Originalinstructions Electricforklifttruck · Originalinstructions Electricforklifttruck RX50-10 RX50-13 RX50-15 RX50-16 5060 5061 5063 5065 5066 55048011501EN-12/2015

Original instructions

Electric forklift truck

RX50-10RX50-13RX50-15RX50-16

5060 5061 5063 5065 5066

55048011501 EN - 12/2015

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

55048011501 EN - 12/2015 I

Table of contentsg

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

Information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Issue date and topicality of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

2 IntroductionUse of 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

Essentials for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

55048011501 EN - 12/2015 III

Table of contentsg

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4 OverviewsGeneral view of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

General view of driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Operating devices and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Operating devices for hydraulic and traction functions . . . . . . . . . . . . . . . . . . . . . . . . . 55Multi-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Identification points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 66

IV 55048011501 EN - 12/2015

Table of contentsg

5 OperationChecks and operations prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Checking the condition of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Adjusting the GS15 driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the MSG 65/MSG 75 driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Climbing on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Connecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Shelf and cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Checking the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Zero adjustment of the load measurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 103

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Driveways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Setting the drive programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Special overhead guard for drive-in racks (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Actuating the drive direction switch, multiple-lever version . . . . . . . . . . . . . . . . . . . . . . 112Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 112Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 113Actuate the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 114Starting drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Starting drive mode, dual-pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Reducing speed when turning (Curve Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . 122

55048011501 EN - 12/2015 V

Table of contentsg

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Multi-lever lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 135Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 136Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 137Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 138Controlling the lifting system with the fingertip console . . . . . . . . . . . . . . . . . . . . . . . . . 140Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Working with loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Transport of swinging loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Picking up a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Driving on ascending and descending slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Working with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Controlling attachments using multi-lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Controlling attachments using multi-lever operation and the 5th function . . . . . . . . . . . 172Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 176Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178Controlling attachments using the three-waymini-lever and the 5th function . . . . . . . . . 180

VI 55048011501 EN - 12/2015

Table of contentsg

Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 182Controlling attachments using the four-way mini-lever and the 5th function . . . . . . . . . . 184Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186Controlling attachments using the joystick 4Plus and the 5th function . . . . . . . . . . . . . . 187Controlling the attachments with fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188Controlling attachments with fingertip and the 5th function . . . . . . . . . . . . . . . . . . . . . . 189Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Operation of additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Switching lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Switching direction indicators on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Accident recorder (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Tow coupling RO*230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Tow coupling RO*244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Cold store application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Operating the display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 222Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Soft key button for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . 223Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Effects on additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Screen content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

55048011501 EN - 12/2015 VII

Table of contentsg

EMERGENCY SWITCHmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230SEAT SWITCHmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230SAFETY BELTmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233APPLY HANDBRAKEmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234LOWER FORKSmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235REFERENCE CYCLEmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235SERVICE BRAKEmessage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Operation in special operating situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Behaviour in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Opening and closing the battery hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254Opening/closing the battery door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261Battery replacement using a bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262Battery transport with crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269Changing the battery using the internal roller channel . . . . . . . . . . . . . . . . . . . . . . . . . 270Battery replacement using an external roller channel . . . . . . . . . . . . . . . . . . . . . . . . . . 273Battery installation or battery replacement without onboard devices . . . . . . . . . . . . . . . 277Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Recommissioning after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

6 MaintenanceGeneral maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

VIII 55048011501 EN - 12/2015

Table of contentsg

Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Maintenance— 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 301Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Removing/installing the valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Removing/installing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Removing/installing the bottom plate for dual pedal operation (variant) . . . . . . . . . . . . . 313

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Checking the battery hood lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316Checking the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Servicing wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Checking the drive axle for oil level, leaks and general condition . . . . . . . . . . . . . . . . . . 320Checking the brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Checking the brake fluid level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Checking the battery condition, acid level and acid density . . . . . . . . . . . . . . . . . . . . . . 324Checking the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Changing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Maintenance for trucks used in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Maintaining the tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

1000-hour maintenance / Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Checking the cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Checking accelerator pedal and brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Checking the brake system for correct operation and leaks . . . . . . . . . . . . . . . . . . . . . 333Checking the dual pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

55048011501 EN - 12/2015 IX

Table of contentsg

Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 334Checking fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

7 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

VDI datasheet: RX50-10 and RX50-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

VDI datasheet: RX50-15 and RX50-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Battery specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

X 55048011501 EN - 12/2015

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 55048011501 EN - 12/2015

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

.

Accessories• Key for key switch (two pieces)• Hexagon socket wrench for emergencylowering (not in multi-lever operation)

55048011501 EN - 12/2015 3

1 ForewordInformation about documentation

Information about 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.

4 55048011501 EN - 12/2015

Foreword 1Information about 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.

55048011501 EN - 12/2015 5


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.

Abbreviation Meaning

°C Degrees Celsius

°F Degrees Fahrenheit

A Amperes

ABE Display operating unit

ArbSchG German labour protection law

BetrSichV German Ordinance on Industrial Safety and Health

BG Employers’ liability insurance association

BGG Employers’ liability insurance association act

BGR Employers’ liability insurance association ruleGerman SocialAccidentInsurance

Employers’ liability insurance association regulation

Approx. Approximately

CE Symbol that confirms conformity with the valid product-specific Europeandirectives

CEE International Commission on the Rules for the Approval of Electrical Equip-ment

cm Centimetres

6 55048011501 EN - 12/2015



cm3 Cubic centimetres

dB Decibels

DFÜ Remote data transmission

DIN German standard

EG European Community

EN European standard

FEM Fédération Européene de la Manutention

Fmax Maximum powerg Grams

GAA Industrial inspectorate

If applicable If applicable

GPRS General Packet Radio Service

h/d Hours per day (time driven each day in hours)

ID no. ID number

ISO International standard

kg Kilogramskg/m3 Kilograms per cubic metre

km/h Kilometres per hour

km/d Kilometres per day (kilometres driven each day)

kN Kilonewtons

kW Kilowatts

kWh/h Energy consumption

l Litres

l/h Litres per hour

l/min Litres per minute

LAN Local area network

LED Light emitting diode

Lp Sound pressure levelLpAZ Continuous sound pressure level in driver’s compartment

LSP Load centre of gravity

o.s. Or similar

m Metres

55048011501 EN - 12/2015 7



m/s Metres per second

m/s2 Metres per second squared

MAK Maximum workplace concentration

Max. Maximum

Min. Minimum

min Minutes

rpm Revolution(s) per minute

mm MillimetresN Newtons

Nm Newton metres

PIN Personal identification number

SE Superelastic

SIT Snap-in tyre for simplified assembly

StVZO German Road Traffic Licensing Regulations

t Tonnes

TRGS Technical Regulations for Hazardous Substances

a.s. And similar

V Volts

VDE Association for Electrical, Electronic & Information Technologies

VDI Association of German Engineers

VDMA German Engineering Federation

W Watts

WLAN Wireless local area networke.g. For example

.

8 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015

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.

55048011501 EN - 12/2015 11

1 ForewordEnvironmental considerations

12 55048011501 EN - 12/2015

2

Introduction

2 IntroductionUse of truck

Use of 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 55048011501 EN - 12/2015

Introduction 2Use of 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".

55048011501 EN - 12/2015 15

2 IntroductionUse of 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 55048011501 EN - 12/2015

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.

The 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

55048011501 EN - 12/2015 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 transportingswinging 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 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015



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

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015



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

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015

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 55048011501 EN - 12/2015

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

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015

Safety 3Essentials for safe operation

Essentials 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.

55048011501 EN - 12/2015 29

3 SafetyEssentials 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 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015


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

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015


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

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015

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 truck insulation must have sufficient insu-lation resistance. For this reason, insulationtesting in accordance with DIN EN 1175 andDIN 43539, VDE 0117 and VDE 0510must beconducted at least once a year.

NOTE

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

55048011501 EN - 12/2015 37

3 SafetySafety tests

Measuring the battery’s insulationresistance

NOTE

Nominal battery voltage < test voltage < 500V.

– Measure the insulation resistance with asuitable measuring device.

The insulation resistance can be consideredsufficient if it measures at least 500 /V for thenominal battery voltage against ground.

– Contact the authorised service centre.

Measuring the insulation resistance ofthe electrical system

NOTE

Nominal battery voltage < test voltage < 500V.

– Ensure that all voltage sources have beendisconnected from the circuit to be tested.

– Measure the insulation resistance with asuitable measuring device.

The insulation resistance can be consideredsufficient if it measures at least 1000 /V forthe nominal battery voltage against ground.

– Contact the authorised service centre.

38 55048011501 EN - 12/2015

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. 6-303).

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.

55048011501 EN - 12/2015 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 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 41


WARNING

Battery acid contains dissolvedsulphuric acid. This is corrosive.– When working with battery acid,always wear a protection suit andeye protection.

– When working with batteryacid, never wear a watch or anyjewellery.

– 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.

Brake fluid

WARNING

Brake fluid is poisonous!– Avoid swallowing. In the eventof swallowing, do not inducevomiting. Rinse out your mouththoroughly with water and ask adoctor for advice.

– Avoid aerosolisation and inha-lation. In the event of inhalation,seek fresh air. Ask a doctor for ad-vice if necessary.

42 55048011501 EN - 12/2015


WARNING

Brake fluid is hazardous to yourhealth!Brake fluid irritates the eyes andcan dry out the skin upon prolongedcontact.– Coat your hands with a protectiveskin cream prior to starting work.

– Avoid prolonged or intensiveskin contact. In the event of skincontact, clean the wetted skin withwater and soap, and subsequentlyapply a skin care product.

– Prevent contact with the eyes. Inthe event of contact with the eyes,wash out the affected eye(s) withclean water for ten minutes andthen ask a doctor for advice.

– Change clothing soiled with brakefluid as soon as possible.

CAUTION

Brake fluid is flammable!– Do not allow brake fluid to come into contact with

hot motor parts.– Smoking, fires and naked flames are prohibited.

CAUTION

Brake fluid has strong dissolving and colour-chan-ging properties.– Immediately rinse off any brake fluid that has

splashed on paint, clothing, and shoes withplenty of water

ENVIRONMENT NOTE

Brake fluid is a water pollutant!• Always store brake fluid in containerscomplying with the regulations..

• Do not spill brake fluid.• Spilt brake fluid must be removed immedia-tely using an oil binding agent and disposedof in accordance with regulations

• Dispose of old brake fluid according to theregulations.

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

55048011501 EN - 12/2015 43


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 thepurpose. Care must be taken to minimise anyenvironmental pollution.

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

– Neutralise any spilt battery acid immedi-ately.

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

44 55048011501 EN - 12/2015

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 levels:

Continuous sound pressure level in thedriver’s compartment

LpAZ

< 70 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


55048011501 EN - 12/2015 45

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

0.68 m/s2 0.204 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 atthe actual place of use in order to consider alladditional influences, such as driving route,intensity of use etc.

NOTE


46 55048011501 EN - 12/2015

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.

55048011501 EN - 12/2015 47

3 SafetyEmissions

48 55048011501 EN - 12/2015

4

Overviews

4 OverviewsGeneral view of truck

General view of truck

1

2

4

5

6

78

9

10

11

12

5060_003-094_V2

3

1 Lift mast2 Overhead guard3 Driver’s compartment4 Battery door5 Battery hood6 Connection for towing bracket / tow coupling

(optional)

7 Drive wheel8 Right-hand bottom plate9 Left-hand bottom plate10 Running axle11 Fork arms12 Lift cylinder

50 55048011501 EN - 12/2015

Overviews 4General view of truck

55048011501 EN - 12/2015 51

4 OverviewsGeneral view of driver’s compartment

General view of driver’s compartment

4

1 2 3 4

5

6

7

8

9

101112

13

14

15

5060_003-093_V2

1 Parking brake lever2 Steering wheel3 Switch key4 Display operating unit5 Document holder and storage location for

operating instructions6 Operating devices for hydraulic and traction

functions7 Emergency stop switch (only in multiple-

lever version)

8 Storage box9 Cup holder for bottles max. 1 l10 Battery hood handle11 Battery hood release12 Driver’s seat13 Accelerator pedal14 Brake pedal15 Signal horn foot switch

52 55048011501 EN - 12/2015

Overviews 4Operating devices and display elements

Operating devices and display elementsDisplay and operating unit

8

9

6

72

0

1

3

5

%75

2

90°

12:15

5060_003-087

12

3 4 5 6 7 8 9 10 11

12

13

14

15161718192021222324

25

26

1 Hazard warning system button2 Front windscreen wiper button3 Front working spotlight button4 Drive program selector button5 Rear working spotlight button6 Rear working spotlight symbol7 Not assigned8 Battery charge display (percent)9 Drive programme display (numerical)10 Left direction indicator light11 Forward travel display12 Right direction indicator light13 Malfunction display

14 Reverse travel display15 Steering position display (degrees)16 Time display (digital)17 Not assigned18 Rotating beacon display19 Not assigned20 Not assigned21 Not assigned22 Not assigned23 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 called upaccording to the menu navigation. For furtherinformation, see the "Operating the displayand operating unit" chapter.

55048011501 EN - 12/2015 53

4 OverviewsOperating devices and display elements

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

54 55048011501 EN - 12/2015


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

55048011501 EN - 12/2015 55


Multi-lever

5060_003-168

1 2 3 4

5

6

1 "Lift/lower" operating lever2 "Tilt" operating lever3 Operating lever for attachment (variant)

4 Operating lever for attachment (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.

56 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 57


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


58 55048011501 EN - 12/2015


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


55048011501 EN - 12/2015 59


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

60 55048011501 EN - 12/2015


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


55048011501 EN - 12/2015 61


7311_003-0561

2

1 Travel direction switch2 Direction indicator switch

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

62 55048011501 EN - 12/2015


55048011501 EN - 12/2015 63

4 OverviewsIdentification points

Identification pointsOverview

12

13

15

1

17

2 3 41718

16

42

10

11

8

84

5

13

5060_003-175_V2

4

8

DANGER

1216

13

15

3

10 11

DANGER

7

1

18

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

*

5

STILL Hamburg

Berzeliusstr. 10

22113 Hamburg

Tel.: 01804 / 784 55 24

Ihr STILL Service

Nächste Prüfung

7339

06

BATTERIESERVICE9

6

2

14

6

9

14

7

15

Zum Öffnen der Haube den FahrersitzZum Öffnen der Haube den Fahrersitzund die Armlehne ganz nach hintenund die Armlehne ganz nach hintenschieben und letztere zusätzlich inschieben und letztere zusätzlich inunterste Position bringenunterste Position bringen

To open the batteryhood the driver seatTo open the batteryhood the driver seatand the armrest must be movedand the armrest must be movedcompletely back and the last onecompletely back and the last onehas to be placed in the lowest positionhas to be placed in the lowest position

ACHTUNG - ATTENTION !ACHTUNG - ATTENTION !

ATCAssistance Truck Control

20xx

IDENT-NR. 0009381511

1

5

4

6

3

2

1

7

6

9

5

7

5

9

5

7

101 2

6

2

11 4

5

Regelmäßige Prüfung(FEM 4.004)

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

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung

5634

4391

019

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

64 55048011501 EN - 12/2015

Overviews 4Identification points

1 Decal information: Actions to be performedwhen replacing battery using a bridge(variant)

2 Decal information: AssistanceTruckControl3 Warning sign: Risk of short circuit due to

shearing4 Warning sign: Risk of crushing5 Warning sign: Cleaning electrical system

parts with water is forbidden6 Decal information: Actions to be performed

before opening the battery hood7 Decal information: Cold store application8 Decal information: Lifting gear attachment

point9 Decal information: Capacity rating plate10 Decal information: FEM test11 Decal information: Battery test

12 Decal information: Hydraulic oil tank13 Warning sign: Do not stand underneath the

fork/Do not stand on the fork14 Decal information: Nameplate15 Warning sign: Do not stand underneath the

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

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

17 Manufacturer’s label text18 Decal information: Caution/read operating

instructions/drive slowly with raised load






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.

55048011501 EN - 12/2015 65

4 OverviewsIdentification 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.

66 55048011501 EN - 12/2015

5

Operation

5 OperationChecks and operations prior to commissioning

Checks and operations 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 devices and

switches.– Do not change 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 start-up, ensure that the truck is safeto be operated:

• The fork arms must be secured againstlifting and shifting.

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

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

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

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

• Check the area under the truck for leakingconsumables.

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

68 55048011501 EN - 12/2015

Operation 5Checks and operations 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 door must be closed correctlyand the door lockmust be properly secured.

• The battery lock latches, the battery doorand the battery hood must not be damagedor deformed.

• The battery hood must be closed correctlyand the hood lockmust beproperly secured.

• The battery hood and battery door mustshow no noticeable damage (e.g. cracks orbreaks).

• 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

• 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.

55048011501 EN - 12/2015 69


WARNING

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

replaced by the authorised service centre.

DANGER

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

Filling the washer system

CAUTION

If there is no anti-freeze in the system, the washersystem can be damaged.Always use washer fluid containing anti-freeze.

NOTE

The washer system container is at the frontright, beneath the valve cover. The fillingopening is accessible from above

70 55048011501 EN - 12/2015


1

5060_003-150_V2

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

– Fill the windscreen washer container withwasher fluid containing anti-freeze ac-cording to the maintenance data table(see ⇒ Chapter "Maintenance data ta-ble", P. 6-303).

NOTE

Fill to a max. level of approx. 1 cm below thefiller neck.

– Close the filler cap.

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

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".

55048011501 EN - 12/2015 71


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".

Adjusting the GS15 driver’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.

72 55048011501 EN - 12/2015


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.

7094_003-007

12

3

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

– Shift the driver’s seat into the desiredposition.

– Release the lever and make sure that thedriver’s seat engages.

Adjusting the seat backrest– Turn the knob (2) to the right or left until theseat backrest is in the desired position.

Adjusting the seat suspension

NOTE

The driver’s seat is designed for people weig-hing between 50 kg and 120 kg. Dependingon the driver’s weight, three different weightclasses can be set for the seat (light, mediumand heavy).

NOTE

This adjustment should only be made whilethe seat is occupied.

– Push the lever (3) and hold.

– Move the lever to the desired weight class.

– Release the lever and make sure that itengages.

55048011501 EN - 12/2015 73


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 can resultin unintentional actuation of the steering or theoperating devices and thus cause uncontrolledmovements of the truck or load.– Do not adjust the seat or seat backrest while

driving.– Adjust the seat and 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 seat’s swivel area.

74 55048011501 EN - 12/2015


7094_003-0061

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

– 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 the lever (2) and hold.

– 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.

55048011501 EN - 12/2015 75


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 MSG 75 seat is equipped with electric airsuspension activated with an electric switchinstead of a lever (3).

– Fully extend 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 correct driver’s weight has been selectedwhen the arrow (4) is in the centre of theinspection window. A noticeable empty lift ontheweight adjusting lever shows that you havereached the minimum or maximum weightsetting.

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.

76 55048011501 EN - 12/2015


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.

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.

55048011501 EN - 12/2015 77


7331_342-001

3 1 2

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

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

– Tighten the star-grip handle by turning itclockwise.

– Check that the armrest is firmly attached.

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

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

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

– Check that the armrest is firmly attached.

78 55048011501 EN - 12/2015

Operation 5Commissioning

Commissioning

1

2

4

35060_003-164

Climbing on/off

WARNING

Risk of injury when climbing on and off the truck dueto slipping, hitting parts of the truck or becomingstuck!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 off thetruck.– Ensure that the footwell cover is non-slip.– Do not jump into or out of the truck.– Ensure that you have a secure grip on the truck.

WARNING

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

CAUTION

Component damage through incorrect use!Truck components, such as the driver’s seat,steering wheel, parking brake lever etc., are notdesigned to be used for climbing on and off thetruck and can be damaged due to misuse.– Only use the devices specifically designed for

the purpose of climbing on and off.

To assist with climbing on and off the truck,the footwell must be used as a step (4) and thehandle (1) must be used for support. The postof the overhead guard (2) can also be used forsupport.

Always climb onto the truck in a forwardsmotion:

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

– Put your left foot on the step (4).

55048011501 EN - 12/2015 79

5 OperationCommissioning

– Use your right foot to enter the truck, and sitdown on the driver’s seat (3).

Always climb off the truck backwards:

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

– Stand up from the driver’s seat and climbout of the truck with your right foot first.

80 55048011501 EN - 12/2015


6327_600-001

1

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

CAUTION

Risk of component damage!If you connect the battery male connector with thekey switch switched on (under load), an arc willbe produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Do not connect the battery male connector with

the 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.Do not crush the battery cable whenclosing the battery cover.– Ensure that the battery cable doesnot come into contact with thebattery cover.

– Close the battery door.

4

5060_003-165

1

2

4

3

Shelf and cup holder

WARNING

Objects may fall into the footwell and obstruct thepedals— there is risk of accident!Objects to be stored must be of the correct size sothey do not fall from the shelves (1, 2) or out of thecup holder (3). Objects that fall into the footwellduring travel as a result of steering or braking canslip between the pedals (4) and stop them workingcorrectly. The truck may subsequently not be ableto be braked when necessary.– Bottles of 1 l or smaller may be stored in the cup

holder.– Make sure that stored objects cannot fall from

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

55048011501 EN - 12/2015 81


Unlocking the emergency off switch

6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

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

82 55048011501 EN - 12/2015


Switching on the key switch

WARNING

Before switching on the key switch, all tests prior tostart-up must be performed without detecting anydefects.– Perform the tests prior to commissioning.– Do not operate the truck if defects have been

detected.– Notify the authorised service centre.

NOTE

If the truck is switched on with the steeringwheel turned, the maximum driving speedis limited. The driving speed limitation isdisabled as soon as the truck is steered out ofcornering to drive in a straight line. A changein steering angle of around half a revolution issufficient for this to be the case.

I

1

0

5060_003-029_V2

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

55048011501 EN - 12/2015 83


7312_003-085

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

When the key switch is switched on, thedisplay shows the welcome screen in the setlanguage.

84 55048011501 EN - 12/2015


5060_003-176_en

The display will indicate the warning messageTILTING / SPEED.

NOTE

The tilt speed of the lift mast in this truck issignificantly higher than for previous productsin this series.

The truck controller is now fully started up.

If the truck has the "access authorisation withPIN code" variant, the display initially changesto the input menu for access authorisation.

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

%75

2

90°

12:15

5060_003-008

1

2

3

4

Standard display elements1 Battery charge

The useable battery capacity appears inthe display field as a percentage.

2 Drive programmeThe current drive program (1-5) appearsin the display field.

3 Steering positionThe position of the steering appears inthe display field.

4 TimeThe current time appears in the displayfield.

NOTE

After connecting the battery, the correctcharge status is not displayed until after beingplaced under load for the first time by drivingor lifting.

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.

55048011501 EN - 12/2015 85


NOTE

Additional information may appear on the dis-play. If malfunctions occur, refer to the infor-mation in the chapter entitled "Malfunctions".

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 driverPIN

86 55048011501 EN - 12/2015


is "99999". Persons with the correspondingaccessauthorisation, e.g. fleetmanagers, canchange the driver PINs in the correspondingmenu.

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.

55048011501 EN - 12/2015 87


8

9

6

7

4

2

0

1

3

5

BQ_023_en_V2

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

8

9

6

7

4

2

0

1

3

5

BQ_024_en_V2

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

88 55048011501 EN - 12/2015


Blue-Q_029_V2

1

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.

8

9

6

7

4

2

0

1

3

5

1

2

BQ_030_en_V2

1

2

6

7

3

4

5

ESC

PASSWORD appears in the display.

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

– Confirm the entry by pressing the ENTER

button (2).

55048011501 EN - 12/2015 89


8

9

6

7

4

2

0

1

3

5

BQ_31_en

1

3 2

CONFIGURATION appears in the display.

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

– Confirm your selection by pressing theENTER button (2).

8

9

6

7

4

2

0

1

3

5

BQ_025_en_V3

1

34 2

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

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

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

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


90 55048011501 EN - 12/2015


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).

8

9

6

7

4

2

0

1

3

5

7

8

1

2

6

7

3

4

5

8

9

0

BQ_026_en

CONFIRM appears in the display.

The CONFIRM submenu is used to confirmthe new driver PIN.

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

55048011501 EN - 12/2015 91


8

9

6

7

4

2

0

1

3

5

BQ_023_en_V2

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

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

8

9

6

7

4

2

0

1

3

5

BQ_024_en_V2

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

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

92 55048011501 EN - 12/2015


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.

8

9

6

7

4

2

0

1

3

5

1

2

BQ_030_en_V2

1

2

6

7

3

4

5

ESC

PASSWORD appears in the display.

– Enter the current password using thebuttons (1).

– Confirm the entry by pressing the ENTER

button (2).

55048011501 EN - 12/2015 93


8

9

6

7

4

2

0

1

3

5

1

23

BQ_032_en

CONFIGURATION appears in the display.

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


8

9

6

7

4

2

0

1

3

5

1

34

BQ_033_en

2

1

PASSWORD/PASSWORD LEVEL appears inthe display.

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


94 55048011501 EN - 12/2015


8

9

6

7

4

2

0

1

3

5

1

2

6

7

3

4

5

ESC

BQ_034_en_V2

1 2 3

4

NEW CODE appears in the display.

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

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.

55048011501 EN - 12/2015 95


F1F1 F2F2

6210_003-095

1

1

1

1

1

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

The signal horn sounds.

NOTE

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

96 55048011501 EN - 12/2015


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.

7311_003-048

1

23

Fastening the seat belt

DANGER

Risk to life when driving without a seat belt!If the truck tips over or crashes into an obstacle andthe driver is not wearing his seat belt, he can behurled out of the truck. The driver could slide underthe 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 inthe display and operating unit, see chapter"SAFETY BELTmessage".

– 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.

55048011501 EN - 12/2015 97


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

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

5051_003-002

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

– Move away carefully on the slope.

– Fasten the seat belt.

Releasing the seat belt

7090_342-0051

4

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

– Slowly guide the belt tongue back to theretractor by hand.

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).

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

98 55048011501 EN - 12/2015


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

out!

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.

55048011501 EN - 12/2015 99


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.

100 55048011501 EN - 12/2015


Checking the emergency stopfunction

WARNING

No electric brake assistance when the emergencyoff 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.

6321_003-145

F1F1 F2F2

1

IV

I

III

II

F1 F2

1

1

1

– Press the emergency off switch (1).

The truck will roll to a stop.

The display and operating unit shows themessage EMERGENCY SWITCH periodically.

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

– 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 load

55048011501 EN - 12/2015 101


measurement (variant) at all times. Zeroadjustment is required• as part of daily commissioning• after changing the fork arms• after fitting or changing attachments.

NOTE

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

NOTE

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

NOTE

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

– Set lift mast to vertical.

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

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.

102 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 103

5 OperationDriving

DrivingSafety regulations when driving

Driving conductThe driver must comply with the highway codewhen driving within the plant.

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 roadways.

The driver must always maintain a safebraking distance from vehicles and persons infront, and must always have the truck undercontrol. He must avoid stopping suddenly,turning at speed and overtaking in dangerousplaces or in blind spots.

– 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• 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.

104 55048011501 EN - 12/2015

Operation 5Driving

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.

55048011501 EN - 12/2015 105

5 OperationDriving

Driveways

Dimensions of the driveways and aislewidthsThe following dimensions and aisle widthrequirements apply under the specified con-ditions to ensure safe manoeuvring. In eachcase, it should be checked whether a largeraisle width is necessary, e.g. with deviatingload dimensions. Within the EU, there mustbe compliance with the 89/654/EEC directive(minimum safety and health requirementsfor the workplace). The respective nationalguidelines apply for the areas outside of theEU.

The required aisle widths depend on thedimensions of the load.

For pallets, these are:

Aisle width [mm]

Model Type With pallet1000x1200crosswise

With pallet800x1200lengthwise

RX50-10compact 5060 2888 3010

RX50-10 5061 2942 3064

RX50-13 5063 3050 3172

RX50-15 5065 3104 3226

RX50-16 5066 3109 3231

The truck may only be used on driveways thatdo not have curves that are too tight, havegradients that are too steep, and entrancesthat are not too narrow or low.

Driving on gradients

WARNING

Driving up and down long gradients may cause thedrive unit to overheat and switch off.It is not permitted to drive up and down long gra-dients due to the minimum specified braking va-lues. The climbing capability values given belowonly apply to overcoming obstacles on the roadwayand to short differences in level, e.g. ramps.

106 55048011501 EN - 12/2015

Operation 5Driving

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

Maximum gradient [%]Model Type

With load Without loadRX50-10compact 5060

RX50-10 5061

RX50-13 5063

RX50-15 5065

RX50-16 5066

19.0 25.0

The upwards and downwards slopes may notexceed the gradient listed above and shouldhave a rough surface.

Smooth and gradual transitions should beprovided at the top and bottom of the gradientto prevent the load from falling on the floor orthe truck being damaged.

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• Fold-out 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.

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

55048011501 EN - 12/2015 107

5 OperationDriving

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

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

NOTE


Hazard areasDangerous locations on the driveways mustbe designated by the signs typical for traffic or,if necessary, by additional warning signs.

2

5060_003-092_V2

1 2

Setting the drive programsThe driving and braking characteristics of thedrive can be set on the display operating unit.

– Push the drive program button (1) repeat-edly until the number of the desired driveprogram appears on the display (2).

Drive programs 1-5 are available.

The basic principle is that the higher the driveprogram number is, the greater the drivingdynamics.

The following drive programs are possible:

108 55048011501 EN - 12/2015

Operation 5Driving

Drive programme 1 2 3 4 5

Speed (km/h) (forwards/backwards) 12.5/10 12.5/10 12.5/10 12.5/10 12.5/10

Acceleration (%) (forwards/backwards) 50 60 70 80 90

Deceleration (%) (forwards/backwards) 50 60 70 70 70

Reversing (%) (forwards/backwards) 50 60 70 80 90

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

7321_003-052_en_V2

Reducing speed with a raised load(variant)This function (variant) reduces the speed ofthe truck with a raised load.

Special overhead guard for drive-inracks (variant)

NOTE

In order to be able to enter "drive-in racks", thetruck can be equipped with a special overheadguard (variant).

55048011501 EN - 12/2015 109

5 OperationDriving

DANGER

Risk of crushing and shearing when driving throughthe racks!The outer contour of the special overhead guard isnarrower than the truck undercarriage. This maycreate the impression that the driver is leaning outof themoving truck unhindered and without danger.Parts projecting from the racks may protrude intothe contour neck and seriously injure the driver.– When travelling, arms and legs must remain

within the truck.– When travelling, do not lean your body outside

the overhead guard contour.

a

c

b

5060_003-172

The following height and width dimensionsfor the truck with special overhead guard maydeviate from the standard equipment.

Max. height to top ofoverhead guard

a(mm) 2050

Max. width of overheadguard

b(mm) 738

Height to overhead guardneck

c(mm) 1270

.

110 55048011501 EN - 12/2015

Operation 5Driving

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 truckfrom 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.

55048011501 EN - 12/2015 111

5 OperationDriving

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. 5-111.

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

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

5060_003-096

F1 F2

1

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

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

112 55048011501 EN - 12/2015

Operation 5Driving

1

6210_003-101

A

B

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

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

F1F1 F2F2

5060_003-097

1

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

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

55048011501 EN - 12/2015 113

5 OperationDriving

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".

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.

114 55048011501 EN - 12/2015

Operation 5Driving

5060_003-082

1

2

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

NOTE

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

3

5060_003-084

– Actuate the accelerator pedal (3).

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

NOTE

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

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.

55048011501 EN - 12/2015 115

5 OperationDriving

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 thetruck 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.



116 55048011501 EN - 12/2015

Operation 5Driving

5060_003-085

2 1

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

NOTE

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

5060_003-083

3

4

The indicator for the selected drive direction("forwards" (3) or "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.

55048011501 EN - 12/2015 117

5 OperationDriving

DANGER

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

tions.– Do not leave the truck without applying the

parking brake!

Changing the drive direction– Remove foot from actuated acceleratorpedal.

– Actuate the accelerator pedal for theopposite direction.

The truck will travel in the selected drivedirection.

NOTE

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

118 55048011501 EN - 12/2015

Operation 5Driving

1

2

5060_003-006

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

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

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

DANGER

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

Use the parking brake if necessary to assist inthis process.

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

brake has been repaired.

DANGER

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

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

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

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

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

55048011501 EN - 12/2015 119

5 OperationDriving

Actuating the mechanical parkingbrake

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

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 on the display.

2

1

5060_003-035_V3

Applying the parking brake– Apply the parking brake lever (2) and allowit to engage.

The truck can no longer be driven. The drivedirection indicator will go out.

Releasing the parking brake– Push and hold the knob (1) on the parkingbrake lever.

– Move the parking brake lever all the wayforward, and then release the knob.

120 55048011501 EN - 12/2015

Operation 5Driving

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. 337.

55048011501 EN - 12/2015 121

5 OperationDriving

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.

122 55048011501 EN - 12/2015

Operation 5Lifting

LiftingLifting system variantsThe movement of the fork carriage and thelift mast heavily depends on the followingequipment:• The lift mast with which the truck isequipped, see ⇒ Chapter "Types of liftmast", P. 5-128

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

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 5-147.

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.

55048011501 EN - 12/2015 123

5 OperationLifting

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.

124 55048011501 EN - 12/2015

Operation 5Lifting

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)

55048011501 EN - 12/2015 125

5 OperationLifting

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.

126 55048011501 EN - 12/2015

Operation 5Lifting

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.

55048011501 EN - 12/2015 127

5 OperationLifting

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:

128 55048011501 EN - 12/2015

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



55048011501 EN - 12/2015 129

5 OperationLifting

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

130 55048011501 EN - 12/2015

Operation 5Lifting

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:

55048011501 EN - 12/2015 131

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 hydraulic functions are disabled wheneverthe seat switch in the driver’s seat is unloadedThis is when the driver stands up from thedriver’s seat or exits the truck. All hydraulicfunctions are disabled in this case:

• Lift the load• Lower the load• Tilt the lift mast• Auxiliary hydraulic functions

To ensure that the hydraulics blocking functiondoes not lock as well, the operating devicemust be in the neutral position for the "Lifting"function.

Enabling the hydraulic blocking functionThe hydraulic blocking function must beenabled after the following incidents:

• The driver has stood up from the driver’sseat whilst lowering the load.

• The driver has left the driver’s seat for morethan one minute.

Proceed as follows to enable the hydraulicblocking function:

– Sit down on the driver’s seat.

– Lift the fork a little.

132 55048011501 EN - 12/2015

Operation 5Lifting

Emergency lowering of the load after thehydraulics blocking function has beentriggeredIf the truck hydraulics are disabled by the ex-haust valve of the hydraulic blocking function,either permanently or due to a technical fault,it is possible to lower a raised load at the valveblock. See the chapter entitled "Emergencylowering".

55048011501 EN - 12/2015 133

5 OperationLifting

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 carryingdevices etc.) can lead to serious injuryor death and is therefore prohibited.– Always observe the safety regulations for hand-

ling loads; see ⇒ Chapter "Safety regulationswhen handing loads", P. 5-147.

– 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.

134 55048011501 EN - 12/2015

Operation 5Lifting

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.

55048011501 EN - 12/2015 135

5 OperationLifting

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.

136 55048011501 EN - 12/2015

Operation 5Lifting

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


55048011501 EN - 12/2015 137

5 OperationLifting

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).

2

DC

6210_003-090


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


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

138 55048011501 EN - 12/2015

Operation 5Lifting

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.

55048011501 EN - 12/2015 139

5 OperationLifting

F1F1 F2F2

6321_003-011

1

2

1 2

6210_003-043

6210_713-002_V2

2

1

Controlling the lifting system with thefingertip console

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


140 55048011501 EN - 12/2015

Operation 5Lifting

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.

55048011501 EN - 12/2015 141

5 OperationLifting

1

2

6210_003-027

Removal– Select a pallet corresponding to the fork armsize.

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

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

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

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

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

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

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

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

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

– Fit and tighten the locking screw (2).

DANGER

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

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

without the locking screw.

NOTE

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

142 55048011501 EN - 12/2015

Operation 5Lifting

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.

55048011501 EN - 12/2015 143

5 OperationLifting

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.

144 55048011501 EN - 12/2015

Operation 5Lifting

Operation with reversible fork arms(variant)

6210_862-013

Normal operationThe reversible fork arms (variant) can be liftedand tilted with the lift mast in the samemanneras a normal fork.

6210_862-014

Max. 600 mm

2

1

Reverse operation

DANGER

Risk to life from falling load!Standard fork arms are not structurally designed forreverse operation. If this is not observed, this canlead to material failure and the load falling.– Do not carry out reverse operation with the

standard fork arms.

WARNING

Risk of accident from slipping load!Loads may slip on the fork arms (1) if there is noload support. A fork extension (variant) cannot besecured against slipping.– Load pick-up on the fork arms is not permitted.– The fork extension (variant) must not be used.

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 the load centre of gravity up to a

max. of 600 mm above the ground.

55048011501 EN - 12/2015 145

5 OperationLifting

NOTE

If the truck is equippedwith the "loadmeasure-ment" comfort feature, then a "zeroadjustmentof the load measurement" is obligatory afterthe reversible fork arms have been changed;see ⇒ Chapter "Zero adjustment of the loadmeasurement (variant)", P. 5-101. Otherwise,correct load measurement cannot be guaran-teed.

146 55048011501 EN - 12/2015

Operation 5Working with loads

Working with 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.

55048011501 EN - 12/2015 147

5 OperationWorking with 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 plates on the truck are 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.

148 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 149


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

150 55048011501 EN - 12/2015


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.

– Set lift mast to vertical.

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

– 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.

55048011501 EN - 12/2015 151


6210_003-073_en

3

When the loadmeasurement has been carriedout correctly, the determined load weight isdisplayed in the operating unit.

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.

152 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 153


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

Transport of swinging loadsContact your national regulatory authorities(employer’s liability insurance associations inGermany) prior to transporting swinging loads.

National regulations may place restrictionson these operations. Contact the relevantauthorities.

DANGER

Swinging loads can result in the 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.

154 55048011501 EN - 12/2015


DANGER

Loss of stability due to slipped, unstable or, inparticular, hanging loads!The following information should be noted whentransporting hanging loads:

• Swinging of the load is to be prevented byusing the proper driving speed and drivingmanner (careful steering, braking).

• Hanging loads must be coupled to the truckin such a way that the harness cannot shiftor release unintentionally, and cannot bedamaged.

• Take particular care to ensure that there areno persons in the direction of travel in thedriving lane.

• Ensure that swinging loads do not putpersons at risk.

• When transporting hanging loads, suitabledevices (e.g. guy wires or hand rails) areto be made available and used by guidepersons.

DANGER

Risk of accidents!When transporting hanging loads, never abruptlyperform or end driving and load movements duringtransport.Never drive on slopes with a hanging load!Containers with fluids cannot be transported ashanging loads.

Picking up a load

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.

– Only store pallets that do not exceed thespecified maximum size. Damaged loadingequipment and incorrectly formed loadsmust not be stored.

55048011501 EN - 12/2015 155


– Attach or secure the load to the liftingaccessory so that the load cannot moveor fall.

– Store the load so that the specified aislewidth is not reduced by protruding parts.

6210_800-005

– Approach the rack carefully, brake gentlyand stop just in front of the rack.

6210_800-006

– Position the forks.

NOTE

The tilt speed of the lift mast in this truck issignificantly higher than for previous productsin this series. This is signalled by a warningmessage shown on the display and operatingunit after the key switch has been switched on.

– Set the lift mast to vertical.

– Lift the fork carriage to the stacking height.

CAUTION

Risk of component damage!When inserting the fork into the rack, ensure thatthe rack and load are not damaged.

156 55048011501 EN - 12/2015


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 loadcentre of gravity must be midway betweenthe fork arms.

6210_800-008

– Lift the fork carriage until the load is restingentirely on the fork.

DANGER

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

CAUTION

Risk of component damage!– Ensure that the roadway behind you is clear.

– Reverse carefully and slowly until the loadis clear of the rack. Brake gently.

DANGER

Due to the risk of tipping, never tilt the lift mast witha raised load!– Lower the load before tilting the lift mast.

55048011501 EN - 12/2015 157


5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

158 55048011501 EN - 12/2015


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".

55048011501 EN - 12/2015 159


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 can be 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 forwards, take parti-

cular care to ensure that the truck does not tipforwards and that the load does not slip.

WARNING

Risk of accident from 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

160 55048011501 EN - 12/2015


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.

– Set the lift mast to vertical.

– Lift the load to the stacking height.

– Approach the rack at a moderate speed.

NOTE

The tilt speed of the lift mast in this truck issignificantly higher than for previous productsin this series. This is signalled by a warningmessage shown on the display and operatingunit after the key switch has been switched on.

6210_800-016

– Lower the load until it rests securely on therack.

– Look behind you!

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

– Lower the fork to the ground clearanceposition.

– Tilt the lift mast backwards and drive away.

55048011501 EN - 12/2015 161


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.

162 55048011501 EN - 12/2015







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. 5-282.

– 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. 5-282, to preventuncontrolled movements of the load or thetruck.

55048011501 EN - 12/2015 163


6210_001-010

Driving on loading bridges

DANGER

Risk of accident if the truck crashes!Steering movements can cause the tail end to veeroff the loading bridge towards the edge. This maycause the truck to crash.For 3-wheel trucks, the useable area of the loadingbridgemust beenclosed so that the rear drivewheeldoes not fall through.The lorry driver and the truck driver must agree onthe lorry’s departure time.– Establish the departure time of the truck.– Determine the actual total 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 andcan support the load of 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 and, ifnecessary, by weighing the load to be lifted.


Tare weight (1)



+ Attachment net weight (variant)

+ Weight of the load to be lifted

+ 100 kg allowance for driver


– Drive slowly and with care on the loadingbridge.

164 55048011501 EN - 12/2015

Operation 5Working with attachments

Working with attachmentsFitting attachmentsIf the truck is equipped with an integratedattachment (variant) at the factory, the specifi-cations in the STILL operating instructions forintegrated attachments must be observed.

If attachments are fitted at the place of use,the specifications in the operating instructionsof the attachment manufacturer must beobserved.

If an attachment is not delivered togetherwith the forklift truck, the specifications andoperating instructions of the attachmentmanufacturer must be observed.

Before initial commissioning, the functionof the attachment and the visibility from thedriver’s position with and without a load mustbe checked by a competent person. If thevisibility is deemed insufficient, visual aidssuch asmirrors, a camera/monitor system etc.must be used.

NOTE

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

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).

55048011501 EN - 12/2015 165

5 OperationWorking 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 theplug 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".

166 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 167


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.

168 55048011501 EN - 12/2015


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• Triple mini-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

55048011501 EN - 12/2015 169


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.

170 55048011501 EN - 12/2015


2060_003-019

1

Controlling attachments usingmulti-lever operationThe attachments (variant) are controlled inthis version using the operating lever (1).

The pictograms on the operating lever showall of the functions that are activated by thislever.

The meanings are as follows:

– 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.

5060_003-166

2 3

6

4

75

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 Push off/pull in load

7 Turn to the left/right

8 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.

55048011501 EN - 12/2015 171


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

The top and bottom parts of the pictograms onthe operating levers always show the functionthat is activated by that lever. The upper partof the pictogram shows that the attachment isequipped with the 5th function.""


– Move operating lever forwards:

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

– Move operating lever backwards:


– Actuate the switch

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

NOTE

Please see the operating instructions of thefitted attachment for the movements/actionsresulting from using this "5th function".

172 55048011501 EN - 12/2015


5060_003-167

2 3

6

4

75

8









NOTE



55048011501 EN - 12/2015 173


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).

174 55048011501 EN - 12/2015


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



55048011501 EN - 12/2015 175


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).

176 55048011501 EN - 12/2015


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



55048011501 EN - 12/2015 177


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).

178 55048011501 EN - 12/2015


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



55048011501 EN - 12/2015 179


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) .

180 55048011501 EN - 12/2015


5060_003-122

3

4

1

2






NOTE



55048011501 EN - 12/2015 181


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).

182 55048011501 EN - 12/2015


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



55048011501 EN - 12/2015 183


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).

184 55048011501 EN - 12/2015


5060_003-122

3

4

1

2






NOTE



55048011501 EN - 12/2015 185


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.


186 55048011501 EN - 12/2015


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.


55048011501 EN - 12/2015 187


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.


– Move operating lever (1) backwards.


6210_003-031

2 3

6

4

7

9 10

5

8


2 Move side shift frame or forksforwards/backwards

3 Move sideshift to the left/to the right


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

6 Release/clamp load retainer


8 Open/close clamps

9 Turn to the left/to the right


NOTE



188 55048011501 EN - 12/2015


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.


– Move operating lever back.


– Actuate the switch (2).

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

55048011501 EN - 12/2015 189


F1F1 F2F2

6210_003-033

4

5

6

– Press the function key (4).

NOTE

The arrow (5) under the function key indicateswhich operating lever is equipped with the "5thfunction".

The "5th function" is switched to the 3rdoperating lever; see adhesive label (6).

F1F1 F2F2

6210_003-034

7

8

9

– Press the function key (7).

NOTE

The arrow (8) under the function key indicateswhich operating lever is equipped with the "5thfunction".

The "5th function" is switched to the 4thoperating lever; see adhesive label (9).

NOTE

The movement/action of this "5th function"can be found in the operating instructions ofthe fitted attachment.

190 55048011501 EN - 12/2015


6210_003-035

10 11

14

12

15

17 18

13

16






14 Release/clamp load retainer


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.

55048011501 EN - 12/2015 191


Multiple-lever

NOTE

Clamping attachments are only available asa special solution when the truck is equippedwith this multi-lever variant. To operate theclamp locking mechanism, please see theoperating instructions that correspond to thespecial solution.

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 control lever(1) forwards again.

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

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

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

192 55048011501 EN - 12/2015


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





55048011501 EN - 12/2015 193


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

1

3

2

6210_003-097

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

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

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

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

NOTE



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

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

194 55048011501 EN - 12/2015


6210_003-080

F1F1 F2F2

1

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


NOTE





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

1

2

3

7090_860-002

Taking up a load using attachments

WARNING

Risk of accidents!Attachments may only be used for their intendedpurpose as described in the relevant operatinginstructions.Drivers must be instructed in the handling of theattachments.

WARNING

Risk of accidents!Loads may only be picked up and transported withattachments if they are securely attached. Wherenecessary, loads should also be secured againstslipping, rolling, falling over, swinging or tippingover. Note that any change to the position of theload’s centre of gravity will affect the stability of theforklift truck.Check the capacity rating plates for theattachmentsor combination of attachments.

55048011501 EN - 12/2015 195

5 OperationOperation of additional equipment

– The rating plates show the permissiblevalues for:

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

Operation of additional equipment

8

9

6

72

0

1

3

5

5060_003-010_V2

1 7 6

2

6210_602-002

3

Switching lighting on and off– Turn the key switch to position "I".

– Press button (1) for the front workingspotlights.

The front working spotlights (4) are switchedon.

– Press button (7) for the rear working spot-lights.

The rear working spotlights (5) are switchedon.

NOTE

The "rear working spotlights" symbol (6)lights up until the rear working spotlights areswitched off again.

NOTE

Depending on the configuration, the rearworking spotlights (5) only light up when thedrive direction switch is set to reverse.

– Press button (2) for lighting.

The parking light (3, 4) is switched on.

– Press button (2) again.

The driving light (3, 4) is switched on.

196 55048011501 EN - 12/2015

Operation 5Operation of additional equipment

5060_003-047

4 5NOTE

Pressing a button again turns the correspon-ding lighting unit off again.

NOTE

The parking light can also be switched onwithout the key switch being switched on.

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.

55048011501 EN - 12/2015 197


5060_003-011_V2

1

2

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

All direction indicators and indicatorlights (2) flash.

NOTE

Pushing the button again switches the hazardwarning system off again.

NOTE

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

Switching direction indicators on andoff

5060_003-096

F1 F2

1

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

The direction indicators and the correspond-ing direction indicator lights (2) or (3) flash.

– Switch off the direction indicators bymovingthe cross lever to the centre position.

198 55048011501 EN - 12/2015


2 3

5060_003-012_V2

F1F1 F2F2

5060_003-100

1Fingertip version– 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.

55048011501 EN - 12/2015 199


2 3

5060_003-012_V2

5060_003-046

1

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


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

200 55048011501 EN - 12/2015


2 3

5060_003-012_V2

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.

55048011501 EN - 12/2015 201


– 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.

202 55048011501 EN - 12/2015


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

5060_003-013_V2

1

– Push the button (1) to actuate the frontwindscreen wiper/washer (variant).

Every time the button is pressed, the wiperinterval increases:Button 1 Operating stage

Off

1st time On

2nd time Interval

3rd timeWasher, hold down thethird time you press it

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.

55048011501 EN - 12/2015 203


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.

6210_003-107

21

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

204 55048011501 EN - 12/2015

Operation 5Trailer operation

Trailer operation

6210_313-001

Towed load

DANGER

There is an increased risk of accident when using atrailer.Using a trailer changes the truck handling charac-teristics. When towing, operate the truck such thatthe trailer train can be safely driven and braked atall times. The maximum permissible speed whentowing is 5 km/h.– Do not exceed the permissible speed of 5 km/h.– Do not couple the truck in front of rail vehicles.– The truck must not be used to push any kind of

trolley.– It must be possible to drive and brake at all times.

CAUTION

Risk of damage to components!The maximum towed load for occasional towingis the rated capacity specified on the nameplate.Overloading can lead to component damage on thetruck. The sum of the actual towed load and theactual load on the fork must not exceed the ratedcapacity. If the 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.

55048011501 EN - 12/2015 205

5 OperationTrailer 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.

Tow coupling RO*230

CAUTION

The intended use of this coupling is restricted to thetowing of unserviceable trucks and, in exceptionalcases, for shunting purposes. It is not permitted touse it for trailer operation.

DANGER

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

designated connection points.

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.

206 55048011501 EN - 12/2015


Coupling

1 7090_900-008

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

5060_003-111

3

42

– Remove the security pin (2) from thecoupling pin (3).

– Pull the coupling pin upwards to take it out.

– Slowly move the truck backwards.

– Insert the tow-bar eye of the trailer into thetowing jaws (4) of the tow coupling.

– Insert the coupling pin and attach thesecurity pin.

DANGER

If the coupling pin is lost or destroyed during towing,the trailer will become loose and uncontrollable.This causes a risk of accident!– Use only original coupling pins that have been

checked for good condition!– Ensure that the coupling pin is correctly inserted

and secured.

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

– Tow or shunt the trailer.

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

– Remove the security pin from the couplingpin.

55048011501 EN - 12/2015 207


– Pull the coupling pin upwards to take it out.

– Slowly drive the truck forward until thetow-bar eye and towing jaws are separated.

– Insert the coupling pin and attach thesecurity pin.

Tow coupling RO*244

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 jackingupand lifting, useonly thedesignated

connection points.

DANGER

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

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

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 of thetowing jaws. If the component moves suddenlythere is a risk of injury!– Use a suitable device to release the coupling pin.– When not in use, close the automatic trailer

coupling.

208 55048011501 EN - 12/2015


NOTE

When manoeuvring in restricted areas, takeinto account the projection of the coupling.

4

7321_003-065

Coupling

NOTE

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

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

– Push the hand lever (4) upwards and openthe tow coupling.

CAUTION

When being coupled, the tow-bar eye must engagein the middle of the coupling jaw. Failure to followthese instructions could result in damage to thecoupling jaw or to the tow-bar eye!– Ensure that the tow-bar eye enters the coupling

jaw centrally.

– Slowly move the truck backwards.

DANGER

If the coupling pin works loose during towing, thetrailer will become loose and uncontrollable. Thiscauses a risk of accident!– Ensure that the coupling pin is engaged cor-

rectly.– If it is not, repeat the coupling procedure.

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

– Tow the trailer.

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

– Push the hand lever upwards.

– Slowly drive the truck forward until thetow-bar eye and towing jaws are separated.

– Close the tow coupling.

55048011501 EN - 12/2015 209


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

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

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

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

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

NOTE


210 55048011501 EN - 12/2015

Operation 5Cold store application

6210_900-002

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

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

Cold store-compatible oils (for hydraulicsand gearbox) and greases (for moving parts,gearing and chains) are used with the coldstore equipment.

Permissible useType of application 1:

• Constant deployment in temperature range-5 °C, brief deployment down to -10 °C.

Type of application 2:

• Alternating between indoor use down to-32 °C and for outdoor use +25 °C, brieflyup to +40 °C. For this application, coldstore-compatible hydraulic oil must beused according to the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-303.

Operation

CAUTION

Changing from a cold inside temperature to a warmoutside temperature may result in the formationof condensation water. 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 should 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 longer than 10minutes,it must remain there at least until the condensationwater has drained off and the truck has dried off.Depending on the weather, this will take at least 30minutes.

55048011501 EN - 12/2015 211

5 OperationCold store application

WARNING

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

– Drive the truck for 5 minutes or so andoperate the brake several times to ensureoperational safety.

– Actuate all of the mast’s lifting functionsseveral times.

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

Electric forklift trucks should not be parkedfor any longer than necessary in a cold area.This also applies to unused batteries. Thecharging station and the parking area fortrucks and batteries should be at normalroom temperature (not below 10°C). Chargingis extremely slow at low temperatures. Attemperatures below 10°C and with the usualcharging parameters, the battery cannot befully charged.

The battery must be fully charged before eachshift.

Purified water (topping-up water) should beused constantly during the gassing phase toensure that it is mixed thoroughly with theremaining acid. If the top-up water is notmixed, it may freeze.

212 55048011501 EN - 12/2015

Operation 5Cold store application

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

On discharge, the battery voltage is thereforegenerally lower at low temperatures, and thefinal discharged voltage is reached earlier, i.e.the battery’s capacity is lower.

55048011501 EN - 12/2015 213

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".

214 55048011501 EN - 12/2015

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%).

55048011501 EN - 12/2015 215


7312_003-106_V2

6

89

75

Additional indicators5 Menu change button

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

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

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

8 Total distanceDisplays the total distance driven inkilometres.

9 Daily kilometresDisplays the kilometres driven for theday.

NOTE

Ask the authorised service centre about thespeed driven indicator.

NOTE

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

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

216 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 217


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

218 55048011501 EN - 12/2015


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

55048011501 EN - 12/2015 219


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.

220 55048011501 EN - 12/2015


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)

55048011501 EN - 12/2015 221


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. 5-217.

– 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. 5-217.

– 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.

222 55048011501 EN - 12/2015


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. 5-217.

– 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.

55048011501 EN - 12/2015 223


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.

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

224 55048011501 EN - 12/2015


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. 5-217

– 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.

55048011501 EN - 12/2015 225

5 OperationBlue-Q efficiency mode

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

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

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

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

NOTE

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

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

226 55048011501 EN - 12/2015

Operation 5Blue-Q efficiency mode

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

Rear workingspotlight* X X Forwards

Top double workingspotlight* X X > 3 km/h

Headlight* X X -

Side light - - -

Front wiper X X Backwards > 3 km/h

Rear wiper X X Forwards

Seat heater X - -

Cab heating X - -

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

Switching efficiencymode Blue-Q onand off

NOTE

The Blue-Q efficiency mode can be swit-ched on and off in the STANDARD and FI-XED-FLEX operating modes. If the FIXEDoperating mode is configured in the displayoperating unit, the Blue-Q button has no func-tion and the Blue-Q efficiency mode is swit-ched on permanently. For information onconfiguring the Blue-Q operating modes, seechapter "Configuring Blue Q efficiency mode".

55048011501 EN - 12/2015 227

5 OperationBlue-Q efficiency mode

2

6210_003-065_V3

1 2

– Press the Blue-Q button (1).

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

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

228 55048011501 EN - 12/2015

Operation 5Malfunctions

Malfunctions

8

9

0

6

7

4

2

1

3

5

7312_003-157

2 3 4

1

Screen contentIf amessage is shown on the display operatingunit, the "Malfunction" message will light up inthe multi-function display(1).

The following messages can appear on thescreen:• A graphic symbol (2)• Message text (3) naming the event• An error code (4), consisting of a letter anda four-digit number.

A message always appears repeatedly andfor a certain period depending on the event.

In the case of successive events, the respec-tivemessages are displayed one after anotheron the screen.

After a few seconds, the screen 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 messagedisappears.

If a malfunction continues to occur, themessage will continue to appear.

– Park the truck securely.

– Inform the service centre.

55048011501 EN - 12/2015 229

5 OperationMalfunctions

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

– Refer to the chapter entitled "Checking theemergency off function."

SEAT SWITCHmessageThe truck is equipped with a seat switch.

If the SEAT SWITCHmessage appears, thedriving functions and theworking hydraulic areblocked.

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 on your truck.

230 55048011501 EN - 12/2015


7312_003-066_en_V2

The seat switch is not actuated while theaccelerator pedal or steering wheel isactuated.The accelerator pedal or steering wheel isactuated even though no one is sitting in thedriver’s seat. SEAT SWITCH appears on thedisplay. The truck will not move.

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

The forklift truck can be driven again withoutrestriction.

7312_003-067_en_V2

F1 F2

The seat switch is not actuated whilethe operating device for the workinghydraulics is actuated.An operating device for the working hydraulicsis actuated even though no one is sitting inthe driver’s seat. SEAT SWITCH appears onthe display. The working hydraulic functionscannot be executed.

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

The working hydraulics can be operatedagain.

55048011501 EN - 12/2015 231


7312_003-067_en_V2

F1 F2

Exceeding the shift time

NOTE

The shift time is adjustable.

If the key switch is switched on and the driverdoes not leave the seat until 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, slowly ornot at all.

– Standing up briefly from the seat, sittingback down again and fastening the seatbelt.

The forklift truck canagain beoperatedwithoutrestriction.

7312_003-064_en_V2

F1 F2

Exceeding the operating time

NOTE

The operating time is adjustable.

If the key switch is switched on, the parkingbrake is released and the driver does notleave the seat until 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, slowly or not at all.

– Standing up briefly from the seat, sittingback down again and fastening the seatbelt.

The forklift truck canagain beoperatedwithoutrestriction.

232 55048011501 EN - 12/2015


7312_003-107_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 therefore recommend that youalso use the seat belt

This device (variant) ensures that if theseat belt is not being used or is being usedincorrectly, the truck will only drive slowly or(optionally) will not drive at all.

Depending on the configuration selected,the working hydraulics functions (lift/tilt) 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 continuously fastened andthe driver’s seat is 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 be operated again withoutrestriction.

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

55048011501 EN - 12/2015 233


DANGER

Risk of accidents!– The speed must be adjusted to suit the driving

situation!The increased safety provided by this function maynot be misused in order to take safety risks.

APPLY HANDBRAKEmessage

DANGER

If the truck rolls away, there is a risk of being runover and therefore a danger to life!Parking the truck without the parking brake appliedis dangerous and is not permitted.– The truck should not be parked on a slope.– Do not leave the truck until the parking brake has

been applied.– In emergencies, secure the truck using wedges

on the side facing downhill.

7312_003-069_en_V3

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 chocks if necessary.

– Notify the authorised service centre.

234 55048011501 EN - 12/2015


LOWER FORKSmessage

DANGER

There is a risk to life caused by a falling load or ifparts of the truck are being lowered!Parking the truck with the load lifted is dangerousand is not permitted under any circumstances! Theincreased safety provided by this function may notbe misused in order to take safety risks.– Before leaving the truck, lower the load fully.

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 forks to the ground.

The message LOWER FORKS disappears.

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 theposition of the fork, themessageREFERENCECYCLE (variant)mayappear in the display. Toalign the position with the control electronics,the fork must be raised.


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

– Raise the fork

55048011501 EN - 12/2015 235


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

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

The truck can now be driven again with nospeed limitation.

8

9

0

6

7

4

3

5

7312_003-176_en

SERVICE BRAKEmessageIf the message SERVICE BRAKE appearsin the display, the brake fluid level must bechecked. Contact your service centre.

236 55048011501 EN - 12/2015

Operation 5Operation in special operating situations

Operation in special operating situationsTransporting

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 be permanently deformed or damaged due tooverloading.– 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.


Tare weight (1)



+ Net weight of attachment (variant)

+ 100 kg allowance for the driver


55048011501 EN - 12/2015 237

5 OperationOperation 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.

5060_003-170

1 1

Wedging

NOTE

Due to its design, the truck can only bechocked securely if the fork carriage is raisedbefore chocking. To ensure secure parkingafter chocking, the fork carriage can belowered as far as the chock.

– Raise the fork carriage high enough so thatthe chocks can be inserted in front of thefront wheels.

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


CAUTION

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

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

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

– Ensure that the key switch is switched off.

– Disconnect the battery male connector.

238 55048011501 EN - 12/2015


Lashing

CAUTION

Abrasive lashing straps can rub against the surfaceof the truck and cause damage.– Position the slip-resistant pads underneath the

lifting points (3) (e.g. rubber mats or foam).

5060_003-171

1

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

5060_003-068

23

3

– Sling lashing straps (2) around the rear ofthe truckwithin the chassis contour and lashthe truck to the front.

DANGER

The truck may slip if the lashing straps slip!The truck must be lashed securely so that it cannotmove during transportation.– Make sure that the lashing straps are tightened

securely and that the pads cannot slip off.

55048011501 EN - 12/2015 239


6036Ba-0265060_003-070

Towing

DANGER

The brake system on the towing vehicle may fail.There is a risk of accident!If the towing vehicle’s brake system is not of thecorrect size, the vehicle cannot be braked securelyor 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 force 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 duringtowing for the power transmission in two directions,the truckmay drive into the towing vehicle when thetowing vehicle brakes. For safety reasons, only atested tow bar may be used.– Use a tested tow bar.

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

CAUTION

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

position.

CAUTION

Risk of component damage!If you remove the battery male connector whilethe key switch is switched on (under load), an arcwill be produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Do not disconnect the battery male connector

while the key switch is switched on.

240 55048011501 EN - 12/2015


DANGER

People can be crushed between the truck andtowing vehicle during manoeuvring. There is a riskto life!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 braking

and control of the truck and towing vehicle at alltimes.

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 the load and lower fork arms closeto the ground.

– Place the drive direction switch in theneutral position.




– Open the battery hood.

55048011501 EN - 12/2015 241


1

5060_003-069

2

– Unscrew the eye bolt (1) from the stowedposition.

– Take the lid (2) out of the wheel cutaway onthe rear weight.

– Place the lid in the stowed position of theeye bolt.

– Close the battery hood again.

1

5060_003-053

– Screw in the eye bolt (1) to the stop on therear weight.

– Check the pulling and braking force of thetowing vehicle.

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

– Secure the tow bar to the towing vehicle andto the eye bolt (1) of the truck.

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

– Where possible, activate the restraintsystems provided.


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

– Tow the truck.

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

– Remove the tow bar.


– Unscrew the eye bolt from the rear weight.

– Take the lid out of the stowed position of theeye bolt and insert into the wheel cutawayon the rear weight.

242 55048011501 EN - 12/2015


– Screw the eye bolt into the stowed position.

CAUTION

The cables can be damaged by being crushed—there is risk of short circuit!Cables must not be crushed when screwing in theeye bolt.– Ensure that the wiring can move freely.


Crane loadingCrane loading is only intended for transportingthe complete truck, including the lift mast,for its initial commissioning. For applicationconditions that require frequent loading or thatare not presented here, please contact themanufacturer with regard to special variants.

Only those persons with sufficient experienceof suitable harnesses and hoists may loadtrucks.






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. 5-282.

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


Tare weight (1)



+ Attachment net weight (variant)

= Actual total weight.

55048011501 EN - 12/2015 243


4

6321_003-069Hooking on the lifting straps

CAUTION

Harnesses may damage the truck’s paintwork!Harnesses can damage paintwork by chafingand pressing on the surface of the truck. Hard orsharp-edged harnesses, such as wires or chains,can quickly damage the surface.– Use textile harnesses, e.g. lifting straps, with

edge protectors or similar protective devices ifnecessary.

DANGER

There is risk of being hit if the hoists and harnessesfail and cause the truck to fall, with potentially fatalconsequences!– Only use hoists and harness with sufficient load

capacity for the actual total weight of the truck.– Only use the truck’s designated lifting points.– Make sure that harnesses such as hooks,

shackles, belts etc. are only used in the indicatedload direction.

– The harnesses must not be damaged by truckparts.

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

NOTE

The lifting points of the truck are markedwith the hook symbol, see ⇒ Chapter "Over-view", P. 4-64.

244 55048011501 EN - 12/2015


5060_003-133_V2

811

5– Loop the lifting straps through the recess (8)in the counterweight, see illustration.

DANGER

Never crane-load the truck using the tow coupling.The tow coupling is not designed for this and couldbe deformed or damaged. The truck could fall off,with potentially fatal consequences!Hooking the crane belt to an available tow coupling(11) is only permitted on an additional lifting eye (5)approved for this purpose.If an additional lifting eye is not present at the towcoupling, one can be retrofitted by the serviceteam or the tow coupling can be removed for craneloading.– Hook crane belt onto the additional lifting eye.– If necessary seek advice from STILL service.

– Determine the truck’s centre of gravity.

NOTE

The centre of gravity is indicated by the symbol"S" in the operating instructions; see the sec-tion entitled "Dimensions" ⇒ Chapter "Techni-cal data", P. 337.

6210_003-046

10 9– Set the length of the harnesses so that thelifting eye (9) is vertically above the truck’scentre of gravity.

This ensures that the truck hangs level whenlifting it.

– Connect the lifting straps to the lifting eyeand insert the safety device (10).

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. Ask your service centreabout this.– Secure harnesses so that they are not touching

any attachment parts.

55048011501 EN - 12/2015 245


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 take care whensetting it down at the intended location.

246 55048011501 EN - 12/2015

Operation 5Behaviour in emergencies

Behaviour in emergencies

6321_003-144

1

F1F1 F2F2

1

1

1

2

5060_003-054

Emergency shutdown

WARNING

No electric brake assistance when the emergencyoff switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply.– 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.This safety system must only be used in an emer-gency or 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



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 willroll to a stop

• The electric brake does not function duringthe first part of brake pedal depression.To brake the truck using the mechanicalbrake, the brake pedal must be pusheddown further

55048011501 EN - 12/2015 247

5 OperationBehaviour in emergencies

• 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 corner-ing) does not function. The truck must bedecelerated with the mechanical brake bypressing the brake pedal

• No hydraulic functions are available

7090_001-005

Procedure if truck tips over

DANGER

If the truck tips over, the driver could fall out andslide under the truck with potentially fatal conse-quences. There is a risk to life.Failure to comply with the limits specified in theseoperating instructions, e.g. driving on unacceptablysteep gradients or failing to adjust speed whencornering, can cause the truck to tip over. If thetruck starts to tip over, do not leave the truck underany circumstances. This increases the danger ofbeing hit by the truck.– Do not release your seat belt.– Never jump off the truck.– You must adhere to the rules of behaviour if the

truck tips over.

Rules of behaviour if truck tips over:

– 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.

Emergency loweringIf the hydraulic control system fails whilst aload is raised, emergency lowering can beperformed. An emergency lowering screw forthis purpose is located on the valve block.

248 55048011501 EN - 12/2015

Operation 5Behaviour in emergencies

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.

NOTE

The hexagon socket wrench that is usedto remove the valve cover is also used foremergency lowering.

– Remove the valve cover.

– Continue using the hexagon socket wrench.

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 the mini-leverversion:

B Multiple-lever version

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

– Using the hexagon socket wrench (2), turnthe emergency lowering screw (5) on thevalve block a maximum of 1.5 revolutions toloosen it.

For the multiple-lever version (B):

– Using the hexagon socket wrench, turn theemergency lowering screw (3) on the valveblock (3) a maximum of 1.5 revolutions toloosen it.(4)

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

55048011501 EN - 12/2015 249

5 OperationBehaviour in emergencies

After lowering:

– Screw in the emergency lowering screwagain.

– Install the valve cover.

– Securely store the hexagon socket wrenchbetween the battery hood and the valvecover.

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.

250 55048011501 EN - 12/2015

Operation 5Handling the battery

Handling the batterySafety regulations when handlingthe battery– National statutory provisions must befollowed when setting up and operatingbattery 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.

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.

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

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 door and theedge of the chassis when the batterydoor is closed, this could lead toinjuries.– Alwayswear safety footwearwhenreplacing the battery.

– Only close the battery door if thereis no part of the body between thebattery door and the edge of thechassis.

55048011501 EN - 12/2015 251

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(detonating gas). This gas mixture isexplosive and must 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.

– Always ensure adequate ventilation in thevicinity.

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

– The battery door must be open whencharging.

– 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.

252 55048011501 EN - 12/2015


Lifting accessory

DANGER

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

Battery removal from trucks with an internalroller channel can be carried out with thefollowing lifting accessories:• Lift truck including external roller channel(variant)

The battery can be removed from trucks witha bridge (variant) using the following liftingaccessories:• Crane

NOTE

The removal of batteries from trucks withouttheir own devices must be carried out by theauthorised service centre.

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.

55048011501 EN - 12/2015 253


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 door.– Check the battery cables fordamage.

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

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

CAUTION

Possible damage to the male battery connector!If the battery male connector is disconnected orconnected while the key switch or battery chargeris under load, an arc will be produced at the batterymale connector. This can lead to corrosion at thecontacts, and can considerably shorten the servicelife of the contacts.– Switch off the key switch or battery charger be-

fore the battery male connector is disconnectedor connected.

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

Opening and closing the batteryhood

CAUTION

Risk of damage through component collision!Driver’s seats with operating devices in the armrestand opened ERS or HRS driver restraint systems(variant) can collide with and damage surroundingcomponents (for example, interior mirror) when thebattery hood is opened.– Position the driver’s seat as far back as it can go.– Carry out preparations for ERS or HRS driver

restraint system (variant).– Only then open the battery hood.

254 55048011501 EN - 12/2015


NOTE

If the truck is fitted with the ERS or HRSdriver restraint system (variant), the followingmeasures must be observed for opening andclosing the battery hood.

Preparations for ERS driver restraintsystem (variant)

CAUTION




– Disconnect the battery male connector;see the chapter entitled "Disconnecting thebattery male connector".

– Pull release button (4).

frs_003-021

4

5

– Swivel restraining brackets (5) downwards.

55048011501 EN - 12/2015 255


Preparations for HRS driver restraintsystem (variant)

frs_003-023

6

– Swivel restraining brackets (6) downwards.

Opening the battery hood

WARNING

Risk of injury from crushing due to falling batteryhood!The battery hood is equipped with a gas springwhich holds the battery hood in the open positionunless there is any other load on it, e.g. heavyobjects, strong winds or other persons. Duringopening, there must be no objects on the batteryhood that are not part of the truck equipment.– Remove loose objects from the battery hood

before opening.– Make sure that the battery hood is not being

pushed down by strong winds or other persons.

– Position the driver’s seat as far back as itcan go.

5060_003-115

1

2

3

– Push the locking lever (1) to the left.

– Lift the battery hood (3) using the handle (2)and bring it forwards.

NOTE

The battery hood can be raised to amax.angleof approx. 30°.

Closing the battery hood

DANGER WARNING

Limbs can become trapped whenclosing the battery hood — risk ofcrushing!When closing the battery hood,nothing should come between thebattery hood and the edge of thechassis.– Carefully close the battery hood.– Only close the battery hood if thereare no parts of the body in the way.

256 55048011501 EN - 12/2015


WARNING

When closing the battery hood, thereis a risk of the battery cable becomingtrapped. If the cable is crushed orsheared off, there is a risk of shortcircuit!When closing the battery hood,nothing should come between thebattery hood and the edge of thechassis.– Carefully close the battery hood.– Only close the battery hood if thebattery cable is not trapped.

DANGER

Risk of accident due to the battery hood opening!In the event of a sharp deceleration, an unlockedbattery hood may swing open towards the seat anddriver, injuring the driver.– Ensure that the battery hood is shut securely.– Drive the truck only when the battery hood is

locked.

DANGER

Risk to life from the battery sliding out!If the battery hood is not locked and the truck tipsover, the battery can slide out of position and canfall on the driver.– Ensure that the battery hood is shut securely.– Drive the truck only when the battery hood is

locked.

NOTE

The aperture running around the hood is usedfor forced ventilation and must not be closed.

NOTE

If the internal roller channel or battery bridge(variant) is not locked correctly, the batteryhood cannot be closed.

55048011501 EN - 12/2015 257


5060_003-115

1

2

3

– Push down and close the battery hood (3)using the handle (2).

– Ensure that the locking lever (1) has en-gaged.

Final measures for ERS driver restraintsystem (variant)

CAUTION

Risk of damage to components!Do not open a closed restraint system by force.

NOTE

If the parking brake is on and the key switch isturned off, the restraining brackets swivel intothe opened position once the power supply isrestored.

CAUTION

Risk of component damage!If you connect the battery male connector with thekey switch switched on (under load), an arc willbe produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Switch off the ignition switch before the battery

male connector is disconnected.

frs_003-022

5

– Connect the battery male connector.

The restraining brackets (5) automaticallyswivel upwards.

Final measures for HRS driver restraintsystem (variant)– Press left restraining bracket (6) inwards.

258 55048011501 EN - 12/2015


frs_003-024

6

– Swivel the restraining brackets upwards.

Opening/closing the battery door

Opening the battery door

NOTE

The battery door is equipped with a springmechanism and an end position latch so that itdoes not close automatically.

1

5060_003-064_V3

– Push the battery door release button (1)in the direction of the arrow, and open thebattery door forwards.

55048011501 EN - 12/2015 259


6210_600-001

Closing the battery door

DANGER WARNING

When closing the battery door,limbs could become trapped - riskof crushing!When closing the battery door,nothing should come between thebattery door and the edge of thechassis.– Carefully close the battery door.– Only close the battery door if thereare no parts of the body in the way.

WARNING

When closing the battery door, thereis a risk of trapping the battery cable.If the cable is crushed or sheared off,there is a risk of short circuit!When closing the battery door,nothing should come between thebattery door and the edge of thechassis.– Carefully close the battery door.– Only close the battery door if thebattery cable is not in the way.

WARNING

Risk of accident due to the battery door opening!An unlocked battery door may open if the truckdecelerates sharply. If the battery door opens whiledriving, there is risk of damage from a collision.– Ensure that the battery door is shut securely.– Drive the truck only when the battery door is

locked.

DANGER

Risk to life from the battery sliding out!If the battery door is not locked and the truck tipsover, this may lead to the battery falling on thedriver!– Ensure that the battery door is shut securely.– Drive the truck only when the battery door is

locked.

260 55048011501 EN - 12/2015


NOTE

The apertures in the door are necessary forforced ventilation and must not be blocked.

NOTE

If the internal roller channel or battery bridge(variant) is not locked correctly, it is notpossible to close the battery door.


– Close the battery door securely by pushingit into the engaged position.

– Ensure that the battery door is shut se-curely.

Disconnecting the battery maleconnector

CAUTION

Risk of component damage!If you remove the battery male connector whilethe key switch is switched on (under load), an arcwill be produced. This can lead to corrosion at thecontacts, which considerably shortens their servicelife.– Do not disconnect the battery male connector

while the key switch is switched on.– Only disconnect the battery male connector

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

– Open the battery door.

55048011501 EN - 12/2015 261


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 cannotbe crushed - either when removing orinserting the battery, or when closingthe battery door.– Check the connecting cable fordamage.

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


Battery replacement using a bridge

Removing the battery

DANGER WARNING

If the truck is not parked on horizontalground, there is nothing to preventthe battery rolling away once the lockhas been opened, leading to a risk ofcrushing and shearing!– The truck must be parked onhorizontal ground.

– People must not stand directly inthe battery’s direction of travel or inthe battery compartment.

– Do not place objects or any partsof the body between the batteryand the truck chassis.

– Use only the handles that areprovided and identified.

262 55048011501 EN - 12/2015


CAUTION

If the battery cable is trapped itmay be damaged, there is a risk ofcrushing!– Position the battery cable on thebattery in such a way that it cannotbe crushed - either when removingor inserting the battery, or whenclosing the battery door.

CAUTION

The battery door may be damaged if it is struck bythe battery!– Ensure that the battery door is fully open and

secured during battery removal.





CAUTION

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

1

5060_003-051

– Disconnect the battery male connector (1)from the plug connection by pulling in thedirection of the arrow.

55048011501 EN - 12/2015 263


The bridge (1) is now freely accessible andshould be folded down for removing thebattery.

– Observe decal information (11) for the indi-vidual procedures for battery replacementshown on the inside of the battery door.

5

6 2

3

45060_003-124_V3

– Raise the bridge support (3) at the red webbelt (2) until the lock (4) audibly engages.

– Ensure that the battery stop (5) is clear ofthe edge of the battery tray (6).

264 55048011501 EN - 12/2015


– Fold down the bridge (1) at the red web belt.

WARNING

If the bridge folds down whilst the battery is beingtaken out, the battery can roll forward in an uncon-trolled manner, creating a risk of crushing!– Ensure that the bridge support stands vertically

under the bridge.

– Grip the side battery stop (7) at the front andfold it up.

WARNING

The battery can nowmove freely and may roll awayunimpeded, creating a risk of crushing!– People must not stand directly in the battery’s

direction of travel or in the battery compartment.– Do not place objects or any parts of the body

between the battery and the truck chassis.– Do not attempt to keep hold of the battery if it rolls

away.

5060_003-126_V26 5

9

– Carefully pull the battery tray (6) with thebattery (9) completely out of the batterycompartment to the battery stop (5) on thebridge.

NOTE

Thebattery stop ismounted ona pull-out pieceand travels with the battery to the end stop ofthe pull-out piece.

– Transfer the battery using the crane; seechapter "Battery transport with crane".

Installing the battery

CAUTION

If when the battery is being installed the batteryhood or the battery door are not fully open, or thebattery stops are not folded in or pulled out, or ifthere are objects in the truck’s battery compart-ment, considerable damage will be done to thesecomponents during installation of the battery.



– Fold down the side battery stop.

55048011501 EN - 12/2015 265


– Pull out the battery stop with the pull-outpiece fully.

– Remove all objects from the battery com-partment.

CAUTION

The battery must be positioned carefully so that itis flat on the horizontal bridge. Setting the batterydown on the battery stops can deform the stops orthe bridge; the battery then cannot be inserted.

– Ensure that the bridge support standsvertically under the bridge.

– Ensure that the battery has not been setdown on the battery stops.

– Ensure that the battery is resting right upagainst the battery stops.

5060_003-147_V3

7

5

9

– Using the crane, carefully set down thebattery (9) on to the bridge and push it upagainst the stops (5) and (7).

– Release the battery from the lifting gear andtake away the crane.

– Push the battery fully into the batterycompartment of the truck.

266 55048011501 EN - 12/2015


– Fold down the side battery stop (7).

– Fully insert the battery stop (5) on the cableguide (10).

– Completely fold up the bridge (1) at the redweb belt (2).

CAUTION

The battery cable may be damaged by becomingtrapped— there is risk of short circuit due to crus-hing!If the battery cable is positioned between thebattery tray and the battery bridge to be foldedup, the battery cable will become trapped. This canlead to the battery cable or battery male connectorbecoming damaged and a short circuit.– Only fold up the battery bridge when the entire

battery cable is positioned on top of the battery.

NOTE

To fold down the bridge support, the lockmust be released. The lock is released witha two-handed operation. This protects theoperator against injuries due to an incorrectsequence of operations.

WARNING

The bridge support can be folded down. Duringfolding down there is risk of crushing if the correctsequence of operations is not followed.– Do not reach into the assembly or locking

mechanisms.– Hold the bridge support at the red web belt until it

is fully folded down.– Follow the sequence of operations.

55048011501 EN - 12/2015 267


6

2

11 4

5

5060_003-128_V3

– To fold down the bridge support, raise thered web belt (2) and keep it raised so as tofree the lock (4).

– Push the release button (11) and hold it.

– Slowly fold the bridge support right down.

– Release the web belt and the releasebutton.

DANGER

If the battery is not locked correctly, the batterycan slide out of the truck, with potentially fatalconsequences!– Ensure that the battery stop (5) is fully pushed in

and engaged behind the battery tray (6).

5060_003-155_V2

12 10– Always lay the battery cable (12) to the leftof the cable guide (10), as shown in thediagram.

CAUTION

The battery cable may be damaged by becomingtrapped— there is risk of short circuit due to crus-hing!If the battery cable (12) is laid to the right of the cableguide (10), the battery cable will become trappedbetween the battery bridge and the battery door.This can lead to the battery cable or battery maleconnector becoming damaged and a short circuit.– Ensure that the battery cable is correctly positio-

ned.



– Close the battery hood.

268 55048011501 EN - 12/2015


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.

55048011501 EN - 12/2015 269


Changing the battery using theinternal roller channel

Activities before removal of the battery

DANGER WARNING

If the truck is not parked on horizontalground, there is nothing to preventthe battery rolling away once the lockhas been opened, leading to a risk ofcrushing and shearing!– The truck must be parked onhorizontal ground.

– People must not stand directly inthe battery’s direction of travel or inthe battery compartment.

– Do not place objects or any partsof the body between the batteryand the truck chassis.

– Use only the handles that areprovided and identified.





CAUTION

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

1

5060_003-051

– Disconnect the battery male connector (1)from the plug connection by pulling in thedirection of the arrow.

270 55048011501 EN - 12/2015


5060_003-134

1

The battery lock (1) is now freely accessibleand must be swung down and pushed underthe battery tray prior to removing the battery.

CAUTION

If the battery cable is trapped itmay be damaged, there is a risk ofcrushing!– Position the battery cable on thebattery in such a way that it cannotbe crushed - either when removingor inserting the battery, or whenclosing the battery door.

CAUTION

The battery door may be damaged if it is struck bythe battery!– Ensure that the battery door is fully open and

secured during battery removal.

CAUTION

If the battery rolls out of the battery compartmentwhen no external device is present, this can lead tomaterial damage.– Before removing the battery, always position

an external device (such as an external rollerchannel; see chapter "Replacing the batteryusing an external roller channel").

4

3

2

1

5060_003-135

– Lift the lock (1) at the handle (2).

– Ensure that the lock catch (3) is clear of theedge of the battery tray (4).

55048011501 EN - 12/2015 271


5060_003-136

4

1

2

– Grip the lock (1) at the handle (2) and fold itdown fully.

– Push the lock fully under the battery tray (4).

WARNING

The battery can nowmove freely and may roll awayunimpeded, creating a risk of crushing!– People must not stand directly in the battery’s

direction of travel or in the battery compartment.– Do not place objects or any parts of the body

between the battery and the truck chassis.– Do not attempt to keep hold of the battery if it rolls

away.

The battery is now freely accessible and canbe pulled out of the battery compartment usingan external device (such as an external rollerchannel; see chapter "Replacing the batteryusing an external roller channel").

Activities after installation of the battery

5060_003-149

4

1

2

– Grip the lock (1) at the handle (2), pull it outfrom under the battery tray and swing it up.

272 55048011501 EN - 12/2015


4

3

2

1

5060_003-148

– Grip the lock (1) at the handle (2) and lowerit vertically, ensuring that the lock catch (3)engages behind the edge of the battery tray(4).

DANGER

If the battery is not locked correctly, the batterycan slide out of the truck, with potentially fatalconsequences!– Ensure that the lock is fully lowered and that

the lock catch engages behind the edge of thebattery tray.




Battery replacement using anexternal roller channel

Preparing the external roller channel forbattery replacement

NOTE

Trucks with an integral roller channel allowthe battery to be changed using a hand pallettruck which is equipped with an external rollerchannel.

DANGER

Risk of crushing due to the hand pallet truck tippingover or rolling away!– The load capacity of the hand pallet truck must

correspond to at least the battery weight (seebattery identification plate).

– The hand pallet truck must be equipped with aparking brake.

– Observe the operating instructions for the handpallet truck.

NOTE

The external roller channel is designed fortransporting a variety of widths of batteries.Before using the external roller channel,the battery type to be transported should bedetermined and the roller channel preparedaccordingly.

55048011501 EN - 12/2015 273


5060_003-140

1 2 3 4 5

4 3 2 1

4 3 2 1

B

C

A

– Determine the battery type on the batteryidentification plate.

– Position the deflector plates (A) and (B)appropriately for the battery type, and boltthem into place.

– Position the guide bolts (C) appropriately forthe battery type, and bolt them into place.

NOTE

The positions shown for the deflector platesand the guide bolts can be found in thefollowing table.

Batterytype (C) (A) (B)

4 Pzs 1 1 1

5 Pzs 1 1 2

6 Pzs 2 2 3

7 Pzs 3 3 4

8 Pzs 4 4 5

– Perform these activities before removingthe battery; see the chapter entitled "Chang-ing the battery using the internal roller chan-nel".

5060_003-15156

7

– Fully open the safety lever (7) by moving itin the direction of the arrow.

– Position the hand pallet truck (5) so that theexternal roller channel (6) is in front of thebattery compartment of the truck.

274 55048011501 EN - 12/2015


2

1

4

3

5060_003-142

– Position the guide bolt (1) directly under-neath the slotted hole (2).

NOTE

The forks of the hand pallet truck should belowered sufficiently far that the guide bolt (1)can be slid under the bottom plate (4) of theforklift truck.

– Lift the forks of the hand pallet truck andguide the guide bolt into the slotted hole untilthe stop plate (3) is against the underside ofthe truck’s bottom plate (4).

– Apply the parking brake on the hand pallettruck to secure it against rolling away.

5060_003-143

8

97

– Carefully pull the battery (8) out of thebattery compartment until it reaches thebattery stop (9) on the external rollerchannel.

– Fully apply the safety lever (7) by movingit in the direction of the arrow in front of thebattery.

– Lower the forks of the hand pallet truck untilthe guide bolt of the stop plate is completelyclear of the slotted hole in the bottom plate.

– Release the parking brake on the handpallet truck.

The battery is now ready to be transported.

55048011501 EN - 12/2015 275


5060_003-153

6

7

8

Transporting and setting down thebattery

DANGER WARNING

If the safety lever (7) is not applied infront of the battery (8), the battery canroll off the external roller channel (6),creating a risk of crushing!– Ensure that the safety lever (7) isfully applied in front of the battery(8).

WARNING

Excessive speed, sharp turns and heavy brakingcan cause the hand pallet truck and battery to tipover, creating a risk of injury!– Take special care when transporting the battery.– Keep the transport speed low, steer carefully

and brake gently.– Do not use the methods described above to

transport the battery over long distances.

– Transport the battery to the intendedstorage space.

CAUTION

If the battery support is not sufficiently strong, itcan be damaged or destroyed by the weight of thebattery.– The battery must be stored on a suitable beam

support or on suitable racking.– The battery must not be stored on a wooden

beam or the like.

– Set down the battery.

Installing the battery

CAUTION

If when the battery is being installed the batteryhood or the battery door are not fully open, or theinterlock is folded up or pulled out, or if there areobjects in the truck’s battery compartment, consi-derable damage will be done to these componentsduring installation of the battery.– Open the battery hood.– Open the battery door.– Remove all objects from the battery compart-

ment.

276 55048011501 EN - 12/2015


2

1

4

3

5060_003-142

– Position the hand pallet truck so that theexternal roller channel is in front of thebattery compartment of the truck.

NOTE

The forks of the hand pallet truck should belowered sufficiently far that the guide bolt (1)can be slid under the bottom plate (4) of theforklift truck.

– Position the guide bolt (1) directly under-neath the slotted hole (2).

– Lift the forks of the hand pallet truck andguide the guide bolt into the slotted hole untilthe stop plate (3) is against the underside ofthe truck’s bottom plate (4).

– Apply the parking brake on the hand pallettruck to secure it against rolling away.

5060_003-15256

7

8

– Fully open the safety lever (7) by moving itin the direction of the arrow.

– Carefully slide the battery (8) from theexternal roller channel (6) fully into thebattery compartment.

– Lower the forks of the hand pallet truck(5) until the guide bolt of the stop plate iscompletely clear of the slotted hole in thebottom plate.

– Release the parking brake of the hand pallettruck and remove the hand pallet truck.

– Perform these activities after installing thebattery; see the chapter entitled "Changingthe battery using the internal roller channel".

Battery installation or batteryreplacement without onboarddevices

CAUTION

Possible risk of injury or risk of damage to compo-nents.The installation or replacement of the batterywithout truck-internal devices requires special toolsand specially trained staff.

55048011501 EN - 12/2015 277


If the truck does not have a battery bridge or aninternal roller channel as optional devices forthe battery installation or battery replacement,these activities must be carried out by theSTILL service centre.

CAUTION

Possible risk of injury or risk of damage to compo-nents.To install or remove the battery, do not disassemblethe available battery lock.

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.

Depending on the equipment, the battery canalso be removed for maintenance. This mustonly be carried out using the specified devices;see section "Lifting accessory" in the chapter"Safety regulations for handling the battery".

278 55048011501 EN - 12/2015


%75

5060_003-062_V2

1Checking the battery charge status

CAUTION

Deep discharges shorten the service life of thebattery.If a battery charge of 0% is shown on the display,this corresponds to a deep discharge of below 20%of the nominal capacity.– Avoid deep discharges (0% shown on the

display).– Charge the batteries at once.– Do not leave batteries in a discharged or partly

discharged state.



– Read the charge state (1) from the display.

– Charge a discharged or partly dischargedbattery.

Charging the battery

CAUTION

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

CAUTION

Possible damage to the male battery connector!If the battery male connector is disconnected orconnected while the ignition switch is switchedon or the battery charger is under load, an arcwill be generated at the battery male connector.This can lead to corrosion at the contacts, and canconsiderably shorten the service life of the contacts.– Switch off the key switch or battery charger be-

fore the battery male connector is disconnectedor connected.

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



55048011501 EN - 12/2015 279


– Always ensure adequate ventilation in thevicinity.

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

– Open the battery door completely.

1

5060_003-051

– Disconnect the battery male connector (1).

– Do not place anymetallic objects or tools onthe battery.

– Keep away from open flames and do notsmoke.

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

– Attach the battery male connector to thebattery charger plug.

NOTE

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

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 corrosion at the contacts, whichconsiderably shortens their service life.– Switch off the battery charger before the char-

ging cable is disconnected.

– Start the battery charger.

Once the charging process is complete:

– Turn off the battery charger.

– Disconnect the batterymale connector fromthe battery charger plug.

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

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

280 55048011501 EN - 12/2015


6210_600-001

– Close the battery door. When doing so,ensure that no cable is crushed betweenthe chassis and the battery door.

55048011501 EN - 12/2015 281

5 OperationDecommissioning

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.


282 55048011501 EN - 12/2015

Operation 5Decommissioning

5060_003-130

– Lower the fork carriage to the ground.

– Tilt the lift mast forwards until the tips of thefork arms rest on the ground.

– If attachments (variant) are fitted, retractthe working cylinders; see the chapterentitled "General instructions for controllingattachments".

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

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.

55048011501 EN - 12/2015 283


5060_003-169

2

1

1

Wheel chock (variant)The wheel chock (variant) is used to preventthe truck from rolling away on a slope.

NOTE

Due to the design, the securely parked truckcan only be chocked at the rear wheel. Thetruck must be parked facing uphill on slopeswhere a wheel chock is to be used.

– Lift the handle (2) on the support mounting.

– Remove the wheel chock (1) from thesupport mounting.

– Slide the wheel chock underneath the backwheel on the side facing downhill.

NOTE

After use, return the wheel chock to thesupport mounting and press the handle (2)down again.

Shutting down and storing the truck

CAUTION

Component damage due to incorrect storage!In the event of incorrect storage or shutdown formore than two months, the truck may suffer corro-sion damage. If the truck is parked in an ambienttemperature of below –10 °C for an extended pe-riod, the batteries cool down. The electrolyte mayfreeze 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 times and, if fitted,moveattachmentrepeatedly.

284 55048011501 EN - 12/2015


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

– Check the hydraulic oil level and top up ifrequired.

– Apply oil or grease thinly to all untreatedmoving parts.

– Grease the truck.

– Lubricate the joints and controls.

– Lubricate the battery hood interlock.

– Apply a suitable contact spray to all exposedelectrical contacts.

CAUTION





– Check the battery condition, acid level andacid density.

– Service the battery.

NOTE

Store only fully charged batteries.

CAUTION

Tyre deformation as a result of continuous loadingon one side!Have the truck raised and jacked up by the authori-sed service centre 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.

55048011501 EN - 12/2015 285


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 facilitates the

formation of condensation water.

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

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

Recommissioning after storageIf the truck has been in storage for longer thansixmonths, itmust be carefully checkedbeforebeing recommissioned. As in the annualinspection, this check should also includeall safety items for the truck.

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

– Lubricate the joints and controls.

– 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.

– Change the brake fluid.

– Put the truck into operation.

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

286 55048011501 EN - 12/2015


NOTE

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

55048011501 EN - 12/2015 287

5 OperationCleaning

CleaningCleaning the truck– Park the truck securely.

CAUTION

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

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

the key switch switched on in an emergency.


WARNING

There is a risk of injury due to fallingwhen climbing onto the truck!When climbing onto the truck, youcan get stuck or slip on componentsand fall. Higher points on the truckshould only be accessed using theappropriate equipment.– Adhere strictly to the followingsteps.

– Use only the steps provided to climb ontothe truck.

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

Preparing the truck for cleaning

CAUTION

If water penetrates the electrical system, there is arisk of short circuit!– Adhere strictly to the following steps.

– Switch the electrical system off beforecleaning.

– Do not spray electric motors and otherelectrical components or their coversdirectly with water.

288 55048011501 EN - 12/2015

Operation 5Cleaning

CAUTION

Excessive water pressure or water and steam thatare too hot can damage truck components.– Adhere strictly to the following steps.

– Only use high-pressure cleaners with amaximum output power of 50 bar and at amaximum temperature of 85°C.

– When using high-pressure cleaners, makesure there is a distance of at least 20 cmbetween the nozzle and the object beingcleaned.

– Do not aim the cleaning jet directly atadhesive labels or decal information.

DANGER

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

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

DANGER

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

– Do not use flammable fluids for cleaning.

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

CAUTION

Abrasive cleaning materials can damage compo-nent surfaces!Using abrasive cleaning materials that are unsuita-ble for plastics may dissolve plastic parts or makethem brittle. The screen on the display operatingunit may become cloudy.– Adhere strictly to the following steps.

55048011501 EN - 12/2015 289

5 OperationCleaning

– Only clean plastic parts with plastic cleaningmaterials.

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

Washing the truck exterior– Clean the truck exterior with water-solublecleaning materials and water (water jet,sponge, cloth).

– Clean all walk-in areas, the oil filling open-ings and their surroundings, and the lubri-cating nipples before lubricating.

NOTE

Please note: The more often the truck iscleaned, the more frequently it must belubricated.

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.

290 55048011501 EN - 12/2015

Operation 5Cleaning

6210_810-004

Cleaning load chains

WARNING

Risk of accident!Load chains are safety elements.The use of cold/chemical cleaners or fluids that arecorrosive or contain acid or chlorine can damagethe chains and is forbidden!– Observe the manufacturer’s guidelines for

working with cleaning materials.

– Place a collection vessel under the lift mast.

– Clean with paraffin derivatives, such asbenzine.

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

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

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

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

ENVIRONMENT NOTE

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

55048011501 EN - 12/2015 291

5 OperationCleaning

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.

292 55048011501 EN - 12/2015

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-

294 55048011501 EN - 12/2015

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

55048011501 EN - 12/2015 295


296 55048011501 EN - 12/2015


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 the accelerator pedal and brake pedal for damage and function, and lubricate

Check driver’s seat for correct function and for damage

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

Check battery hood, interlock and sensor for correct function and for damage

Check the dual pedal variant for damage and 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 unit: Check that it is securely attached and check for leaks

Gearbox oil: Check oil level

Steering

Check the steering system for correct function and for leaksCheck that the steering wheel is securely attached and check the turning handle fordamageCheck the steering stop

Check steering chain; if necessary, adjust the tension and apply oil

Brake

Check all mechanical brake parts for condition, wear and correct function

Check the brake fluid level

Check brake fluid switch for correct function

Carry out brake test

Electrical system

Check all power cable connections

Check main contactor contacts

55048011501 EN - 12/2015 297


At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check the switches, transmitters and sensors for correct function

Check the lighting and indicator lights

Battery and accessoriesCheck battery for damage and acid density; observe manufacturer’s maintenanceinstructionsCheck battery male connector and cable for damage

Hydraulics

Check the hydraulic system for condition, correct function and leaks

Check the hydraulics blocking function (ISO valve)

Check the oil level

Lift mast

Check the mast bearings for damage and lubricate. Check the tightening torque

Check the mast profiles for damage and wear, and lubricate

Check the load chains for damage and wear, adjust and lubricate

Check the lift cylinder and connections for damage and leaks

Check the guide pulleys for damage and wear

Check the support rollers and chain rollers for damage and wear

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

Check the tilt cylinder and connections for damage and leaks

Check the fork carriage for damage and wear

Check the fork arm interlock for damage and correct function

Check the fork arms for wear and deformation

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

Special equipmentCheck the attachments for wear and damage; observe themanufacturer’s mainten-ance instructionsCheck the trailer coupling for wear and damage; observe the manufacturer’s mai-ntenance instructionsGeneral

Read out error numbers and delete list

Reset the maintenance interval

298 55048011501 EN - 12/2015


At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check labelling to ensure it is complete

Perform a test drive

55048011501 EN - 12/2015 299


300 55048011501 EN - 12/2015


Maintenance - 3000 hours/every two years

At operating hours Carriedout

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work

Power unit

Change the gearbox oil

Brake

Change the brake fluid

Hydraulics

Change the hydraulic oil.

Replace the return line filter, breather filter and high-pressure filter (variant)

Ordering spare parts and wearingpartsSpare parts are provided by our spare partsservice department. The information requiredfor ordering parts can be found in the spareparts list.

Only use spare parts as per the manufac-turer’s instructions. The use of unapprovedspare parts can result in an increased risk ofaccidents due to insufficient quality or incor-rect assignment. Anyone using unapprovedspare parts shall assume unlimited liability inthe event of damage or harm.

Quality and quantity of the requiredoperating materialsOnly the operating materials specified in themaintenance data table may be used.

– The required consumables and lubricantscan be found in themaintenance data table.

Oil and grease types of a different qualitymust not be mixed. This negatively affectsthe lubricity. If a change between different

55048011501 EN - 12/2015 301


manufacturers 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!

302 55048011501 EN - 12/2015


Maintenance data table

General lubrication points

Unit Operating materials Specifications QuantityLubrication Grease DIN 51825-KPF2

N-20penetration class 2,lithium-saponified,ID no. 141001

As required

Battery

Unit Operating materials Specifications QuantitySystem filling Distilled water As required

Insulation resistance DIN 43539VDE 0510

Min. 500 /V againstground

Electrical system

Unit Operating materials Specifications QuantityInsulation resistance DIN EN 1175

VDE 0117Min. 1000 /V against

ground

Controls/joints

Unit Operating materials Specifications QuantityGrease DIN 51825-KPF2

N-20penetration class 2,lithium-saponified,ID no. 163488

As requiredLubrication

Oil SAE 80MIL-L2105API-GL4

As required

55048011501 EN - 12/2015 303


Hydraulic system

Unit Operating materials Specifications QuantityHydraulic oil HVLP 68

DIN 51524, part 3Hydraulic oil for thefood industry (variant)

USDA H1DIN 51524

System filling

Hydraulic oil for coldstore application

HVLP 68DIN 51524, part 3

Lift mast height up to2100 mm =max. 20 lLift mast height over2100 mm =max. 26 l

Lubrication Grease RIVOLTA S.K.D.3400/M.T.X.60ID no. 127905

As required

Tyres

Unit Operating materials Specifications QuantitySuperelastic tyres Wear limit To wear mark

Solid rubber tyres Wear limit To wear mark

Steering axle/drive axle

Unit Operating materials Specifications QuantityWheel nuts/screws Torque wrench 195 Nm

Wheel gear Gearbox oil ARAL Degol GS 220

Running axle

Unit Operating materials Specifications QuantityWheel nuts/screws Torque wrench 195 Nm

Brakes Brake fluid ATE DOT 4 SL.6 0.2 l

Lift mastUnit Operating materials Specifications Quantity

Lubrication Super-pressureadhesive lubricant

ID no. 147873 As required

Stop Play min. 2 mm

Mast bearing screws Torque wrench 275 Nm

Load chainsUnit Operating materials Specifications Quantity

Lubrication Chain spray ID no. 141001ID no. 156428

As required

Setting Support roller distance 35 mm under the topedge of the inner mast

304 55048011501 EN - 12/2015


Washer system

Unit Operating materials Specifications QuantitySystem filling Screen wash Winter, ID no. 172566 As required

.

55048011501 EN - 12/2015 305

6 MaintenanceSafety regulations for maintenance

Safety regulations for maintenanceGeneral informationTo prevent accidents during maintenance andrepair work, all necessary safety measuresmust be taken, e.g.:


– Turn off the key switch and remove the key.


– Ensure that the truck cannot move uninten-tionally or start up inadvertently.

– If required, have the truck jacked up by theauthorised service centre.

– Have the raised fork carriage or the ex-tended lift mast secured against accidentallowering by the authorised service centre.

– Insert an appropriately sized wooden beamas an abutment between the lift mast andthe cab, and secure the lift mast to preventit tilting backwards unintentionally.

– Observe the maximum lift height of the liftmast, and compare the dimensions fromthe technical data with the dimensions ofthe hall into which the truck is to be driven.These steps are taken to prevent a collisionwith the ceiling of the hall and to avoid anydamage caused as a result.

Working on the hydraulic equipmentThe hydraulic systemmust be depressurisedprior to all work on the system.

Working on the electrical equipmentWork may only be performed on the electricalequipment of the truck when it is in a voltage-free state. Function checks, inspectionsand adjustments on energised parts mustonly be performed by trained and authorisedpersons, taking the necessary precautionsinto account. Rings, metal bracelets etc.must be removed before working on electriccomponents.

306 55048011501 EN - 12/2015

Maintenance 6Safety regulations for maintenance

To prevent damage to electronic systemswith electronic components, such as anelectronic driving regulator or lift control, thesecomponents must be removed from the truckprior to the start of electric welding.

Work on the electrical system (e.g. connectinga radio, additional headlights etc.) is onlypermitted with approval from the authorisedservice centre.

Safety devicesAfter maintenance and repair work, all safetydevices must be reinstalled and tested foroperational reliability.

Set valuesThe device-dependent set values must beobserved when making repairs and whenchanging hydraulic and electrical compo-nents. These are listed in the appropriatesections.

Lifting and jacking up

DANGER

There is a risk to life if the truck tips over!If not raised and jacked up properly, the truck maytip over and fall off. Only the hoists specified in theworkshop manual for this truck are allowed and aretested for the necessary safety and load capacity.– Only have the truck raised and jacked up by the

authorised service centre.– Only jack the truck up at the points specified in

the workshop manual.

The truck must be raised and jacked up forvarious types of maintenance work. Theauthorised service centre must be informedthat this is to take place. Safe handling ofthe truck and the corresponding hoists isdescribed in the truck’s workshop manual.

55048011501 EN - 12/2015 307

6 MaintenanceSafety regulations for maintenance

Working at the front of the truck

DANGER

Risk of accident!If the lift mast or fork carriage is raised, no workmay be performed on the lift mast or at the front ofthe truck unless the following safety measures areobserved.– When securing, only use chains with sufficient

load-bearing capacity.– Contact the authorised service centre.

CAUTION

Possibility of damage to the ceiling!– Note the maximum lift height of the lift mast.

Securing the lift mast against tiltingbackwardsA hardwood beam with a cross-section of120 x 120 mm is required. The length ofthe hardwood beam must approximatelycorrespond to the width of the fork carriage(b3). To avoid impact injuries, the hardwoodbeam must not protrude beyond the outercontour of the truck. A maximum lengthmatching the total width (b1) of the truck isrecommended.

– Obtain the dimensions (b1) and (b3) fromthe corresponding VDI datasheet.

308 55048011501 EN - 12/2015

Maintenance 6Safety regulations for maintenance

1 2

3

6210_001-030_V3

– Clamp the hardwood beam (1) between thedriver protection structure (2) and the liftmast (3).

Removing the lift mast

DANGER

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

remove the lift mast.

Securing the lift mast against falling off

DANGER

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

secure the lift mast.

55048011501 EN - 12/2015 309

6 MaintenanceProviding access to maintenance points

Providing access to maintenance pointsRemoving/installing the valve cover

Removing the valve cover

NOTE

A 4-mm hexagon socket wrench (2) is locatedbetween the battery hood (1) and valve cover(5) to assist in carrying out the following work.This hexagon socket wrench must remain inthe truck at all times.

In the single-pedal version:

– Remove the right bottom plate (4) ⇒ Chap-ter "Removing/installing the bottomplate", P. 6-311.

In the dual-pedal version:

3

5

123

4

5060_003-049_V2

– Remove the right bottom plate (4) ⇒ Chap-ter "Removing/installing the bottom plate fordual pedal operation (variant)", P. 6-313.

– Unscrew the four screws (3).

– Lift up the valve cover (5) and remove.

Installing the valve cover– Position the valve cover and attach it withfour screws.

– Install the right bottom plate.

– Return the hexagon socket wrench to itsposition between the battery hood and valvecover.

310 55048011501 EN - 12/2015

Maintenance 6Providing access to maintenance points

Removing/installing the bottom plate

5060_003-118

4

1

Removing the left bottom plate

CAUTION

There is a risk of short circuit if thecables are damaged.– Check the connecting cable fordamage.

– When removing and reinstallingthe bottom plate, ensure thatthe connecting cables are notdamaged.

DANGER WARNING

When closing the bottom plate,nothing should come between thebottom plate and the edge of thechassis. There is a risk of crushing!– When closing the bottom plate,make sure nothing is between thebottom plate and the edge of thechassis.

NOTE

The left bottom plate (1) has a recess whichthe operator can insert his fingers into to lift it.The recess is underneath the rubber covering(4).

– Fold the rubber covering (4) forwards andreach into the recess.

2

5060_003-057_V2

3

1

– Lift up the bottom plate (1).

– Disconnect the connecting plug (2) for thesignal horn foot switch (3).

– Remove the bottom plate.

Installing the left bottom plate– Position the bottom plate.

– Connect the connecting plug for the signalhorn foot switch.

– Close the bottom plate.

55048011501 EN - 12/2015 311


5060_003-132_V2

6 5

Removing the right bottom plate

NOTE

The accelerator pedal is attached to the rightbottom plate and is removed with it. Theconnecting plug for the accelerator is locatedunderneath the bottom plate.

– Lift the bottom plate (5) forwards andcarefully guide it upwards over the brakepedal (6).

– Disconnect the connecting plug for theaccelerator.


Installing the right bottom plate– Position the bottom plate.

– Connect the connecting plug for the accel-erator.

– Lower the bottom plate, carefully guiding itdownwards over the brake pedal.


312 55048011501 EN - 12/2015

Maintenance 6Providing access to maintenance points

Removing/installing the bottom platefor dual pedal operation (variant)

5060_003-117

51 2 3

4

Removing the right bottom plate

CAUTION

There is a risk of short circuit if thecables are damaged.– Check the connecting cable fordamage.

– When removing and reinstallingthe bottom plate, ensure thatthe connecting cables are notdamaged.

DANGER WARNING

When closing the bottom plate,nothing should come between thebottom plate and the edge of thechassis. There is a risk of crushing!– When closing the bottom plate,make sure nothing is between thebottom plate and the edge of thechassis.

NOTE

The accelerator pedals (3) and (5) are atta-ched to the left bottom plate and are removedwith it. Due to the design, the right bottomplate must always be removed first.

– Lift the bottom plate (1) forwards andcarefully guide it upwards over the brakepedal (2) and the forwards acceleratorpedal (3).


Installing the right bottom plate– Position the bottom plate.

– Lower the bottom plate, carefully guiding itdownwards over the brake pedal and theforwards accelerator pedal.


Removing the left bottom plate– Lift up the bottom plate (4).

55048011501 EN - 12/2015 313


– Disconnect the connecting plug for theaccelerator.


Installing the left bottom plate– Position the bottom plate.

– Connect the connecting plug for the accel-erator.


314 55048011501 EN - 12/2015

Maintenance 6Maintenance

Maintenance

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. 6-303.

• Driver’s seat guide• Cab door hinges (variant)• Battery door hinges or battery cover hinges• Control linkage (1) for valves

Checking the battery hood lock

DANGER

The battery could fall on the driver — there is a riskto life!If the hood lock malfunctions and the truck tips overor is subjected to sharp deceleration, the batteryhood can open and the battery can fall out.– If the hood lock is deformed, damaged or stiff,

inform STILL Service immediately and do notoperate the truck.

– Always check the hood lock after an accident.– Check the hood lock for secure function.– Pivot points must be greased and move easily.

NOTE

The interval for greasing is influenced signifi-cantly by the application conditions and envi-ronmental conditions affecting the truck. Asrequired and after every 1000 hours, performa visual inspection and function check of thehood lock. Grease all moving parts of the hoodlock if necessary.

55048011501 EN - 12/2015 315

6 MaintenanceMaintenance

5060_003-079_V2

1 2 3 4

– Open the battery hood (4), see ⇒ Chap-ter "Opening and closing the batteryhood", P. 5-254.

– Check components (1) and (2) of the hoodlock (3) for ease of movement.

– Grease the lock mechanism.


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.– A defective belt must only be 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.

316 55048011501 EN - 12/2015


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 locksinto place properly.

When the belt tongue (2) is inserted, the beltmust be held securely.

7090_342-0051

4

– The belt tongue (2) must release when thered button (4) is pressed.

– The automatic blocking mechanism mustbe tested at least once a year:

– Park the forklift truck on level ground.

– Pull out the belt with a jerk.

The automatic blocking mechanism mustblock extension of the belt.

– Tilt the seat at least 30°. In order to dothis, open the battery hood fully, see⇒ Chapter "Opening and closing the batteryhood", P. 5-254.

– 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 replaced afteran accident.

55048011501 EN - 12/2015 317


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.

Servicing wheels and tyres

WARNING

Risk of accident! Uneven wear decreases thestability of the truck and increases the brakingdistance.– 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 partsmust never be changed and rim parts fromdifferent manufacturers must not be mixed.

318 55048011501 EN - 12/2015


5060_003-116_V2

21

6311_003-005

Checking condition and wear of the tyres

WARNING

Tyre quality affects the stability and handling of thetruck.Changes can only be made in consultation with themanufacturer.When changingwheels or tyres, always ensure thatthis does not cause the truck to tilt to one side (e.g.always change right and left wheels at the sametime).

NOTE

The wear of the tyres on an axle must beapproximately the same.• Superelastic tyres and solid rubber tyrescan be worn down to the wear mark (2).

– If necessary, remove any foreign bodies (1)imbedded in the tyre tread.

55048011501 EN - 12/2015 319


5060_003-131_V2

3

Checking wheel fastenings– Check wheel fastening nuts (3) and bolts forsecure positioning, and retighten them asnecessary.

– Observe the torques; see the "maintenancedata table".

5051_200-001_V2

1

2

3

Checking the drive axle for oil level,leaks and general condition

Drive axle: checking the oil level

DANGER

Consumables are toxic!– Note safety regulations for working with gearbox

oil, see ⇒ Chapter "Oils", P. 3-39.

NOTE

See the workshop manual for the fillingquantity for gearbox oil as well as for thetightening torque of the oil filler plug (1), orask the relevant service centre.

– Turn the steering completely to the right, inorder to make the oil filling opening at thegearbox housing (2) accessible.

– Park the truck securely; see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 5-282.

NOTE

The truck must be standing on a flat, levelsurface.

– Unscrew the oil filler plug (1).

320 55048011501 EN - 12/2015


– The oil level must reach the lower edge ofthe bore; top up if necessary, see ⇒ Chap-ter "Maintenance data table", P. 6-303.

ENVIRONMENT NOTE

Carefully collect any spilled oil and dispose ofit in accordance with regulations.

Checking the drive axle for leaks– Check the gearbox housing (2) around thedrive axle and gearbox cover (3) for leaks(traces of oil).

– In the event of leaks, inform the serviceteam.

8

9

0

6

7

4

3

5

7312_003-176_en

Checking the brake fluid levelIf the message SERVICE BRAKE appears inthe display operating unit, the brake fluid levelmust be checked.

WARNING

Risk of injury from becoming trapped in movingparts!– Observe the safety regulations for working at the

front of the truck; see ⇒ Chapter "Working at thefront of the truck", P. 6-308.

WARNING

Brake fluid is hazardous to your health!– Observe the safety regulations for working with

brake fluid, see ⇒ Chapter "Brake fluid", P. 3-42.

WARNING

Risk of accident as a result of a low brake fluid level!If the brake fluid level is low, there are leakages.– Top up the brake fluid.– Check the brake system for leaks and repair any

that are found.– Do not place the truck back into operation until

the cause is repaired.

55048011501 EN - 12/2015 321


4

1

2

3

5060_003-163

– Check the brake fluid level at the expansiontank (1).

The brake fluid level must be between theMAX and MIN marks.

WARNING

The brake fluid level sensor cables can tear offwhen the filler cap is opened!When the filler cap (2) is unscrewed, the cables (4)must not be rotated also, otherwise the cables maytear off. The brake fluid level sensor (3) is stored inthe rotatable filler cap and can be held in positionwhen turning the cover.– Keep the brake fluid level sensor with cables in

position and unscrew the cover.– If necessary, remove the cables before opening

the cover and reattach after servicing.

– Top up any missing brake fluid to the MAXmark according to the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-303.

4

1

2

3

5060_003-163

Checking the brake fluid level sensor

WARNING

Risk of injury from becoming trapped in movingparts!– Observe the safety regulations for working at the

front of the forklift truck, see ⇒ Chapter "Workingat the front of the truck", P. 6-308.

WARNING

Brake fluid is hazardous to your health!– Observe the safety regulations for working with

brake fluid, see ⇒ Chapter "Brake fluid", P. 3-42

WARNING

The brake fluid level sensor cables can tear offwhen the filler cap is opened!When the filler cap (2) is unscrewed, the cables (4)must not be rotated also, otherwise the cables maytear off. The brake fluid level sensor (3) is stored inthe rotatable filler cap and can be held in positionwhen turning the cover.– Keep the brake fluid level sensor with cables in

position and unscrew the cover.

322 55048011501 EN - 12/2015



– Unscrew filler cap (2).

– Press brake fluid level sensor switch (3).

TheSERVICE BRAKEmessagemust appearin the display.

– If the message does not appear in thedisplay, inform the service centre.

– When testing is complete, screw the fillercap back on.

55048011501 EN - 12/2015 323


Checking the battery condition, acidlevel and acid density

CAUTION

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

ons for the battery.

– Remove the battery from the truck, seechapter "Handling the battery".

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

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!

– Have defective battery overhauled.

6321_003-126

1

2

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

For batteries with "caged cell plugs", theacid must reach the bottom of the cage; forbatteries without "caged cell plugs", it mustcover the lead plates by about 10–15 mm.

– Topupmissing fluidwith distilledwater only.

The battery cell coversmust be kept clean anddry.

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

– Tighten the battery terminals (2).

– Check acid density with an acid siphon.

After charging, this value must be between1.24 and 1.29 kg/l.

324 55048011501 EN - 12/2015


Checking the 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.

CAUTION




NOTE

Depending on the equipment, not all fuses willbe present in the truck.

The fuses are located at the rear, within thecontrol electronics section.


55048011501 EN - 12/2015 325


5060_003-158

1

– Open the cover (1).

– Remove the cover from the control electron-ics.

5060_003-159

3

3

2

– Check the condition of the main fuse (2)(no damage to the porcelain body) andcheck that it is securely attached; tightenthe clamping screws if necessary.

– Check the condition of fuses (3), check thatthe cable connections are secure and checkfor oxidation residues. Clean if necessary.

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 completion ofthe activities.

– Close the cover of the control electronics.

– Close the cover.



– Carry out a functional test.

326 55048011501 EN - 12/2015


Changing 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.

CAUTION




DANGER

Risk of fire!Using the wrong fuses can resultin lack of protection against shortcircuits.– Only use fuses with the prescribednominal current.

NOTE


The fuses are located at the rear, within thecontrol electronics section.


55048011501 EN - 12/2015 327


5060_003-158

1

– Open the cover (1).

– Remove the cover from the control electron-ics.

5060_003-159

3

3

2

– Locate the blown fuse; see the sectionentitled "Fuse assignment".

– Unscrew the faulty fuse (2) or remove thefaulty fuse (3) and replace it with a new fusewith the specified nominal current.

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 completion ofthe activities.

– Close the cover of the control electronics.

– Close the cover.



– Carry out a functional test.

328 55048011501 EN - 12/2015


Checking the hydraulic oil level

CAUTION

Hydraulic oils are hazardous to your health and areunder pressure during operation.– Observe the safety regulations in the chapter

"Hydraulic fluid".


– Remove the left bottom plate.

CAUTION

The maximum oil volume is dependent on theheight of the attached lift mast.The filling quantities vary by 6 l depending onthe lift mast version. Always observe the fillingquantities for the height of the lift mast, see thechapter "Maintenance data table".– For lift masts up to 2100 mm in height, the oil

level must be within the lower mark (2).– For lift masts over 2100mm in height, the oil level

must be within the upper mark (3).– The corresponding minimum marking must be

exceeded.

1

5060_003-065_V3

1

2

3

– Unscrew breather filter with oil dipstick (1).

– Check the oil level.

NOTE

The oil level must lie within the mark (2) or wi-thin the mark (3) on the dipstick, depending onthe height of the lift mast. The correspondingminimummarking must be exceeded.

– If necessary, pour hydraulic oil of thecorrect specification as specified in themaintenance data table into the filler neck.

ENVIRONMENT NOTE

• Carefully collect up any spilled oil anddispose of it in an environmentally friendlymanner.

– Screw in the breather filter with oil dipstick.

– Install the left bottom plate.

55048011501 EN - 12/2015 329


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

330 55048011501 EN - 12/2015


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. 6-303.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

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.

Maintaining the tow coupling

NOTE

Wear to moving parts can be significantlyreduced by appropriate servicing and regularlubrication of the coupling.

– Avoid over-greasing!

55048011501 EN - 12/2015 331


5060_003-111

3

42

Model RO*230– Check the condition of the pin retainer (2),change if necessary.

– Grease the supporting surface for thetow-bar eye (4) and the coupling pin (3).

4

7321_003-093

Model RO*244– Grease via the lubricating nipple in ac-cordance with the maintenance data ta-ble; see ⇒ Chapter "Maintenance data ta-ble", P. 6-303.

– For couplings without a lubricating nipple,unscrew the end cover (4), then open thecoupling and grease it.

– Grease the supporting surface for thetow-bar eye.

332 55048011501 EN - 12/2015

Maintenance 61000-hour maintenance / Annual maintenance

1000-hour maintenance / Annual maintenanceOther tasks– Perform all maintenance work; see the"Maintenance" chapter.

Checking the cable connections– Check that the feed cables of the pumpmotor and traction motor are securelyattached, in good condition and insulated.

NOTE

Oxidised connections and brittle cables resultin voltage drops and cause malfunctions.

– Remove oxidation residues and replacebrittle cables.

Checking accelerator pedal andbrake pedal– Check the accelerator pedal and brakepedal for damage and function.

– Remove the bottom plate as necessary andlubricate the mechanism.

7311_003-012

Checking the brake system forcorrect operation and leaks– Perform a functional check of the brakesystem; see⇒Chapter "Checking the brakesystem for correct function", P. 5-99.

If you determine that the pedal stop is soft,the pipe lines and hoses must be checkedfor condition and leaks and the brake systemmust be bled.

– Contact your service centre.

DANGER

Risk of accident!Do not put trucks with a defective brake system intoservice.

55048011501 EN - 12/2015 333

6 Maintenance1000-hour maintenance / Annual maintenance

Checking the dual pedal– Check the accelerator pedals for forwardsand reverse travel for damage and function.

– Remove the bottom plate; see ⇒ Chap-ter "Removing/installing the bottom plate fordual pedal operation (variant)", P. 6-313.

– Check that the support and springs of themechanism are securely positioned.

– Perform visual inspection to verify thatall screws are coated with retaining com-pound.

7094_810-004

Checking the lift cylinders andconnections for leaks

WARNING

Risk of injuryObserve safety regulations for working on the liftmast, see the "Working at the front of the truck"chapter.

– Check the hydraulic connections and liftcylinder for leaks (visual inspection).

– Have leaking screw joints or leaking hy-draulic cylinders repaired by the authorisedservice centre.

334 55048011501 EN - 12/2015

Maintenance 61000-hour maintenance / Annual maintenance

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.

6210_842-003

1

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.

55048011501 EN - 12/2015 335

6 Maintenance1000-hour maintenance / Annual maintenance

336 55048011501 EN - 12/2015

7

Technical data

7 Technical dataDimensions

Dimensions

1 Seat is adjustable ± 90 mm 2 Fork spacing is adjustable

338 55048011501 EN - 12/2015

Technical data 7VDI datasheet: RX50-10 and RX50-13

NOTE

Measurements h1, h3, h4, h6 and b1 arecustomer-specific and can be taken from theorder confirmation.

Centre of gravity position— centre of gravity"S"(Distance measured from the front axle)

RX50-10c 576 mm

RX50-10 592 mm

RX50-13 663 mm

RX50-15 720 mm

RX50-16 717 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.

VDI datasheet: RX50-10 andRX50-13Characteristics

Model RX50-10c RX50-10 RX50-13

Type number 5060 5061 5063

Manufacturer STILL GmbH STILL GmbH STILL GmbH

DriveElectric Electric Electric

Operation Seated Seated Seated

Rated capacity/load Q (kg) 1000 1000 1250

Load centre of gravity distance c (mm) 500 500 500

Load distance x (mm) 330 330 330

Wheelbase y (mm) 974 1028 1136.

55048011501 EN - 12/2015 339

7 Technical dataVDI datasheet: RX50-10 and RX50-13

Weight


Type number 5060 5061 5063

Net weight including battery kg 2358 2372 2561

Front axle load with load kg 2833 2832 3247

Rear axle load with load kg 525 540 564

Front axle load without load kg 981 1025 1084

Rear axle load without load kg 1377 1347 1477.

Wheels, chassis frame


Type number 5060 5061 5063

Tyres Superelastic Superelastic Superelastic

Front tyre size 180/70-8 180/70-8 180/70-8

Rear tyre size 180/70-8 180/70-8 180/70-8

Number of front wheels (x = driven) 2 2 2

Number of rear wheels (x = driven) 1x 1x 1x

Front track width b10 (mm) 840 840 840

Rear track width b11 (mm) — — —.

Basic dimensions


Type number 5060 5061 5063Tilt of lift mast/fork carriage,forwards

α (degrees) 3 3 3

Tilt of lift mast/fork carriage,backwards

β (degrees) 5 5 5

Height with lift mast retracted h1 (mm) 2160 2160 2160

Free lift h2 (mm) 150 150 150

Lift1 h3 (mm) 3230 3230 3230

Height with lift mast extended h4 (mm) 3805 3805 3805

1 The specified lift takes into account the tyre deflection and the tolerances of the tyre diameter.

340 55048011501 EN - 12/2015



Type number 5060 5061 5063Height to top of overhead guard(cab) h6 (mm) 1980 1980 2050

Seat height (in relation to SIP) h7 (mm) 953 953 953

Coupling height h10 (mm) — — —

Total length l1 (mm) 2359 2413 2521

Length including fork back l2 (mm) 1559 1613 1721

Total width b1 (mm) 990 990 990

Fork arm thickness s (mm) 40 40 40

Fork arm width e (mm) 80 80 80

Fork arm length l (mm) 800 800 800

Fork carriage according toISO 2328, class/form A, B ISO II/A ISO II/A ISO II/A

Fork carriage width b3 (mm) 980 980 980Ground clearance with load underlift mast

m1 (mm) 90 90 90

Ground clearance at centre ofwheelbase

m2 (mm) 90 90 90

Aisle width for pallet 1000 x 1200crosswise

Ast (mm) 2888 2942 3050

Aisle width for pallet 800 x 1200longitudinal Ast (mm) 3010 3064 3172

Turning radius Wa (mm) 1229 1283 1391

Smallest pivot point distance b13 (mm) — — —.

Performance data


Type number 5060 5061 5063

Driving speed with load km/h 12.0 12.0 12.0

Driving speed without load km/h 12.5 12.5 12.5

Lifting speed with load m/s 0.38 0.38 0.33

Lifting speed without load m/s 0.54 0.54 0.54

Lowering speed with load m/s 0.54 0.54 0.54

Lowering speed without load m/s 0.60 0.60 0.60

55048011501 EN - 12/2015 341



Type number 5060 5061 5063

Pulling force with load N 1650 1650 1400

Pulling force without load N 1950 1950 1700

Max. pulling force without load N 2840 2840 3500

Max. pulling force without load N 7150 7150 7150

Climbing capability with load % 6.5 6.5 5.0

Climbing capability without load % 11.0 11.0 8.5

Max. climbing capability with load % 19.0 19.0 19.0Max. climbing capability withoutload % 25.0 25.0 25.0

Acceleration time with load s 5.1 5.1 5.3

Acceleration time without load s 4.7 4.7 4.8Service brake Hydraulic Hydraulic Hydraulic

.

Elec. motor


Type number 5060 5061 5063Traction motor, power rating at S2:60 min.

kW 4.9 4.9 4.9

Lift motor, power rating at S3: 15% kW 7.6 7.6 7.6Battery in accordance with DIN43531/35/36 A, B, C, no

DIN 43535 A DIN 43535 A DIN 43535 A

Battery voltage U (V) 24 24 24

Battery capacity K5 (Ah) 460 575 805Battery weight kg 372 445 600

Energy consumption: 60 VDIworking cycles/hour kWh/h 3.7 3.7 4.2

.

Other


Type number 5060 5061 5063

Working pressure for attachments bar 230 230 230

Oil flow for attachments l/min 30 30 30

342 55048011501 EN - 12/2015



Type number 5060 5061 5063Sound pressure level LpAZ (driver’scompartment)2 dB (A) 63.9 63.9 63.9

Human vibration: accelerationaccording to EN 13059 m/s2 < 0.7 < 0.7 < 0.7

Tow coupling, DIN type/model — — —.

VDI datasheet: RX50-15 andRX50-16Characteristics

Model RX50-15 RX50-16

Type number 5065 5066

Manufacturer STILL GmbH STILL GmbH

DriveElectric Electric

Operation Seated Seated

Rated capacity/load Q (kg) 1000 1000

Load centre of gravity distance c (mm) 500 500

Load distance x (mm) 335 335

Wheelbase y (mm) 1190 1190.

Weight



Net weight including battery kg 2826 2833

Axle load with front load kg 3679 3866

Axle load with rear load kg 647 567

Axle load without front load Kg 1133 1143

Axle load without rear load kg 1693 1690.

2 Without cab. Values differ with a cab.

55048011501 EN - 12/2015 343


Wheels, chassis frame



Tyres Superelastic Superelastic

Front tyre size 180/70-8 180/70-8

Rear tyre size 180/70-8 180/70-8

Number of front wheels (x = driven) 2 2

Number of rear wheels (x = driven) 1x 1x

Front track width b10 (mm) 840 840

Rear track width b11 (mm) — —.

Basic dimensions



Tilt of lift mast/fork carriage, forwards α (degrees) 3 3

Tilt of lift mast/fork carriage, backwards β (degrees) 5 5

Height with lift mast retracted h1 (mm) 2160 2160

Free lift h2 (mm) 150 150

Lift3 h3 (mm) 3230 3230

Height with lift mast extended h4 (mm) 3805 3805

Height to top of overhead guard (cab) h6 (mm) 2050 2050

Seat height (in relation to SIP) h7 (mm) 953 953

Coupling height h10 (mm) — —

Total length l1 (mm) 2575 2580

Length including fork back l2 (mm) 1775 1780

Total width b1 (mm) 990 990

Fork arm thickness s (mm) 40 40

Fork arm width e (mm) 80 80

Fork arm length l (mm) 800 800

Fork carriage according to ISO 2328,class/form A, B ISO II/A ISO II/A

3 The specified lift takes into account the tyre deflection and the tolerances of the tyre diameter.

344 55048011501 EN - 12/2015




Fork carriage width b3 (mm) 980 980

Ground clearance with load under lift mast m1 (mm) 90 90

Ground clearance at centre of wheelbase m2 (mm) 90 90

Aisle width for pallet 1000 x 1200 cross-wise

Ast (mm) 3104 3109

Aisle width for pallet 800 x 1200 longitudi-nal

Ast (mm) 3226 3231

Turning radius Wa (mm) 1445 1445

Smallest pivot point distance b13 (mm) — —.

Performance data



Driving speed with load km/h 12.0 12.0

Driving speed without load km/h 12.5 12.5

Lifting speed with load m/s 0.32 0.30

Lifting speed without load m/s 0.54 0.54

Lowering speed with load m/s 0.54 0.54

Lowering speed without load m/s 0.60 0.60

Pulling force with load N 1280 1240

Pulling force without load N 1670 1670

Max. pulling force without load N 3770 3470

Max. pulling force without load N 7150 7150

Climbing capability with load % 4.0 4.0

Climbing capability without load % 8.0 7.5

Max. climbing capability with load % 16.0 15.0

Max. climbing capability without load % 25.0 25.0

Acceleration time with load s 5.5 5.6

Acceleration time without load s 4.9 5.0Service brake Hydraulic Hydraulic

.

55048011501 EN - 12/2015 345


Elec. motor



Tractionmotor, power rating at S2: 60min. kW 4.9 4.9

Lift motor, power rating at S3: 15% kW 7.6 7.6Battery in accordance with DIN43531/35/36 A, B, C, no

DIN 43535 A DIN 43535 A

Battery voltage U (V) 24 24

Battery capacity K5 (Ah) 920 920Battery weight Kg 676 676

Energy consumption: 60 VDI workingcycles/hour kWh/h 4.8 4.9

.

Other



Working pressure for attachments bar 230 230

Oil flow for attachments l/min 30 30Sound pressure level LpAZ (driver’scompartment)4 dB (A) 63.9 63.9

Human vibration: acceleration accordingto EN 13059 m/s2 < 0.7 < 0.7

Tow coupling, DIN type/model — —.

4 Without cab. Values differ with a cab.

346 55048011501 EN - 12/2015

Technical data 7Ergonomic 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.

55048011501 EN - 12/2015 347

7 Technical dataBattery specifications

Battery specifications

NOTE

Battery specifications to DIN 43535 A

CAUTION

The battery weight and dimensions affect thestability of the truck.When replacing the battery, the weight ratiosmust not be changed. The battery weight mustremain within the weight range specified on thenameplate. The location of ballast weightsmust notbe changed. The bottom of the battery tray must beclosed.– Use batteries that meet DIN standards.– Do not change the position of ballast weights.– Check the battery weight against the information

on the nameplate.– Only use a battery tray that is closed at the

bottom.

RX50-10 (5060)

Battery compartment dimensions in mmBatterydesigna-tion

Capac-ity

in Ah

Weightin kg± 5% Length Width Height

Tray Ballastweightin kg

4 PzV 440 440

4 PzS 460 460372 284 845 645 104 -

.

RX50-10 (5061)


Capac-ity

in Ah



4 PzV 440 440

4 PzS 460 460372 284 845 645 104 78

5 PzV 500 500

5 PzV 550 550

5 PzS 575 575

5 PzS 625 6255 CSM625 625

445 338 845 645 105 -

.

348 55048011501 EN - 12/2015

Technical data 7Battery specifications

RX50-13 (5063)


Capac-ity

in Ah



5 PzV 500 500

5 PzV 550 550

5 PzS 575 575

5 PzS 625 6255 CSM625 625

445 338 105 156

6 PzV 600 600

6 PzS 690 690

6 PzS 750 7506 CSM750 750

524 392 106 78

7 PzV 700 700

7 PzS 805 805

7 PzS 875 8757 CSM875 875

600 446

845 645

107 -

.

RX50-15 (5065), RX50–16 (5066)


Capac-ity

in Ah



6 PzV 600 600

6 PzS 690 690

6 PzS 750 7506 CSM750 750

524 392 106 156

7 PzV 700 700

7 PzS 805 805

7 PzS 875 8757 CSM875 875

600 446 107 78

8 PzV 800 800

8 PzV 880 880

8 PzS 920 920

676 500

845 645

108 -

55048011501 EN - 12/2015 349

7 Technical dataBattery specifications


Capac-ity

in Ah



8 PzS1000 1000

8 CSM1000 1000

.

350 55048011501 EN - 12/2015

Technical data 7Fuse assignment

Fuse assignment

1

2

3

4

5

6

78

910

13

1112

5060_003-139_V2

1 Electric parking brake F21 30 A

2 CAN power port (CPP) 1— standard F13 30 A

3 CAN power port (CPP) 2— lighting F18 20 A

4 12 V voltage transformer supply F14 10 A

5 Enable hydraulics multi-lever F19 10 A

6Switch lock, display and operating unit, main control unit (MCU),diagnostic connector F11 10 A

7 Proportional technology F17 10 A

8 5th hydraulic function F16 10 A

9 Not assigned F15 10 A

55048011501 EN - 12/2015 351

7 Technical dataFuse assignment

10 Horn F12 10 A

11 Pre-charging the converter F20 10 A

12 Traction motor main fuse 1 F01 355 A

13 Pump motor main fuse 2 F01 355 A

NOTE


352 55048011501 EN - 12/2015

Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 93Defining the driver PIN . . . . . . . . . . . . 89Entering the access code . . . . . . . . . 87Selecting the driver PIN . . . . . . . . . . . 90

Access authorisation with PIN code . . . . 86Accessories . . . . . . . . . . . . . . . . . . . . . . . 3Accident recorder . . . . . . . . . . . . . . . . . 204Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 113Joystick 4Plus version . . . . . . . . . . 113Mini-console version . . . . . . . . . . . . 114Mini-lever version . . . . . . . . . . . . . . 112Multiple-lever version . . . . . . . . . . . 112

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 77Adjusting the fork . . . . . . . . . . . . . . . . . 153After washing . . . . . . . . . . . . . . . . . . . . 292

AttachmentsAssembly . . . . . . . . . . . . . . . . . . . . 165Controlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 174Controlling using multi-lever

operation . . . . . . . . . . . . . . . . . . 171Controlling using the double

mini-lever and the 5th function . . 176Controlling using the four-way

mini-lever and the 5th function . . 184Controlling using the three-way

mini-lever and the 5th function . . 180Controlling via the joystick 4Plus . . . 186Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 182Controlling with a triple mini-lever . . . 178Controlling with fingertip . . . . . . . . . 188Controlling with fingertip and

5th function . . . . . . . . . . . . . . . . 189Controlling with multi-lever

operation and the 5th function. . . . . . . . . . . . . . . . . . . . . . . . . 172

General controlling . . . . . . . . . . . . . 169Mounting . . . . . . . . . . . . . . . . . . . . 166Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 167Special risks . . . . . . . . . . . . . . . . . . . 18Taking up a load . . . . . . . . . . . . . . . 195

Automatic lift cut out . . . . . . . . . . . . . . . 123

55048011501 EN - 12/2015 353

Indexg

BBattery

Activities after installation using theinternal roller channel . . . . . . . . . 272

Activities before removal using theinternal roller channel . . . . . . . . . 270

Changing using the internal rollerchannel . . . . . . . . . . . . . . . . . . . 270

Charging . . . . . . . . . . . . . . . . . . . . . 279Checking condition, acid level and

acid density . . . . . . . . . . . . . . . . 324Checking the charge status . . . . . . . 279Disposal . . . . . . . . . . . . . . . . . . . . . . 11Installing using a bridge . . . . . . . . . . 265Maintaining . . . . . . . . . . . . . . . . . . . 278Removing using a bridge . . . . . . . . . 262Replacing using a bridge . . . . . . . . . 262Replacing using an external roller

channel . . . . . . . . . . . . . . . . . . . 273Safety regulations . . . . . . . . . . . . . . 251

Battery acid . . . . . . . . . . . . . . . . . . . . . . 41Battery hood

Closing . . . . . . . . . . . . . . . . . . . . . . 254Opening . . . . . . . . . . . . . . . . . . . . . 254

Battery specifications . . . . . . . . . . . . . . 348Battery transport with crane . . . . . . . . . 269Before taking up load . . . . . . . . . . . . . . 148Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 224Functional description . . . . . . . . . . . 226Switching off . . . . . . . . . . . . . . . . . . 227Switching on . . . . . . . . . . . . . . . . . . 227

Bottom plateInstalling . . . . . . . . . . . . . . . . . . . . . 311Installing, dual pedal operation . . . . 313Removing . . . . . . . . . . . . . . . . . . . . 311Removing, dual pedal operation . . . 313

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . 42Checking the brake fluid level . . . . . 321Checking the function of the sensor . 322

Brake systemChecking for correct operation . . . . . 333Checking for leaks . . . . . . . . . . . . . . 333

CCE labelling . . . . . . . . . . . . . . . . . . . . . . . 2Changes to the truck . . . . . . . . . . . . . . . 29Changing the drive direction . . . . . . . . . 115

Dual-pedal version . . . . . . . . . . . . . 118Changing the fork arms . . . . . . . . . . . . 141Changing the password . . . . . . . . . . . . . 93Checking accelerator pedal and brake

pedal . . . . . . . . . . . . . . . . . . . . . 333Checking fork arms . . . . . . . . . . . . . . . 335Checking the battery hood lock . . . . . . . 315Checking the cable connections . . . . . . 333Checking the drive axle for oil level,

leaks and general condition . . . . 320Checking for leaks . . . . . . . . . . . . . . 321Checking the oil level . . . . . . . . . . . . 320

Checking the driver’s seat . . . . . . . . . . 318Checking the dual pedal . . . . . . . . . . . . 334Checking the emergency stop function . 101Checking the lift cylinders and

connections for leaks . . . . . . . . . 334Checking wheel fastenings . . . . . . . . . . 320Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 191Cleaning the electrical system . . . . . . . 290Cleaning the truck . . . . . . . . . . . . . . . . 288Climbing off . . . . . . . . . . . . . . . . . . . . . . 79Climbing on . . . . . . . . . . . . . . . . . . . . . . 79Clipboard . . . . . . . . . . . . . . . . . . . . . . . 204Cold store application . . . . . . . . . . . . . . 211

Operation . . . . . . . . . . . . . . . . . . . . 211Permissible use . . . . . . . . . . . . . . . 211

Condition of the roadways . . . . . . . . . . 107Connecting the battery male connector . . 81

354 55048011501 EN - 12/2015

Indexg

Consumables . . . . . . . . . . . . . . . . . . . . 39Brake fluid safety information . . . . . . . 42Disposal . . . . . . . . . . . . . . . . . . . . . . 44Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 41Safety information for handling oils . . . 39Safety information for hydraulic fluid . . 40

Contact details . . . . . . . . . . . . . . . . . . . . . ICopyright and trademark rights . . . . . . . . . 5Crane loading . . . . . . . . . . . . . . . . . . . 243Curve Speed Control . . . . . . . . . . . . . . 122

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 33Danger area . . . . . . . . . . . . . . . . . . . . 153Danger to employees . . . . . . . . . . . . . . . 23Declaration of conformity . . . . . . . . . . . . . 3Defects . . . . . . . . . . . . . . . . . . . . . . . . . 33Defining the driver PIN . . . . . . . . . . . . . . 89Definition of directions . . . . . . . . . . . . . . . 9Dimensions . . . . . . . . . . . . . . . . . . . . . 338Dimensions of driveways . . . . . . . . . . . 106Direction indicators . . . . . . . . . . . . . . . 198

Fingertip version . . . . . . . . . . . . . . . 200Mini-console version . . . . . . . . . . . . 201Mini-lever version . . . . . . . . . . . . . . 199

Disconnecting the battery maleconnector . . . . . . . . . . . . . . . . . 261

Display and operating unit . . . . . . . . . . . 53Additional indicators . . . . . . . . . . . . 216Adjusting the displays . . . . . . . . . . . 217Configure Blue Q . . . . . . . . . . . . . . . 224Indicators . . . . . . . . . . . . . . . . . . . . 214Standard display elements . . . . . . . . 85

Display operating unitResetting the daily kilometres . . . . . 222Setting the date . . . . . . . . . . . . . . . . 222Setting the language . . . . . . . . . . . . 223Setting the time . . . . . . . . . . . . . . . . 222Standard displays . . . . . . . . . . . . . . 214

Display symbols . . . . . . . . . . . . . . . . . . 217Auxiliary equipment soft key

functions . . . . . . . . . . . . . . . . . . 219Error messages . . . . . . . . . . . . . . . 219Menu navigation soft key functions . . 220Numeric keypad . . . . . . . . . . . . . . . 221Operating messages . . . . . . . . . . . . 218Status LEDs . . . . . . . . . . . . . . . . . . 220Warning messages . . . . . . . . . . . . . 218

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 11Components . . . . . . . . . . . . . . . . . . . 11

Documentation scope . . . . . . . . . . . . . . . 4Double mini-lever . . . . . . . . . . . . . . . . . . 57

Lifting/lowering the fork carriage . . . 135Tilting the lift mast . . . . . . . . . . . . . . 135

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 27

Driver’s compartment . . . . . . . . . . . . . . . 52Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 27Driveways . . . . . . . . . . . . . . . . . . . . . . 106Driving

on ascending and descendingslopes . . . . . . . . . . . . . . . . . . . . 162

Driving on gradients . . . . . . . . . . . . . . . 106Driving on lifts . . . . . . . . . . . . . . . . . . . 162Driving on loading bridges . . . . . . . . . . 164

EEC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 3

Effects on additional consumers . . . . . . 226Emergencies

Truck tipping over . . . . . . . . . . . . . . 248Emergency lowering . . . . . . . . . . . . . . 248Emergency shutdown . . . . . . . . . . . . . 247Emissions . . . . . . . . . . . . . . . . . . . . . . . 45

Battery . . . . . . . . . . . . . . . . . . . . . . . 47Noise emissions . . . . . . . . . . . . . . . . 45Vibrations . . . . . . . . . . . . . . . . . . . . . 46

Entering the access code . . . . . . . . . . . . 87Ergonomic dimensions . . . . . . . . . . . . . 347

55048011501 EN - 12/2015 355

Indexg

Example . . . . . . . . . . . . . . . . . . . . . . . 149

FFilling the washer system . . . . . . . . . . . . 70Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 61

Lifting/lowering the fork carriage . . . 140Tilting the lift mast . . . . . . . . . . . . . . 140

Fitting attachments . . . . . . . . . . . . . . . 165FleetManager . . . . . . . . . . . . . . . . . . . 203

Accident recorder . . . . . . . . . . . . . . 204Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 35Fork extension . . . . . . . . . . . . . . . . . . . 143Four-way mini-lever . . . . . . . . . . . . . . . . 59

Lifting/lowering the fork carriage . . . 137Fuse assignment . . . . . . . . . . . . . . . . . 351Fuses

Changing . . . . . . . . . . . . . . . . . . . . 327Checking . . . . . . . . . . . . . . . . . . . . 325

GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 2General view . . . . . . . . . . . . . . . . . . . . . 50GS15 driver’s seat

Adjusting . . . . . . . . . . . . . . . . . . . . . 72Adjusting the seat backrest . . . . . . . . 73Adjusting the seat suspension . . . . . . 73Moving . . . . . . . . . . . . . . . . . . . . . . . 73

HHandling gas springs and accumulators . 35Hazard areas . . . . . . . . . . . . . . . . . . . . 108Hazard warning system . . . . . . . . . . . . 198Hazards and countermeasures . . . . . . . . 20Hydraulic blocking function . . . . . . . . . . 132

Enabling . . . . . . . . . . . . . . . . . . . . . 132Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 40Hydraulic system

Checking for leaks . . . . . . . . . . . . . . 330Checking the oil level . . . . . . . . . . . . 329

IIdentification points . . . . . . . . . . . . . . . . 64Impermissible use . . . . . . . . . . . . . . . . . 14Information for carrying out mainte-

nance . . . . . . . . . . . . . . . . . . . . 294Maintenance timeframe . . . . . . . . . . 295

Information symbols . . . . . . . . . . . . . . . . . 5Insulation testing . . . . . . . . . . . . . . . . . . 37Insurance cover on company premises . . 29Issue date of the operating instructions . . . 5

JJacking up . . . . . . . . . . . . . . . . . . . . . . 307Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 60

Fork-carriage sideshift . . . . . . . . . . . 139Lifting/lowering the fork carriage . . . 138Tilting the lift mast . . . . . . . . . . . . . . 138

LLashing . . . . . . . . . . . . . . . . . . . . . . . . 239Lift cut out

Automatic . . . . . . . . . . . . . . . . . . . . 123Lift mast

Lubricating the roller track . . . . . . . . 331Removing . . . . . . . . . . . . . . . . . . . . 309Securing against falling off . . . . . . . . 309Securing against tilting backwards . . 308

Lift mast versionsHi-Lo lift mast . . . . . . . . . . . . . . . . . 129Triplex lift mast . . . . . . . . . . . . . . . . 130

Lift mast vertical position . . . . . . . . . . . 124Automatic approach . . . . . . . . . . . . 126Calibrating . . . . . . . . . . . . . . . . . . . 128Description . . . . . . . . . . . . . . . . . . . 124Display . . . . . . . . . . . . . . . . . . . . . . 126Possible restrictions . . . . . . . . . . . . 128Run-in to end stops . . . . . . . . . . . . . 126Tilting the lift mast backwards . . . . . 127Tilting the lift mast forwards . . . . . . . 127

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 307

356 55048011501 EN - 12/2015

Indexg

Lifting systemControlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 135Controlling using a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 137Controlling using a triple mini-lever . . 136Controlling using the joystick 4Plus . 138Controlling with the fingertip

console . . . . . . . . . . . . . . . . . . . 140Multi-lever . . . . . . . . . . . . . . . . . . . . 134Operating devices . . . . . . . . . . . . . . 131

Lighting . . . . . . . . . . . . . . . . . . . . . . . . 197List of abbreviations . . . . . . . . . . . . . . . . . 6Load

Picking up . . . . . . . . . . . . . . . . . . . . 155Setting down . . . . . . . . . . . . . . . . . . 160transporting . . . . . . . . . . . . . . . . . . 159

Load capacity . . . . . . . . . . . . . . . . . . . 148Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 291Load measurement . . . . . . . . . . . . . . . 149

Description . . . . . . . . . . . . . . . . . . . 149Execution . . . . . . . . . . . . . . . . . . . . 150Zero adjustment . . . . . . . . . . . . . . . 101

Lubricating the joints and controls . . . . . 315

MMaintenance data table . . . . . . . . . . . . 303

Battery . . . . . . . . . . . . . . . . . . . . . . 303Controls/joints . . . . . . . . . . . . . . . . . 303Electrical system . . . . . . . . . . . . . . . 303General lubrication points . . . . . . . . 303Hydraulic system . . . . . . . . . . . . . . 304Lift mast . . . . . . . . . . . . . . . . . . . . . 304Load chains . . . . . . . . . . . . . . . . . . 304Running axle . . . . . . . . . . . . . . . . . . 304Steering axle/drive axle . . . . . . . . . . 304Tyres . . . . . . . . . . . . . . . . . . . . . . . 304Washer system . . . . . . . . . . . . . . . . 305

Maintenance for trucks used in coldstores . . . . . . . . . . . . . . . . . . . . 331

Maintenance personnel for batteries . . . 294

Maintenance work without specialqualifications . . . . . . . . . . . . . . . 294

Malfunctions during lifting mode . . . . . . 130Measuring the battery’s insulation

resistance . . . . . . . . . . . . . . . . . . 38Measuring the insulation resistance of

the electrical system . . . . . . . . . . . 38Medical equipment . . . . . . . . . . . . . . . . . 34Message

APPLY HANDBRAKE . . . . . . . . . . . 234EMERGENCY SWITCH . . . . . . . . . 230LOWER FORKS . . . . . . . . . . . . . . . 235REFERENCECYCLE . . . . . . . . . . . 235SAFETY BELT . . . . . . . . . . . . . . . . 233SEAT SWITCH . . . . . . . . . . . . . . . . 230SERVICE BRAKE . . . . . . . . . . . . . . 236

MessagesScreen content . . . . . . . . . . . . . . . . 229

Mini console . . . . . . . . . . . . . . . . . . . . . . 62Misuse of safety systems . . . . . . . . . . . . 33MSG 65/MSG 75 driver’s seat

Adjusting . . . . . . . . . . . . . . . . . . . . . 74Adjusting the backrest extension . . . . 77Adjusting the lumbar support . . . . . . . 76Adjusting the seat backrest . . . . . . . . 75Adjusting the seat suspension . . . . . . 76Moving . . . . . . . . . . . . . . . . . . . . . . . 75Switching the seat heater on and off . . 77

Multi-lever . . . . . . . . . . . . . . . . . . . . . . . 56Lifting/lowering the fork carriage . . . 134Tilting the lift mast . . . . . . . . . . . . . . 134

NNameplate . . . . . . . . . . . . . . . . . . . . . . . 65Neutral position . . . . . . . . . . . . . . . . . . 111

OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Opening/closing the battery door . . . . . 259Operating company . . . . . . . . . . . . . . . . 26Operating devices for hydraulic and

traction functions . . . . . . . . . . . . . 55

55048011501 EN - 12/2015 357

Indexg

Operating materialsQuality and quantity . . . . . . . . . . . . 301

Operating procedures . . . . . . . . . . . . . . . 9Operating the service brake . . . . . . . . . 119Operating the signal horn . . . . . . . . . . . . 96Ordering spare parts andwearing parts . 301Overhead guard

Drilling . . . . . . . . . . . . . . . . . . . . . . . 32Roof loads . . . . . . . . . . . . . . . . . . . . 32Welding . . . . . . . . . . . . . . . . . . . . . . 32

OverviewAccessories . . . . . . . . . . . . . . . . . . . . 3Identification points . . . . . . . . . . . . . . 64

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 11Parking brake

Mechanical parking brake . . . . . . . . 120Parking the truck securely . . . . . . . . . . 282Personnel qualifications . . . . . . . . . . . . 294Picking up loads . . . . . . . . . . . . . . . . . . 152Place of use . . . . . . . . . . . . . . . . . . . . . . 15Procedure if truck tips over . . . . . . . . . . 248Production number . . . . . . . . . . . . . . . . 66Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 28Proper usage . . . . . . . . . . . . . . . . . . . . . 14

QQuadruple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 137

RRecommissioning after storage . . . . . . 286Reducing speed when turning . . . . . . . 122Reducing speed with a raised load . . . . 109Resetting the daily kilometres . . . . . . . . 222Resetting the daily operating hours . . . . 222Residual dangers . . . . . . . . . . . . . . . . . . 17Residual risks . . . . . . . . . . . . . . . . . . . . 17Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 29

Reversible fork armChecking . . . . . . . . . . . . . . . . . . . . 335

Reversible fork arms . . . . . . . . . . . . . . 145Roadways . . . . . . . . . . . . . . . . . . 107 – 108Rotating beacon . . . . . . . . . . . . . . . . . . 197Rules for roadways and the working

area . . . . . . . . . . . . . . . . . . . . . . 108

SSafety devices . . . . . . . . . . . . . . . . . . . 307Safety inspection . . . . . . . . . . . . . . . . . . 37Safety regulations for maintenance

General information . . . . . . . . . . . . 306Safety devices . . . . . . . . . . . . . . . . 307Set values . . . . . . . . . . . . . . . . . . . . 307Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 306Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 306Safety regulations for working on the lift

mast . . . . . . . . . . . . . . . . . . . . . 308Safety regulations when driving . . . . . . 104Safety regulations when handing loads . 147Safety regulations when handling the

battery . . . . . . . . . . . . . . . . . . . . 251Battery weight and dimensions . . . . 253Damage to cables and battery male

connectors . . . . . . . . . . . . . . . . . 254Fire protection measures . . . . . . . . . 252Lifting accessory . . . . . . . . . . . . . . . 253Maintenance personnel . . . . . . . . . . 251

Schematic views . . . . . . . . . . . . . . . . . . . 9Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 97

Checking . . . . . . . . . . . . . . . . . . . . 317Cleaning . . . . . . . . . . . . . . . . . . . . . 317Fastening . . . . . . . . . . . . . . . . . . . . . 97Fastening on a steep slope . . . . . . . . 98Maintaining . . . . . . . . . . . . . . . . . . . 316Malfunctions due to cold . . . . . . . . . . 98Releasing . . . . . . . . . . . . . . . . . . . . . 98Replacement after an accident . . . . 317

Selecting the drive direction . . . . . . . . . 111Selecting the driver PIN . . . . . . . . . . . . . 90

358 55048011501 EN - 12/2015

Indexg

Set values . . . . . . . . . . . . . . . . . . . . . . 307Setting the date . . . . . . . . . . . . . . . . . . 222Setting the drive programs . . . . . . . . . . 108Setting the language . . . . . . . . . . . . . . 223Setting the time . . . . . . . . . . . . . . . . . . 222Shutting down the truck . . . . . . . . . . . . 284Special overhead guard for drive-in

racks . . . . . . . . . . . . . . . . . . . . . 109Special risks . . . . . . . . . . . . . . . . . . . . . 18Stability . . . . . . . . . . . . . . . . . . . . . . . . . 18Starting drive mode . . . . . . . . . . . . . . . 114

Dual-pedal version . . . . . . . . . . . . . 116Status LEDs . . . . . . . . . . . . . . . . . . . . 220Steering . . . . . . . . . . . . . . . . . . . . . . . . 121Steering system

Checking for correct function . . . . . . 100Storing the truck . . . . . . . . . . . . . . . . . . 284StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 66Switching off the truck . . . . . . . . . . . . . 282Switching on the key switch . . . . . . . . . . 83

TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 338Three-waymini-lever . . . . . . . . . . . . . . . 58

Lifting/lowering the fork carriage . . . 136Topicality of the operating instructions . . . 5Tow coupling

Maintaining . . . . . . . . . . . . . . . . . . . 331Tow coupling RO*230 . . . . . . . . . . . . . 206

Coupling . . . . . . . . . . . . . . . . . . . . . 207Uncoupling . . . . . . . . . . . . . . . . . . . 207

Tow coupling RO*244 . . . . . . . . . . . . . 208Coupling . . . . . . . . . . . . . . . . . . . . . 209Uncoupling . . . . . . . . . . . . . . . . . . . 209

Towed load . . . . . . . . . . . . . . . . . . . . . 205Towing . . . . . . . . . . . . . . . . . . . . . . . . 240

Proper use . . . . . . . . . . . . . . . . . . . . 14Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 210Transport of swinging loads . . . . . . . . . 154

Transporting . . . . . . . . . . . . . . . . . . . . 237Transporting pallets . . . . . . . . . . . . . . . 154Triple mini-lever

Tilting the lift mast . . . . . . . . . . . . . . 136Types of lift mast . . . . . . . . . . . . . . . . . 128

Telescopic mast . . . . . . . . . . . . . . . 129Tyres

Safety principles . . . . . . . . . . . . . . . . 33

UUnlocking the emergency off switch . . . . 82Using batteries in the cold store . . . . . . 212Using working platforms . . . . . . . . . . . . . 16

VValve cover

Installing . . . . . . . . . . . . . . . . . . . . . 310Removing . . . . . . . . . . . . . . . . . . . . 310

VariantsAccess authorisation with PIN code . . 86Accident recorder . . . . . . . . . . . . . . 204Automatic lift cut out . . . . . . . . . . . . 123Clamp locking mechanism . . . . . . . . 191Clipboard . . . . . . . . . . . . . . . . . . . . 204FleetManager . . . . . . . . . . . . . . . . . 203Fork extension . . . . . . . . . . . . . . . . 143Hi-Lo lift mast . . . . . . . . . . . . . . . . . 129Lift mast vertical position . . . . . . . . . 124Lifting systems . . . . . . . . . . . . . . . . 123Load measurement . . . . . . . . . . . . . 149Reducing speed with a raised load . . 109Reversible fork arms . . . . . . . . . . . . 145Special overhead guard for drive-in

racks . . . . . . . . . . . . . . . . . . . . . 109Triplex lift mast . . . . . . . . . . . . . . . . 130Wheel chock . . . . . . . . . . . . . . . . . . 284

VDI datasheetRX50-10 and RX50-13 . . . . . . . . . . 339RX50-15 and RX50-16 . . . . . . . . . . 343

Vertical lift mast positionChecking for correct function . . . . . . 103

View of functions and operations . . . . . . . . 9

55048011501 EN - 12/2015 359

Indexg

View of operating procedures . . . . . . . . . . 9Views of the display operating unit . . . . . 10Visual inspections . . . . . . . . . . . . . . . . . 68

WWarning regarding non-original parts . . . 32Wedging . . . . . . . . . . . . . . . . . . . . . . . 238Wheel chock . . . . . . . . . . . . . . . . . . . . 284Wheels and tyres

Checking condition and wear of thetyres . . . . . . . . . . . . . . . . . . . . . 319

Checking the condition . . . . . . . . . . . 71Checking wheel fastenings . . . . . . . 320Servicing . . . . . . . . . . . . . . . . . . . . 318

Windscreen wiper/washer . . . . . . . . . . 203Working at the front of the truck . . . . . . . 308Working on the electrical equipment . . . 306Working on the hydraulic equipment . . . 306Working spotlights

Automatically switching on/off . . . . . 202Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 202Manually switching on/off . . . . . . . . 201Switching on and off . . . . . . . . . . . . 201

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 101

360 55048011501 EN - 12/2015

STILL GmbH

55048011501 EN – 12/2015

Documents

Originalinstructions Electricforklifttruck · Originalinstructions Electricforklifttruck RX50-10 RX50-13 RX50-15 RX50-16 5060 5061 5063 5065 5066 55048011501EN-12/2015