Still R70-40T, R70-45T, R70-50T Operating Instructions Manual

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Operating Instructions

LPG forklift truck

R70-40T R70-45T R70-50T

7081 7082 7083

Ident no. 171673 - EN

Table of contents

1 Foreword

Your industrial truck ................................................... 2

General ............................................................ 2

ECdeclarationofconformity,ECmarkofconformity ........................... 2

Information about documentation ......................................... 3

Documentationscope ................................................. 3

Issuedateandcurrentnessofmanual ...................................... 4

Copyrightandproprietaryrights .......................................... 4

Explanations of the signal terms used: ..................................... 5

Explanation of the cross-references ....................................... 5

Definitionofdirections ................................................. 6

Sample graphics ..................................................... 6

Environmental considerations ........................................... 7

Packaging .......................................................... 7

Disposalofunitsandbatteriesduringrepairwork ............................. 7

2 Introduction

Use of truck ........................................................ 10

Proper use ......................................................... 10

Proper towing usage . . ............................................... 10

Impermissibleuse ................................................... 10

Placeofuse ........................................................ 11

Useofworkingplatforms .............................................. 12

Residual risk ....................................................... 13

Residual dangers, residual risks ......................................... 13

Specialriskswhenusingtheforklifttruckandattachments ...................... 14

Overviewofhazardsandcountermeasures ................................. 16

Riskforemployees ................................................... 18

3Safety

Definition of terms used for responsible persons ............................. 20

Operatingcompany .................................................. 20

Specialist .......................................................... 20

Drivers ........................................................... 20

Essentials for safe operation ........................................... 23

Insurancecoverageoncompanypremises ................................. 23

Changes and retrofitting ............................................... 23

Warning regarding non-original parts ..................................... 24

Damage, defects and misuse of safety devices .............................. 24

171673 [EN] I

Table of contents

Tyres ............................................................. 25

Medicalequipment ................................................... 25

Safety inspections ................................................... 26

Regularsafetycheckoftheindustrialtrucks ................................ 26

Regularsafetycheckofthefuelgassystem ................................ 27

Regular checking of harmful substances in the exhaust ........................ 27

Insulationtesting .................................................... 28

Safety regulations when handling consumables ............................. 29

Permissibleconsumables ............................................. 29

Oils .............................................................. 29

LPG .............................................................30

Hydraulicfluid ...................................................... 33

Batteryacid ........................................................ 34

Coolant ........................................................... 35

Disposalofconsumables .............................................. 36

Emissions ......................................................... 37

4Overviews

General view ....................................................... 40

Versions of driver’s compartment ........................................ 42

Driver’scompartment,singlepedalversion ................................. 42

Driver’s compartment, dual-pedal version .................................. 44

Operating and display elements ......................................... 46

Display and operating unit . . . .......................................... 46

Directionoftravel/flasher/faultmulti-functiondisplay .......................... 47

Mini-console ....................................................... 47

Identification points .................................................. 48

Overview .......................................................... 48

Nameplate ......................................................... 49

C.U.R.data ....................................................... 50

Vehicle identification number . .......................................... 50

Accessories ........................................................ 51

Special equipment and variants ......................................... 51

Attachments ....................................................... 52

Accessoryoverview .................................................. 52

II 171673 [EN]

Table of contents

5 Operation

Checks and operations prior to start-up .................................... 54

Visualinspections ................................................... 54

Openingthebonnet .................................................. 55

Checking the engine oil level ........................................... 56

Fillingthewashersystem .............................................. 57

Checking the condition of the wheels and tyres .............................. 57

OpeningLPGcylinders ............................................... 58

OpeningtheLPGtankshut-offvalve ...................................... 59

AdjustingtheMSG65/MSG75driver’sseat ................................ 60

AdjustingtheMSG20driver’sseat ....................................... 63

Adjustingthesteeringcolumn ........................................... 65

Start-up ........................................................... 66

Turningonthekeyswitch .............................................. 66

Starting the engine ................................................... 68

Operating the signal horn .............................................. 69

Restrainingbelt ..................................................... 70

Checkingfunctionofbrakesystem ....................................... 73

Checkingfunctionofsteeringsystem ..................................... 74

Settingthetractionprograms ........................................... 75

Driving ............................................................ 76

Safety regulations when driving ......................................... 76

Driveways ......................................................... 78

Driving (single-pedal operation with multiple lever version) ..................... 80

Driving (single-pedal operation with version including mini-console) . .............. 84

Driving (two-pedal operation) ........................................... 88

Servicebrake ....................................................... 91

Operatingtheparkingbrake ............................................ 93

Steering ........................................................... 94

Lifting ............................................................ 95

Liftingsystemvariants ................................................ 95

Liftmastversions .................................................... 95

Malfunction during a lifting operation ...................................... 96

Controls,liftingsystem ................................................ 98

Liftingsystem,multi-leveroperation ...................................... 99

Forkextension ......................................................100

Operationwithreversibleforks ..........................................100

Working with loads ...................................................102

Safety regulations when handling loads . . . ................................102

Priortotakingupaload ...............................................103

Carryingloadingunits ................................................104

171673 [EN] III

Table of contents

Hazardarea ........................................................104

Transportingpallets ..................................................105

Transportofswingingloads ............................................106

Takinguploads .....................................................107

Transporting loads ...................................................110

Depositingandretrievingloadingunits ....................................113

Driving on ascending and descending slopes ...............................114

Drivingonlifts ......................................................114

Drivingonloadingbridges .............................................115

Workingwithattachments .............................................116

Assemblingattachments ..............................................116

Depressurising connections for attachments ................................117

General information on control of attachments ...............................118

Controllingattachmentsusingmulti-levercontrols ............................119

Operating attachments using multi-lever controls and the 5th function . . ...........120

Takingupaloadusingattachments ......................................121

Operation of additional equipment .......................................122

Switchinglightingonandoff(specialequipment) .............................122

Switchingflashinglightoffandon ........................................123

Switching hazard warning system off and on (special equipment) .................124

Switchingdirectionindicatorsoffandon ...................................125

Operatingthewindscreenwiper/washer ...................................125

Cab ............................................................. . 126

Heater ............................................................127

Drivingwithcruisecontrol ..............................................127

Trailer operation ....................................................130

Towedload ....................................................... . 130

Couplingthetrailer ...................................................131

Towingtrailers ......................................................133

Operation of indicator and operating unit ...................................134

Displays ..........................................................134

Setting and changing the displays ........................................135

Settingthedateortime ................................................135

Resetting the daily kilometres and daily operating hours .......................136

Setting the language .................................................136

Fleet Manager functions ...............................................137

Additional settings ...................................................137

Error messages .....................................................138

Diagram ......................................................... . 138

Faultcodetable .....................................................139

SAFETYBELTmessage .............................................. 142

IV 171673[EN]

Table of contents

Message SITZSCHALTER (SEAT SWITCH) ...............................145

AIRFILTERmessage ................................................ 147

BREMSEANZIEHEN(APPLYHANDBRAKE!)message .......................147

GABELN ABSENKEN (LOWER FORKS) message ...........................148

REFERENCELIFTmessage ...........................................149

FAHRGEBER(ACCEL.SENSOR)message ...............................149

BREMSGEBER (BRAKE SENSOR) message ..............................150

SURVEILLANCEmessage ............................................150

MOT/GEN-TEMP(MOT/GENTEMP)message .............................151

LENKEN(STEERING)message ........................................151

OELDRUCK (OIL PRESSURE) message . . ................................152

KUEHLMITTELSTAND(COOLANTLEVEL)message ........................152

KUEHLMITTELTEMP(COOLANTTEMP.)message .........................153

UEBERTEMPERATUR(OVERHEATING)message ..........................153

Operation in special operating situations ...................................154

Transport ..........................................................154

Towing .......................................................... . 156

Crane loading ......................................................156

Frequent short-term operation ..........................................159

Jumpstarting .......................................................160

Behaviour in emergencies .............................................162

Procedure if truck tips over .............................................162

Emergency lowering . . ...............................................163

Disconnecting the battery ..............................................164

Refuelling .........................................................165

Changing the LPG cylinder .............................................165

FillingtheLPGtank ..................................................168

Shut-down .........................................................171

Parkingthetrucksecurely .............................................171

Measures for prolonged shutdown, storage of truck ...........................173

Returningtoserviceafterstorage ........................................174

6 Maintenance

General maintenance information ........................................178

Qualifications of personnel .............................................178

Information regarding performing maintenance ..............................178

Overview of areas requiring maintenance . . ................................180

Intervalsformaintenanceandinspection ..................................181

Orderingsparepartsandwearingparts ....................................185

Quality and quantity of the required operating materials ........................185

171673 [EN] V

Table of contents

Maintenancedatatable ...............................................186

Safety instructions for maintenance ......................................188

General information ..................................................188

Carrying out work on the hydraulic equipment ...............................188

Workingonelectricalequipment .........................................188

Workingontheignitionsystem ..........................................189

Workingongasfuel(LPG)system .......................................189

Safetydevices ......................................................190

Setvalues .........................................................190

Raisingandjackingup ................................................191

Workingatthefrontoftheforklifttruck .....................................192

Preparation for maintenance ...........................................194

Installingandremovingthefloorplate .....................................194

Removingandinstallingtherearcovering ..................................195

Cleaning ..........................................................196

Cleaning the truck ...................................................196

Cleaning the electrical system ..........................................197

Cleanloadchains ...................................................197

Cleaning the windscreens . . . ..........................................198

Afterwashing .......................................................198

Maintenance after first 50 operating hours ..................................199

Maintenanceduringthebreak-inperiod ...................................199

Maintenance as required ..............................................200

Cleaning the radiator, checking for leaks ...................................200

Topping up coolant and checking coolant concentration .......................200

Changing the air filter insert . . ..........................................202

Servicingthebattery .................................................204

Maintaining hydraulic equipment ........................................207

Servicingwheelsandtyres .............................................208

Checkingadjustmentofthefootbrake .....................................209

Checkingtheparkingbrakesetting .......................................210

Lubricatingjointsandcontrols ..........................................211

Checking the door latch ...............................................211

Maintainingthesteeringaxle ...........................................211

Servicing the mast bearing . . . ..........................................214

Load chain maintenance ..............................................214

Lubricatingtheliftmastandrollertrack ....................................217

Maintainingtherestrainingbelt ..........................................217

Maintainingtherestraintsystem .........................................219

Checkdriver’sseat ...................................................219

Replacingfuses .....................................................219

VI 171673[EN]

Table of contents

Attachment maintenance ..............................................221

500-hour maintenance/semi-annual maintenance ............................222

Checking the evaporator and pressure regulator .............................222

1000-hour maintenance/annual maintenance ...............................223

Workthatmustalsobecarriedout .......................................223

Maintainanceofdriveaxle .............................................223

Adjustingtheparkingbrake ............................................224

Lubricating the parking brake lever bearing and ratchet ........................224

Checking the counterweight attachment . . . ................................224

Changing the engine oil and filter ........................................224

Checking the ribbed V-belt .............................................226

Replacingthesparkplugs .............................................227

Checking the exhaust gas system ........................................227

Changing the LPG filter ...............................................227

OverhaulingtheLPGsystem ......................................... . . 229

Checkingthelambdacontrolsystem ......................................230

Checking the heating system for leaks ....................................230

Check lift cylinders and connections for leaks. ...............................230

Maintainliftingsystem ................................................231

Checkingtheclearancebetweenforkcarriagestopandrun-outstop ..............233

Checkingtheforkarms ................................................233

Checkingreversibleforkarms ..........................................234

3000-hour maintenance/two-year maintenance .............................235

Workthatmustalsobecarriedout .......................................235

Changing the gear lubricant oil ..........................................235

Checking the wheel bearing ............................................236

Checking the engine mountings .........................................236

ReplacinghosesintheLPGsystem .................................... . . 237

6000-hour maintenance ...............................................239

Workthatmustalsobecarriedout .......................................239

Changing the hydraulic oil and filter .......................................239

9000-hour maintenance/five-year maintenance .............................243

Workthatmustalsobecarriedout .......................................243

Changing the coolant . . ...............................................243

10-year maintenance .................................................246

CheckingtheLPGtank .............................................. . . 246

171673 [EN] VII

Table of contents

7 Technical data

Dimensions ........................................................248

VDI datasheet ......................................................249

Wheels and tyres ....................................................252

Fuse assignment ....................................................253

Fuseassignmentinmainfuseholder .....................................253

Fuseassignmentspecialequipment ......................................254

8 Circuit diagrams

Hydraulics .........................................................256

Hydrauliccircuitdiagram ..............................................256

Electrical equipment .................................................258

Legendforcircuitdiagrams ............................................258

VIII 171673 [EN]

Foreword

1 Foreword

Your industrial truck

General

The industrial trucks described in this user manual are built to the applicable standards and safety regulations. If your industrial truck is to be driven on public roads it must satisfy the applicable Road Traffic Act provisions for the country concerned. The vehicle excise licence must be obtained from the appropriate office.

The industrial trucks are fitted with the most up-to-date technology Now it’s up to you to operate your industrial truck safely and obtain the benefits of its functional capabilities.

This user manual gives you the necessary information for this. Read it and follow these instructions before bringing your industrial trucks into use! This way you will avoid accidents, spare yourself worry and maintain the warranty.

EC declaration of conformity, EC mark of conformity

With the EC declaration of conformity, the manufacturer confirms the compliance of the industrial truck with the standards and regulations valid at the time of marketing. The EC conformity mark is shown on the factory nameplate and indicates compliance with the above regulations.

A structural change or addition to the industrial truck on one’s own authority can affect the safety in an unreliable way 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 171673 [EN]

Foreword 1

Information about documentation

Documentation scope

• Operating and maintenance manual

• Operating and maintenance manual for attachments (special equipment)

• Maintenance data table

• Spare parts list

• VDMA rules for the proper use of industrial trucks

• Inspection and test log book for powerdriven industrial trucks (Germany only)

This operating and maintenance manual describes all necessary measures for safe operation and correct maintenance of your industrial truck. It includes all variants available up to the time of going to press. Special designs to meet customer requirements are documented in a separate operating and maintenance manual. For further information, please contact your service centre.

Please enter the factory no. and year of manufacture from the factory nameplate in the space provided ⇒ Chapter "Nameplate", P. 4-49 below:

Factory no. ...............................................

Year of manufacture

...................................................

Please provide these numbers for all technical questions.

An operating and maintenance manual is provided with every industrial truck. This manual must be stored carefully and mustbe available to the driver and operator at any time. The storage location is specified in the Overviews chapter ⇒ Chapter "Overviews", P. 39.

If the operating instructions are lost, the operator must obtain a replacement from the manufacturer immediately.

The operating and maintenance manual is included in the spare parts list and can be reordered as a spare part.

171673 [EN] 3

1 Foreword

Information about documentation

This operating and maintenance manual must be drawn to the attention of staff responsible for the operation and maintenance of the trucks.

The operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must ensure that all users have received, read and understood this manual.

Thank you for reading and complying with this manual. For further information or improvement suggestions, or if you have identified errors, please contact our service centre.

Issue date and currentness of manual

May 2007

STILL is constantly engaged in the further development of industrial trucks. Please note that these operating instructions are subject to change and any claims based on the information and figures contained in these operating instructions cannot be asserted.

If you require technical support for your industrial truck, please contact the responsible service centre.

We hope you enjoy your driving

STILL GmbH

Berzeliusstr. 4

22113 Hamburg, Germany

This manual - and any excerpts thereof - may not be reproduced, translated or tansmitted in any form to third parties without the express written permission of the manufacturer.

4 171673 [EN]

Foreword 1

Information about documentation

Explanations of the signal terms used:

DANGER

In the case of work procedures that must be strictly adhered to in order to prevent a danger to the life or physical condition of persons.

WARNING

In the case ofprocedures thatmust be strictly adhered to in order to prevent injury to persons.

CAUTION

In the case of procedures that must be strictly adhered to in order to preventmaterial damageand/or destruction.

NOTE

For technical requirements that require special attention.

ENVIRONMENT NOTE

To prevent environmental damage.

Explanation of the cross-references

Cross references are used to direct the reader to the appropriate section or chapter.

Examples:

• Cross reference to a section: ⇒ Chapter "Explanation of the cross-references",P.1-5

• Cross reference to a chapter: ⇒ Chapter "Definition of terms used for responsible persons", P. 20

171673 [EN] 5

1 Foreword

Information about documentation

Definition of directions

The directions forwards (1), backwards (3), right (2), left (4) give the installation locations of parts as seen from the driving position; the load is at the front.

Sample graphics

This documentation explains the (usually sequential) sequence of certain functions or operations. Schematic diagrams of a counterbalance truck are used to illustrate these sequences.

NOTE

These schematic diagrams are not representative of the constructed state of the documented industrial truck. They serve only to illustrate the sequences.

6210_001-031

6 171673 [EN]

6210_001-009

Foreword 1

Environmental considerations

Packaging

During delivery of the industrial 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 properly disposed of after delivery of the industrial truck.

Disposal of units and batteriesduring repair work

It may be necessary to replace units as part of maintenance work. Replaced units must then be disposed of.

Your vehicle is comprised of different materials. Each of these materials must be

• disposed of,

• treated or

• recycled in accordance with regional and national regulations.

NOTE

When disposing of batteries, please refer to the battery manufacturer’s documentation.

ENVIRONMENT NOTE

We recommend working with a waste management company for disposal purposes.

171673 [EN] 7

1 Foreword

Environmental considerations

8 171673 [EN]

Introduction

2 Introduction

Use of truck

Proper use

The forklift truck described in this operating manual is suitable for lifting, transporting and stacking loads.

The truck may only be used for its proper purpose, as set out and described in this operating manual.

If the truck is to be used for other purposes than those specified in the operating manual, the approval of the manufacturer and, if necessary, the responsible regulator authorities, must be obtained beforehand to prevent hazards.

The maximum load to be lifted is specified on the capacity plate (load diagram) and may not be exceeded.

Proper towing usage

This forklift truck is suitable for the occasional towing of trailers and is equipped with a towing device for this purpose. This occasional towing may not exceed 2% of the daily operating time. If you want to use the forklift truck for more frequent towing, the manufacturer must be consulted.

The trailer operation provisions must be followed. See ⇒ Chapter "Trailer operation", P. 130.

Impermissible use

Every hazard caused by impermissible use is the responsibility of the operator or driver and not of the manufacturer (also see in this matter ⇒ Chapter "Definition of terms used for responsible persons", P. 20).

Use for purposes other than those described in these operating instructions is prohibited.

10 171673 [EN]

Introduction 2

Use of truck

WARNING

Risk of accident! Passengers are not allowed.

The forklift truck may not be operated in areas where is a risk of fire, explosion or corrosion, or areas that are particularly dusty.

Stacking or unstacking is not permissible on inclined surfaces or ramps.

Place of use

The truck can be used outside and, with the correct equipment, in buildings.

Use on public roads is only permitted if special equipment in accordance with StVZO (Road Traffic Licensing Regulations) is installed.

The various regulations applicable in different countries for driving the truck on public roads must be observed.

The ground must have sufficient load-bearing capacity (concrete, asphalt). It should have a rough surface. The driveways, work areas and aisle widths must correspond with the specifications in these operating instructions (see ⇒ Chapter "Driveways", P. 5-78).

Driving on ascending and descending slopes is permitted if the indicated data and specifications are observed (see ⇒ Chapter "Driveways",P.5-78).

The forklift truck is suitable for use in countries ranging from the Topics to Nordic regions (temperature range: -20°C to +40°C).

This forklift truck is not designedfor use in cold stores.

The operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must ensure suitable fire protection in the surroundings of the truck for all applications of the truck. Depending on the application, additional fire protection must be provided on the industrial truck. In cases of doubt, contact the relevant authorities.

171673 [EN] 11

2 Introduction

Use of truck

Use of working platforms

WARNING

The use of working platforms is governed by national law. This law must be observed. This allowed only if the law allows the use of working platforms in your country.

Consult your national authorities (in Germany the trade association) before any use.

12 171673 [EN]

Introduction 2

Residual risk

Residual dangers, residual risks

Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the industrial truck cannot be entirely excluded.

The industrial 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 hazard areas of the industrial truck itself, a residual risk cannot be excluded. Persons in this area around the industrial 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 industrial truck must be instructed regarding these risks that arise through use of the industrial truck.

In addition,we draw attentionto the safety regulations in these operating instructions.

Risks can include:

• Escape of consumables due to leaks, rupture of lines and containers etc.

• Accident risk when driving over difficult ground such as gradients, smooth or irregular surfaces, or poor visibility etc.

• Falling, tripping etc. when moving on the industrial truck, especially in the wet, with leaking consumables or icy surfaces.

• The stability of the industrial truck has been tested to the latest standards. These standards only take into account the static and dynamic tipping forces that can arise during specified use in accordance with the operating rules and intended purpose. Risks that arise from improper use or incorrect operation and result in tipping forces that exceed the stability cannot be excluded in extreme cases.

171673 [EN] 13

2 Introduction

Residual risk

• Loss of stability due to the load being unstable or the load slipping etc.

• Fire and explosionrisks due to batteries and electrical voltages.

• Human error - disregarding safety regulations.

Special risks when using the forklift truck and attachments

The manufacturer’s approval must be obtained for any unconventional use during which the driver cannot ensure proper and safe execution.

In particularly difficult cases such as the simultaneous use of two forklift trucks for transporting heavy or bulky loads, the supervisor must be present at the place of use and accept responsibility and control of this transport.

14 171673 [EN]

Introduction 2

Residual risk

171673 [EN] 15

2 Introduction

Residual risk

Overview of hazards and countermeasures

NOTE

This flat sheet is intended to help evaluate the hazards in your facility and applies to all drive types.

NOTE

Observe the national regulations for your country!

Hazard Action

Industrial truck equipment does not comply with local regulations.

Lack of skills and qualification of driver

Usage by unauthorised persons

Industrial truck not in safe operating condition

Impaired visibility through load

Contamination of respiratory air

Testing

Driver training (sit-on and stand-on)

Access with key only for authorised persons

Recurrent testing and rectification of defects

Resource planning

Assessment of diesel exhaust gases

Assessment of LPG exhaust gases

Check note √ actioned

- not affected O If in doubt, consult

O BGG 925

O BetrSichVO

O TRGS 554 and

O MAK (Maximum

Notes

competent factory inspectorate or employers’ liability insurance association

VDI 3313 driver permit

(Workplace Safety Ordinance)

BetrSichVO (Workplace Safety Ordinance)

Workplace Concentrations) list and BetrSichVO (Workplace Safety Ordinance)

16 171673 [EN]

Introduction 2

Residual risk

Hazard Action

Impermissible usage (improper usage)

When fuelling

a) Diesel Observe BetrSichVO

b) LPG Observe BGV D34,

When charging traction batteries

When using battery chargers

When parking LPG vehicles

Issue of operating instructions

Written notice of instruction to driver

Observe BetrSichVO (Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules

(Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules

operating instructions and VDMA (German Engineering Federation) rules

Observe BetrSichVO (Workplace Safety Ordinance), operating instructions and VDMA (German Engineering Federation) rules

Observe BetrSichVO, BGR 104 and the operating instructions.

Check note √ actioned

- not affected O BetrSichVO

O BetrSichVO

O BetrSichVO and BGR

Notes

(Workplace Safety Ordinance) and ArbSchG (Health and Safety at Work Act)

VDE 0510: In particular

- Ensure ventilation

- Insulation value within permissible range

104

171673 [EN] 17

2 Introduction

Residual risk

Risk for employees

According to the operating safety ordinance (BetrSichVO) and German Law on Health and Safety at Work (ArbSchG) the operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must ascertain and assess the hazards present at his plant. He must specify the necessary measures for health and safety for employees (BetrSichVO). The operator must thus draw up operating instructions applicable to his plant (§ 6 ArbSchG) and inform the driver accordingly. A person responsible for health and safety must be appointed.

Construction and equipment of the industrial truck correspond to the Machinery Directive 98/37/EEC and they are therefore identified with the CE symbol. They are therefore not included in the hazard assessment, and the attachments likewise on account of their own CE marking . The operator must however select the type and equipment of the industrial

trucks so as to comply with the local provisions for usage.

The result must be documented (Section 6 ArbSchG). Inthe case of industrial truckusage involving similar hazard situations it is permitted to summarise the results . The overview provided (see ⇒ Chapter"Overview of hazards and countermeasures", P. 2-16)means we are helping you to comply with these regulations. The overview specifies key hazards which are most frequently the cause of accidents in the event of non-compliance. If other major hazards are involved at a specific plant , these must be taken into consideration additionally.

In many plants the conditions of use for industrial trucks are by and large similar so that the hazards can be summarised in one overview. Take note of information of the respective employers’ liability insurance association as regards this topic.

18 171673 [EN]

Safety

3 Safety

Definition of terms used for responsible persons

Operating company

The operating company is the natural or legal person that operates the industrial truck or in whose employment the industrial truck is used.

The operating company must ensure that the industrial truck is used only for its proper purposes and in compliance with the safety instructions inthese operating and maintenance instructions.

The operating company must ensure that all users read and understand the safety information.

The operating company is responsible for the scheduling andcorrect performance of regular safety checks.

We recommend that the national performance specifications are adhered to.

Specialist

A specialist is considered to be someone whose technical training and experience have enabled them to develop an appropriate knowledge of industrial trucks and who is sufficiently familiar with the applicable national health and safety regulations, accident prevention regulations, directives and generally recognised technical conventions (standards, VDE regulations, technical regulations of other member states of the European Union or other countries that are signatories to the treaty establishing the European Economic Area) as to be able to assess the condition of industrial trucks in terms of health and safety.

Drivers

This industrial truck may only be driven by suitable persons who are at least 18 years old, who have been trained in driving, have demonstrated their skills in driving and handling loads to the operator or an authorised

20 171673 [EN]

Safety 3

Definition of terms used for responsible persons

representative and have been specifically instructed to drive the truck. Specific knowledge of the industrial 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 satisfied if the driver has been trained in accordance with the BGG (General Employers’ Liability Insurance Association Act) 925. Follow the national regulations for your country.

Rights, duties and rules of behaviour for the driver,

The driver must be trained in his rights and duties.

The driver must be granted the required rights.

The driver must wear appropriate protective equipment (protective clothing, safety shoes, safety helmet, protective goggles, gloves) for the conditions, the job and the load to be lifted. Strong footwear should be worn to ensure safe driving and braking.

The driver must be familiarised with the operating manual and it must be accessible to him at all times.

The driver must:

• have read and understood the operating manual,

• have familiarised himself with safe operation of an industrial truck,

• be physically and psychologically able to drive an industrial truck safely.

DANGER

Taking drugs, alcohol or medications that affect the response of an individual limits the ability of that individual to drive an industrial truck!

Individuals under the influence of the above-mentioned substances are not permitted to perform any work on or with an industrialtruck.

171673 [EN] 21

3 Safety

Definition of terms used for responsible persons

Prohibition on use by unauthorised persons

The driver is responsiblefor theindustrial truck during working hours. He may not allow unauthorised persons to operate the truck.

When leaving the truck, he must secure it against unauthorised use.

22 171673 [EN]

Safety 3

Essentials for safe operation

Insurance coverage on company premises

In many cases, company premises are restricted public traffic areas.

NOTE

We advise checking your public liability insurance to determine whether you have insurance coverage for your industrial truck with respect to third parties in the event of damage in restricted public traffic areas.

Changes and retrofitting

If your forklift truck is used for work not listed in the guidelines or in these instructions and must be consequently converted or retrofitted, be aware that each change to the structural state can affect the handling and the stability of the forklift truck and can result in accidents. Therefore, contact your service centre in advance. Changes that will disadvantageously affect stability among other things may not be made without our approval.

The forklift truck can only be converted with our written approval. Approval from the responsible authority must be obtained if necessary.

We warn against the installation and use of restraint systems not approved by us.

DANGER

Even when using a restraint system there is some residual risk that the driver might be injured if the truck tips over. This risk of injury can be reduced through the combined use of a restraint system and the seat belt. In addition, the belt protects against the consequences of rear-end collisions and falling off a ramp.

Accordingly, we recommend use of the seat belt as well.

171673 [EN] 23

3 Safety

Essentials for safe operation

For safety reasons, it is prohibited to drill holes in the driver’s overhead guard or to perform welding on it. In the case of welding to other locations of the forklift truck, the battery and all connections to the electronic control cards must be disconnected. Please contact your service centre.

DANGER

Failure to comply with the above voids the CE conformity!

Operation of the forklift truck without the overhead guard at a lift heightof over 1800 mm is prohibited.

Warning regarding non-originalparts

Original parts, attachments and accessories are specially designed for this vehicle. We specifically draw your attention to the fact that parts, attachments and accessories supplied by other companies have not been tested and approved by us.

CAUTION

Installation and/or use of such products may therefore have a negative impact on the design features of your industrial truck and thus impair active and/or passive driving safety.

We recommend that you obtain approval from us and, if necessary, from the responsible regulatory authorities,before installing suchparts. The manufacturer accepts no liability for any damage caused by the use of non-original parts and accessories without our approval.

Damage, defects and misuse of safety devices

The driver must report any damage or other defects to the truck or attachment immediately to the supervisory personnel.

Trucks and attachments that are notfunctional or safe todrive may notbe used until they have been properly repaired.

Do not remove or deactivate safety devices and switches.

24 171673 [EN]

Safety 3

Essentials for safe operation

Fixed set values may only be changed with the approval of the manufacturer.

Work on the electrical system (e.g. connecting a radio, additional headlights etc.) is only permitted with the manufacturer’s written approval. All electrical system interventions must be documented.

Even if they are removable, roof panels may not be removed, as they are designed to protect against small falling objects.

Tyres

Tyre quality affects the stability and handling of the forklift truck. Changes can only be made in consultation with the manufacturer. When changing wheels or tyres, always ensure that no tilting of theforklift truckoccurs (e.g. always change right and left wheels at the same time).

Medical equipment

When a driver is wearing medical equipment, e.g. heart pacemaker or hearing aids, the operation of this equipment may be affected. A doctor or the manufacturer of the medical equipment should be asked whether the equipment is sufficiently protected against electromagnetic interference.

171673 [EN] 25

3 Safety

Safety inspections

Regular safety check of the industrial trucks

Safety check based on time and extraordinary incidents

The operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must make sure that the industrial truck is checked by a specialist at least once per year or after special incidents (audit in line with accident prevention guidelines in Germany; please observe your national guidelines) (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20).

A complete audit of the technical condition of the industrial truck is performed with regard to accident safety. In addition, the industrial truck must also be thoroughly checked for damage, that could have potentially been caused by improper use. An audit log must be created. The results from the audit must be retained until a further two audits have been carried out.

The schedule is indicated by a sticker on the vehicle. Use the "Test log book for powerdriven industrial trucks"! Order No. 135745

Observe the guidelines for testing on your vehicles in accordance with accident prevention regulations (GERMAN ACCIDENT PREVENTION REGULATIONS FOR INDUSTRIAL TRUCKS).

The operator must ensure faults are rectified without delay. Please contact the service centre.

jährliche Prüfung

gem. UVV

Mängel siehe Prüfbuch

letzte Prüfung

nächste Prüfung

7090_001-001

NOTE

Observe the national regulations for your country.

26 171673 [EN]

Safety 3

Safety inspections

Regular safety check of the fuel gas system

Technical safety check of the fuel gas system

In accordance with § 37 of the Trade Union Ordinance BGV D34 "accident prevention regulations for the use of liquid gas "(please observe your national regulations). the operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) make sure that the fuel gas system is checked by a specialist (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20):

• recurring in regular intervals, but at least once per year,

• after maintenance that can influence the operational safety,

• after changes that can influence operational safety,

• after interruptions in operation of more than one year.

The following is checked: proper composition, sealing, function, adjustment and the functional ability of the safety devices.

The results of the tests must be retained in the test certification in accordance with BGG 936 (please observe your national regulations), that must be kept until the next test. The test certification must be presented for authorities to look at upon request at any time.

Type and scope of the tests can be different based on the country. Observe different legal determinations in the respective operating countries when using fuel gas trucks.

The operator must ensure continuous correction of defects. Please contact the service centre.

Regular checking of harmful substances in the exhaust

In accordance with § 37 of the Trade Union Ordinance BGV D34 "accident prevention regulations for the use of LPG "(please observe your national regulations) the operator

171673 [EN] 27

3 Safety

Safety inspections

(see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) must ensure that the harmful substances in the exhaust are checked by a specialist at recurring and regular intervals, at least every six months, (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20).

Type and scope of tests may differ according to thecountry. Observe different statutory provisions in the respective operating countries when using LPG trucks.

Insulation testing

The industrial truck insulation must have a sufficient insulation resistance. For this reason, an insulation test in accordance with DIN 57117 and DIN 43539, VDE 0117 and VDE 0510 must be conducted at least once every year.

NOTE

Contact your service centre to arrange for an insulation test.

Testing the insulation resistance of the electrical system

NOTE

Nominal battery voltage < test voltage < 500 V.

– Ensure that all voltage sources have been

disconnected from the circuit to be tested.

– Measure the insulation resistance with a

suitable gauge.

The insulation resistance can be considered sufficient if it measures at least 1000 nominal battery voltage against ground.

28 171673 [EN]

/V for

Safety 3

Safety regulations when handling consumables

Permissible consumables

WARNING

Consumables can be dangerous. Follow the safety regulations when handling these

substances.

Refer to the maintenance data table for the permissible substances necessary for operation. (See ⇒ Chapter "Maintenance data table", P. 6-186).

Oils

WARNING

Oils are flammable! – Comply with applicable legal

regulations.

– Donotallowoilstocomeinto

contact with hot engine parts.

Do not smoke!

WARNING

Oils are toxic! – Avoid contact and consumption. – If oil mist or vapours have been

inhaled, seek fresh air.

– If oil comes into contact with the

eyes, flush thoroughly (at least 10 minutes) with water and then seek medical assistance (e.g. from an ophthalmologist).

– If oil is swallowed, do not induce

vomiting, but rather seek medical assistance immediately.

171673 [EN] 29

3 Safety

Safety regulations when handling consumables

WARNING

Prolonged intensivecontact with the skin can result in loss of skin oils and irritate the skin!

– Avoid contact and consumption. – Wear protective gloves. – After coming into contact with

oil, wash the skin with soap and water,andthenapplyaskincare product.

– Change oil-soaked shoes and

clothing immediately.

WARNING

Risk of slippingon spilled oil, particularly when combined with water!

– Immediately treat spilled oil with an oil binding

agent, and then dispose of it in accordance with applicable regulations.

ENVIRONMENT NOTE

Oils are water pollutants!

– Always store oil in legally approved contain-

ers.

– Avoid spilling oil.

– Immediately treat spilled oil with an oil bind-

ing agent, and then dispose of it in accordance with applicable regulations.

– Dispose of used oil in accordance with ap-

plicable regulations.

LPG

Always observe the accident prevention regulations, "Use of LPG" (BGV D34) published by the main trade association, or the national guidelines.

Liquid gases are the combustible gases, PROPANE, BUTANE and their mixtures.

They are located in LPG cylinders or LPG tanks, and are kept ready there to drive combustion engines.

30 171673 [EN]

Safety 3

Safety regulations when handling consumables

The pressure of these gases in the container depends on the external temperature and may reachupto25barormore.

NOTE

In these operating instructions, liquid gases are called LPG.

DANGER

Risk of explosion! LPG immediatelybecomes gaseous

when it escapes; this means that a hazardous explosive atmosphere will occur at once.

DANGER

Risk of fire! Not permitted: open flames (stoves,

storm lanterns, activities producing sparks etc.), smoking in storage rooms and when working on the LPG system!

– With fires involving LPG only, car-

bon dioxide dry fire extinguishers or carbon dioxide gas extinguishers should be used.

DANGER

Risk of poisoning! It must be ensured that trucks with

LPG systems are only operated in rooms that are entirely or partially enclosed if no hazardous concentrations of exhaust constituents harmful to health can be produced in the room air.

CAUTION

Industrial trucks fuelled by LPG should only be parked in rooms that are above ground level and have adequate ventilation. They must not be parked near openingsto rooms below ground level.

Sufficient space must be left around trucks that have been parked; such areas must not include cellar openings or access points, pits or similar cavities, drains without liquid traps, ventilation shafts and light wells or combustible material.

171673 [EN] 31

3 Safety

Safety regulations when handling consumables

Safe use of LPG trucks

The LPG system must be checked for damage and leaks at least once per year by a specialist in LPG systems, see ⇒ Chapter "Regular safety check of the fuel gas system", P. 3-27.

The LPG system is subject to prescribedmaintenance intervals that must be maintained, see ⇒ Chapter "Intervals for maintenance and inspection", P. 6-181.

A specialist in LPG systems should be hired for testing if you are unsure of the type and condition of the evaporator pressure regulator, or if the LPG system has not been checked in alongtime.

WARNING

Risk of explosion! When operating a truck with an

LPG system, make sure that the floor opening (1) below the engine compartment is not closed. Make sure there are sufficiently large ventilation openings (at least

200 cm

in total) in the engine compartment floor, so that gas cannot accumulate.

7081_003-006

Storing pressurised-gas vessels

Cylinder and main shut-off valves should be closed as soon as trucks are parked.

The special regulations governing the storage of pressurised-gas vessels must be observed without fail, as well as specific national regulations where appropriate.

For example, pressurised-gas vessels must not be stored:

• in rooms below ground level

• in stairwells, in hallways/landings, confined yards and passageways/thoroughfares or in their immediate vicinity

• on steps of outdoor installations

• on specially marked escape routes

• in garages

•inworkrooms.

32 171673 [EN]

Safety 3

Safety regulations when handling consumables

NOTE

Please also take into account the section ""General requirements for pressurised-gas vessels; Using pressurised-gas vessels"" in the technical regulations applicable to pressurised-gas vessels TRG 380 and 404, as well as national regulations where applicable.

Electric hand lamps used in these rooms must be provided with an enclosed sealed cover and a strong basket guard.

Storage rooms and maintenance workshops must be well ventilated. Here it should be borne in mind that LPG is heavier than air. It collects at floor level, in work pits and other depressions in the ground where it may produce hazardous explosive mixtures of gas and air.

Hydraulic fluid

WARNING

These fluids are pressurised during operation of the forklift truck and are hazardous to your health.

– Do not spill the fluids. – Follow the statutory regulations. – Do not allow to come into contact

with hot motor parts.

171673 [EN] 33

3 Safety

Safety regulations when handling consumables

WARNING

These fluids are pressurised during operation of the forklift truck and are hazardous to your health.

– Do not allow to come into contact

with the skin. – Avoid inhaling spray. – Penetration of pressurised

fluids into the skin is particularly

dangerous if these fluids escape

at high pressure due to leaks in

the hydraulic 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).

ENVIRONMENT NOTE

Hydraulic fluid is a substance hazardous to water.

•

Always store hydraulic fluid in containers complying with the regulations.

•

Avoid spilling.

•

Spilt hydraulic fluid should be removed with oil-binding agents at once 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 contact and consumption. – In case of injury, seek medical

advice immediately.

34 171673 [EN]

Safety 3

Safety regulations when handling consumables

WARNING

Battery acid contains dissolved sulphuric acid. This is corrosive.

– Whenworkingwithbatteryacid,

always wear protective clothing and eye protection.

– Do not allow any acid to get onto

theclothingorskinorintothe 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.

Coolant

WARNING

Coolant and coolant additive are hazardous to health.

– Store only in original vessels, do

not spill.

– Never use empty food containers,

bottles or other vessels for storing coolant.

– The legal regulations must be

observed.

ENVIRONMENT NOTE

– Immediately remove escaped coolant with

an oil binding agent and dispose of in line with the regulations.

– Dispose of used coolant in line with the

regulations.

171673 [EN] 35

3 Safety

Safety regulations when handling consumables

Disposal of consumables

ENVIRONMENT NOTE

Materials that have to be disposed of following maintenance, repair, and cleaning must be systematically collected and disposed of in accordance with regulations. Follow the national regulations for your country. Work may only be carried out in areas designated for the purpose. Care must be taken to minimise, as far as possible, any impact on the environment.

• Any spillage of fluids such as hydraulic oil, brake fluid or gear lubricant oil must be immediately soaked up with an oil-binding agent.

• The regulations for disposal of used oil are applicable.

• Any spillage of battery acid must be neutralised immediately.

36 171673 [EN]

Safety 3

Emissions

Noise emissions

The values were determined based on measurement procedures from the standard EN 12053 (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 levels:

Continuous sound-pressure level in the driver’s compartment

pAZ

Uncertainty K

The values were determined in the test cycle on an identical machine from the weighted values for operating conditions and idling.

Time percentages:

• Lifting 18%

• Idling 58%

• Driving 24%

However, the indicated noise levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003/10/EC (daily personal noise pollution). If necessary, these should be determined directly at the workplace under the actual conditions there (additional noise sources, special operating conditions, sound reflections) by the operating company; (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20).

<76dB(A)

4dB(A)

Vibrations

The vibrations of the machine must be determined on an identical machine in accordance with the standard EN 13059 "Vibration measurements on industrial trucks".

Weighted effective value of the acceleration the body (feet or seat surface) is subjected to

Uncertainty K

Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel

171673 [EN] 37

<0.6m/s

0.18 m/s

3 Safety

Emissions

or the operating elements in the truck are less than 2.5 m/s

. There are therefore no measurement guidelines for these measurements. The personal vibration load on the driver over a working day shall be determined in accordance with the Directive 2002/44/EC by the operating company (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) at the actual place of use, in order to consider all additional influences, such as driving route, intensity of use etc.

Exhaust gases

The engine releases exhaust gases into the environment during operation. The exhaust gases mainly consist of water vapour, carbon dioxide (CO

), carbon monoxide (CO), hydro-

carbons (CH), aldehydes and nitrogen oxide (NO

). The components CO, CH and NO

are toxic or harmful to health and must not be inhaled in high concentrations.

For this reason, the engine cannot be operated in closed areas without sufficient ventilation.

Heat

WARNING

The exhaust gases are very hot and canignitecombustiblematerial.

– Accordingly, keep the exhaust

pipe away from combustible materials.

Battery

WARNING

During charging, the battery releases a mixture of oxygen and hydrogen (detonating gas). This gas mixture is explosive and must not be ignited.

Suitable ventilation and keeping it away from open flames can avoid the danger of explosion.

– Observe the safety regulations for

handling the battery.

38 171673 [EN]

Overviews

4 Overviews

General view

1Liftmast 2 Overhead guard 3 Steering wheel 4 Driver’s seat

5 Steering axle 6Driveaxle 7 Tilt cylinder 8 Fork arms

7081_003-001

40 171673 [EN]

Overviews 4

General view

171673 [EN] 41

4 Overviews

Versions of driver’s compartment

Driver’s compartment, single pedal version

42 171673 [EN]

7081_003-010

Overviews 4

Versions of driver’s compartment

1 Steering wheel 2 Steering column adjustment lever 3 Direction of travel/flasher/faultmulti-function

display 4 Travel direction switch 5 "Lift-lower" operating lever 6 "Tilt" operating lever 7 "Attachments" operating lever 8 "Attachments" operating lever 9 Display and operating unit

10 Storage box 11 Bottle holder for 1 l PET bottles 12 Parking brake lever 13 Storage shelf for user and maintenance

manual (special equipment) 14 Driver seat 15 Accelerator pedal 16 Bonnet release 17 Brake pedal 18 Alarm horn foot switch

171673 [EN] 43

4 Overviews

Versions of driver’s compartment

Driver’s compartment, dual-pedal version

44 171673 [EN]

7081_003-039

Overviews 4

Versions of driver’s compartment

1 Steering wheel 2 Steering column adjustment lever 3 Direction of travel/flasher/faultmulti-function

display 4 Alarm horn button 5 "Lift-lower" operating lever 6 "Tilt" operating lever 7 "Attachments" operating lever 8 "Attachments" operating lever 9 Display and operating unit

10 Storage box 11 Bottle holder for 1 l-PET bottles 12 Parking brake lever 13 Storage compartment for operating and

maintenance manual 14 Driver’s seat 15 Forwards accelerator pedal 16 Bonnet release 17 Brake pedal 18 Reverse accelerator pedal

171673 [EN] 45

4 Overviews

Operating and display elements

Display and operating unit

234 5

20 19

1 Front windscreen wiper switch 2 Work light switch 3 Rear windscreen wiper switch 4 Flashing light switch 5 Lighting switch 6 Switch - hazard warning lights 7 Traction program switch 8 Menu change key 9 Fleet Manager smart card reader 10 Interior light display 11 Interior light switch 12 Rear window heater display

1 0 0 %

2 3 6 0,4 h

12 : 15

1314

1112

13 Rear window heater switch 14 Rear searchlight display 15 Rear searchlight switch 16 Time symbol 17 Time 18 Operating hours symbol 19 Operating hours display 20 Traction program symbol 21 Current traction program 22 Fuel tank symbol 23 Fuel level in % (special equipment)

7311_560-001

NOTE

The displays (10, 12, 14, 23) and buttons (11, 13, 15) are assigned on the basis of the additional electrical special equipment.

46 171673 [EN]

Overviews 4

Operating and display elements

Direction of travel/flasher/fault multifunction display

The direction of travel/flasher/fault multi-function display is used to display the direction of travel. In addition, the flasher is used to indicate that messages are shown on the display and operating unit.

1 Forward travel display 2 Right flasher display 3 Reverse travel display 4 Message display 5 Left flasher display

7071_003-004

Mini-console

The mini console is located on the steering column below the steering wheel.

NOTE

Switch (1) is not assigned in trucks with the travel direction switch on the "lift-lower" operating lever.

171673 [EN] 47

1 Travel direction switch 2 Direction indicator switch

7311_003-056

4 Overviews

Identification points

Overview

1 2

16 17 18

13 14

10 11 12

8 9

STOP

10 bar

T E C H N O L O G Y

STILL GmbH Hamburg

jährliche Prüfung

gem. UVV

Mängel siehe Prüfbuch

letzte Prüfung

20..

UVV

48 171673 [EN]

nächste Prüfung

STOP

20..

STOP

7081_003-040

Overviews 4

Identification points

1 Warning sign 2 Decal information 3 Safe working load diagram 4 Hook symbol 5 Decal information 6 Decal information 7 Label text 8 Warning sign 9 Warning sign 10 Nameplate

Nameplate

It is possible to identify your forklift truck from the information on the nameplate.

11 Decal information 12 Accident prevention audit label 13 Decal information 14 Decal information 15 Warning sign 16 Safe working load diagram for attachment

(special equipment) 17 Decal information 18 Decal information(special equipment) 19 Company logo

1 Type

2 Factory no. ...............................................

3 Year of construction 4 Tare weight kg 5 Permissible battery weight, max. (only for

electric lift trucks) 6 Permissible battery weight, min. (only for

electric lift trucks) 7 Ballast weight (only for electric lift trucks) 8 Refer to the technical data listed in these

operating instructions for more detailed

information 9CEmark 10 Nominal drive rating 11 Battery voltage V 12 Nominal forklift capacity kg

6210_921-003

171673 [EN] 49

4 Overviews

Identification points

C. U. R. data

This label provides information on the weight and the load distribution of your truck.

7090-921-003

1 Admisssible rear axle load in kg 2 Admissible total weight kg 3 Admissible front axle load in kg

Vehicle identification number

NOTE

Please state this serial number when making technical inquiries.

The serial number contains the following information:

1 Production site

2 Type

3 Variant

4 Serial number

50 171673 [EN]

xx xxxx x xxxxx

7090_921-004

Overviews 4

Accessories

Special equipment and variants

Driver’s seat

MSG 20 driver’s seat:

• Imitation leather

MSG 65 driver’s seat:

• Textile cover, lumbar support

• Imitation leather, lumbar support, heater, backrest extension

• Textile cover, lumbar support, heater, backrest extension

MSG 75 driver’s seat:

• Imitation leather, lumbar support, heater, backrest extension

• Textile cover, lumbar support, heater, backrest extension

Overhead guard and cab

• Overhead guard

• Weather protection, levels 1 to 3

• Cab with heater

Lift mast

NOTE

Overall height and lift height; see ⇒ Chapter "Technical data", P. 247.

•Tele

•Triple

• Load backrest

Electrical equipment

• Lighting system (various versions)

• Dual-pedal control travel actuation

• FleetManager

• Accident recorder

• Cruise control

LPG system

•LPGtank

171673 [EN] 51

4 Overviews

Accessories

Attachments

• Fork extension

• Warning beam

•Grille

• Mandril

• Crane arm

• Snow remover

• Shovel

• Sideshift

• Clamp forks without sideshift

• Bale clamp without sideshift

• Clamp forks with sideshift

• Bale clamp with sideshift

• Fork arm adjustment

Accessory overview

• Key for key switch (2 pieces)

• Key for cab (special equipment)

• Emergency lowering key

• Release tool for bonnet

52 171673 [EN]

Operation

5 Operation

Checks and operations prior to start-up

Visual inspections

WARNING

Damage or other defects of the forklift truck or attachment (special equipment) can result in accidents.

If damage or other defects are identified on the forklift truck or attachment (special attachment) during the following inspections, do not use the vehicle until it has be repaired properly. Do not remove or deactivate safety devices and switches. Do not change predefined set values.

WARNING

Risk of falling! When working on high-level areas of the truck, do

not use truck componentsfor access or to stand on. – Always use suitable equipment for this.

Prior to start-up, a safe operating state must be ensured:

– The retaining devices (1) of the fork arms

for preventing lifting and shifting should not show any defects.

– Fork arms or other load-carrying equipment

may not have any noticeable damage (e.g. bends, cracks, significant wear).

– The chains must be undamaged and evenly

and adequately tensioned.

– Check the area under the forklift truck for

leaking consumables.

– The guard grille (special equipment) and

overhead guard must be undamaged and secure.

– Attachments (special equipment) must be

properly secured and function according to their operating instructions.

– Check whether all information labels/no-

tices are present and legible. Damaged or missing stickers must be replaced according to the overview of sticker locations ⇒ Chapter "Overview", P. 4-48.

6210_000-002

54 171673 [EN]

Operation 5

Checks and operations prior to start-up

– The roller tracks (2) must be lubricated with

a visible lubricant film.

– Check the hydraulic system and hydraulic

oil tank where visible for damage and leaks. Damaged hoses must be replaced.

– Check the fuel system and fuel tank where

visible for damage and leaks. Damaged hoses must be replaced.

– The motor hood must be securely closed.

– Steps must be clean and free of ice.

– In the case of versions with a cabin (special

equipment) all windows must be clean and free of ice. Switch on the heater (special equipment) and set the air vents so that the windows remain free of ice.

– Report defects to the supervisor.

Opening the bonnet

WARNING

Risk of injury! – Before opening the bonnet,switch off the engine.

– Lock steering column (1) into the frontmost

position.

– Slide the driver’s seat completely forward

and, in trucks with a rear window, fold the seat backrest (2) forward; see ⇒ Chapter "Adjusting the MSG 65/MSG 75 driver’s seat", P. 5-60 or ⇒ Chapter "Adjusting the MSG 20 driver’s seat", P. 5-63.

171673 [EN] 55

7071_003-006

5 Operation

Checks and operations prior to start-up

– Insert the release tool (3) and release the

catch. To open it, use the release tool from the accessories.

NOTE

The catch can be secured with a lock. If necessary, open the lock beforehand.

– Using the handle (4) next to the driver’s

seat, open the bonnet towards the rear.

WARNING

Risk of accident! The release tool must always remain with the truck,

so that the bonnet can be opened at any time, even in an emergency!

Checking the engine oil level

7311_120-002

NOTE

The vehicle should be as level as possible when performing this check.

– Remove and wipe off dipstick.

– Insert dipstick to contact and pull out again.

The oil level must be between the markings (arrows).

– If the oil level only reaches the bottom mark,

unscrew filler cap and add oil according to maintenance data table(1). ⇒ Chapter "Maintenance data table", P. 6-186.

7081_003-035

56 171673 [EN]

Operation 5

Checks and operations prior to start-up

Filling the washer system

– Open the sealing cap (1).

– Fill the washer reservoir (2) with windscreen

washer fluid.

CAUTION

If there is no anti-freeze in the system, the washer system (special equipment) may be damaged.

– Always use windscreen washer fluid with anti-

freeze.

– Fill the reservoir completely with clean wa-

ter.

– Closethesealingcap(1).

– Operate the washer system until washer

fluid exits from the spray nozzles.

7090_341-002

Checking the condition of the wheels and tyres

WARNING

Risk of accident! With uneven wear or incorrect air pressure, the stability of the forklift truck decreases and the braking distance increases.

Renew left and rightworn or damaged tyres without delay.

NOTE

Only permissible tyre types may be

•

used, see ⇒ Chapter "Wheels and tyres", P. 7-252.

– Check tyres (1) for wear or damage.

Tyres cannot be damaged or worn. They must be worn evenly on both sides.

– Check air pressure. The air pressure given

on the stickers (2) must be observed.

NOTE

Note the safety principles for tyres, see ⇒ Chapter "Tyres", P. 3-25.

171673 [EN] 57

7071_003-043

5 Operation

Checks and operations prior to start-up

Opening LPG cylinders

DANGER

There is a risk of explosion if LPG escapes.

– Do not smoke or use a naked

flame / fire.

– LPG cylinders should only be

changed in well ventilated rooms and not near openings in the ground.

Note safety regulations for working with LPG ⇒ Chapter "LPG", P. 3-30.

– Check whether smell of gas is discernable.

DANGER

There is a risk of explosion if LPG escapes.

– Do not start engine if there are

leaks, the smell of gas, among other things.

– Contact your customer service

office.

– Check whether the hose (2) is securely

connected to the gas cylinder.

DANGER

Risk of explosion from spark discharge!

Opening and closing may not be aidedwithstrikingtools.

WARNING

LPG can cause frostbite on the skin. – Protective gloves should there-

fore always be worn.

CAUTION

Opening quickly can lead to the system icing over. – Open the cylinder valve (1) by slowly turning the

star handle to the left.

58 171673 [EN]

7311_136-003

Operation 5

Checks and operations prior to start-up

Opening the LPG tank shut-off valve

DANGER

There is a risk of explosion if LPG escapes!

Do not smoke or use a naked flame/fire.

– LPG tank shut-off valves (special

equipment) should only be opened in well-ventilatedrooms and not near openings in the floor.

– Follow the safety regulations

when handling LPG, see ⇒ Chapter "LPG", P. 3-30.

– Check whether smell of gas is discernable.

DANGER

There is a risk of explosion if LPG escapes!

Do not start the engine if a leak, the smell of gas or the like is noted!

– Contact your service centre.

– Check whether the hose (1) is firmly con-

nected to the LPG tank.

DANGER

Risk of explosion from spark discharge!

Striking tools should not be used for opening/closing.

7081_003-044

WARNING

LPG can cause frostbite on the skin! – Accordingly, always wear protec-

tive gloves.

CAUTION

Opening quickly can lead to the system icing over. – Open the shut-off valve (2) by slowly turning it to

the "OPEN" position.

171673 [EN] 59

5 Operation

Checks and operations prior to start-up

The fuel display (3)(special equipment) shows you how much LPG is available.

Adjusting the MSG 65/MSG 75 driver’s seat

DANGER

Risk of accident! Do not adjust the seat whilst driving.

– Adjust the seat in such a way that you can

safely reach and operate all the controls.

WARNING

On some versions (special equipment), the amount of head clearance on your forklift truck may be restricted.

On these versions, the distance between the head and the lower edge of the roofing sheet must be at least 40 mm.

101.1 h

02 : 30

85 %

7311_003-040

NOTE

If your truck comes with separate operating instructions for the seat, they must be followed.

60 171673 [EN]

Operation 5

Checks and operations prior to start-up

WARNING

Risk of injury! To obtain optimum seat cushioning, you must ad-

just the seat suspension to your own body weight. This helps your back and protects your health.

To prevent injury, make sure that there are no objects in the swivel area of the seat.

Moving the driver’s seat

– Pull lever (1) up and move the seat.

– Release the lever.

WARNING

Risk of injury! – Make sure that the seat is securely engaged.

Adjusting the backrest

– Pull lever (2) upwards and adjust the incline

of the seat backrest using your body weight.

– Release the lever.

WARNING

Risk of injury! – Make sure that the backrest is engaged.

171673 [EN] 61

7094_003-006

7094_003-008

5 Operation

Checks and operations prior to start-up

Adjusting the seat suspension to your weight

NOTE

This adjustment should only be made while the seat is occupied.

NOTE

The MSG 75 seat is equipped with an electric air suspension activated with an electric switch instead of a lever (3).

– Completely fold open lever (3) and adjust

the driver’s weight by pumping up or down.

– Return the lever (3) back to the initial central

position before each new lift (audible click).

NOTE

A noticeable empty lift on the operating handle shows you have reached the minimum or maximum weight setting.

The correct driver’s weight has been selected when the arrow (4) is in the middle of the viewing window.

6321_003-038

Adjusting the lumbar support (special equipment)

– Adjust the lumbar support by turning the

hand wheel (5).

By turning upwards, the convexity moves to the upper region of the lumbar support, and by turning downwards, to the lower region of the lumbar support. This convexity can be adjusted to your individual lumbar vertebrae.

62 171673 [EN]

6321_003-039

Operation 5

Checks and operations prior to start-up

Adjusting the backrest extension (special equipment)

– Adjust the backrest extension (6) by pulling

it out or pushing it in to the desired position.

To remove the backrest extension, move it past the end stop by jolting it upwards.

Switching the seat heater (special equipment) on and off

– Switch the seat heater on or off using switch

(7).

6321_003-040

Adjusting the MSG 20 driver’s seat

DANGER

Risk of accident! Do not adjust the seat whilst driving.

– Adjust the seat in such a way that you can

safely reach and operate all the controls.

171673 [EN] 63

6321_003-041

5 Operation

Checks and operations prior to start-up

WARNING

On some versions (special equipment), the amount of head clearance on your forklift truck may be restricted.

On these versions, the distance between the head and the lower edge of the roofing sheet must be at least 40 mm.

NOTE

If your truck comes with separate operating instructions for the seat, they must be followed.

WARNING

Risk of injury! To obtain optimum seat cushioning, you must ad-

just the seat suspension to your own body weight. This helps your back and protects your health.

To prevent injury, make sure that there are no objects in the swivel area of the seat.

Moving the driver’s seat

– Pull lever (2) up and move the seat.

– Release the lever.

WARNING

Risk of injury! – Make sure that the seat is securely engaged.

Adjusting the backrest

– Pull lever (3) upwards and adjust the incline

of the seat backrest using your body weight.

The seat backrest has three detent positions with an adjustment range of -5° to +5°.

– Release the lever.

WARNING

Risk of injury! – Make sure that the backrest is engaged.

64 171673 [EN]

6321_003-044

Operation 5

Checks and operations prior to start-up

Adjusting the seat suspension to your weight

NOTE

Make this adjust only whilst sitting in the seat.

– Adjust your individual suspension comfort

using the adjusting lever (1).

Adjusting the steering column

– Loosen the knob (1) of the steering column

locking device.

– Position the steering column (2) and

retighten the knob (1).

DANGER

Risk of accident! – Make sure that the steering column is secured in

position.

Never adjust the steering column whilst driving!

6321_003-044

7071_003-008

171673 [EN] 65

5 Operation

Start-up

Turningonthekeyswitch

WARNING

Before switching on the key switch, all tests before commissioning must be performed without detecting any defects.

– First perform all tests before commissioning,

see ⇒ Chapter "Checks and operations prior to start-up", P. 54.

If any malfunctions are detected, do not put the truck into operation! Pleasecontact your supervisor or service centre.

DANGER

Risk of accident! Drive only with a secured bonnet.

– Insert the ignition key (1) into the key switch

and turn it to the right to operating position "I".

This initiates a self-test. All lamps in the multifunction display light up briefly.

7071_003-009

66 171673 [EN]

7071_003-099

Operation 5

Start-up

Upon switching on the key switch, the display shows the welcome screen in the set language until the truck controls have completely started up.

Displays during the switching-on operation

• (2) Fuel level (special equipment)

The fuel level can be displayed as either a percentage or bar display in the display field.

– Top up if necessary, see ⇒ Chapter "Refu-

elling", P. 165.

• (3) Traction program

The current traction program appears in the display.

• (4) Operating hours

The operating hours appear on the display.

– Inform your service centre when a mainte-

nance interval is reached.

100 %

2360,4 h

12 : 15

7071_003-100

NOTE

Have all repair and maintenance work performed by your responsible service centre. Defects can only be corrected permanently in this manner.

• (5) Time display

The time appears on the display.

171673 [EN] 67

5 Operation

Start-up

CAUTION

Additional information can appear on the display. – If there are fault displays, please consult the

instructions in the corresponding chapter, see ⇒ Chapter "Error messages", P. 138.

Starting the engine

– Apply the parking brake.

WARNING

Toxicity hazard from exhaust gases. Do not allow the engine to run in unventilated

rooms.

– Insert the key (1) into the key switch and

turn it to position "I".

– When the display

lights up, turn the key to position "II" and hold in this position until the engine starts.

– As soon as the engine has started, release

the key.

– If the engine doesnot start after 20 seconds,

end the starting operation and start again after one minute.

STARTEN (START)

0 I

7071_003-101

68 171673 [EN]

Operation 5

Start-up

– If the message OELDRUCK (OIL PRES-

SURE)

in the display does not go out or reappears after starting the engine, switch off the engine immediately.

– Refer to the information in the chapter en-

titled Fault displays; see ⇒ Chapter "Error messages", P. 138.

NOTE

OELDRUCK

If the engine cannot be started due to a discharged battery, it can be jump-started; see ⇒ Chapter "Jump starting", P. 5-160.

7071_003-053

Operating the signal horn

– On trucks with single-pedal operation:

press foot switch (1).

The signal horn sounds.

7071_003-010

171673 [EN] 69

5 Operation

Start-up

– On trucks with two-pedal operation: press

button (2).

The signal horn sounds.

Restraining belt

DANGER

Driving without a seat belt is dangerous and never permitted!

– Always fasten the belt before

starting to drive.

7081_003-045

DANGER

Only a fully enclosedcab with closed, fixed doorsor bracket doors is an operator restraint system. PVC doors are not a restraint system.

Ifthedoorsareopenorremoved,youmustusea different, suitable restraint system (e.g. restraining belt).

70 171673 [EN]

Operation 5

Start-up

Fastening the restraining belt

WARNING

Risk of injury! – Always fasten the belt before moving the truck.

Make sure that the belt is not twisted when fastening.

– Use the belt only to secure a person! – If you notice any malfunction in the belt while

fastening, do not put the truck into operation before the belt has been repaired.

NOTE

The buckle has a buckle switch (special equipment). If there is an operating error or malfunction, the message

(SAFETY BELT)

SICHERHEITSGURT

appears in the display and

7311_003-048

operating unit (see ⇒ Chapter "SAFETY BELT message", P. 5-142).

– Pull the belt (3) smoothly out of the retrac-

tor and fasten belt tightly against the body above the thigh.

NOTE

Sit back as far as possible, so that your back is against the seat backrest. The automatic blocking mechanism permits sufficient freedom of movement.

– Insert the tongue (2) of the belt into the

buckle (1) until it latches.

– Check the belt tension. It should be close to

the body.

171673 [EN] 71

5 Operation

Start-up

Fastening on a steep slope

The automatic blocking mechanism prevents the belt from being extended whenever the forklift truck is on a steep gradient. It is not possible to pull the belt any further out of the retractor.

– Drive off the slope carefully.

– Fasten the belt.

7081_003-008

Releasing the restraining belt

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

72 171673 [EN]

7090_342-005

Operation 5

Start-up

– Slowly guide the belt tongue (2) back to the

retractor (3) by hand.

NOTE

Do not allow the belt to retract too quickly. The automatic blocking mechanism may be triggered if the belt tongue strikes the housing.

It will then no longer be possible to pull the belt out again with the usual force.

– Using increased force, pullthe belt out of the

retractor approx. 10-15 mm, thus releasing the blocking mechanism.

– Allow the belt to retract slowly.

– Prevent the belt becoming dirty (for exam-

ple, by covering).

7311_003-048

Malfunctions due to cold

– Thaw a frozen buckle or retractor and dry

the parts to prevent repeated freezing.

CAUTION

Risk of damage to components! When thawing, do not subject the buckle or retrac-

tor to excessive heat. – The temperature of the warm air should not ex-

ceed 60°C when thawing.

Checking function of brake system

DANGER

Risk of accident! Do not put forklift trucks with a defective brake sys-

tem into service.

Checking foot brake

– Check pedal clearance.

The brake must have sufficient distance from the pressure point to the pedal stop.

– Accelerate empty truck in a clear area.

– Press the brake pedal (1) firmly.

Check brake for noticeable delay.

171673 [EN] 73

7081_003-011

5 Operation

Start-up

Checking the parking brake

– Check operation of parking brake (2) at

walking speed or on a large gradient.

DANGER

Risk of accident! During operation, the forklift truck must never be

parked on slopes. In an emergency, secure the forklift truck by inserting chocks on the downhill side.

7081_003-008

Checking function of steering system

– Operate steering wheel (1). The play of the

steering wheel while stationary may not be more than two finger widths.

DANGER

Risk of accident! If the hydraulics malfunction, steering is stiff. The forklift truck may not be operated with a defec-

tive steering system.

74 171673 [EN]

7071_003-015

Operation 5

Start-up

Setting the traction programs

The driving and braking response of the drive can be set on the display and operating unit.

– Press the traction programme key (1) un-

til the number of the desired traction programme appears on the (2) display.

Traction programs 1-5 are available.

The basic principle is that the higher the traction program number is, the greater the traction dynamics.

The following settings are possible:

2 3 6 0,4 h

12 : 15

59 %

7311_560-004

Traction program

Speed (km/h)

Acceleration (%) (forward / backward)

Deceleration (%) (forward / backward)

Reversing (%) (forward / backward)

Brake retardation (%) (electric brake booster)

1 2 3 4

21 21 21 21 21

50 100 120 140 160

80 90 100 100 100

171673 [EN] 75

5 Operation

Driving

Safety regulations when driving

Driving conduct

The driver must observepublic road traffic regulations when driving on company grounds.

Driving speed must be appropriate to the local conditions.

For example, the driver must drive slowly around corners, in tight passage ways, when driving through swing-doors, at blind spots or on uneven surfaces.

The driver must always maintain a safe braking distancefrom vehicles and persons in front and always have the vehicle under control. Sudden stopping, quick turning and overtaking at dangerous or blind spots must be avoided.

– Initial driving practice must be performed in

an empty space or on a clear driving lane.

The following are forbidden during driving:

• Allowing arms and legs to hang out

• Leaning over the outer edge of the forklift truck

• Crossing from one vehicle to another or to fixed components

• Moving the driver seat

• Adjusting the steering column

• Releasing the restraining belt

• Disabling the restraint system

• Driving with the load raised impermissibly high

• Using mobile phones or radios.

WARNING

Risk of accident! Use of mobile phones or radios in the vehicle is

permitted. However, these devices must not be used while

driving or manipulating loads, since this affects your concentration.

The volume of radios or hands-free systems must be adapted to local conditions and must not affect your concentration.

76 171673 [EN]

Operation 5

Driving

WARNING

In areas where use of mobile phones is prohibited, use of a mobile phones or radio telephones is generally not permitted.

– Turn off the devices.

Visibility when driving

The driver must look in the direction of travel and have a sufficient view of the driving lane.

Particularly when driving backwards, the driver must be sure that the driving lane is clear.

When transporting goods that impair visibility, the driver must drive the vehicle backwards.

If this is not possible, a second person acting as a guide must walk ahead of the vehicle.

Only drive at walking pace and always take extracareinsuchsituations.Theforklifttruck must be stopped immediately if eye contact with the guide is lost.

Driving with the load raised unnecessarily high is not permitted.

Rear-view mirrors are only to be used for observing the road area behind the vehicle and not for driving backwards. If visual aids (mirror, monitor) are necessary to achieve sufficient visibility, their use most be carefully practised. When driving backwards using visual aids, extra care should be used.

When using attachments, special conditions apply, see ⇒ Chapter "Assembling attachments",P.5-116.

In models with cabins, the windows must always be clean and free of ice.

171673 [EN] 77

5 Operation

Driving

Driveways

Dimensions of the driveways and aisle widths

The following dimensions and aisle width requirements apply under the specified conditions to ensure safe manoeuvring. In each case, it should be checked whether a larger aisle width is necessary, e.g. with deviating load dimensions. Within the EU, there must be compliance with the 89/654/EEC directive (minimum safety and health requirements for the workplace). The respective national guidelines apply for areas outside of the EU.

The required aisle widths (Ast) depend on the dimensions of the load. For pallets, these are:

7071_003-012

Aisle width (mm)

R70-40T 4418 4618

R70-45T 4470 4670

R70-50T 4510 4710

Theforklifttruckmayonlybeusedondriveways with curves that are not too tight, slopes that are not too steep, and thoroughfares that are not too narrow or low.

With pallet 1000x1200

crosswise

With pallet

800x1200

lengthwise

Drivingonslopes

Thetruckmaybedrivenonthefollowingupwards or downwards slopes:

Max. gradient in %

R70-40T 23.5 34

R70-45T 21.6 33

R70-50T 20 32

The upwards and downwards slopes may not exceed the gradient listed above and should have a rough surface.

Smooth and gradual transitions should be provided at the top and bottom of the gradient

With load Without load

78 171673 [EN]

Operation 5

Driving

to avoid the load from falling on the floor or the forklift truck being damaged.

Condition of the driveways

Driveways must be made sufficiently firm, level and free of dirt and fallen objects. Compensation must be made for drainage channels, railway crossings and similar items; and if necessary, ramps must be provided, so that trucks can drive over them with as few bumps as possible.

Ensure sufficient load-bearing capacity of manhole/drain covers and the like.

There must be sufficient clearance between the highest points of the forklift truck or the load and the fixed points of the surroundings. The height is based on the overall height of the truck’s lift mast and the dimensions of the load. Observe the technical data (see ⇒ Chapter "Technical data", P. 247).

Rules for driveways and the working area

Only those routes authorised for traffic by the operator (see ⇒ Chapter "Definition of terms used for responsible persons", P. 20) or his representative may be driven. The traffic routes must be free of obstacles. The load may only be set down and stored in the designated locations. The operator and his representative must ensure that unauthorised third parties keep away from the working area.

Dangerous locations

Dangerous locations on the driveways must be designated by the signs typical for traffic or, if necessary, by additional warning signs.

171673 [EN] 79

5 Operation

Driving

Driving (single-pedal operation with multiple lever version)

DANGER

Risk of accident! – Operate the truck only from the driver’s seat.

NOTE

Please take note of the safety regulations while driving; see ⇒ Chapter "Safety regulations when driving", P. 5-76.

– Sit on the driver’s seat.

The driver’s seat is equipped with a seat switch. If there is an operating error or malfunction, the message

(SEAT SWITCH)

and operating unit (see ⇒ Chapter "Message SITZSCHALTER (SEAT SWITCH)", P. 5-145.

– Fasten the safety belt.

The buckle has a buckle switch (special equipment). If there is an operating error or malfunction, the message

(SAFETY BELT)

operating unit; see ⇒ Chapter "SAFETY BELT message", P. 5-142.

– Pull the "raise–lower"(1) operating lever

backward and raise the fork carriage until the necessary ground clearance has been reached.

– Pull the "tilt" operating lever (2) backward,

thereby tilting the mast backward.

– Do not accept any load yet!

SITZSCHALTER

appears in the display

SICHERHEITSGURT

appears in the display and

7081_003-012

80 171673 [EN]

Operation 5

Driving

Travel direction switch

– Using the direction switch (5), select the

desired direction of travel.

The appropriate arrow for the selected direction of travel lights up on the travel direction/flasher/fault multi-function display (4).

NOTE

When the seat is vacated, the travel direction switch is set to neutral.

Forwards travel

– Release the parking brake (6).

– Toggle the direction switch (5) downward.

The arrow for forward travel (4) lights up.

– Depress the accelerator pedal (3).

The forklift truck moves forwards. The speed is controlled by the accelerator pedal position. Upon releasing the accelerator pedal, the truck brakes electrically. On a gradient the truck creeps downhill slowly after a stop.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

7081_003-013

6210_501-003

171673 [EN] 81

5 Operation

Driving

Reverse travel

– Release the parking brake (6).

– Toggle the direction switch (5) upward.

The arrow for reverse travel (4) lights up.

NOTE

At the same time, an acoustic signal sounds (special equipment) as a warning or the back-up light and the front headlights light up (only if there is a lighting system (special equipment) in accordance with StVZO — the Road Traffic Licensing Regulations).

– Depress the accelerator pedal (3).

The forklift truck travels backwards. The speed is controlled by the accelerator pedal position. Upon releasing the accelerator pedal, the truck brakes electrically. On a gradient the truck creeps downhill slowly after a stop.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

7081_003-013

6210_501-003

82 171673 [EN]

Operation 5

Driving

Changing direction of travel

NOTE

You can also change the direction of travel whilst driving. Your foot can remain on the accelerator pedal. The truck is then braked and accelerated again in the opposite direction (reversing).

– Take your foot off the accelerator pedal (3).

– Operate the travel direction switch (5) to

select the opposite direction (up for reverse, down for forwards).

– Depress the accelerator pedal (3) again.

Neutral position

– To switch to the neutral position, tap the di-

rection switch (5) briefly for the opposite direction (up for reverse, down for forwards).

7081_003-013

6210_501-003

171673 [EN] 83

5 Operation

Driving

Driving (single-pedal operation with version including mini-console)

DANGER

Risk of accident! – Operate the truck only from the driver’s seat.

NOTE

Please take note of the safety regulations while driving, see ⇒ Chapter "Safety regulations when driving", P. 5-76.

– Sit on the driver’s seat.

The driver’s seat is equipped with a seat switch. If there is an operating error or malfunction, the message

(SEAT SWITCH)

and operating unit (see ⇒ Chapter "Message SITZSCHALTER (SEAT SWITCH)", P. 5-145.

– Fasten the safety belt.

The buckle has a buckle switch (special equipment). If there is an operating error or malfunction, the message

(SAFETY BELT)

operating unit (see ⇒ Chapter "SAFETY BELT message", P. 5-142.

– Pull the "raise–lower" operating lever (1)

backward and raise the fork carriage until the necessary ground clearance has been reached.

– Pull the "tilt" operating lever (2) backward,

thereby tilting the mast backward.

– Do not accept any load yet!

SITZSCHALTER

appears in the display

SICHERHEITSGURT

appears in the display and

7081_003-012

84 171673 [EN]

Operation 5

Driving

Travel direction switch

– Using the direction switch (5), select the

desired direction of travel.

The appropriate arrow for the selected direction of travel lights up on the travel direction/flasher/fault multi-function display (4).

NOTE

When the seat is vacated, the travel direction switch is set to neutral.

Forwards travel

– Release the parking brake (6).

– Press the direction switch (5) forward.

The arrow for forward travel (4) lights up.

– Depress the accelerator pedal (3).

The forklift truck moves forwards. The speed is controlled by the accelerator pedal position. When releasing the accelerator pedal, the forklift truck decelerates. On a gradient the truck creeps downhill slowly after a stop.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

7081_003-041

7071_003-102

171673 [EN] 85

5 Operation

Driving

Reverse travel

– Release the parking brake (6).

– Press the direction switch (5) backward.

The arrow for reverse travel (4) lights up.

NOTE

– Depress the accelerator pedal (3).

The forklift truck travels backwards. The speed is controlled by the accelerator pedal position. When releasing the accelerator pedal, the forklift truck decelerates. On a gradient the truck creeps downhill slowly after a stop.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

7081_003-041

7071_003-102

86 171673 [EN]

Operation 5

Driving

Changing direction of travel

NOTE

You can also change the direction of travel whilst driving. Your foot can remain on the accelerator pedal. The truck is then braked and accelerated again in the opposite direction (reversing).

– Take your foot off the accelerator pedal (3).

– Press the direction switch (5) for the oppo-

site direction of travel(backwards to reverse and forwards to move forwards).

– Depress the accelerator pedal (3) again.

Neutral position

– To switch to the neutral position, tap the

direction switch (5) briefly for the opposite direction of travel (backwards to reverse and forwards to move forwards).

7081_003-041

171673 [EN] 87

7071_003-102

5 Operation

Driving

Driving (two-pedal operation)

DANGER

Risk of accident! – Operate the truck only from the driver’s seat.

NOTE

Please take note of the safety regulations while driving; see ⇒ Chapter "Safety regulations when driving", P. 5-76.

– Sit on the driver’s seat.

The driver’s seat is equipped with a seat switch. If there is an operating error or malfunction, the message

(SEAT SWITCH)

and operating unit (see ⇒ Chapter "Message SITZSCHALTER (SEAT SWITCH)", P. 5-145.

– Fasten the safety belt.

The buckle has a buckle switch (special equipment). If there is an operating error or malfunction, the message

(SAFETY BELT)

operating unit (see ⇒ Chapter "SAFETY BELT message", P. 5-142.

– Pull the "raise–lower"(1) operating lever

backward and raise the fork carriage until the necessary ground clearance has been reached.

– Pull the "tilt" operating lever (2) backward,

thereby tilting the mast backward.

– Do not accept any load yet!

SITZSCHALTER

appears in the display

SICHERHEITSGURT

appears in the display and

7081_003-012

88 171673 [EN]

Operation 5

Driving

Forwards travel

– Release the parking brake (6).

– Depress the accelerator pedal (3).

The arrow for forward travel (4) lights up.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

7081_003-042

Reverse travel

– Release the parking brake (6).

– Depress the accelerator pedal (5).

The arrow for reverse travel (4) lights up.

NOTE

The forklift truck travels backwards. The speed is controlled by the accelerator pedal

171673 [EN] 89

5 Operation

Driving

position. When releasing the accelerator pedal, the forklift truck decelerates. On a gradient the truck creeps downhill slowly after a stop.

DANGER

Risk of accident! Trucks with zero braking (special equipment) do not have an electrical braking function!

– Use the footbrake to slow the truck.

NOTE

You can stop the truck on ascending and descending slopes briefly without actuating the parking brake (6) (electric brake). The truck begins to creep downhill slowly.

DANGER

Risk of accident! This electric brake only functions while the key

switch is switched on and the parking brake is released. Press the brake pedal!

– Do not leave the truck without applying the par-

king brake!

Changing direction of travel

– Take your foot off the accelerator pedal (3)

or (5).

– Depress the accelerator pedal for the oppo-

site direction of travel (3) or (5).

The corresponding arrow (4) lights up.

90 171673 [EN]

7081_003-042

Still R70-40T, R70-45T, R70-50T Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual