the batteries immediately.– Do not leave batteries in a discharged or partly

discharged state.



– Read the charging state (1) from 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 period.

Charging the battery

DANGER

Danger to life and limb!– Observe the instructions in the chapter entitled

"Safety regulations when handling the battery".

56338011803 EN - 10/2016 287


WARNING

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

entitled "Battery acid".

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

Possibility of damaging the battery male connec-tors!Ensure that the key switch or battery charger isswitched off before the battery male connectors aredisconnected or connected.

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer’s opera-ting instructions! The operating instructionsfor the battery charger must also be followed.Only the instructions that camewith the batterycharger are valid. If any of these instructionsare missing, please request them from thedealer.

To read the battery charging state, see thesection entitled "Checking the battery chargestatus".

– Park the truck securely.

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

– Open battery cover completely.

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

– Keep away from open flames and do notsmoke.

– Check the battery cable and the chargingcable for damage, and have them replaced

288 56338011803 EN - 10/2016


by the authorised service centre if neces-sary.

6327_003-036

2

– Disconnect the battery male connector (2)by pulling the handle.

DANGER

Explosive gases are generatedduring charging!– Ensure that work areas areadequately ventilated.

– For trucks with a cab (includingfabric-covered cabs), ensureadequate ventilation in the cab(variant).

6321_003-127

3

– Attach the battery male connector (3) to thebattery charger connector.

NOTE

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

– Start the battery charger.

– The ventilation gaps between the cover andchassis must not be blocked.

DANGER

Risk of explosion!The battery cover must be kept openduring charging to ensure adequateventilation.

After charging

– Switch off the battery charger.

– Disconnect the batterymale connector fromthe battery charger plug.

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6327_600-001

1

– Insert the battery male connector (1) fullyinto the plug connection on the truck.

CAUTION

There is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable doesnot come into contact with thebattery cover.

6210_600-001

– Close the battery cover completely. Whendoing so, ensure that no cables are crushedbetween the chassis and the cover.

The battery cover must be locked, otherwisethe CLOSE THE DOOR error message willappear in the display and the truck will notdrive.

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

290 56338011803 EN - 10/2016


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.


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

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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 unitmust 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.

• When changing to TENSOR® batteries, themaximum speed of the truckmust be limitedto 17 km/h for technical reasons.

– Contact the authorised service centreregarding this matter.

General information on replacing thebattery

CAUTION

Risk of components being damaged by the liftingaccessory and battery rolling away!The lifting accessory and batterymay roll away in anuncontrolled manner if the battery is not removedon a level, smooth floor with sufficient load-bearingcapacity.– Follow the operating instructions for the lifting

accessories used.– Always remove the battery on a level, smooth

floor with sufficient load-bearing capacity.

The battery can be removed using the follo-wing lifting accessories:• Truck• Change frame (variant)• Hydraulic drive

The load capacity of the lifting accessory usedmust at least match the battery weight (seebattery identification plate).

292 56338011803 EN - 10/2016


Replacing the battery using forklifttruck or pallet truck

CAUTION

Risk of damage!The battery should only be removed on a level,smooth floor in accordance with the operatinginstructions of the truck or pallet truck used.

Preparation– Park the truck safely.


CAUTION




6327_600-001

1

– Disconnect the battery plug (1).

CAUTION

There is a risk of short circuit if thecables are damaged!Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing thebattery cover.– Check the connecting cables fordamage.


DANGER WARNING

Risk of crushing/shearing!Personnel must not stand directlynext to the battery or between thebattery and the forklift truck whenremoving and inserting the batterywith the forklift truck or lift truck.

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WARNING

Risk of accident!The load capacity of the truck in use must at leastmatch the battery weight (see battery identificationplate).

6210_606-011

A

B

– Before picking up the battery, the fork armsmust be adjusted to match the opening inthe chassis (A).Move the fork arms togetherwhile maintaining the maximum possibledistance between them.

Taking up the battery

CAUTION

Risk of component damage!– The fork arms must not be moved underneath

the battery beyond the length of the opening inthe chassis.

NOTE

It is helpful if this measurement (B), measuredfrom the fork tips, is marked on the fork arms.

6321_003-086

2

– Fold the battery safety catches (2) to theside.

– Move fork arms carefully underneathbattery.

– Carefully lift the battery up and out of thetruck. Pay attention to the distance to thechassis.

WARNING

Risk of crushing/shearing!The battery must be transported very carefully, i.e.at a low speed, using slow steeringmovements andcareful braking.– Do not use the methods described above to

transport the battery over long distances.

– Carefully remove the battery from the truck.

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6321_003-002

– Put the battery down on a stable base sothat it is secure. Position the battery againstthe stops on the base.

– Pick up the new battery and transport it tothe forklift truck.

– Position the battery cable on the batteryso that it will not become trapped when thebattery is inserted.

– Position the battery at a right angle to theforklift truck.

– Carefully insert the battery into the batterycompartment.

Once the battery is positioned correctlyin the battery compartment:– Release the battery carefully.

– Carefully retract the load-carrying equip-ment under the battery.

– Close the battery safety catches until theylock into place.

6327_600-001

1

– Plug in the battery plug (1).

CAUTION

There is a risk of short circuit if thecables are damaged!Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable doesnot come into contact with thebattery cover.


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6210_003-012

1

2Battery transport with crane

DANGER

If the load is dropped, the conse-quences could potentially be fatal!– Never walk or stand underneathsuspended loads.

– Ensure there is sufficient distance betweenthe truck and any obstacles so that the truckis not damaged when the crane is used.

To avoid short circuits, batteries with openterminals or connectors should be coveredwith a rubber mat.

– Attach battery (1) to suitable lifting gear (2).

Observe the operating instructions for thelifting gear.

The lifting gear should be vertical when lifting,so that no lateral pressure is applied to thetray.

– Lift the battery from the roller channel.Ensure that there is sufficient distance fromthe battery door.

– Set the battery down carefully.

– Do not place or allow slack lifting gear to fallon the battery cells.

Replacing the battery using a changeframe (variant)

CAUTION

Risk of damage!Place the battery change frame along with the trac-tion battery only onto a firm surface with sufficientload-bearing capacity.Do not place the battery change frame with thetraction battery onto a soft surface or in a rack.

The battery change frame (variant) featuresan advantageous design that allows a truckor pallet stacker to pick up the battery quickly.The battery along with the change frame canbe set down and charged. The change frame

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fits between the battery holding fixtures in thebattery compartment of the truck. Once thebattery has been set down onto its holdingfixtures, the change frame is moved back outof the truck.

Preparation– Park the truck securely.


CAUTION

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



6327_600-001

1

– Disconnect the battery male connector (1).

CAUTION

There is a risk of a short circuitoccurring if the cables are damaged!Position the battery cable on thebattery in such a way that it cannot becrushed when removing or insertingthe battery or when closing thebattery cover.– Check the connection cable fordamage.


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 or lift truck.

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WARNING

Risk of accident!The load capacity of the truck/lift truck in use mustat least match the battery weight (see batteryidentification plate).

– Ensure that the maximum load capacity ofthe change frame is not exceeded.

The maximum load capacity of the changeframe is specified on the identification plate.

– Before picking up the change frame, adjustthe fork arm distance.

– Position the change frame (3) under thebattery (2) so that the centre of the battery(1) is in line with the recess (4) in the changeframe.

This alignment ensures that the battery ispositioned centrally on the change frame. Thebattery must be positioned centrally on thechange frame in order for the change frame tobe moved into the truck and to reduce the riskof the battery tipping over when being moved.If multiple batteries are used, it is advisable topermanently mark the centre of the battery (1)(e.g. using a strip of adhesive tape).

Picking up the battery

CAUTION

Risk of component damage!– Move the change frame under the battery only

up to the edge of the stop.

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6321_003-086

2

– Fold the battery safety catches (2) to theside.

– Carefully move the change frame under thebattery.

– Carefully lift the battery up and out of thetruck. Pay attention to the distance to thechassis.

WARNING

Risk of crushing/shearing!The battery must be transported very carefully, i.e.at a low speed, using slow steeringmovements andcareful braking.– Do not use the methods described above to

transport the battery over long distances.

– Carefully remove the battery from the truck.

The battery (1) can remain on the changeframe (2). The change frame can then beused to set the battery down.

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– If a substructure (3) is used to set down thebattery (1), ensure that the change frame(2) does not protrude beyond the battery.

– Set the battery down on a stable base sothat it is secure. Position the battery againstthe stops on the base.

– Move the change frame out from under thebattery.

– Pick up the new battery using the changeframe and transport the new battery to thetruck.

– Position the battery cable on the batteryso that it will not become trapped when thebattery is inserted.

– Position the battery at a right angle to thetruck.

– Carefully insert the battery into the batterycompartment.

Once the battery is positioned correctlyin the battery compartment:– Carefully place the battery onto the batteryholding fixtures.

– Carefully move the change frame out fromunder the battery.

– Close the battery safety catches (2) untilthey latch into place.

– Plug in the battery male connector (1)

CAUTION

There is a risk of a short circuitoccurring if the cables are damaged!Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable doesnot come into contact with thebattery cover.


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Replacing the battery with thehydraulic battery carrier

PreconditionsThe following preconditions apply whenchanging a battery using the hydraulic batterycarrier:

• The extension area must be free of obsta-cles

• The ground must be stable, clean and even

NOTE

When the battery is fully discharged, it is notpossible to use the battery carrier.

1

6321_003-016

Emergency stop when moving thebatteryWhen working with the hydraulic batterycarrier, it may not be possible to reach theemergency off switch. In an emergency,disconnect the battery male connector (1).

CAUTION

Component damage possible!If you remove the battery male connector when thekey switch is switched on (under load), an arcwill beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Turn off the key switch before the battery male



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6321_003-074

Extending the battery hydraulically– Apply the parking brake.

6321_003-075

– Make sure that there is no load on thedriver’s seat.

– Open the battery cover fully.

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6321_003-076

– Open the battery safety catches.

WARNING

Risk of crushing/shearing!When extending the battery carrier, there must beno personnel in the extension area. There is a riskof crushing and shearing when the battery carrierextends.The battery male connector must remain in reachas an emergency off mechanism.– Place it beside the counterweight and outside

the extension area.

6321_003-077

– Press the extend push button until thecarriage has reached its end position.

During the extension procedure the supportalso extends automatically.

CAUTION

Component damage possible!Whenextending the carriage, the battery cablemaycollide with components and become damaged.– Make sure that the battery cable does not

become stuck or crushed.– In the event of a malfunction, release the exten-

sion button and correct the malfunction.

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DANGER DANGER

6321_003-078

– Ensure that the battery cable is not dam-aged when the carriage is extended.

NOTE

If the movement of the carriage is restrictedby obstacles, release the push button. Thecarriage can only be retracted. If the pushbutton is actuated continuously, the driveswitches off after 50 seconds.

WARNING

Risk of crushing!Never reach under the battery to remove obstacles.– Retract the battery again and remove obstacle.

NOTE

If the motor protection function is triggered:The motor protection function is controlled bya counter. After retracting and extending fivetimes, the hydraulic battery carrier is disabledfor 60 minutes. The counter is reset whenthe motor has been running for less thanfive minutes and there is no actuation for 15minutes.

6321_003-079

After extending the battery fully:– To avoid short-circuits, place a rubbermat on the battery with open terminals orconnectors.

CAUTION

Component damage possible!If you remove the battery male connector when thekey switch is switched on (under load), an arcwill beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Turn off the key switch before the battery male




– Disconnect the battery male connector andplace it on the battery.

– Attach the battery to suitable lifting gear.Observe the operating instructions for thelifting gear.

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6327_003-046

– Lift the battery sideways out of the truck.Ensure that there is sufficient distance fromthe battery cover.

CAUTION

Component damage possible!– Do not allow slack lifting gear to fall onto the

battery cells.

DANGER

Risk of death from suspended loads!– Never walk or stand underneathsuspended loads.

– Lift the battery out of the battery tray and setit down carefully.

– Ensure that there is sufficient distancewhen setting down so that the truck is notdamaged when the crane is used.

– Before inserting the battery, check that thebattery tray is free of objects.

– Carefully insert the replacement battery intothe battery tray.

6321_003-081

After inserting the battery into the batterytray:

CAUTION

Component damage possible!If you connect the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Switch off the key switch before the battery male

connector is connected.– Do not connect the battery male connector

while the key switch is switched on, except inan emergency.

– Connect the battery male connector.


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WARNING

Risk of injury!– Personnel must stand beside the counterweight

outside the retraction area.

CAUTION

Component damage possible!When retracting the carriage, the battery cable maycollide with components and become damaged.– Make sure that the battery cable does not

become stuck or crushed.– In the event of a malfunction, release the retrac-

tion button and correct the malfunction.

DANGER DANGER

6321_003-083

– Make sure that the battery cable is notdamaged when the carriage is retracted.

WARNING

Risk of crushing!Do not reach into the battery compartment while thebattery carrier is being operated.

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6321_003-082

– Press the retract push button until thecarriage has reached its end position.

– Release the push button.

NOTE

If the movement of the carriage is restricted byobstacles, release the push button.

WARNING

Risk of crushing!Never reach under the battery to remove obstacles.– Extend the carriage again.– Lift the battery with the crane again, swivel the

battery to the side and remove the obstacle.

CAUTION

Risk of damage!If the drive system overheats, the battery carrier isswitched off automatically. After a cooling-downperiod of about 60 minutes, the battery carrier canbe reactivated.– Notify the authorised service centre if the battery

carrier is blocked.

6321_003-084

– Close the battery safety catches.


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Messages and errors during use of the hydraulic battery carrier

Error code Cause Remedy

5920 The unit is overheated. Allow the truck to cool down forone hour.

5910

5930

5931

Notify authorised servicecentre

Message Cause Remedy

BATTERY CHANGER The battery support is not fullyretracted

Press the "Retract battery"push button until the supportis fully retracted. Notify theauthorised service centre ifthis step is not successful.

CLOSE THE DOORThe battery cover is notcorrectly closed. Close the battery cover.

.

Charging the battery with the batterycharging flap

DANGER

Risk of explosion!– Observe the safety regulations when handling

the battery; see chapter "Safety regulationswhen handling the battery".

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer’s opera-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.

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6321_003-103

1

2

Battery charging flap (variant)– Park the truck securely.

– Press the release buttons (1).

The release buttons pop out.

– Turn the release buttons (1).

The release buttons unlock the battery charg-ing flap (2).

– Open the battery charging flap (2) com-pletely.

CAUTION




6321_003-101

3

– Disconnect the battery male connector (3)from the truck.

DANGER

Explosive gases are generatedduring charging!– Always ensure adequate ventila-tion in the vicinity.

– Ensure adequate ventilation in thecab (variant) for trucks with a cab(including fabric-covered cabs).

DANGER

There is a risk of damage, short circuiting andexplosions!– Do not place any metallic objects or tools on the

battery.– Keep away from open flames and do not smoke.

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WARNING

The electrolyte (dilute sulphuric acid) is poisonousand caustic!– Observe safety regulations for handling battery

acid; see chapter "Battery acid".– Rinse away spilt battery acid immediately with

plenty of water!

– Before charging, check the battery cableand the charging cable for damage, andhave the cables replaced by the authorisedservice centre if necessary.

CAUTION

Risk of component damage!If you connect the charging cable while the batterycharger is switched on (under load), an arc will beproduced. This can lead to erosion at the contacts,which considerably shortens their service life.– Switch off the battery charger before the char-

ging cable is connected.

6321_003-105

4

3

– Connect the battery male connector (3) tothe battery charger plug (4).

– Start the battery charger.

NOTE

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

DANGER

Risk of explosion!The battery charging flap must bekept open during charging to ensureadequate ventilation.

– The ventilation gaps between the cover andchassis must not be blocked.

Upon completion of charging:

– Turn off the battery charger.

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CAUTION

Risk of component damage!If you disconnect the charging cable while the bat-tery charger is switched on, an arc will be produced.This can lead to erosion at the contacts, which con-siderably shortens their service life.– Switch off the battery charger before the char-

ging cable is disconnected.

WARNING

Risk of explosion!The plug may only be disconnectedfrom the socket when the truck andbattery charger are switched off.


6321_003-101

3

– Reattach the battery male connector (3) tothe plug on the truck.

CAUTION

There is a risk of short circuit if thecables are damaged.Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable doesnot come into contact with thebattery cover.

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6210_600-001

– Close the battery cover completely. Whendoing so, ensure that no cable is crushedbetween the chassis and the cover.

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Operation 5Decommissioning

DecommissioningParking the truck securely andswitching it off

DANGER

There is a risk of fatal injury frombeing run over if the truck rolls away.– The truck must not be parked on aslope.

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

– Do not leave the truck until 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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5 OperationDecommissioning

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.

6321_003-144

1

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 through incorrect storage!In the event of incorrect storage or shutdownfor more than two months, the truck may suffercorrosion damage! If the truck is parked in anambient temperature below -10°C for an extendedperiod, the batteries cool down. The electrolytemay freeze and damage the batteries.– Store the truck in a dry, clean, frost-free and well

ventilated environment.– Carry out the following measures before shut-

down.

Measures before shutdown– Clean the truck thoroughly; see chapter"Cleaning".

– Lift fork carriage to stop several times.

– 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.

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– Apply oil or grease thinly to all untreatedmoving parts.

– Grease the forklift truck.

– Lubricate the joints and controls.

– Lubricate the slide elements and guides ofthe hydraulic battery carrier (variant); seechapter "Lubricating the slide elements".

– Lubricate the catch rail of the hydraulicbattery carrier (variant); see chapter "Lubri-cating the catch rail".

– Lubricate the battery interlock and batterycover; see chapter "Checking the batteryinterlock and battery cover".

CAUTION

Risk of component damage!If you remove the battery male connector with thekey switch switched on (under load), an arc will beproduced. This can cause the contacts to erode,which considerably shortens their service life.– Switch off the key switch before the battery male




– Check the battery condition, acid level andacid density.

– Service the battery.

NOTE

Store only fully charged batteries.

– Apply a suitable contact spray to all exposedelectrical contacts.

CAUTION

Risk of tyre deformation by continuously loading onone side!Jack up the truck so that all the wheels are clear ofthe ground. This prevents permanent deformationof the tyres.– Only have the truck raised and jacked up by the

authorised service centre.

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CAUTION

Risk of damage from corrosion due to condensationon the truck!Many plastic films and synthetic materials arewatertight. Condensation water on the truck cannotescape through these covers.– Do not use plastic film as this encourages the

formation of condensation water.– Cover with vapour permeable material, e.g.

cotton.

– Cover the truck to protect against dust.

If the truck is to be shut down for even longerperiods, contact your authorised servicecentre to find out about additional measures.

Recommissioning after storageIf the truck has been in storage for longerthan six months, it must be carefully checkedbefore being recomissioned. As in the annualinspection, this check should also include allsafety items for the truck.

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

– Lubricate the joints and controls.

– Lubricate the slide elements and guides ofthe hydraulic battery carrier (variant); seechapter "Lubricating the slide elements".

– Lubricate the catch rail of the hydraulicbattery carrier (variant); see chapter "Lubri-cating the catch rail".

– Check the battery condition, acid level andacid density.

– Check hydraulic oil for condensation water;change if necessary.

– Carry out checks and operations before thefirst commissioning.

– Commission the truck; see chapter "Com-missioning".

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

NOTE

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

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Operation 5Cleaning

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




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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5 OperationCleaning

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.

320 56338011803 EN - 10/2016

Operation 5Cleaning

– 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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5 OperationCleaning

6321_003-020

Cleaning load chains

WARNING

Risk of accident!Load chains are safety elements.The use of cold cleaning solvents, chemical clea-ners or fluids that are corrosive or contain acid orchlorine can damage the chains; use of these itemsis forbidden!– Observe the manufacturer’s guidelines for

working with cleaning materials.

– Place a collection vessel under the lift mast.

– Clean with paraffin derivatives, such asbenzine.

– When using a steam jet, do not use addi-tional cleaning agents.

– Remove any water in the chain links usingcompressed air immediately after cleaning.Move the chain several times during thisprocedure.

– Immediately after drying the chain, spray itwith chain spray. Move the chain severaltimes during this procedure.

ENVIRONMENT NOTE

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

– Observe the national regulations for thecountry of use.

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Operation 5Cleaning

6321_003-089

1

Cleaning the windowsAny panes of glass, e.g. cab windows (vari-ant), must always be kept clean and free of ice.This is the only means of guaranteeing goodvisibility.

CAUTION

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

(1) and do not use any objects with sharp edges.

– Clean the windows.

NOTE

Cleaning can be done using a commerciallyavailable glass cleaner.

6210_001-029

After washing– Carefully dry truck (e.g. with compressedair).

– Sit on the driver’s seat and start up the truckin accordance with regulations.

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.

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5 OperationCleaning

324 56338011803 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-

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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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328 56338011803 EN - 10/2016


Maintenance— 1000 hours/annuallyAt operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Chassis, bodywork and fittings

Check chassis for cracks

Check overhead guard/cab and panes of glass for damage

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

Check driver’s seat for correct function and for damage

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

Check battery door, interlock and sensor for correct function and for damage

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

Tyres and wheels

Check tyres for wear and check the air pressure

Check wheels for damage and check the tightening torques

Power unit

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

Gearbox oil and multi-disc brake: Check oil level

Steering

Check steering system for correct function and for leaksCheck that the steering wheel is firmly attached and check the turning handle fordamageSteering axle: Check that it is firmly attached, check for leaks, and apply grease

Check steering stop

Brake

Check all mechanical brake parts for condition and correct function

Carry out brake test

Check the electric parking brake variant for damage and correct function

Electric parking brake variant: Check relubrication device

Electrical system

Check all power cable connections

Check main contactor contacts

Test switches, transmitters and sensors for correct function

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check lighting and indicator lights

Battery and accessoriesCheck the lead-acid battery for damage and check the acid density; observe themanufacturer’s maintenance instructionsLead-acid battery with electrolyte circulation: replace the non-return valve

Lithium-ion battery: observe the manufacturer’s maintenance instructions

Check the interlock for damage

Check the appliance plug and truck harness for damage

Check the battery male connector and battery harness for damage

Hydraulic battery carrier: Check oil level and check for leaks

Hydraulic battery carrier: Check all moving parts for wear, and lubricate

Hydraulics

Check hydraulic system for condition, correct function and leaks

Check the hydraulics blocking function (ISO valve)

Check oil level

Lift mast

Check mast bearings for damage, and lubricate. Check the tightening torque

Check mast profiles for damage and wear, and lubricate

Check load chains for damage and wear, adjust and lubricate

Check lift cylinders and connections for damage and leaks

Check guide pulleys for damage and wear

Check support rollers and chain rollers for damage and wear

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

Check tilt cylinders and connections for damage and leaks

Check fork carriage for damage and wear

Check fork arm interlock for damage and correct function

Check fork arms for wear and deformation

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

Special equipmentCheck heating system for damage; observe manufacturer’s maintenance instructi-ons

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check attachments for wear and damage; observe manufacturer’s maintenanceinstructionsCheck trailer coupling for wear and damage; observe manufacturer’s maintenanceinstructionsGeneral

Read out error numbers and delete list

Reset maintenance interval

Check labelling for completeness

Test drive the truck

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332 56338011803 EN - 10/2016


Maintenance - 3000 hours/every two years

At operating hours Carriedout

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work

Power unit

Check the gearbox and multi-disc brake and change the gearbox oil

Brake

Electric parking brake variant: Replace actuation push button

Hydraulics

Renew the hydraulic oil

Replace return line filter, breather filter and high-pressure filter (variant)

For RX60-50 LSP600 (6330) only: Replace the accumulator

Ordering spare parts and wearingpartsSpare parts are provided by our spare partsservice department. The information requiredfor ordering parts can be found in the spareparts list.

Only use spare parts as per the manufac-turer’s instructions. The use of unapprovedspare parts can result in an increased risk ofaccidents due to insufficient quality or incor-rect assignment. Anyone using unapprovedspare parts shall assume unlimited liability inthe event of damage or harm.

Quality and quantity of the requiredoperating materialsOnly the operating materials specified in themaintenance data table may be used.

– The required consumables and lubricantscan be found in themaintenance data table.

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

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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!

Lubrication plan

334 56338011803 EN - 10/2016


Code1 Lubrication point

(A) Four lubricating nipples on each side of the steering axle for the axle stub bearing andtrack rod arm

(B) Sliding surfaces on the lift mast

(C) Load chains

(D) One lubricating nipple on each of the two lift mast bearings1See the following chapter, "Maintenance data table", under this Code. for the respective lubri-cant specification.

.

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Maintenance data table

General lubrication points

Code Unit Operating materials Specifications AmountLubrication High-pressure

greaseID no. 0147873 As required

Battery

Code Unit Operating materials Specifications AmountSystem filling Distilled water As required

Insulationresistance

DIN 43539VDE 0510

For furtherinformation, referto the workshop

manual for the truckin question.

Electrical system

Code Unit Operating materials Specifications AmountInsulationresistance

DIN EN 1175VDE 0117

For furtherinformation, referto the workshop

manual for the truckin question.

Controls/joints

Code Unit Operating materials Specifications AmountHigh-pressuregrease

ID no. 0147873 As requiredLubrication

Oil SAE 80MIL-L2105API-GL4

As required

Dual-pedaloperation

High-pressuregrease

ID no. 0147873 As required

336 56338011803 EN - 10/2016


Hydraulic system

Code Unit Operating materials Specifications AmountHydraulic oil HVLP 68

DIN 51524 Part 3Hydraulic oil forthe food industry(variant)

USDA H1DIN 51524

Hydraulic oil,fire-retardant

HFC/HFDU

Hydraulic oil,biological

HEES

System filling

Hydraulic oil for coldstore application

HVLP 68DIN 51524 Part 3

Max. 32.5 l

Hydraulic battery carrier

Code Unit Operating materials Specifications AmountCatch rail Multi-purpose oil,

acid-free, resin-freeRivolta TRS PlusID no. 0149847

As required

Slide elements andguide rails

High-pressuregrease


System filling Hydraulic oil HVLP 68DIN 51524 Part 3

Max. 2 l

Tyres

Code Unit Operating materials Specifications AmountSuperelastic tyres Wear limit To wear mark

Solid rubber tyres Wear limit To wear mark

Pneumatic tyres Minimum treaddepth

Air pressure: seeinformation on the

truckMin. tread depth:

1.6 mm

Steering axle

Code Unit Operating materials Specifications Amount(A) Axle stub bearing,

spherical bearingHigh-pressuregrease


Wheel nuts/screws Torque wrench 220 Nm

Axle stub nut Torque wrench 310 Nm

56338011803 EN - 10/2016 337


Drive axleCode Unit Operating materials Specifications Amount

Wheel nuts/screws Torque wrench 640 Nm

Wheel gear Gearbox oil Fuchs TITAN GearHyp LDSAE 80W-90API-GL5

Lift mastCode Unit Operating materials Specifications Amount(B) Lubrication High-pressure

greaseID no. 0147873 As required

Stop Play Min. 2 mm

(D)

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

Fill with grease untila small amountof fresh grease

escapesScrews for the liftmast bearing

Torque wrench 310 Nm

Load chainsCode Unit Operating materials Specifications Amount(C) Lubrication High-load chain

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

As required

Washer system

Code Unit Operating materials Specifications AmountSystem filling Washer fluid Winter, ID

no. 172566As required

.

338 56338011803 EN - 10/2016

Maintenance 6Safety 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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6 MaintenanceSafety 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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Maintenance 6Safety 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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6 MaintenanceSafety 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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Maintenance 6Providing access to maintenance points

Providing access to maintenance pointsRemoving/installing the valve cover

2

223

6210_762-002

Removing the valve cover– For trucks with a heating system (variant),unscrew the five screws (2) and remove theheating system panelling (3).

6321_003-052

5

5

4

– Unscrew the four screws (5) and removethe valve cover (4) by pulling it upwards andout.

Installing the valve cover– Reattach the valve cover (4).

– Refit the heater cover(3).

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6 MaintenanceServicing

Servicing

6210_606-030_V2

1Lubricating the joints and controls– Oil or grease other bearing points andjoints according to the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-336.

• Driver’s seat guide• Cab door hinges (variant)• Battery door hinges or battery cover hinges• Control linkage (1) for valves

Checking the battery interlock andbattery cover

DANGER

Amalfunction of the battery interlock and batterycover can cause the battery cover to open and thebattery could possibly fall out when the truck is tiltedor during sharp deceleration. If the battery falls outthere is a danger of being crushed.– If the interlock is deformed, damaged or difficult

to move, inform STILL Service immediately. Donot operate the truck.

– Check that the interlocks function correctly.– Interlocks must be greased and move easily.– Always check the interlock after an accident.

NOTE

The interval for greasing is influenced signi-ficantly by the application conditions and en-vironmental conditions affecting the truck.Every 1000 hours and as necessary visuallyinspect and check the function of the interlockand all of its moving parts.

– Open the battery cover; see ⇒ Chap-ter "Opening/closing the batterycover", P. 5-280.

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Maintenance 6Servicing

6321_003-137

1

– Check that the battery lock (1) moves easilyand that it is not deformed or damaged.

6321_003-136

2

3

– Check that the battery cover lock (3) moveseasily and that it is not deformed or dam-aged.

– Check that the rest plate (2) of the batterycover lock is seated correctly, and that it isnot deformed or damaged.

– Grease the lock mechanisms.

– Close the battery cover again.

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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.

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.

346 56338011803 EN - 10/2016


7090_342-0051

4

– The belt tongue (2) must release when thered button (4) is pressed.

– The automatic blocking mechanism mustbe tested at least once a year:

– Park the forklift truck on level ground.

– Pull out the belt with a jerk.

The automatic blocking mechanism mustblock extension of the belt.

– Tilt the seat at least 30 ° (if necessary,remove the seat).

– Slowly extend the belt.

The automatic blocking mechanism mustblock extension of the belt.

Cleaning the seat belt

– Clean the seat belt as necessary, butwithout using chemical cleaning materials(a brush will suffice).

Replacement after an accidentAs a rule, the seat belt must be changed afteran accident.

6327_342-010

Checking the driver’s seat

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.

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Maintaining wheels and tyres

WARNING

Risk of accident!Uneven wear reduces the stability of the truck andincreases the braking distance.– 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 froma differentmanufacturer, 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.

6311_003-004

Checking the condition and wear of thetyres

WARNING

Tyre quality affects the stability and handling of thetruck.Changes can only be made after consultation withthe manufacturer.When changingwheels or tyres, always ensure thatthis does not cause the truck to tilt to one side (e.g.always replace right-hand and left-hand wheels atthe same time).

348 56338011803 EN - 10/2016


21

6311_003-005

– If necessary, remove any foreign bodiesimbedded in the tyre profile (1).

NOTE

The wear of the tyres on an axle must beapproximately the same.• Super elastic tyres and solid rubber tyrescan be worn down to the wear mark (2)

6210_460-004

3

Checking wheel fastenings– Check wheel fastening nuts (3) and boltsfor secure positioning, and retighten asnecessary.

– Observe the torques; see the "maintenancedata table".

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Servicing the steering axle– Park the truck securely.

Checking the steering axle– Check the condition and wear of the rubberparts of the axle swivel bearings.

– Check the stub axle bearing (1) and tie rodjoint (2) for play and wear.

– Check the steering cylinder (3) for leaktight-ness (traces of oil).

NOTE

In the case of excessive play or wear, haveyour service centre change the relevant parts.

Lubricating the steering axle

ENVIRONMENT NOTE

Dispose of old grease and contaminateddevices in accordance with the nationalregulations for the country in which the truck isbeing used.

350 56338011803 EN - 10/2016


– At the lubricating nipples (4), lubricate theaxle stub bearing and the steering leverbearingswith grease in accordancewith the"maintenance data table".

If, after a few strokes, there is no longer anyold grease escaping, actuate the steering.

WARNING

Risk of crushing!Do not actuate the steering during lubrication.

– Switch on the truck.

– Actuate the steering.

– Park the truck securely again.

– Repeat the lubrication procedure.

NOTE

Please note: the more often the truck iscleaned, the more frequently it must belubricated.

Checking the lines for leaks– Retighten leaky connections.

NOTE

Have faulty lines replaced by your authorisedservice centre.

– After repairs, force out any trapped air byturning the steering wheel from stop to stopseveral times.

Checking the tightening torque of theaxle stub nuts– Set steering to end stop.

– Park the truck securely again.

56338011803 EN - 10/2016 351


– Check the tightening torque of the axle stubnut (5) in accordancewith the "maintenancedata table" and tighten the axle stub nut asnecessary.

Checking the battery– For information on checking the battery, seethe chapter entitled "Checking the batterycondition, acid level and acid density".

Checking the fuses

DANGER

Hazard from electrical current!Take care when handling; residualcapacity may be present.Before starting the followingmainten-ance work:– Park the truck securely.– Disconnect the battery maleconnector.

352 56338011803 EN - 10/2016


CAUTION




6210_604-001

1

Fuses for standard equipment and equipmentvariants are located in the rear part of thecontrol electronics (1).

– Open the cover.

– Remove the cover from the control electron-ics.

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2 3 4 5

79 8

6

6210_600-004

– Check the condition of the main fuse (2) (nodamage to the porcelain body) and checkthat it is securely positioned; tighten theclamping screws if necessary.

– Check the condition of fuses (3) to (3),check that the cable connections are secureand check for oxidation residues. Clean ifnecessary.(9)

NOTE

Depending on the specification, not all fuseswill be present in the truck.

CAUTION

Water in the electrical system cancause damage to components!In order to protect the electricalsystem against ingress of water, thecover must be closed.– Refit the cover after these taskshave been completed.


– Carry out a functional test.

Replacing fuses

DANGER

Hazard from electrical current!Take care when handling; there maybe residual capacity present.Before starting the followingmainten-ance work:– Park the truck securely.– Disconnect the battery maleconnector.

354 56338011803 EN - 10/2016


CAUTION




DANGER

Risk of fire!Using the wrong fuses can result inshort circuits.– Only use fuses with the prescribednominal current.

NOTE

Depending on the equipment, not all fuses willbe present in the truck.

6210_604-001

1

Fuses for standard equipment and equipmentvariants are located in the rear part of thecontrol electronics (1).

– Open the cover.

– Remove the cover from the control electron-ics.

– Replace the blown fuse; see the sectionentitled "Fuse assignment".

CAUTION

Water in the electrical system cancause damage to components!In order to protect the electricalsystem against ingress of water, thecover must be closed.– Refit the cover after these taskshave been completed.


– Carry out a functional test.

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Checking the hydraulic oil level– Park the truck securely.

CAUTION





– Remove maintenance lid or bottom plate.

CAUTION

Hydraulic oils are hazardous to your health and areunder pressure during operation.– Note the safety regulations in the "Hydraulic

fluid" chapter.

CAUTION

Risk of damage to components!Remove connector for drive unit.

1

2

6210_700-002

– Unscrew breather filter (1).

– Check the oil level on the oil dipstick. The oillevel must be between the markings (2).

– If the oil level is too low, pour hydraulic oil ofthe correct specification as specified in themaintenance data table into the filler neck.

– Fill the hydraulic oil no higher than the uppermarking on the oil dipstick.

NOTE

Use a funnel.

ENVIRONMENT NOTE

Carefully collect up any spilled oil and disposeof it in an environmentally friendly manner.

– Screw in the breather filter with oil dipstick.

– Close maintenance lid or bottom plate.

356 56338011803 EN - 10/2016



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

Pipes must be changed if:• There is abrasion with the loss of material• There are unnatural deformations anddetectable bending stress

• They are leaking

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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. 6-336.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

Greasing the automatic tow coupling

NOTE

Wear to moving parts can be significantlyreduced by appropriate servicing and regularlubrication of the coupling.

– Avoid over-greasing!

NOTE

Close the coupling before cleaning witha high-pressure cleaner. After cleaning,lubricate the coupling pin, tow bar eye andits supporting surface again.

358 56338011803 EN - 10/2016


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. 6-336.

– Close the coupling by raising the couplingpin with a suitable tool.

– For journeys with a rigid drawbar trailer,lubricate the underside of the tow bar eyeand the supporting surface on the coupling.

7321_003-092

– Determine the wear on the coupling pin.

The diameter of the spherical part must not beless than 36.5 mm.

Model RO*244 A– Open coupling.

Wartung_Rockinger 244 A

1– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-336.

– Grease coupling pin, tow bar eye and itssupporting surface.

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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. 6-336.

– Grease the supporting surface for thetow-bar eye.

7321_003-095

Model RO*841– Lubricate via the points provided for thispurpose (lubricating nipple, opened cou-pling) in accordance with the maintenancedata table; see ⇒ Chapter "Maintenancedata table", P. 6-336.

– Grease the supporting surface for thetow-bar eye.

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6210_900-002

Maintenance for trucks used in coldstores– On trucks used in cold stores (variant),check all rollers and chains in the lift mastfor ease of movement once a week.

6321_003-091

1

2

Maintaining the heater– Loosen the fixing screw (1) and remove thecover (2).

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6321_003-092

3

– Check the filter mat (3) for soiling.

If the filter mat is grey in colour, replace it.

NOTE

Change the filter mat at least every 2 months.

6321_003-093

4

– Clean the fresh-air inlet (4) of dust and dirt.

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Maintenance 61000-hour maintenance/annual maintenance

1000-hour maintenance/annual maintenanceOther tasks– Perform all maintenance work; see the"Maintenance" chapter.

6321_003-030

1

2

Checking the cable connections– Check that the pump motor feed cable(1) and traction motor feed cable (2) aresecurely attached, in good condition andinsulated.

NOTE

Oxidised connections and brittle cables resultin voltage drops and cause malfunctions.

– Remove oxidised connections and replacebrittle cables.

Checking the function of the batterycover sensor– Open the battery cover; see ⇒ Chap-ter "Opening/closing the batterycover", P. 5-280.

– Switch on the key switch; see ⇒ Chap-ter "Switching on the key switch", P. 5-81.

56338011803 EN - 10/2016 363

6 Maintenance1000-hour maintenance/annual maintenance

6327_900-061

1

5 mm

When the battery cover sensor (1) is func-tioning correctly, the message CLOSE THEDOOR will appear in the display.

– If the message CLOSE THE DOOR appearsin the display, close the battery cover.

The message CLOSE THE DOOR disappears.

– If the message CLOSE THE DOOR does notappear in the display, check that the settingdimension between the sensor and lock is5 mm, and adjust if necessary.


6327_003-045

1

Checking the hydraulic oil level of thehydraulic battery carrier

WARNING

Hydraulic oils are hazardous to your health and areunder pressure during operation.– Note safety regulations for working with hydrau-

lic oils; see ⇒ Chapter "Hydraulic fluid", P. 3-40.

Checking the hydraulic oil level– Park the forklift truck on level ground.

– Remove the battery (see ⇒ Chapter "Re-placing the battery with the hydraulic bat-tery carrier", P. 5-301) and place it next tothe truck so that the battery male connectorcan be inserted again.

The minimum distance between the batteryand the truck should be > 0.5 m. This is toensure that the hydraulic battery carrier pushbuttons can be accessed.

– Connect the battery plug.

364 56338011803 EN - 10/2016


WARNING

If the battery carrier is not at a sufficient safetydistance from mechanical components when it isactuated hands or feet can be crushed. There isrisk of injury!– Actuating beyond the carrier is prohibited.– It is not permitted to walk on the battery holder

plate.

– Retract the hydraulic battery carrier.

– Withdraw sealing plug (1) through theopening in the mounting plate.

The oil level must lie between 65 and 70mm when measured from the base of thecontainer.

– If the oil level is below the required level,top up the hydraulic oil via the filler neckaccording to the maintenance data table(see ⇒ Chapter "Maintenance data ta-ble", P. 6-336).

NOTE

Use a funnel.

– Screw sealing plugs (1) back in.

– Reinstall the battery.

ENVIRONMENT NOTE

Carefully collect up any spilled oil and disposeof it in an environmentally friendly manner.

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Lubricating the slide elements

2

6321_003-124

6321_003-125

3

Lubricating the slide elements– Extend the battery with the hydraulicbattery carrier and remove the battery, see⇒ Chapter "Replacing the battery with thehydraulic battery carrier", P. 5-301.

– Remove dirt and contaminated lubricantresidues.

– Lubricate the slide elements and guide rails(2) and (3) in accordance with the mainte-nance data table (see ⇒ Chapter "Mainte-nance data table", P. 6-336.

– Reinstall the battery.

Oiling the catch rails

WARNING

Risk of injury!If the battery carrier is not at a sufficiently safetydistance from mechanical components when it isactuated, hands or feet may be crushed.– Actuating beyond the battery carrier is prohibi-

ted.– It is not permitted to walk on the battery holder

plate.

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WARNING

Risk of injury!If the battery carrier is actuated while maintenancework is being carried out, hands or feet may becrushed.– De-energise the truck before performing mai-

ntenance work.

WARNING

Risk of crushing!If the support rollers swing away when the batteryis inserted, the battery carrier with the battery canland on feet.If the catch rails are not clean and are insufficientlyoiled, there is no guarantee that the support rollerswill lock correctly.Toensure that theoil is evenly distributedand to testthe functionality, fully retract and then fully extendthe battery carrier once after the oiling is complete.The support rollers must be swung out fully andlocked in position after lubrication.

NOTE

The catch rails of the support rollers are loca-ted beneath the battery carrier. If necessaryuse a mirror to gain a better view.

– Park the forklift truck on level ground.

6210_003-007

– Remove the battery, see "Replacing thebattery with the hydraulic battery carrier".

– Place the battery next to the truck so that thebattery male connector can be reinserted.

The minimum distance between the batteryand the truck must be > 0.5 m. This distanceensures that the hydraulic battery carrieractuation buttons can be accessed.


– Retract the battery carrier until the sup-port rollers are directly underneath (thebattery carrier is then extended by approx.300 mm).

– Pull out the switch key.

– Push the emergency off switch.


– Remove any dirt from the catch rails.

56338011803 EN - 10/2016 367


6210_003-049_V2

– Lubricate the catch rails with oil accordingto the maintenance data table - do not usegrease!


– Pull the emergency off switch.


– Retract the battery carrier fully and thenextend again.

WARNING

Risk of crushing!The support rollers must be swung out fully andlocked in position after lubrication.

– Check that the support rollers are swung allthe way out and are locked in position.

– If the support rollers are fully swung out andlocked, reinstall the battery.

– If the support rollers do not swing outcorrectly or are not in the locked position,inform your authorised service centre.

6321_003-020

Checking the lift cylinders andconnections for leaks

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.

368 56338011803 EN - 10/2016


6210_842-002

1

23

Checking fork arms– Inspect the fork arms (1) for any visibledeformation. The wear must not amount tomore than 10% of the original thickness.

CAUTION

Worn fork arms should always be replaced in pairs.

– Check the securing mechanism (3) forproper operation.

– The locking screw (2) that prevents dislodg-ing must be present.

Checking the reversible fork arms

NOTE

This check is only required for reversible forkarms (variant).

– Check the outside of the fork bend (1) forcracks. Contact your service centre.

56338011803 EN - 10/2016 369


6327_003-026

Checking the double pedal– Remove the floorplate.

– Check that the support and springs of thedouble pedal mechanism are securelypositioned.

– Check that all screws are sealed withlocking varnish.

Checking the battery changeoverframe– The screw joints and welded seams ofthe battery changeover frame must besubjected to a visual inspection.

370 56338011803 EN - 10/2016

7

Technical data

7 Technical dataDimensions

Dimensions

1 Seat is adjustable ±90 mm 2 Fork spacing is adjustable

372 56338011803 EN - 10/2016

Technical data 7Dimensions

NOTE

Measurements h1, h3, h4, h6 and b1 arecustomised and can be taken from the orderconfirmation.

Centre of gravity "S" (distance measuredfrom the front axle)

RX60-25 (6345) 774 mm

RX60-25/600 (6346) 774 mm

RX60-25L (6347) 842 mm

RX60-25L/600 (6348) 842 mm

RX60-30 (6353) 823 mm

RX60-30L (6354) 830 mm

RX60-30L/600 (6355) 830 mm

RX60-35 (6356) 892 mm

NOTE

The specified centre of gravity "S" relatesto trucks with standard equipment. If, forexample, the truck is equipped with a differentlift mast, attachment or driver protectionstructure, this value is only a guide value. Ifnecessary, the centre of gravity "S" must bedetermined on an individual basis for eachtruck.

56338011803 EN - 10/2016 373

7 Technical dataVDI datasheet for RX60-25 and RX60-25/600

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

NOTE

This VDI datasheet specifies only the techni-cal values of the truck version with standardequipment. Different tyres, lift masts, additio-nal units etc. may produce different values.

Characteristics

Model RX60-25 RX60-25/600

Type number 6345 6346

Manufacturer STILL GmbH STILL GmbH

Drive Electric Electric

Operation Seated Seated

Rated capacity/load Q (kg) 2500 2500

Load centre of gravity distance c (mm) 500 600

Load distance x (mm) 445 450

Wheelbase y (mm) 1595 1595.

Weights

Model RX60-25 RX60-25/600


Net weight including battery kg 4585 4840

Axle load with front load kg 6287 6502

Axle load with rear load kg 798 838

Axle load without front load kg 2306 2356

Axle load without rear load kg 2279 2484.

Wheels, chassis frame

Model RX60-25 RX60-25/600


Tyres SE SE

Front tyre size 225/75-10(23x9-10)

225/75-10(23x9-10)

374 56338011803 EN - 10/2016

Technical data 7VDI datasheet for RX60-25 and RX60-25/600

Model RX60-25 RX60-25/600


Rear tyre size 180/70-8(18x7-8)

180/70-8(18x7-8)

Number of front wheels (x = driven) 2x 2x

Number of rear wheels (x = driven) 2 2

Front track width b10 (mm) 992 992

Rear track width b11 (mm) 900 900.

Basic dimensions

Model RX60-25 RX60-25/600


Tilt of lift mast/fork carriage, forwards Degrees 5 5

Tilt of lift mast/fork carriage, backwards1 Degrees 7 7

Height with lift mast retracted h1 (mm) 2200 2200

Free lift h2 (mm) 160 160

Lift2 h3 (mm) 3020 3020

Height with lift mast extended h4 (mm) 3650 3800

Height above overhead guard h6 (mm) 2210 2210

Seat height in relation to SIP h7 (mm) 1262 1262

Coupling height h10 (mm) 485 / 365 485 / 365

Total length l1 (mm) 3353 3558

Length including fork back l2 (mm) 2353 2358

Total width b1 (mm) 1199 1199

Fork arm thickness s (mm) 40 45

Fork arm width e (mm) 100 100

Fork arm length l (mm) 1000 1200Fork carriage according to ISO 2328,class/form A, B ISO II A ISO II A

Fork carriage width b3 (mm) 1040 1040

Ground clearancewith load under lift mast m1 (mm) 125 125

1 Applies to telescopic, NiHo and triple lift masts.2 The specified nominal lift takes into account the tyre deflection and tolerances of the tyre diameter.

56338011803 EN - 10/2016 375

7 Technical dataVDI datasheet for RX60-25 and RX60-25/600

Model RX60-25 RX60-25/600


Ground clearance at centre of wheelbase m2 (mm) 125 125Aisle width for pallet 1000x1200 cross-wise3

Ast (mm) 3678 36834

Aisle width for pallet 800x1200 length-wise5

Ast (mm) 3877 3882

Turning radius Wa (mm) 2032 2032

Smallest pivot point distance b13 (mm) 539 539.

Performance data

Model RX60-25 RX60-25/600


Driving speed with load km/h 19 19

Driving speed without load km/h 20 20

Lifting speed with load m/s 0.53 0.52

Lifting speed without load m/s 0.55 0.55

Lowering speed with load m/s 0.54 0.54

Lowering speed without load m/s 0.45 0.45

Tractive force with load kg 8000 7950

Tractive force without load kg 8110 8060

Max. tractive force with load kg 17,440 17,420

Max. tractive force without load kg 17,220 17,090

Climbing capability with load % 21.3 20.4

Climbing capability without load % 29.5 29.1

Max. climbing capability with load % 25.5 24.0

Max. climbing capability without load % 29.7 28.3

Acceleration time with load s 4.5 4.6

Acceleration time without load s 4.2 4.2Service brake Electr./mech. Electr./mech.

.

3 Applies to telescopic, NiHo and triple lift masts.4 Does not take the protruding fork arms into consideration.5 Applies to telescopic, NiHo and triple lift masts.

376 56338011803 EN - 10/2016

Technical data 7VDI datasheet for RX60-25 and RX60-25/600

Electric motor

Model RX60-25 RX60-25/600


Traction motor, power rating S3 60 min kW 15 15

Lift motor, power rating at 15% ED kW 16.3 16.3Battery in accordance with DIN43531/35/36 A, B, C, no DIN 43536 A DIN 43536 A

Battery voltage U (V) 80 80

Nominal capacity K5 K5 (Ah) 560 - 620 560 - 620

Battery weight kg 1558 1558Energy consumption: 60 VDI workingcycles/hour kWh/h 6.7 6.9

.

Other

Model RX60-25 RX60-25/600


Working pressure for attachments bar 250 250

Oil flow for attachments l/min 30 30Sound pressure level LpAZ (driver’scompartment)6 dB (A) < 70 < 70

Human vibration: acceleration in accor-dance with EN 13059 m/s2 < 0.7 < 0.7

Tow coupling, DIN type/model Bolt Bolt.

6 Without cab. Values with cab differ.

56338011803 EN - 10/2016 377

7 Technical dataVDI datasheet for RX60-25L and RX60-25L/600

VDI datasheet for RX60-25Land RX60-25L/600

NOTE


Key data

Model RX60-25L RX60-25L/600









Weight











Tyres SE SE

Front tyre size 225/75-10(23x9-10)

225/75-10(23x9-10)

378 56338011803 EN - 10/2016

Technical data 7VDI datasheet for RX60-25L and RX60-25L/600




180/70-8(18x7-8)





Basic dimensions



Tilt of lift mast/fork carriage, forwards Degree 5 5

Tilt of lift mast/fork carriage, backwards7 Degree 7 7



Lift8 h3 (mm) 3020 3020










Fork arm length l (mm) 1000 1200Fork carriage according to ISO 2328,class/form A, B ISO II A ISO II A


Ground clearance with load under lift mast m1 (mm) 125 125


56338011803 EN - 10/2016 379





Ast (mm) 3830 383510


Ast (mm) 4030 4035



Performance data











Max. tractive force with load kg 17390 17420

Max. tractive force without load kg 17210 17130






Acceleration time without load s 4.2 4.2Service brake electr./mech. electr./mech.

.


380 56338011803 EN - 10/2016


Electric motor








.

Other




Oil flow for attachments l/min 30 30Sound pressure level LpAZ (driver’s com-partment)12 dB (A) < 70 < 70




56338011803 EN - 10/2016 381

7 Technical dataVDI datasheet for RX60-30 and RX60-35

VDI datasheet for RX60-30and RX60-35

NOTE


Characteristics

Model RX60-30 RX60-35









Weights











Tyres SE SE

Front tyre size 250/60-12(23x10-12) 315/45-12

382 56338011803 EN - 10/2016

Technical data 7VDI datasheet for RX60-30 and RX60-35




180/70-8(18x7-8)





Basic dimensions







Lift14 h3 (mm) 3020 3020










Fork arm length l (mm) 1000 1000Fork carriage according to ISO 2328,class/form A, B ISO III A ISO III A


Ground clearance with load under lift mast m1 (mm) 125 125


56338011803 EN - 10/2016 383

7 Technical dataVDI datasheet for RX60-30 and RX60-35




Ast (mm) 3760 3879


Ast (mm) 3960 4079



Performance data



















.

15 Applies to telescopic, NiHo and triple lift masts.16 Applies to telescopic, NiHo and triple lift masts.

384 56338011803 EN - 10/2016

Technical data 7VDI datasheet for RX60-30 and RX60-35

Electric motor








.

Other








56338011803 EN - 10/2016 385


VDI datasheet for RX60-30Land RX60-30L/600

NOTE


Characteristics










Weights











Tyres SE SE

Front tyre size 250/60-12(23x10-12) 315/45-12

386 56338011803 EN - 10/2016





180/70-8(18x7-8)





Basic dimensions







Lift19 h3 (mm) 3020 3020










Fork arm length l (mm) 1000 1200Fork carriage according to ISO 2328,class/form A, B ISO III A ISO III A


Ground clearancewith load under lift mast m1 (mm) 125 125


56338011803 EN - 10/2016 387





Ast (mm) 3850 385021


Ast (mm) 4050 4050



Performance data



















.


388 56338011803 EN - 10/2016


Electric motor








.

Other








56338011803 EN - 10/2016 389

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.

390 56338011803 EN - 10/2016

Technical data 7Battery specifications

Battery specifications

CAUTION

The battery weight and the battery dimensionsaffect the stability of the truck.When replacing the battery, the weight ratiosmust not be changed. The battery weight mustremain within the weight range specified on thenameplate. The location of ballast weightsmust notbe changed. The bottom of the battery tray must beclosed.– Use batteries that meet DIN standards.– Do not change the position of ballast weights.– Check the battery weight against the information

on the nameplate.– Only use a battery tray that is closed at the

bottom.

NOTE

Battery specifications according toDIN 43536;cells in accordancewith DINEN60254-2, 80 Vcircuit B.

– The battery weight can be found on thenameplate of the battery.

RX60-25 (6345), RX60-25/600 (6346), RX60-30 (6353)

Battery compartment dimensions [mm] TrayBatterydesignation

Capacity[Ah]

Depth Width Height

4 PzV 480 4804 PzW 560HAWKER®

wf 200plus560

4 PzS 560 560

4 PzS 620 620

4 CSM 640 640TENSOR®

TCSM 1235 640

1028 711 784 234

.

56338011803 EN - 10/2016 391

7 Technical dataBattery specifications

RX60-25L (6347), RX60-25L/600 (6348), RX60-30L (6354), RX60-30L/600 (6355),RX60-35 (6356)

Battery compartment dimensions [mm] TrayBatterydesignation

Capacity[Ah]

Depth Width Height


wf 200plus560

4 PzS 560 560

4 PzS 620 620

4 CSM 640 640

1028 711 784 234


wf 200plus700

5 PzS 700 700

5 PzS 775 775

5 CSM 800 800TENSOR®TCSM 1620 840

1028 855 784 235

NOTE

When converting to TENSOR® batteries, themaximum speed of the truck must be limitedto 17 km/h for technical reasons. Contactthe authorised service centre regarding thismatter.

392 56338011803 EN - 10/2016

Technical data 7Fuse assignment

Fuse assignment

12 3 4 5 6 7 8

910

111213

14

6210_604-002

Fuse assignment standard equip-ment

1 Main fuse F01 400 A

2 Heating system F22 50 A

3 Voltage converter F21 20 A

4 CPP rear F24 10 A

5 Option board, solenoid valve on the attachment F23 10 A

6 CPP/RPP roof F26 25 A

7 CPP/RPP seat F27 25 A

8 MMS option board F29 15 A

9 CPP/RPP front F28 10 A

10 Proportional technology F25 10 A

11 U4 voltage converter F15 10 A

Solenoid valve on attachment F15 10 A

12 U1 voltage converter F14 15 A

U1/U2 voltage converter F14 30 A

48 V working spotlight F14 15 A

13 SU/MCU F11 10 A

14 Horn F12 10 A.

56338011803 EN - 10/2016 393

7 Technical dataFuse assignment

8

9

0

6

7

4

2

13

5

F1 F2

7312_003-042

%75

h

2

234,7

12:15

12 3

Fuse assignment equipment vari-ants

1 5th hydraulic function 24/48 V F1 10 A

2 Variant (e.g. MMS) F3 10 A

3 Variant (e.g. light) F2 10 A.

394 56338011803 EN - 10/2016

Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 91Defining the driver PIN . . . . . . . . . . . . 87Entering the access code . . . . . . . . . 85Selecting the driver PIN . . . . . . . . . . . 88

Access authorisation with PIN code . . . . 84Accessories . . . . . . . . . . . . . . . . . . . . . . . 4Accident recorder . . . . . . . . . . . . . . . . . 207Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 112Joystick 4Plus version . . . . . . . . . . 111Mini-console version . . . . . . . . . . . . 112Mini-lever version . . . . . . . . . . . . . . 111Multiple-lever version . . . . . . . . . . . 110

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 76Adjusting the fork . . . . . . . . . . . . . . . . . 158Adjusting the steering column . . . . . . . . . 77After washing . . . . . . . . . . . . . . . . . . . . 323

AttachmentsAssembly . . . . . . . . . . . . . . . . . . . . 170Controlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 179Controlling using multi-lever

operation . . . . . . . . . . . . . . . . . . 176Controlling using the double

mini-lever and the 5th function . . 181Controlling using the four-way

mini-lever and the 5th function . . 189Controlling using the three-way

mini-lever and the 5th function . . 185Controlling via the joystick 4Plus . . . 191Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 187Controlling with a triple mini-lever . . . 183Controlling with fingertip . . . . . . . . . 193Controlling with fingertip and

5th function . . . . . . . . . . . . . . . . 194Controlling with multi-lever

operation and the 5th function. . . . . . . . . . . . . . . . . . . . . . . . . 177

General controlling . . . . . . . . . . . . . 174Mounting . . . . . . . . . . . . . . . . . . . . 171Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 172Special risks . . . . . . . . . . . . . . . . . . . 18Taking up a load . . . . . . . . . . . . . . . 199

Automatic lift cut out . . . . . . . . . . . . . . . 129Automatic tow coupling . . . . . . . . . . . . 219

Coupling RO*243 . . . . . . . . . . . . . . 221Coupling RO*244 A . . . . . . . . . . . . . 223Coupling RO*245 . . . . . . . . . . . . . . 225Coupling RO*841 . . . . . . . . . . . . . . 226Uncoupling RO*243 . . . . . . . . . . . . 222Uncoupling RO*244 A . . . . . . . . . . . 224Uncoupling RO*245 . . . . . . . . . . . . 226Uncoupling RO*841 . . . . . . . . . . . . 227

Axle stub nutsChecking the tightening torque . . . . 351

56338011803 EN - 10/2016 395

Indexg

BBattery

Changing the battery type . . . . . . . . 292Charging . . . . . . . . . . . . . . . . . . . . . 287Charging to equalise . . . . . . . . . . . . 290Charging with the battery charging

flap . . . . . . . . . . . . . . . . . . . . . . 308Check interlock . . . . . . . . . . . . . . . . 344Checking . . . . . . . . . . . . . . . . . . . . 352Checking condition, acid level and

acid density . . . . . . . . . . . . . . . . 286Checking the changeover frame . . . 370Checking the charge status . . . . . . . 287Disposal . . . . . . . . . . . . . . . . . . . . . . 11Maintaining . . . . . . . . . . . . . . . . . . . 284Safety regulations . . . . . . . . . . . . . . 277

Battery acid . . . . . . . . . . . . . . . . . . . . . . 41Battery cover

Check interlock . . . . . . . . . . . . . . . . 344Battery specifications . . . . . . . . . . . . . . 391Battery transport with crane . . . . . . . . . 296Before taking up load . . . . . . . . . . . . . . 153Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 245Functional description . . . . . . . . . . . 243Switching off . . . . . . . . . . . . . . . . . . 244Switching on . . . . . . . . . . . . . . . . . . 244

CCab

Open door . . . . . . . . . . . . . . . . . . . 208Opening the side windows . . . . . . . . 209Operating the interior lighting . . . . . . 210Operating the rear window heating . . 211

CE labelling . . . . . . . . . . . . . . . . . . . . . . . 2Changes to the truck . . . . . . . . . . . . . . . 29Changing the drive direction . . . . . . . . . 114

Dual-pedal version . . . . . . . . . . . . . 116Changing the fork arms . . . . . . . . . . . . 146Changing the password . . . . . . . . . . . . . 91Checking fork arms . . . . . . . . . . . . . . . 369Checking the cable connections . . . . . . 363

Checking the charge status . . . . . . . . . 287Checking the double pedal . . . . . . . . . . 370Checking the driver’s seat . . . . . . . . . . 347Checking the emergency off function . . 100Checking the function of the battery

cover sensor . . . . . . . . . . . . . . . 363Checking the lift cylinders and

connections for leaks . . . . . . . . . 368Checking wheel fastenings . . . . . . . . . . 349Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 196Cleaning the electrical system . . . . . . . 321Cleaning the truck . . . . . . . . . . . . . . . . 319Cleaning the windows . . . . . . . . . . . . . 323Climbing into the truck . . . . . . . . . . . . . . 78Climbing out of the truck . . . . . . . . . . . . . 78Clipboard . . . . . . . . . . . . . . . . . . . . . . . 215Closing the cab door . . . . . . . . . . . . . . . 209Closing the side windows . . . . . . . . . . . 209Cold store application

Batteries . . . . . . . . . . . . . . . . . . . . . 230Types of application . . . . . . . . . . . . 229

Condition of the roadways . . . . . . . . . . 107Connecting the battery male connector . . 80Consumables . . . . . . . . . . . . . . . . . . . . 39

Disposal . . . . . . . . . . . . . . . . . . . . . . 42Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 41Safety information for handling oils . . . 39Safety information for hydraulic fluid . . 40

Contact details . . . . . . . . . . . . . . . . . . . . . ICopyright and trademark rights . . . . . . . . . 6Coupling pin in the counterweight . . . . . 217Crane loading . . . . . . . . . . . . . . . . . . . 267

Determining the loading weight . . . . 267Hooking on the lifting straps . . . . . . . 268

Curve Speed Control . . . . . . . . . . . . . . 128

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 33Danger area . . . . . . . . . . . . . . . . . . . . 158Danger to employees . . . . . . . . . . . . . . . 23

396 56338011803 EN - 10/2016

Indexg

Declaration of conformity . . . . . . . . . . . . . 3Defects . . . . . . . . . . . . . . . . . . . . . . . . . 33Defining the driver PIN . . . . . . . . . . . . . . 87Definition of directions . . . . . . . . . . . . . . . 9Dimensions . . . . . . . . . . . . . . . . . . . . . 372Dimensions of roadways . . . . . . . . . . . 105Direction indicators . . . . . . . . . . . . . . . 202

Fingertip version . . . . . . . . . . . . . . . 203Mini-console version . . . . . . . . . . . . 203Mini-lever version . . . . . . . . . . . . . . 202

Disconnecting the battery maleconnector . . . . . . . . . . . . . . . . . 283

Display and operating unitAdditional indicators . . . . . . . . . . . . 234Adjusting the displays . . . . . . . . . . . 235Configure Blue Q . . . . . . . . . . . . . . . 245Indicators . . . . . . . . . . . . . . . . . . . . 232

Display messagesDisplay content . . . . . . . . . . . . . . . . 247Drive-specific . . . . . . . . . . . . . . . . . 259General . . . . . . . . . . . . . . . . . . . . . 250

Display operating unit . . . . . . . . . . . . . . . 52Resetting the daily kilometres . . . . . 240Setting the date . . . . . . . . . . . . . . . . 240Setting the language . . . . . . . . . . . . 241Setting the time . . . . . . . . . . . . . . . . 240Standard displays . . . . . . . . . . . . . . 232

Display symbols . . . . . . . . . . . . . . . . . . 235Auxiliary equipment soft key

functions . . . . . . . . . . . . . . . . . . 237Error messages . . . . . . . . . . . . . . . 237Menu navigation soft key functions . . 238Numeric keypad . . . . . . . . . . . . . . . 239Operating messages . . . . . . . . . . . . 236Status LEDs . . . . . . . . . . . . . . . . . . 238Warning messages . . . . . . . . . . . . . 236

Display-operating unitStandard display elements . . . . . . . . 83

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 11Components . . . . . . . . . . . . . . . . . . . 11

Documentation scope . . . . . . . . . . . . . . . 5

Double mini-lever . . . . . . . . . . . . . . . . . . 56Lifting/lowering the fork carriage . . . 140Tilting the lift mast . . . . . . . . . . . . . . 140

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 27

Driver’s cabUse . . . . . . . . . . . . . . . . . . . . . . . . . 98

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 27Driving

on ascending and descendingslopes . . . . . . . . . . . . . . . . . . . . 167

Driving lightsSwitching on and off . . . . . . . . . . . . 200

Driving on gradients . . . . . . . . . . . . . . . 106Driving on lifts . . . . . . . . . . . . . . . . . . . 167Driving on loading bridges . . . . . . . . . . 169

EEC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 3

Effects on additional consumers . . . . . . 243Electric parking brake

Emergency operation . . . . . . . . . . . 275Emergencies

Emergency operation of the electricparking brake . . . . . . . . . . . . . . . 275

Truck tipping over . . . . . . . . . . . . . . 272Using the emergency hammer . . . . . 273

Emergency hammer . . . . . . . . . . . . . . . 273Emergency lowering . . . . . . . . . . . . . . 273Emergency shutdown . . . . . . . . . . . . . 271Emissions . . . . . . . . . . . . . . . . . . . . . . . 43

Battery . . . . . . . . . . . . . . . . . . . . . . . 45Noise emissions . . . . . . . . . . . . . . . . 43Vibrations . . . . . . . . . . . . . . . . . . . . . 44

Entering the access code . . . . . . . . . . . . 85Ergonomic dimensions . . . . . . . . . . . . . 390Error code table . . . . . . . . . . . . . . . . . . 247Example . . . . . . . . . . . . . . . . . . . . . . . 154

FFilling the washer system . . . . . . . . . . . . 70

56338011803 EN - 10/2016 397

Indexg

Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 60Lifting/lowering the fork carriage . . . 145Tilting the lift mast . . . . . . . . . . . . . . 145

Fitting attachments . . . . . . . . . . . . . . . 170FleetManager . . . . . . . . . . . . . . . . . . . 206

Accident recorder . . . . . . . . . . . . . . 207Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 35Fork extension . . . . . . . . . . . . . . . . . . . 148Four-way mini-lever . . . . . . . . . . . . . . . . 58

Lifting/lowering the fork carriage . . . 142Fuse assignment

Equipment variants . . . . . . . . . . . . . 394Standard equipment . . . . . . . . . . . . 393

FusesChecking . . . . . . . . . . . . . . . . . . . . 352Replacing . . . . . . . . . . . . . . . . . . . . 354

GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 2General view . . . . . . . . . . . . . . . . . . . . . 48

Driver’s compartment . . . . . . . . . . . . 50

HHandling gas springs and accumulators . 35Hazard areas . . . . . . . . . . . . . . . . . . . . 108Hazard warning system . . . . . . . . . . . . 201Hazards and countermeasures . . . . . . . . 20Heating system . . . . . . . . . . . . . . . . . . 212Hydraulic battery carrier

Checking the oil level . . . . . . . . . . . . 364Lubricating the slide elements . . . . . 366Oiling the catch rails . . . . . . . . . . . . 366

Hydraulic blocking function . . . . . . . . . . 138Releasing . . . . . . . . . . . . . . . . . . . . 138

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 40Hydraulic system

Checking for leaks . . . . . . . . . . . . . . 357Checking the oil level . . . . . . . . . . . . 356

IImpermissible use . . . . . . . . . . . . . . . . . 14

Information for carrying out mainte-nance . . . . . . . . . . . . . . . . . . . . 326

Maintenance timeframe . . . . . . . . . . 327Information symbols . . . . . . . . . . . . . . . . . 6Insulation testing . . . . . . . . . . . . . . . . . . 37

Drive battery test values . . . . . . . . . . 38Truck test values . . . . . . . . . . . . . . . . 38

Insurance cover on company premises . . 29Interior lighting . . . . . . . . . . . . . . . . . . . 210Issue date of the operating instructions . . . 6

JJacking up . . . . . . . . . . . . . . . . . . . . . . 340Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 59

Fork-carriage sideshift . . . . . . . . . . . 144Lifting/lowering the fork carriage . . . 143Tilting the lift mast . . . . . . . . . . . . . . 143

LLashing . . . . . . . . . . . . . . . . . . . . . . . . 264Lift cut out

Automatic . . . . . . . . . . . . . . . . . . . . 129Lift mast

Lubricating the roller track . . . . . . . . 358Removing . . . . . . . . . . . . . . . . . . . . 342Securing against falling off . . . . . . . . 342Securing against tilting backwards . . 341

Lift mast versionsHi-Lo lift mast . . . . . . . . . . . . . . . . . 135Triplex lift mast . . . . . . . . . . . . . . . . 136

Lift mast vertical position . . . . . . . . . . . 130Automatic approach . . . . . . . . . . . . 132Calibrating . . . . . . . . . . . . . . . . . . . 134Description . . . . . . . . . . . . . . . . . . . 130Display . . . . . . . . . . . . . . . . . . . . . . 132Possible restrictions . . . . . . . . . . . . 134Run-in to end stops . . . . . . . . . . . . . 132Tilting the lift mast backwards . . . . . 133Tilting the lift mast forwards . . . . . . . 133

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 340

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Lifting systemControlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 140Controlling using a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 142Controlling using a triple mini-lever . . 141Controlling using the joystick 4Plus . 143Controlling with the fingertip

console . . . . . . . . . . . . . . . . . . . 145Multi-lever . . . . . . . . . . . . . . . . . . . . 139Operating devices . . . . . . . . . . . . . . 137

LightingSwitching on and off . . . . . . . . . . . . 200

List of abbreviations . . . . . . . . . . . . . . . . . 7Load

Picking up . . . . . . . . . . . . . . . . . . . . 160Setting down . . . . . . . . . . . . . . . . . . 165transporting . . . . . . . . . . . . . . . . . . 164

Load capacity . . . . . . . . . . . . . . . . . . . 153Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 322Load measurement . . . . . . . . . . . . . . . 154

Description . . . . . . . . . . . . . . . . . . . 154Execution . . . . . . . . . . . . . . . . . . . . 155Zero adjustment . . . . . . . . . . . . . . . 100

Lubricating the joints and controls . . . . . 344

MMaintaining the heater . . . . . . . . . . . . . 361Maintenance data table . . . . . . . . . . . . 336

Battery . . . . . . . . . . . . . . . . . . . . . . 336Controls/joints . . . . . . . . . . . . . . . . . 336Drive axle . . . . . . . . . . . . . . . . . . . . 338Electrical system . . . . . . . . . . . . . . . 336General lubrication points . . . . . . . . 336Hydraulic battery carrier . . . . . . . . . 337Hydraulic system . . . . . . . . . . . . . . 337Lift mast . . . . . . . . . . . . . . . . . . . . . 338Load chains . . . . . . . . . . . . . . . . . . 338Steering axle . . . . . . . . . . . . . . . . . . 337Tyres . . . . . . . . . . . . . . . . . . . . . . . 337Washer system . . . . . . . . . . . . . . . . 338

Maintenance for trucks used in coldstores . . . . . . . . . . . . . . . . . . . . 361

Maintenance personnel for batteries . . . 326Maintenance work without special

qualifications . . . . . . . . . . . . . . . 326Malfunctions during lifting mode . . . . . . 136Manual tow coupling

Coupling . . . . . . . . . . . . . . . . . . . . . 217Uncoupling . . . . . . . . . . . . . . . . . . . 218

Medical equipment . . . . . . . . . . . . . . . . . 34Message

! PARKING BRAKE OIL PRES-SURE . . . . . . . . . . . . . . . . . . . . 259

? VERTICAL POSITION . . . . . . . . . 254ACCELERATOR . . . . . . . . . . . . . . . 252APPLY HANDBRAKE . . . . . . . . . . . 251ARE YOU SURE ? . . . . . . . . . . . . . 256BRAKE SENSOR . . . . . . . . . . . . . . 252CLOSE THEDOOR . . . . . . . . . . . . 260CODEDENIED . . . . . . . . . . . . . . . . 252EMERGENCY SWITCH . . . . . . . . . 254LIFT HEIGHT . . . . . . . . . . . . . . . . . 260LOWER FORKS . . . . . . . . . . . . . . . 253MOT/GEN. TEMP. . . . . . . . . . . . . . 259NOT VALID . . . . . . . . . . . . . . . . . . . 259OVERHEATING . . . . . . . . . . . 258, 260PARKING BRAKE ACTIVE . . . . . . . 252PARKING BRAKE: APPLY

HANDBRAKE! . . . . . . . . . . . . . . 253REFERENCECYCLE . . . . . . . . . . . 254RELEASE PARKING BRAKE . . . . . 252SAFETY BELT . . . . . . . . . . . . . . . . 255SEAT SWITCH . . . . . . . . . . . . . . . . 256SERVICE BRAKE . . . . . . . . . . . . . . 251STEERING . . . . . . . . . . . . . . . . . . . 253SURVEILLANCE . . . . . . . . . . . . . . 259SWITCHOFF TRUCK? . . . . . . . . . . 252TILTING SPEED . . . . . . . . . . . . . . . 253

MessagesGeneral . . . . . . . . . . . . . . . . . . . . . 250

Mini console . . . . . . . . . . . . . . . . . . . . . . 61Misuse of safety systems . . . . . . . . . . . . 33

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MSG 65/MSG 75 driver’s seatAdjusting . . . . . . . . . . . . . . . . . . . . . 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

Multi-lever . . . . . . . . . . . . . . . . . . . . . . . 55Lifting/lowering the fork carriage . . . 139Tilting the lift mast . . . . . . . . . . . . . . 139

NNameplate . . . . . . . . . . . . . . . . . . . . . . . 64Neutral position . . . . . . . . . . . . . . . . . . 109

OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Opening the cab door . . . . . . . . . . . . . . 208Opening the side windows . . . . . . . . . . 209Opening/closing the battery cover . . . . . 280Operating company . . . . . . . . . . . . . . . . 26Operating devices for hydraulic and

traction functions . . . . . . . . . . . . . 54Operating materials

Quality and quantity . . . . . . . . . . . . 333Operating procedures . . . . . . . . . . . . . . . 9Operating the parking brake

when the truck is moving . . . . . . . . . 124Operating the service brake . . . . . . . . . 117Operating the signal horn . . . . . . . . . . . . 94Ordering spare parts andwearing parts . 333Overhead guard

Drilling . . . . . . . . . . . . . . . . . . . . . . . 32Roof loads . . . . . . . . . . . . . . . . . . . . 32Welding . . . . . . . . . . . . . . . . . . . . . . 32

OverviewAccessories . . . . . . . . . . . . . . . . . . . . 4Identification points . . . . . . . . . . . . . . 62

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 11

Parking brake . . . . . . . . . . . . . . . . . . . 118Electric parking brake . . . . . . . . . . . 120Mechanical parking brake . . . . . . . . 118

Parking the truck securely . . . . . . . . . . 313Personnel qualifications . . . . . . . . . . . . 326Picking up loads . . . . . . . . . . . . . . . . . . 157Place of use . . . . . . . . . . . . . . . . . . . . . . 15Procedure if truck tips over . . . . . . . . . . 272Production number . . . . . . . . . . . . . . . . 65Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 28Proper usage . . . . . . . . . . . . . . . . . . . . . 14Push-up roof window . . . . . . . . . . . . . . 215

QQuadruple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 142

RRadio . . . . . . . . . . . . . . . . . . . . . . . . . 211Rear window heating . . . . . . . . . . . . . . 211Recommissioning after storage . . . . . . 317Reducing speed when turning . . . . . . . 128Reducing speed with a raised load . . . . 109Replacing the battery

General information . . . . . . . . . . . . 292Using a change frame . . . . . . . . . . . 296using a forklift truck . . . . . . . . . . . . . 293with the hydraulic battery carrier . . . . 301

Resetting the daily kilometres . . . . . . . . 240Resetting the daily operating hours . . . . 240Residual dangers . . . . . . . . . . . . . . . . . . 17Residual risks . . . . . . . . . . . . . . . . . . . . 17Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 29Reversible fork arm

Checking . . . . . . . . . . . . . . . . . . . . 369Reversible fork arms . . . . . . . . . . . . . . 150Roadways . . . . . . . . . . . . . . 105, 107 – 108

Dimensions . . . . . . . . . . . . . . . . . . 105Driving on gradients . . . . . . . . . . . . 106

Rotating beacon . . . . . . . . . . . . . . . . . . 201

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Rules for roadways and the workingarea . . . . . . . . . . . . . . . . . . . . . . 107

SSafety devices . . . . . . . . . . . . . . . . . . . 340Safety inspection . . . . . . . . . . . . . . . . . . 37Safety regulations for handling the

batteryDamage to cables and battery male

connectors . . . . . . . . . . . . . . . . . 279Safety regulations for maintenance

General information . . . . . . . . . . . . 339Safety devices . . . . . . . . . . . . . . . . 340Set values . . . . . . . . . . . . . . . . . . . . 340Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 339Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 339Safety regulations for working on the lift

mast . . . . . . . . . . . . . . . . . . . . . 341Safety regulations when driving . . . . . . 103Safety regulations when handing loads . 152Safety regulations when handling the

battery . . . . . . . . . . . . . . . . . . . . 277Battery weight and dimensions . . . . 279Fire protection measures . . . . . . . . . 278Maintaining the battery . . . . . . . . . . 279Maintenance personnel . . . . . . . . . . 277

Schematic views . . . . . . . . . . . . . . . . . . . 9Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 95

Checking . . . . . . . . . . . . . . . . . . . . 346Cleaning . . . . . . . . . . . . . . . . . . . . . 347Fastening . . . . . . . . . . . . . . . . . . . . . 95Fastening on a steep slope . . . . . . . . 96Maintaining . . . . . . . . . . . . . . . . . . . 346Malfunction due to cold . . . . . . . . . . . 97Releasing . . . . . . . . . . . . . . . . . . . . . 97Replacement after an accident . . . . 347

Selecting the drive direction . . . . . . . . . 109Selecting the driver PIN . . . . . . . . . . . . . 88Set values . . . . . . . . . . . . . . . . . . . . . . 340Setting chocks . . . . . . . . . . . . . . . . . . . 263Setting the date . . . . . . . . . . . . . . . . . . 240

Setting the drive programme . . . . . . . . . 108Setting the language . . . . . . . . . . . . . . 241Setting the time . . . . . . . . . . . . . . . . . . 240Shutting down the truck . . . . . . . . . . . . 315Special risks . . . . . . . . . . . . . . . . . . . . . 18Stability . . . . . . . . . . . . . . . . . . . . . . . . . 18Standard display elements . . . . . . . . . . . 83Starting drive mode . . . . . . . . . . . . . . . 112

Dual-pedal version . . . . . . . . . . . . . 115Status LEDs . . . . . . . . . . . . . . . . . . . . 238Steering . . . . . . . . . . . . . . . . . . . . . . . . 127Steering axle

Checking . . . . . . . . . . . . . . . . . . . . 350Checking the lines for leaks . . . . . . . 351Lubrication . . . . . . . . . . . . . . . . . . . 350Servicing . . . . . . . . . . . . . . . . . . . . 350

Steering systemChecking for correct function . . . . . . . 99

Storing the truck . . . . . . . . . . . . . . . . . . 315StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 65Switching off the truck . . . . . . . . . . . . . 313Switching on the key switch . . . . . . . . . . 81

TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 372Three-waymini-lever . . . . . . . . . . . . . . . 57

Lifting/lowering the fork carriage . . . 141Topicality of the operating instructions . . . 6Towed load . . . . . . . . . . . . . . . . . . . . . 216Towing . . . . . . . . . . . . . . . . . . . . . . . . 265

Proper use . . . . . . . . . . . . . . . . . . . . 14Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 227Transport . . . . . . . . . . . . . . . . . . . . . . . 262Transporting pallets . . . . . . . . . . . . . . . 159Transporting suspended loads . . . . . . . 159Triple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 141Types of lift mast . . . . . . . . . . . . . . . . . 134

Telescopic mast . . . . . . . . . . . . . . . 135

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TyresSafety principles . . . . . . . . . . . . . . . . 33

UUnlocking the emergency off switch . . . . 81Use in cold stores . . . . . . . . . . . . . . . . . 229

Operation . . . . . . . . . . . . . . . . . . . . 230Using working platforms . . . . . . . . . . . . . 16

VValve cover

Installing . . . . . . . . . . . . . . . . . . . . . 343Removing . . . . . . . . . . . . . . . . . . . . 343

VariantsAccess authorisation with PIN code . . 84Accident recorder . . . . . . . . . . . . . . 207Automatic lift cut out . . . . . . . . . . . . 129Clamp locking mechanism . . . . . . . . 196Clipboard . . . . . . . . . . . . . . . . . . . . 215FleetManager . . . . . . . . . . . . . . . . . 206Fork extension . . . . . . . . . . . . . . . . 148Heating system . . . . . . . . . . . . . . . . 212Hi-Lo lift mast . . . . . . . . . . . . . . . . . 135Lift mast vertical position . . . . . . . . . 130Lifting systems . . . . . . . . . . . . . . . . 129Load measurement . . . . . . . . . . . . . 154Push-up roof window . . . . . . . . . . . . 215Radio . . . . . . . . . . . . . . . . . . . . . . . 211Reducing speed with a raised load . . 109Reversible fork arms . . . . . . . . . . . . 150Triplex lift mast . . . . . . . . . . . . . . . . 136Wheel chock . . . . . . . . . . . . . . . . . . 315Windscreen wiper/washer . . . . . . . . 206

VDI datasheetRX60-25 . . . . . . . . . . . . . . . . . . . . . 374RX60-25/600 . . . . . . . . . . . . . . . . . 374RX60-25L . . . . . . . . . . . . . . . . . . . . 378RX60-25L/600 . . . . . . . . . . . . . . . . 378RX60-30 . . . . . . . . . . . . . . . . . . . . . 382RX60-30L . . . . . . . . . . . . . . . . . . . . 386RX60-30L/600 . . . . . . . . . . . . . . . . 386RX60-35 . . . . . . . . . . . . . . . . . . . . . 382

Vertical lift mast positionChecking for correct function . . . . . . 102

View of functions and operations . . . . . . . . 9View of operating procedures . . . . . . . . . . 9Views of the display operating unit . . . . . 10Visual inspections . . . . . . . . . . . . . . . . . 68

WWarning regarding non-original parts . . . 32Wheel chock . . . . . . . . . . . . . . . . . . . . 315Wheels and tyres

Checking the condition . . . . . . . . . . . 71Checking the condition and wear of

the tyres . . . . . . . . . . . . . . . . . . . 348Checking wheel fastenings . . . . . . . 349Maintaining . . . . . . . . . . . . . . . . . . . 348

Windscreen wiper/washer . . . . . . . . . . 206Working at the front of the truck . . . . . . . 341Working on the electrical equipment . . . 339Working on the hydraulic equipment . . . 339Working spotlights

Automatically switching on/off . . . . . 205Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 205Manually switching on/off . . . . . . . . 204Switching on and off . . . . . . . . 200, 204

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 100

402 56338011803 EN - 10/2016

STILL GmbH

56338011803 EN – 10/2016

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