FM X EN Manual
FM X EN Manual
FM X EN Manual
Reach trucks
FM-X, FM-X N, FM-X W, FM-X EW,
Li-ion
FM-X-10
FM-X-12
FM-X-14
FM-X-17
FM-X-20
FM-X-20 HD
FM-X-25
50988078001 EN - 10/2018
Preface
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50988078001 EN - 10/2018 I
Table of contents
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1 Foreword
Your truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . ... 3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4
Labelling points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 5
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6
Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 7
Nameplate of a lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 7
Using the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 8
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 8
Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 8
Intended use of the lithium-ion battery (variant) . . . . . . . . . . . . . . . . . . . . . . . . .... ... 8
Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 9
Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ... 9
Parking in temperatures below -10°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 10
Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 11
Information about the documentation . . . . . . . . . . . . . . . . . . . . ............... .. 12
Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 12
Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 13
Issue date and topicality of the operating instructions . . . . . . . . . ............... .. 14
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 14
Explanation of information symbols used . . . . . . . . . . . . . . . . . ............... .. 14
List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 15
Defining directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 17
Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 18
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Safety
Definition of responsible persons ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 22
Operating company . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 22
Specialist . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 22
Drivers . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 23
Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . ............... .. 25
Insurance cover on company premises . . . . . . . . . . . . . . . . . . . ............... .. 25
Special notes when using lithium-ion batteries (variant) . . . . . . . ............... .. 25
Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 29
3 Overviews
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Overview of the driver's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shelves and cup holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Operating devices and display elements . . . . . . . . . . . . . . . . . . . . . . . ............ 59
Display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 59
Operating status displays on the display and operating unit . . . . . . . . . ............ 60
Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 61
Entering truck operating data via the display and operating unit . . . . . . ............ 65
Lithium-ion battery display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 70
Operating devices for hydraulic and traction functions . . . . . . . . . . . . . ............ 70
IV 50988078001 EN - 10/2018
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Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Operation
Testing and activities before daily use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 74
Visual inspections and function checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 74
Climbing into and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 77
Adjusting the MSG 65/MSG 75 driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 79
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 83
Filling the washer system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 84
Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 84
Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85
Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 87
Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 88
Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 88
Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90
Checking the emergency off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90
Checking the "automatic tilting centre position" (variant) for correct function . . . . . . . .. 91
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
STILL SafetyLight (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Switching the working spotlights (variant) on and off . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Efficiency and drive modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
OPTISPEED - Continuously variable reduction in driving speed or hydraulic functions
(variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 96
Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 96
Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 98
Side chassis supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 101
Enabling truck functions using the foot switch and seat switch . . ............... .. 101
Setting the drive programme . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 104
Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 105
Actuating the drive direction switch, joystick 4Plus . . . . . . . . . . . ............... .. 106
Actuating the drive direction switch, fingertip . . . . . . . . . . . . . . . ............... .. 106
Starting drive mode, single-pedal version . . . . . . . . . . . . . . . . . ............... .. 107
Starting drive mode, dual-pedal version (variant) . . . . . . . . . . . . ............... .. 109
Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 111
Applying the electromagnetic parking brake . . . . . . . . . . . . . . . ............... .. 112
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... .. 114
Emergency operation of the reach measurement system . . . . . . ............... .. 115
50988078001 EN - 10/2018 V
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Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Parking the truck securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 119
Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 119
Lift mast versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 119
Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 120
Joystick 4Plus lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 121
Fingertip lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 124
Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 126
Reach-lower lock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 128
Automatic centre position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 129
Speed limitation safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 131
Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 131
Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 134
Load backrest (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 135
Working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 136
Malfunctions in lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 136
Handling loads . . . . . . . . . . . . . . . . . . . . . ...... ............... ............ 138
Safety regulations when handing loads . . . ...... ............... ............ 138
Before picking up a load . . . . . . . . . . . . . . ...... ............... ............ 138
Picking up loads . . . . . . . . . . . . . . . . . . . . ...... ............... ............ 140
Danger area . . . . . . . . . . . . . . . . . . . . . . ...... ............... ............ 142
Transporting pallets . . . . . . . . . . . . . . . . . ...... ............... ............ 143
Transporting suspended loads . . . . . . . . . ...... ............... ............ 143
Picking up a load . . . . . . . . . . . . . . . . . . . ...... ............... ............ 144
Transporting loads . . . . . . . . . . . . . . . . . . ...... ............... ............ 147
Setting down loads . . . . . . . . . . . . . . . . . . ...... ............... ............ 149
Driving on upward and downward gradients ..... ............... ............ 151
Driving onto lifts . . . . . . . . . . . . . . . . . . . . ...... ............... ............ 151
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Releasing the pressure from the auxiliary hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 155
General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Controlling attachments (variant) using the joystick 4Plus (5th/6th hydraulic function)
............................................................... 157
Controlling attachments (variant) with the fingertip (5th/6th hydraulic function) . . . . . . . 160
Operating the clamp locking mechanism (variant) with a joystick 4Plus . . . . . . . . . . . . . 162
Operating the clamp locking mechanism (variant) with the fingertip switch . . . . . . . . . . 164
Picking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
VI 50988078001 EN - 10/2018
Table of contents
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Impermissible use of the lithium-ion battery in the shock cold store (-45°C) . . . . . . . . . . 210
Before entering the cold store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 212
Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 212
Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 213
Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 214
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... 215
Connecting and disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . 217
Connecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Disconnecting the battery male connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Handling the lead-acid battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 219
Safety regulations when handling the battery . . . . . . . . . . . . . . . . . . . ............ 219
Maintaining the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 222
Checking the battery condition, acid level and acid density . . . . . . . . . . ............ 223
Checking the battery charge status . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 225
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 225
Equalising charging to preserve the battery capacity . . . . . . . . . . . . . . ............ 228
Handling the lithium-ion battery (variant) . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 230
Safety regulations for handling the lithium-ion battery . . . . . . . . . . . .... . . . . . . . . . . 230
Approved lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 233
Lithium-ion batteries "GGS Li-ion 48 V (BG4)" 9.8 kWh and 39.2 kWh ... . . . . . . . . . . 234
Regulations for storing lithium-ion batteries . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 235
Checking the battery charge status (lithium-ion battery) . . . . . . . . . . .... . . . . . . . . . . 236
Charging the lithium-ion battery upon delivery . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 238
Charging the lithium-ion battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 239
Recommissioning the lithium-ion battery following deep discharge . . .... . . . . . . . . . . 241
Replacing and transporting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 242
Commissioning batteries that are delivered separately . . . . . . . . . . . . . . . .... . . . . . 242
Alternating between a lead-acid battery and a lithium-ion battery . . . . . . . . .... . . . . . 243
General information on battery replacement . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 244
Actuating the battery lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 246
Adjusting the battery lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 247
Special notes for installing the lithium-ion battery . . . . . . . . . . . . . . . . . . . . .... . . . . . 249
Replacing the battery using a lifting device . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 249
Changing the battery using the internal roller channel (variant) . . . . . . . . . . .... . . . . . 254
Setting the battery data (lead acid batteries) . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 259
Transporting the battery using a lifting device (lead acid batteries) . . . . . . . .... . . . . . 261
Transporting the battery using a lifting device (lithium-ion batteries) . . . . . . .... . . . . . 263
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
5 Maintenance
Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 286
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 286
Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 286
Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 286
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 287
Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 287
Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 287
Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 288
General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 289
Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 289
Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 290
Maintenance - 1000 hours/year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 293
Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 297
Additional maintenance guidelines for using the truck in a cold store - 500 hours or
every 12 weeks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 297
Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 298
Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . .. 298
Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 299
Maintaining operational readiness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 300
Checking the driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 300
Maintaining wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 301
Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 302
Greasing the lift mast and roller tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 303
Checking the battery change frame (variant) . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 303
Replacing the heating system filter for the cab (variant) . . . . . . . . . . . . . . . . . ..... .. 304
Maintenance for trucks used in cold stores . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 305
Maintenance tasks for lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. 305
50988078001 EN - 10/2018 IX
Table of contents
g
6 Technical data
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
VDI datasheet for FM-X 10 / Li-ion (N), FM-X 12 / Li-ion (N)* . . . . . . . . . . . . . . . . . . . . . 309
VDI datasheet for FM-X 14 / Li-ion (N, W, EW)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
VDI datasheet for FM-X 17 / Li-ion (N, W, EW)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
VDI datasheet for FM-X 20 / Li-ion (N, W, EW)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
VDI datasheet for FM-X 20 HD / Li-ion* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
VDI datasheet for FM-X 25 / Li-ion (W, EW)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Battery specifications for lithium-ion batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
X 50988078001 EN - 10/2018
1
Foreword
1 Foreword
Your truck
Your truck
General
The truck described in these operating instruc- These operating instructions provide the
tions corresponds to the applicable standards necessary information to do this. Read and
and safety regulations. observe the information provided before
commissioning the truck. This will prevent
The trucks have been fitted with state-of-the-
accidents and ensure that the warranty
art technology. All that remains is to handle
remains valid.
the truck safely and maintain its functionality.
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
CE-Symbol
2 50988078001 EN - 10/2018
Foreword 1
Your truck
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
STILL GmbH
50988078001 EN - 10/2018 3
1 Foreword
Your truck
Accessories
• Key for key switch (2 pieces), not for trucks
with the FleetManager™ or "PIN code"
variants
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering (in the driver's compartment below
the steering wheel)
• Battery change frame (variant)
4 50988078001 EN - 10/2018
Foreword 1
Your truck
Labelling points
1 2
5 5
1
3
13
2
15 17
14 16 18
2
4
12 3
9 4
10
11 5
5 6
6
7
BATTERIESERVICE
Nächste Prüfung
7 8 9 10
50634391022
11
Ihr STILL Service
13
12 14
mm
800
mm mm
700 400-600 18
15 16 17
kg kg kg mm
750 850 1000 10200
860 980 1150 9800
970 1110 1300 9500
1050 1200 1400 9300
1080 1240 1450 9000
1160 1320 1500 8750
1200 1600 1600 8300
X 1270 1700 1700 7100
X<= 15mm
50988078001 EN - 10/2018 5
1 Foreword
Your truck
1 Warning sign: Do not place below the fork 10 Decal information: FEM test
/ Do not place on the fork / Danger due to 11 Decal information: FEM test (inspection
shearing / Danger due to high fluid pressure sticker)
2 Warning sign: Danger due to shearing 12 Decal information: Nameplate
3 Decal information: Battery version 13 Decal information: Speed limitation based
4 Decal information: Hydraulic oil tank on lift height
5 Decal information: Lifting point 14 Decal information: Unlock the battery
6 Warning sign: Crushing and shearing points 15 Warning sign: Passengers prohibited
on base 16 Warning sign: Reverse steering
7 Decal information: Cold store version 17 Decal information: Load capacity diagram,
(variant) load capacity diagram for attachments
8 Decal information: Electrical seat adjust- (example)
ment (variant) 18 Decal information: Caution/Read the oper-
9 Decal information: Battery test ating instructions
Nameplate
The truck can be identified from the informa- 1 2 3
tion on the nameplate.
The information for the battery weights (5,
6) and the ballast weight (7) only applies to Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
4
electric forklift trucks. 13 Rated capacity Unladen mass
Capacité nominale kg Masse à vide kg
12 Nenn-Tragfähigkeit
Battery voltage
Leergewicht
max kg 5
Tension batterie V
11
Batteriespannung min.* kg
10 9 8
6210_921-003_V3
1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg
6 Min. permissible battery weight in kg
7 Ballast weight in kg
8 Address of manufacturer
9 Refer to the technical data listed in these
operating instructions for more detailed
information
10 CE labelling
11 Nominal drive power in kW
12 Battery voltage in V
13 Rated capacity in kg
6 50988078001 EN - 10/2018
Foreword 1
Your truck
Production number
NOTE xx xxxx x xxxxx
The production number is used to identify the
truck. It can be found on the nameplate and
must be referred to in all technical questions. 1
The production number contains the following
coded information:
2
(1) Production location
(2) Model 3
(3) Year of manufacture
(4) Sequential number 4
7090_921-004
Nominal voltage:
Capacity:
1 Nameplate
Energy:
Capacity equivalent: 13
4
Weight:
2 Manufacturer
P/N:
B-P/N: 14
SN:
5
Do not crush. Do not heat or incinerate.
Do not short-circuit. Do not dismantle.
Do not immerse in any liquid it may vent
6 CE labelling
or rupture.
50988078001 EN - 10/2018 7
1 Foreword
Using the truck
Proper usage
The truck described in these operating in-
structions is suitable for lifting, transporting
and stacking loads.
The truck may only be used for its proper
purpose as set out and described in these
operating instructions.
If the truck is to be used for purposes other
than those specified in the operating instruc-
tions, the approval of the manufacturer and, if
applicable, the relevant regulatory authorities
must be obtained beforehand to prevent haz-
ards.
The maximum load to be lifted is specified on
the capacity rating plate (load diagram) and
must not be exceeded; see also the chapter
entitled "Before picking up a load".
8 50988078001 EN - 10/2018
Foreword 1
Using the truck
Impermissible use
The operating company or driver, and not the
manufacturer, is liable for any hazards caused
by improper use.
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
Use for purposes other than those described
in these operating instructions is prohibited.
DANGER
There is a risk of fatal injury from falling
off the truck while it is moving!
– It is prohibited to carry passengers
on the truck.
Place of use
The truck is only approved for indoor use.
The ground must have an adequate load
capacity (concrete, asphalt) and a rough
surface. Roadways, working areas and aisle
widths must conform to the specifications in
these operating instructions; see the chapter
entitled "Roadways".
50988078001 EN - 10/2018 9
1 Foreword
Using the truck
NOTE
Please observe the definition of the following
responsible person: "operating company".
CAUTION
Batteries can freeze!
If the truck is parked in an ambient temperature
below -10°C for an extended period, the batteries
will cool down. The electrolyte may freeze and
damage the batteries. The truck is then not ready
for operation.
– When the ambient temperature is below -10°C,
only park the truck for short periods of time.
10 50988078001 EN - 10/2018
Foreword 1
Using the truck
WARNING
The use of working platforms is regulated by na-
tional law. The use of working platforms is only
permitted by virtue of the jurisdiction in the country
of use.
– Observe national legislation.
– Before using working platforms, consult the
national regulatory authorities.
50988078001 EN - 10/2018 11
1 Foreword
Information about the documentation
NOTE
Refer to the additional information in the
section entitled "Rules for the operating
company of industrial trucks".
These operating instructions describe all
measures necessary for the safe operation
and proper maintenance of the truck in all
possible variants available at the time of
printing. Special versions to meet customer
requirements (UPA) are documented in
separate operating instructions. If you have
any questions, please contact your authorised
service centre.
12 50988078001 EN - 10/2018
Foreword 1
Information about the documentation
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any errors, please contact
the authorised service centre.
Supplementary documentation
Unlike the standard equipment and the vari-
ants, this truck may be fitted with unplanned
equipment (UPA).
This UPA may be, for example:
• Special sensors
• Special attachments
• Towing devices
• Customer-specific attachments
In this case, the truck is supplied with addi-
tional documentation. This may be in the form
of an insert or separate operating instructions.
The original operating instructions for this
truck are valid for the operation of standard
equipment and variants without restriction.
The operational and safety information in the
original operating instructions continues to be
valid in its entirety, unless it is countermanded
in this additional documentation.
The requirements for the qualification of
personnel as well as the time for maintenance
may vary. This is defined in the additional
documentation.
50988078001 EN - 10/2018 13
1 Foreword
Information about the documentation
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered
to in order to prevent the risk of injuries.
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
14 50988078001 EN - 10/2018
Foreword 1
Information about the documentation
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
List of abbreviations
NOTE
This list of abbreviations applies to all types
of operating instructions. Not all of the abbre-
viations that are listed here will necessarily
appear in these operating instructions.
Abbrevi-
Meaning Explanation
ation
ABE Display operating unit
German implementation of EU occupa-
ArbSchG Arbeitsschutzgesetz
tional health and safety directives
Betr- German implementation of the EU working
Betriebssicherheitsverordnung
SichV equipment directive
German insurance company for the com-
BG Berufsgenossenschaft
pany and employees
German principles and test specifications
BGG Berufsgenossenschaftlicher Grundsatz
for occupational health and safety
German rules and recommendations for
BGR Berufsgenossenschaftliche Regel
occupational health and safety
DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations
Confirms conformity with product-specific
CE Communauté Européenne
European directives (CE mark)
Commission on the Rules for the Approval International commission on the rules for
CEE
of the Electrical Equipment the approval of electrical equipment
DC Direct Current Direct current
DFÜ Datenfernübertragung Remote data transmission
DIN Deutsches Institut für Normung German standardisation organisation
EG European Community
EN European standard
European Federation of Materials Han-
FEM Fédération Européene de la Manutention
dling and Storage Equipment
Fmax maximum Force Maximum power
50988078001 EN - 10/2018 15
1 Foreword
Information about the documentation
Abbrevi-
Meaning Explanation
ation
German authority for monitoring/issuing
regulations for worker protection, environ-
GAA Gewerbeaufsichtsamt
mental protection, and consumer protec-
tion
Transfer of data packets in wireless
GPRS General Packet Radio Service
networks
ID no. ID number
International Organization for Standard-
ISO International standardisation organisation
ization
LAN Local Area Network Local area network
Uncertainty of measurement of sound
KpA
pressure levels
LED Light Emitting Diode Light emitting diode
16 50988078001 EN - 10/2018
Foreword 1
Information about the documentation
Defining directions
1 2 5 6
8
4
General:
• left (1)
• right (2)
Drive directions:
• Travelling in the load direction (backwards)
(3)
• Travelling in the drive direction (forwards)
(4)
Movements of the reach carriage:
• Extending the reach carriage (in the load
direction) (5)
• Retracting the reach carriage (in the drive
direction) (6)
Tilting the lift mast or fork:
• Backward tilt (7)
• Forward tilt (8)
The driver sits crosswise to the drive direction.
50988078001 EN - 10/2018 17
1 Foreword
Information about the documentation
Schematic views
View of functions and operating proce-
dures
At many points in this documentation, the
operation of certain functions or operating
procedures is explained. To illustrate these
operations, schematic views of a reach truck
are used.
NOTE
These schematic views are not representative
of the structural state of the documented truck.
The views are used solely for the purpose of
clarifying procedures.
NOTE
18 50988078001 EN - 10/2018
Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
50988078001 EN - 10/2018 19
1 Foreword
Environmental considerations
20 50988078001 EN - 10/2018
2
Safety
2 Safety
Definition of responsible persons
Specialist
A qualified person is defined as a service
engineer or a person who fulfils the following
requirements:
• A completed vocational qualification that
demonstrably proves their professional
expertise. This proof should consist of
a vocational qualification or a similar
document.
• Professional experience indicating that
the qualified person has gained practical
experience of industrial trucks over a
proven period during their career During
this time, this person has become familiar
with a wide range of symptoms that require
checks to be carried out, such as based
on the results of a hazard assessment or a
daily inspection
• Recent professional involvement in the
field of the industrial truck test in question
and an appropriate further qualification
are essential. The qualified person must
have experience of carrying out the test
in question or of carrying out similar tests.
Moreover, this person must be aware of
the latest technological developments
22 50988078001 EN - 10/2018
Safety 2
Definition of responsible persons
Drivers
This truck may only be driven by suitable per-
sons who are at least 18 years of age, have
been trained in driving, have demonstrated
their skills in driving and handling loads to
the operating company or an authorised rep-
resentative, and have been specifically in-
structed to drive the truck. Specific knowledge
of the truck to be operated is also required.
The training requirements under §3 of the
Health and Safety at Work Act and §9 of the
plant safety regulations are deemed to have
been satisfied if the driver has been trained in
accordance with BGG (General Employers'
Liability Insurance Association Act) 925.
Observe the national regulations for your
country.
50988078001 EN - 10/2018 23
2 Safety
Definition of responsible persons
DANGER
The use of drugs, alcohol or medications that affect
reactions impair the ability to drive the truck!
Individuals under the influence of the aforementio-
ned substances are not permitted to perform work
of any kind on or with the truck.
24 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
NOTE
The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.
DANGER
Risk of explosion!
Heating to over 80°C, mechanical
stress and incorrect use may cause
the battery to explode.
50988078001 EN - 10/2018 25
2 Safety
Basic principles for safe operation
A B
2
1
Lithium-ion battery
A Battery group 4.1
B Battery group 4.2, 4.3
1 Hot area on the brake resistor (position
depends on the battery group; observe the
warning sign )
2 Safety valve (position depends on the
battery group)
WARNING
Risk of burns due to hot surfaces!
The battery has an integrated brake
resistor that can heat up to over 100°C
during operation.
It can take several hours for the
brake resistor to cool down to a safe
temperature.
– Do not touch the hot area (1).
The position of the brake resistor
depends on the battery model.
Observe the position of the warning
sign.
WARNING
Risk of injury!
Risk of injury if the safety valve (2) trips!
– Leave the area around the battery immediately.
Maintain a minimum distance of 5 m.
26 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
NOTE
The brake resistor (1) is installed differently
depending on the battery group. The build-up
of heat in the area around the brake resistor
is harmless. The safety valve (2) opens when
the battery is subjected to over pressure or
catches fire.
All lithium-ion batteries are associated with the
risk of a fire starting, of the battery exploding
and of the battery causing chemical burns.
When used as intended, no hazardous
substances escape from the closed tray and
contact with toxic substances will not occur.
There is a risk of contact only in the event of
incorrect use (mechanical, thermal, electrical)
that leads to activation of the safety valve
or to the housing cracking. As a result, the
electrolyte fluid may leak out, the electrode
material may react with humidity/water,
or battery venting/a fire/or an explosion
can occur, depending on the surrounding
circumstances. The position of the safety
valve (2) on the battery depends on the battery
group.
Touching live components can lead to an
electric shock, which can have thermal or
paralysing effects. The latter can cause ven-
tricular fibrillation, cardiac arrest or respiratory
paralysis, leading to death.
If a battery combusts, the resulting smoke or
vapours can cause irritation of the eyes, skin
and respiratory system.
50988078001 EN - 10/2018 27
2 Safety
Basic principles for safe operation
Hazard assessment
In accordance with §3 of the German Ordi-
nance on Industrial Safety and Health (Betr-
SichV), the operating company is obliged to
perform a separate hazard assessment in or-
der to assess the risks posed to the company
by lithium-ion batteries.
– Observe the national regulations for the
country in which the truck is being used.
Driver qualification
The following qualification requirements for
the driver are in addition to the conditions
described in the chapter entitled "Definition of
responsible persons" ("Driver" section):
• The driver must be trained in the operation
of the lithium-ion battery
• Only trained drivers may drive these trucks
28 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
Transportation
Transporting the lithium-ion battery outside
the premises may require a special trans-
portation container.
– Contact your authorised service centre for
more information.
50988078001 EN - 10/2018 29
2 Safety
Basic principles for safe operation
30 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
DANGER
Work on the overhead guard or on the weather
protection cab/cold store cab reduces its stability.
A falling load or the truck tipping over can cause
the modified chassis, bodywork and fittings to fail.
There is a risk of fatal injury!
– Do not weld on the overhead guard or the
weather protection cab/cold store cab.
– Do not drill on the overhead guard or the weather
protection cab/cold store cab.
– Do not make any incisions on the overhead
guard or the weather protection cab/cold store
cab.
DANGER
Risk of explosion from additional
bores on the truck chassis, weather
protection cab or cold store cab!
Explosive gases can escape and
lead to potentially fatal injuries if they
explode. Sealing bores with plugs
is not sufficient to prevent gas from
escaping.
– Do not drill any additional holes
in the truck chassis, weather
protection cab or cold store cab.
Roof loads
CAUTION
Additional roof loads impair the overhead guard or
the weather protection cab/cold store cab.
– Do not mount any additional roof loads on the
truck.
Seat belt
The truck may be equipped with a safety belt
for the driver only after consultation with the
authorised service centre.
50988078001 EN - 10/2018 31
2 Safety
Basic principles for safe operation
CAUTION
Trucks with an electrical adjustment mechanism
for the driver's compartment (variant) must not be
equipped with a safety belt for the driver.
32 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
DANGER
Risk to stability!
Failure to observe the following information and
instructions can lead to a loss of stability. The truck
may tip over — risk of accident!
50988078001 EN - 10/2018 33
2 Safety
Basic principles for safe operation
Medical equipment
WARNING
Electromagnetic interference may occur on medical
devices!
Only use equipment that is sufficiently protected
against electromagnetic interference.
34 50988078001 EN - 10/2018
Safety 2
Basic principles for safe operation
WARNING
Gas springs are under high pressure. Improper
removal results in an elevated risk of injury.
For ease of operation, various functions on the
truck can be supported by gas springs. Gas springs
are complex components that are subject to high
internal pressures (up to 300 bar). They may under
no circumstances be opened unless instructed to
do so, and may be installed only when not under
pressure. If required, the authorised service centre
will depressurise the gas spring in accordance with
the regulations before removal. Gas springs must
be 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. Improper
installation of an accumulator results in an elevated
risk of injury.
Before starting work on the accumulator it must be
depressurised.
– Contact the authorised service centre.
DANGER
Risk of accident due to the incorrect selection of
fork arms!
– The fork arms must match the depth of the load.
50988078001 EN - 10/2018 35
2 Safety
Basic principles for safe operation
36 50988078001 EN - 10/2018
Safety 2
Residual risk
Residual risk
Residual dangers, residual risks
Despite careful working and compliance with
standards and regulations, the occurrence
of other risks when using the truck cannot be
entirely excluded.
The truck and all other system components
comply with current safety requirements.
Nevertheless, even when the truck is used
for its proper purpose and all instructions
are followed, some residual risk cannot be
excluded.
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck
must be instructed regarding these risks that arise
through use of the truck.
In addition, we draw attention to the safety regulati-
ons in these operating instructions.
50988078001 EN - 10/2018 37
2 Safety
Residual risk
Stability
The stability of the truck has been tested to the
latest technological standards and is guaran-
teed provided that the truck is used properly
and according to its intended purpose. These
standards only take into account the dynamic
and static tipping forces that can arise during
specified use in accordance with the operat-
ing rules and intended purpose. However, the
danger of exceeding the moment of tilt due to
improper use or incorrect operation and losing
stability 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 suitable
containers.
– Always drive slowly when cornering.
– Drive with the load lowered.
– Even with sideshifts, align the load as
centrally as possible with the truck and
transport in this position.
– Avoid turning and diagonally driving across
slopes or gradients.
– Never have the load facing downhill when
travelling on slopes or gradients.
– Pick up only loads of the approved width.
– Always take great care when transporting
suspended loads.
– Do not drive over ramp edges or steps.
38 50988078001 EN - 10/2018
Safety 2
Residual risk
50988078001 EN - 10/2018 39
2 Safety
Residual risk
40 50988078001 EN - 10/2018
Safety 2
Residual risk
50988078001 EN - 10/2018 41
2 Safety
Residual risk
42 50988078001 EN - 10/2018
Safety 2
Residual risk
Danger to employees
According to the German Ordinance on Indus-
trial Safety and Health (BetrSichV) and labour
protection law (ArbSchG), the operating com-
pany must determine and assess hazards
during operation, and establish the labour
protection measures required for employ-
ees (BetrSichVO). The operating company
must therefore draw up appropriate operating
instructions (§ 6 ArbSchG) and make them
available to the driver. A responsible person
must be appointed.
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
The construction and equipment of the
truck correspond to the Machinery Directive
2006/42/EC and are therefore marked with
CE labelling. These elements are therefore
not included in the hazard assessment. At-
tachments possess their own CE labelling and
likewise are not included for that reason. The
operating company must, however, select the
type 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 may
be summarised. This overview (see chapter
"Overview of hazards and countermeasures")
provides help on complying with this regula-
tion. The overview specifies the main hazards
that are the most frequent cause of accidents
in the event of non-compliance. If other major
operational hazards are involved, they must
also be taken into consideration.
The conditions of use for trucks are broadly
similar in many plants, so the hazards can
be summarised in one overview. Observe
the information provided by the relevant
employers' liability insurance association on
this subject.
50988078001 EN - 10/2018 43
2 Safety
Safety tests
Safety tests
Carrying out regular inspections on
the truck
The operating company must ensure that the
truck is checked by a specialist at least once a
year or after particular incidents.
As part of this inspection, the technical con-
dition of the truck must be completely tested
with regard to accident safety. In addition, the
truck must be thoroughly checked for damage
that may have been caused by improper use.
A test log must be created. The results of the
inspection must be retained at least until a fur-
ther two inspections have been carried out.
The inspection date is indicated by an adhe-
sive label on the truck.
– Arrange for the authorised service centre to
perform regular testing on the truck.
– Observe the guidelines for tests carried out
on the truck in accordance with FEM 4.004.
The operating company is responsible for
ensuring that any defects are remedied
without delay.
– Notify your authorised service centre.
NOTE
In addition, observe the national regulations
for the country of use.
Insulation testing
The insulation of the truck must have sufficient
insulation resistance. For this reason, insula-
tion testing in accordance with DIN EN 1175
and DIN 43539, VDE 0117 and VDE 0510
must be conducted at least once yearly as part
of the FEM testing.
The insulation testing results must be at least
the test values given in the following two
tables.
– For insulation testing, contact the autho-
rised service centre.
44 50988078001 EN - 10/2018
Safety 2
Safety regulations for handling consumables
NOTE
The truck's electrical system and drive batte-
ries must be checked separately.
DANGER
Failure to observe the safety regulations relating to
consumables may result in a risk of injury, death or
damage to the environment.
– Observe the safety regulations when handling
these materials.
50988078001 EN - 10/2018 45
2 Safety
Safety regulations for handling consumables
Oils
DANGER
Oils are flammable!
– Follow the statutory regulations.
– Do not allow oils to come into
contact 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 the
eyes, rinse thoroughly (for at least
10 minutes) with water and then
consult an eye specialist.
– If swallowed, do not induce
vomiting. Seek immediate medical
attention.
WARNING
Prolonged intensive contact with the
skin can result in dryness and irritate
the skin!
– Avoid contact and consumption.
– Wear protective gloves.
– After any contact, wash the skin
with soap and water, and then apply
a skin care product.
– Immediately change soaked
clothing and shoes.
WARNING
There is a risk of slipping on spilled oil, particularly
when combined with water!
– Spilt oil should be removed immediately with
oil-binding agents and disposed of according to
the regulations.
46 50988078001 EN - 10/2018
Safety 2
Safety regulations for handling consumables
ENVIRONMENT NOTE
Oil is a water-polluting substance!
• Always store oil in containers that comply
with the applicable regulations.
• Avoid spilling oils.
• Spilt oil should be removed immediately
with oil-binding agents and disposed of
according to the regulations.
• Dispose of old oils according to the regula-
tions.
Hydraulic fluid
WARNING
These fluids are pressurised during
operation of the truck and are hazar-
dous to your health.
– Do not spill the fluids.
– Follow the statutory regulations.
– Do not allow the fluids to come into
contact with hot engine parts.
WARNING
These fluids are pressurised during
operation of the truck and are hazar-
dous to your health.
– Do not allow the fluids to come into
contact with the skin.
– Avoid inhaling spray.
– Penetration of pressurised fluids
into the skin is particularly danger-
ous if these fluids escape at high
pressure due to leaks in the hydrau-
lic system. In case of such injury,
immediate medical assistance is
required.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
50988078001 EN - 10/2018 47
2 Safety
Safety regulations for handling consumables
ENVIRONMENT NOTE
Hydraulic fluid is a water-polluting substance.
• Always store hydraulic fluid in containers
that comply with regulations
• Avoid spills
• Spilt hydraulic fluid should be removed
immediately with oil-binding agents and
disposed of according to the regulations
• Dispose of old hydraulic fluid according to
the regulations
Battery acid
WARNING
Battery acid contains dissolved
sulphuric acid. This is toxic.
– Avoid touching or swallowing the
battery acid at all costs.
– In case of injury, seek medical
advice immediately.
WARNING
Battery acid contains dissolved
sulphuric acid. This is corrosive.
– When working with battery acid,
use appropriate PSA (rubber
gloves, apron, protection goggles).
– When working with battery acid,
never wear a watch or jewellery.
– Do not allow any acid to get
onto clothing or skin or into the
eyes. If this does happen, rinse
immediately with plenty of clean
water.
– In case of injury, seek medical
advice immediately.
– Immediately rinse away spilt
battery acid with plenty of water.
– Follow the statutory regulations.
ENVIRONMENT NOTE
– Dispose of used battery acid in line with the
applicable regulations.
48 50988078001 EN - 10/2018
Safety 2
Safety regulations for handling consumables
Brake fluid
WARNING
Brake fluid is poisonous!
– Avoid swallowing. In the event of
swallowing, do not induce vomiting.
Rinse out your mouth thoroughly
with water and ask a doctor for
advice.
– Avoid aerosolisation and inhala-
tion. In the event of inhalation, seek
fresh air. Ask a doctor for advice if
necessary.
WARNING
Brake fluid is hazardous to your
health!
Brake fluid irritates the eyes and
can dry out the skin upon prolonged
contact.
– Coat your hands with a protective
skin cream prior to starting work.
– Avoid prolonged or intensive
skin contact. In the event of skin
contact, clean the wetted skin with
water and soap, and subsequently
apply a skin care product.
– Prevent contact with the eyes. In
the event of contact with the eyes,
wash out the affected eye(s) with
clean water for ten minutes and
then ask a doctor for advice.
– Change clothing soiled with brake
fluid 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 with
plenty of water
50988078001 EN - 10/2018 49
2 Safety
Safety regulations for handling consumables
ENVIRONMENT NOTE
Brake fluid is a water pollutant!
• Always store brake fluid in containers
complying with the regulations..
• Do not spill brake fluid.
• Spilt brake fluid must be removed immedia-
tely using an oil binding agent and disposed
of in accordance with regulations
• Dispose of old brake fluid according to the
regulations.
• Observe the national regulations for the
country in which the truck is being used.
Disposal of consumables
ENVIRONMENT NOTE
Materials that accumulate during repair,
maintenance and cleaning must be collected
properly and disposed of in accordance with
the national regulations for the country in
which the truck is being used. Work must
only be carried out in areas designated for the
purpose. Care must be taken to minimise any
environmental pollution.
– Soak up any spilt fluids such as hydraulic
oil, brake fluid or gearbox oil using an
oil-binding agent.
– Neutralise any spilt battery acid immedi-
ately.
– Always observe national regulations con-
cerning the disposal of used oil.
50 50988078001 EN - 10/2018
Safety 2
Commissioning the FleetManager™ (variant)
CAUTION
Danger associated with use by unauthorised per-
sons
The FleetManager™ regulates the access authori-
sation to the truck. To activate the access control,
the FleetManager must be put into operation im-
mediately following delivery. This ensures that only
persons authorised by the operating company have
access to the truck.
If the FleetManager is not put into operation imme-
diately after delivery, the operator must convert the
truck to a different access control.
– Put the FleetManager™ into operation imme-
diately after delivery. Make the truck accessible
only to people who are authorised by the opera-
ting company.
– In order to convert the truck to a different access
control, contact your authorised service centre.
Emissions
The values specified apply to a standard truck
(compare the specifications in the "Technical
data" chapter). Different tyres, lift masts,
50988078001 EN - 10/2018 51
2 Safety
Emissions
Noise emissions
The values were determined using the mea-
suring procedures from the EN 12053 stan-
dard (noise measurement for industrial trucks
based on EN 12001 and EN ISO 3744 and the
requirements of EN ISO 4871).
This machine emits the following sound
pressure level:
Continuous sound pressure level in the
driver's compartment
LpAZ
< 69.5 dB(A)
NOTE
Please observe the definition of the following
responsible person: "operating company".
Vibrations
The vibrations of the machine have been
determined on an identical machine in ac-
cordance with the standards DIN EN 13059
"Safety of industrial trucks - Test methods
for measuring vibration" and DIN EN 12096
52 50988078001 EN - 10/2018
Safety 2
Emissions
Battery
DANGER
Risk of explosion due to flammable
gases!
During charging, lead-acid batteries
release a mixture of oxygen and
hydrogen (oxyhydrogen gas). This
gas mixture is explosive and must not
be ignited.
– Make sure that there is always
sufficient ventilation in working
areas that are entirely or partially
enclosed.
– Keep away from open flames and
flying sparks.
– Do not smoke.
– Observe the safety regulations for
handling the battery.
Radiation
In accordance with the guidelines
DIN EN 62471:2009-03 (VDE 0837-471:2009-
03), the STILL SafetyLight (variant) is as-
signed to risk group 2 (medium risk) due to its
photobiological hazard potential.
50988078001 EN - 10/2018 53
2 Safety
Emissions
54 50988078001 EN - 10/2018
3
Overviews
3 Overviews
Overview
Overview
1 2 3
11 7 6
10 9 8
56 50988078001 EN - 10/2018
Overviews 3
Overview of the driver's compartment
NOTE
The truck equipment may differ from the
equipment shown.
1 2 3 4 5 6 7 8
10
11
12
16 15 14 13
NOTE
The truck equipment may differ from the
equipment shown.
50988078001 EN - 10/2018 57
3 Overviews
Shelves and cup holders
58 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
50988078001 EN - 10/2018 59
3 Overviews
Operating devices and display elements
60 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
Display messages
Event-related operating information and
malfunctions are shown in the display field
(2). In addition, the "Caution"symbol (1) lights
up if there is a malfunction.
Messages are always shown periodically and
for a certain period of time, according to the
event.
In the case of successive events, the respec-
tive messages are displayed one after another
on the display.
After a few seconds, the display will alternate
between the last shown operating display and
the message.
50988078001 EN - 10/2018 61
3 Overviews
Operating devices and display elements
General messages
Text message/error number Description Remedy
● Clean the sensor glass and
the reflector. Observe the
information in the chapter
entitled "Cleaning the optical
height measuring system".
Contamination will affect the ● Check the light signal path
measuring signal between between the sensor and the
CLEAN HEIGHT SENSOR
the LED height sensor and reflector. Remove obstacles.
reflector. Then fully lower the fork to
reference the system.
● If the message is still
displayed after cleaning,
contact your authorised service
centre.
● Emergency off switch of the
Switch off the truck. Unlock the
truck is actuated
EMERGENCY SWITCH emergency off switch. Switch
● All truck functions are
the truck on again.
disabled
● Check the FleetManager™
documentation.
● The truck can be operated in
● Only for trucks with FleetMan-
emergency operation without
EMERGENCY OPERATION ager™ (variant)
access authorisation.
● Truck functions are restricted
● To eliminate the cause,
contact the authorised service
centre.
If the battery carrier has been
BATTERY CARRIER MODE The driver has activated the accidentally actuated:
ACTIVE battery carrier. Fully push in the reach carriage
with the battery.
● Intermediate lift or end
lift limitation is active after Execute the "Lower" truck
0300 / 0301
switching on function.
● "Lift" truck function is disabled
62 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
50988078001 EN - 10/2018 63
3 Overviews
Operating devices and display elements
64 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
Level 1 (driver)
Access: Press the OK button for two seconds
Authorisations: Set the time (can be moved to a higher authori-
sation level)
Set the date (can be moved to a higher authori-
sation level)
Set the language (can be moved to a higher
authorisation level)
50988078001 EN - 10/2018 65
3 Overviews
Operating devices and display elements
PASSWORD
____
66 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
PASSWORD
NOT VALID
PASSWORD
DENIED 5 min
50988078001 EN - 10/2018 67
3 Overviews
Operating devices and display elements
68 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
Authori-
sation Main menu Submenu
(level) Edit/select Comment
CONFIGU-
1 2 3 1 2 3
RATION
HW1
HW2
SW1 VX.XX
SW2
SW3
km
UNITS DISTANCE
miles
kg
LOAD
lb
CUSTOMER
ERROR LIST MODE
SERVICE
A–Z, *: all
DEVICE X
devices
0:
current error
1:
TYPE X
since reset
2:
since deletion
Error e.g. A 12
X XX XX
12
Teach-in
ADJUST Lift heights
SERVICE IN XXX h
ERROR A–Z, *: all
RESET devices
.
50988078001 EN - 10/2018 69
3 Overviews
Operating devices and display elements
70 50988078001 EN - 10/2018
Overviews 3
Operating devices and display elements
Joystick 4Plus
6
7
2 3
1 8
5
9
4
10
15
11
14 13 12
50988078001 EN - 10/2018 71
3 Overviews
Operating devices and display elements
Fingertip
1 2 3
7
8
12
11
10
72 50988078001 EN - 10/2018
4
Operation
4 Operation
Testing and activities before daily use
DANGER
Risk of explosion if hydrogen builds up
in the cab!
1
If the truck is equipped with a cab, hy-
drogen from the battery compartment
can ingress into the cab through un-
sealed bores. A build-up of hydrogen
can lead to an explosion.
There must be no unsealed bores in
the cab wall. Sealing bores with plugs
is not sufficient to prevent gas from
entering.
– Have unused bores in the cab wall
sealed by the authorised service
centre.
Load lift system unit
WARNING
Risk of accident due to damage or other defects on
the truck or on the attachment (variant)!
Damage to the truck or the attachment (variant) can
lead to unpredictable and dangerous situations.
– Do not remove or deactivate safety systems or
switches.
– Do not change any predefined set values.
– Do not use the truck until it has been properly
repaired.
WARNING
Risk of falling when working on high parts of the
truck.
– Use only the steps provided on the truck.
– Do not use any truck components as mounting
aids or platforms.
– Use suitable equipment.
74 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
CAUTION
Risk of component damage!
A deformed or damaged battery male connector
can cause overheating and related consequential
damage.
– Check the battery male connector for damage.
– If necessary, have the battery male connector
replaced by the authorised service centre.
Ensure that the truck is safe for operation each day before it is used:
Component Course of action
Perform a visual inspection for deformation and wear
(for example, bent, broken, significant wear).
Fork arms, general lifting accessories
Check the condition and function of fuses (1) to
prevent lifting and shifting.
Roller tracks (2) Make sure that there is a film of grease.
Perform a visual inspection to ensure that the chains
Load chains
are intact and have adequate and even tension.
Ensure correct mounting in accordance with the
operating instructions of the manufacturer.
Perform a visual inspection to ensure the attach-
Attachments (variant)
ments are intact and not leaking.
Perform checks to ensure the attachments are
working correctly.
Perform the load measurement once for testing
Load measurement
purposes.
Perform a visual inspection for damage and leak-
Lift and tilt cylinders, tank, valve block, ages.
hoses, pipes, connections Have damaged components replaced by the autho-
rised service centre.
Check the area under the truck for leaking consum-
Underside
ables.
50988078001 EN - 10/2018 75
4 Operation
Testing and activities before daily use
76 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
WARNING
Risk of injury when climbing into and out of the truck
due to slipping or becoming stuck!
If the footwell cover is very dirty, smeared with oil or
iced over, there is a risk of slipping. There is a risk
of getting caught by your clothing when climbing out
of the truck.
– Make sure that the step and the footwell of the
driver's compartment have a non-slip surface
and are not iced over.
– Do not wear loose-fitting workwear.
– Do not jump into or out of the truck.
– Ensure that you have a secure grip on the truck.
50988078001 EN - 10/2018 77
4 Operation
Testing and activities before daily use
WARNING
Risk of injury when jumping out of the truck!
If the driver jumps out the truck while it is moving,
he or she could fall under the truck or be crushed by
an obstacle.
If the driver's clothing or jewellery (watch, ring etc.)
become stuck on components, this can lead to
serious injuries, e.g. from falling, loss of fingers.
– Only climb into or out of the truck when the truck
is at a standstill.
– Do not jump out of the truck.
– Do not wear jewellery at work.
– Do not wear loose-fitting workwear.
CAUTION
Components may become damaged through
incorrect use!
Truck components, such as the driver's seat,
steering wheel, parking brake lever etc., are not
designed to be used for climbing in and out of the
truck and may be damaged due to misuse.
– Only use the fittings specifically designed for the
purpose of climbing into and out of the truck.
78 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
WARNING
Risk of accident from sudden adjustment of the seat
or of the seat backrest!
If the seat or the seat backrest is adjusted uninten-
tionally, it can lead to uncontrolled movements by
the driver. This may result in unintentional actuation
of the steering or of the operating devices, thereby
causing the truck or load to move in an uncontrolled
fashion.
– Do not adjust the seat or the 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 the seat backrest are
securely engaged.
WARNING
On some equipment variants, the
amount of head clearance on the truck
may be restricted.
On these specific equipment variants,
the distance between the head and
the lower edge of the roofing sheet
must be at least 40 mm.
NOTE
Observe any separate operating instructions
for the seat.
WARNING
To obtain optimum seat cushioning, you must ad-
just the seat suspension to your own body weight.
This course of action 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.
50988078001 EN - 10/2018 79
4 Operation
Testing and activities before daily use
NOTE
The backwards tilt angle of the seat backrest
can be restricted by the structural condition of
the truck.
80 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
NOTE
The MSG 75 seat is equipped with electric air
suspension that is activated using an electric
switch instead of a lever (3). 4
The driver's seat can be adjusted to suit the
weight of the individual driver. To achieve the
best seat suspension setting, the driver must
perform the adjustment whilst sitting on the
seat.
– Fully extend the weight adjusting lever (3).
– Pump it up or down to set the driver's weight.
3
The correct driver's weight has been selected
when the arrow (4) is in the centre of the
inspection window. If the seat does not
move any further when you pump the weight
adjusting lever, the minimum or maximum
weight setting has been reached.
– Return the weight adjusting lever to the
initial central position before each new lift (a
click can be heard).
– Fully fold in the weight adjusting lever once
adjustment is complete.
50988078001 EN - 10/2018 81
4 Operation
Testing and activities before daily use
NOTE
The seat heater only functions if the seat
contact switch is active, i.e. when the driver is
sitting on the driver's seat.
– Switch the seat heater (7) on or off using the
7
switch.
82 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
1801_342-002
DANGER
Risk of accident!
– Ensure that the steering column is securely
attached.
Never adjust the steering column while driving.
50988078001 EN - 10/2018 83
4 Operation
Testing and activities before daily use
84 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
WARNING
Before switching on the key switch, all tests prior
to commissioning must be performed without any
defects being detected.
– Carry out checks prior to commissioning (refer
to the chapter entitled "Checks and tasks to be
carried out prior to commissioning").
– Do not operate the truck if defects have been
identified.
– If defects are detected, notify the authorised
service centre.
NOTE
The switch key, FleetManager card (variant),
FleetManager transponder chip (variant) or
FleetManager PIN code (variant) must not be
passed to others unless explicit instructions to
this effect have been given.
50988078001 EN - 10/2018 85
4 Operation
Testing and activities before daily use
Displays after the switch-on process (for trucks with default options)
1 2
5 4 3
NOTE
Depending on the truck equipment, further
information may be visible on the display and
operating unit.
Battery charge(1)
The usable battery charge is shown in the
display field.
NOTE
After connecting a partially charged battery:
• If the current battery charge level is higher
than the value stored most recently by
the truck, the most recently stored value
is initially displayed. The correct battery
charge level is not displayed until the current
value drops below the most recently stored
value
Steering position(2)
The symbol for the neutral steering position is
shown in the display field. The actual drive
86 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
NOTE
If malfunctions are displayed, refer to the
information in the chapter entitled "Display
messages".
50988078001 EN - 10/2018 87
4 Operation
Testing and activities before daily use
DANGER
If the brake system fails, the truck will be braked
insufficiently or not braked at all, posing a risk of
accident!
– Do not commission the truck with a defective
brake system.
88 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
50988078001 EN - 10/2018 89
4 Operation
Testing and activities before daily use
NOTE
In the "180° steering" variant, the drive's
maximum steering angle is ±90°.
5060_003-031
90 50988078001 EN - 10/2018
Operation 4
Testing and activities before daily use
50988078001 EN - 10/2018 91
4 Operation
Lighting
Lighting
STILL SafetyLight (variant)
STILL SafetyLight is a visual warning unit
to enable early detection of trucks in driving
areas with low visibility (such as drive lanes,
high racks), as well as at blind junctions.
STILL SafetyLight is mounted on a support on
the overhead guard such that it is not affected
by jolts and vibrations. It projects one or more
light blue light spots approximately 5 meters
in front of or behind the truck and thus warns
others about the approaching truck.
WARNING
Danger of damage to eyes when
looking into the STILL SafetyLight.
Do not look into the STILL SafetyLight.
92 50988078001 EN - 10/2018
Operation 4
Lighting
50988078001 EN - 10/2018 93
4 Operation
Efficiency and drive modes
94 50988078001 EN - 10/2018
Operation 4
Efficiency and drive modes
DANGER
Risk of tipping if cornering speed is too high!
If the controller is switched off or fails while driving,
the driving speed will no longer be reduced on
cornering.
– Do not switch off the truck while driving.
– Actuate the emergency off switch in emergen-
cies only.
– Always adapt your driving style to the conditions.
– Do not take risks with safety.
50988078001 EN - 10/2018 95
4 Operation
Driving
DANGER
Risk of tipping due to change in vibration characte-
ristics of the load!
If the controller is switched off or fails, the speed of
the hydraulic functions will no longer be reduced.
– Always adapt the use of the hydraulic functions
to suit the situation.
– Do not take risks with safety.
Driving
Safety regulations when driving
Driving conduct
The driver must comply with the highway code
when driving within the plant.
The speed must be appropriate to the local
conditions.
For example, the driver must drive slowly
around corners, in and around tight passage-
ways, when driving through swing doors, at
blind spots or on uneven roadways.
The driver must always maintain a safe
braking distance from trucks and persons
in front, and must always have the truck under
control. He must avoid stopping suddenly,
turning at speed and overtaking in dangerous
places or in blind spots.
Before driving with or without a load, the forks
must be lowered as far as possible.
96 50988078001 EN - 10/2018
Operation 4
Driving
WARNING
In areas where the use of mobile phones is prohi-
bited, it is absolutely not permitted to use a mobile
phone or radio telephone.
– Switch off the devices.
50988078001 EN - 10/2018 97
4 Operation
Driving
Panoramic mirror
The panoramic mirror (1) may only be used for
observing the road area on the load side of the
truck and not for travelling in the load direction.
Extra care should be taken when travelling in
the load direction if you are using visual aids.
The panoramic mirror must always be clean
and free of ice.
Any damage to the panoramic mirror that 1
could restrict the driver's visibility must be
rectified immediately.
The position of the panoramic mirror may only
be changed in such a way that the area behind
the lift mast remains visible.
Roadways
Dimensions of roadways and aisle widths
Within the EU, Directive 89/654/EEC (mini-
mum safety and health requirements for the
workplace) must be observed. The respective
national guidelines apply for areas outside
of the EU. In each case, it must be checked
whether a larger aisle width is necessary, e.g.
in the case of different load dimensions.
98 50988078001 EN - 10/2018
Operation 4
Driving
50988078001 EN - 10/2018 99
4 Operation
Driving
Hazard areas
Hazard areas on roadways must be marked
by standard traffic signs or, if necessary, by
additional warning signs.
NOTE
Once the truck has been switched on, the
parking brake must first be released one time.
The parking brake will only be released once
the accelerator pedal is activated slightly.
Trucks with two accelerator pedals (variant)
The hydraulic functions are only enabled if:
• The seat switch has been actuated
• The switch is functioning correctly
The drive function is only enabled if:
• The parking brake has been released
• The seat switch has been actuated but the
accelerator pedals have not
NOTE
The parking brake is released once one of the
accelerator pedals is actuated slightly.
NOTE
If the truck remains switched on for longer
than eight hours in total, the switch status of
the seat switch must change at least once.
As a rule, this does happen during normal
operation. If this has not happened, the seat
switch must be released and then re-actuated
once while the truck is switched on.
Code 1 2 3 4
Vmax
10 12 14 14
(km/h)
*m/s2 0.6 1.1 1.4 1.8
2
**m/s 0.8 1.0 1.0 1.2
NOTE
Only the drive programme can be changed.
The characteristic for the relevant drive pro-
gramme can only be changed by authorised
service personnel.
Adjustment process
– The drive profile changes each time the "P"
button (1) is pressed (P1 - 4).
– The selected drive programme is indicated
on the display (2).
NOTE
The drive direction can also be changed during
travel. Your foot can remain on the accelerator
pedal. The truck decelerates and is then
accelerated again in the opposite direction
(reversing).
After actuating the drive direction switch, the
drive direction is shown on the display and
operating unit (2).
Neutral position
If the truck is stopped for an extended period,
select the neutral position to prevent the truck
from suddenly starting if the accelerator pedal
is pressed inadvertently.
– Lightly actuate the drive direction switch for
the drive direction opposite to the current
direction.
The drive direction indicator on the display and
operating unit changes to show the "neutral
position" symbol.
– Actuate the drive direction switch again to
select a drive direction.
NOTE
When the driver leaves the seat, the direction
switch is set to neutral. To drive, the direction
switch must be actuated again.
DANGER
Being trapped under a rolling or tipping truck could
cause fatal injuries.
– Sit down on the driver's seat.
– During work, ensure that you have a secure grip
on the truck and a stable seat position. Hold on
tight to the steering wheel with your left hand.
NOTE
Depending on the equipment, an acoustic or
visual warning signal is issued in relation to
the drive direction (variant).
NOTE
The truck can be held at a standstill briefly
on upward or downward gradients without
actuating the parking brake (anti-roll brake
for slopes). The truck will then begin to creep
downhill slowly.
NOTE
The drive direction can also be changed during
travel. Your foot can remain on the accelerator
pedal while doing so. The truck decelerates
and is then accelerated again in the opposite
direction (reversing).
NOTE
In the event of an electrical fault with the
accelerator the drive unit is shut down. The
truck is braked by regenerative braking.
The truck cannot be driven again until the
accelerator pedal has been released and then
actuated again. If the truck still cannot be
operated, park it securely and contact your
authorised service centre.
DANGER
Being trapped under a rolling or tipping truck could
cause fatal injuries.
– Sit down on the driver's seat.
– During work, ensure that you have a secure grip
on the truck and a stable seat position. Hold on
tight to the steering wheel with your left hand.
NOTE
In the dual pedal version, any drive direction
switches on the operating devices will not
function.
NOTE
Depending on the equipment, an acoustic or
visual warning signal is issued in relation to
the drive direction (variant).
The truck will travel in the selected drive direc-
tion. The speed is controlled by the accelera-
tor pedal position. When the accelerator pedal
is released, the truck decelerates.
NOTE
The truck can be held at a standstill briefly
on upward or downward gradients without
actuating the parking brake (anti-roll brake
for slopes). The truck will then begin to creep
downhill slowly.
NOTE
In the event of an electrical fault with the
accelerator the drive unit is shut down. The
truck is braked by regenerative braking.
The truck cannot be driven again until the
accelerator pedal has been released and then
actuated again, provided that the electrical
fault has been corrected. If the truck still
cannot be operated, park it securely and
contact your authorised service centre.
DANGER
At speeds that are too high, there is a danger that
the truck could slip or overturn!
The braking distance of the truck depends on the
weather conditions and the level of contamination
on the roadway.
– 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 provide
a sufficient stopping distance.
DANGER
There is a risk of fatal injury from being run over if
the truck rolls away.
– Only leave the truck once the parking brake has
been applied.
– The truck must not be parked on a slope.
– In emergencies, secure with wedges on the side
facing downhill.
Cause Effect
After 3 seconds, the parking brake closes
If the driver's seat is vacated or the foot switch is audibly. The symbol (2) is shown in the display-
released: operating unit.
The parking brake is applied immediately and
audibly. The symbol (2) is shown briefly on the
If the truck is switched off:
display and operating unit until the control units
switch off.
The parking brake is applied immediately and
If the emergency off switch is actuated or as a
audibly, and the symbol (2) is shown on the
result of an emergency off function:
display and operating unit.
.
NOTE
Braking with the parking brake while the
truck is in motion will result in heavy wear
of the brake linings. Therefore, always use
regenerative braking or the mechanical brake
to brake while the truck is in motion. Only use 2
the parking brake while the truck is in motion
in the event of an emergency.
– Ensure the truck has a secure grip. Hold 1
on tight to the steering wheel with your left
hand.
– Push the push button (1) to apply the
parking brake.
The parking brake is applied immediately and
audibly, and brings the truck to a standstill.
Cause Effect
The parking brake is applied immediately and
audibly. The symbol (2) is shown briefly on the
If the truck is switched off:
display and operating unit until the control units
switch off.
The parking brake is applied immediately and
If the emergency off switch is actuated or as a
audibly, and the symbol (2) is shown on the
result of an emergency off function:
display and operating unit.
NOTE
If the driver's seat is vacated or the foot switch
is released while the truck is in motion, the
parking brake is not applied. The truck is then
brought to a standstill by regenerative braking.
Steering
NOTE
Please do not steer when the truck is at a
standstill, as this causes the drive wheel to
be put under extreme pressure and therefore
increases wear.
Parking
Parking the truck securely
DANGER
There is a risk of fatal injury from being run over if
the truck rolls away.
– The truck must not be parked on a slope.
– In emergencies, secure with wedges on the side
facing downhill.
– Only leave the truck once the parking brake has
been applied.
DANGER
There is a risk to life caused by a falling load or if
parts of the truck are being lowered!
– Before leaving the truck, lower the load fully.
CAUTION
Batteries may freeze!
At an ambient temperature of below –10°C for a
prolonged period, the batteries cool down. The
electrolyte may freeze and damage the batteries.
The truck is then not ready for operation.
– At ambient temperatures of below -10°C, only
park the truck for short periods of time.
NOTE
The switch key, FleetManager card (variant),
FleetManager transponder chip (variant) or
FleetManager PIN code (variant) must not be
passed to others unless explicit instructions to
this effect have been given.
Lifting
Lifting system variants
The movement of the fork carriage and the
lift mast heavily depends on the following
equipment:
• The lift mast fitted on the truck; see the
chapter entitled "Lift mast versions"
• The operating device that is used to control
the hydraulic functions; see the chapter
entitled "Lifting system operating devices"
Regardless of the equipment variants of the
truck, the basic specifications and procedures
must be observed; see the chapter entitled
"Safety regulations for working with loads".
DANGER
Risk of accident due to collision of the lift mast or
load with low ceilings or entrances.
– Note that the inner lift mast or load may be higher
than the fork carriage.
– Observe the heights of ceilings and entrances.
E G F
C D
B
A
DANGER
Reaching or climbing between moving parts of the
truck (e.g. lift mast, sideshifts, working equipment,
load carrying devices etc.) can lead to serious injury
or death and is therefore prohibited.
– Always observe the safety regulations for hand-
ling loads; see ⇒ Chapter "Safety regulations
when handing loads", P. 4-138.
– Only operate the lifting system from the driver's
seat.
1 2
B
1
Shifting
To extend the reach carriage:
– Push the joystick (4) in the direction of "G". 4
To retract the reach carriage: G
– Push the joystick (4) in the direction of "H".
NOTE
The pictograms on the base of the joystick
show the direction of movement for the
corresponding hydraulic function. H
3 4
1 Lowering/lifting the fork carriage 3 Tilting the lift mast or fork carriage (variant)
2 Shifting 4 Transition shift (variant)
DANGER
Reaching or climbing between moving parts of the
truck (e.g. lift mast, sideshifts, working equipment, 1 2 3 4
load carrying devices etc.) can lead to serious injury
or death and is therefore prohibited.
– Always observe the safety regulations for hand-
ling loads; see ⇒ Chapter "Safety regulations
when handing loads", P. 4-138.
– Only operate the lifting system from the driver's
seat.
Shifting
To extend the reach carriage:
– Push the "shift" operating lever (2) forwards.
To retract the reach carriage: 3 4
– Pull the "shift" operating lever (2) back-
wards.
NOTE
The pictograms on the operating levers
show the direction of movement for the
corresponding hydraulic function.
WARNING
There is always an increased risk of the truck tipping
if it is driven with a raised load.
The system is a support for the driver when placing
items into stock and removing items from stock.
The responsibility for safe operation and complying
with safety regulations remains with the driver.
1
In main lift load mode, the truck can only ac-
celerate to a maximum of 6 km/h. If the current
driving speed is already above this maximum
speed, the truck brakes regeneratively to the
set maximum speed. The speed limitation is
removed as soon as the current lift height is
lowered to below the specified value.
The speed limitation cannot be deactivated.
The maximum speed can be set to a value of
between 1 km/h and 6 km/h by the authorised
service centre.
While the maximum speed is being limited,
the "tortoise" symbol (1) appears on the
display-operating unit.
DANGER
There is a risk of fatal injury from being run over if
the truck rolls away.
– Do not park the truck on a gradient.
– 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 fork
arms; the fork arms' weight could cause them to fall
on your legs, feet or knees. The space to the left
and right of the fork is a danger area.
– Always wear protective gloves and safety
footwear when changing the fork arms.
– Ensure that no one stands in the danger area!
– Do not pull on the fork arms.
– The fork arms must always be carried by two
people; if necessary, use a hoist.
NOTE
• For installation and removal, a transport
pallet is recommended for supporting
the fork arms. The pallet size depends
on the fork arm size used and should be
dimensioned such that the fork arms do not
protrude after being placed on the pallet.
This means the fork arms can be safely
placed down and transported.
• Both fork arms can be pushed over onto one
side.
Removal
1
– Extend the reach carriage fully. 2
Installation
– Position the fork arms on a pallet to the left
or right of the fork carriage.
– Pull the locking lever (1) upwards.
– Push the fork arms onto the fork carriage
from the outside towards the centre.
– Move the fork arms into the desired position.
Ensure that the locking lever snaps into
place.
– 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.
DANGER
There is a risk of being run over if the truck rolls
away, and therefore a danger to life.
– Do not park the truck on a gradient.
– Apply the parking brake.
– Change the fork extension in a separate, safe
location on a level surface.
WARNING
There is a risk of crushing!
The weight of the fork extension can cause crushing
or 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 extension
affect the stability of the truck. The permissible
weights stated on the capacity rating plate must be
reduced in proportion to the actual load distance.
– Observe load capacity, see the "Before picking
up a load" chapter.
Attachment
1
DANGER
Risk to life from falling load!
At least 60% of the length of the fork extension must
lie on the fork arm. A maximum 40% overhang over
the fork arm end is permissible. The fork extension
must also be secured against slipping from the fork
arm.
If the fork extension (1) is not secured with a secu-
ring bolt (2) and linch pin (3), the load with the fork
extension may fall. 3
– 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 2
bolt.
7071_003-104_V2
Removal
– Remove the linch pin (3) from the securing
bolt (2).
– Remove the securing bolt from the fork
extension (1).
– Pull the fork extension from the fork arms.
– Insert the securing bolt fully into the fork
extension.
– Insert the linch pin into the securing bolt and
secure.
Working platforms
The use of working platforms in conjunction
with industrial trucks is regulated by national
law.
This legislation should be observed. The use
of working platforms is only permitted by virtue
of the legislation in the country of use. Before
using working platforms, consult your national
regulatory authorities.
WARNING
No one should ever stand on the forks to be raised
or transported!
Handling loads
Safety regulations when handing
loads
The safety regulations for handling loads are
shown in the following sections.
DANGER
There is a risk to life caused by falling loads or if
parts of the truck are being lowered.
– Never walk or stand underneath suspended
loads or raised fork arms.
– Never exceed the maximum load indicated on
the capacity rating plate. Otherwise stability
cannot be guaranteed!
DANGER
6210_003-030
DANGER
Risk of accident from a falling load!
– When transporting small items, attach a load
safety guard (variant) to prevent the load from
falling on the driver.
– Use a closed roof covering (variant) in addition.
WARNING
The figures show examples.
Only the capacity rating plates on the truck are valid!
Example
Weight of load to be lifted (1)
Permissible lift height (2)
Load distance from fork back (3)
WARNING
Risk of accident from the truck losing stability!
The permissible loading of the attachments (va-
riant) and the reduced load capacity of the combi-
nation of truck and attachment must not be excee-
ded.
– Observe the special capacity rating plate infor-
mation shown on the truck and the attachment.
1 2
880 kg 5230
500
3
Picking up loads
To make sure that the load is securely sup-
ported, it must be ensured that the fork arms
are sufficiently far apart and are positioned as
far as possible under the load.
Danger area
The danger area is the area in which people
are at risk due to the movements of the truck,
its working equipment, its load-carrying
equipment (e.g. attachments) or the load.
Also included are the areas where loads
could fall or working equipment could fall or
be 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 the
truck!
The danger area of the truck must be completely
clear of all personnel, except the driver in his
normal operating position. If persons fail to leave
the danger area despite warnings:
– Cease work with the truck immediately.
– Secure the truck against use by unauthorised
parties.
DANGER
Danger of death from falling loads!
– Never walk or stand underneath
suspended loads.
Transporting pallets
As a rule, loads (e.g. pallets) must be transpor-
ted individually. Transporting multiple loads at
the same time is only permitted:
• when instructed by the supervisor and
• when the technical requirements have been
met.
The driver must ensure proper condition of
the load. Only safely and carefully positioned
loads may be transported.
6327_003-009
Picking up a load
NOTE
Loads may only be picked up and set down on
flat surfaces.
DANGER
There is a risk to life caused by a falling load or if
parts 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 stability
cannot be guaranteed.
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 tilted
forward is not permitted.
– Only drive with the load lowered.
– Lower the load until ground clearance is reached
(lift height below 500 mm).
– Only drive with the lift mast tilted backwards.
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".
DANGER
Risk of accident due to changed moment of tilt!
Please note that when the load is raised the lift mast
can be tilted far enough forward to cause the truck
to tip over.
The load centre of gravity and the moment of tilt
both change when the load slips. The truck may tip
forwards.
– Only tilt the lift mast forwards with a raised lifting
accessory when it is directly above the stack.
– When the lift mast is tilted forwards, take parti-
cular care to ensure that the truck does not tip
forwards and that the load does not slip.
WARNING
Risk of accident from falling load!
If the fork or the load remains suspended during
lowering, the load may fall.
– When removing from stock, move the truck far
enough back so that the load and the fork can be
lowered freely.
DANGER
Danger to life!
On upward and downward gradients, the load must
be carried facing uphill.
It is only permitted to drive on upward and down-
ward gradients if they are marked as traffic routes
and can be used safely.
The driver must check that the ground is clean with
a good grip.
It is not permitted to perform turns on upward
gradients, to approach them diagonally or to park
the truck on them.
Drive at a reduced speed on downward gradients.
It is not permitted to put items into stock or to remove
them from stock while on an upward or downward
gradient.
The forklift truck must not be parked on a slope.
– In case of emergency, secure the truck with
wedges.
Attachments
Fitting attachments
If the truck is equipped with an integrated
attachment (variant) at the factory, the specifi-
cations in the STILL operating instructions for
integrated attachments must be observed.
If attachments are fitted at the place of use,
the specifications in the operating instructions
of the attachment manufacturer must be
observed.
If an attachment is not delivered together
with the forklift truck, the specifications and
operating instructions of the attachment
manufacturer must be observed.
Before initial commissioning, the function
of the attachment and the visibility from the
driver's position with and without a load must
be checked by a competent person. If the
visibility is deemed insufficient, visual aids
such as mirrors, a camera/monitor system etc.
must be used.
In addition, it is essential that the warnings
below are observed.
CAUTION
Attachments must be CE-certified. If the truck is
not fitted with an attachment-specific residual load
capacity rating plate and the operating devices are
not marked with corresponding pictograms, the
truck must not be used.
– Order the residual load capacity rating plate and
pictograms from your authorised service centre
in good time.
– The authorised service centre must adapt the
hydraulic system to the requirements of the
attachment (e.g. by adjusting the pump motor
speed).
DANGER
There is risk to life caused by a falling load!
Attachments that hold the load by exerting pressure
on it (e.g. clamps) must be controlled additionally by
a second operating function (lock) that is actuated
to 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 the
sideshift is actuated.
– Notify your authorised service centre before
installation.
– Never grab or climb on moving parts of the truck.
Hydraulic connection
– Before installing the attachment, release
the pressure from the hydraulic system.
CAUTION
Risk of damage to components!
Open connections of plug connectors can become
dirty. The plug connectors can become stiff and dirt
can enter the hydraulic system.
– Once the attachment has been disassembled,
attach the protective caps to the plug connectors.
Mounting attachments
Mounting an attachment and connecting
the energy supply for an attachment must
7090_900-001
NOTE
Please observe the definition of the following
responsible person: "competent person".
7090_900-001
WARNING
Use of attachments can give rise to additional
hazards such as a change in the centre of gravity,
additional danger areas etc.
Attachments must only be used for their intended
purpose as described in the relevant operating
instructions. Drivers must be taught how to operate
the attachments.
Loads may only be picked up and transported with
attachments if the loads are securely grasped and
attached. Where necessary, loads must also be
secured against slipping, rolling away, falling over,
swinging or tipping over. Note that any change to
the position of the load centre of gravity will affect
the stability of the truck.
– Refer to the capacity rating plate for the attach-
ments being used.
NOTE
Further variants and functions are available
in addition to the functions described below.
The directions of movement can be seen on
the pictograms on the operating devices or
battery hood.
NOTE
All the attachments described fall into the
category of equipment variants. An exact de-
scription of the respective movements/actions
of the attachment fitted can be found in the
respective operating instructions.
NOTE 6
NOTE
The pictograms on the joystick are applied
according to the attachments fitted to this
truck at the factory. If an attachment with other
functions is fitted, the pictograms must be
checked for the correct representation and
changed if necessary. Please contact the
service centre if necessary.
– Note the following attachment functions and
pictograms!
1 2 3 4
5 6 7 8
Vertical rocker
2 button + shift button Fork positioner: forwards/backwards
"F"
Vertical rocker
3 button + shift button Rotator: left/right
"F"
Vertical rocker
4 button + shift button Clamp: close/open
"F"
Vertical rocker
5 button + shift button Load retainer: close/open
"F"
Vertical rocker
6 button + shift button Additional fork carriage: lift/lower
"F"
Joystick + shift Fork prong positioner: close/open
button "F"
7 Vertical rocker
button + shift button Rotator: left/right
"F"
Joystick + shift
Fork prong positioner: close/open
button "F"
8 Vertical rocker
button + shift button Fork positioner: forwards/backwards
"F"
In the pictograms for possible attachments,
the outlined graphic in the centre of the pic-
togram indicates the combination of operating
devices required for the particular attachment.
NOTE
The movement/action of these additional
functions can be found in the operating
instructions of the fitted attachment.
NOTE
The pictograms for the operating levers are
attached according to the attachments fitted to
this truck at the factory. If an attachment with
other functions is fitted, the pictograms must
be checked for the correct representation and
1 5
2 6
3 7
4 8
NOTE
The joystick actuation that has the "clamp
release" function assigned to it is (1) marked
by a pictogram; also refer to the chapter
entitled "Working with attachments".
NOTE
The clamp locking mechanism is locked again:
• as soon as shift button "F" is released
• if the clamp is not opened within a specified
period of time
NOTE
The operating lever that has the "clamp
release" function assigned to it is (1) marked
by a pictogram; also refer to the chapter
entitled "Working with attachments".
NOTE
The clamp locking mechanism is locked again:
• as soon as shift button "F" is released
• if the clamp is not opened within a specified
period of time
WARNING
Risk of accident!
Attachments must only be used for their intended
purpose as described in the relevant operating
instructions.
Drivers must be taught how to operate the attach-
ments.
WARNING
Risk of accident!
Loads may only be picked up and transported
with attachments if they are securely grasped
and attached. Where necessary, loads must also
be secured against slipping, rolling, falling over,
swinging or tipping over. Note that any change to
the position of the load centre of gravity will affect
the stability of the truck.
Check the capacity rating plates for the attachments
or combination of attachments.
Auxiliary equipment
FleetManager (variant)
FleetManager is an equipment variant and
can be fitted to the truck in different versions.
The description and operating information can
be found in the separate operating instructions
for the corresponding FleetManager versions.
FleetManager regulates the access authori-
sation for the truck. To activate the access
control, FleetManager must be put into opera-
tion immediately following delivery.
– To do this, observe the information in the
chapter entitled "Activating the access
control after delivery of the truck".
CAUTION
Risk of accident due to collision of the lift mast or
load with the racking or low ceilings.
Active vibration damping of the lift mast changes
the vibration characteristics of the lift mast and load
in comparison to the standard truck.
– When handling loads, take the varying vibration
characteristics into consideration.
CAUTION
Risk of accident due to failure of active vibration
damping of the lift mast.
If active vibration damping of the lift mast fails, the
vibration characteristics of the lift mast and load will
change. Even if vibration damping of the lift mast is
inactive, the driver can still operate all of the truck's
hydraulic functions.
– If active vibration damping fails, take the change
in vibration characteristics into consideration.
– Complete the stock placement/removal process
without the support of active vibration damping.
– Park the truck securely.
– Notify the authorised service centre.
NOTE
The LED height sensor and reflector are
adjusted at the factory. Follow-up adjustments
must be performed by the authorised service
centre.
CAUTION
Incorrect cleaning can damage the sensor glass
and the reflector.
The components must never be cleaned using dry
materials.
Do not use agents containing hydrocarbons, e.g.
acetone, methanol, ethanol or propane.
CAUTION
Risk of damage to the LED height sensor through
pressure cleaning
A high-pressure cleaner can damage the LED
height sensor due to the penetration of water. This
can result in incorrect measurements.
– Never direct the spray from a high-pressure
cleaner at the LED height sensor.
NOTE
A misaligned sensor or bent reflector must be
adjusted only by the authorised service centre.
The driver can resolve a temporary interrup- 1
tion of the light signal due to contamination
or foreign objects in the signal path. If the
malfunction in the system still exists, please
contact the authorised service centre.
In the event of a malfunction, an error num-
ber is shown in the display. The system is
automatically available again as soon as the
malfunction is no longer present or has been
rectified.
Truck functions that are dependent on the
lift height are restricted in the event of a
malfunction in the height measurement.
The malfunctions must therefore be rectified
immediately.
General
The "load measurement" variant helps the
driver by displaying the weight of the lifted load
on the display and operating unit.
The weight is measured by an additional
weight sensor at the valve block. The sensor
measures the weight with a deviation of
+/-10% of the nominal load of the truck.
The calculated data is also evaluated by
assistance systems such as OPTISPEED
and Active Load Stabilisation (ALS).
To ensure correct functionality, the load
measurement must be performed once
for testing purposes as one of the daily
commissioning tasks for the truck.
NOTE
The displayed value of the load measurement
is invalid if the fork carriage is positioned
exactly between the free lift height and main
lift height during the measurement. In this
case, the measurement must be repeated at
a different position. In addition, the load must
be lifted completely off the ground during the
measurement.
WARNING
There is always an increased risk of the truck tipping
if it is driven with a raised load.
The system is a support for the driver when placing
items into stock and removing items from stock.
The responsibility for safe operation and complying
with safety regulations remains with the driver.
1
Once a specified lift height has been ex-
ceeded, the truck can be accelerated only
up to a set maximum speed. If the current
driving speed is already above this maximum
speed, the truck brakes regeneratively to the
set maximum speed. The speed limitation is
removed as soon as the current lift height is
lowered to below the specified value.
The lift height and the value for the maximum
speed can be set by the authorised service
centre. The factory setting for the maximum
speed is 5 km/h.
While the maximum speed is being limited, the
"tortoise" symbol (1) appears on the display
and operating unit.
CAUTION
Risk of accident due to collision of the lift mast or
load with the racking or low ceilings.
– Also, when using the system, always consider
the vibration characteristics of the lift mast and
the load.
– Note that the camera image only shows a small
part of the surrounding area.
2
6
1 3
hand.
2
1
0
CAUTION
Risk of component damage.
Adjustment of the driver's compartment must only
be carried out in the seated position by persons
weighing a maximum of 150 kg.
– Observe the total permissible weight during
adjustment of the driver's compartment.
NOTE
Before operating the seat-adjustment me-
chanism, make sure that there is sufficient
clearance between the driver's seat and the
side wall. This will ensure that the driver's seat
is not damaged when it is raised.
The electrical driver's compartment adjust-
ment mechanism, together with the adjust-
ment mechanisms for the seat and for the
steering column, is a system that allows the
driver's compartment to be adapted as effec-
tively as possible. The position of the driver's
seat and the pedal plate are electrically ad-
justed in proportion to one another.
– Press the rocker switch (1) in the operating
panel up or down until the optimum working
position is reached.
Clipboard (variant)
You have the option of using a clipboard (1) to
secure your work papers. This clipboard can
be inserted into a slot in the multifunctional
panel. To do so, the standard cover of the
multifunctional panel must be removed.
Safe handling
WARNING
Risk of physical injury
Battery racks are used for moving heavy weights.
Especially for versions with manual drive, there
is always the risk of being trapped or crushing
hands or fingers. The greatest possible care must
therefore be taken to ensure that the battery is
against its stop and that when the battery moves
along the guides your fingers or hands are not in the
way.
So that the forces arising from the moving battery
are kept as small as possible, the horizontal position
of the truck and battery rack and the transfer height
must be matched as accurately as possible. The
speed of movement should be kept as low as
possible.
The locking mechanisms on the truck and battery
rack should always be used.
Under no circumstances should batteries be moved
on battery racks not intended for them.
Load capacity
Each battery rack is intended for a particular
battery type. This means that the dimensions
and the maximum permissible weight are
pre-determined. The dimensions and the tray
number of the intended battery are to be taken
from the order documentation. The maximum
load capacity of the battery rack and its net
weight are to be taken from the nameplate.
WARNING
Danger of overloading
For mobile use, it must be ensured that the load
bearing capacity of the truck to be used for trans-
portation is sufficient for the weight of the battery
and the net weight of the battery rack.
Area of application
Mobile use
The battery rack for the truck is intended for
mobile use only. For mobile use, the empty
battery rack is moved to the relevant truck. If
a double battery rack is available, a freshly
DANGER
Risk of physical injury
1
Before unlocking the swing bolt, check that the
battery rack is on a horizontal surface and that the
floor has a sufficient load capacity. This is the only
way to ensure that the battery does not move in an
uncontrolled manner and trap or crush parts of the
operator's body.
CAUTION
Risk of damage to property
It depends on conditions on site whether or not
an extension cable for connecting the battery to
the truck is required during battery replacement.
If an extension cable is required, only a cable with
an appropriate cross-section and approved plugs
must be used.
When an extension cable is in use, the operator
must take great care when positioning the truck not
to pull the cable out of the socket.
NOTE
The fork arms must be in the "0° position" to
ensure their height position is calculated cor-
rectly. The "Automatic tilt to centre position"
option is very useful for this!
1 2 3
Definition of terms
Level
One target height can be assigned to each
level. Valid levels can be reached semi-
automatically.
Area
A warehouse can be divided into eight areas 1 Level 1-20
and each area can contain up to 20 levels. 2 Area A-H
Placing into stock
Placing into stock (3) is the insertion of a pallet
into the rack.
Removing from stock
Removing from stock (4) is the removal of a
pallet from the rack.
Assistant
The display includes an assistant (5) that
shows the possible movements via symbols
and corresponding direction arrows. During
automatic operation, the display shows only
the direction arrows for function symbols that
are currently allowed.
The individual symbols mean:
• Main lift lowering/lifting (6)
• Shift to drive side/load side (7) 5 6 7 8 9
• Tilt to drive side/load side (8)
• Transition shift left/right (9)
Pallet free lift
The pallet free lift (10) is the difference in
height by which the load support is raised
or lowered after shifting in order to place a load
into stock or remove a load from stock. This
value can be individually adjusted for placing
into and removing from stock at each level by
using the service software. The default setting
is 150 mm.
Reference drive
The process of passing the reference switch
located on the upper part of the lift mast is
known as referencing. This process sets the
reference value for the height position.
Reference height
The reference height is the distance from the
upper edge of the load support to the floor
when the reference switch is tripped. The
reference height differs according to the lift
mast height and can be set using the service
software.
The set value also determines which basic
height is shown in the display if the free lift has
ended and the main lift is beginning.
NOTE
If height preselection is active, only the arrow
symbols for movements that are still possible
will light up on the function symbols in the 1
assistant (1). The required movement is
identified in each case by a corresponding
flashing arrow symbol. Function symbols
without arrow symbols mean that the function
is blocked. If the load support is above the
free lift height, a reference drive must be
performed after switching on to activate the
height display.
The initial position for this description is a re-
tracted reach carriage (shifting measurement
system reports DS end position) and a lift mast
in free lift. Other combinations are also possi-
ble. However, they lead to different displays
on the assistant (1). The assistant specifies 2 5 6
the function that must be carried out. The fol-
lowing description is intended as an example.
When the truck has been switched ON, area
"A" (2) is automatically selected. The area can
be changed by pressing the button (3). If "H"
is reached, "A" is repeated. This enables area
preselection. A level can be selected (1-20)
by entering a digit using the alphanumeric
keypad (4). The complete selection (level and
area) is shown in the display (5). The stored
target height is displayed under (6).
NOTE
During free lift, the difference between the re-
ference height and the target height is shown 4 3
on the display as the "lift height remaining un-
til target (target difference)" (6). The display
does not show the difference between the cur-
rent lift height and target height until after the
Teach-in, general
The teach-in for height preselection is carried
out using the truck display.
In order to carry out the teach-in, the user must
be logged in to the truck with a PIN code with
authorisation level "2" or "3".
NOTE
Before a new height can be set via the display,
a reference drive must be carried out. Heights
that are below the reference height can be
saved by entering them manually. However,
if such a level is selected, automatic operation
cannot be used.
Only preset heights can be changed via
the display. No other truck-specific height
preselection parameters can be changed.
This can only be done using the service
software.
The following parameters, among others, can
be changed using the service software:
• Pallet free lift height
• Pallet free lowering height
• Accuracy and speed of pallet free lift and
pallet free lowering
• Accuracy and speed of homing
Performing a teach-in
The teach-in for height preselection is carried
out using the display and the enter keys for the
display and operating unit.
The values for the programmable lift heights
must be entered via the enter keys on the
numeric keypad. It is not possible to move the
fork to a lift height and transfer this value to the
height preselection system.
1 2
4 3
– For information on the general operation of
the truck configuration, as well as entering
a password with a specific authorisation
level, see the chapter entitled "Onboard
truck configuration/General".
– Press the "ESC" (4) and "OK" (6) buttons for
three seconds. The following appears on
the display field (1):
PASSWORD _ _ _ _
9 8 7
Programming the lift height (example: area A, level 07, lift height 5500 mm)
Button Action Display
Programming the lift height (example: area A, level 07, lift height 5500 mm)
Button Action Display
A07 05 (X flashes) XX
Press, the flashing digit is
5 --> the cursor advances one
replaced
place
A07 055 (X flashes) X
Press, the flashing digit is
5 --> the cursor advances one
replaced
place
A07 0550 (X flashes) X
Press, the flashing digit is
0 --> the cursor advances one
replaced
place
A07 0550 (X flashes)
Press, the flashing digit is
0 --> cursor remains in the last
replaced
position
Input complete; the value you
"OK" button (6) Press
have entered is displayed
.
NOTE
As an alternative to using "easy Target", the
target heights for the lift height preselector can
also be entered using the buttons for the input
field.
NOTE
As an alternative to using "easy Target Plus",
the function can also be executed using the
"Automatic tilt to centre position" button.
Cancel easy Target: Press the MAN button in the input field or release the foot switch (dead
man's switch).
.
Cancel easy Target Plus: Press the MAN button in the input field or release the foot switch
(dead man's switch).
.
Cab (variant)
General information about the cab
Depending on the area of application, the truck
can be equipped with a weather protection cab
or a cold store cab.
DANGER
Risk of fatal injury as a result of driving with the cab
door open!
The driver can be injured if he does not keep his
entire body within the protective cab, or if he falls off
the truck.
– Always close the cab door before driving off, and
keep it closed when driving.
DANGER
Risk of fatal injury as a result of driving with the cab
door open!
The driver can be injured if he does not keep his
entire body within the protective cab, or if he falls off
the truck.
– Always close the cab door before driving off, and
keep it closed when driving.
DANGER
There is a risk of damage caused by collision if the
cab door opens while driving.
– The cab door must be latched securely in the
engaged position.
1 2 3 4 5 6
WARNING
Risk of accident from actuating the operating
devices in the cab while the truck is in motion.
If the driver briefly stands up from the driver's seat in
order actuate operating devices, the driver may be
injured due to an insecure grip or may lose control
of the truck.
– Only actuate the operating devices in the cab
when the truck is stationary
1 2 3 4
DANGER
There is a risk of poisoning if heavily
polluted surrounding air is aspirated
into the closed cab!
The heater must not be operated in
the vicinity of storage areas or the like,
in which fuel vapours or fine dust (e.g.
coal, wood or grain dust) can build up.
DANGER
There is a risk of explosion due to
gases expanding or igniting as a result
of heat.
– Do not expose spray cans or gas
cartridges to the flow of hot air.
DANGER
The heating system overheats if the
hot air cannot escape from it. There is
a risk of fire!
The heating system may only be
switched on if the blower is running
and the heating system is not covered
by objects (such as a jacket or cover).
– Always switch the blower on first.
– Do not switch the heating system
on until the blower is switched on.
– Move any objects away from the
heating system or air outlets.
DANGER
The heating system housing can
become very hot when the heating
system is operating. There is a risk of
burns if it is touched!
– Do not touch the heating system
housing during operation.
– Only touch the switches provided.
Changing fuses
DANGER
Using the wrong fuses can result in
short circuits. There is a risk of fire!
– To change the fuses, contact the
authorised service centre.
CAUTION
The emergency exit window is only intended for
leaving the truck in the event of an emergency.
There is a risk of damage caused by collision if the
truck is driven with the window open or if the window
opens while driving.
Do not drive with the emergency exit window open.
If the window has been opened, make sure that the
window is latched securely in the engaged position
before driving off again.
Areas of application
Distinction is drawn between 4 different areas
of application, and between various different
modes of operation within these areas:
Cold store Temperature
Area of application Operating time Comment
equipment range up to
1 Not required -10°C Brief Typical
application for
trucks that take
the load from the
cooling truck into
the cold store,
where the load
is handled by
storage and
retrieval trucks.
2 Required -30°C Continuous Alternating
between indoor
and outdoor
use: time spent
outdoors long
enough for the
condensation to
drain off at least
(generally min. 30
minutes) or short
enough so that no
condensation can
form (generally
max. 10 minutes).
Parking outside of
the cold area.
CAUTION
Risk of component damage.
The lithium-ion battery is not approved for use in
shock cold stores (-45°C).
– Do not drive into a shock cold store with the
lithium-ion battery (even for a short period).
NOTE
In exceptional cases, the truck may also be
driven into the cold store with a small amount
of condensation. When doing so, prevent the
condensation water on the truck from freezing.
Water droplets on the sensor system and on
the mechanical components must be removed
by actuating the lift mast.
• Before entering the cold store, fully raise the
lift mast once and lower it again
• Repeat the operation after entering the cold
store
Procedure in emergencies
Emergency shutdown
CAUTION
If the battery male connector (1) is disconnected or
the emergency off switch (2) is actuated, the truck's
electrical functions are switched off.
This safety system must only be used in an emer-
gency or to safely park the truck.
1
CAUTION
Risk of component damage!
If you remove the battery male connector when the
key switch is switched on (under load), an arc will be
produced. This can lead to erosion at the contacts,
which considerably shortens their service life.
– Switch off the truck before the battery male
connector is disconnected.
– Do not disconnect the battery male connector
while the truck is switched on except in the case
of an emergency.
CAUTION
2
Risk of accident in the event of an emergency
shutdown of the truck whilst the load is raised.
In the event of an emergency shutdown of the truck
whilst the load is raised, the fork carriage must
be fully lowered once and the reach carriage fully
retracted once. This ensures that the electronic
support systems which prevent the truck from
tipping over with a raised load are recalibrated.
– Before continuing to drive the truck, fully lower
the load and fully retract the reach carriage.
DANGER
If the truck tips over, the driver could fall out and
slide under the truck with potentially fatal conse-
!
quences. There is a risk to life.
Failure to comply with the limits specified in these D
A
operating instructions, e.g. driving on unacceptably N
G
steep gradients or failing to adjust speed when E
cornering, can cause the truck to tip over. If the R
truck starts to tip over, do not leave the truck under
any circumstances. This increases the danger of
being hit by the truck.
– Never jump off the truck.
– You must adhere to the rules of behaviour if the
truck tips over.
Emergency lowering
DANGER
Risk to life if the load drops too quickly!
– Do not walk underneath the raised
load!
1
DANGER
If the truck is operated with the hydraulic controller
blocked, there is an increased risk of accident!
– After the emergency lowering procedure, have
the malfunction rectified.
– Notify your authorised service centre.
Towing
DANGER
The brake system on the towing vehicle may fail.
There is a risk of accident!
If the brake system of the towing vehicle is not
adequately sized, the vehicle may not brake safely
or the brakes may fail. The towing vehicle must be
able to absorb the tractive and braking forces from
the unbraked towed load (total actual weight of the
truck).
– Check the tractive and braking forces of the
towing vehicle.
DANGER
The truck could drive into the towing vehicle when
the towing vehicle brakes. There is a risk of acci-
dent!
When towing the truck, do not exceed the maximum
recommended speed of 2.5 km/h. When towing on
gradients, reduce speed to an absolute minimum
and keep wheel chocks at hand.
CAUTION
If the truck is not steered while it is being towed, it
may veer out in an uncontrolled manner!
– The truck being towed must also be steered by a
driver.
CAUTION
Risk of component damage!
If the battery male connector is connected while
the key switch is on (under load), a jump spark will
be produced. This can damage the contacts and 1
considerably shorten their service life.
– Do not connect the battery male connector while
the key switch is switched on.
CAUTION
There is a risk of short circuit if the
cables are damaged.
– Ensure that the battery cable is not
crushed when inserting the battery
tray into the truck.
NOTE
The battery male connector of a lithium-ion
battery has additional contacts to allow the
battery to communicate with the truck control
unit. The connection procedure is the same
for all battery male connectors.
CAUTION
Risk of component damage!
If the battery male connector is disconnected while
the key switch is on (under load), an arc will be
produced. This can lead to erosion at the contacts,
which considerably shortens their service life.
– Do not disconnect the battery male connector
while the key switch is switched on.
CAUTION
There is a risk of short circuit if the
cables are damaged. 1
– Lay the battery cable on the battery.
Ensure that the cable is not crushed
when either removing or inserting
the battery.
NOTE
The battery male connector of a lithium-ion
battery has additional contacts to allow the
battery to communicate with the truck control
unit. The disconnection procedure is the same
for all battery male connectors.
CAUTION
Risk of component damage!
Incorrect connection or incorrect
operation of the charging station or
battery charger may result in damage
to components.
– Follow the operating instructions
for the charging station or battery
charger and for the battery.
Maintenance personnel
Batteries may only be charged, maintained
or replaced by properly trained personnel
in accordance with the instructions from the
manufacturers of the battery, battery charger
and truck.
– Follow the handling instructions for the
battery and the operating instructions for
the battery charger.
– Observe the following safety regulations
when maintaining, charging and changing
the battery.
WARNING
Risk of crushing/shearing!
The battery is very heavy. There is a
risk of serious injury if any parts of the
body are caught under the battery.
There is a risk of serious injury if limbs
get crushed between the battery and
the truck frame.
– Always wear safety shoes when
replacing the battery.
– When handling the battery, always
make sure that no limbs get
crushed between the battery and
the truck frame.
Lifting accessories
The battery may only be removed with suitable
lifting accessories; see the chapter entitled
"Replacing the battery using a crane"
DANGER
Risk of accident!
The battery could fall from the lifting accessory,
or the lifting accessory could tip over or become
damaged. There is a risk of fatal injury.
– Use a suitable lifting accessory with a load ca-
pacity (see operating instructions or nameplate)
that at least matches the battery weight (see bat-
tery identification plate).
– Only remove the battery when the truck is
on level, smooth ground with sufficient load
capacity.
CAUTION
Potential for damage to the male battery connector.
If the battery male connector is disconnected or
connected while the key switch is switched on or the
battery charger is under load, an arc is produced at
the battery male connector. This can lead to erosion
at the contacts and can considerably shorten the
service life of the contacts.
– Switch off the key switch or battery charger be-
fore the battery male connector is disconnected
or connected.
– Do not disconnect the battery male connector
while under load, except in an emergency.
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 instructions
for the battery charger must also be followed.
Only the instructions that came with the battery
charger are valid. If any of these instructions
are not available, please request them from
the dealer.
The battery maintenance is composed of the
following sections "Checking the battery con-
dition, acid level and acid density", "Checking
the battery charge status", "Charging the bat-
tery" and "Equalising charge to prevent a deep
discharge of the battery" together.
DANGER
Danger to life and limb!
– Observe the instructions in the chapter entitled
"Safety regulations when handling the battery".
WARNING
Battery acid is toxic and corrosive!
– Observe the safety regulations in
the chapter entitled "Battery acid".
CAUTION
Damage to the battery possible!
– Follow the information in the operating instructi-
ons for the battery.
CAUTION 1
Deep discharges shorten the service life of the
battery.
Avoid a discharge to below 25% of the nominal
capacity (0% on the display). This can cause a
potential deep discharge of the battery.
– Charge batteries if a residual capacity of 0% is
displayed. Never leave batteries in a discharged
state. This also applies to partially discharged
batteries.
NOTE
The battery discharge indicator characteristic
curve must be set in accordance with the
battery installed. See "Setting battery data".
– Press the emergency off switch.
– Switch the truck on.
– Read the charge status on the display-
operating unit.
After connecting a fully charged battery:
• All of the display segments (1) light up
(100%) after a few moments. As the
capacity decreases, the segments go
out one after the other. If the permissible
discharge level of 25% residual capacity is
reached, only the last segment continues
to flash. An optional hydraulic limitation
or driving limitation can be activated by
the operating company or the authorised
service centre.
DANGER
Danger to life and limb!
– Observe the instructions in the chapter entitled
"Safety regulations when handling the battery".
WARNING
Battery acid is toxic and corrosive!
– Observe the safety regulations in the chapter
entitled "Safety regulations for handling consu-
mables/battery acid".
CAUTION
Risk of component damage!
Incorrect connection or operation of
the charging station or battery charger
may result in damage to components!
– Follow the operating instructions
for the charging station or battery
charger and for the battery.
CAUTION
Potential for damage to the male battery connector!
– Before the battery male connector is discon-
nected or connected, the truck and the battery
charger must be switched off.
NOTE
Battery maintenance is carried out in accor-
dance with the battery manufacturer's opera-
ting instructions. The operating instructions
of the battery charger used must also be follo-
wed. If any of these instructions are missing,
they must be requested from the dealer.
Lead or gel batteries are used as traction
batteries. Because the various types have
different structures, the respective matching
battery chargers must be used. Gel batteries
are subject to special charging and mainte-
nance provisions. The guidelines from the
respective manufacturer must be followed.
– Fully extend the battery together with the
reach carriage to the load side before
charging the battery in the truck (refer to the
chapter entitled "Replacing the battery").
– Switch off the truck.
NOTE
Note the information in the operating in-
structions for the battery charger (equalising
charge).
– After the charging operation is completed,
switch off the battery charger.
WARNING
Risk of explosion!
The plug may only be disconnected
from the socket when the truck and
battery charger are switched off.
NOTE
Dependent on the battery charger used, the
equalising charge might not begin until 24
hours have elapsed. Therefore, a period when
no shifts are running, such as the weekend, is
ideal for performing the equalising charge.
– Observe the information in the operating
instructions of the charger regarding how to
perform an equalising charge.
Maintenance personnel
The lithium-ion battery is virtually mainte-
nance-free and can be charged by the driver.
– If you have any questions, please contact
your authorised service centre.
– The handling instruction for the battery and
the operating instructions for the battery
charger must be followed.
– Observe the following safety regulations
when maintaining, charging and changing
the battery.
WARNING
Risk of crushing/shearing!
The battery is very heavy. There is a
risk of serious injury if any parts of the
body are caught under the battery.
If parts of the body are wedged
between the battery door and the edge
of the chassis when the battery door is
closed, this could lead to injuries.
– Always wear safety shoes when
replacing the battery.
– Only close the battery door if there
is no part of the body between the
battery door and the edge of the
chassis.
DANGER
Increased risk of fire!
Damaged lithium-ion batteries pose
an increased fire hazard.
In the event of a fire, large quantities
of water are the best option to cool the
battery.
DANGER
Risk of tipping if the truck is operated with an
incorrect battery
Installation of an incorrect battery reduces the
stability of the truck.
The batteries approved for this truck vary in terms
of their size, weight and capacity.
The truck may only be operated with a battery that
is approved for its battery tray.
A B 2
1 2
1
3
4 4
3
5
5
WARNING
Risk of accident as a result of weakened lifting eyes.
If bent lifting eyes are straightened, they will lose
their rigidity. The lifting eyes will then be unable to
support the weight of the battery. The battery may
fall.
– Do not straighten bent lifting eyes.
– Have any bent lifting eyes replaced by your
authorised service centre.
NOTE
When changing from lead-acid batteries to
lithium-ion batteries, the authorised service
centre must adjust the truck electronics.
Service LED
The service LED (1) lights up red if the battery
function is significantly restricted or if opera-
tion is not possible.
– Contact your authorised service centre.
Temperature LED
The temperature LED indicates an increased
temperature. Battery power is reduced or
switched off.
The LED remains active for the duration of the
run-on time or until the temperature falls to
within the normal range.
CAUTION
Risk of damage to components!
Battery male connectors and battery charger
connectors from different manufacturers are not
compatible and may cause damage.
– Use battery male connectors and battery charger
connectors produced by the same manufacturer.
– If the connectors are from different manufac-
turers, please contact your authorised service
centre.
NOTE
To prevent deep discharge of the lithium-ion
battery, truck performance limitations are
imposed once the charge state of the battery
drops to a certain level. The battery must be
charged before the charge state drops below
15%.
For information on reading the charge state of
the battery, see the section on "Checking the
battery charge status".
– Fully extend the battery and the reach
carriage to the load side before charging
the battery in the truck (see the chapter on
"Replacing the battery").
– Switch off the truck.
– Disconnect the battery male connector.
– If fitted, open the door of the driver's cab
(variant) fully.
– Keep away from naked flames and do not
smoke.
NOTE
Observe the information in the operating
instructions for the battery and the battery
charger.
After charging
The battery charger will switch off automati-
cally.
– Disconnect the battery male connector
from the plug on the battery charger. Do
not disconnect the battery male connector
while the charger is switched on.
– Fully insert the battery male connector into
the plug connection on the truck.
CAUTION
There is a risk of short circuit if the
cables are damaged.
Do not crush the battery cable when
retracting the reach carriage with the
battery.
– Check the battery cable for da-
mage.
CAUTION
Damage to the battery from deep discharge!
A deeply discharged battery results in considerable
cost and, potentially, an unusable battery due to
cell damage.
– Always charge the battery before deep dis-
charge begins.
– When taking the battery out of operation for a
prolonged period (e.g. for company holidays),
always ensure the battery is charged (30% -
100%).
NOTE
The only intended use of a lead-acid battery
in a truck with a lithium-ion battery is in the
event of an emergency; for example, if the
lithium-ion battery is faulty.
Trucks with lithium-ion-battery ex works
Battery tray Truck operation ex works After the conversion
323 Lithium-ion Lithium-ion/lead-acid
324 Lithium-ion Lithium-ion/lead-acid
325 Lithium-ion Lithium-ion (*) / lead-acid (*)
326 - -
(*) Also requires a change of battery tray
CAUTION
Risk of components being damaged by the lifting
accessory and battery rolling away!
The lifting accessory and battery may roll away in an
uncontrolled manner if the battery is not removed
on a level, smooth floor with sufficient load capacity.
– Follow the operating instructions for the lifting
accessory used.
– Always remove the battery on a level, smooth
floor with sufficient load capacity.
WARNING
Risk of crushing from moving parts!
Observe the information signs on the truck; see the
chapter entitled "Labelling points".
NOTE
If the reach system of the truck is not working
due to a battery problem, the battery must be
removed by your authorised service centre.
NOTE
In normal operation, the acoustic warning
signal together with the "lock" and "creep
speed" symbols indicate that the battery lock
sensor has a mechanical defect. Have any
defects rectified by the authorised service
centre.
DANGER
The battery weight and its dimensions affect the
stability of the truck.
When replacing the battery, the weight ratios
must not be changed. The battery weight must
remain within the weight range specified on the
nameplate. The location of ballast weights must not
be changed.
WARNING
Risk of crushing if the battery falls out.
The battery lock must only be released on horizon-
tal, level ground using suitable devices.
Suitable devices include:
– Suitable lifting equipment (e.g. forklift truck,
crane) with sufficient load capacity for lifting the
battery
– Suitable harnesses
– A stationary or mobile battery change frame
(follow the operating instructions for the battery
change frame)
The battery lock lever may be actuated only when
the truck is stationary and the reach carriage is fully
retracted.
CAUTION
There is a risk of short circuit if the
cables are damaged!
Lay the battery cable on the battery.
Ensure that the cable is not crushed
when removing and inserting the
battery.
3
– Check the connection cables for
damage.
WARNING
Risk of explosion
The openings in the area of the battery where gas
may be released must not be covered or sealed.
An unrestricted air supply prevents the formation of
potentially explosive gas mixtures. Do not create
openings in the area of the battery where gas may
be released, to ensure that any gases released
cannot penetrate the driver's compartment.
NOTE
• Compare the nameplates on the truck
and the battery. The battery must comply
with the specifications on the nameplate
regarding the voltage and weight.
• Gel batteries and lithium-ion batteries are
subject to special charging/handling in-
structions. Follow the instructions provided
by the respective manufacturer.
CAUTION
Risk of component damage!
If the battery male connector is connected while
the key switch is on (under load), a jump spark will
be produced. This can damage the contacts and
considerably shorten their service life.
– Do not connect the battery male connector while
the key switch is switched on.
WARNING
Risk of crushing if the battery falls out.
Releasing the battery lock, as described below,
must only be carried out on horizontal, level ground
using a suitable battery change frame.
The battery lock lever may be actuated only when
the truck is stationary and the reach carriage is fully
retracted.
CAUTION
There is a risk of short circuit if the
cables are damaged!
Position the battery cable on the
battery in such a way that it cannot be
crushed when removing or inserting
the battery.
3
– Check the connection cables for
damage.
4
Releasing the swing bolt
CAUTION
If the battery rolls out of the battery compartment
when no external device is present, this can lead to
material damage.
Before removing the battery, always have an
external device in position.
CAUTION
Risk of injury from crushing and shearing points
Always actuate the swing bolts with just one hand
and make sure that fingers are kept away from the
rotation and clamping range.
NOTE
• The battery must comply with the specifica-
tions on the nameplate regarding voltage
and weight. Compare the nameplates for
the truck and battery.
• Gel batteries are subject to special char-
ging/maintenance/handling instructions.
The guidelines from the respective manu-
facturer must be observed.
CAUTION
Risk of component damage!
If the battery male connector is connected when the
truck is switched on (under load), a jump spark will
be produced. This can damage the contacts and
considerably shorten their service life.
– Do not connect the battery male connector when
the truck is switched on.
– Make sure that the truck is switched off before
connecting the battery male connector.
Adjustment instructions
To enable the truck controller to determine the
residual capacity of the battery correctly, the
technical data for the installed battery must
be entered using the following buttons on the
display:
– Push the "OK" button on the keypad (2)
for approx. 2 seconds. This calls up the
onboard diagnostics function.
– The display (1) provides information on the
selected menu item.
– Push the arrow buttons on the keypad (2) to
scroll within the menus. The selected menu
items are highlighted on the display.
The following menu items are available:
• Information
• Parameter
• Diagnosis
NOTE
The height preselection option also offers the
Teach in menu item.
– Select the Parameter menu.
– Push the "OK" button on the keypad (2) to
confirm the selection.
The correct battery type (batt_type) and
capacity (batt_cap) for the installed battery
can now be selected from the six options
by entering the number that represents the
capacity value.
DANGER
Risk of fatal injury from falling load
– Never walk or stand underneath
suspended loads.
– Determine the weight of the battery 1
(battery identification plate). Note
the load capacity of the lifting
device.
– Always lift the battery with suitable
lifting gear (bridge piece).
– Do not use the methods described
here to transport the battery over
long distances.
When removing and inserting the
battery using a lifting device, always
ensure that no one is standing directly
next to the battery or between the
battery and the lifting device.
WARNING
Risk of crushing/shearing!
The battery must be transported very carefully, i.e.
at low speed, using slow steering movement and
careful braking.
DANGER
Risk of fatal injury from falling load
– Never walk or stand below suspen-
ded loads.
– Determine the weight of the battery 1
(battery identification plate). Note
the load capacity of the lifting
device.
– Always lift the battery with suitable
lifting gear (bridge piece).
– Do not use the methods described
here to transport the battery over
long distances.
When removing and inserting the
battery using a lifting device, always
ensure that no one is standing directly
next to the battery or between the
battery and the lifting device.
WARNING
Risk of crushing/shearing!
The battery must be transported very carefully, i.e.
at low speed, using slow steering movement and
careful braking.
NOTE
Do not straighten any bent lifting eyes; have
them replaced by the authorised service
centre.
– Hook the lifting gear onto the four lifting
eyes. Follow the operating instructions for
the lifting gear.
To prevent the battery tray being compressed,
the lifting gear must lift vertically.
– Slowly and using a vertical movement, lift
the battery out of the battery frame or insert
it into the battery frame. Ensure that there
is sufficient distance from the lift mast and
from the chassis of the truck. Avoid any
oscillating motions.
– Transport the battery to the intended
storage space.
CAUTION
Risk of damage!
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 any similar object.
CAUTION
Risk of component damage!
If you remove the battery male connector when the
key switch is switched on (under load), an arc will be
produced. This can lead to erosion at the contacts,
which considerably shortens their service life.
– Switch off the key switch before the battery male
connector is disconnected
– Do not disconnect the battery male connector
while the key switch is switched on, except in an
emergency
WARNING
There is a risk of injury due to falling
when climbing onto the truck!
When climbing onto the truck, it
is possible to get stuck or slip on
components and fall. Higher points
on the truck must only be accessed
using the appropriate equipment.
– Adhere strictly to the following
steps
DANGER
Risk of fire!
Deposits/accumulations of combusti-
ble materials may ignite in the vicinity
of hot components (e.g. drive units).
– Adhere strictly to the following
steps
DANGER
Flammable fluids can be ignited by hot
components on the truck, causing a
risk of fire!
– Adhere strictly to the following
steps
NOTE
The more often the truck is cleaned, the more
frequently it must be lubricated.
WARNING
Danger of electric shocks due to residual capacity!
– Never reach into the electrical system with your
bare hands.
CAUTION
Cleaning electrical system parts
with water can damage the electrical
system.
Cleaning electrical system parts with
water is forbidden!
– Do not remove covers etc.
– Only use dry cleaning materials
according to the specifications in
the section "Cleaning the truck".
WARNING
Risk of accident!
Load chains are safety elements.
The use of cold cleaning solvents, chemical clea-
ners or fluids that are corrosive or contain acid or
chlorine can damage the chains; use of these items
is forbidden!
– Observe the manufacturer's guidelines for
working with cleaning materials
ENVIRONMENT NOTE
Dispose of any fluid that has been spilled
or collected in the collection vessel in an
environmentally friendly manner. Follow the
statutory regulations.
NOTE
Cleaning can be performed using a commer-
cially available glass cleaner.
After cleaning
– Carefully dry the truck (e.g. with com-
pressed air).
– Sit on the driver's seat and start the truck in
line with applicable regulations.
CAUTION
Risk of short circuit!
– If any moisture has penetrated the battery male
connector despite the precautionary measures
taken, first dry the battery male connector using
compressed air.
CAUTION
Risk of material damage from overloading!
The load capacity/lifting capacity of the means of
transport, the ramps and the loading bridges must
be greater than the actual total weight of the truck.
Components can be permanently deformed or
damaged due to overloading.
– Determine the total actual weight of the truck.
– Only load the truck if the load capacity of the
means of transport, the ramps and loading
bridges is greater than the total actual weight
of the truck.
DANGER
Risk of accident from the truck crashing!
Steering movements can cause the tail end to veer
off the loading bridge towards the edge. This may
cause the truck to crash.
– Before driving across a loading bridge, ensure
that the loading bridge is properly attached and
secured.
– Ensure that the transport vehicle onto which the
truck is to be driven has been sufficiently secured
against moving.
– Maintain a safe distance from loading bridges,
ramps, working platforms and similar objects.
– Drive slowly and carefully onto the transport
vehicle.
CAUTION
Abrasive lashing ropes may damage the surface of
the truck.
– Position slip-resistant pads underneath the lifting
points (e.g. rubber mats or foam).
DANGER
If the lashing ropes slip, the load can move!
The truck must be lashed securely so that it cannot
move during transportation.
– Make sure that the lashing straps are tightened
securely and that the pads cannot slip off.
DANGER
If the lashing ropes slip, the load can move!
1
The truck must be lashed securely so that it cannot
move during transportation.
– Make sure that the lashing straps are tightened
securely and that the pads cannot slip off.
= Loading weight
.
= Loading weight
.
CAUTION
Harnesses may damage the paintwork on the truck!
Harnesses may damage paintwork by rubbing and
pressing on the surface of the truck. Particularly
hard or sharp-edged harnesses, such as wire ropes
or chains, can quickly damage the surface.
– Use textile harnesses, e.g. lifting straps, with
edge protectors or similar protective devices
where necessary.
CAUTION
Incorrectly fitted harnesses may damage attach-
ment parts!
Pressure from the harnesses can damage or de-
stroy attachment parts when the truck is lifted.
Attachment parts that are in the way (e.g. lighting
etc.) must be removed before crane loading com-
mences. Ask your authorised service centre about
this.
– Secure harnesses in such a way that they do not
touch any attachment parts.
NOTE 3 45°
The space under the reach cylinder for the
lifting strap can be increased by extending the
reach cylinder.
– Guide the loose ends of the lifting strap
through the loop.
– Guide the loose ends of the lifting strap to
the right and left of the side chassis support
(5) and upwards towards the bridge piece.
– Hook the lifting straps onto the bridge piece
and secure the straps in place.
Decommissioning
Shutting down and storing the truck
CAUTION
Component damage due to incorrect storage!
Corrosion damage is possible in the event of incor-
rect storage or shutdown for more than 2 months.
When the ambient temperature is below –10°C for
an extended period the batteries cool down. The
electrolyte may freeze and damage the batteries.
– Store the truck in a dry, clean, frost-free and
well-ventilated environment.
– Implement the following measures before
shutting down.
NOTE
Only store batteries that are fully charged.
CAUTION
Danger of damage from corrosion due to conden-
sation on the truck!
Many plastic films and synthetic materials are
watertight. Condensation water on the truck cannot
escape through these covers.
– Do not use plastic film as this facilitates the
formation of condensation water.
– Cover with vapour-permeable material, e.g.
cotton.
NOTE
For further information, see the workshop
manual for the truck or contact the authorised
service centre.
Maintenance
5 Maintenance
Safety regulations for maintenance
Safety devices
After maintenance and repair work, all safety
devices must be reinstalled and tested for
operational reliability.
Set values
The device-dependent set values must be
observed when making repairs and when
changing hydraulic and electrical compo-
nents. These are listed in the appropriate
sections.
DANGER
There is a risk to life if the truck tips over!
If not raised and jacked up properly, the truck may
tip over and fall off. Only the hoists specified in the
workshop manual for this truck are allowed and are
tested 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.
DANGER
Risk of accident!
If the lift mast or fork carriage is raised, no work
may be performed on the lift mast or at the front of
the truck unless the following safety measures are
observed!
DANGER
Risk of accident!
– Use only chains with adequate lifting capacity to
secure the particular lift mast.
CAUTION
Potential damage to the ceiling!
– Note the maximum lift height of the lift mast.
NOTE
Extend the lift mast to slacken the chain.
NOTE
Extend the lift mast to slacken the chain.
Maintenance timeframe
– The maintenance check lists indicate the
maintenance work that is due.
– Carry out maintenance work on the truck
based on the hour meter.
The intervals are defined for standard use.
Shorter maintenance intervals can be defined
in consultation with the operating company,
At operating hours
1000 2000 4000 5000 7000 Carried out
8000 10000 11000 13000 14000
Steering
Check that the steering wheel is securely attached and check the turning handle for
damage
Check the steering column for the level of play
Check the adjustment mechanism of the steering for functionality
Check the function of the steering system
Check the steering turntable bearing for ease of movement and wear
Check the steering gears for play, and lubricate
Hydraulic brake system
Check the condition of all mechanical and hydraulic brake parts, check for correct
function and clean
Check the brake linings and replace if necessary
Check the brake clearance
Check the brake retardation values after each adjustment
Check the brake fluid level
If available, check switch for the brake fluid
Perform brake test
Electric parking brake
At operating hours
1000 2000 4000 5000 7000 Carried out
8000 10000 11000 13000 14000
Use air to blast dust from the surfaces
Remove dirt and dust from the heat sinks
Check the fans for correct function and for damage, and clean
Lead acid battery and accessories
Check the battery for damage and acid density; observe the manufacturer's mainten-
ance instructions
Check the battery male connector and cables for damage
Perform insulation testing
Measure the tray for short circuits
Lithium-ion battery and accessories
NOTE: Lithium-ion batteries are charged using high currents. Minor damage to the
contact surfaces can therefore damage the battery plug. Replace the battery male
connector in good time.
Check the battery for damage; follow the manufacturer's maintenance instructions
Check the battery male connector, contacts and cable for damage; replace if neces-
sary.
Check the battery male connector, contacts and cable on the battery charger for
damage; replace if necessary.
Perform insulation testing
Hydraulic system
Check the condition of the hydraulic system, check that it is working correctly, check
for damage and check for leak tightness.
Check the hydraulic pump for leak tightness
Check the hydraulic oil level
Check the oil filter (visual inspection, replace if contaminated)
Test the oil tank for leak tightness
Clean the breather filter and replace if necessary
Lift mast
Check the mast mounting for damage and check the tightening torques. For mast
traversing, check and lubricate the sliding faces
Check the mast profiles for damage and wear. Lubricate the mast profiles
Check the load chains for damage and wear. Adjust and lubricate the load chains.
Replace the main lift chains after 5000 operating hours (recommendation)
Check the lift cylinders and connections for damage and check for leak tightness.
At operating hours
1000 2000 4000 5000 7000 Carried out
8000 10000 11000 13000 14000
Check the guide pulleys for damage and wear
Check the mast rollers and chain rollers for damage and wear
Check the tilt cylinders and connections for damage and check for leak tightness.
Check the joints of the tilt attachment for play and ease of movement
Check the reach cylinders and connections for damage and check for leak tightness.
Check the joints of the reach cylinder for play and ease of movement, and lubricate
Check the fork carriage for damage and wear
Check the fork height setting and adjust the chain length if necessary
Check the fork arm interlock for damage and correct function
Check the fork arms for wear and deformation
Check that there is a safety screw on the fork carriage or on the attachment
Check the hydraulic hoses, re-adjust, replace if necessary
Lubricate the fork tilter/sideshift
Special equipment
Replace the filter mat for the heating system.
Check the heating system for damage; observe the manufacturer's maintenance
instructions
Check the optical height measuring system (visual inspection), clean the sensor and
reflector
Check the attachments for wear and damage; observe the manufacturer's mainten-
ance instructions
Clean excessive dirt from the battery change frame and check the frame for defor-
mation/damage. Check the freedom of movement of the rollers and keep the surface
of the rollers free of corrosion by applying a film of oil.
Lubricating
Lubricate using approved lubricants in accordance with the lubrication plan
General
Check labelling to ensure it is complete
Perform a test drive
Read out and check the error numbers and delete list
Reset the maintenance interval
Additional maintenance guidelines for using the truck in a cold store - 500 hours
or every 12 weeks
At operating hours
500 1000 1500 2000 2500 Carried out
3000 3500 4000 4500
Truck components
Perform a function check of the entire truck, including all special equipment, special
heating systems, switch-off thermostats etc.
Check all important screw connections for secure attachment
Check the condition and mounting of the wheels
Check the function of the steering system
Check the steering play; check the setting of the steering chain if necessary
Perform a special function check of the brake assemblies
Check the hydraulic system for leaks
Check all rollers and wear strips in the lift mast for ease of movement
Perform a visual inspection of chains and pinion gears, lubricate as required.
Perform a visual inspection of the fork arms
Check the ease of movement of the limit switches
At operating hours
500 1000 1500 2000 2500 Carried out
3000 3500 4000 4500
Lubricating
Lubricate using approved lubricants in accordance with the lubrication plan
Lubricate the fork tilter/sideshift
In addition, lubricate the lubricating nipple for the door hinges and the door closing
mechanism every six weeks
CAUTION
Risk of damage to property
Trucks for cold store operation must be lubricated
using different lubricants; see the chapter entitled
"Cold store application".
WARNING
Risk of injury!
– After an accident, check the driver's seat and the
mounting.
WARNING
Risk of accident!
Uneven wear reduces the stability of the truck and
increases the braking distance.
– Worn or damaged tyres (left or right) must be
replaced immediately.
WARNING
Risk of tipping!
Tyre quality affects the stability of the truck.
If you wish to use a different type of tyre on the truck
from the tyres approved by the truck manufacturer,
or tyres from a different manufacturer, you must first
obtain approval from the truck manufacturer.
NOTE
The wear of the tyres must be approximately
the same.
• Polyurethane tyres can be worn down to the
wear mark (3)
The tyres must be replaced if:
• Large cracks have formed in the tread This
can be detected by a "whirring sound" when
driving
• The tread has broken away significantly
• The tyre diameter has reduced by approx.
9%
A wear mark (1) in the lateral flank of the lining
serves as a visual indication of the wear limit.
WARNING
Hydraulic oil under pressure can
escape from leaking lines and cause
injuries to the skin.
Wear suitable protective gloves,
industrial goggles etc.
WARNING
Hydraulic hoses become brittle over time!
Hydraulic hoses must not be used for a period
longer than six years.
The BGR 237 specifications must be complied with.
Differing national laws must be taken into account.
NOTE
Spray the tracks evenly from a distance of
approx. 15 - 20 cm. Wait approx. 15 minutes
1
until the device is ready for operation again.
6210_800-020
6210_900-002
Technical data
6 Technical data
Dimensions
Dimensions
Characteristics
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
1.1 Manufacturer STILL STILL STILL STILL
Manufacturer's type FM-X 10 / FM-X 12 /
1.2 FM-X 10 N FM-X 12 N
designation Li-ion Li-ion
1.3 Drive Electric Electric Electric Electric
Seating Seating Seating Seating
1.4 Operation
device device device device
1.5 Load capacity/load Q kg 1000 1000 1200 1200
1.6 Load centre of gravity c mm 600 600 600 600
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
1.8 Load distance 1 x mm 278 184 278 184
1.9 Wheelbase y mm 1275 1275 1275 1275
.
Weights
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Net weight (including
2.1 kg 3230 3200 3240 3210
battery)
Axle load without
2.3 kg 2040/1190 1970/1230 2130/1100 1970/1230
front/rear load
Axle load with fork
2.4 forwards with front/rear kg 960/3270 920/3280 850/3580 920/3280
load
Front/rear axle load, fork
2.5 kg 1730/2500 1590/2610 1820/2610 1590/2610
backwards, with load
.
Basic dimensions
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Lift mast/fork carriage tilt,
4.1 α/β ° 1/3 2/4 1/3 2/4
forwards/backwards 3
Height with lift mast
4.2 h1 mm 2450 2450 2450 2450
retracted
4.3 Free lift h2 mm 1890 1890 1890 1890
4.4 Lift h3 mm 5750 5750 5750 5750
Height with lift mast
4.5 h4 mm 6310 6310 6310 6310
extended
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Height of overhead guard
4.7 h6 mm 2200 2200 2200 2200
(cab) 4
4.8 Seat height h7 mm 1140 1140 1140 1140
Height of load wheel
4.10 h8 mm 308 308 308 308
supports
4.19 Total length 2, 5, 6 l1 mm 2366 2462 2366 2462
Length including fork
4.20 l2 mm 1216 1312 1216 1312
back 2, 5, 6
4.21 Total width b1/b2 mm 1270 1140 1270 1140
Fork arm dimensions, 40/ 80/ 40/ 100/ 40/ 100/
4.22 s/e/l mm 40/ 80/ 1150
DIN ISO 2331 1150 1150 1150
Fork carriage to ISO
4.23 2/A 2/A 2/A 2/A
2328, class/model A, B
4.24 Fork carriage width b3 mm 760 760 760 760
Width across forks,
4.25 b5 mm 296/600 296/600 296/600 296/600
min./max.
Width between load
4.26 b4 mm 920 790 920 790
wheel supports
4.28 Reach forward 1 l4 mm 449 364 449 364
Ground clearance with
4.31 m1 mm 70 70 70 70
load under lift mast
Ground clearance at
4.32 m2 mm 70 70 70 70
centre of wheelbase
4.34 Aisle width for a 1000 x
Ast mm 2679 2733 2679 2733
.1 1200 pallet, crosswise 2
4.34 Aisle width for a 800 x
Ast mm 2746 2812 2746 2812
.2 1200 pallet, lengthwise 2
4.35 Turning radius Wa mm 1540 1520 1540 1520
Length across the load
4.37 l7 mm 1639 1641 1639 1641
wheel supports
4.43 Step height mm 345 345 345 345
.
Performance data
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Driving speed
5.1 km/h 14/14 14/14 14/14 14/14
with/without load
Reverse driving speed
5.1.1 km/h 14/14 14/14 14/14 14/14
with/without load
Lifting speed with/without
5.2 m/s 0.47/0.70 0.47/0.70 0.47/0.70 0.47/0.70
load
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Lowering speed
5.3 m/s 0.56/0.50 0.56/0.50 0.56/0.50 0.56/0.50
with/without load
Reach speed with/without
5.4 m/s 0.18 0.18 0.18 0.18
load
Climbing capability
5.7 % 10/15 10/15 10/15 10/15
with/without load
Max. climbing capability
5.8 % 15/20 15/20 15/20 15/20
with/without load
Acceleration time (over
5.9 s 4.5/4.0 4.5/4.0 4.5/4.0 4.5/4.0
10 m with/without load)
Regenera- Regen- Regen- Regen-
tive, elec- erative, erative, erative,
5.10 Service brake electrical/ electrical/ electrical/
trical/ hy-
draulic hydraulic hydraulic hydraulic
.
Electric motor
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Traction motor, power
6.1 kW 6.5 6.5 6.5 6.5
rating at S2 = 60 min
Lift motor, power rating at
6.2 kW 14 13 14 14
S3 = 15%
Battery in accordance
43531 43531 43531 43531
6.3 with DIN 43531/35/36 A,
C/254-2 B/254-2 C/254-2 B/254-2
B, C, no
48/465, 48/465,
Battery voltage/nominal
6.4 V/Ah Li-ion: 48/465 Li-ion: 48/465
capacity K5
48/204 48/204
Battery weight (±5%
6.5 depending on the kg 750 750 750 750
manufacturer)
Energy consumption in
kWh/
6.6 accordance with VDI 2.88 2.88 3.23 3.23
h
cycle
.
Other
FM-X 10 / FM-X 12 /
FM-X 10 N FM-X 12 N
Li-ion Li-ion
Working pressure for
10.1 bar 200 200 200 200
attachment
10.2 Oil flow for attachments l/min 20 20 20 20
Sound pressure level in dB(
10.7 69 69 69 69
driver's compartment A)
.
Key data
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
1.1 Manufacturer STILL STILL STILL STILL
Manufacturer's type FM-X 14 / FM-X 14 W FM-X 14
1.2 FM-X 14 N
designation Li-ion / Li-ion EW / Li-ion
1.3 Drive Electric Electric Electric Electric
Seating Seating Seating Seating
1.4 Operation
device device device device
1.5 Load capacity/load Q kg 1400 1400 1400 1400
1.6 Load centre of gravity c mm 600 600 600 600
1.8 Load distance 1 x mm 348 335 276 276
1.9 Wheelbase y mm 1381 1453 1381 1381
.
Weights
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Net weight (including
2.1 kg 3470 3430 3700 3750
battery)
Front/rear axle load
2.3 kg 2250/1220 2120/1310 2290/1410 2330/1420
without load
Front/rear axle load, fork
2.4 kg 850/4010 860/3970 960/1410 1000/4150
forwards, with load
Front/rear axle load, fork
2.5 kg 1950/2910 1770/3060 1920/3180 1960/3190
backwards, with load
.
Basic dimensions
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Lift mast/fork carriage tilt,
4.1 α/β ° 1/3 2/4 1/3 1/3
forwards/backwards 3
Height with lift mast
4.2 h1 mm 2450 2450 2450 2450
retracted
4.3 Free lift h2 mm 1890 1890 1890 1890
4.4 Lift h3 mm 5750 5750 5750 5750
Height with lift mast
4.5 h4 mm 6310 6310 6310 6310
extended
Height of overhead guard
4.7 h6 mm 2200 2200 2200 2200
(cab) 4
4.8 Seat height h7 mm 1140 1140 1140 1140
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Height of load wheel
4.10 h8 mm 308 308 308 308
supports
4.19 Total length 2, 5, 6 l1 mm 2402 2488 2474 2474
Length including fork
4.20 l2 mm 1252 1338 1324 1324
back 2, 5, 6
4.21 Overall width b1/b2 mm 1270 1140 1470 1670
Fork arm dimensions, 40/ 100/ 40/ 100/ 40/ 100/ 40/ 100/
4.22 s/e/l mm
DIN ISO 2331 1150 1150 1150 1150
Fork carriage to ISO
4.23 2/A 2/A 2/A 2/A
2328, class/model A, B
4.24 Fork carriage width b3 mm 760 760 760 760
Width over forks,
4.25 b5 mm 316/620 316/620 316/620 316/620
min./max.
Width between load
4.26 b4 mm 920 790 1120 1320
wheel supports
4.28 Reach forward 1 l4 mm 529 515 457 457
Ground clearance with
4.31 m1 mm 70 70 70 70
load below lift mast
Ground clearance at the
4.32 m2 mm 70 70 70 70
centre of the wheelbase
4.34 Aisle width for a 1000 x
Ast mm 2727 2787 2821 2861
.1 1200 pallet, crosswise 2
4.34 Aisle width for a 800 x
Ast mm 2782 2845 2887 2927
.2 1200 pallet, lengthwise 2
4.35 Turning radius Wa mm 1640 1691 1680 1720
Length across the load
4.37 l7 mm 1745 1817 1745 1745
wheel supports
4.43 Step height mm 345 345 345 345
.
Performance data
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Driving speed
5.1 km/h 14/14 14/14 14/14 14/14
with/without load
5.1. Reverse driving speed
km/h 14/14 14/14 14/14 14/14
1 with/without load
Lifting speed with/without
5.2 m/s 0.45/0.68 0.45/0.68 0.45/0.68 0.45/0.68
load
Lowering speed
5.3 m/s 0.56/0.52 0.56/0.52 0.56/0.52 0.56/0.52
with/without load
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Reach speed with/without
5.4 m/s 0.18 0.18 0.18 0.18
load
Climbing capability
5.7 % 10/15 10/15 10/15 10/15
with/without load
Max. climbing capability
5.8 % 15/20 15/20 15/20 15/20
with/without load
Acceleration time (over
5.9 s 4.5/4.0 4.5/4.0 4.5/4.0 4.5/4.0
10 m) with/without load
Regenera- Regen- Regen- Regen-
tive, elec- erative, erative, erative,
5.10 Service brake electrical/ electrical/ electrical/
trical/ hy-
draulic hydraulic hydraulic hydraulic
.
Electric motor
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
Traction motor, power
6.1 rating at S2 = 60 min kW 6.5 6.5 6.5 6.5
Lift motor, power rating at
6.2 kW 14 14 14 14
S3 = 15%
Battery in accordance
43531 43531 43531 43531
6.3 with DIN 43531/35/36 A,
C/254-2 B/254-2 C/254-2 C/254-2
B, C, no
48/465, 48/620, 48/620,
Battery voltage/nominal
6.4 V/Ah Li-ion: 48/465 Li-ion: Li-ion:
capacity K5
48/204 48/204 48/204
Battery weight (±5%
6.5 depending on the kg 750 750 940 940
manufacturer)
Energy consumption in
kWh/
6.6 accordance with the VDI 3.40 3.40 3.40 3.40
h
cycle
.
Other
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
10. Working pressure for
bar 200 200 200 200
1 attachment
10.
Oil flow for attachments l/min 20 20 20 20
2
10. Sound pressure level in
dB(A) 69 69 69 69
7 driver's compartment
.
Key data
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
1.1 Manufacturer STILL STILL STILL STILL
Manufacturer's type FM-X 17 / FM-X 17 W FM-X 17
1.2 FM-X 17 N
designation Li-ion / Li-ion EW / Li-ion
1.3 Drive Electric Electric Electric Electric
Seating Seating Seating Seating
1.4 Operation
device device device device
1.5 Load capacity/load Q kg 1700 1700 1700 1700
1.6 Load centre of gravity c mm 600 600 600 600
1.8 Load distance 1 x mm 410 325 338 338
1.9 Wheelbase y mm 1453 1453 1453 1453
.
Weights
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Net weight (including
2.1 kg 3470 3500 3740 3790
battery)
Front/rear axle load
2.3 kg 2290/1180 2220/1280 2390/1350 2440/1350
without load
Front/rear axle load, fork
2.4 kg 730/4440 670/4520 900/4550 950/4550
forwards, with load
Front/rear axle load, fork
2.5 kg 2030/3140 1850/3340 2050/3390 2100/3390
backwards, with load
.
Basic dimensions
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Lift mast/fork carriage tilt,
4.1 α/β ° 1/3 2/4 1/3 1/3
forwards/backwards 3
Height with lift mast
4.2 h1 mm 2450 2450 2450 2450
retracted
4.3 Free lift h2 mm 1880 1880 1880 1880
4.4 Lift h3 mm 5750 5750 5750 5750
Height with lift mast
4.5 h4 mm 6320 6320 6320 6320
extended
Height of overhead guard
4.7 h6 mm 2200 2200 2200 2200
(cab) 4
4.8 Seat height h7 mm 1140 1140 1140 1140
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Height of load wheel
4.10 h8 mm 308 308 308 308
supports
4.19 Total length 2, 5, 6 l1 mm 2412 2499 2484 2484
Length including fork
4.20 l2 mm 1262 1349 1334 1334
back 2, 5, 6
4.21 Overall width b1/b2 mm 1270 1140 1470 1670
Fork arm dimensions, 50/ 100/ 50/ 100/ 50/ 100/ 50/ 100/
4.22 s/e/l mm
DIN ISO 2331 1150 1150 1150 1150
Fork carriage to ISO
4.23 2/A 2/A 2/A 2/A
2328, class/model A, B
4.24 Fork carriage width b3 mm 760 760 760 760
Width over forks,
4.25 b5 mm 316/620 316/620 316/620 316/620
min./max.
Width between load
4.26 b4 mm 920 790 1120 1320
wheel supports
4.28 Reach forward 1 l4 mm 591 505 519 519
Ground clearance with
4.31 m1 mm 70 70 70 70
load below lift mast
Ground clearance at the
4.32 m2 mm 70 70 70 70
centre of the wheelbase
4.34 Aisle width for a 1000 x
Ast mm 2752 2795 2844 2879
.1 1200 pallet, crosswise 2
4.34 Aisle width for a 800 x
Ast mm 2796 2854 2901 2936
.2 1200 pallet, lengthwise 2
4.35 Turning radius Wa mm 1710 1691 1750 1785
Length across the load
4.37 l7 mm 1817 1819 1817 1817
wheel supports
4.43 Step height mm 345 345 345 345
.
Performance data
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Driving speed
5.1 km/h 14/14 14/14 14/14 14/14
with/without load
5.1. Reverse driving speed
km/h 14/14 14/14 14/14 14/14
1 with/without load
Lifting speed with/without
5.2 m/s 0.45/0.68 0.45/0.68 0.45/0.68 0.45/0.68
load
Lowering speed
5.3 m/s 0.55/0.52 0.55/0.52 0.56/0.52 0.56/0.52
with/without load
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Reach speed with/without
5.4 m/s 0.18 0.18 0.18 0.18
load
Climbing capability
5.7 % 10/15 10/15 10/15 10/15
with/without load
Max. climbing capability
5.8 % 15/20 15/20 15/20 15/20
with/without load
Acceleration time (over
5.9 s 4.5/4.0 4.5/4.0 4.5/4.0 4.5/4.0
10 m) with/without load
Regenera- Regen- Regen- Regen-
tive, elec- erative, erative, erative,
5.10 Service brake electrical/ electrical/ electrical/
trical/ hy-
draulic hydraulic hydraulic hydraulic
.
Electric motor
FM-X FM-X
FM-X 17 /
FM-X 17 N 17 W / 17 EW /
Li-ion
Li-ion Li-ion
Traction motor, power
6.1 rating at S2 = 60 min kW 6.5 6.5 6.5 6.5
Lift motor, power rating at
6.2 kW 14 14 14 14
S3 = 15%
Battery in accordance
43531 43531 43531 43531
6.3 with DIN 43531/35/36 A,
C/254-2 B/254-2 C/254-2 C/254-2
B, C, no
48/465, 48/420, 48/620,
Battery voltage/nominal
6.4 V/Ah Li-ion: 48/465 Li-ion: Li-ion:
capacity K5
48/204 48/817 48/817
Battery weight (±5%
6.5 depending on the kg 750 750 940 940
manufacturer)
Energy consumption in
kWh/
6.6 accordance with the VDI 3.56 3.56 3.56 3.56
h
cycle
.
Other
FM-X FM-X
FM-X 14 /
FM-X 14 N 14 W / 14 EW /
Li-ion
Li-ion Li-ion
10. Working pressure for
bar 200 200 200 200
1 attachment
10.
Oil flow for attachments l/min 20 20 20 20
2
10. Sound pressure level in
dB(A) 69 69 69 69
7 driver's compartment
.
Characteristics
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
1.1 Manufacturer STILL STILL STILL STILL
FM-X
Manufacturer's type FM-X 20 / FM-X 20
1.2 FM-X 20 N 20 W /
designation Li-ion EW / Li-ion
Li-ion
1.3 Drive Electric Electric Electric Electric
Seating Seating Seating Seating
1.4 Operation
device device device device
1.5 Load capacity/load Q kg 2000 2000 2000 2000
1.6 Load centre of gravity c mm 600 600 600 600
1.8 Load distance 1 x mm 410 307 410 410
1.9 Wheelbase y mm 1525 1525 1525 1525
.
Weights
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Net weight (including
2.1 kg 3820 3830 3870 3920
battery)
Axle load without
2.3 kg 2470/1350 2450/1380 2490/1380 2510/1410
front/rear load
Axle load with fork
2.4 forwards with front/rear kg 820/5000 830/5010 840/5030 860/5060
load
Front/rear axle load, fork
2.5 kg 2180/3640 2010/3820 2200/3670 2220/3700
backwards, with load
.
Basic dimensions
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Lift mast/fork carriage tilt,
4.1 α/β ° 1/3 2/4 1/3 1/3
forwards/backwards 3
Height with lift mast
4.2 h1 mm 2450 2450 2450 2450
retracted
4.3 Free lift h2 mm 1880 1880 1880 1880
4.4 Lift h3 mm 5580 5580 5580 5580
Height with lift mast
4.5 h4 mm 6150 6150 6150 6150
extended
Height of overhead guard
4.7 h6 mm 2200 2200 2200 2200
(cab) 4
4.8 Seat height h7 mm 1140 1140 1140 1140
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Height of load wheel
4.10 h8 mm 373 373 373 373
supports
4.19 Total length 2, 5, 6 l1 mm 2484 2589 2484 2484
Length including fork
4.20 l2 mm 1334 1439 1334 1334
back 2, 5, 6
4.21 Total width b1/b2 mm 1270 1140 1470 1670
Fork arm dimensions, 50/ 100/ 50/ 100/ 50/ 100/ 50/ 100/
4.22 s/e/l mm
DIN ISO 2331 1150 1150 1150 1150
Fork carriage to ISO
4.23 2/A 2/A 2/A 2/A
2328, class/model A, B
4.24 Fork carriage width b3 mm 760 760 760 760
Width across forks,
4.25 b5 mm 316/620 316/620 316/620 316/620
min./max.
Width between load
4.26 b4 mm 920 790 1120 1320
wheel supports
4.28 Reach forward 1 l4 mm 623 520 623 623
Ground clearance with
4.31 m1 mm 70 70 70 70
load under lift mast
Ground clearance at
4.32 m2 mm 70 70 70 70
centre of wheelbase
4.34 Aisle width for a 1000 x
Ast mm 2820 2879 2857 2892
.1 1200 pallet, crosswise 2
4.34 Aisle width for a 800 x
Ast mm 2864 2941 2901 2936
.2 1200 pallet, lengthwise 2
4.35 Turning radius Wa mm 1778 1762 1815 1850
Length across the load
4.37 l7 mm 1922 1924 1922 1922
wheel supports
4.43 Step height mm 345 345 345 345
.
Performance data
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Driving speed
5.1 km/h 14/14 14/14 14/14 14/14
with/without load
5.1. Reverse driving speed
km/h 14/14 14/14 14/14 14/14
1 with/without load
Lifting speed with/without
5.2 m/s 0.37/0.58 0.37/0.58 0.37/0.58 0.37/0.58
load
Lowering speed
5.3 m/s 0.53/0.50 0.53/0.50 0.53/0.50 0.53/0.50
with/without load
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Reach speed with/without
5.4 m/s 0.18 0.18 0.18 0.18
load
Climbing capability
5.7 % 10/15 10/15 10/15 10/15
with/without load
Max. climbing capability
5.8 % 15/20 15/20 15/20 15/20
with/without load
Acceleration time (over
5.9 s 4.5/4.0 4.5/4.0 4.5/4.0 4.5/4.0
10 m) with/without load
Regenera- Regen- Regen- Regen-
tive, elec- erative, erative, erative,
5.10 Service brake electrical/ electrical/ electrical/
trical/ hy-
draulic hydraulic hydraulic hydraulic
.
Electric motor
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
Traction motor, power
6.1 rating at S2 = 60 min kW 6.5 6.5 6.5 6.5
Lift motor, power rating at
6.2 kW 14 14 14 14
S3 = 15%
Battery in accordance
43531 43531 43531 43531
6.3 with DIN 43531/35/36 A,
C/254-2 B/254-2 C/254-2 C/254-2
B, C, no
48/620, 48/620, 48/620,
Battery voltage/nominal
6.4 V/Ah Li-ion: 48/620 Li-ion: Li-ion:
capacity K5
48/817 48/817 48/817
Battery weight (±5%
6.5 depending on the kg 940 940 940 940
manufacturer)
Energy consumption in
kWh/
6.6 accordance with VDI 3.59 3.59 3.59 3.59
h
cycle
.
Other
FM-X
FM-X 20 / FM-X 20
FM-X 20 N 20 W /
Li-ion EW / Li-ion
Li-ion
10. Working pressure for
bar 200 200 200 200
1 attachment
10.
Oil flow for attachments l/min 20 20 20 20
2
10. Sound pressure level in
dB(A) 69 69 69 69
7 driver's compartment
.
Key data
FM-X 20 HD / Li-ion
1.1 Manufacturer STILL
1.2 Manufacturer's type designation FM-X 20 HD / Li-ion
1.3 Drive Electric
1.4 Operation Seating device
1.5 Load capacity/load Q kg 2000
1.6 Load centre of gravity c mm 600
1.8 Load distance 1 x mm 482
1.9 Wheelbase y mm 1669
.
Weights
FM-X 20 HD / Li-ion
2.1 Net weight (including battery) kg 5110
2.3 Front/rear axle load without load kg 3030/2080
Front/rear axle load with fork forwards and kg
2.4 900/6410
with load
Front/rear axle load, fork backwards, with kg
2.5 2810/4500
load
.
FM-X 20 HD / Li-ion
3.1 Tyres Polyurethane
3.2 Front tyre size mm ∅ 360 x 140
3.3 Rear tyre size mm ∅ 350 x 100
3.5 Number of wheels (x = driven), front/rear 1x/2
3.7 Rear track width b11 mm 1167
.
Basic dimensions
FM-X 20 HD / Li-ion
Lift mast/fork carriage tilt, forwards/back-
4.1 α/β ° 2/4
wards 3
4.2 Height with lift mast retracted h1 mm 5200
4.3 Free lift h2 mm 4578
4.4 Lift h3 mm 12,500
4.5 Height with lift mast extended h4 mm 13,122
4.7 Height of overhead guard (cab) 4 h6 mm 2200
4.8 Seat height h7 mm 1140
4.10 Height of load wheel supports h8 mm 373
4.19 Total length 2, 5, 6 l1 mm 2556
4.20 Length including fork back 2, 5, 6 l2 mm 1406
4.21 Overall width b1/b2 mm 1270
4.22 Fork arm dimensions, DIN ISO 2331 s/e/l mm 50/ 120/ 1150
Fork carriage to ISO 2328, class/model A,
4.23 2/A
B
FM-X 20 HD / Li-ion
4.24 Fork carriage width b3 mm 760
4.25 Width across forks, min./max. b5 mm 336/640
4.26 Width between load wheel supports b4 mm 920
4.28 Reach forward 1 l4 mm 695
4.31 Ground clearance with load under lift mast m1 mm 70
4.32 Ground clearance at centre of wheelbase m2 mm 50
Aisle width for a 1000 x 1200 pallet,
4.34.1 Ast mm 2908
crosswise 2
Aisle width for a 800 x 1200 pallet, length-
4.34.2 Ast mm 2937
wise 2
4.35 Turning radius Wa mm 1915
4.37 Length across the load wheel supports l7 mm 2066
4.43 Step height mm 345
.
Performance data
FM-X 20 HD / Li-ion
5.1 Driving speed with/without load km/h 14/14
5.1.1 Reverse driving speed with/without load km/h 14/14
5.2 Lifting speed with/without load m/s 0.34/0.50
5.3 Lowering speed with/without load m/s 0.52/0.50
5.4 Reach speed with/without load m/s 0.18
5.7 Climbing capability with/without load % 10/15
5.8 Max. climbing capability with/without load % 15/20
Acceleration time (over 10 m) with/without
5.9 s 4.5/4.0
load
Regenerative,
5.10 Service brake
electrical/ hydraulic
.
Electric motor
FM-X 20 HD / Li-ion
6.1 Traction motor, power rating at S2 = 60 min kW 6.5
6.2 Lift motor, power rating at S3 = 15% kW 14
Battery in accordance with DIN
6.3 43531 C/254-2
43531/35/36 A, B, C, no
FM-X 20 HD / Li-ion
48/775, Li-ion:
6.4 Battery voltage/nominal capacity K5 V/Ah
48/817
Battery weight (±5% depending on the
6.5 kg 1120
manufacturer)
Energy consumption in accordance with
6.6 kWh/h 3.59
VDI cycle
.
Other
FM-X 20 HD / Li-ion
10.1 Working pressure for attachment bar 200
10.2 Oil flow for attachments l/min 20
Sound pressure level in driver's compart-
10.7 dB(A) 69
ment
.
Characteristics
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
1.1 Manufacturer STILL STILL STILL
Manufacturer's type FM-X 25 / FM-X 25 W FM-X 25 EW
1.2
designation Li-ion / Li-ion / Li-ion
1.3 Drive Electric Electric Electric
Seating Seating Seating
1.4 Operation
device device device
1.5 Load capacity/load Q kg 2500 2500 2500
1.6 Load centre of gravity c mm 600 600 600
1.8 Load distance 1 x mm 482 482 482
1.9 Wheelbase y mm 1669 1669 1669
.
Weights
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
2.1 Net weight (including battery) kg 4110 4140 4170
Axle load without front/rear kg
2.3 2640/1470 2620/1520 2600/1570
load
Axle load with fork forwards
2.4 kg 810/5790 790/5840 770/5890
with front/rear load
Front/rear axle load, fork
2.5 kg 2420/4190 2400/4240 2380/4290
backwards, with load
.
Basic dimensions
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
Lift mast/fork carriage tilt,
4.1 α/β ° 1/3 1/3 1/3
forwards/backwards 3
4.2 Height with lift mast retracted h1 mm 2450 2450 2450
4.3 Free lift h2 mm 1828 1828 1828
4.4 Lift h3 mm 5580 5580 5580
4.5 Height with lift mast extended h4 mm 6202 6202 6202
Height of overhead guard
4.7 h6 mm 2200 2200 2200
(cab) 4
4.8 Seat height h7 mm 1140 1140 1140
4.10 Height of load wheel supports h8 mm 373 373 373
4.19 Total length 2, 5, 6 l1 mm 2556 2556 2556
Length including fork back 2,
4.20 l2 mm 1406 1406 1406
5, 6
Performance data
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
Driving speed with/without
5.1 km/h 14/14 14/14 14/14
load
5.1. Reverse driving speed
km/h 14/14 14/14 14/14
1 with/without load
Lifting speed with/without
5.2 m/s 0.34/0.50 0.34/0.50 0.34/0.50
load
Lowering speed with/without
5.3 m/s 0.52/0.50 0.52/0.50 0.52/0.50
load
Reach speed with/without
5.4 m/s 0.18 0.18 0.18
load
Climbing capability with/with-
5.7 % 10/15 10/15 10/15
out load
Max. climbing capability
5.8 % 15/20 15/20 15/20
with/without load
Electric motor
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
Traction motor, power rating
6.1 kW 6.5 6.5 6.5
at S2 = 60 min
Lift motor, power rating at S3
6.2 kW 14 14 14
= 15%
Battery in accordance with 43531 43531 43531
6.3
DIN 43531/35/36 A, B, C, no C/254-2 C/254-2 C/254-2
Battery voltage/nominal 48/775, 48/775, 48/775,
6.4 V/Ah
capacity K5 Li-ion: 48/817 Li-ion: 48/817 Li-ion: 48/817
Battery weight (±5% depend-
6.5 kg 1120 1120 1120
ing on the manufacturer)
Energy consumption in
6.6 kWh/h 4.49 4.49 4.49
accordance with VDI cycle
.
Other
FM-X 25 / FM-X 25 W / FM-X 25 EW /
Li-ion Li-ion Li-ion
Working pressure for
10.1 bar 200 200 200
attachment
10.2 Oil flow for attachments l/min 20 20 20
Sound pressure level in
10.7 dB(A) 69 69 69
driver's compartment
.
Drive wheel
Polyurethane - direct bond
Model Tyres
FM-X 10 (N) (standard versions) ∅ 360 x 130
FM-X 12 (N) (standard versions) ∅ 360 x 130
FM-X 14 (N) (standard versions) ∅ 360 x 130
FM-X 17 (N) (standard versions) ∅ 360 x 130
FM-X 20 (N, W, EW) (standard versions) ∅ 360 x 130
FM-X 22 (standard versions) ∅ 360 x 140
FM-X 25 (standard versions) ∅ 360 x 140
.
Load wheels
Polyurethane - direct bond
Model Tyres
FM-X 10 (N) (standard versions) ∅ 285 x 100
FM-X 12 (N) (standard versions) ∅ 285 x 100
FM-X 14 (N) (standard versions) ∅ 285 x 100
FM-X 17 (N) (standard versions) ∅ 285 x 100
FM-X 20 (N, W, EW) (standard versions) ∅ 350 x 100
FM-X 22 (standard versions) ∅ 350 x 100
FM-X 25 (standard versions) ∅ 350 x 100
.
Performance characteristics
Battery group Group 4.1 Group 4.2 Group 4.3
Cell connections 3 x 13s1p 12 x 13s1p 12 x 13s1p
Nominal energy 9800 Wh 39200 Wh 39200
Nominal capacity 201 Ah 804 Ah 804 Ah
Nominal voltage 48 V 48 V 48 V
Max. discharge current 400 A 400 A 400 A
Max. discharge power 18 kW 18 kW 18 kW
.
Reduction of speed when turning . . . . . . 95 Safety regulations for working on the lift
Regular inspections . . . . . . . . . . . . . . . . 44 mast . . . . . . . . . . . . . . . . . . . . . 288
Regulations for storing lithium-ion Removing the lift mast . . . . . . . . . . . 288
batteries . . . . . . . . . . . . . . . . . . 235 Securing the telescopic lift mast . . . . 289
Removing the lift mast . . . . . . . . . . . . . 288 Securing the triple mast . . . . . . . . . . 289
Replacing the battery Safety regulations for working with
Lithium-ion battery . . . . . . . . . . . . . 249 lithium-ion batteries . . . . . . . . . . 232
Using a lifting device . . . . . . . . . . . . 249 Safety regulations when driving . . . . . . . 96
Replacing the heating system filter . . . . 304 Safety regulations when handing loads . 138
Residual dangers . . . . . . . . . . . . . . . . . . 37 Safety regulations when handling the
battery . . . . . . . . . . . . . . . . . . . . 219
Residual risks . . . . . . . . . . . . . . . . . . . . 37
Fire protection measures . . . . . . . . . 220
Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 29
Maintaining the battery . . . . . . . . . . 221
Reverse steering . . . . . . . . . . . . . . . . . 115
Maintenance personnel . . . . . . . . . . 219
Roadways . . . . . . . . . . . . . . . . . . . . 98 – 99
Schematic views
Condition . . . . . . . . . . . . . . . . . . . . 100
Functions and operations . . . . . . . . . 18
Hazard areas . . . . . . . . . . . . . . . . . 100
View on the display-operating unit . . . 18
Rules for roadways and the working
area . . . . . . . . . . . . . . . . . . . . . . 100 Scope of the documentation
Roof loads . . . . . . . . . . . . . . . . . . . . . . . 31 UPA solutions . . . . . . . . . . . . . . . . . . 13
Seat switch . . . . . . . . . . . . . . . . . . . . . 103
S Securing the telescopic lift mast . . . . . . 289
Safety devices . . . . . . . . . . . . . . . . . . . 287 Securing the triple mast . . . . . . . . . . . . 289
Safety inspection . . . . . . . . . . . . . . . . . . 44 Selecting the drive direction
Safety regulations for handling Drive direction switch, joystick
lithium-ion batteries . . . . . . . . . . 230 4Plus variant . . . . . . . . . . . . . . . 106
Battery weight and dimensions . . . . 232 Fingertip drive direction switch . . . . . 106
Fire protection measures . . . . . . . . . 231 General . . . . . . . . . . . . . . . . . . . . . 105
Maintenance personnel . . . . . . . . . . 230 Set values . . . . . . . . . . . . . . . . . . . . . . 287
Safety regulations for handling the Setting the battery data
battery Onboard diagnostics . . . . . . . . . . . . 259
Battery weight and dimensions . . . . 221 Shock recognition . . . . . . . . . . . . . . . . 166
Damage to cables . . . . . . . . . . . . . . 222 Shutting down the truck . . . . . . . . . . . . 282
Lifting accessories . . . . . . . . . . . . . 221 Side chassis supports . . . . . . . . . . . . . 101
Safety regulations for maintenance Special risks . . . . . . . . . . . . . . . . . . . . . 38
General information . . . . . . . . . . . . 286 Speed limitation
Safety devices . . . . . . . . . . . . . . . . 287 Button . . . . . . . . . . . . . . . . . . . . . . . 176
Set values . . . . . . . . . . . . . . . . . . . . 287 Speed limitation based on lift height . 175
Working on the electrical equip- Speed limitation safety function . . . . 131
ment . . . . . . . . . . . . . . . . . . . . . 286 Stability . . . . . . . . . . . . . . . . . . . . . . . . . 38
Working on the hydraulic equip- Standard steering . . . . . . . . . . . . . . . . 114
ment . . . . . . . . . . . . . . . . . . . . . 286
Starting drive mode
Dual-pedal version . . . . . . . . . . . . . 109
Single-pedal version . . . . . . . . . . . . 107
Steering . . . . . . . . . . . . . . . . . . . . . . . . 114 V
Steering column
Variants
Adjusting . . . . . . . . . . . . . . . . . . . . . 83 Access authorisation with PIN code . . 87
Steering system
Clamp locking mechanism with
Checking for correct function . . . . . . . 90 fingertip switch . . . . . . . . . . . . . . 164
Storing the truck . . . . . . . . . . . . . . . . . . 282 Clamp locking mechanism with
Switching on the key switch . . . . . . . . . . 85 joystick . . . . . . . . . . . . . . . . . . . 162
FleetManager . . . . . . . . . . . . . . . . . 166
T Fork extension . . . . . . . . . . . . . . . . 134
Technical data Lifting systems . . . . . . . . . . . . . . . . 119
Dimensions . . . . . . . . . . . . . . . . . . 308 View of functions and operating
Lithium-ion batteries . . . . . . . . . . . . 336 procedures . . . . . . . . . . . . . . . . . 18
VDI datasheet . . . . . . . . . . . 309, Visual inspections and function
313, 318, 323, 328, 332 checking . . . . . . . . . . . . . . . . . . . 74
Topicality of the operating instructions . . 14
W
Towing . . . . . . . . . . . . . . . . . . . . . . . . 215
Transportation . . . . . . . . . . . . . . . . . . . 269 Warning regarding non-original parts . . . 32
Transporting pallets . . . . . . . . . . . . . . . 143 Wheels and tyres
Transporting suspended loads . . . . . . . 143 Checking the condition and wear of
the tyres . . . . . . . . . . . . . . . . . . . 301
Transporting the battery using a lifting
device (lead acid batteries) . . . . . 261 Checking the wheel fastenings . . . . 302
Transporting the battery using a lifting Maintaining . . . . . . . . . . . . . . . . . . . 301
device (lithium-ion batteries) . . . . 263 Safety principles . . . . . . . . . . . . . . . . 33
Transporting the lithium-ion battery . . . . . 29 Technical data . . . . . . . . . . . . . . . . 335
Working at the front of the truck . . . . . . . 288
U Working on the electrical equipment . . . 286
Unlocking the emergency off switch . . . . 84 Working on the hydraulic equipment . . . 286
Using working platforms . . . . . . . . . . . . . 11
50988078001 EN – 10/2018