Still FM-X N Series User manual

Original instructions
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
1900 1901 1902 1903 1904
1905 1906 1907 1908 1909
1910 1914 1915 1916 1917
1918 1919 1920 1921 1922
50988078001 EN - 10/2018

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
50988078001 EN - 10/2018 I

Table of contents
g
1 Foreword
Your truck .......................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Accessories ......................................................... 4
Labelling points ...................................................... 5
Nameplate .......................................................... 6
Production number . . . ................................................ 7
Nameplateofalithium-ionbattery ......................................... 7
Using the truck ....................................................... 8
Commissioning ...................................................... 8
Proper usage ........................................................ 8
Intended use of the lithium-ion battery (variant) ............................... 8
Impermissibleuse .................................................... 9
Placeofuse ......................................................... 9
Parkingintemperaturesbelow-10°C ..................................... 10
Using working platforms ............................................... 11
Information about the documentation ..................................... 12
Documentationscope ................................................ 12
Supplementary documentation .......................................... 13
Issuedateandtopicalityoftheoperatinginstructions .......................... 14
Copyrightandtrademarkrights .......................................... 14
Explanation of informationsymbolsused .................................. 14
Listofabbreviations .................................................. 15
Definingdirections ................................................... 17
Schematicviews .................................................... 18
Environmental considerations .......................................... 19
Packaging ......................................................... 19
Disposal of components andbatteries ..................................... 19
2Safety
Definition of responsible persons ........................................ 22
Operatingcompany .................................................. 22
Specialist .......................................................... 22
Drivers ........................................................... 23
Basic principles for safe operation ....................................... 25
Insurance cover on company premises .................................... 25
Specialnoteswhenusinglithium-ionbatteries(variant) ........................ 25
Changes and retrofitting ............................................... 29
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Modifications to the overhead guard and cabs ............................... 31
Seatbelt .......................................................... 31
Safety information for FM-X Wide,ExtraWide(W,EW) ........................ 32
Warning regarding non-original parts ..................................... 32
Damage, defects and misuse of safety systems . . . ........................... 33
Wheels and tyres .................................................... 33
Medicalequipment ................................................... 34
Exercise caution when handling gas springs and accumulators .................. 35
Lengthoftheforkarms ................................................ 35
Residual risk ....................................................... 37
Residual dangers, residual risks ......................................... 37
Special risks associated withusingthetruckandattachments ................... 38
Overview of hazards and countermeasures ................................. 40
Danger to employees ................................................. 43
Safety tests ........................................................ 44
Carrying out regular inspections on the truck ................................ 44
Insulationtesting .................................................... 44
Safety regulations for handling consumables ............................... 45
Permissibleconsumables ............................................. 45
Oils .............................................................. 46
Hydraulicfluid ...................................................... 47
Batteryacid ........................................................ 48
Brakefluid ......................................................... 49
Disposal of consumables .............................................. 50
Commissioning the FleetManager™ (variant) ............................... 51
Activatingtheaccesscontrolafterdeliveryofthetruck ......................... 51
Emissions ......................................................... 51
3Overviews
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
Displaymessages ................................................... 61
Entering truck operating data via the display and operating unit .................. 65
Lithium-ion batterydisplay ............................................. 70
Operatingdevicesforhydraulicandtractionfunctions ......................... 70
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Table of contents
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Joystick4Plus ...................................................... 71
Fingertip .......................................................... 72
4 Operation
Testing and activities before daily use ..................................... 74
Visualinspectionsandfunctionchecking .................................. 74
Climbingintoandoutofthetruck ........................................ 77
Adjusting the MSG 65/MSG 75 driver'sseat ................................ 79
Adjustingthesteeringcolumn ........................................... 83
Fillingthewashersystem(variant) ....................................... 84
Unlocking the emergency offswitch ...................................... 84
Switchingonthekeyswitch ............................................ 85
AccessauthorisationwithPINcode(variant) ................................ 87
Operating the signal horn .............................................. 88
Checkingthebrakesystemforcorrectfunction .............................. 88
Checkingthesteeringsystemforcorrectfunction ............................ 90
Checking the emergency offfunction ..................................... 90
Checking the "automatic tilting centre position" (variant) for correct function ......... 91
Lighting ........................................................... 92
STILL SafetyLight (variant) ............................................. 92
Switchingtheworkingspotlights(variant)onandoff .......................... 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 whendriving ......................................... 96
Roadways ......................................................... 98
Side chassis supports . ...............................................101
Enabling truck functionsusingthefootswitchandseatswitch ...................101
Settingthedriveprogramme ............................................104
Selectingthedrivedirection ............................................105
Actuating the drive directionswitch,joystick4Plus ............................106
Actuating the drive direction switch, fingertip ................................106
Starting drive mode, single-pedal version . . ................................107
Starting drive mode, dual-pedal version (variant) .............................109
Operatingtheservicebrake ............................................111
Applying the electromagnetic parking brake ................................112
Steering ...........................................................114
Emergency operation of the reach measurement system .......................115
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Parking ...........................................................118
Parkingthetrucksecurely .............................................118
Lifting ............................................................119
Liftingsystemvariants ................................................119
Liftmastversions ....................................................119
Lifting system operating devices .........................................120
Joystick4Plusliftingsystem ............................................121
Fingertipliftingsystem ................................................124
Automatic lift cut out (variant) ...........................................126
Reach-lowerlock(variant) .............................................128
Automaticcentreposition(variant) .......................................129
Speed limitation safety function .........................................131
Changing the fork arms ...............................................131
Forkextension(variant) ...............................................134
Loadbackrest(variant) ................................................1
35
Workingplatforms ...................................................136
Malfunctionsinliftingmode ............................................136
Handling loads ......................................................138
Safety regulations when handing loads ....................................138
Beforepickingupaload ...............................................138
Picking up loads .....................................................140
Danger area .......................................................142
Transportingpallets ..................................................143
Transporting suspended loads ..........................................143
Pickingupaload ....................................................144
Transporting loads ...................................................147
Setting down loads ...................................................149
Drivingonupwardanddownwardgradients ................................151
Drivingontolifts .....................................................151
Attachments .......................................................153
Fittingattachments ..................................................153
Releasingthepressurefromtheauxiliaryhydraulics ..........................155
General instructions for controllingattachments .............................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
Pickingupaloadusingattachments ......................................165
Auxiliary equipment ..................................................166
FleetManager (variant) ................................................166
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Shock recognition (variant) .............................................166
ActiveLoadStabilisationALS(variant) ....................................166
Optical height measuring system(variant) ..................................168
Loadmeasurement(variant) ...........................................173
Speedlimitationbasedonliftheight ......................................175
Button for speed limitation, creepspeed(variant) ............................176
Camera/monitorsystem(variant) ........................................176
Electrical adjustment mechanism for the driver's compartment (variant) ............177
Overhead guard with optimisedvisibility(variant) ............................178
Clipboard (variant) ...................................................179
Battery change frame (variant) ..........................................179
General ......................................................... . . 179
Safe handling ......................................................180
Loadcapacity .................................................... . . 180
Area of application ...................................................180
Adjustingthetransferheight ............................................181
Locking the battery change frame ........................................181
Battery replacement area ..............................................182
Lift height preselector/easy Target (variant) ................................184
General ......................................................... . . 184
Definitionofterms ...................................................185
AUTOMODEfunction ................................................ 186
Operatingtheliftheightpreselector .......................................189
Teach-in, general ....................................................192
Performingateach-in .................................................193
easyTarget/easyTargetPlus(variants) ...................................196
Approaching target heightsusing"easyTarget" .............................198
Positioningtheforkhorizontallyusing"easyTargetPlus" .......................199
Cab (variant) .......................................................200
General information aboutthecab .......................................200
Opening the cab door . . ...............................................201
Closingthecabdoor ............................................... . . 202
Cab operating devices ................................................203
Cabinteriorlighting(variant) ............................................204
Heatingsysteminthecab(variant) .......................................204
Emergency exit windowinthecab .......................................207
Cold store application .................................................207
General ......................................................... . . 207
Areas of application ..................................................208
Description of the cold store equipment ....................................209
Batteryinthecoldstore ...............................................210
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Impermissible use of the lithium-ion battery in the shock cold store (-45°C) ..........210
Beforeenteringthecoldstore ...........................................211
Procedure in emergencies .............................................212
Emergency shutdown ................................................212
Procedureiftrucktipsover .............................................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 handlingthebattery ...............................219
Maintainingthebattery ................................................222
Checkingthebatterycondition,acidlevelandaciddensity ......................223
Checking the battery chargestatus .......................................225
Chargingthebattery ..................................................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
Approvedlithium-ionbatteries ..........................................233
Lithium-ion batteries "GGSLi-ion48V(BG4)"9.8kWhand39.2kWh .............234
Regulationsforstoringlithium-ionbatteries .................................235
Checkingthebatterychargestatus(lithium-ionbattery) ........................236
Charging the lithium-ionbatteryupondelivery ...............................238
Chargingthelithium-ionbattery .........................................239
Recommissioning the lithium-ion battery following deep discharge ................241
Replacing and transporting the battery ....................................242
Commissioning batteries that are delivered separately ........................242
Alternatingbetweenalead-acidbatteryandalithium-ionbattery .................243
General information on batteryreplacement ................................244
Actuatingthebatterylock ..............................................246
Adjustingthebatterylock ..............................................247
Special notes for installingthelithium-ionbattery .............................249
Replacingthebatteryusingaliftingdevice .................................249
Changing the battery using the internal roller channel (variant) ...................254
Setting the battery data(leadacidbatteries) ................................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
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Cleaningtheelectricalsystem ..........................................267
Cleaningloadchains .................................................268
Cleaning panes of glass and mirrors ......................................268
After cleaning .......................................................269
Transporting the truck ................................................269
Transportation ......................................................269
Crane loading (standard truck with overhead guard) ..........................272
Crane loading (trucks with a cab) ........................................276
Decommissioning ...................................................282
Shuttingdownandstoringthetruck ......................................282
Re-commissioningaftershutdown .......................................283
5 Maintenance
Safety regulations for maintenance .......................................286
Generalinformation ..................................................286
Workingonthehydraulicequipment ......................................286
Working on the electrical equipment ......................................286
Safetydevices ......................................................287
Setvalues ....................................................... . . 287
Lifting and jacking up .................................................287
Workingatthefrontofthetruck ..........................................288
General maintenance information ........................................289
Personnel qualifications ...............................................289
Informationforcarryingoutmaintenance ..................................290
Maintenance - 1000 hours/year .........................................293
Maintenance - 3000 hours/everytwoyears .................................297
Additional maintenance guidelines for using the truck in a cold store - 500 hours or
every12weeks ...................................................297
Orderingsparepartsandwearingparts ....................................298
Quality and quantity of the required operating materials ........................298
Maintenance data table ...............................................299
Maintaining operational readiness .......................................300
Checking the driver's seat .............................................300
Maintainingwheelsandtyres ...........................................301
Checkingthehydraulicsystemforleaks ...................................302
Greasing the lift mast and rollertracks .....................................303
Checking the battery change frame (variant) ................................303
Replacing the heating system filter for the cab (variant) ........................304
Maintenance for trucks usedincoldstores .................................305
Maintenance tasks for lithium-ion batteries . ................................305
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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
X50
988078001 EN - 10/2018

1
Foreword

1Foreword
Your truck
Your truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
The trucks have been fitted with state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
CE-Symbol
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.
250
988078001 EN - 10/2018

Foreword 1
Your truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
50988078001 EN - 10/2018 3

1Foreword
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)
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988078001 EN - 10/2018

Foreword 1
Your truck
Labelling points
11
10
8
750
860
970
1050
1080
1160
1200
1270
850
kgkg
800
mm
kg mm
980
1110
1200
1240
1320
1600
1700
700
mm
1000
1150
1300
1400
1450
1500
1600
1700
mm
400-600
10200
9800
9500
9300
9000
8750
8300
7100
X<= 15mm
X
17
12
1
15
13
7
18
2
6
4
7
17
12
9
10
11
14
13
8
1
2
18
15
16
2
3
4
5
6
55
5
14
16
BATTERIESERVICE
Nächste Prüfung
50634391022
STILL GmbH Hamburg
Berzeliusstraße 10
22113 Hamburg
Tel.: [phone]
Ihr STILL Service
9
3
50988078001 EN - 10/2018 5

1Foreword
Your truck
1 Warning sign: Do not place below the fork
/ Do not place on the fork / Danger due to
shearing / Danger due to high fluid pressure
2 Warning sign: Danger due to shearing
3 Decal information: Battery version
4 Decal information: Hydraulic oil tank
5 Decal information: Lifting point
6 Warning sign: Crushing and shearing points
on base
7 Decal information: Cold store version
(variant)
8 Decal information: Electrical seat adjust-
ment (variant)
9 Decal information: Battery test
10 Decal information: FEM test
11 Decal information: FEM test (inspection
sticker)
12 Decal information: Nameplate
13 Decal information: Speed limitation based
on lift height
14 Decal information: Unlock the battery
15 Warning sign: Passengers prohibited
16 Warning sign: Reverse steering
17 Decal information: Load capacity diagram,
load capacity diagram for attachments
(example)
18 Decal information: Caution/Read the oper-
ating instructions
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
Rated capacity
Capacité nominale
Nenn-Tragfähigkeit
Battery voltage
Tension batterie
Batteriespannung
Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.
Unladen mass
Masse à vide
Leergewicht
max
min.*
* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung
kg kg
kg
kg
kg
kW
V
*
D-22113 Hamburg
Berzeliusstr. 10
123
4
4
5
6
7
9
10
11
12
13
6210_921-003_V3
8
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
Nameplate
The truck can be identified from the informa-
tion on the nameplate.
The information for the battery weights (5,
6) and the ballast weight (7) only applies to
electric forklift trucks.
650
988078001 EN - 10/2018

Foreword 1
Your truck
7090_921-004
xx xxxx x xxxxx
1
2
3
4
Production number
NOTE
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.
The production number contains the following
coded information:
(1) Production location
(2) Model
(3) Year of manufacture
(4) Sequential number
STILL Gmbh
Berzeliusstraße 10
22113 Hamburg
Rechargeable Lithium Ion Battery
Produced by BMZ GmbH
IEC: 13IMP46/174/133-14
Nominal voltage:
Capacity:
Energy:
Capacity equivalent:
Weight:
P/N:
B-P/N:
SN:
Custumer order no.:
Still order no.:
Date:
Made in Germany
Safety Advices for Lithium-Ion Batteries
Do not crush. Do not heat or incinerate.
Do not short-circuit. Do not dismantle.
Do not immerse in any liquid it may vent
or rupture.
8
1
9
10
11
12
13
14
15
16
17
7
6
5
2
3
4
Nameplate of a lithium-ion battery
NOTE
The CE labelling confirms compliance with
the EC machinery directive and with all
regulations applicable to the lithium-ion
battery.
1 Nameplate
2 Manufacturer
3 Address of manufacturer
4 Data/technical data
5 Safety information
6 CE labelling
7 Data matrix code
Transport information
8 "Do not lift in a manner that allows the
battery to tilt to one side"
9 "Use a lifting traverse"
General operating notes
10 "Read the operating instructions"
11 "Do not stack"
12 "Do not climb on the battery"
13 "Do not force open"
14 "Do not immerse in water"
15 "Do not throw into fire"
50988078001 EN - 10/2018 7

1Foreword
Using the truck
16 "Do not dispose with household waste"
17 "Recycling - recyclable material"
Using the truck
Commissioning
Commissioning is the initial intended use of
the truck.
The necessary steps for the commissioning
vary depending on the model and equipment
of the truck. These steps require preparatory
work and adjustment work that cannot be per-
formed by the operating company. See also
the chapter entitled "Definition of responsible
persons".
– To commission the truck, contact the
authorised service centre.
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".
Intended use of the lithium-ion
battery (variant)
The lithium-ion battery must only be operated
in accordance with these operating instruc-
tions and the manufacturer's operating in-
structions for the battery.
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