Still FM-X User manual

Original instructions
Reach trucks
FM-X, FM-X N, FM-X W,
FM-X EW
FM-X-10
FM-X-12
FM-X-14
FM-X-17
FM-X-20
FM-X-22
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 - 04/2015

Table of contents
g
1 Foreword
Your truck .......................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Information about the documentation ...................................... 4
Documentationscope ................................................. 4
Issuedateandtopicalityoftheoperatinginstructions ........................... 5
Copyright and trademark rights ........................................... 5
Explanation of information symbols used . . ................................. 5
Listofabbreviations ................................................... 6
Definingdirections .................................................... 9
Schematicviews .................................................... 10
Environmental considerations .......................................... 11
Packaging ......................................................... 11
Disposal of components and batteries ..................................... 11
2 Introduction
Using the truck ...................................................... 14
Proper usage ....................................................... 14
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 15
Parking in temperaturesbelow-10°C ..................................... 15
Usingworkingplatforms ............................................... 16
Residual risk ....................................................... 17
Residual dangers, residual risks ......................................... 17
Specialrisksassociatedwithusingthetruckandattachments ................... 18
Overviewofhazardsandcountermeasures ................................. 20
Danger to employees ................................................. 22
3Safety
Definition of terms used for responsible persons ............................. 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
Changes and retrofitting ............................................... 29
Modifications to the overhead guard and cabs ............................... 31
50988078001 [EN] I

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SafetyinformationforFM-XWide,ExtraWide(W,EW) ........................ 32
Warning regarding non-original parts ..................................... 32
Damage, defects and misuse of safetysystems .............................. 33
Tyres ............................................................. 33
Medicalequipment ................................................... 34
Exercise caution when handlinggasspringsandaccumulators .................. 34
Safety tests ........................................................ 35
Regularsafetyinspectionofthetruck ..................................... 35
Insulationtesting .................................................... 35
Safety regulations for handling consumables ............................... 36
Permissibleconsumables ............................................. 36
Oils .............................................................. 37
Hydraulicfluid ...................................................... 38
Batteryacid ........................................................ 39
Brakefluid ......................................................... 40
Disposalofconsumables .............................................. 41
Emissions ......................................................... 41
4Overviews
Overview .......................................................... 46
Overview of the driver’s compartment ..................................... 47
Operating devices and display elements ................................... 48
Display and operatingunit ............................................. 48
Operatingdevicesforhydraulicandtractionfunctions ......................... 48
Joystick4Plus ...................................................... 49
Fingertip .......................................................... 50
Identification points .................................................. 51
Overview .......................................................... 51
Nameplate ......................................................... 52
Productionnumber .................................................. 53
5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 56
Visual inspections ................................................... 56
Fillingthewashersystem(variant) ....................................... 58
Checking the condition of the wheels and tyres . . . ........................... 59
Adjusting the MSG65/MSG75driver’sseat ................................ 60
Electricaldriver’scompartmentadjustment(variant) .......................... 64
Adjustingthesteeringcolumn ........................................... 65
II 50988078001 [EN]

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Commissioning ..................................................... 65
Climbingintoandoutofthetruck ........................................ 65
Shelvesandcupholders .............................................. 67
Connecting the battery male connector .................................... 67
Enablingtruckfunctionsusingthefootswitchandseatswitch ................... 68
Unlocking the emergency off switch ...................................... 70
Switchingonthekeyswitch ............................................ 70
AccessauthorisationwithPINcode(variant) ................................ 73
Entering truck operating dataviathedisplayandoperatingunit .................. 74
Operating the signal horn .............................................. 79
Checkingthebrakesystemforcorrectfunction .............................. 79
Checking the steering systemforcorrectfunction ............................ 81
Checking the emergency off function ..................................... 81
Checking the "automatic tilting centre position" (variant) for correct function ......... 82
Setting the drive programme ............................................ 83
OPTISPEED - Continuously variable reduction in driving speed or hydraulic functions
(variant) ......................................................... 84
Driving ............................................................ 85
Safety regulations when driving ......................................... 85
Roadways ......................................................... 88
Side chassis supports . ............................................... 90
Selecting the drive direction ............................................ 91
Actuatingthedrivedirectionswitch,joystick4Plus ............................ 92
Actuating the drive direction switch, fingertip ................................ 92
Starting drive mode, single-pedal version . . ................................ 92
Starting drive mode, dual-pedal version (variant) ............................. 94
Operatingtheservicebrake ............................................ 96
Applying the electromagnetic parking brake ................................ 97
Steering ...........................................................100
Lifting ............................................................102
Lifting system variants ................................................102
Automaticliftcutout(variant) ...........................................103
Reach-lowerlock(variant) .............................................104
Automatic centre position(variant) .......................................105
Liftmastversions ....................................................106
Malfunctionsinliftingmode ............................................107
Lifting system operatingdevices .........................................108
Joystick4Plusliftingsystem ............................................109
Fingertip lifting system . ...............................................112
Load backrest (variant) ................................................114
Changing the fork arms ...............................................114
50988078001 [EN] III

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Forkextension(variant) ...............................................117
Workingplatforms ...................................................118
Handling loads ......................................................119
Safety regulations when handing loads ....................................119
Beforepickingupaload ...............................................119
Picking up loads .....................................................121
Danger area .......................................................122
Transportingpallets ..................................................123
Transporting swinging loads ............................................124
Pickingupaload ....................................................125
Transporting loads ...................................................128
Setting down loads ...................................................130
Drivingonupwardanddownwardgradients ................................132
Drivingontolifts .....................................................132
Workingwithattachments .............................................134
Fittingattachments ..................................................134
Releasingthepressurefromtheauxiliaryhydraulics ..........................136
General instructions forcontrollingattachments .............................137
Controlling attachments (variant) using the joystick 4Plus (5th/6th hydraulic function)
...............................................................138
Controlling attachments (variant) with the fingertip (5th/6th hydraulic function) .......141
Operating the clamp locking mechanism (variant) with a joystick 4Plus . ............143
Operating the clamp locking mechanism (variant) with the fingertip switch ..........145
Pickingupaloadusingattachments ......................................146
Operating auxiliary equipment ..........................................147
Switchingtheworkingspotlights(variant)onandoff ..........................147
Clipboard (variant) ...................................................148
FleetManager (variant) ................................................148
Accident recorder (variant) . . . ..........................................148
Active Load Stabilisation ALS (variant) ....................................149
Camera/monitor system(variant) ........................................150
Loadmeasurement ................................................. . 150
Battery change frame (variant) ..........................................152
General . . .........................................................152
Safe handling ......................................................153
Load capacity ......................................................153
Area of application ...................................................153
Adjustingthetransferheight ............................................154
Lockingthebatterychangeframe ........................................154
Battery replacementarea ..............................................155
IV 50988078001 [EN]

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Lift height preselector (variant) ..........................................156
General ......................................................... . . 157
Definitionofterms ...................................................157
AUTOMODEfunction ................................................ 158
Operatingtheliftheightpreselector .......................................161
Teach-in, general ....................................................165
Performingateach-in .................................................166
Cab operation (variant) ...............................................169
General information about thecab .......................................169
Opening the cab door . . ...............................................170
Closingthecabdoor ............................................... . . 171
Emergency exit window in thecab .......................................171
Cab operating devices . ...............................................172
Cabinteriorlighting(variant) ............................................173
Heating system in the cab (variant) .......................................174
Cold store application .................................................175
General ......................................................... . . 175
Areasofapplication ..................................................176
Batteryinthecoldstore ...............................................177
Description of the cold store equipment ....................................177
Warmingupthetruck ............................................... . . 178
Operating the display and operating unit ...................................178
Operating status displays on the display and operating unit .....................178
Blue-Q efficiency mode ...............................................180
Functional description . ...............................................180
SwitchingtheBlue-Qefficiencymodeonandoff .............................180
Fault displays ......................................................181
View on the display and operating unit .....................................181
Operating in special operating situations ...................................181
Transportation ......................................................181
Towing .......................................................... . 184
Crane loading ......................................................186
Procedure in emergencies .............................................189
Emergency shutdown . ...............................................190
Procedure if truck tips over .............................................191
Emergency lowering .................................................192
Handling the battery ..................................................192
Safety regulations when handling the battery ...............................192
General informationonbatteryreplacement ................................196
Actuatingthebatterylock ..............................................197
50988078001 [EN] V

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Disconnecting the battery male connector ..................................199
Batteryreplacementusingacrane .......................................200
Changing the battery using the internal roller channel (variant) ...................205
Batterycommissioning ................................................211
Adjustingthebatterylock ..............................................211
Settingthebatterydata ...............................................213
Batterytransportwithcrane ............................................215
Maintainingthebattery ................................................216
Decommissioning ...................................................220
Parkingthetrucksecurely .............................................220
Shuttingdownandstoringthetruck ......................................222
Re-commissioning after shutdown .......................................223
Cleaning ..........................................................224
Cleaning the truck ...................................................224
Cleaning load chains .................................................225
After cleaning .......................................................226
6 Maintenance
General maintenance information ........................................228
Personnel qualifications ...............................................228
Information for carrying out maintenance ..................................228
Maintenance-1000hours/year .........................................231
Maintenance - 3000 hours/everytwoyears .................................235
Additional maintenance guidelines for using the truck in a cold store - 500 hours or
every12weeks ...................................................238
Orderingsparepartsandwearingparts ....................................239
Quality and quantity of the required operating materials ........................239
Maintenancedatatable ...............................................240
Safety regulations for maintenance .......................................242
General information ..................................................242
Working on the hydraulic equipment ......................................242
Workingontheelectricalequipment ......................................242
Safetydevices ......................................................243
Setvalues .........................................................243
Liftingandjackingup .................................................243
Working at the frontofthetruck ..........................................243
Servicing ..........................................................245
Checkingthebatterycondition,acidlevelandaciddensity ......................245
Maintaining wheelsandtyres ...........................................246
Checkingthehydraulicsystemforleaks ...................................248
VI 50988078001 [EN]

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Greasingtheliftmastandrollertracks .....................................249
Checking the battery change frame .......................................249
7 Technical data
Dimensions ........................................................252
VDI datasheet FM-X 10 (N), FM-X 12 (N)* ..................................253
VDI datasheet FM-X 14 (N), FM-X 17 (N)* ..................................257
VDI datasheet FM-X 20 (N, W,EW)* ......................................261
VDI datasheet FM-X 22* ...............................................264
VDI datasheet FM-X 25* ...............................................269
Wheels and tyres ....................................................272
50988078001 [EN] VII

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.
25
0988078001 [EN]

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] 3

1Foreword
Information about the documentation
Information about the documentation
Documentation scope
• Operating instructions
• Operating instructions for attachments
(variant)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of your truck in all pos-
sible variants available at the time of printing.
Special versions to meet customer require-
ments are documented in separate operating
instructions. If you have any questions, please
contact your authorised service centre.
Enter the production number and year of
manufacturer from the nameplate in the space
provided:
Production number
...............................................
Year of manufacture
...................................................
Please quote the production number during all
technical enquiries.
Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operating company at any time. The
storage location is specified in the "Overviews"
chapter.
If the operating instructions are lost, the
operator must obtain a replacement from the
manufacturer immediately.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company must ensure that all
users have received, read and understood
these instructions.
45
0988078001 [EN]

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 instructions. If you have any questions
or suggestions for improvements, or if you
have found any errors, please contact your
authorised service centre.
Issue date and topicality of the
operating instructions
The issue date of these operating instructions
can be found on the title page.
STILL is constantly engaged in the further
development of trucks. These operating
instructions are subject to change, and any
claims based on the information and/or
illustrations contained in them cannot be
asserted.
Please contact your authorised service centre
for technical support relating to your truck.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of information symbols
used
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.
50988078001 [EN] 5

1Foreword
Information about the documentation
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
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.
Abbreviation Meaning
°C Degrees Celsius
°F Degrees Fahrenheit
AAmperes
ABE Display operating unit
ArbSchG German labour protection law
BetrSichV German Ordinance on Industrial Safety and Health
BG Employers’ liability insurance association
BGG Employers’ liability insurance association act
BGR Employers’ liability insurance association rule
BGV Employers’ liability insurance association regulation
Approx. Approximately
CE Symbol that confirms conformity with the valid product-specific European
directives
CEE International Commission on the Rules for the Approval of Electrical Equip-
ment
cm Centimetres
cm3Cubic centimetres
65
0988078001 [EN]

Foreword 1
Information about the documentation
Abbreviation Meaning
dB Decibels
DFÜ Remote data transmission
DIN German standard
EG European Community
EN European standard
FEM Fédération Européene de la Manutention
Fmax Maximum power
gGrams
GAA Industrial inspectorate
If applicable If applicable
GPRS General Packet Radio Service
h/d Hours per day (time driven each day in hours)
ID no. ID number
ISO International standard
kg Kilograms
kg/m3Kilograms per cubic metre
km/h Kilometres per hour
km/d Kilometres per day (kilometres driven each day)
kN Kilonewtons
kW Kilowatts
kWh/h Energy consumption
lLitres
l/h Litres per hour
l/min Litres per minute
LAN Local area network
LED Light emitting diode
LpSound pressure level
LpAZ Continuous sound pressure level in driver’s compartment
LSP Load centre of gravity
o.s. Or similar
mMetres
m/s Metres per second
50988078001 [EN] 7

1Foreword
Information about the documentation
Abbreviation Meaning
m/s2Metres per second squared
MAK Maximum workplace concentration
Max. Maximum
Min. Minimum
min Minutes
rpm Revolution(s) per minute
mm Millimetres
N Newtons
Nm Newton metres
PIN Personal identification number
SE Superelastic
SIT Snap-in tyre for simplified assembly
StVZO German Road Traffic Licensing Regulations
tTonnes
TRGS Technical Regulations for Hazardous Substances
a.s. And similar
VVolts
VDE Association for Electrical, Electronic & Information Technologies
VDI Association of German Engineers
VDMA German Engineering Federation
W Watts
WLAN Wireless local area network
e.g. For example
.
85
0988078001 [EN]

Foreword 1
Information about the documentation
Defining directions
56
8
7
1
3
4
2
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)
•Forwardtilt(8)
Thedriversitscrosswisetothedrivedirection.
50988078001 [EN] 9

1Foreword
Information about the documentation
Schematic views
View of functions and operating proce-
dures
At many points in this documentation, the
(mostly sequential) operation of certain func-
tions 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.
View of the display and operating unit
NOTE
Views of operating statuses and values in the
display of the display and operating unit are
examples and partly dependent on the truck
equipment. As a result, the displays shown of
the actual operating statuses and values may
vary.
10 50988078001 [EN]